How to replace Intermediate Shaft on 2006 Chevrolet Cobalt ?

Intermediate Shaft

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and support the vehicle.
3. Remove the RH tire and wheel assembly.
4. Disconnect the ball joint pinch bolt.
5. Rotate the steering knuckle to access the halfshaft inner joint.
6. Separate the halfshaft from the intermediate drive shaft.
7. Reposition and support the halfshaft from the intermediate drive shaft.
   
   
   

   

   Fig. Separate the halfshaft from the intermediate drive shaft
8. Inspect the halfshaft-to-intermediate drive shaft seal for excessive wear, damage, and/or contamination and replace if necessary.
9. Remove the rear, or LH intermediate drive shaft bracket-to-engine block bolts.
   
   
   

   

   Fig. Remove the remaining intermediate shaft bracket-to-engine block bolts
10. Remove the remaining intermediate shaft bracket-to-engine block bolts.
    
    
    

    

    Fig. Intermediate shaft removal
11. Using care to not damage the transaxle output shaft seal, remove the intermediate drive shaft assembly.
12. Inspect the transaxle output shaft seal for damage and/or contamination and replace if necessary.

To install:

1. Install tool J 44394 into the transaxle output shaft seal.
2. Install the intermediate drive shaft into the transaxle until the drive shaft splines are past the seal, remove the tool, then fully install the drive shaft.
3. Install, but do NOT tighten the intermediate drive shaft bracket-to-engine block forward, or RH bolt.
4. Tighten the intermediate drive shaft bracket-to-engine block bolts, beginning with the upper bolt. Tighten the bolts to 37 ft. lbs. (50 Nm).
5. Apply a very small amount of grease, GM P/N 1051344 (Canadian P/N 993037), or equivalent to the splines of the halfshaft inner joint.
6. Install the halfshaft into the intermediate drive shaft.
7. Verify that the halfshaft is properly engaged:
   1. Grasp the inner tripod housing and pull the inner housing outward. Do NOT pull on the wheel drive axle shaft.
   2. The halfshaft will remain firmly in place when properly engaged.
8. Install the tire and wheel assembly.
9. Lower the vehicle.
10. Inspect the transaxle fluid level.

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