Driveline Repair Instructions For The 1959 Chevrolet Passenger Car
Task Timeline: Driveline Removal: 30 minutes to 1 hour Driveline Repair: 1 to 2 hours Driveline Installation: 30 minutes to 1 hour Assumes a working knowledge of hand tools. Assumes a flat hard surface on which to park the vehicle. Assumes counter-clockwise rotation to loosen bolts and nuts. Assumes clockwise rotation to tighten bolts and nuts. Assumes vehicle has working emergency brake. 7/16 inch boxed end wrench. 9/16 inch boxed end wrench. One large straight-bladed screwdriver. An assortment of shop rags. One roll of Duct Tape. One pair of automotive repair ramps. One pair of wheel blocks -- 2x4 wood cut to 15 inches in length. One Carrier Bearing Support. Three Universal Joints.

Task Assumptions:

Task Necessities:
Modules 1. Secure Vehicle
Steps 1.1 Place ramps behind rear wheels. 1.2 Back the vehicle onto the ramps. 1.3 Set the emergency brake. 1.4 Place transmission in neutral. 1.5 Place blocks ahead of the front tires. 1.6 Kick the blocks lightly towards tread with foot, to secure against tire. 2. Remove Carrier 2.1 Choose the 9/16 inch boxed end wrench. Bearing Support 2.2 Identify the two bolts in the center of the vehicle frame. 2.3 Remove each bolt. 2.4 Place removed bolts in safe storage area. 2.5 Replace bolts if worn or broken. 3. Remove 3.1 Choose the 7/16 inch boxed end wrench. Universal Joint 3.2 Identify the differential yolk under the rear portion of the car. Attachment 3.3 Identify the driveline's rear universal joint attached to the differential yolk. 3.4 Remove the four nuts and washers holding driveline to the differential yolk. 3.5 Replace nuts and washers if worn. 3.6 Remove two u-bolts from universal joint. 4. Prep Driveline 4.1 Place shop rag on ground below rear of driveline. For Removal 4.2 Choose the large straight-bladed screwdriver. 4.3 Place screwdriver in space between universal joint and differential yolk. 4.4 Place hand on driveline for support. 4.5 Pry forward carefully with screwdriver to unseat universal joint from its holder. 4.6 Lower rear of driveline to the shop rag. 5. Remove Driveline 5.1 Pull slowly and carefully on driveline towards back of vehicle. 5.2 Remove driveline completely from driveline tunnel. 5.3 Pull driveline from underneath vehicle.
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Sub-Tasks Steps 6. Prepare For 6.1 Gather driveline, universal joints and carrier bearing support. Machine Shop Work 6.2 Deliver driveline, universal joints and carrier bearing support to machine shop. 6.3 Instruct worker to install new parts on driveline. 7. Prepare For 7.1 Wrap shop rag around the front yolk of the driveline. Driveline Installation 7.2 Secure shop rag to yolk with duct tape. 7.3 Place front of driveline inside driveline tunnel. 7.4 Push forward on driveline slowly and carefully. 7.5 Watch for front of driveline to appear through the forward portion of the tunnel. 7.6 Remove shop rag. 7.7 Place yolk into rear of transmission. 7.8 Slide yolk forward slowly until it no longer moves. 8.1 Identify the two slotted holes in the bottom of the differential tunnel. 8.2 Line holes up with threaded holes in carrier bearing support inside tunnel. 8.3 Choose 9/16 inch boxed end wrench. 8.4 Thread bolts into holes one rotation. 8.5 Confirm that the bolts are loose enough for the driveline to move. 9.1 Remove carefully the black tape holding universal joint caps in place. 9.2 Raise rear of driveline to the differential yolk. 9.3 Line up universal joint caps with the differential yolk by rotating driveline.
8. Attach Carrier Bearing Support: Initial Phase
9. Attach Driveline To Differential
9.4 Place universal joint caps slowly into corresponding cradle of differential yolk. 9.5 Place u-bolts through holes in differential yolk. 9.6 Place nuts on threaded ends of the u-bolts. 9.7 Choose 1/2 inch boxed end wrench. 9.8 Tighten nuts in an x-pattern, applying torque evenly to each one. 10. Attach Carrier 10. 1 Identify Carrier Support Bolts that were left hand tight. Bearing Support: 10. 2 Choose 9/16 inch boxed end wrench. Final Phase 10.3 Tighten bolts. 11. Prepare Vehicle 11.1 Remove all remaining tools and rags from underneath the vehicle. For Driving 11.2 Kick blocks away from front of tires. 11.3 Release emergency brake. 11.4 Drive vehicle forward, slowly off ramps.