CHEVROLET PLYMOUTH ACCLAIM 1993 Owners Manual

(2) Slide the tripod back along the shaft, either by
hand or by tapping the body with a brass drift. This
will expose the circlip on the end of the interconnect-
ing bar. (3) Remove the circlip from the end of intercon-
necting bar (Fig. 6).
(4) Remove the tripod from the interconnecting
bar. It is not necessary to remove the stop ring from
the interconnecting bar unless the bar is being re-
placed (Fig. 7). S.S.G. AND G.K.N. WITH SINGLE RING TRIPOD
RETENTION.
Remove the tripod assembly to interconnecting
shaft retaining snap ring from the interconnecting
shaft end groove (Fig. 8). Remove the tripod assem-
bly from the interconnecting shaft by hand or by tap-
ping the body of the tripod assembly with a brass
punch (Fig. 9).
G.K.N. WITH DOUBLE RING TRIPOD RETENTION. (1) Expand and remove the outer tripod assembly
to interconnecting shaft, retaining snap ring (Fig.
10). (2) Remove the tripod assembly from the intercon-
necting shaft. Tripod can be removed either by hand
or by tapping the tripod body with a brass drift (Fig.
4). Do not hit the outer tripod bearings in an attempt
to remove tripod assembly from interconnecting
shaft. (3) Remove inner tripod assembly to interconnect-
ing shaft, retaining snap ring from interconnecting
shaft (Fig. 11).
Fig. 5 Removing Stop Ring (G.K.N.)
Fig. 6 Removing Circlip
Fig. 7 Tripod Removed From The Interconnecting Bar
Fig. 8 Outer Tripod Retaining Snap Ring Removal
Ä SUSPENSION AND DRIVESHAFTS 2 - 33

INSPECT TRIPOD AND HOUSING
Remove as much grease as possible from assembly
and inspect joint housing ball raceway and tripod components for EXCESSIVE wear and replace if nec-
essary.
Inspect the spring, spring cup, and the spherical end
of the connecting shaft for EXCESSIVE wear or dam-
age and replace, if necessary.
ASSEMBLE C/V JOINT
TRIPOD ASSEMBLY INSTALLATION G.K.N.
(1) Slide rubber washer seal over stub shaft and
down into the groove provided (Fig. 12). The rubber
washer seal is used only on the right inner C/V
joint on the Equal Length Drive Shaft Systems.
(2) Fasten the (new) boot to the interconnecting
shaft. See Boots Install. (3) Slide the stop ring back into the stop ring groove
on the interconnecting bar (Fig. 5). (4) Install a new circlip in the circlip groove on the
interconnecting bar (Fig. 6). (5) With the chamfered end (Fig. 13 & 14 ) of the
tripod facing the stop ring. Align the tripod splines and
push or tap on the body of the tripod assembly with a
SOFT drift, until tripod is seated on the shaft. Check
to make sure that the Tripod is Engaged by
attempting to pull the tripod off of the shaft by
hand.
TRIPOD ASSEMBLY INSTALLATION S.S.G. (1) Slide rubber washer seal over stub shaft and
down into the groove provided (Fig. 12). The rubber
washer seal is used only on the right inner C/V
joint on the Equal Length Drive Shaft Systems. (2) Fasten the (new) boot to the interconnecting
shaft. See Boots Install. (3) Install first wire ring tripod retainer over inter-
connecting shaft, slide tripod on the shaft, both ends
are the same (Fig. 15).
Fig. 9 Tripod Assembly Removal From Interconnecting Shaft
Fig. 10 Removing Outer Tripod Retaining Snap Ring (G.K.N.)
Fig. 11 Removing Inner Tripod Retaining Snap Ring(G.K.N.)
Fig. 12 Rubber Washer Seal Installation
2 - 34 SUSPENSION AND DRIVESHAFTS Ä

(4) Install the snap ring into the groove on the in-
terconnecting shaft to lock the tripod in position (Fig.
16) Should the wire ring tripod retainer not be suitable
for reuse or a new one is not available,the following
procedure should be used: (1) Install tripod on the shaft.
(2) Install spring and cup assembly into inner joint
housing. (3) Position small end of boot in locating grooves
on the interconnecting shaft. (4) Clamp the small end boot clamp onto boot, re-
taining boot to the interconnecting shaft. (5) Distribute 1/2 packet of grease into boot and
1/2 into housing. (6) Install tripod into housing.
(7) Place large clamp over shaft.
(8) Install driveshaft into vehicle, see Driveshaft
Install. (9) Position large end of boot into locating groove.
(10) Slide large clamp into position.
(11) See Boot Install for clamping instructions.
TRIPOD ASSEMBLY INSTALLATION S.S.G. & G.K.N. WITH
SINGLE RING RETENTION
(1) Fasten the (new) boot to the interconnecting
shaft. See Boots Install. (2) Install the tripod assembly onto the intercon-
necting shaft until it is past the snap ring groove on
the shaft (Fig. 17). If required the tripod assembly
can be tapped onto the interconnecting shaft using a
brass drift, on the body of the tripod assembly (Fig.
4). Do not hit the outer tripod assembly bearings in
an attempt to install tripod on interconnecting shaft.
Fig. 13 G.K.N. Tripod Thick Ring Side
Fig. 14 G.K.N. Tripod Circlip Side
Fig. 15 Tripod Snap Ring Installation
Fig. 16 Tripod Installation
Ä SUSPENSION AND DRIVESHAFTS 2 - 35

(3) Install a NEWouter tripod assembly to inter-
connecting shaft retaining snap ring, into intercon-
necting shaft snap ring groove (Fig. 18). Be sure that
the snap ring is fully seated into the snap ring
groove around the entire interconnecting shaft.
TRIPOD ASSEMBLY INSTALLATION G.K.N. WITH DOUBLE
RING RETENTION
(1) Fasten the (new) boot to the interconnecting
shaft. See Boots Install. (2) Install the inner tripod assembly retaining
snap ring into the retaining groove on the intercon-
necting shaft (Fig. 19). (3) Install the tripod assembly onto the intercon-
necting shaft until it is past the outer snap ring
groove on the shaft (Fig. 17). If required the tripod
assembly can be tapped onto the interconnecting
shaft using a brass drift, on the body of the tripod as-
sembly (Fig. 4). Do not hit the outer tripod assembly
bearings in an attempt to install tripod on intercon-
necting shaft. (4) Install outer tripod assembly to intermediate
shaft retaining snap ring into snap ring groove on
intermediate shaft (Fig. 20).
INNER C/V JOINT HOUSING INSTALLATION
G.K.N.
(1) Distribute 1/2 the amount of the grease provided
into the housing and the remaining amount into the
boot. (2) Position the spring in the housing spring pocket
with the spring cup attached to the exposed end of the
spring (Fig. 21). Place a small amount of grease on the
concave surface of the spring cup.
CAUTION: Care must be taken to ensure proper
spring positioning. The spring must remain centered
in the housing spring pocket when the tripod is
installed and seated in the spring cup (Fig. 13).
(3) Clamp the stub shaft of the housing in a vise.
Use protective caps on jaws of vise so stub shaft
does not get damaged by the vise. Position the
interconnecting shaft and the tripod assembly on top of
Fig. 17 Interconnecting Shaft Snap Ring Groove
Fig. 18 Outer Tripod Retaining Snap Ring Installation
Fig. 19 Inner Snap Ring Installation
Fig. 20 Outer Snap Ring Installation
2 - 36 SUSPENSION AND DRIVESHAFTS Ä

the plastic retaining collar. Carefully insert each of the
tripod rollers into the retaining collar, one at a time
while holding the interconnecting shaft on an angle.
Carefully push down on the shaft until the rollers are
locked into retaining collar in the housing.(4) Position the boot over the boot retaining groove
in the housing and clamp in place. See Boots Install.
S.S.G.
(1) Distribute 1/2 the amount of the grease provided
into the housing and the remaining amount into the
boot. (2) Position the spring in the housing spring pocket
with the spring cup attached to the exposed end of the
spring (Fig. 21). Place a small amount of grease on the
concave surface of the spring cup.
CAUTION: Care must be taken to ensure proper
spring positioning. The spring must remain centered
in the housing spring pocket when the tripod is
installed and seated in the spring cup (Fig. 21).
(3) Slip tripod into housing and install the tripod
wire retaining ring into position. Check for the ability
of the retaining ring to hold the tripod in the housing. (4) Position the boot over the boot retaining groove
in the housing and clamp in place. See Boots Install.
OUTER C/V JOINT
DISASSEMBLE
(1) Remove boot clamps on boot and discard (Fig. 1).
(2) Wipe away grease to expose joint.
(3) G.K.N. Remove outer C/V Joint from shaft by
supporting the interconnecting shaft in a vise. Use
protective caps on the jaws of the vise to prevent
damage to the interconnecting shaft. Give a sharp tap to the top of housing to dislodge joint from
internal circlip installed in a groove at the outer end
of the shaft (Fig. 2).
S.S.G. A single circlip located in a groove on the
cross, is used to retain the cross to the shaft (Fig. 3).
Loosen the damper weight bolts and slide it and the
boot towards the inner joint. Expand the circlip with
snap ring pliers and slide joint from shaft. Install
damper weight, see Damper Weights.WEAR SLEEVE
A wear sleeve installed on the outer C/V joint
housing (Fig. 1) provides a wipe surface for the hub
bearing seal (installed in the steering knuckle). (4) If bent or damaged, carefully pry wear sleeve
from C/V joint machined ledge. (5) Remove circlip from shaft groove and discard
(Fig. 4). A replacement boot package will include this
circlip. (6) Unless the shaft is damaged and needs replac-
Fig. 1 Outer C/V Joint Components
Fig. 2 Remove Joint from Shaft .
Fig. 21 Spring and Cup Installation
Ä SUSPENSION AND DRIVESHAFTS 2 - 37

ing, do not remove the heavy spacer ring from the
shaft, G.K.N. only (Fig. 4).
(7) With joint separated from the interconnecting
shaft proceed as follows:
² If outer C/V joint was operating satisfactorily and
grease does not appear to be contaminated, just re-
place boot. Bypass the following disassembly proce-
dure for the C/V joint assembly, See Boots Install.
² If outer joint is noisy or badlyworn. Bypass the
following disassembly and replace entire unit. It is
also recommended that the boot be replaced. The
Boot Package includes the boot, clamps, retaining
ring (circlip), and lubricant. See boots install. (8) Hold joint vertically in vise by clamping on
splined shaft, using soft jaws to prevent damage. (9) Wipe off surplus grease and mark relative po-
sition of inner cross, cage and housing with a dab of
paint (Fig. 5). (10) Press down on one side of inner race to tilt
cage and remove ball from opposite side (Figs.5 and
6). If joint is tight, use a hammer and brass drift to
tap inner race. Do not hit the cage. Repeat this step
until all 6 balls are removed. A screwdriver may be
used to pry balls loose. (11) Tilt the cage and inner race assembly verti-
cally and position two opposing cage windows in area
between the ball grooves. Remove the cage and inner
race assembly by pulling upward away from the
housing (Fig. 7). (12) Turn inner cross (driver) 90É to cage and align
one of the race spherical lands with cage window.
Raise land into cage window and remove inner race
by swinging out (Fig. 8).
INSPECT
Check grease for contamination and all parts for
defects as follows: (1) Wash all parts in suitable solvent and dry,
preferably with compressed air. (2) Inspect housing ball races for excessive wear
and scouring.
Fig. 3 Circlip Retainer in Cross S.S.G.
Fig. 4 Remove Circlip
Fig. 5 Rotate Cage & Cross to Remove Balls
Fig. 6 Ball Released
2 - 38 SUSPENSION AND DRIVESHAFTS Ä

(3) Check splined shaft and nut threads for dam-
age. (4) Inspect all 6 balls for pitting, cracks, scouring
and wear. Dulling of surface is normal. (5) Inspect cage for excessive wear on inside and
outside spherical surfaces, surface ripples on cage
window, cracks, and chipping. (6) Inspect inner race (cross) for excessivewear or
scouring of ball races. Any of the above defects will warrant replac-
ing the C/V assembly as a unit. Polished areas in races (cross and housing) and on
cage spheres are normal and do not indicate need for
joint replacement. Unless they are suspected of caus-
ing noise and vibration.
ASSEMBLE
If outer joint was not disassembled nor the
wear sleeve damaged go to step 11. (1) Position new wear sleeve on joint housing ma-
chined ledge (Fig. 1). Assemble Installer, Special Tool
C-4698 (Tool is provided with handle and dual purpose
drive head for installing wear sleeve onto C/V joint
housing and (head reversed) seal into knuckle). See
KNUCKLE BEARING SEAL. (2) See (Fig. 1). Assemble tool and install wear
sleeve.
(3) Lightly oil all components before assembling
outer joint. (4) Align parts according to paint markings.
Fig. 7 Removing Cage & Cross Assembly from Housing
Fig. 8 Removing Cross from Cage
Fig. 1 Tool Set-Up for Wear Sleeve Installation
Ä SUSPENSION AND DRIVESHAFTS 2 - 39

(5) Insert one of the inner race (cross) lands into
cage window (Fig. 2) and feed race into cage. Pivot
cross 90É to complete cage assembly (Fig. 3).
(6) Align opposing cage windows with housing
land and feed cage assembly into housing (Fig. 4).
Pivot cage 90É to complete installation. When properly assembled the large counterbore in
the cross should be facing outward from the joint on
G.K.N. units (Figs.3 and 6). On the S.S.G. joint the
internal circlip in the cross will be facing outward
from the housing (Fig. 5). (7) Apply lubricant to ball races from packet pro-
vided in boot kit and distribute equally between all
sides of ball grooves. One packet is sufficient to lu-
bricate the joint.
Fig. 4 Installing Cage & Cross into Housing
Fig. 5 Cage & Cross Assembled S.S.G.
Fig. 6 Cage & Cross Installed in Housing G.K.N.
Fig. 2 Installing Cross into Cage
Fig. 3 Cage & Cross Assembled G.K.N.
2 - 40 SUSPENSION AND DRIVESHAFTS Ä

(8) Insert balls into raceway by tilting cage and in-
ner race assembly (Fig. 7). (9) Fasten boot to shaft. See Boots Install.
(10) On G.K.N. units insert the new circlip, pro-
vided with kit in shaft groove. Do not over expand
or twist circlip during assembly (Fig. 8). The S.S.G.
unit has a reusable circlip retainer that is an inte-
gral part of driver assembly.
(11) Position outer joint on splined end with hub
nut on stub shaft. Engage splines, and tap sharply
with mallet (Fig. 9). (12) Check that circlip is properly seated by at-
tempting to pull joint from the shaft. (13) Locate large end of boot over joint housing
checking that boot is not twisted. (14) Fasten boot to housing. See Boots Install.
INTERMEDIATE SHAFT ASSEMBLY RECONDITION
Reconditioning of intermediate shaft assembly (Fig.
1), for Equal Length Drive Shaft System vehicles is
the same for manual and automatic transaxles.
INTERMEDIATE SHAFT ASSEMBLY
REMOVE
(1) Remove right driveshaft. See Driveshaft As-
semblies Remove. (2) Remove speedometer pinion from the extension
housing (Fig. 2). (3) Remove the two bolts which mount the bearing
assembly bracket to the engine block (Fig. 1). (4) Remove assembly from transaxle extension by
pulling outward on the yoke (Fig. 3).
UNIVERSAL JOINT AND ROLLER
Disassemble
(1) Mark relationship of shaft to shaft to ensure
proper alignment at assembly. Apply penetrating oil
to bushings and remove snap rings. (2) Support yoke in vise and place a socket large
enough to receive bushing on top of yoke. A 1-1/8
inch socket is suitable (Fig. 4). (3) Striking socket with hammer will cause yoke to
move down and bushing to move up out of yoke into
socket. (4) After removing one bushing, turn parts in a
vise and remove other bushing in same manner.
Assemble (1) Hold cross in position between yoke ears with
one hand and start one bushing assembly into yoke
with other hand (Fig. 5). (2) Continue to hold cross in position, then ham-
mer bushing assembly into yoke and install snap
ring. (3) Install opposite bushing and snap ring in the
same manner.
Fig. 7 Inserting Balls into Raceway
Fig. 8 Installing New Circlip
Fig. 9 Position Joint onto Shaft Splines
Ä SUSPENSION AND DRIVESHAFTS 2 - 41

(4) Repeat process for stub shaft yoke after align-
ing marks on yoke and shaft.
BRACKET, BEARING, AND SLINGER ASSEMBLY
Disassemble
(1) Remove the two screws that hold the bearing
assembly to the support bracket. (2) Press the intermediate shaft out of the bearing
assembly and outer slinger. Do not dent or damage the
inner slinger. Also avoid damaging the end of the stub
shaft, the rubber seal on the right driveshaft mates
with this surface. Excessive wear to the rubber seal
would result and allow moisture to enter, corroding the
internal splines. (3) If either slinger is damaged, it should be re-
placed. Carefully press the shaft through the slinger,
discard the slinger. The bearing assembly is not serviceable and
must be replaced as an assembly.
Assemble(1) Place new slinger on stub shaft and drive it on until
it bottoms out on the shoulder of the shaft (Fig. 6). A tool
for this purpose can be fabricated from a piece of pipe that
has the dimensions noted in (Fig. 6).
Fig. 1 Intermediate Shaft Assembly
Fig. 2 Remove Speedometer Pinion
Fig. 3 Removing Intermediate Shaft Assembly
2 - 42 SUSPENSION AND DRIVESHAFTS Ä