Tools Required

1. With the vehicle on the ground, depress the brake pedal and remove the cotter and drive axle nut. Discard the nut and cotter.
2. Raise the vehicle on a hoist.
3. Remove the wheel and tire assembly corresponding to the drive axle being removed.



4. Remove the tie rod end torque prevailing nut and discard the nut.




Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

5. Using the SA91100C , separate the tie rod end from the steering knuckle.



6. Remove the lower control arm to steering knuckle nut and bolt.
7. Separate the lower control arm from the steering knuckle.

Important: If difficulty is encountered in separating the axle from the hub, tap on the end of the drive axle, using a block of wood and a hammer. Do not hammer directly on the end of the axle.




8. While pulling the knuckle/strut assembly away from the vehicle, pull the outer end of the drive axle out of the wheel hub.



9. Support or suspend the drive axle assembly.




Important: Before removing the drive axle, place an approved container under the transaxle to catch any fluid spillage.

10. Using a pry bar, remove the drive axle from the transaxle.



11. Remove the shaft retaining the ring from the end of the drive axle or stub shaft and discard. The stub shaft is shown.

1. Install a new axle or stub shaft retaining ring.

Important: On vehicles equipped with automatic transaxles, apply output shaft lubricant Saturn P/N 7847638 to the splines of the output shaft.

2. Install the SA91112T on vehicles with manual transaxles.
3. Insert the drive axle into the transaxle.



4. After the drive axle splines have safely passed the transaxle oil seal, remove the seal protector and fully seat  the drive axle into the transaxle.

Important: 

•	Use a new nut. The torque retention of the old nut may not be sufficient.

•	Do not tighten the fastener at this time.

5. Insert the outer end of the drive axle into the wheel hub. Install the drive axle to hub washer and the new nut.




Important: Use a new nut and bolt. The torque retention of old fasteners may not be sufficient.

6. Install the lower control arm ball stud into the steering knuckle. Hold the bolt stationary and tighten the nut.

Tighten
Tighten the lower control arm-to-steering knuckle to 100 N·m (75 lb ft).





Important: The tie rod ends must be thoroughly cleaned before installing and tightening.

7. Install the tie rod end into the steering knuckle.
8. Using the J 44015 , or equivalent, seat the tie rod end into knuckle.

Tighten
Tighten the tie rod end linkage installer to 45 N·m (33 lb ft).

Important: Use a new nut. The torque retention of the old nut may not be sufficient.

9. Inspect the boot for damage and replace any part if damaged.



10. Remove the linkage installer and install the NEW tie rod end nut.

Tighten
Tighten the tie rod end-to-steering knuckle nut to 60 N·m (44 lb ft).

11. Install the wheel and tire assemblies onto the hub.
12. Install the wheel bolts and tighten them in a crisscross pattern.

12.1.

Hand tighten all 5 wheel bolts.

12.2.

Use a torque wrench to tighten the wheel bolts using a crisscross pattern.

Tighten
Tighten the wheel bolts -- initial torque to 63 N·m (46 lb ft).

12.3.

Use a torque wrench to final tighten the wheel bolts using a crisscross pattern.

Tighten
Tighten the wheel bolts -- final torque to 125 N·m (92 lb ft).




13. Lower the vehicle from the hoist.
14. Tighten the axle shaft to hub nut in the following sequence.

Tighten

•	Tighten the axle shaft-to-hub -- initial torque to 63 N·m (46 lb ft) then release nut until it is free to turn by hand.

•	Tighten the axle shaft-to-hub -- final torque to 63 N·m (46 lb ft) + 90 degrees. If required, continue turning nut until a hole for the cotter pin is aligned properly.

15. Install the cotter pin.