Repair Procedures

REMOVAL

1. Loosen the wheel nuts slightly.
2. Raise the front of the vehicle and support it with safety stands in a proper location.
3. Remove the front wheel and tire.
4. Remove the drain plug(A). Drain the transaxle oil.
A. Lay a bottle keeping the gear oil under transaxle.
B. Remove drain plug(A) and washer(B) in the lower part of transaxle(C).




5. Remove the split pin(A), the lock nut(B) and the washer(C) from the front hub(D) under applying the brake.




6. Disconnect the tie rod end ball joint(A) from the knuckle(B) using the Special Tool (09568-34A000) after removing the split pin and lock nut.




7. Remove the wheel speed sensor(A) from the knuckle(B).




8. Remove the lower arm mounting bolts(A) from the knuckle.




9. Using a plastic hammer(A), disconnect the drive shaft(B) from the axle hub(C).




10. Push the axle hub(C) outward and separate the drive shaft(B) from the axle hub(C).
11. Insert a pry bar(A) between the transaxle case(B) and joint case(C), and separate the drive shaft from the transaxle case(B).





CAUTION:
- Use a pry bar(A) being careful not to damage the transaxle and joint.
- Do not insert the pry bar(A) too deep, as this may cause damage to the oil seal. [max. depth : 7mm (0.28 in.)]
- Do not pull the drive shaft by excessive force it may cause components inside the BJ or TJ joint(C) kit to dislodge resulting in a torn boot(E) or a damaged bearing.

12. Pull out the drive shaft(F) from the transaxle case(B).

CAUTION:
- Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
- Support the drive shaft properly.
- Replace the retainer ring whenever the drive shaft is removed from the transaxle case.

INSTALLATION

1. Apply gear oil on the drive shaft splines(A) and the contacting surface of differential case oil seal(B).
2. Before installing the drive shaft(C), set the opening side of the clip(D) facing downward.




3. After installation, check that the drive shaft cannot be removed by hand.
4. Install the drive shaft into the knuckle.

CAUTION:
Be careful not to damage the boot.

5. Install the lower arm assembly bolts(A) to the knuckle.

Tightening torque Nm(kgf-m, lb-ft) :
100 - 120 (10 - 12, 72 - 86)




6. Install the tie rod end(A) to the knuckle(B).

Tightening torque Nm(kgf-m, lb-ft) :
16 - 34 (1.6 - 3.4, 12 - 25)




7. Install the wheel speed sensor(A) to the knuckle(B).




8. After installing the washer(B) with convex surface outward, install the lock nut(A) and the split pin(C).




9. Install the wheel and tire.

INSPECTION

1. Check the drive shaft boots for damage and deterioration.
2. Check the ball joints for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks and wear.






DISASSEMBLY

NOTE:
- Do not disassemble the BJ assembly.
- Special grease must be applied to the drive shaft joint. Do not substitute with another type of grease.
- The boot band should be replaced with a new one.

1. Remove the clip(B) from drive shaft splines(A) of the transaxle side.




2. Remove both boot bands from the transaxle side UTJ case.




3. Pull out the boot from the transaxle side joint(UTJ).
4. When separating the joint and boot(A), remove the grease from the UTJ case(B).





CAUTION:
- Be careful not to damage the boot.
- Make alignment marks on spider roller assembly(A), UTJ case(B), and shaft splines(C) to aid reassembly.




5. Using a plier or flat-tipped (-) screwdriver, remove the snap ring(A).




6. Remove the spider assembly(B) from drive shaft(A) by using the Special Tool(09495-33000).




7. Clean the spider assembly.
8. Remove the boot(A), of the transaxle side joint(UTJ).

CAUTION:
Wrap tape(B) around the driveshaft splines(C) to protect the boot(A).




9. Remove both side of bands(B,C) of the dynamic damper(A).




10. Fix the drive shaft(A) with a vice(B) as illustrated.




11. Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper when the dynamic damper is removed.
12. Separate dynamic damper(A) from the shaft(B) carefully.




13. Remove both bands on the side of wheel.




14. Pull out the joint(BJ) boot on the side of wheel into the transaxle direction.

CAUTION:
Be careful not to damage the boot.