Use Balljoint Separator Tool To Remove The Track Rod End; Unscrew Nut And Remove Clamp Bolt Securing Lower Arm Balljoint; Expand The Lower Portion Of The Swivel Hub; Tap End Of The Driveshaft With A Soft-Faced Hammer - Opel Zafira B MPV 2006 Owners Workshop Manual

10•4 Suspension and steering
5 To prevent rotation of the wheel hub as the
driveshaft retaining nut is slackened, make up
a holding tool and bolt the tool to the wheel
hub using two wheel bolts (see Tool Tip).
6 With the holding tool in place, slacken and
remove the driveshaft retaining nut using a
socket and long bar. Where necessary, support
the socket on an axle stand to prevent it
slipping off the nut. This nut is very tight; make
sure that there is no risk of pulling the car off
the axle stands as the nut is slackened.
7 Unscrew the nut securing the track rod end
to the steering arm on the swivel hub, then
use a balljoint separator tool to remove the
track rod end (see illustration).
2.9 Use a chisel or screwdriver as a
wedge to expand the lower portion of the
swivel hub
2.11 b ... then free the driveshaft from the
swivel hub
2. 7 Use a balljoint separator tool to
remove the track rod end
8 Unscrew the nut and remove the clamp
bolt securing the front suspension lower arm
balljoint to the swivel hub (see illustration}.
Note that a new clamp bolt and nut will be
required for refitting.
9 Use a chisel or screwdriver as a wedge to
expand the lower portion of the swivel hub
(see illustration).
10 Using a lever, push down on the
suspension lower arm to free the balljoint from
the swivel hub, then move the swivel hub to
one side and release the arm, taking care
not to damage the balljoint rubber boot. It is
advisable to place a protective cover over the
rubber boot such as the plastic cap from an
aerosol can, suitably cut to fit.
11 The hub must now be freed from the end
of the driveshaft. It may be possible to pull
2.11 a Tap the end of the driveshaft with a
soft-faced hammer ...
2.13 Slacken and remove the two nuts and
bolts securing the suspension strut to the
swivel hub
2.8 Unscrew the nut and remove the
clamp bolt securing the lower arm balljoint
to the swivel hub
the hub off the driveshaft, but if the end of
the driveshaft is tight in the hub, temporarily
refit the driveshaft retaining nut to protect the
driveshaft threads, then tap the end of the
driveshaft with a soft-faced hammer while
pulling outwards on the swivel hub (see
illustrations). Alternatively, use a suitable
puller to press the driveshaft through the hub.
12 Mark the position of the suspension strut
on the swivel hub by drawing a circle around
the heads of the two retaining bolts. Note: This
is important to maintain the camber setting.
13 Slacken and remove the two nuts and
bolts securing the suspension strut to the
swivel hub, noting that new nuts and bolts
will be required for refitting {see illustration).
Disengage the swivel hub from the strut and
remove it from the car.
14 Ensure that the driveshaft outer constant
velocity joint and hub splines are clean, then
slide the hub onto the driveshaft splines. Fit
the new driveshaft retaining nut, tightening it
by hand only at this stage.
15 Engage the swivel hub with the suspension
strut, and insert the new bolts from the front of
the strut so that their threads are facing to the
rear. Fit the new nuts, tightening them by hand
only at this stage.
16 Locate the lower arm balljoint in the swivel
hub. Insert the new clamp bolt from the front
of the swivel hub, so that its threads are facing
to the rear. Fit the new nut to the clamp bolt,
and tighten it to the specified torque.
17 With the hub correctly located, align the
strut-to-swivel hub bolt heads with the marks
made on the strut during removal. Tighten the
bolts to the specified torque and through the
specified angles given in the Specifications,
using a torque wrench and angle-tightening
gauge.
18 Engage the track rod balljoint in the swivel
hub, then fit the new retaining nut and tighten
it to the specified torque setting.
19 Refit the brake disc together with the brake
caliper and pads as described in Chapter 9.
20 Reconnect the ABS wheel speed sensor
wiring connector and, where applicable, the
break pad wear warning indicator wire. Secure
the wiring in the relevant support brackets and
clips.