EGS_3.PDF

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SPECIFICATIONSTORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 14

Vehicles equipped with automatic transaxles use asolid short interconnecting shaft on the left side. Theright side of the vehicle uses a lonnecting shaft.

Driveshafts used on both the rigthe vehicle use a tuned rubber damper weight. The

inner and outer joints. The inner joint of both drive-shaft assemblies is a tripod joint, and the outer jointof both driveshaft assetripod joints and Rzevelocity (C/V) joint assallows for the changes

into the transaxle side gears. The inner tripod jointsare retained in the side gears of the transaxle using

in the stub shaft of the tripodjoint has a stub shaft that is

el hub and retained by a hub nutd cotter pin, hub nut retention

system.

metal bearing shield which is pressed onto the endof the outer C/V joint housing. This design detersdirect water splash on bearing seal while allowing

t the bottom of theugh to thoroughly

wheel bearing areais assembled after

NS/GSmblies is a Rzeppa joint. Bothppa joints are true constantemblies. The inner tripod joint

in driveshaft length through

any water that gets in, to run oubearing shield. It is important thoclean the outer C/V joint and thein the steering knuckle before itdamper weight on the right side is a single clampstyle damper. The damper weight on the left side is adouble clamp style damper. When replacing a drive-shaft, be sure the replacement driveshaft has thesame damper weight as the original.

Both driveshaft assemblies use the same type ofNOTE: This vehicle does not use a rubber lip bear-ing seal as on past front wheel drive cars, to pre-vent contamination of the front wheel bearing. Onthese vehicles, the face of the outer C/V joint has ager solid intercon-

ht and left sides of

a snap ring locatedjoint. The outer C/Vsplined into the wheusing a nut lock anDRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . 2DIAGNOSIS AND TESTING

DRIVESHAFT DIAGNOSIS . . . . . . . . . . . . . . . . . 3REMOVAL AND INSTALLATION

FRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . 3DISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITIONING PROCEDURE . 9

GENERAL INFORMATION

FRONT DRIVESHAFTSVehicles equipped with either an automatic or

manual transmission uses an unequal length drive-shaft system.SPECIAL TOOLSDRIVESHAFTSPECIAL TOOLS . . . . . . . . . . . . 14

the jounce and rebound travel of the front suspen-sion.

On vehicles equipped with ABS brakes, the outerC/V joint is equipped with a tone wheel used todetermine vehicle speed for ABS brake operation.

The inner tripod joint of both driveshafts is splinedDIFFERENTIAL A

CONT

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DRIVELINE MODULE AND REARDRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . 15

FRONT DRI

IND

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GENERAL INFORMATIONFRONT DRIVESHAFT IDENTIFICATION . . . . . . . 2FRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATIONND DRIVELINE

NTS

page

FRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . 1

ESHAFTS

X

page

INNER TRIPOD JOINT SEAL BOOT . . . . . . . . . . 9OUTER C/V JOINT BEARING

SHIELD SERVICE . . . . . . . . . . . . . . . . . . . . . 13OUTER C/V JOINT SEALING BOOT SERVICE . 13

DIFFERENTIAL AND DRIVELINE 3 - 1servicing.

BEARING SHIELD OUTER C/V JOINT TUNED DAMPER WEIGHTINTERCONNECTING SHAFTINNER TRIPOD JOINTTRIPOD JOINT SEALING BOOT(SILICONE)INTERCONNECTINGSHAFTRIGHT SIDE DRIVESHAFT OUTER C/V JOINTSEALING BOOT(THERMO PLASTIC)OUTER C/V JOINT BEARING SHIELDTONE WHEEL(IF ABS EQUIPPED)OUTER C/V JOINT SEALINGBOOT(THERMO PLASTIC)LEFT SIDE DRIVESHAFTTUNEDDAMPERWEIGHTTRIPOD JOINT SEALINGBOOT(THERMO PLASTIC)FRONT DRIVESHAFT IDENTIFICATIONDriveshafts and driveshaft inner and outer boots

can be identified as shown in (Fig. 1). Driveshaft bootlocation on the driveshaft assemblies, is determinedby the number of convolutes used on the driveshaftboot. Refer to (Fig. 1) for the correct location of thesealing boots.

DESCRIPTION AND OPERATION

DRIVESHAFT SERVICE

CAUTION: The outer C/V joint used on this vehicleuses a new design for retaining the cross to theinterconnecting shaft. These driveshafts incorpo-rate a slight twist (helical) in the spline on the inter-connecting shaft where the cross is installed. Thistwist causes a interference fit between the intercon-necting shaft and the cross when the outer C/Vjoint is installed on the interconnecting shaft. Thisdesign eliminates the clearance between the crossand the interconnecting shaft resulting in quieteroperation of the driveshaft assembly. This designthough, eliminated the capability of removing theouter C/V joint from the interconnecting shaft. For

quarter shaft (outer C/V joint/sealing boot, intercon-necting shaft and vibration damper) in the event ofa outer C/V joint boot failure. The inner joint sealingboot will be serviced, as on past applications, as aseparate component of the driveshaft assembly.

CAUTION: Boot sealing is vital to retain speciallubricants and to prevent foreign contaminantsfrom entering the C/V joint. Mishandling, such asallowing the assemblies to dangle unsupported, orpulling or pushing the ends, can cut boots or dam-age C/V joints. During removal and installation pro-cedures, always support both ends of the driveshaftto prevent damage.

DIAGNOSIS AND TESTING

DRIVESHAFT DIAGNOSIS

VEHICLE INSPECTION(1) Check for grease in the vicinity of the inboard

tripod joint and outboard C/V joint; this is a sign ofinner or outer joint seal boot or seal boot clamp dam-

Fig. 1 Driveshaft Identification3 - 2 DIFFERENTIAL AND DRIVELINE

GENERAL INFORMATION (Continued)this reason the driveshafts will be serviced as aNS/GSage.

HUB NUTNUT LOCKCOTTER PINSPRINGWASHERFRONTHUB

NS/GS DIFFERENTIAL AND DRIVELINE 3 - 3(2) A light film of grease may appear on the rightinner tripod joint seal boot; this is considered normaland should not require replacement of the seal boot.

NOISE AND/OR VIBRATION IN TURNSA clicking noise and/or a vibration in turns could

be caused by one of the following conditions:(1) Damaged outer C/V or inner tripod joint seal

boot or seal boot clamps. This will result in the lossand/or contamination of the joint grease, resulting ininadequate lubrication of the joint.

(2) Noise may also be caused by another compo-nent of the vehicle coming in contact with the drive-shafts.

CLUNKING NOISE DURING ACCELERATIONThis noise may be a result of one of the following

conditions:(1) A torn seal boot on the inner or outer joint of

the driveshaft assembly.(2) A loose or missing clamp on the inner or outer

joint of the driveshaft assembly.(3) A damaged or worn driveshaft C/V joint.

SHUDDER OR VIBRATION DURINGACCELERATION

This problem could be a result of:(1) A worn or damaged driveshaft inner tripod

joint.(2) A sticking tripod joint spider assembly (inner

tripod joint only).(3) Improper wheel alignment. See Wheel Align-

ment in this group for alignment checking and set-ting procedures and specifications.

VIBRATION AT HIGHWAY SPEEDSThis problem could be a result of:(1) Foreign material (mud, etc.) packed on the

backside of the wheel(s).(2) Out of balance front tires or wheels. See Group

22, Wheels And Tires for the required balancing pro-cedure.

(3) Improper tire and/or wheel runout. See Group22, Wheels And Tires for the required runout check-ing procedure.

REMOVAL AND INSTALLATION

FRONT DRIVESHAFTS

REMOVAL

CAUTION: The driveshaft, when installed, acts as abolt and secures the front hub/bearing assembly. If

DIAGNOSIS AND TESTING (Continued)vehicle is to be supported or moved on its wheelswith a driveshaft removed, install a PROPERSIZEDBOLT AND NUT through front hub. Tighten bolt andnut to 244 Nm (180 ft. lbs.). This will ensure thatthe hub bearing cannot loosen.

(1) Remove cotter pin, nut lock, and spring washerfrom the end of the outer C/V joint stub axle (Fig. 2).

(2) Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicleis on the floor with the brakes applied (Fig. 3). Thefront hub and driveshaft are splined together andretained by the hub nut.

(3) Raise vehicle on jack stands or centered on aframe contact type hoist. See Hoisting, in the Lubri-cation and Maintenance section, for required liftingprocedure to be used for this vehicle.

(4) Remove front tire and wheel assembly from thehub.

Fig. 2 Cotter Pin, Nut Lock and Spring Washer

Fig. 3 Loosening Front Hub Retaining Nut

DISC BRAKE CALI-PER ASSEMBLYSTEERINGKNUCKLECALIPER ASSEMBLYGUIDE PIN BOLTSROTOR DISC BRAKE CALI-PER ASSEMBLY OUTBOARDBRAKESHOESTEERINGKNUCKLELIFT THIS END OF CALIPERAWAY FROM STEERINGKNUCKLE FIRSTABS SPEED SEN-

SOR CABLESTEERINGKNUCKLEROTORUPPER CONTROL ARMDISC BRAKE CALI-PER ASSEMBLYWIRE HANGER TIE ROD ENDHEATSHIELDSTEERINGKNUCKLETIE RODEND STUD NUTSPECIALTOOLMB-991113 TIE ROD END HEAT SHIELDSTEERINGKNUCKLELOWER CONTROL ARM

3 - 4 DIFFERENTIAL AND DRIVELINE NS/GS

REMOVAL AND INSTALLATION (Continued)(5) Remove front disc brake caliper assembly tosteering knuckle guide pin attaching bolts (Fig. 4).

(6) Remove disc brake caliper assembly from steer-ing knuckle. Caliper is removed by first lifting bot-tom of caliper away from steering knuckle, and thenremoving top of caliper out from under steeringknuckle (Fig. 5).

(7) Support brake caliper/adapter assembly using awire hook (Fig. 6). Do not support assembly bythe brake flex hose.

(8) Remove braking disc from front hub.(9) Remove nut attaching outer tie rod end to

steering knuckle. Remove nut from tie rod end byholding tie rod end stud with a 11/32 socket andloosen and remove nut (Fig. 7).

(10) Remove the tie rod end stud from steeringknuckle arm, using remover, Special Tool MB-991113(Fig. 8).

Fig. 4 Caliper Guide Pin Attaching Bolts

Fig. 5 Removing Disc Brake CaliperFig. 6 Correctly Supported Brake Caliper

Fig. 7 Removing Tie Rod End Attaching Nut

Fig. 8 Tie Rod End Removal from Steering Knuckle

WHEEL SPEED SEN-SOR CABLESPEED SENSOR CABLE ROUTINGBRACKET STEERINGKNUCKLEATTACHINGBOLTBRAKE CALIPER FLEXHOSECASTLENUT BALL JOINT STUDSTEERINGKNUCKLECOTTER PINLOWER CONTROLARMBALL JOINT STEERINGKNUCKLELOWER CONTROLARMSTEERINGKNUCKLE BOSSHAMMER HUB/BEARINGBEARING SHIELDOUTER C/VJOINTSTEERINGKNUCKLE(11) If equipped with antilock brakes, remove thespeed sensor cable routing bracket from the steeringknuckle (Fig. 9).

(12) Remove cotter pin and castle nut (Fig. 10)from stud of lower ball joint at the steering knuckle.

CAUTION: No tool is to be inserted between thesteering knuckle and the lower ball joint to separatestud of lower ball joint from the steering knuckle.The steering knuckle is to be separated from thestud of the ball joint only using the procedure asdescribed in Step 13.

(13) Turn steering knuckle so the front of thesteering knuckle is facing as far outboard in thewheel well as possible. Using a hammer strike steer-ing knuckle boss until steering knuckle separatesfrom stud of lower ball joint (Fig. 11). When strik-ing steering knuckle, care MUST be taken notto hit lower control arm or ball joint grease

Fig. 9 Wheel Speed Sensor Cable Routing Bracket

Fig. 10 Lower Ball Joint to Steering KnuckleAttachment

NS/GS

REMOVAL AND INSTALLATION (Continued)seal.NOTE: Care must be taken not to separate theinner C/V joint during this operation. Do not allowdriveshaft to hang by inner C/V joint. Driveshaftmust be supported.

(14) Pull steering knuckle assembly out and awayfrom outer C/V joint of the driveshaft assembly (Fig. 12).

CAUTION: When inserting pry bar between inner tri-pod joint and transaxle case, care must be used toensure no damage occurs to oil seal in transaxle case.

(15) Support the outer end of the driveshaftassembly. Insert a pry bar between inner tripod jointand transaxle case (Fig. 13). Pry against inner tripodjoint, until tripod joint retaining snap ring is disen-gaged from transaxle side gear.

(16) Hold inner tripod joint and interconnectingshaft of driveshaft assembly. Remove inner tripodjoint from transaxle, by pulling it straight out of

Fig. 11 Separating Ball Joint Stud from SteeringKnuckle

STUD

Fig. 12 Separating Steering Knuckle from Outer C/VJoint

DIFFERENTIAL AND DRIVELINE 3 - 5transaxle side gear and transaxle oil seal (Fig. 14).When removing tripod joint, do not let spline or

INNER TRIPODJOINT TRANSAXLECASEPRYBAR INNER TRIPODJOINTTRANSAXLESPLINEOILSEAL SNAP RING INTERCON-NECTINGSHAFT THIS AREA OFOUTER C/V JOINTMUST BE FREE OFALL DEBRIS ANDMOISTURE BEFOREINSTALLING INSTEERINGKNUCKLE.OUTER C/V JOINTBEARING SHIELD HUB/BEARINGBEARING SHIELDOUTER C/VJOINTSTEERINGKNUCKLEsnap ring drag across sealing lip of the tran-saxle to tripod joint oil seal.

CAUTION: The driveshaft, when installed, acts as abolt and secures the front hub/bearing assembly. Ifvehicle is to be supported or moved on its wheelswith a driveshaft removed, install a PROPERSIZEDBOLT AND NUT through front hub. Tighten bolt andnut to 183 Nm (135 ft. lbs.). This will ensure thatthe hub bearing cannot loosen.

INSTALLATION(1) Thoroughly clean spline and oil seal sealing

surface, on tripod joint. Lightly lubricate oil sealsealing surface on tripod joint with fresh clean trans-mission lubricant.

(2) Holding driveshaft assembly by tripod joint andinterconnecting shaft, install tripod joint into tran-

Fig. 13 Disengaging Inner Tripod Joint FromTransaxle

Fig. 14 Tripod Joint Removal from Transaxle

3 - 6 DIFFERENTIAL AND DRIVELINE

REMOVAL AND INSTALLATION (Continued)saxle side gear as far as possible by hand (Fig. 14).(3) Grasp inner tripod joint an interconnectingshaft. Forcefully push the tripod joint into side gearof transaxle, until snap ring is engaged with tran-saxle side gear. Test that snap ring is fullyengaged with side gear by attempting toremove tripod joint from transaxle by hand. Ifsnap ring is fully engaged with side gear, tripodjoint will not be removable by hand.

(4) Clean all debris and moisture out of steeringknuckle, in the area were outer C/V joint will beinstalled into steering knuckle.

(5) Ensure that front of outer C/V joint which fitsagainst the face of the hub and bearing is free ofdebris and moisture before installing outer C/V jointinto hub and bearing assembly (Fig. 15).

(6) Slide driveshaft back into front hub (Fig. 16).Then install steering knuckle onto the lower controlarm ball joint stud.

Fig. 15 Outer C/V Joint Inspection

Fig. 16 Steering Knuckle Installation on Outer C/VJoint

NS/GS

CASTLENUT BALL JOINT STUDSTEERINGKNUCKLECOTTER PINLOWER CONTROLARMWHEEL SPEED SEN-SOR CABLESPEED SENSOR CABLE ROUTINGBRACKET STEERINGKNUCKLEATTACHINGBOLTBRAKE CALIPER FLEXHOSE TIE ROD ENDHEATSHIELDSTEERINGKNUCKLETIE RODEND STUD NUTHEATSHIELDTIE ROD ENDSTEERINGKNUCKLETORQUEWRENCH11/32 SOCKETCROWFOOTROTOR DISC BRAKE CALI-PER ASSEMBLY OUTBOARDBRAKESHOESTEERINGKNUCKLELIFT THIS END OF CALIPERAWAY FROM STEERINGKNUCKLE FIRST(7) Install the steering knuckle to ball joint studcastle nut (Fig. 17). Tighten the castle nut to 95 Nm(70 ft. lbs.).

(8) If equipped with antilock brakes, install thespeed sensor cable on the steering knuckle andsecurely tighten bolt (Fig. 18).

(9) Install tie rod end into the steering knuckle.Start tie rod end to steering knuckle nut onto stud oftie rod end. While holding stud of tie rod end station-ary (Fig. 19), tighten tie rod end to steering knucklenut. Using a crowfoot and 11/32 socket, tighten thenut to 61 Nm (45 ft. lbs.) (Fig. 20).

(10) Install braking disc back on hub and bearingassembly.

(11) Install disc brake caliper assembly on steeringknuckle. Caliper is installed by first sliding top ofcaliper under top abutment on steering knuckle.Then installing bottom of caliper against bottomabutment of steering knuckle (Fig. 21).

Fig. 17 Lower Ball Joint to Steering KnuckleAttachment

Fig. 18 Wheel Speed Sensor Cable Routing Bracket

NS/GS

REMOVAL AND INSTALLATION (Continued)(12) Install caliper assembly to steering knuckleguide pin bolts (Fig. 22). Tighten caliper assemblybolts to 31 Nm (23 ft. lbs.).

Fig. 19 Installing Tie Rod End Nut

Fig. 20 Torquing Tie Rod End Nut

Fig. 21 Disc Brake Caliper Assembly Installation

DIFFERENTIAL AND DRIVELINE 3 - 7

DISC BRAKE CALI-PER ASSEMBLYSTEERINGKNUCKLECALIPER ASSEMBLYGUIDE PIN BOLTSHUB AND BEAR-ING WASHER HUB NUTSTUBAXLE TORQUE WRENCHHUBBRAKING DISC COTTER PINPULL THROUGH ANDWRAP TIGHTNUT LOCK TORQUEWRENCH

NS/GS(13) Clean all foreign matter from the threads ofthe outer C/V joint stub axle. Install hub nut ontothreads of stub axle and tighten nut. (Fig. 23).

(14) With vehicle brakes applied to keep brakingdisc from turning, tighten hub nut to 244 Nm (180ft. lbs.) (Fig. 24).

(15) Install the spring washer, hub nut lock, andnew cotter pin on end of stub axle. Wrap cotter pinprongs tightly around the hub nut lock (Fig. 25).

(16) Install front wheel and tire assembly. Installfront wheel lug nuts and tighten in the correctsequence (Fig. 26). Tighten lug nuts to 135 Nm (100ft. lbs.).

(17) Lower vehicle.(18) Check for correct fluid level in transaxle

assembly. Refer to Group 21, Transaxle for the cor-rect fluid level checking procedure for the type oftransaxle being checked.

(19) Set front toe on vehicle to required specifica-

Fig. 22 Disc Brake Caliper Bolts

Fig. 23 Install Washer and Hub Nut


REMOVAL AND INSTALLATION (Continued)tion.Fig. 24 Torquing Front Hub Nut

Fig. 25 Spring Washer, Nut Lock and CotterPinInstallation

Fig. 26 Wheel Lug Torquing Sequence

TRIPOD JOINTHOUSINGSPIDER ASSEM-BLYSEALINGBOOTINTERCONNECTINGSHAFT SPIDER ASSEM-BLYRETAININGSNAP RINGDISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITIONING PROCEDURE

CAUTION: The outer C/V joint used on this vehicleuses a new design for retaining the cross to theinterconnecting shaft. These driveshafts incorpo-rate a slight twist (helical) in the spline on the inter-connecting shaft where the cross is installed. Thistwist causes a interference fit between the intercon-necting shaft and the cross when the outer C/Vjoint is installed on the interconnecting shaft. Thisdesign eliminates the clearance between the crossand the interconnecting shaft resulting in quieteroperation of the driveshaft assembly. This designthough eliminated the capability of removing theouter C/V joint from the interconnecting shaft. Forthis reason the driveshafts will be serviced as aquarter shaft (outer C/V joint/sealing boot, intercon-necting shaft and vibration damper) in the event ofa outer C/V joint boot failure.

NOTE: The only service which is to be performedon the driveshaft assemblies is the replacement ofthe driveshaft seal boots on the inner tripod joints.

If any failure of internal driveshaft components isdiagnosed during a vehicle road test or disassemblyof the driveshaft, the driveshaft will need to bereplaced as an assembly.

CAUTION: Lubricant requirements and quantitiesare different for inner joints than for outer joints.Use only the recommended lubricants in therequired quantities when servicing driveshaftassemblies.

INNER TRIPOD JOINT SEAL BOOT

REMOVALTo remove sealing boots from driveshafts, the

driveshaft assemblies must be removed from thevehicle. See Servicing Driveshaft for the requireddriveshaft removal and replacement procedure.

The inner tripod joints use no internal retention inthe tripod housing to keep the spider assembly in thehousing. Therefore, do not pull on the interconnect-ing shaft to disengage tripod housing from transmis-sion stub shaft. Removal in this manner will causedamage to the inboard joint sealing boots.

(1) Remove the driveshaft requiring boot replace-ment from the vehicle. See Servicing Driveshaft forthe required driveshaft removal procedure.

(2) Remove large boot clamp which retains innertripod joint sealing boot to tripod joint housing and

NS/GSdiscard. Remove small clamp which retains inner tri-pod joint sealing boot to interconnecting shaft anddiscard. Remove the sealing boot from the tripodhousing and slide it down the interconnecting shaft.

CAUTION: When removing the tripod joint housingfrom the spider assembly, hold the bearings inplace on the spider trunions to prevent the bearingsfrom falling away.

(3) Slide the tripod joint housing off the spiderassembly and the interconnecting shaft (Fig. 27).

(4) Remove snap ring which retains spider assem-bly to interconnecting shaft (Fig. 28). Remove thespider assembly from interconnecting shaft. If spiderassembly will not come off interconnecting shaft byhand, it can be removed by tapping spider assemblywith a brass drift (Fig. 29). Do not hit the outertripod bearings in an attempt to remove spiderassembly from interconnecting shaft.

Fig. 27 Spider Assembly Removal from Tripod JointHousing

Fig. 28 Spider Assembly Retaining Snap Ring

DIFFERENTIAL AND DRIVELINE 3 - 9(5) Slide sealing boot off interconnecting shaft.

SPIDER ASSEM-BLY DO NOT HIT SPIDERASSEMBLY BEARINGSWHEN REMOVING SPIDERASSEMBLYBRASSDRIFTINTERCONNECTING SHAFT SEALINGBOOT RAISED BEAD IN THISAREA OF SEALINGBOOT GROOVEINTERCONNECTING SHAFTSPIDER ASSEMBLYINTERCONNECTINGSHAFTDO NOT HIT BEARINGSWHEN INSTALLING THESPIDER ASSEMBLYSPIDER ASSEM-BLYINTERCONNECTINGSHAFTBRASSDRIFT

)(6) Thoroughly clean and inspect spider assembly,tripod joint housing, and interconnecting shaft forany signs of excessive wear. If any parts showsigns of excessive wear, the driveshaft assemblywill require replacement. Component parts ofthese driveshaft assemblies are not serviceable.

INSTALLATION

NOTE: The inner tripod joint sealing boots aremade from two different types of material. Hightemperature applications use silicone rubber whereas standard temperature applications use hytrelplastic. The silicone sealing boots are soft and pli-able. The Hytrel sealing boots are stiff and rigid.The replacement sealing boot MUST BE the sametype of material as the sealing boot which wasremoved.

(1) Slide inner tripod joint seal boot retainingclamp, onto interconnecting shaft. Then, slide thereplacement inner tripod joint sealing boot onto theinterconnecting shaft. Inner tripod joint seal bootMUST be positioned on interconnecting shaft,so the raised bead on the inside of the seal bootis in groove on interconnecting shaft (Fig. 30).

(2) Install spider assembly onto interconnectingshaft (Fig. 31). Spider assembly must be installed oninterconnecting shaft far enough to fully install spi-der retaining snap ring. If spider assembly will notfully install on interconnecting shaft by hand, it canbe installed by tapping the spider body with a brassdrift (Fig. 32). Do not hit the outer tripod bear-ings in an attempt to install spider assembly oninterconnecting shaft.

(3) Install the spider assembly to interconnectingshaft retaining snap ring into groove on end of inter-

Fig. 29 Spider Assembly Removal fromInterconnecting Shaft


DISASSEMBLY AND ASSEMBLY (ContinuedFig. 30 Sealing Boot Installation on InterconnectingShaft

Fig. 31 Spider Assembly Installation onInterconnecting Shaft

Fig. 32 Installing Spider Assembly onInterconnecting Shaft

NS/GS

INTERCONNECTINGSHAFT SPIDER ASSEM-BLYRETAININGSNAP RING TRIPOD JOINTHOUSINGSPIDER ASSEM-BLYSEALINGBOOT SPECIALTOOL C-4975AINTERCON-NECTING SHAFTCLAMPSEALINGBOOT CLAMP JAWS OF SPECIAL TOOLC-4975A MUST BECLOSED COMPLETELYTOGETHER HEREINTERCONNECTINGSHAFTSEALINGBOLT

NS/GSconnecting shaft (Fig. 33). Be sure the snap ring isfully seated into groove on interconnecting shaft.

(4) Distribute 1/2 the amount of grease provided inthe seal boot service package (DO NOT USE ANYOTHER TYPE OF GREASE) into tripod housing. Putthe remaining amount into the sealing boot.

(5) Align tripod housing with spider assembly andthen slide tripod housing over spider assembly andinterconnecting shaft (Fig. 34).

(6) Install inner tripod joint seal boot to intercon-necting shaft clamp evenly on sealing boot.

(7) Clamp sealing boot onto interconnecting shaftusing crimper, Special Tool C-4975-A and the follow-ing procedure. Place crimping tool C- 4975-A overbridge of clamp (Fig. 35). Tighten nut on crimpingtool C- 4975-A until jaws on tool are closed com-pletely together, face to face (Fig. 36).

Fig. 33 Spider Assembly Retaining Snap RingInstalled

Fig. 34 Installing Tripod Housing on SpiderAssembly

DISASSEMBLY AND ASSEMBLY (Continued)CAUTION: Seal must not be dimpled, stretched orout of shape in any way. If seal is NOT shaped cor-rectly, equalize pressure in seal and shape it byhand.

(8) Position sealing boot into the tripod housingretaining groove. Install seal boot retaining clampevenly on sealing boot.

CAUTION: The following positioning proceduredetermines the correct air pressure inside the innertripod joint assembly prior to clamping the sealingboot to inner tripod joint housing. If this procedureis not done prior to clamping sealing boot to tripodjoint housing sealing boot durability can beadversely affected.

Fig. 35 Crimping Tool Installed on Sealing BootClamp

Fig. 36 Sealing Boot Retaining Clamp Installed


INNER TRIPOD JOINT SEAL-ING BOOT SEALING BOOTCLAMP

INNER TRIPODJOINT HOUSINGTRIM STICK CLAMPTRIPODJOINTHOUSINGSPECIAL TOOLC-4975ASEALING BOOT CLAMPTRIPOD HOUSINGSPECIALTOOLC-4975AJAWS OF SPE-CIAL TOOLC-4975A MUSTBE CLOSEDCOMPLETELYTOGETHERHERESEALINGBOOT

NS/GSCAUTION: When venting the inner tripod jointassembly, use care so inner tripod sealing bootdoes not get punctured, or in any other way dam-aged. If sealing boot is punctured, or damaged inany way while being vented, the sealing boot cannot be used.

(9) Insert a trim stick between the tripod joint andthe sealing boot to vent inner tripod joint assembly(Fig. 37). When inserting trim stick between tri-pod housing and sealing boot ensure trim stickis held flat and firmly against the tripod hous-ing. If this is not done damage to the sealingboot can occur. If inner tripod joint has a Hytrel(hard plastic) sealing boot, be sure trim stick isinserted between soft rubber insert and tripod hous-ing not the hard plastic sealing boot and soft rubberinsert.

(10) With trim stick inserted between sealing bootand tripod joint housing, position the interconnectingshaft so it is at the center of its travel in the tripodjoint housing. Remove the trim stick from betweenthe sealing boot and the tripod joint housing. Thisprocedure will equalize the air pressure in thetripod joint, preventing premature sealing bootfailure.

(11) Position trilobal boot to interface with the tri-pod housing. The lobes of the boot must be properlyaligned with the recesss of the tripod housing.

(12) Clamp tripod joint sealing boot to tripod joint,using required procedure for type of boot clampapplication.

CRIMP TYPE BOOT CLAMPIf seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using

Crimper, Special Tool C-4975-A.

Fig. 37 Trim Stick Inserted for Venting Tripod Joint


DISASSEMBLY AND ASSEMBLY (Continued Place crimping tool C- 4975-A over bridge ofclamp (Fig. 38). Tighten nut on crimping tool C- 4975-A untiljaws on tool are closed completely together, face toface (Fig. 39).

LATCHING TYPE BOOT CLAMPIf seal boot uses low profile latching type boot

clamp: Clamp sealing boot onto tripod housing using

clamp locking tool, Snap-On YA3050 or an equiva-lent.

Place prongs of clamp locking tool in the holes ofthe clamp (Fig. 40).

Squeeze tool together until top band of clamp islatched behind the two tabs on lower band of clamp(Fig. 41).

(1) Install the driveshaft back on the vehicle. SeeServicing Driveshaft, for the required driveshaftinstallation procedure.

Fig. 38 Crimping Tool Installed on Sealing BootClamp

Fig. 39 Sealing Boot Retaining Clamp Installed

)

SPECIAL TOOLYA3050SEALING BOOTCLAMPINNER TRIPODJOINT HOUSING TOP BAND OF CLAMP MUST BERETAINED BY TABS AS SHOWNHERE TO CORRECTLY LATCHBOOT CLAMPSEALING BOOT DRIFTOUTER C/V JOINTBEARINGSHIELD


)OUTER C/V JOINT SEALING BOOT SERVICE

CAUTION: The outer C/V joint used on this vehicleis not a serviceable joint.

CAUTION: The outer C/V joint used on this vehicleuses a new design for retaining the cross to theinterconnecting shaft. These driveshafts incorpo-rate a slight twist (helical) in the spline on the inter-connecting shaft where the cross is installed. Thistwist causes a interference fit between the intercon-necting shaft and the cross when the outer C/Vjoint is installed on the interconnecting shaft. Thisdesign eliminates the clearance between the crossand the interconnecting shaft resulting in quieteroperation of the driveshaft assembly. This designthough eliminated the capability of removing theouter C/V joint from the interconnecting shaft. For

Fig. 40 Clamping Tool Installed on Sealing BootClamp

Fig. 41 Sealing Boot Clamp Correctly Installed

NS/GS

DISASSEMBLY AND ASSEMBLY (Continuedthis reason the driveshafts will be serviced as aquarter shaft (outer C/V joint/sealing boot, intercon-necting shaft and vibration damper) in the event ofa outer C/V joint boot failure.

OUTER C/V JOINT BEARING SHIELD SERVICEThe front hub/bearing shield on the outer C/V joint

is a serviceable component of the outer C/V. If it isdamaged in use on a vehicle or during servicing of adriveshaft it can be replaced using the following pro-cedure.

To remove the bearing shield from the outer C/Vjoint, the driveshaft assemblies must be removedfrom the vehicle. See Servicing Driveshaft, for therequired driveshaft removal and replacement proce-dure.

BEARING SHIELD REMOVAL FROM OUTERC/V JOINT

(1) Clamp driveshaft in a vise by the interconnect-ing shaft.

(2) Using a drift (Fig. 42) tap around the entireedge of the bearing shield until it is removed fromthe outer C/V Joint.

BEARING SHIELD INSTALLATION ON OUTERC/V JOINT

(1) Install bearing shield by hand on outer C/VJoint so that it is installed squarely on the C/V joint.

(2) Position installer, Special Tool, C-4698-2 andhandle, Special Tool, C-4698-1 on face of bearingshield (Fig. 43).

CAUTION: If bearing shield is not installed flushagainst the face of the outer C/V joint, interferencewith steering knuckle will occur when driveshaft isinstalled.

Fig. 42 Removing Bearing Shield from Outer C/VJoint

SPECIFICATIONS

SPECIAL TOOLC-46982 SPECIAL TOOL C-46981BEARING SHIELDOUTER C/VJOINTHAMMER SPECIAL TOOLC-46982 BEARING SHIELDBEARING SEAL MUST BEFLUSH WITH FRONT OFOUTER C/V JOINTSPECIAL TOOLC-46981


DISASSEMBLY AND ASSEMBLY (Continued)(3) Using a hammer, drive the bearing shield onthe outer C/V joint until it is flush against the frontof the outer C/V joint (Fig. 44).

Fig. 43 Special Tools for Installing Bearing Shield

Fig. 44 Correctly Installed Bearing ShieldTORQUE SPECIFICATIONS

DESCRIPTION TORQUECaliper To Knuckle Bolts . . . . . . 31 Nm (23 ft. lbs.)Driveshaft Nut . . . . . . . . . . . . 244 Nm (180 ft. lbs.)Front Wheel Lug Nuts . . . . . . 135 Nm (100 ft. lbs.)Knuckle To Ball Stud Nut . . . . . 95 Nm (70 ft. lbs.)Tie Rod End To Knuckle . . . . . . . 61 Nm (45 ft. lbs.)

SPECIAL TOOLS

DRIVESHAFTSPECIAL TOOLS

Tie Rod Remover MB-990635

Bearing Shield Installer C-4698

Boot Clamp Installer C-4975A

ENERGIZED) . . . . . . . . . . . . . . . . . . . . . . . . . 50

90% of the torque is allocated to the front wheels.The viscous coupling allows more torque to the rearwheels in accordance with the amount of the slippageat the front wheels. The variable torque distributionis automa

The reaferential w

fill plug is located on the side of the overrunningclutch case. When filling the overrunning clutch withlubricant use Mopart Type 7176 Automatic Trans-

verselutch.tic with no driver inputs required.r carrier contains a conventional open dif-ith hypoid ring gear and pinion gear set.

mission fluid or equivalent.The dog-clutch provides All Wheel Drive in re

by bridging and locking out the overrunning cDRIVE PINION SEAL AND/OR REAROVERRUNNING CLUTCH SEAL . . . . . . . . . . . 31

FRONT OVERRUNNING CLUTCH SEAL . . . . . . 28HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 45OVERRUNNING CLUTCH CASE . . . . . . . . . . . . 41

GENERAL INFORMATION

REAR DRIVELINE MODULEThe rear drive line module assembly consists of

five main parts: the rear carrier, torque tube, over-running clutch assembly, a vacuum operated dogclutch, and a viscous coupling.

The primary benefit of All Wheel Drive is: Superior straight line acceleration, and corner-

ing on all surfaces Better traction and handling under adverse con-

ditions, resulting in improved hill climbing abilityand safer driving.

The heart of the system is an inter-axle viscouscoupling. The vehicle retains predominantly front-wheel drive characteristics, but the All Wheel Drivecapability takes effect when the front wheels start toslip. Under normal level road, straight line driving,SPECIFICATIONSTHREAD SIZE CHART . . . . . . . . . . . . . . . . . . . 51TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SPECIAL TOOLSDIFFERENTIAL AND DRIVELINE . . . . . . . . . . . . 52

The hypoid gears are lubricated by SAE 80W-90 gearlubricant.

The torque tube assembly attaches to the overrun-ning clutch case. The front torque shaft bearing islocated in the torque tube. The front torque shaftbearing is permanently sealed and does not requiremaintenance. The torque shaft is located within thetorque tube assembly. The vacuum reservoir andsolenoid assembly are attached to the top of thetorque tube.

The overrunning clutch allows the rear wheels tooverrun the front wheels during a rapid front wheellock braking maneuver. The overrunning action pre-vents any feed-back of front wheel braking torque tothe rear wheels. It also allows the braking system tocontrol the braking behavior as a two wheel drive(2WD) vehicle.

The overrunning clutch has a separate oil sumpand is filled independently from the differential. TheDRIVELINE MODULE AN

IND

page

GENERAL INFORMATIONHALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 16PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 16REAR DRIVELINE MODULE . . . . . . . . . . . . . . . 15VISCOUS COUPLER . . . . . . . . . . . . . . . . . . . . . 16

DESCRIPTION AND OPERATIONREAR CARRIER COMPONENT

IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 16TORQUE TUBE AND OVERRUNNING CLUTCH

COMPONENTS IDENTIFICATION . . . . . . . . . . 18DIAGNOSIS AND TESTING

FLUID LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . 20REAR DRIVE LINE NOISE DIAGNOSIS . . . . . . . 19REAR DRIVELINE MODULE VACUUM

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 21REMOVAL AND INSTALLATION

CASE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . 35

NS/GSD REAR DRIVESHAFTS

EX

page

OVERRUNNING CLUTCH VACUUM MOTOR . . . 40OVERRUNNING CLUTCH . . . . . . . . . . . . . . . . . 43PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 38REAR CARRIER OUTPUT SHAFT SEALS . . . . . 27REAR CARRIER UNIT . . . . . . . . . . . . . . . . . . . . 26REAR DRIVE LINE MODULE ASSEMBLY . . . . . 25REAR DRIVELINE MODULE DIFFERENTIAL

SIDE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . 34VISCOUS COUPLER . . . . . . . . . . . . . . . . . . . . . 37

DISASSEMBLY AND ASSEMBLYHALF SHAFT RECONDITION . . . . . . . . . . . . . . 46TORQUE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . 47

SCHEMATICS AND DIAGRAMSVACUUM SCHEMATIC (SOLENOIDS DE-

ENERGIZED) . . . . . . . . . . . . . . . . . . . . . . . . . 51VACUUM SCHEMATIC (SOLENOIDS

DIFFERENTIAL AND DRIVELINE 3 - 15The dog-clutch is operated by a double-acting servo

using intake manifold vacuum as its power source.Two vacuum solenoids, controlled by the back uplight switch, engage and disengage the dog-clutch. Aspring in the vacuum servo disengages the dog clutchif vacuum is lost.

Located in front of the torque tube is the viscouscoupling. The viscous coupling controls and distrib-utes torque/power to the rear wheels. The coupling issimilar to a multi-plate clutch. It consists of a seriesof closely spaced discs. The discs are alternately con-nected to the front and rear drive units, which oper-ate in silicone fluid. The unit is totally sealed andpartially filled with silicone fluid. There is no adjust-ment, maintenance or fluid checks required duringthe life of the unit.

VISCOUS COUPLERThe heart of the all-wheel drive system is the

inter-axle viscous coupler. Under normal driving thevehicle retains predominantly front wheel drive char-acteristics. The all-wheel drive takes effect when thefront wheels start to slip. Under normal level road,straight line driving, 90% of the torque is allocated tothe front wheels. The viscous coupler allows more

PROPELLER SHAFTThe propeller shaft is a hollow shaft. It has a

plunging tripod joint on the front of the shaft and afixed tripod joint on the rear of the shaft. There areno serviceable parts. The shaft is serviced as anassembly. The flange patterns are different at eachend to prevent installing the shaft backwards.

HALF SHAFTThe half shaft assemblies are three piece units.

Each half shaft has one tripod joint at each end anda solid interconnecting shaft. The procedure to recon-dition the inner or outer joint is identical.

Note that lubricant requirements and quantitiescould be different than other axle shaft joints locatedon the vehicle. Only use the correct lubricant andamount supplied with the boot package or joint. Donot use standard wheel bearing grease or other lubri-cants, joint failure will result.

DESCRIPTION AND OPERATION


GENERAL INFORMATION (Continued)torque to the rear wheels in accordance with theamount of slippage at the front wheels. The variabletorque distribution is automatic with no driverinputs required.REAR CARRIER COMPONENT IDENTIFICATION

NS/GS DIFFERENTIAL AND DRIVELINE 3 - 17

DESCRIPTION AND OPERATION (Continued)

TORQUE TUBE AND OVERRUNNING CLUTCH COMPONENTS IDENTIFICATION


DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING

REAR DRIVE LINE NOISE DIAGNOSISDifferent sources can be the cause of noise that the

rear drive line module assembly is suspected of mak-ing. Refer to the following causes for noise diagnosis.

REAR CARRIER ASSEMBLY NOISEThe most important part of rear carrier service is

correctly identifying the cause of failures and noisecomplaints. The cause of most rear carrier failures isrelatively easy to identify. The cause of rear carriernoise is more difficult to identify.

If vehicle noise becomes intolerable, an effortshould be made to isolate the noise. Many noises thatare reported as coming from the rear carrier mayactually originate at other sources. For example:

Tires Road surfaces Wheel bearings Engine Transmission Exhaust Propeller shaft (vibration) Vehicle body (drumming)Rear carrier noises are normally divided into two

categories: gear noise or bearing noise. A thoroughand careful inspection should be completed to deter-mine the actual source of the noise before replacingthe rear carrier.

The rear carrier assembly rubber mounting bush-ings help to dampen-out rear carrier noise when cor-rectly installed. Inspect to confirm that no metalcontact exists between the rear carrier case and thebody. The complete isolation of noise to one arearequires expertise and experience. Identifying certaintypes of vehicle noise baffles even the most capabletechnicians. Often such practices as:

Increase tire inflation pressure to eliminate tirenoise.

Listen for noise at varying speeds with differentdriveline load conditions

Swerving the vehicle from left to right to detectwheel bearing noise.

All rear carrier assemblies produce noise to a cer-tain extent. Slight carrier noise that is noticeableonly at certain speeds or isolated situations should beconsidered normal. Carrier noise tends to peak at avariety of vehicle speeds. Noise is NOT ALWAYS anindication of a problem within the carrier.

TIRE NOISETire noise is often mistaken for rear carrier noise.

Tires that are unbalanced, worn unevenly or areworn in a saw-tooth manner are usually noisy. They

NS/GSoften produce a noise that appears to originate in therear carrier.Tire noise changes with different road surfaces, butrear carrier noise does not. Inflate all four tires withapproximately 20 psi (138 kPa) more than the recom-mended inflation pressure (for test purposes only).This will alter noise caused by tires, but will notaffect noise caused by the differential. Rear axlenoise usually ceases when coasting at speeds lessthan 30 mph (48 km/h); however, tire noise contin-ues, but at a lower frequency, as the speed isreduced.

After test has been completed lower tire pressureback to recommended pressure.

GEAR NOISE (DRIVE PINION AND RING GEAR)Abnormal gear noise is rare and is usually caused

by scoring on the ring gear and drive pinion. Scoringis the result of insufficient or incorrect lubricant inthe carrier housing.

Abnormal gear noise can be easily recognized. Itproduces a cycling tone that will be very pronouncedwithin a given speed range. The noise can occur dur-ing one or more of the following drive conditions:

Drive Road load Float CoastAbnormal gear noise usually tends to peak within

a narrow vehicle speed range or ranges. It is usuallymore pronounced between 30 to 40 mph (48 to 64km/h) and 50 to 60 mph (80 to 96 km/h). When objec-tionable gear noise occurs, note the driving condi-tions and the speed range.

BEARING NOISE (DRIVE PINION ANDDIFFERENTIAL)

Defective bearings produce a rough growl that isconstant in pitch and varies with the speed of vehi-cle. Being aware of this will enable a technician toseparate bearing noise from gear noise.

Drive pinion bearing noise that results from defec-tive or damaged bearings can usually be identified byits constant, rough sound. Drive pinion front bearingis usually more pronounced during a coast condition.Drive pinion rear bearing noise is more pronouncedduring a drive condition. The drive pinion bearingsare rotating at a higher rate of speed than either thedifferential side bearings or the axle shaft bearing.

Differential side bearing noise will usually producea constant, rough sound. The sound is much lower infrequency than the noise caused by drive pinion bear-ings.

Bearing noise can best be detected by road testingthe vehicle on a smooth road (black top). However, itis easy to mistake tire noise for bearing noise. If adoubt exists, the tire treads should be examined forirregularities that often causes a noise that resem-

DIFFERENTIAL AND DRIVELINE 3 - 19bles bearing noise.

ENGINE AND TRANSMISSION NOISESometimes noise that appears to be in the rear car-

rier assembly is actually caused by the engine or thetransmission. To identify the true source of the noise,note the approximate vehicle speed and/or RPMwhen the noise is most noticeable. Stop the vehiclenext to a flat brick or cement wall (this will helpreflect the sound). Place the transaxle in NEUTRAL. Accelerate the engine slowly up through the enginespeed that matches the vehicle speed noted when thenoise occurred. If the same noise is produced, it usu-ally indicates that the noise is being caused by theengine or transaxle.

FLUID LEAK DIAGNOSISWhen diagnosing fluid leaks on the rear drive line

module assembly two weep holes are provided todiagnose certain seal leaks. These holes are locatedon the bottom side of the assembly (Fig. 1).

If fluid leak is detected from either weep hole, sealreplacement is necessary. Do not attempt to repair

If fluid is leaking from weep hole B (Fig. 1) thetype of fluid leaking will determine which seal isleaking. If the fluid leaking is red in color (transmis-sion fluid) this indicates that the rear overrunningclutch seal should be replaced. If the fluid leaking is

Fig. 1 Weep Hole Locations


DIAGNOSIS AND TESTING (Continued)the leak by sealing weep holes, they must be keptclear of sealants for proper seal operation.

If fluid is leaking from weep hole A (Fig. 1) and itis automatic transmission fluid, the front overrun-ning clutch seal is leaking. For replacement of thisseal, refer to Rear Drive Line Assembly Service Pro-cedures.light brown (hypoid gear lube) this indicates that thedrive pinion seal should be replaced. For replacementof these seals refer to Rear Drive Line Assembly Ser-vice Procedures.

REAR WHEELS NOT OVER-RUNNINGINSPECT FOR BURRS,KNICKS, ETC.; REPAIR ASREQUIREDORC SPRAGS INSTALLEDBACKWARDS?INSTALL ORC ASSEMBLYCORRECTLYDOG CLUTCH JAMMED ONSPLINE?VAC. ACTUATION FUNC-TIONING?DOG CLUTCH STUCKENGAGED?ORC SPRAGS FAILED?REPLACE OVERRUNNINGCLUTCH COMPONENTS ASREQUIREDDOG CLUTCH BOUND UP(TORSIONAL WIND-UP)INSPECT DOG CLUTCH ANDUN-JAMVACUUM HOSES MIS-ROUTED?REROUTE VACUUM HOSESCORRECTLYREPLACE REVERSE LAMPRELAYSHIFT FORK INTERFER-ENCE?REPAIR INTERFERENCEPROBLEM AS REQUIREDHAS ELEC. SIGNAL, VEH.NOT IN REVERSE*FAILED REVERSE LAMPRELAY?REPAIR SHORT IN WIRINGHARNESSREPLACE VACUUM MOTORREPLACE SPRING ANDREPAIR VACUUM SYSTEMVACUUM SOLENOIDSFAILED?REPLACE VACUUM SOLE-NOIDSFAILED REVERSE LAMPSWITCH?VAC. MOTOR FAILURE?LOSS OF VAC. & ORC.SPRING (SAME TIME)VENT PLUGGED?UNPLUG VENT SYSTEMREPLACE REVERSE LAMPSWITCHYESYESYESNONOYESNONOYESYESYESNONOYESYESYESNONONOYESYESNOYESNONOYESYES*TO DRIVELINE SOLENOIDSREAR DRIVELINE MODULE VACUUM DIAGNOSIS


DIAGNOSIS AND TESTING (Continued)REAR WHEELS NOT OVERRUNNING

NO AWD. IN FORWARD;PROPSHAFT TURNING

REPLACE PARTS ASREQUIREDNO AWD FORWARD ORREVERSE

REPLACE VISCOUS COUPLENO ALL WHEEL DRIVE IN FORWARD, PROPELLERSHAFT TURNING


DIAGNOSIS AND TESTING (Continued)NO ALL WHEEL DRIVE FORWARD OR REVERSE

NO AWD, REVERSE ONLY;PROPSHAFT TURNING

INSTALL MISSING PARTSNO ALL WHEEL DRIVE, REVERSE ONLY;PROPELLER SHAFT TURNING


DIAGNOSIS AND TESTING (Continued)

DOG CLUTCH JAMMED DIS-ENGAGED?

NO

3 - 24 DIFFERENTIAL AND DRIVELINE NS/GSDIAGNOSIS AND TESTING (Continued)NO ALL WHEEL DRIVE, REVERSE ONLY;PROPELLER SHAFT TURNING (CONT.)

SHAFTFLANGETORQUE SHAFT HOLDINGTOOLPROPELLER SHAFT

REAR CARRIER RETAININGBOLT

RUBBER ISOLATOR

FRONT MOUNTING BOLTSREMOVAL AND INSTALLATION

REAR DRIVE LINE MODULE ASSEMBLY

REMOVAL(1) Raise vehicle on hoist.(2) Remove right and left inner half shaft joint

mounting bolts (Fig. 2).

(3) Support inner side of half shaft with mechanicswire or equivalent. Do not allow half shafts to hangfreely.

(4) Remove mounting bolts from the rear side ofpropeller shaft (Fig. 3).

CAUTION: Do not allow propeller shaft to hangfreely

(5) Support propeller shaft with mechanics wireand/or jack stand

(6) Disconnect main vacuum line for rear drive

Fig. 2 Half Shaft Mounting Bolts

Fig. 3 Propeller Shaft Mounting Bolts

NS/GSline module assembly. Also disconnect electrical con-nections at the front of the module.(7) Support rear drive line module assembly withtransmission jack or equivalent.

WARNING: BE SURE TO CHAIN REAR DRIVE LINEMODULE ASSEMBLY SECURELY TO THE JACK TOPREVENT IT FROM FALLING.

(8) Remove rear drive line module assembly rearmounting bolts (Fig. 4).

(9) Remove rear drive line module assembly frontmounting bolts (Fig. 5).

(10) Partially lower rear drive line module assem-bly and disconnect remote solenoid vent and remotecarrier vent.

(11) Remove rear drive line module assembly.

INSTALLATION(1) To install, reverse removal procedure. Refer to

TORQUE SPECIFICATION in the rear of this sec-

Fig. 4 Rear Drive Line Module Assembly RearMounting Bolts

Fig. 5 Rear Drive Line Module Front Mounting Bolts

DIFFERENTIAL AND DRIVELINE 3 - 25tion for tightening specifications.

REAR CARRIER UNIT

REMOVAL(1) Remove rear drive line module assembly from

vehicle.(2) Drain oil from overrunning clutch case.(3) Remove overrunning clutch case to rear carrier

case bolts (Fig. 6).

REAR CARRIER CASEOVERRUNNING CLUTCHCASE REAR CARRIER CASEOVERRUNNING CLUTCHCASE


REMOVAL AND INSTALLATION (Continued)(4) Separate rear carrier case from overrunningclutch case (Fig. 7).

INSTALLATION(1) For installation, reverse removal procedure.

Fig. 6 Overrunning Clutch Case To Rear CarrierCase BoltsFig. 7 Separate Rear Carrier Case FromOverrunning Clutch Case

DRIVE PINION SEALOUTPUT SHAFT SEALREAR CARRIER CASEOVERRUNNING CLUTCHCASE

SHAFTFLANGE WOOD BLOCKPRYBAROUTPUT SHAFTPRYBAR

NS/GSREAR CARRIER OUTPUT SHAFT SEALSThe rear drive line module assembly does not have

to be removed from vehicle to service the carrier out-put shaft seals.

The output flange seals are located on the rear car-rier unit (Fig. 8).

REMOVAL(1) Remove inner half shaft retaining bolts (Fig. 9).

(2) Support inner side of half shaft with mechanicswire or equivalent.

(3) Using two pry bars and wooden support blocks,pop out output shaft (Fig. 10).

Fig. 8 Rear Drive Line Module Oil Seal Location

Fig. 9 Inner Half Shaft BoltsREMOVAL AND INSTALLATION (Continued)CAUTION: Do not allow half shafts to hang freelyDIFFERENTIAL AND DRIVELINE 3 - 27Fig. 10 Output Flange Removal

(4) Using a pry bar, pry out oil seal (Fig. 11), beingcareful not to damage race.

REAR CARRIER CASEPRYBAROUTPUT SHAFT SEALREAR CARRIER CASEHAMMER

SPECIAL TOOLMD998334OUTPUT FLANGEREAR CARRIERREAR CARRIER CASEOVERRUNNING CLUTCHCASE


REMOVAL AND INSTALLATION (Continued)INSTALLATION(1) Clean and inspect shaft and seal area.(2) Install oil seal with special tool MD998334

(Fig. 12).

(3) Install output shaft (Fig. 13). Lightly tap shaftto seat retainer ring into differential side gear.

(4) Check differential fluid level, fill as required.

Fig. 11 Seal Removal

Fig. 12 Installing Oil SealFRONT OVERRUNNING CLUTCH SEALThe rear drive line module must be removed to ser-

vice this seal.The front overrunning clutch seal is located in the

overrunning clutch case.


vehicle.(2) Remove viscous coupling unit.(3) Remove overrunning clutch cover assembly.(4) Drain fluid from overrunning clutch case.(5) Remove overrunning clutch case to rear carrier

bolts (Fig. 14).

Fig. 13 Installing Output Shaft

Fig. 14 Overrunning Clutch Case To Rear Carrier

NS/GSBolts

REAR CARRIER CASEOVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHCASE

OVERRUNNING CLUTCHINNER RACE OVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHCASEBEARING SHIELDSNAP RING

NS/GS(6) Separate overrunning clutch case from rearcarrier case (Fig. 15).

(7) Remove overrunning clutch inner race snapring (Fig. 16).

(8) Slide overrunning clutch inner race off of shaft(Fig. 17).

(9) Remove shaft snap ring and slide dog clutch offof the shaft (Fig. 18).

CAUTION: Note the position that the snap ring wasremoved. The snap ring can be accidentallyinstalled backwards. The snap ring is concave andthe fingers on the snap ring must angle towards the

Fig. 15 Separate Housings

Fig. 16 Inner Race Snap Ring Removal

REMOVAL AND INSTALLATION (Continued)bearing shield.(10) Remove torque shaft snap ring (Fig. 19) andtorque tube bearing shield.

Fig. 17 Remove Overrunning Clutch Inner Race

OVERRUNNING CLUTCHINNER RACE

Fig. 18 Remove Snap Ring

SNAP RING

Fig. 19 Remove Torque Shaft Snap Ring And

TORQUE TUBE

DIFFERENTIAL AND DRIVELINE 3 - 29Torque Tube Bearing Shield

OVERRUNNING CLUTCHCASE

OUTER TORQUE SHAFTBEARING SNAP RINGSPECIAL TOOLC-4967(11) Remove torque tube retaining bolts (Fig. 20).

(12) Remove inner torque shaft bearing snap ring.(13) Separate overrunning clutch case from torque

tube.(14) Remove rear torque shaft bearing retaining

outer snap ring in overrunning clutch case (Fig. 21).

(15) Remove rear torque shaft bearing.(16) Drive out seal with special tool C-4967 (Fig.

Fig. 20 Torque Tube Bolts

Fig. 21 Torque Shaft Rear Bearing Snap Ring


REMOVAL AND INSTALLATION (Continued)22).INSTALLATION(1) Clean and inspect shaft sealing surface and

case for nicks or grooves. Replace as required.(2) Install new seal with special tool MD998334.

Seal should be flush with outside edge of case (Fig.23).

(3) Install rear torque shaft bearing and outersnap ring.

(4) Install overrunning clutch case onto torquetube. Tighten bolts to 28 Nm (250 in. lbs.).

(5) Install torque shaft inner snap ring.(6) Slide dog clutch onto shaft and install snap

ring.(7) Slide overrunning clutch inner race onto shaft

and install retaining snap ring (tapered end of innerrace must face outward).

(8) Clean all sealing surfaces. Apply a bead ofMopar Gasket Maker or equivalent and reinstall theoverrunning clutch housing to the rear carrier case.Install retaining bolts and tighten to 28 Nm (250 in.lbs.).

(9) Apply Mopart Gasket Maker or equivalent andreinstall overrunning clutch cover. When installingcover be sure that the overrunning clutch forkengages into the overrunning clutch dog.

Fig. 22 Seal Removal

NS/GS(10) Install rear drive line module assembly intovehicle.

SPECIAL TOOLMD998334 REAR CARRIER CASEOVERRUNNING CLUTCHCASEREAR CARRIER CASEOVERRUNNING CLUTCHCASE


REMOVAL AND INSTALLATION (Continued)(11) Check and fill fluid levels as required.

DRIVE PINION SEAL AND/OR REAROVERRUNNING CLUTCH SEAL

The rear drive line module must be removed to ser-vice these seals. The drive pinion seal is located inthe front carrier cover, behind the overrunning clutchrear seal. The overrunning clutch seal must beremoved to gain access to the drive pinion seal. Donot reuse overrunning clutch seal.

REMOVAL(1) Remove rear drive line module from vehicle.(2) Remove overrunning clutch case to rear carrier

bolts (Fig. 24).(3) Separate overrunning clutch case from differen-

tial carrier case (Fig. 25).

Fig. 23 Installing New SealFig. 24 Overrunning Clutch Case To Rear CarrierBolts

Fig. 25 Separate Cases

OVERRUNNING CLUTCHOUTER RACE

SNAP RING

PINIONOVERRUNNING CLUTCHOUTER RACE PINION NUTSPECIAL TOOL6534FRONT CARRIER COVERFRONT CARRIER COVERCARRIER CASESHIM(4) Remove overrunning clutch outer race snapring (Fig. 26).

(5) Slide overrunning clutch outer race off of shaft(Fig. 27).

(6) Using Spline Socket Tool 6534 and a wrench,remove pinion nut (Fig. 28).

(7) Remove front carrier cover retaining screws(Fig. 29).

(8) Remove front carrier cover from carrier case(Fig. 30).

(9) Place a block of wood under the end of the pin-ion shaft. Tap end of pinion against the wood to drivethe pinion spacer off of the pinion shaft (Fig. 31).

CAUTION: Shim should be installed with front car-rier cover. This will eliminate the potential of cuttingthe O-Ring with the shim.

(10) Reinstall front carrier cover into carrier case

Fig. 26 Overrunning Clutch Snap Ring Removal

Fig. 27 Overrunning Clutch Outer Race Removal


REMOVAL AND INSTALLATION (Continued)(Fig. 32). Install carrier retaining bolts and tighten to12 Nm (105 in. lbs.).(11) Use seal puller 7794-A (Fig. 33) to remove theoverrunning clutch seal and drive pinion seal. The

Fig. 28 Remove Pinion Nut

Fig. 29 Front Carrier Cover Retaining Screws

Fig. 30 Front Carrier Cover

NS/GSoverrunning clutch seal must be removed first togain access to the drive pinion seal. The overrunning

FRONT CARRIER COVERPINION SHAFTWOOD BLOCKPINION SPACER

FRONT CARRIER COVERFRONT CARRIER COVERCARRIER CASESPECIAL TOOL7794A

HAMMERSPECIAL TOOL6507

FRONT CARRIER COVERDRIVE PINION SPACER

DIFFERENTIAL AND DRIVELINE 3 - 33clutch seal must be replaced after the drive pinionseal is installed, do not reuse old seal.

Fig. 31 Removing Drive Pinion Spacer

Fig. 32 Reinstalling Front Carrier Cover

Fig. 33 Removing Seals

NS/GS

REMOVAL AND INSTALLATION (Continued)INSTALLATION(1) Clean and inspect seal area.(2) Apply a light coat of oil onto the drive pinion

seal and install with Seal Installer 6507. Seal mustbe installed with the spring side in towards the rearcarrier case (Fig. 34).

CAUTION: If the drive pinion spacer is grooved ordamaged it must be replaced. A new drive pinionbearing shim may be required. Refer to Drive PinionBearing Shim Selection in this section before con-tinuing with this procedure.

(3) Apply a light coat of oil onto the drive pinionspacer. Then slide onto the pinion shaft with thetapered side facing outward (Fig. 35).

Fig. 34 Input Seal Installation

Fig. 35 Installing Drive Pinion Spacer OntoPinion

HAMMERSPECIAL TOOL6508

MICROMETERDRIVE PINION SPACER

)(4) Apply a light coat of oil onto the overrunningclutch seal and install with Seal Installer 6508. Sealmust be installed with the spring side away from therear carrier case (Fig. 36).

(5) Clean pinion nut and pinion shaft threads withMopart Brake and Parts Cleaner, Loctite CleaningPrimer or equivalent.

(6) Apply Mopart Lock and Seal Adhesive to boththe pinion nut and pinion shaft threads.

(7) Install pinion and tighten nut to 380 Nm (280ft. lbs.) torque.

(8) Wipe off all excess adhesive.(9) Install overrunning clutch outer race and snap

ring.(10) Apply Loctite Sealer to overrunning clutch

sealing surface and reinstall the overrunning clutchcase to rear carrier case.

(11) Reinstall rear drive line module assembly intothe vehicle.

(12) Check and fill all fluids as required.

DRIVE PINION BEARING SHIM SELECTIONThis procedure must be performed whenever the

drive pinion spacer has been replaced.(1) Using a one inch micrometer, measure the

thickness of the original spacer (Fig. 37).(2) Measure the thickness of the new spacer the

same way that the original spacer was measured.(3) The difference in the measurements of the old

spacer and the new spacer will determine whichshim to use.

(4) If the new drive pinion spacer is the samethickness as the original, use the original shim.

(5) If the new drive pinion spacer is thinner thanthe original drive pinion spacer, a thicker shim mustbe used. This will compensate for the difference in

Fig. 36 Overrunning Clutch Seal Installation


REMOVAL AND INSTALLATION (Continuedsize.(a) Determine the difference in size between thenew spacer and the original spacer. Record thisdimension.

(b) Measure the thickness of the original shim.Record this dimension.

(c) Add together the two dimensions recorded insteps (a) and (b). Use a new shim that is equal tothis size.For Example: The new spacer is 0.010 thinner

than the original spacer. The original shim measures0.205. Adding 0.205 and 0.010 equals a new shimthickness of 0.215.

(6) If the new drive pinion spacer is thicker thanthe original drive pinion spacer, a thinner shim mustbe used. This will compensate for the difference insize.

(a) Determine the difference in size between thenew spacer and the original spacer. Record thisdimension.

(b) Measure the thickness of the original shim.Record this dimension.

(c) Subtract the dimensions recorded in step (a)from the dimension recorded in step (b). Use a newshim that is equal to this size.For Example: The new spacer is 0.010 thicker than

the original spacer. The original shim measures0.205. Subtracting 0.010 from 0.205 equals a newshim thickness of 0.195.

REAR DRIVELINE MODULE DIFFERENTIAL SIDEGEARS

Fig. 37 Measuring Drive Pinion Spacer Thickness

NS/GS(1) Disconnect both half shafts from rear drivelinemodule.

WOOD BLOCKPRYBAROUTPUT SHAFTPRYBAR

CARRIER END COVER(2) Using two pry bars, pop out output shaft (Fig.38).

(3) Remove output shaft.(4) Remove end cover retaining bolts (Fig. 39).

(5) Remove differential end cover.(6) Remove differential assembly from rear driv-

eline case.

Fig. 38 Output Flange Removal

Fig. 39 Remove End Cover Bolts

NS/GS

REMOVAL AND INSTALLATION (Continued)(7) Remove ring gear bolts and separate differen-tial case from differential body.(8) Using a punch and hammer remove the differ-ential pinion shaft pin.

(9) Slide differential pinion shaft out of differentialcase.

(10) Inspect and replace pinion gears, pinion shaftor pinion washers as required.

(11) Reverse steps 7 through 10 to assemble differ-ential. Torque the ring gear bolts to 95 Nm (70 ft.lbs.).

(12) Install differential assembly into drivelinemodule case.

(13) Clean and inspect sealer surfaces.(14) Apply Mopart Gasket Maker or equivalent

and install end cover. Tighten to 28 Nm (250 in.lbs.).

(15) Tighten bolts in proper sequence (Fig. 40).Retighten first bolt after all others are tight.

(16) Install output shafts(17) Reconnect both half shafts.(18) Fill differential to the bottom of the fill hole

with proper lubricant.

CASE SEALS

DIFFERENTIAL CARRIER END COVER(RESEAL)

(1) Remove left half shaft.(2) Using two pry bars, pop out output shaft (Fig.

41).(3) Remove output shaft.(4) Remove end cover retaining bolts (Fig. 42).

Fig. 40 Bolt Tightening Sequence

DIFFERENTIAL AND DRIVELINE 3 - 35(5) Remove differential end cover.

WOOD BLOCKPRYBAROUTPUT SHAFTPRYBAR

REAR CARRIER CASEOVERRUNNING CLUTCHCASE REAR CARRIER CASEOVERRUNNING CLUTCHCASE(6) Clean and inspect sealer surfaces.(7) Apply Mopart Gasket Maker or equivalent and

install end cover. Tighten to 28 Nm (250 in. lbs.).(8) Tighten bolts in the sequence shown in (Fig.

43). Retighten first bolt after all others are tight.(9) Fill differential to the bottom of the fill hole

(level unit) with SAE 80W-90 gear lubricant.

Fig. 41 Output Flange Removal

Fig. 42 Remove End Cover Bolts


REMOVAL AND INSTALLATION (Continued)OVERRUNNING CLUTCH COVER (RESEAL)(1) Remove rear drive line module assembly from

vehicle.(2) Remove overrunning clutch cover assembly


(3) Lift overrunning clutch cover off of overrunningclutch housing.

(4) Clean and inspect sealing surfaces.(5) Apply Mopart Gasket Maker or equivalent and

reinstall cover and vacuum hose clip. When installingcover be sure that the overrunning clutch forkengages into the overrunning clutch dog.

(6) Install overrunning clutch cover mounting boltsand tighten bolts to 28 Nm (250 in. lbs.).

Fig. 43 Bolt Tightening Sequence

Fig. 44 Mounting Bolts

NS/GS

REAR CARRIER CASEOVERRUNNING CLUTCHCASE OVERRUNNING CLUTCHCASETORQUE SHAFT HOLDINGTOOLPROPELLER SHAFT(7) Reinstall rear drive line module assembly intovehicle.

(8) Check and fill fluid levels as required. Use onlyMOPARt TYPE 7176 Automatic Transmission Fluidor equivalent in the overrunning clutch case.

OVERRUNNING CLUTCH CASE TO REARCARRIER CASE (RESEAL)

(1) Remove rear drive line module assembly fromvehicle.

(2) Drain fluid from overrunning clutch case.(3) Remove overrunning clutch case to rear carrier

bolts (Fig. 45).

(4) Separate overrunning clutch case from rearcarrier unit (Fig. 46).

(5) Clean and inspect sealing surfaces.(6) Apply a bead of Mopart Gasket Maker, or

equivalent to sealing surfaces and reassemble.(7) Reinstall rear drive line module assembly.(8) Check and fill fluid levels as required. Use only

MOPARt TYPE 7176 Automatic Transmission Fluidor equivalent in the overrunning clutch housing.

VISCOUS COUPLERThe heart of the all-wheel drive system is the

inter-axle viscous coupler. Under normal driving thevehicle retains predominantly front wheel drive char-acteristics. The all-wheel drive takes effect when thefront wheels start to slip. Under normal level road,straight line driving, 90% of the torque is allocated tothe front wheels. The viscous coupler allows more

Fig. 45 Overrunning Clutch Case To RearCarrierBolts

NS/GS

REMOVAL AND INSTALLATION (Continued)torque to the rear wheels in accordance with theamount of slippage at the front wheels. The variabletorque distribution is automatic with no driverinputs required.

REMOVAL(1) Hoist vehicle, Refer to Group 2, Lubrication

and Maintenance.(2) Mark flange at propeller shaft and viscous cou-

pler for reference.(3) Install a thin 1-1/4 inch open-end (Snap-On

LTA4042 or equivalent) wrench behind the viscouscoupler. Slip the wrench onto the flats of the torqueshaft.

(4) Remove bolts at propeller shaft flange (Fig. 47).

Fig. 46 Separate Rear Carrier Case FromOverrunningClutch Case

Fig. 47 Propeller Shaft Bolts


PROPELLER SHAFT SUP-PORT

PROPELLER SHAFT

VISCOUS COUPLERSHAFT HOLDING TOOL VISCOUS COUPLERVISCOUS COUPLERPROPELLER SHAFTTORQUE WRENCH


REMOVAL AND INSTALLATION (Continued)(5) Remove shaft from coupler and secure shaft tounderbody (Fig. 48). Do not let the propeller shafthang freely, damage may occur.

(6) Hold the torque shaft from turning. Removeviscous coupler retaining nut (Fig. 49).

(7) Slide coupler off torque shaft (Fig. 50).

INSTALLATION(1) Slide viscous coupler onto torque shaft.(2) Install a thin 1-1/4 inch open-end (Snap-On

LTA4042 or equivalent) wrench onto the flats of thetorque shaft. Install NEW viscous coupler retainingnut. Tighten retaining nut to 244 Nm (180 ft. lbs.).

(3) Detach the propeller shaft from support strap.(4) Position propeller shaft at the reference marks.(5) Install propeller shaft bolts (Fig. 51). Tighten

bolts to 28 Nm (250 in. lbs.).

Fig. 48 Support Propeller Shaft

Fig. 49 Retaining Nut RemovalPROPELLER SHAFT

REMOVAL(1) Place vehicle in neutral and lift vehicle on

hoist.(2) Mark orientation of propeller shaft rear flange.

CAUTION: Do not allow end of propeller shaft tohang free.

(3) Remove propeller shaft rear mounting boltsand support end of propeller shaft (Fig. 52).

Fig. 50 Viscous Coupler Removal

Fig. 51 Tighten Propeller Shaft RetainingBolts

TORQUE SHAFT HOLDINGTOOLPROPELLER SHAFTMARK FLANGEP.T.U. OUTPUT SHAFT


REMOVAL AND INSTALLATION (Continued)(4) Mark orientation of propeller shaft front flange(Fig. 53).

(5) Remove propeller shaft front mounting boltsand remove propeller shaft assembly (Fig. 54).

CAUTION: Do not allow the propeller shaft to hangfreely while installing.

Fig. 52 Propeller Shaft Mounting Bolts (Rear)

Fig. 53 Mark Propeller Shaft Front FlangeINSTALLATION(1) Match up marks on front flange of the propel-

ler shaft to the marks on the P.T.U. output shaft.(2) Mate front flange of the propeller shaft to the

P.T.U. output shaft.(3) Support the rear of the propeller shaft.(4) Install the front flange retaining bolts (Fig. 55).

Tighten bolts to 28 Nm (250 in. lbs.).

(5) Match up marks on rear flange of the propellershaft to the marks on the viscous coupler.

(6) Mate rear flange of the propeller shaft to theviscous coupler.

(7) Install the rear flange retaining bolts. Tightenbolts to 28 Nm (250 in. lbs.).

Fig. 54 Propeller Shaft Bolts (Front)

Fig. 55 Tighten Propshaft FrontFlange Bolts

P.T.U. OUTPUT SHAFTTORQUE WRENCHPROPELLER SHAFT

REAR CARRIER CASEOVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHCOVER

SOFT JAWED VISE

3 - 40 DIFFERENTIAL AND DRIVELINEOVERRUNNING CLUTCH VACUUM MOTOR


vehicle.(2) Cut clamps and disconnect vacuum hose to vac-

uum motor.(3) Remove overrunning clutch cover assembly


(4) Lift overrunning clutch cover assembly off ofoverrunning clutch case.

(5) Clamp assembly in soft jawed vise (Fig. 57).

(6) Remove three E-clips from vacuum motor shaft

Fig. 56 Mounting Bolts

Fig. 57 Clamp Housing In Vise

REMOVAL AND INSTALLATION (Continued)(Fig. 58).(7) Holding the overrunning clutch shift fork, slideshift motor out of housing (Fig. 59).

CAUTION: Shift fork can be installed backwards.Note its position before removing.

(8) Clean and inspect all parts and sealing sur-faces. Replace worn or damaged parts.

Fig. 58 Remove Three E-Clips

SCREW DRIVEROVERRUNNING CLUTCHCOVER

Fig. 59 Shift Fork Removal

OVERRUNNING CLUTCHCOVER

NS/GS

SHAFT FORK OFF SET REAR CARRIER CASEOVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHCASE


)INSTALLATION(1) Slide vacuum shift motor into housing and

through shift fork. Shift fork offset must angle awayfrom vacuum motor (Fig. 60).

(2) Install three E-clips. Two onto vacuum shiftmotor shaft and one on the vacuum motor bushing.

(3) Apply Mopart Gasket Maker or equivalent andreinstall cover. When installing cover be sure thatthe overrunning clutch fork engages into the over-running clutch dog.

(4) Install overrunning clutch cover assemblymounting bolts. Tighten bolts to 28 Nm (250 in. lbs.).Replace hose clamps.

(5) Reinstall rear drive line assembly into vehicle.(6) Check and fill fluid levels as required.

OVERRUNNING CLUTCH CASE

REMOVAL(1) Remove rear drive line module assembly.(2) Remove overrunning clutch cover assembly.(3) Drain fluid from overrunning clutch case.(4) Remove overrunning clutch case to rear carrier

case bolts (Fig. 61).(5) Separate the overrunning clutch housing from

the rear carrier case.(6) Remove overrunning clutch inner race snap

ring (Fig. 62).(7) Slide overrunning clutch inner race off of the

shaft.(8) Remove dog-clutch snap ring and slide dog-

clutch off of the shaft.

Fig. 60 Shift Fork Position

NS/GS

REMOVAL AND INSTALLATION (Continued(9) Remove torque shaft rear bearing snap ring.(10) Remove torque tube retaining bolts (Fig. 63).(11) Separate overrunning clutch case from torquetube.

(12) Remove rear bearing retaining snap ring inoverrunning clutch case (Fig. 64).

(13) Remove rear torque shaft bearing.(14) Drive out front overrunning clutch seal with

special tool C-4967 (Fig. 65).

INSTALLATION(1) Install new seal with special tool MD998334. Seal

should be flush with outside edge of housing (Fig. 66).(2) Install rear torque shaft bearing and snap ring.(3) Install overrunning clutch case onto torque

tube. Tighten bolts to 28 Nm (250 in. lbs.).(4) Install torque shaft snap ring.(5) Slide dog clutch onto shaft and install snap ring.

Fig. 61 Overrunning Clutch Case To Rear Carrier Bolts

Fig. 62 Inner Race Snap Ring


SPECIAL TOOL C-4967SPECIAL TOOL MD998334OVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHCASE

OUTER TORQUE SHAFTBEARING SNAP RING(6) Slide overrunning clutch inner race onto shaftand install retaining snap ring.

(7) Clean all sealing surfaces. Then apply a bead ofMopart Gasket Maker or equivalent. Then reinstall theoverrunning clutch case to the rear carrier case. Installretaining bolts and tighten to 28 Nm (250 in. lbs.).

(8) Apply Mopart Gasket Maker or equivalent andreinstall vacuum shift cover. When installing coverbe sure that the overrunning clutch fork engages intothe overrunning dog clutch.




REMOVAL AND INSTALLATION (Continued)(9) Install rear drive line module into vehicle.(10) Check and fill all fluid levels as required.Fig. 65 Seal Removal

NS/GSFig. 66 Installing New Seal

(6) Remove overrunning clutch snap ring (Fig. 69).

REAR CARRIER CASEOVERRUNNING CLUTCHCASEREAR CARRIER CASEOVERRUNNING CLUTCHCASE REAR CARRIER CASEOVERRUNNING CLUTCHSNAP RINGOVERRUNNING CLUTCHOUTER RACE


OVERRUNNING CLUTCH

DIFFERENTIAL AND DRIVELINE 3 - 43OVERRUNNING CLUTCH

REMOVAL(1) Remove rear drive line module assembly.(2) Remove overrunning clutch cover assembly.(3) Drain fluid from overrunning clutch case.(4) Remove overrunning clutch case to rear carrier

case bolts (Fig. 67).

(5) Separate the overrunning clutch case from therear carrier case (Fig. 68).

Fig. 67 Overrunning Clutch Case To Rear Carrier Bolts

NS/GS

REMOVAL AND INSTALLATION (Continued)Fig. 68 Separate Rear Carrier Case FromOverrunning Clutch Case(7) Remove spacers and overrunning clutch. Over-running clutch can be installed backwards. Keep thespacers and overrunning clutch in order when takingthe unit apart (Fig. 70).

Fig. 69 Overrunning Clutch Snap Ring

Fig. 70 Overrunning Clutch Removal


SNAP RING

PINIONOVERRUNNING CLUTCHOUTER RACE OVERRUNNING CLUTCHCASE




SNAP RINGOVERRUNNING CLUTCHCASE(8) Remove overrunning clutch outer race snapring (Fig. 71).

(9) Slide overrunning clutch outer race off of shaft(Fig. 72).

(10) Remove overrunning clutch inner race snapring (Fig. 73).

(11) Slide overrunning clutch inner race off of theshaft (Fig. 74).

(12) Remove dog-clutch snap ring (Fig. 75).(13) Slide dog-clutch off of the shaft (Fig. 76).(14) Clean and inspect all parts. Replace worn or

damaged parts.

INSTALLATION(1) Install outer overrunning clutch race and

retaining snap ring.(2) Install overrunning clutch spacers and snap

ring.

Fig. 71 Overrunning Clutch Snap Ring Removal

Fig. 72 Overrunning Clutch Outer Race Removal


REMOVAL AND INSTALLATION (Continued)CAUTION: The overrunning clutch can be installedbackwards.(3) To check for proper installation of the overrun-ning clutch, temporarily install the inner race intothe overrunning clutch. The tapered end must go in


Fig. 74 Remove Overrunning Clutch Race

Fig. 75 Dog Clutch Snap Ring

NS/GSfirst (Fig. 77). The inner race should spin when


DOG CLUTCH






OVERRUNNING CLUTCHINNER RACEturned counterclockwise (Fig. 78) and grab whenturned clockwise (Fig. 79).

Fig. 76 Dog Clutch Removal

Fig. 77 Temporarily Install Inner Race

Fig. 78 Turn Inner Race Counterclockwise

NS/GS

REMOVAL AND INSTALLATION (Continued)(4) Install dog clutch onto shaft and reinstall snapring.

(5) Install overrunning clutch on the shaft withthe tapered end facing outward and install snap ring.

(6) Clean all sealing surfaces. Apply a bead ofMopart Gasket Maker or equivalent. Then reinstallthe overrunning clutch case to the rear carrier case.Install retaining bolts and tighten to 28 Nm (250 in.lbs.).

(7) Apply Mopart Gasket Maker or equivalent andreinstall cover. When installing cover be sure thatthe overrunning clutch fork engages into the over-running dog clutch.

(8) Install rear drive line module assembly into thevehicle.

(9) Check and fill fluid levels as required.

HALF SHAFT

REMOVAL(1) Lift vehicle on hoist so that the wheels hang

freely.(2) Remove rear wheel.(3) Remove cotter pin, nut lock and spring washer

(Fig. 80).(4) Remove hub nut and washer.

CAUTION: The half shaft outer C.V. joint, wheninstalled, acts as a bolt and secures the hub/bear-ing assembly. If the vehicle is to be supported ormoved on its wheels, install and torque a boltthrough the hub. This will ensure that the hub/bear-ing assembly cannot loosen.

(5) Remove inner half shaft retaining bolts (Fig.81).

(6) The half shaft is spring loaded. Compress innerhalf shaft joint slightly and pull downward to clear

Fig. 79 Turn Inner Race Clockwise


HUB NUTNUT LOCKCOTTER PINSPRINGWASHERSHAFTFLANGEBRAKE BACKING PLATEHALF SHAFT HALF SHAFT BOOTHALF SHAFT

VISEHALF SHAFT BOOTCLAMP

NS/GSrear differential. Then pull half shaft assembly out-ward to remove (Fig. 82).

INSTALLATION(1) For installation, reverse removal procedure.

Fig. 80 Cotter Pin, Nut Lock, And SpringWasher

Fig. 81 Inner Half Shaft Bolts

Fig. 82 Half Shaft Removal


REMOVAL AND INSTALLATION (Continued)DISASSEMBLY AND ASSEMBLY

HALF SHAFT RECONDITION

REAR HALF SHAFT JOINT/BOOTREPLACEMENT

(1) Remove half shaft from vehicle. Refer to HalfShaft Service in this section for removal procedure.

(2) Clean and inspect all parts for wear or damage,replace any worn or damaged parts.

(3) To install, reverse removal procedure.

Fig. 83 Clamp Shaft In Soft Jawed Vice

Fig. 84 Remove Boot Clamps

HALF SHAFT BOOTHALF SHAFT JOINTHALF SHAFT JOINT HOUS-ING

BOOT

SNAP RINGHALF SHAFT BOOTTRIPOD ASSEMBLYSNAP RING PLIERS

TRIPOD ASSEMBLYAXLE SHAFTHALF SHAFT BOOTTORQUE TUBE(1) Remove rear drive line module assembly from

vehicle.(2) Remove viscous coupling.(3) Remove snap ring and torque tube bearing

shield (Fig. 90).

CAUTION: Note the position that the snap ring was

Fig. 85 Pull Back Boot

Fig. 86 Remove Housing

NS/GS

DISASSEMBLY AND ASSEMBLY (Continued)removed. The snap ring can be accidentallyinstalled backwards. The snap ring is concave andthe fingers on the snap ring must angle towards thebearing shield.

(4) Remove torque tube to overrunning clutch casebolts (Fig. 91).

(5) Slide torque tube off of torque shaft.

FRONT BEARINGThe rear drive line module must be removed to ser-

Fig. 87 Remove Snap Ring

Fig. 88 Slide Tripod Off The Shaft

DIFFERENTIAL AND DRIVELINE 3 - 47vice this bearing.

HALF SHAFT BOOT REAR CARRIER CASEOVERRUNNING CLUTCHCASE

NS/GS(1) Remove rear drive line module assembly fromvehicle.

(2) Remove viscous coupling.(3) Remove overrunning clutch cover assembly.(4) Drain fluid from overrunning clutch case.(5) Remove overrunning clutch case to rear carrier

case bolts (Fig. 92).(6) Separate overrunning clutch case from differen-

tial carrier case (Fig. 93).(7) Remove overrunning clutch inner race snap

ring (Fig. 94).(8) Slide overrunning clutch inner race off of shaft

(Fig. 95).

Fig. 89 Remove Boot

Fig. 90 Remove Torque Shaft Snap RingAndBearing Shield


DISASSEMBLY AND ASSEMBLY (Continued)(9) Remove shaft snap ring and slide dog clutch offof the shaft.

(10) Remove torque shaft rear bearing snap ring.(11) Remove overrunning case to torque tube bolts

(Fig. 96).(12) Separate torque tube from overrunning clutch

housing.


Fig. 92 Overrunning Clutch Housing To RearCarrierBolts

OVERRUNNING CLUTCHCASEOVERRUNNING CLUTCHINNER RACE



OVERRUNNING CLUTCHCASETORQUE TUBEBEARING SHIELDSNAP RINGCAUTION: Note the position that the snap ring wasremoved. The snap ring can be accidentallyinstalled backwards. The snap ring is concave andthe fingers on the snap ring must angle towards thebearing shield.

(13) Remove front snap ring and torque tube bear-ing shield (Fig. 97).

(14) Slide shaft out of torque tube.(15) Drive bearing out of housing.(16) To install bearing, reverse removal procedure.

REAR BEARING

Fig. 93 Separate Rear Carrier Case FromOverrunningClutch Case

REAR CARRIER CASE



NS/GS

DISASSEMBLY AND ASSEMBLY (ContinuedThe rear drive line module assembly must beremoved to service this bearing.Fig. 95 Remove Overrunning Clutch Race



)Fig. 97 Remove Torque Shaft Snap Ring AndShield


OUTER TORQUE SHAFTBEARING SNAP RING


DISASSEMBLY AND ASSEMBLY (Continued)(1) Remove rear drive line module assembly fromvehicle.

(2) Remove viscous coupling unit.(3) Remove overrunning clutch cover assembly.(4) Drain fluid from overrunning clutch case.(5) Remove overrunning clutch case to differential

carrier bolts.(6) Separate overrunning clutch case from differen-

tial carrier case.(7) Remove overrunning clutch inner race snap

ring.(8) Slide overrunning clutch inner race off of shaft.(9) Remove shaft snap ring and slide dog clutch off

of the shaft.(10) Remove torque shaft rear bearing inner snap

ring.(11) Remove torque tube retaining bolts.(12) Separate overrunning clutch case from torque

tube.(13) Remove rear bearing retaining snap ring in

overrunning clutch case (Fig. 98).

(14) Remove rear torque shaft bearing.(15) To install, reverse removal procedure.

SCHEMATICS AND DIAGRAMS

VACUUM SCHEMATIC (SOLENOIDS ENERGIZED)


LOCKED UP: ENERGIZEDSOLENOIDS COMMONPORTS: MIDDLE AND BOT-TOMVACUUM RESERVOIRVACUUM CHECK VALVEFRONT SOLENOIDREAR SOLENOIDTO VENTVACUUM MOTORVACUUMATMOSPHERELOCKED-UPSHIFT FORKOVERRUNNINGTOP PORTBOTTOM PORTMIDDLE PORTTOP PORTMIDDLE PORTBOTTOM PORTTO VAC. SOURCE= VACUUM= ATMOSPHERE(VIEW FROM LEFT SIDE OFVEHICLE)VACUUM SCHEMATIC (SOLENOIDS DE-ENERGIZED)

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUEAssy. Nut Torque Tube . . . . . . . 28 Nm (250 in. lbs.)Drive Pinion Nut . . . . . . . . . . 380 Nm (280 ft. lbs.)End Cover . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.)Fill Plug . . . . . . . . . . . . . . . . . . 27 Nm (240 in. lbs.)Front Cover . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.)Inspection Plug . . . . . . . . . . . . 20 Nm (180 in. lbs.)O/Running Clutch to Carr. . . . . 28 Nm (250 in. lbs.)O/Running Clutch Cover . . . . . 28 Nm (250 in. lbs.)Propshaft PTU & VCU . . . . . . . 28 Nm (250 in. lbs.)Ring Gear . . . . . . . . . . . . . . . . . . 95 Nm (70 ft. lbs.)Rear Halfshafts . . . . . . . . . . . . . 61 Nm (45 ft. lbs.)Sol. to Bracket . . . . . . . . . . . . . . . 7 Nm (65 in. lbs.)Torque Tube Isolator . . . . . . . . . . 54 Nm (40 ft. lbs.)Vacuum Harness Clip . . . . . . . 12 Nm (105 in. lbs.)Vacuum Reservoir . . . . . . . . . . . . 7 Nm (65 in. lbs.)Viscous Clutch . . . . . . . . . . . . 244 Nm (180 ft. lbs.)

THREAD SIZE CHART

DESCRIPTION THREAD SIZEAssy. Nut Torque Tube . . . . . . . . . . . . . . . M8 x 1.25Drive Pinion Nut . . . . . . . . . . . . . . . . . . . M30 x 1.5End Cover . . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25Fill Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 x 20Front Cover . . . . . . . . . . . . . . . . . . . . . . . M6 x 1.00Inspection Plug . . . . . . . . . . . . . . . . . . . . . M50 x 1.5O/Running Clutch to Carr. . . . . . . . . . . . . M8 x 1.25O/Running Clutch Cover . . . . . . . . . . . . . M8 x 1.25Propshaft PTU & VCU . . . . . . . . . . . M8 x 1.25 x 25Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.0Rear Halfshafts . . . . . . . . . . . . . . . . M10 x 1.5 x 25Sol. to Bracket . . . . . . . . . . . . . . . . . . . . . . M6 x 1.0Torque Tube Isolator . . . . . . . . . . . . . M10 x 1.5 x 35Vacuum Harness Clip . . . . . . . . . . . . . . . . . M6 x 1.0Vacuum Reservoir . . . . . . . . . . . . . . . . . . . . 1/4 x 14Viscous Clutch . . . . . . . . . . . . . . . . . . . . . M16 x 1.5NS/GS

SCHEMATICS AND DIAGRAMS (Continued)DIFFERENTIAL AND DRIVELINE 3 - 51

OVERRUNNING: DE-ENER-GIZED SOLENOIDS COM-MON PORTS: MIDDLE ANDTOPVACUUM RESERVOIRVACUUM CHECK VALVEFRONT SOLENOIDREAR SOLENOIDTO VENTVACUUM MOTORATMOSPHEREVACUUMSHIFT FORKLOCKED-UPOVERRUNNINGTOP PORTBOTTOM PORTMIDDLE PORTTOP PORTMIDDLE PORTBOTTOM PORTTO VAC. SOURCE= VACCUM= ATMOSPHERE(VIEW FROM LEFT SIDE OFVEHICLE)

3 - 52 DIFFERENTIAL AND DRIVELINESPECIAL TOOLS

DIFFERENTIAL AND DRIVELINE

C-4967 Seal Remover

6507 Seal Installer

6508a Seal Installer

6534 Spline ToolNS/GS

7794-a Seal Remover


SPECIAL TOOLS (Continued)

DIFFERENTIAL AND DRIVELINEGENERAL INFORMATIONFRONT DRIVESHAFTSFRONT DRIVESHAFT IDENTIFICATION

DESCRIPTION AND OPERATIONDRIVESHAFT SERVICE

DIAGNOSIS AND TESTINGDRIVESHAFT DIAGNOSISVEHICLE INSPECTIONNOISE AND/OR VIBRATION IN TURNSCLUNKING NOISE DURING ACCELERATIONSHUDDER OR VIBRATION DURING ACCELERATIONVIBRATION AT HIGHWAY SPEEDS

REMOVAL AND INSTALLATIONFRONT DRIVESHAFTSREMOVALINSTALLATION

DISASSEMBLY AND ASSEMBLYDRIVESHAFT RECONDITIONING PROCEDUREINNER TRIPOD JOINT SEAL BOOTREMOVALINSTALLATION

OUTER C/V JOINT BEARING SHIELD SERVICEBEARING SHIELD REMOVAL FROM OUTER C/V JOINT

OUTER C/V JOINT SEALING BOOT SERVICEBEARING SHIELD INSTALLATION ON OUTER C/V JOINT

SPECIFICATIONSTORQUE SPECIFICATIONS

SPECIAL TOOLSDRIVESHAFTSPECIAL TOOLS

GENERAL INFORMATIONREAR DRIVELINE MODULEPROPELLER SHAFTHALF SHAFTVISCOUS COUPLER

DESCRIPTION AND OPERATIONREAR CARRIER COMPONENT IDENTIFICATIONTORQUE TUBE AND OVERRUNNING CLUTCH COMPONENTS IDENTIFICATION

DIAGNOSIS AND TESTINGREAR DRIVE LINE NOISE DIAGNOSISREAR CARRIER ASSEMBLY NOISEGEAR NOISE (DRIVE PINION AND RING GEAR)BEARING NOISE (DRIVE PINION AND DIFFERENTIAL)TIRE NOISEENGINE AND TRANSMISSION NOISE

FLUID LEAK DIAGNOSISREAR DRIVELINE MODULE VACUUM DIAGNOSIS

REMOVAL AND INSTALLATIONREAR DRIVE LINE MODULE ASSEMBLYREMOVALINSTALLATION

REAR CARRIER UNITREMOVALINSTALLATION

REAR CARRIER OUTPUT SHAFT SEALSREMOVAL

FRONT OVERRUNNING CLUTCH SEALINSTALLATIONREMOVALINSTALLATION

DRIVE PINION SEAL AND/OR REAR OVERRUNNING CLUTCH SEALREMOVALINSTALLATIONDRIVE PINION BEARING SHIM SELECTION

REAR DRIVELINE MODULE DIFFERENTIAL SIDE GEARSCASE SEALSDIFFERENTIAL CARRIER END COVER (RESEAL)OVERRUNNING CLUTCH COVER (RESEAL)OVERRUNNING CLUTCH CASE TO REAR CARRIER CASE (RESEAL)REMOVAL

VISCOUS COUPLERPROPELLER SHAFTREMOVALINSTALLATIONINSTALLATION

OVERRUNNING CLUTCH VACUUM MOTORREMOVALINSTALLATION

OVERRUNNING CLUTCH CASEREMOVALINSTALLATION

OVERRUNNING CLUTCHREMOVALINSTALLATION

HALF SHAFTREMOVAL

DISASSEMBLY AND ASSEMBLYHALF SHAFT RECONDITIONREAR HALF SHAFT JOINT/BOOT REPLACEMENTINSTALLATION

TORQUE TUBEFRONT BEARINGREAR BEARING

SCHEMATICS AND DIAGRAMSVACUUM SCHEMATIC (SOLENOIDS ENERGIZED)VACUUM SCHEMATIC (SOLENOIDS DE- ENERGIZED)

SPECIFICATIONSTORQUE THREAD SIZE CHART

SPECIAL TOOLSDIFFERENTIAL AND DRIVELINE

EGS_3.PDF

Documents

inner joint

rzevelocity cv joint

outer cv joint housing

outercv joint

rzeppa joint

outer joints

driveshaft assemblies

outer jointof