Axle Shaft: Service and Repair

NOTE:
- The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed.



- Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with the 09608-16042 (09608-02021, 09608-02041) Special Service Tool (SST).






REMOVAL
1. Remove the front wheel and front fender apron seal.
Tighten lug nuts to 103 Nm (76 ft.lbs.).

2. Remove the drive shaft lock nut, by performing the following.



a. Remove the cotter pin and lock cap.
b. While applying brakes, remove the nut.
NOTE: When installing the nut, tighten it to 294 Nm (217 ft.lbs.).

3. Drain the ATF.
4. Disconnect the tie rod end from the steering knuckle.
5. Disconnect the lower ball joint from the lower suspension arm.
6. Disconnect the drive shaft from the axle hub by following these procedures.



a. Using a plastic hammer, disconnect the drive shaft from the axle hub.
NOTE: Cover the drive shaft boot with a cloth to protect it from damage.
b. Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub.

7. Remove the left side drive shaft by performing the following.



a. Using a brass bar and hammer, remove the snap ring, and remove the drive shaft.

NOTE:
- Coat gear oil to the inboard joint shaft and differential case sliding surface.
- Before installing the drive shaft, set the snap ring opening side facing downward.
- Whether or not the inboard joint shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
- After installation, check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in the axial direction.
- After installation, check that the drive shaft cannot be removed by hand.

b. Using a screwdriver, remove the snap ring from the inboard joint shaft.

8. Remove the right side drive shaft by following these procedures.
a. Remove the bearing lock bolt.
NOTE: When installing the bolt, tighten the bolt to 32 Nm (24 ft.lbs.).




b. Using pliers, remove the snap ring and drive shaft.
NOTE: Coat the inboard joint shaft and differential case sliding surface with gear oil.


DISASSEMBLY
1. Check the drive shaft by performing the following.



a. Check to see that there is no play in the outboard joint shaft.
b. Check to see that the inboard joint shaft slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint shaft.
d. Check for damage to boots.

2. Remove the inboard and outboard joint boot clamps by performing the following.
a. Using pliers, draw the hook together and remove the large inboard joint boot clamp and remove them.
b. Using a side cutter, cut the small inboard and two outboard joint boot clamps and remove them.

3. Remove the inboard joint shaft from outboard joint shaft, after performing the following.



a. Place matchmarks on the inboard and outboard joint shafts.
NOTE: Do not punch the marks.
b. Using a snap ring expander, pull out the outboard joint shaft expanding the snap ring.

4. Remove the inboard and outboard joint boots then slide out the two boots.
5. Remove the dust covers as follows.
- For the left hand drive shaft, using a screwdriver and hammer, remove the dust cover from the inboard joint shaft.



- For the right hand drive shaft, using a press, remove the dust cover from the inboard joint shaft.

6. For the right side drive shaft, disassemble the inboard joint shaft by following these procedures.



a. Using the SST# 09950-00020 and a press, remove the dust cover.
b. Using a snap ring expander, remove the snap ring.



c. Using a press, remove the bearing.
d. Remove the snap ring.

7. Remove the No.2 dust deflector after performing the following.
a. Mount outboard joint shaft in a soft jaw vise.
b. Using a screwdriver and hammer, remove the No.2 dust deflector.
NOTE: Be careful not to damage the ABS speed sensor rotor.


ASSEMBLY



1. Using the 09309-36010, 09316-20011 SST and a press, install a new No.2 dust deflector.
2. For the right hand drive shaft, assemble the inboard joint shaft by doing these procedures.
a. Install a new snap ring to the inboard joint shaft.



b. Using the SST# 09223-56010 and a press, install a new bearing.
c. Using a snap ring expander, install a new snap ring.



d. Using the 09223-56010 SST and a press, install a new dust cover.

3. Install the dust cover performing the following.



- For the left hand drive shaft, using the 09223-56010, 09555-55010 SST and a press, install a dust cover.



- For the right hand drive shaft, using the 09223-56010 SST and a press, install a new dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specification, as shown in the illustration.




4. Temporarily install the outboard and inboard joint boots and the new boot clamps.
NOTE: Before installing the boot:
- Wrap vinyl tape around the spline of the drive shaft to prevent damaging the boot.
- Place three new clamps to the small boot ends and large end (wheel side) and install its to drive shaft.

5. Install the inboard joint shaft to outboard joint shaft.



- Align the matchmarks placed at removal, and using a snap ring expander, put in the inboard joint shaft expanding the snap ring.

6. Install the boot to the outboard joint. Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
7. Install the boot to inboard joint shaft, performing the following.
a. Pack the inboard joint and boot with grease in the boot kit.
b. Install the boot to the inboard joint shaft.
8. Assemble the boot clamps to both boots and do the following.
a. Make sure that the two boots are on the shaft groove.
b. Make sure that the two boots are not stretched or contracted when the drive shaft is at standard length.
The drive shaft standard lengths are as follows:



Left side: 586.0 ± 2.0 mm (23.071 ± 0.079 inch)
Right side: 881.6 ± 2.0 mm (34.709 ± 0.079 inch)




c. Holding the clamp near the closing hooks, using pliers, position the holes in the clamp's free end over the closing hooks.
d. Secure clamp by drawing the closing hooks together.
e. Secure the clamp onto the boot.



f. Place the SST# 09521-24010 onto the clamp.
g. Tighten the SST so that the clamp is pinched.
NOTE: Do not overtighten the SST.




h. Using the 09240-00020 SST, adjust the clearance of the clamp.
The clearance should be 1.9 mm (0.075 inch) or less

9. Re-check the drive shaft as described in step 1 of the DISASSEMBLY procedure.

INSTALLATION
Installation is in the reverse order of removal, noting the following:
- check the ABS speed sensor signal
- check the front wheel alignment