Tuesday, February 8, 2011

2008 Chevy impala parts disassembly?






Lower ball joints Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the wheel.
  3. Remove the lower control arm from the vehicle.
  4. Remove the ball joint from the lower control arm by drilling out the 4 rivets retaining the ball joint to the control arm. Use an 1 / 8 in. drill bit to make a pilot hole through the rivets. Finish drilling the rivets using a1 / 2 in. drill bit.
  5. Remove the ball joint.

To install:

  1. Install or connect the following:
    NOTE
    A 4-wheel alignment is recommended after any steering/suspension repairs are performed.



    Ball joint to the control arm
    Bolts with the heads facing down and torque them to 50 ft. lbs. (68 Nm)
    Lower control arm to the vehicle
    Wheel



LOWER CONTROL ARMS:-----

Bushing Replacement



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Front wheel
    Lower control arm

  3. Mark the lower control arm along the flat edge of the bushing flange.
  4. Coat the threads of tool J 21474-27 with a high pressure lubricant.

    Click image to see an enlarged view

    Fig. Removing the control arm bushing

  5. Assemble the following bushing removal tools as illustrated:

    J 21474-27
    J 21474-13
    J 34126
    J 35379
    J21474-2
    J 21474-4

  6. Tighten J 21474-4 to remove the bushing.

To install:

Click image to see an enlarged view

Fig. Positioning the control arm bushing



Click image to see an enlarged view

Fig. Installing the control arm bushing


NOTE
You MUST install the lower control arm vertical bushing in the same position in order to maintain the original vehicle ride, handling, and road feel.

  1. Align the flat edge of the bushing flange to the mark in the control arm (1). Ensure that the flat edge of the bushing flange is 30 degrees (2) from the centerline of the lower control arm. Ensure that the thin slot in the bushing is facing outboard. Insert the bushing into the control arm. Refer to the accompanying illustration for clarification of positions (1) and (2).
  2. Coat the threads of tool J 21474-27 with a high pressure lubricant.
  3. Assemble the following bushing installation tools as illustrated:

    J 21474-27
    J 21474-13
    J 21474-5
    J 21474-4

  4. Tighten J 21474-4 to remove the bushing.
  5. Install the lower control arm.

    Front wheel


Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Front wheel
    Antilock Brake System (ABS) wheel speed sensor connector and jumper harness from the retainer
    Stabilizer shaft link
    Cotter pin from the ball stud and loosen the nut

  3. Install a ball joint removal tool over the ball joint and lower control arm. Rotate the ball stud nut counterclockwise to separate the ball stud from the steering knuckle.
  4. Remove the lower control arm.

To install:

  1. Install the lower control arm and bolts. Do not tighten the nuts at this time.
    NOTE
    Align the ball stud cotter pin hole parallel to the knuckle to ease the cotter pin installation.

  2. Install the ball stud to the steering knuckle. Tighten to 22 ft. lbs. (30 Nm) plus an additional 120 degrees.
  3. Install or connect the following:

    New cotter pin and bend the ends. Make certain the ends do not make contact with the ABS wheel speed sensor
    Stabilizer shaft link
    ABS wheel speed sensor wire harness to the retainer clips
    ABS wheel speed sensor connector

  4. Install the lower control arm nuts and torque them to 83 ft. lbs. (113 Nm) on all models except Lumina. On Lumina models tighten the control arm-to-frame nuts to 52 ft. lbs. (70 Nm).

    Front wheel
STEERING KNUCKLES:---

The steering knuckle is a machined aluminum casting. Do not use a hammer to loosen suspension components from the knuckle.

Removal & Installation




WARNING
Special tools are recommended for removing both the front hub spindle, the tie rod end and the ball joint. Use only the recommended tools for separating the ball joint from the knuckle. Do NOT hammer or pry the ball joint from the knuckle. Remember that the steering knuckle is cast aluminum and can be damaged if care is not used. Failure to use the recommended tools or their functional equivalent may cause damage to the ball joint and seal.

  1. Raise and safely support the vehicle.
  2. Remove the wheel and tire assembly.
  3. Remove the front hub and bearing assembly.
  4. Disconnect the lower ball joint.
  5. Remove the outer tie rod end.
  6. If the knuckle is to be reused, scribe a mark around the strut bracket to the knuckle. This will help align the strut at assembly.
  7. Remove the bolts connecting the strut to the knuckle and remove the knuckle from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cotter pin, then loosen the ball joint stud's slotted nut



    Click image to see an enlarged view

    Fig. Separating the ball joint from the steering knuckle using a special ball joint press tool



    Click image to see an enlarged view

    Fig. Use a suitable puller to separate the tie rod ends from the steering knuckle


To install:

  1. Install the knuckle to the vehicle. If the original knuckle is being reused, align the scribe marks made at removal to help get the strut-to-knuckle alignment as close as possible to the original location.
  2. Install the strut-to-knuckle bolts and tighten to 90 ft. lbs. (123 Nm).
  3. Install the outer tie rod end to the steering knuckle. Use a new torque prevailing nut and tighten to 22 ft. lbs. (30 Nm).
  4. Connect the lower control arm ball joint stud to the knuckle, install the slotted nut and torque to 40 ft. lbs. (55 Nm). Align the slots in the nut to the hole in the ball joint stud by tightening the nut. DO NOT loosen the nut to align the holes for the cotter pin. Install a new cotter pin. The bent ends of the cotter pin MUST NOT face the ABS wheel speed sensor or the drive axle.
  5. Install the front hub and bearing assembly.
  6. Install the front wheel and tire assemblies. Torque the wheel nuts to 100 ft. lbs. (140 Nm).
  7. Lower the vehicle.

STABILIZER BAR(SWAY BAR):--------

Removal & Installation



Because the front stabilizer shaft is mounted to the powertrain subframe, the subframe (with the powertrain) must be lowered to service the stabilizer bar. This is a lengthy and exacting procedure requiring special lifting and jacking equipment. In addition, the rack and pinion steering assembly stub shaft must be disconnected from the steering column. GM specifies that the subframe-to-body bolts, once disturbed, must be replaced with new service replacement parts. Procure the necessary hardware before beginning this procedure. This is not a job for the inexperienced or ill-equipped.

  1. Center the front wheels to the straight ahead position and lock the steering column. This is important because it protects the steering wheel airbag coil from damage.
  2. Raise and safely support the vehicle.
  3. Remove the front wheel and tire assemblies.
  4. Locate the steering shaft dust seal and move it back to gain access to the pinch bolt that joins the steering column intermediate shaft to the rack and pinion input shaft (stub shaft).
    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the rack and pinion steering gear assembly and/or the steering intermediate shaft. The damage can cause loss of steering control which could result in personal injury.

  5. Remove the pinch bolt from the lower intermediate steering shaft, noting the following:

    Click image to see an enlarged view

    Fig. Remove the pinchbolt and separate the lower intermediate shaft from the rack and pinion stub shaft

    1. The wheels of the vehicle must be in the straight ahead position and the steering column in the LOCK position before disconnecting the steering column or the intermediate shaft from the rack and pinion steering gear.
    2. Failure to do this will cause the SIR (airbag) coil, which feeds power to the steering wheel airbag module, to become uncentered, which will cause damage to the airbag coil.

  6. Loosen the stabilizer shaft insulator clamp attaching nuts and bolts.
  7. Place an adjustable safety stand or hydraulic jack under the center of the rear subframe crossmember.
  8. Locate the large subframe-to-body retaining bolts. Remove the two rear frame-to-body bolts.
  9. Carefully lower the rear of the subframe just enough to access the stabilizer shaft.
  10. Remove the stabilizer shaft insulator clamps and insulators from the subframe.
  11. Remove the stabilizer shaft links from the control arms and pull the stabilizer shaft rearward. Swing the stabilizer shaft down and remove from the left side of the vehicle.

To install:

  1. Insert the stabilizer shaft from the left side of the vehicle.
    WARNING
    DO NOT tighten the stabilizer link nuts at this time. The weight of the vehicle must be supported by the control arms so the vehicle will have the proper trim heights before the tightening the link nuts.

  2. Loosely install the stabilizer shaft links at the control arms.
  3. Connect the stabilizer shaft insulator clamps to the frame and tighten the bolts to 35 ft. lbs. (48 Nm).
    WARNING
    Make sure the rack and pinion stub shaft is properly seated in the lower intermediate steering shaft coupler prior to installing the pinch bolt. The two mating shafts may disengage if the pinchbolt inserts into the coupling before shaft installation. This is absolutely critical. Otherwise, the vehicle steering will be compromised.

  4. Raise the subframe back into position, while guiding the intermediate steering shaft onto the rack and pinion stub shaft. When satisfied with the fit of the intermediate shaft to the rack and pinion stub shaft, install the pinchbolt and torque to 35 ft. lbs. (48 Nm).
  5. Install new service replacement frame-to-body attaching bolts noting the following:
    1. Do not overtighten the body mount. A collapsed spacer or stripped bolt may result.
    2. When subframe insulator bolts are removed, always discard the bolts and replace with new bolts.
    3. Proper clamping by the mount depends on clean and dry surfaces. If the subframe bolt does not screw in smoothly, it may be necessary to run a tap through the subframe crossmember nut in the body to remove foreign material. Take care that the tap does not punch through the underbody.
    4. If for any reason, the rubber frame insulators were removed, generously lubricate with a suitable rubber lube, at installation. Failure to lubricate may prevent proper seating of the insulators in the frame.
    5. Carefully and evenly torque the new subframe-to-body bolts to 133 ft. lbs. (180 Nm).
    6. When satisfied with the fit of the subframe, remove the support from under the subframe.

  6. Support the weight of the vehicle by the control arms. Tighten the stabilizer shaft link nuts to 17 ft. lbs. (23 Nm).
  7. Install the wheel and tire assemblies and lower the vehicle.


Tie rod ends:---

Normally, the only steering linkage components that may require service are the tie rod ends which connect the rack and pinion steering gear to the wheel knuckles.

  1. Raise and safely support the vehicle.
  2. The outer tie rod ends may be retained to the steering knuckle by either a slotted nut and cotter pin or a torque-prevailing nut. If a slotted nut and cotter pin is used, remove and discard the cotter pin and remove the slotted nut.
  3. If a torque prevailing nut is used, remove the nut from the tie rod end's ball stud at the wheel knuckle. GM specifies that this torque prevailing nut be discarded and a new torque prevailing nut be used at assembly. Most service replacement tie rod ends come with new hardware.
  4. The position of the tie rod ends determines the toe angle of the steering alignment. To get the replacement tie rod end positioned as closely as possible to the original tie rod end's position, the jam nut's position should be marked. Some technicians, after thoroughly wire-brushing the jam nut and the inner tie rod shaft threads, will mark one flat of the jam nut with paint. Then, the jam nut is loosened exactly one turn.
  5. Remove the tie rod end from the wheel knuckle. GM says that the tapered joint of the ball stud has been designed to separate easily, unlike previous joints of this type. If required, use a tie rod puller to separate the tie rod end from the wheel knuckle.
  6. Unscrew the tie rod end from the inner tie rod shaft. Do not disturb the jam nut. It should have been loosened one turn only from its original position.

  1. Click image to see an enlarged view

    Fig. Although the outer tie rod ends are supposed to be easy to remove, a puller may be required to separate the joint end from the wheel knuckle



    Click image to see an enlarged view

    Fig. Separate the tie rod end from the knuckle and inspect for damage



    Click image to see an enlarged view

    Fig. Unscrew the tie rod end from the tie rod, counting the number of turns for later reference at installation



    Click image to see an enlarged view

    Fig. Some tie rod ends may have plugs which can be removed so grease fittings can be installed



    Click image to see an enlarged view

    Fig. Exploded view of the outer tie rod end assembly



    Click image to see an enlarged view

    Fig. The tie rod ends have to be removed to renew the rack and pinion steering gear dust boots



    Click image to see an enlarged view

    Fig. Apply grease to the areas shown when installing a new rack and pinion dust boot


To install:

  1. Clean all parts well. Make sure mating surfaces of the stud and knuckle are clean.
  2. Thread the replacement tie rod end onto the inner tie rod shaft until it just touches the jam nut. Loosen the tie rod end exactly one turn.
  3. Install the tie rod end ball stud to the wheel knuckle. If equipped with a torque prevailing nut, tighten to 18 ft. lbs. (25 Nm). Tighten the nut an additional 180 degrees (one-half turn). If equipped with a slotted nut for a cotter pin, tighten the retaining nut to 45 ft. lbs. (60 Nm) maximum to align the cotter pin slot. DO NOT back off (loosen) the nut to align the slots in the nut with the cotter pin hole in the ball stud. Install a new cotter pin.
  4. Turn the jam nut one turn. This should tighten the jam nut against the end of the tie rod threaded portion. Tighten the jam nut to 50 ft. lbs. (68 Nm).
  5. Check that the rubber rack and pinion dust boot is not twisted or puckered.

STEERING WHEEL:-- REMOVAL AND INSTALLATION:---
  1. Center the front wheels and lock the steering column. Remove the key from the ignition.
  2. Disable the SIR (air bag) system. Refer to the Chassis Electrical Section. Refer to the Chassis Electrical Section.
  3. Remove the air bag module from the steering wheel using the following procedure:
    1. Verify that the SIR system has been disabled.
      NOTE
      The air bag can be retained to the steering wheel with several different types of fasteners, depending on Model Year and vehicle equipment. A small mirror may be helpful to examine the back of the steering wheel to determine how the air bag is retained on your vehicle. It could be by Torx®screws which are unscrewed using the proper bit (usually a no. 30 driver bit). An alternate method of attachment is by small leaf-type springs which are unclipped with a small flat-blade prytool.

    2. On the back side of the steering wheel, locate and remove the air bag fasteners.
    3. Gently pull on the air bag module to free it from the steering wheel.
    4. Detach the electrical connections from the steering wheel to the air bag module.
    5. Place the air bag in a safe place, with the trim pad facing upwards.

  4. Scribe an alignment mark on the steering wheel hub in line with the existing mark on the steering shaft.
  5. Loosen, but do not remove the steering wheel shaft nut, positioning it flush with the end of the steering column shaft. This is protect the steering column shaft threads from the foot of the steering wheel puller center screw.
  6. Assemble a suitable steering wheel puller (GM recommends their J 1859-A puller with J 36541 special legs) to the steering wheel and pull the wheel loose from the shaft.
  7. Remove the steering wheel shaft nut and the remove the steering wheel. Detach the electrical connectors.

    Click image to see an enlarged view

    Fig. If leaf-type springs are used to retain the air bag, release the spring clip retainers and separate the air bag module from the steering wheel



    Click image to see an enlarged view

    Fig. Carefully pull the air bag module away from the steering wheel, then detach the electrical connector



    Click image to see an enlarged view

    Fig. Exploded view of the air bag module and electrical connections-Buick shown, Chevrolet and Pontiac similar



    Click image to see an enlarged view

    Fig. Typical steering wheel and the recommended puller with special legs to fit steering wheels designed for air bags


To install:

  1. Route the SIR connector through the steering wheel.
  2. Align the scribe mark on the steering wheel made at removal with the existing mark on the steering column shaft. Make sure the steering wheel is seated.
  3. Install the steering wheel shaft nut and tighten to 33 ft. lbs. (45 Nm).
  4. Install the air bag module using the following procedure:
    1. Attach the electrical connections to the air bag module.
    2. If equipped with leaf-spring type clips, line up the air bag module retainers with the openings in the steering wheel. Gently press the air bag module into place until it 'snaps' into place.
    3. If equipped with screws to retain the air bag, install the screws using care to line up the screw openings.

  5. Enable the SIR system.
  6. Check the operation of the horn and steering wheel. Check the operation of the steering wheel switches, as equipped.

--------------
Power rack & pinion steering gear:---
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:
    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft may result in damage to the steering gear. This damage may cause a loss of steering control and may cause personal injury.


    NOTE
    Set the steering shaft so that the block tooth on the upper steering shaft is at the 12 o'clock position. The wheels should be straight ahead. Set the ignition key lock to the LOCK position. Failure to follow these procedures could result in damage to the SIR coil assembly.



    Negative battery cable
    Front wheels

  3. Remove or disconnect the following:

    Intermediate steering shaft lower pinch bolt from the steering gear stub shaft
    Intermediate steering shaft
    Both tie rod ends from the steering knuckles

  4. Support the frame at the center rear.
    NOTE
    DO NOT lower the frame too far. Engine components near the firewall may be damaged.

  5. Remove or disconnect the following:

    Frame bolts from the rear of the frame. Lower the frame slightly
    Power steering pressure line from the steering gear
    Power steering return hose
    Magnasteer Variable Assist electrical connector from the power steering gear assembly, if equipped
    Steering gear mounting bolts
    Power steering gear through the left wheel opening

    Click image to see an enlarged view

    Fig. Common rack and pinion steering gear mounting



To install:

  1. Install or connect the following:

    Power steering gear through the left wheel opening
    Mounting bolts and torque them to 66 ft. lbs. (90 Nm)
    Magnasteer Variable Assist electrical connector to the power steering gear assembly, if equipped
    Power steering lines with new O-rings to the steering gear. Torque the fasteners to 20 ft. lbs. (27 Nm).
    Power steering return hose

  2. Raise the rear frame to its original position.
  3. Install or connect the following:

    New rear frame bolts and torque them to 133 ft. lbs. (180 Nm) on all models except Impala and Monte Carlo models. On Impala and Monte Carlo models, align the frame to the body by inserting two 19 x 203 mm (0.74 x 8.0 in) pins in the alignment holes on the right side of the frame. Tighten the front bolts to 118 ft. lbs. (160 Nm) and the rear bolts to 122 ft. lbs. (165 Nm)
    Tie rod ends to the steering knuckles and torque the nuts to 22 ft. lbs. (30 Nm)
    Intermediate steering shaft to the steering gear stub shaft and torque the lower pinch bolt to 35 ft. lbs. (48 Nm)
    Front wheels
    Negative battery cable

  4. Fill and bleed the power steering system.
  5. Start the vehicle and check for leaks, repair if necessary.
  6. Check the front end alignment and adjust as needed.

---------------
CV-JOINTS REMOVAL & INSTALLATION:--

CV-Joints



Overhaul
Inner
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Front wheel
    Halfshaft
    Swage ring using a hand grinder
    Large CV-joint boot clamp, cut and discard it
    CV-joint boot by sliding it away from the tri-pod joint
    Tri-pod housing from the tri-pod spider
    Trilobal tri-pod bushing from the housing
    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers Tool J-8059
    Outboard retaining ring using Snapring Pliers Tool J-8059
    Tri-pod joint spider assembly
    Inboard spacer ring and CV-joint boot

  3. Thoroughly clean and inspect all parts.

    Click image to see an enlarged view

    Fig. Exploded view of the inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Positioning the inner CV-joint boot seal and swage ring-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. View of the swage ring crimping tool-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Boot measurement-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Crimping the large CV-joint boot ring-Inner (tri-pod) joint


To install:

  1. Install or connect the following:

    Swage ring clamp
    CV-joint boot

  2. Position the CV-joint boot seal into the axle shaft-s joint seal groove and align the swage ring clamp on the boot.
  3. Secure the swage ring clamp as follows:
    1. Mount the lower half of Tool J-41048 in a vise.
    2. Position the outboard of the halfshaft in the tool.
    3. Position the upper end of Tool J-41048 onto the lower half.
      WARNING
      Make sure that there are no pinch points on the inboard seal.

    4. Insert both bolts and tighten by hand until snug.
    5. Tighten each bolt 180 degree ( 1 / 2 turn) at a time, alternating between the bolts, until both sides are bottomed.
    6. Remove the tool.

  4. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Inboard spacer ring, slide it rearward on the shaft using Snapring Pliers Tool J-8059
    Tri-pod joint spider assembly onto the shaft
    Outboard retaining ring into the axle shaft groove using Snapring Pliers Tool J-8059
    Tri-pod joint spider assembly, slide it against the outboard retaining ring
    Inboard spacer ring, seat it in the groove
    1 / 2 kit grease into the boot
    1 / 2 kit grease into the tri-pod housing
    Trilobal tip-pot bushing flush with the tri-pod housing face
    New large seal clamp onto the CV-joint boot
    Tri-pod housing, slide it over the tri-pod joint spider assembly
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pod bushing with the seal lip in the groove

  5. Position the CV-joint boot so it measures 4.9 in. (125mm).
  6. Using the Crimp Tool J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot camp to 130 ft. lbs. (176 Nm).
  7. Install or connect the following:

    Halfshaft
    Front wheel


Outer
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Front wheel
    Halfshaft
    Swage ring using a hand grinder
    Large boot clamp, cut and discard it
    CV-joint boot, slide it away from the CV-joint
    CV-joint assembly by spreading the inner race-to-axle shaft retaining ring ears using Snapring Pliers Tool J-8059
    CV-joint boot from the axle shaft and discard it

  3. Disassemble the chrome alloy balls from the CV-joint cage as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2. Chrome alloy ball from the cage.
    3. Tilt the cage in the opposite direction.
    4. Remove the opposite chrome alloy ball.
    5. Repeat the procedure until all 6 balls are removed.

  4. Disassemble the CV-joint cage and inner race as follows:
    1. Pivot the cage and race 90 degrees to the center line of the outer race.
    2. Align the cage windows with outer race lands.
    3. Remove the cage from the outer race.
    4. Rotate the inner race upward and remove it from the cage.

  5. Thoroughly clean and inspect all parts.

    Click image to see an enlarged view

    Fig. Disconnecting the outer CV-joint from the axle shaft



    Click image to see an enlarged view

    Fig. Tilting the cage-Outer CV-joint



    Click image to see an enlarged view

    Fig. View the cage and inner race-Outer CV-joint



    Click image to see an enlarged view

    Fig. Positioning the boot-Outer CV-joint


To install:

  1. Lubricate the parts with a light coat of grease.
  2. Assemble the CV-joint cage and inner race, as follows:
    1. Rotate the inner race 90 degrees to the cage centerline.
    2. Align the cage windows with inner race lands.
    3. Insert the inner race into the cage by rotating the inner race downward.
    4. Insert the cage/inner race into the outer race.

  3. Assemble the chrome alloy balls into the CV-joint cage, as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2. Insert the 1st chrome alloy ball into the cage.
    3. Tilt the cage in the opposite direction.
    4. Insert the opposite chrome alloy ball.
    5. Repeat the procedure until all 6 balls are inserted.

  4. Install or connect the following:

    1 / 2 kit grease into the CV-joint boot
    1 / 2 kit grease into the CV-joint
    Swage ring clamp
    CV-joint boot
    CV-joint onto the axle shaft until the retaining ring seats into the groove

  5. Position the CV-joint boot seal into the axle shaft-s joint seal groove and align the swage ring clamp on the boot.
  6. Secure the swage ring clamp as follows:
    1. Mount the lower half of tool J-41048 in a vise.
    2. Position the outboard of the halfshaft in the tool.
    3. Position the upper end of tool J-41048 onto the lower half.
      WARNING
      Make sure that there are no pinch points on the inboard seal.

    4. Insert both bolts and tighten by hand until snug.
    5. Tighten each bolt 180 degree ( 1 / 2 ) turn at a time, alternating between the bolts, until both sides are bottomed.
    6. Remove the tool.

  7. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the outer race.



    New large seal clamp onto the CV-joint boot
    CV-joint boot/clamp, slide it into place, over the outer race with the seal lip in the groove

  8. Using the Crimp Tool J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  9. Install or connect the following:

    Halfshaft
    Front wheel


Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Front wheel
    Stabilizer shaft link
    Drive shaft nut
    Outer tie rod end from the steering knuckle
    Ball joint from the steering knuckle

  3. Press the axle shaft through the hub.
    WARNING
    To prevent damage to the inner CV-joint, do not pull on the axle shaft to remove it from the transaxle.



    Click image to see an enlarged view

    Fig. Use a puller to press the axle shaft through the hub/bearing assembly

  4. Place a drain pan under the transaxle to catch any transaxle fluid that leaks out when the axle shaft is removed.
  5. Remove the axle shaft from the transaxle by prying between the transaxle and the inner CV-joint housing.

To install:

  1. Install or connect the following:

    Axle shaft in the transaxle. Verify that it is seated by pulling on the housing
    Axle shaft through the hub/bearing assembly
    Ball joint and torque the nut to 15 ft. lbs. (22 Nm) plus 120 degrees
    Tie rod end and torque the nut to 22 ft. lbs. (30 Nm) plus an additional 120 degree turn
    New drive shaft nut and torque it to 118 ft. lbs. (160 Nm)
    Stabilizer shaft link and torque the nut to 17 ft. lbs. (23 Nm)
    Front wheel

  2. Check the transaxle fluid level.
  3. Check the front alignment and adjust, if necessary.

TRANS AXLE REMOVAL &INSTALLATION:--
NOTE
These transaxles were used in a variety of General Motor-s vehicles. Due to model year, vehicle model and installed options, the removal and installation procedures may vary slightly. The procedures given here should suffice for most all vehicles using these transaxles.

4T60-E




NOTE
These transaxles were used in a variety of General Motor-s vehicles. Due to model year, vehicle model and installed options, the removal and installation procedures may vary slightly. The procedures given here should suffice for most all vehicles using these transaxles.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the transmission fluid.
  3. Install an engine support fixture.
  4. Remove or disconnect the following:

    Negative battery cable
    Throttle body air inlet duct
    Engine mount struts
    Wire harness connectors from the transmission
    Vacuum hose and pipe from the modulator
    Range selector cable from the Park/Neutral Position (PNP) switch
    PNP switch
    Fluid filler tube
    Upper transmission bolts
    Wire harness grounds
    Both front wheels
    Engine splash shields
    Both tie rod ends from the steering knuckles
    Power steering gear from the frame and secure it to the body of the vehicle
    Power steering cooler line clamps
    Engine mount lower nuts
    Lower ball joints from the steering knuckles
    Torque converter cover
    Starter motor
    Torque converter bolts
    Oil cooler hoses
    Drive axles and secure them to the steering knuckles and struts
    Wheel Speed Sensor (WSS) connectors
    Vehicle Speed Sensor (VSS) connectors

  5. Use a transmission table to support the transmission.

    Transmission brace
    Lower transmission bolts
    Frame-to-body bolts

  6. Lower the frame from the vehicle.
  7. Remove the transmission from the frame.

To install:

  1. Install or connect the following:

    Transmission
    Lower transmission bolts and torque them to 55 ft. lbs. (75 Nm)
    New frame to body bolts and torque them to 125 ft. lbs. (170 Nm)
    Transmission brace and torque the bolts to 35 ft. lbs. (47 Nm)
    VSS electrical connector
    WSS electrical connectors
    Drive axles to the transmission
    Oil cooler hoses
    Torque converter bolts and torque them to 46 ft. lbs. (63 Nm)
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
    Lower ball joints to the steering knuckle and torque the nuts to 40 ft. lbs. (55 Nm)
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
    Power steering cooler line clamps to the frame
    Power steering gear to the frame and torque the bolts to 59 ft. lbs. (80 Nm)
    Tie rod ends to the steering knuckles and torque the nuts to 63 ft. lbs. (85 Nm)
    Engine splash shields
    Front wheels
    Fluid filler tube
    Upper transaxle bolts and torque them to 55 ft. lbs. (75 Nm)
    PNP switch and torque the bolts to 18 ft. lbs. (25 Nm)
    Range selector cable with the bracket and torque the nut to 15 ft. lbs. (20 Nm)
    Range selector cable to the PNP switch
    Wire harness connectors to the transmission
    Vacuum hose and pipe to the modulator
    Engine mount struts and torque the bolts to 37 ft. lbs. (50 Nm)

  2. Remove the engine support fixture.

    Throttle body air inlet duct
    Negative battery cable

  3. Fill the transmission with fluid.
  4. Start the engine and check the engine and transaxle oil level. Add oil if necessary.

4T65-E




NOTE
These transaxles were used in a variety of General Motor-s vehicles. Due to model year, vehicle model and installed options, the removal and installation procedures may vary slightly. The procedures given here should suffice for most all vehicles using these transaxles.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the transmission fluid.
  3. Install an engine support fixture.
  4. Remove or disconnect the following:

    Negative battery cable
    Throttle body air inlet duct
    Engine mount struts
    Wire harness connectors from the transmission
    Range selector cable from the Park Neutral Position (PNP) switch
    Range selector cable and bracket
    PNP switch
    Power steering gear to frame retaining bolts
    Fluid filler tube
    Upper transmission bolts
    Wire harness grounds
    Both front wheels
    Engine splash shields
    Both tie rod ends from the steering knuckles
    Power steering gear from the frame and secure it to the body of the vehicle
    Power steering cooler line clamps
    Engine mount lower nuts
    Lower ball joints from the steering knuckles
    Torque converter cover
    Starter motor
    Torque converter bolts
    Oil cooler hoses
    Drive axles and secure them to the steering knuckles
    Wheel Speed Sensor (WSS) electrical connectors
    Vehicle Speed Sensor (VSS) electrical connectors

  5. Use a transmission table to support the transmission.

    Engine mount lower nuts
    Transmission brace
    Lower transmission bolts
    Frame-to-body bolts

  6. Separate the transmission from the engine.
  7. Lower the transmission and frame from the vehicle.
  8. Remove the transmission.

To install:

  1. Install or connect the following:

    Transmission to the frame and raise the assembly into position
    New frame-to-body bolts and torque them to 133 ft. lbs. (180 Nm)
    Lower transmission-to-engine bolts and torque them to 55 ft. lbs. (75 Nm)
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
    VSS electrical connector
    WSS electrical connectors
    Drive axles to the transmission
    Oil cooler hoses
    Torque converter bolts and torque them to 46 ft. lbs. (63 Nm)
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm).
    Lower ball joints to the steering knuckle and torque the nuts to 40 ft. lbs. (55 Nm)
    Engine mount lower nuts and torque them to 35 ft. lbs. (47 Nm)
    Power steering cooler line clamps to the frame
    Power steering gear to the frame and torque the bolts to 59 ft. lbs. (80 Nm)
    Tie rod ends to the steering knuckles and torque the nuts to 63 ft. lbs. (85 Nm)
    Engine splash shields
    Front wheels
    Fluid filler tube
    Upper transmission bolts and torque them to 55 ft. lbs. (75 Nm)
    PNP switch and torque the bolts to 18 ft. lbs. (25 Nm)
    Range selector cable with the bracket and torque the nut to 15 ft. lbs. (20 Nm)
    Range selector cable to the PNP switch
    Wire harness connectors to the transmission
    Engine mount strut and torque the bolts to 37 ft. lbs. (50 Nm)

  2. Remove the engine support fixture.

    Throttle body air inlet duct
    Negative battery cable

  3. Fill the transmission with fluid.
  4. Adjust the wheel alignment.
  5. Start engine and check the engine and transaxle oil levels. Add oil if necessary.