Help removing front axle/drive shafts

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JoshL

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Post Date: Fri, 09/12/2016 - 10:08am

Hi all,

I need help removing the front drivers side drive shaft in a 1999 5 door iO (in Australia) to replace a boot.

I've been following the instructions in the manuals linked in the resources section (section 26 pages 19-20). I've removed / loosened everything I can but cannot work out how to remove the drive shaft itself. The manual says to pull the strut, hub/knuckle assembly and lower arm towards me but nothings going to move unless I remove other bolts not mentioned in the instructions unless I'm wrong. What do I need to do to remove the shaft?

Here's a photo of where I'm up to if it helps:

Claude io

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Joined: 11/10/2011
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Post Number: #1
Post Date: Fri, 09/12/2016 - 11:51am

CV

Where are you located ?

This is from memory....from tyour picture you need to disconnect the tie rod end from the hub, diconnect the lower ball joint from the hub, disconnect the lower strut from the hub. Sometime the shaft can be stuck in the hub, you will have to put the nut back on and tap it with a hammer to push it in, the nut is to not damage the thread of the CV.

It should look like this, I have done the front disc here as well, you may not have to remove the lower strut fixation. Careful with the brake hose.

I hope this help, happy io.

My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io

JoshL

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Post Number: #2
Post Date: Fri, 09/12/2016 - 12:33pm

Thanks Claude, I'm located in

Thanks Claude, I'm located in the Lake Macquarie (Newcastle) area.

I'll have another go tomorrow. The shaft isn't stuck in the hub as I can push it back and forward, just don't have enough room to get it out with the hub assembly still in place. The lower ball joint and tie rod end are both stuck in the hub so I'll have to work on getting those unstuck.

Claude io

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Post Number: #3
Post Date: Fri, 09/12/2016 - 1:03pm

CV

The ball joint or tie rod can be a bit hard to remove if you haven't done it before. You can buy a ball joint separator like this https://www.sparesbox.com.au/toledo-ball-joint-separator-300mm-311273?gclid=CJPfkc_-5dACFc6bvQodWewNPg

These do help but they damage the boot, another one is this one http://www.harborfreight.com/3-4-quarter-inch-forged-ball-joint-separator-99849.html

This said, I have done lot of it with just a hammer like on this video, you do need a heavy hammer, small one won't do it.

https://

Using the hammer, because of location the tie rod is the easier one to do. For the lower ball joint you could leave it and disconnect the radius rod (2 x 14 mm nut under the arm, close to the ball joint, and disconnect the lower control arm from the cross member. This way you still can pull the hub away from the car without removing the ball joint, this should work, maybe even without removing the tie rod. If you still don't have enough room (ie because you cannot remove the tie rod ) removing the 2 lower bolt of the bottom strut should do it. The idea is for you to get enough room to move the hub away. It seems hard but all in all it is only a few more bolt and nut to remove, you already done most of it.

Happy io

My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io

JoshL

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Post Number: #4
Post Date: Fri, 09/12/2016 - 1:20pm

Thanks, that will be a big

Thanks, that will be a big help. I'll try with a hammer first like in the video and if that doesn't work I'll try your other method.

bob_oz

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Joined: 31/03/2011
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Post Number: #5
Post Date: Fri, 09/12/2016 - 5:11pm

replace boots

I'll hapily rebuild my gearbox or engine but I just take my io to people and get them to change boots -

CV's are a right pain and a boot repair is an hour job at best for a mechanic - i'd ebay the boot and drop it off somewhere to get it fitted

Claude io

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Post Number: #6
Post Date: Fri, 09/12/2016 - 6:23pm

cv

Once you have done it once, it is very very easy....some car are a pain but the io is very simple. It take me under an hour and a half to remove the cv, put new boot and fit it back to the car. A boot cost around $20 to $40.

Happy io

My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io

JoshL

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Post Number: #7
Post Date: Mon, 12/12/2016 - 11:44am

Thanks Claude, I was able to

Thanks Claude,

I was able to get it done on the weekend. The video for removing the tie-rod and lower arm was very helpful. A few strong hits with a 1.5kg club hammer was enough to remove both ball joints from the hub assembly. I had to remove the two 14mm bolts for the radius rod as well to get the lower arm to push out of the way.

Claude io

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Joined: 11/10/2011
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Post Number: #8
Post Date: Mon, 12/12/2016 - 6:13pm

great

Great to hear and well done, the hammer trick doesn't always work but it is always a good start, will work 90% of the time. I forgot the over tricky bit is to tight the clamps that comes with the new cv boot, again not hard if you know how.

Happy io

My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io

Help removing front axle/drive shafts

CV

Thanks Claude, I'm located in

CV

Thanks, that will be a big

replace boots

cv

Thanks Claude, I was able to

great

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