Repair Procedures

REMOVAL

1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire from front hub.





CAUTION:
Be careful not to damage to the hub bolts when removing the front wheel and tire.

3. Remove the split pin (A), then remove castle nut (B) and washer from the front hub under applying the brake.




4. Remove the ball joint assembly mounting bolt (A) from the knuckle.




5. Using a plastic hammer, disconnect driveshaft (A) from the axle hub (B).




6. Remove the bearing & bracket assembly.
(Gasoline 2.7 RH side only)
A. Remove the heat protector (A).




B. Remove the bearing & bracket assembly (A).




7. Insert a pry bar between the transaxle case and joint case, and separate the driveshaft (A) from the transaxle case.

[LH]





[RH]





CAUTION:
- Use a pry bar being careful not to damage the transaxle and joint.
- Do not insert the pry bar too deep, as this may cause damage to the oil seal.
- Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.

8. Pull out the driveshaft (A) from the transaxle case.





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

INSTALLATION

1. Apply gear oil on the oil seal contacting surface (B) of transaxle case and the driveshaft splines (A).

CAUTION:
- Replace circlip with new one.
- Be careful not to install a different kind, when replacing the circlip.




2. Before installing the driveshaft (C), set the opening side of the circlip (D) facing upward.
3. After installation, check that the driveshaft (C) cannot be removed by hand.
4. Install the driveshaft (A) to the axle hub (B).





CAUTION:
- Be careful not to damage the both boots.
- Keep clean without contamination on contacting point between the hub-bearing and BJ.

5. Install the ball joint assembly mounting bolt (A) to the knuckle.

Tightening torque Nm (kgf.m, lb-ft) :
98.1 - 117.7 (10 - 12, 72.3 - 86.8)




6. Install the washer (C), castle nut (B) and new split pin (A) to the front hub assembly.

Tightening torque Nm (kgf.m, lb-ft) :
196.1 - 274.6 (20 - 28, 144.7 - 202.5)





CAUTION:
The washer (C) should be assembled with convex surface outward when installing the castle nut (B) and split pin (A).




7. Install the wheel and the tire to the front hub.

Tightening torque Nm (kgf.m, lb-ft) :
88.3 - 107.9 (9 - 11, 65.1 - 79.6)





CAUTION:
Be careful not to damage the hub bolts when installing the front wheel and tire.

INSPECTION

1. Check the driveshaft boots for damage and deterioration.
2. Check the boots for grease leak.
3. Check the ball joint for wear and damage.
4. Check the splines for wear and damage.
5. Check the dynamic damper for cracks, wear and position.




6. Check the driveshaft for cracks and wears.

DISASSEMBLY

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

1. Remove the circlip (B) from driveshaft splines (A) of the transaxle side UTJ case.




2. Remove the both boot clamps from the transaxle side UTJ case, using the special tool(09495-39100).




3. Pull out the boot from the transaxle side joint(UTJ).
4. While dividing joint(UTJ) boot (A) of the transaxle side, wipe the grease in UTJ case (B) and collect them respectively.





CAUTION:
- Be careful not to damage the boot.
- According to illustration below, put alignment marks (D) across spider roller assembly (A), UTJ case (B), shaft splines (C) to aid in reassembly.




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




6. Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).




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

CAUTION:
For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).




9. Remove the band(B) from the dynamic damper(A) using the special tool(09495-39100).

[Gasoline 2.4 RH side]




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

[Gasoline 2.4 RH side]




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 the dynamic damper (A) from the shaft (B) carefully.

[Gasoline 2.4 RH side]






INSPECTION

1. Check the driveshaft boots for damage and deterioration.
2. Check the boots for grease leak.
3. Check the ball joint for wear and damage.
4. Check the splines for wear and damage.
5. Check the dynamic damper for cracks, wear and position.




6. Check the driveshaft for cracks and wears.

REASSEMBLY

1. Wrap tape around the driveshaft splines (UTJ. side) to prevent damage to the boots.
2. To reassemble the dynamic damper, keeping the shaft in the straight, tighten the dynamic damper with dynamic damper band.









3. Install the UTJ boot bands and UTJ boot.
4. Install the spider assembly (A) and the circlip (B) to the spline (C) on driveshaft.
At this time align the marks (D) each other.








5. Add the specified grease to the UTJ as mush as wiped away at inspection.
6. Install the UTJ boots.
7. To control the air in the UTJ boot, keep the specified distance between the boot bands when they are tightened.









8. Using the SST(09495-39100), secure the UTJ boot bands.