1. Front-Wheel-Drive (Transaxle and CV Joint) Service
Chapter 78

2. Objectives Diagnose CV joint problems Service CV joints
Replace CV joint boots
Disassemble and repair transaxles

3. Introduction
Removal, service, and replacement of front drive axles and constant velocity (CV) joint
Lucrative service area
Transaxle removal
Relatively straightforward
Once axle removal is accomplished

4. Transaxle and Front-Wheel-Drive Service and Repair
Checks of the axle assemblies
Some can be made with the axle on the car

5. Leaking CV Joint Boot Front-wheel-drive axles
Require service as a vehicle ages
Some checks and services can be made with axle on vehicle
Others require removal and disassembly of components

6. CV Joint Boot Service Boots age over time Boot fails
Repeated flexing and exposure to elements
Boot fails
Grease leaks out
If not replaced: entire joint will fail
Most common problem with CV joints
Replacement boot kits
Come with new clamps and correct amount of high pressure grease

7. Axle Inspection and Diagnosis
Check halfshaft for obvious looseness
Noises can be detected from the test drive
Weight must be on the suspension when checking for a noise
Questions to ask customer:
What does the noise sound like?
Does it occur during acceleration, deceleration, or when turning?

9. CV Joint Diagnosis Clicking sound during a turn
Indicates bad outboard joint
Always check the splines on a shaft
Bad plunge joint makes clunking sound
Starting from a stop
During deceleration
Braking
Excess wear
Hard to detect visually

10. Axle Shaft Removal Major steps Loosen axle nut
Remove the stub shaft from the hub
Remove the stub shaft
Remove the axle
Remove snap rings and clips
Remove boot

12. CV Joint Replacement Internal circlip
Common way of retaining a fixed joint to shaft
Called knock-off-type joint
Different version used in some Japanese vehicles
CV joint has been removed from axle
Boot is removed
Fixed Rzeppa joints
Held to their shafts by external snap ring or internal clip

13. Fixed Joint Disassembly and Inspection
Major steps
Use drift punch to move inner race to the side for a more complete inspection
Wipe the parts off and look for wear
Disassemble Rzeppa joint
Mark all major components
Remove the balls
Wipe and lightly grease
Install the boot and joint

14. CV Joint Boot Clamps Several types Installing small-end clamp
Universal clamp
Bridge-type clamp
Earless clamp
Pressed-fit ring
Installing small-end clamp
Pull big end of the boot over CV joint and install retaining clamp
Vent the small end of the boot

16. Servicing an Inner Tripod Joint
Major steps
Before removing: tape shaft and joint
Cut away the clamps and boot
Check to see if tripod rollers come off of spider
Inspect condition of inside tulip
Align any marks
After boot and tripod are reinstalled: grease rollers and fill boot with rest of grease

17. Double Offset Plunge Joints
Vary in how they are connected to axle shaft
Most held by internal circlip
Joint must be disassembled before it can be removed
Other kind has a circlip that can be removed by pounding on outer housing
Metal retaining ring holds parts in the housing

18. Cross Groove Joint Service and Rebuilt Halfshafts
Key points
Cross groove joint is serviced in similar manner to Rzeppa joints
Disassembled by turning inner race and cage perpendicular to outer cage and removing them
Complete rebuilt halfshaft is a popular repair
Installing rebuilt halfshafts is often in the best interest of the customer

19. Installing the Axle Major steps
To install a spline-type joint into transaxle: push in on axle while turning it to align splines
After inner end is installed: position stub shaft into hub as far as it can go
Do not forget to torque ball joint stud bolt
When vehicle is back on ground: torque new stub shaft nut
Check clearance of boot clamps before test-driving

20. Transaxle Repair and Removal
Key points
Transaxles used with transverse engines
Differential gears are helical gears
No pinion depth or backlash adjustments
Front-wheel-drive vehicles
Easier to pull engine with transaxle
Support the engine if it is easier to leave it in the vehicle
Unbolt transaxle from engine
Axles are pulled in manner previously described

22. Manual Transaxle Repair
Key points
Separate halves of case on a transaxle
Check service manual for any specifics
Service and assembly are similar to RWD transmissions
End play of gears is checked with feeler gauge or dial indicator
Thrust washers, shims, or snap rings can be used to make adjustments

23. Automatic Transaxle Repair
Same as RWD automatic transmissions
Differences
Gar or a chain is driven by transmission output shaft to turn differential section
Automatic transaxles have a differential

24. Transaxle Differential Side Bearing Adjustment
Case halves are reassembled
Differential side bearing preload is adjusted
Some use special tools

25. Install the Transaxle
Installation of transaxle is the reverse of removal sequence
After installation: be sure to check transaxle lubricant level
Some have a fill plug on the side
Some have a dipstick
Others require removal of speedometer gear