Saturn 25921572 Front Wheel Drive Intermediate Shaft Assembly

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To remove the axle shaft, start by setting the parking brake and removing the wheel cover or hubcap. Loosen the axle shaft/hub nut with a large socket and breaker bar, but do not remove it completely yet. Then, loosen the front wheel lug nuts, raise the vehicle, and support it securely on jackstands before removing the wheel. Proceed to remove the axle shaft hub nut. Disconnect the stabilizer bar end link and the tie-rod end from the steering knuckle, and also disconnect the ABS wheel speed sensor. Separate the control arm from the steering knuckle and tap the end of the axle shaft with a soft-faced hammer to loosen it from the hub splines. If it's stuck, a puller may be required. Once the axle shaft is loosened, pull out on the steering knuckle and detach the axle shaft from the hub, suspending the outer end with a bungee cord or wire. Before removing the axle shaft completely, check for lubricant leakage around the differential seal; if there's evidence of a leak, replace the seal after removing the axle shaft. To remove the axle shaft assembly, carefully pry the inner joint off the transaxle side gear shaft (or drive shaft for the right-side axle shaft). Avoid using the axle shaft to pull on the inner joint to prevent damage to its components. Be cautious not to over-extend the inner joint or damage the axleshaft boots during removal. Should the vehicle need to be moved while the axle shaft is out, a large bolt with washers can be inserted through the hub and tightened securely. For installation, remove the old set-ring from the transaxle stub shaft or drive shaft and install a new one. Apply multi-purpose grease around the joint splines. When installing the axle shaft, hold it straight out and push it sharply to seat the axle shaft set-ring. Check if the set-ring is properly seated by attempting to pull the inner CV joint housing out of the transaxle by hand. Clean the axle shaft outer CV joint threads, coat the splines with grease, and guide the axle shaft into the hub splines. Install the new axle shaft/hub nut and tighten it securely. Reconnect the control arm and tie-rod end, and tighten the suspension fasteners to their torque specifications. Install the wheel and lug nuts, then lower the vehicle. Tighten the axle shaft/hub nut and wheel lug nuts to their specified torques. Add transaxle lubricant if needed. To remove the Drive Shaft, first remove the right-side driveaxle, then take out the Drive Shaft bracket bolts and the wheel speed sensor before pulling the Drive Shaft out of the transaxle. If necessary, replace the oil seal. For installation, reverse the removal steps, starting by installing the lower bracket bolt closest to the drivebelt end of the engine, but do not tighten it. Install the other two bolts and then tighten the Drive Shaft bracket bolts, beginning with the upper bolt, to their torque specifications. Finally, install the driveaxle.

When installing the driveaxle, hold it straight out and push it sharply to seat the driveaxle set-ring. Check if the set-ring is properly seated by attempting to pull the inner CV joint housing out of the transaxle by hand. Clean the driveaxle outer CV joint threads, coat the splines with grease, and guide the driveaxle into the hub splines. Install the new driveaxle/hub nut and tighten it securely. Reconnect the control arm and tie-rod end, and tighten the suspension fasteners to their torque specifications. Install the wheel and lug nuts, then lower the vehicle. Tighten the driveaxle/hub nut and wheel lug nuts to their specified torques. Add transaxle lubricant if needed.

To install the rear axle assembly, raise it to approximate ride height before tightening the through-bolts (if removed for bushing replacement).

Proceed to remove the drive axle hub nut. Disconnect the stabilizer bar end link and the tie-rod end from the steering knuckle, and also disconnect the ABS wheel speed sensor. Separate the control arm from the steering knuckle and tap the end of the driveaxle with a soft-faced hammer to loosen it from the hub splines. If it's stuck, a puller may be required. Once the driveaxle is loosened, pull out on the steering knuckle and detach the driveaxle from the hub, suspending the outer end with a bungee cord or wire.

Start by loosening the rear wheel lug nuts and raising the rear of the vehicle on jackstands. Remove the rear wheels and disconnect the brake pipes from the hoses at the trailing arms, plugging the fittings to prevent dirt or fluid loss. If applicable, disconnect the ABS electrical connectors at the rear axle. Release the ends of the parking brake cables from the rear brakes and remove the coil springs. Support the rear axle with floor jacks and remove the mounting bolts securing the axle bushing brackets to the body. Carefully lower the rear axle assembly to the floor and inspect the trailing arm pivot bushings.

Start by loosening the rear wheel lug nuts and raising the rear of the vehicle on jackstands. Remove the rear wheels and disconnect the brake pipes from the hoses at the trailing arms, plugging the fittings to prevent dirt or fluid loss. If applicable, disconnect the ABS electrical connectors at the rear axle. Release the ends of the parking brake cables from the rear brakes and remove the coil springs. Support the rear axle with floor jacks and remove the mounting bolts securing the axle bushing brackets to the body. Carefully lower the rear axle assembly to the floor and inspect the trailing arm pivot bushings.