Published: 11-May-2011

Front Drive Halfshafts -

General Specification
Item Specification
Type Fully floating, solid shafts with inner and outer constant velocity joints
Recommended Lubricant
Item Specification
Front drive halfshaft (auto only) W eicon anti-seize grease
Outboard joint Use grease supplied with replacement boot kit
Inboard joint Use grease supplied with replacement boot kit
Torque Specifications
Description Nm lb-ft
Extension shaft bearing anchorage to block bolts - 3.2L Petrol 48 35
Extension shaft bearing anchorage to transmission bolts - 3.2L Petrol 25 18
Extension shaft bearing anchorage to block bolts- 2.2L Diesel 65 48
Extension shaft bearing anchorage to transmission bolts - 2.2L Diesel 25 18
Front halfshaft to hub bolt* 45 + 80° 33 + 80°
Heat shield to bearing anchorage 10 7
* New nuts/bolts must be fitted
 Published: 11-May-2011
Front Drive Halfshafts - Front Drive Halfshafts
Description and Operation

COMPONENT LOCATION

Item Part Number Description

1 - Halfshaft - RH (right-hand)
2 - Halfshaft - LH (left-hand)

OVERVIEW
Constant Velocity Joints
 Item Part Number Description
A - Inner constant velocity joint
B - Outer constant velocity joint
Each halfshaft comprises a solid steel shaft with inner and outer constant velocity joints. The inner joint is the 'tripode'
type with spherical bushing to reduce sliding resistance; the shaft and inner joint are one assembly.

The outer joint is the 'ball and socket' type, with a splined connection between the joint and the shaft. The joints are
packed with grease and protected by gaiters.

The halfshafts are of equal length to eliminate stiffness-related torque-steer.

Bearing Anchorage - Diesel Derivative

 Item Part Number Description
1 - Bearing anchorage - diesel derivative
Bearing Anchorage - Petrol Derivative

Item Part Number Description

1 - Bearing anchorage - petrol derivative
An extension shaft attached to the right-hand halfshaft is supported by a bearing anchorage arrangement. The bearing
anchorage on the diesel and petrol derivatives are of different construction, each designed to support the specific engine
torque loadings.
 Published: 11-May-2011
Front Drive Halfshafts - Front Drive Halfshafts
Diagnosis and Testing

For additional information.

REFER to: Driveline System (205-00 Driveline System - General Information, Diagnosis and Testing).
 Published: 13-May-2011
Front Drive Halfshafts - Front Halfshaft LH
Removal and Installation

Special Tool(s)
204-619
G-Clamp

205-754A
Splitter, Ball Joints

205-857
Remover, Halfshaft

Removal
• NOTE: The seal protector is not a special tool but is available from the parts catalogue.

1. Remove the plenum chamber panel.

Refer to: Plenum Chamber (412-01 Climate Control, Removal and

Installation).

2. Release the hood support struts and secure the hood in

an upright position.

3. 3. WARNING: Make sure to support the vehicle with axle

stands.

Raise and support the vehicle.

4. Remove the wheel and tire.

Refer to: Wheel and Tire (204-04 W heels and Tires, Removal and
Installation).
5. 5. WARNING: Make sure that a new nut is
installed.

Torque: 60 Nm

6. 6. NOTE: This step requires the aid of another

technician.

Compress the spring and damper assembly.

Special Tool(s): 204-619

7. 7. WARNING: Make sure that a new bolt is

installed.

Torque:
Stage 1:45 Nm
Stage 2:60°

8. Partially release the halfshaft from the wheel knuckle.

Special Tool(s): 205-857

 9. 9. CAUTION: Do not allow halfshafts to hang
unsupported at one end or joint damage will occur.

Partially release the halfshaft from the wheel knuckle.

10. 10. WARNING: Make sure that a new lower arm

ball joint nut is installed.

CAUTION: Make sure that the ball joint ball does

not rotate.

Torque: 100 Nm

11. Special Tool(s): 205-754A

12. 12. CAUTION: Do not use a hammer to detach the

halfshaft from the hub assembly, failure to follow this
instruction may result in damage to the halfshaft.

Remove the halfshaft from the wheel knuckle.

 13. 13. WARNING: Manual transmission: Fluid loss is
unavoidable, use absorbent cloth or a container to
collect the fluid.

Installation

1. 1. NOTE: Do not fully engage the halfshaft until the oil

seal protector has been removed.

To prevent oil seal damage use the protector when

installing the shaft into the transmission. It is not a
special tool but is available from the Parts Catalogue.

2. 2. CAUTIONS:

Install the halfshaft nut finger tight.

Do not use air tools to install the nut. Failure to follow this
instruction may result in damage to the component.

To install, reverse the removal procedure.

3. Manual transmission vehicles only: Check and top-up the

transmission fluid level.

Refer to: Transmission Fluid Level Check (308-03 Manual

Transmission/Transaxle, General Procedures).
 Published: 18-May-2011
Front Drive Halfshafts - Front Halfshaft RH
Removal and Installation

Special Tool(s)
204-619
G-Clamp

205-754A
Splitter, Ball Joints

205-857
Remover, Halfshaft

Removal

1. Remove the plenum chamber panel.

Refer to: Plenum Chamber (412-01 Climate Control, Removal and

Installation).

2. Release the hood support struts and secure the hood in

an upright position.

3. 3. WARNING: Make sure to support the vehicle with axle

stands.

Raise and support the vehicle.

4. Remove the wheel and tire.

Refer to: Wheel and Tire (204-04 W heels and Tires, Removal and
Installation).
5. 5. WARNING: Make sure that a new nut is
installed.

Torque: 60 Nm

6. 6. NOTE: This step requires the aid of another

technician.

Compress the spring and damper assembly.

Special Tool(s): 204-619

7. 7. WARNING: Make sure that a new bolt is

installed.

Torque:
Stage 1:45 Nm
Stage 2:60°

8. Partially release the halfshaft from the wheel knuckle.

Special Tool(s): 205-857

 9. 9. CAUTION: Do not allow halfshafts to hang
unsupported at one end or joint damage will occur.

Partially release the halfshaft from the wheel knuckle.

10. 10. WARNING: Make sure that a new lower arm

ball joint nut is installed.

CAUTION: Make sure that the ball joint ball does

not rotate.

Torque: 100 Nm

11. Special Tool(s): 205-754A

12. 12. CAUTION: Do not use a hammer to detach the

halfshaft from the hub assembly, failure to follow this
instruction may result in damage to the halfshaft.

Remove the halfshaft from the wheel knuckle.

 13. 13. WARNING: Manual transmission: Fluid loss is
unavoidable, use absorbent cloth or a container to
collect the fluid.

• NOTE: Petrol illustration shown, diesel uses studs

and nuts. The torque figure is the same for all models.

Torque: 25 Nm

Installation

1. 1. CAUTIONS:

Install the halfshaft nut finger tight.

Do not use air tools to install the nut. Failure to follow this
instruction may result in damage to the component.

To install, reverse the removal procedure.

2. Manual transmission vehicles only: Check and top-up the

transmission fluid level.

Refer to: Transmission Fluid Level Check (308-03 Manual

Transmission/Transaxle, General Procedures).
 Published: 11-May-2011
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal and Installation

Special Tool(s)
303-D121
Puller, General Purpose

Removal
• NOTE: RH inner constant velocity joint boot shown, LH is similar.

1. Remove the halfshaft.

Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal

and Installation).
Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal
and Installation).

2. 2. NOTE: Discard the retaining clips.

3. 3. CAUTION: Make sure that filings and swarf do
not enter the component.

4. 4. NOTE: Discard the retaining clip.

 5. Special Tool(s): 303-D121

Installation

1. 1. CAUTION: Extreme cleanliness must be exercised when

handling these components.

Clean and inspect the components for deterioration.

2. Install the inner CV boot onto the halfshaft.

3. 3. NOTE: Install a new retaining clip.

Install the inner CV joint inner onto the halfshaft.

4. 4. CAUTION: Make sure that these components are installed to

the noted removal position.

Install the inner CV joint outer onto the halfshaft.

5. Pack the inner CV joint with the grease supplied.

6. 6. NOTE: Install new retaining clips.

Secure the inner CV joint boot to the inner CV joint.

7. Install the halfshaft.

Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal

and Installation).
Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal
and Installation).
 Published: 11-May-2011
Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Installation

Special Tool(s)
303-D121
Puller, General Purpose

Removal
• NOTE: The outer constant velocity joint must not be removed from the shaft. The inner joint and boot have to be
removed to allow the outer joint boot to be replaced. The inner and outer boots are supplied together as a kit.

1. 1. WARNING: Make sure to support the vehicle with axle

stands.

Raise and support the vehicle.

2. Remove the halfshaft.

Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal

and Installation).
Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal
and Installation).

3. 3. NOTE: Discard the retaining clips.

4. 4. NOTE: Discard the retaining clips.

5. 5. CAUTION: Make sure that filings and swarf do
not enter the component.

6. 6. NOTE: Discard the retaining clip.

 7. Special Tool(s): 303-D121

Installation

1. 1. CAUTION: Extreme cleanliness must be exercised when

handling these components.

Clean and inspect the components for deterioration.

2. Install the inner and outer CV boots onto the halfshaft.

3. 3. NOTE: Install a new retaining clip.

Install the inner CV joint inner onto the halfshaft.

4. 4. CAUTION: Make sure that these components are installed to

the noted removal position.

Install the inner CV joint outer onto the halfshaft.

5. Pack the inner CV joint with the grease supplied.

6. Pack the outer CV joint with the grease supplied.

7. 7. NOTE: Install new retaining clips.

Secure the inner CV joint boot to the inner CV joint.

8. 8. NOTE: Install new retaining clips.

Secure the outer CV joint boot to the outer CV joint.

9. Install the RH halfshaft.

Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal

and Installation).
Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal
and Installation).