Rear Drive Shaft Assy
OVERHAUL
HINT:
^ Use the same procedures for the RH side and LH side.
^ The procedures listed are for the LH side.
^ A bolt without a torque specification is shown in the standard bolt chart.
1. REMOVE REAR WHEEL
a. Remove the 10 bolts and ornament.
b. Remove the 5 nuts and wheel.
2. REMOVE REAR AXLE SHAFT LH NUT
a. Remove the cotter pin and lock cap.
b. While depressing the brake pedal, remove the nut.
3. REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and brace.
4. REMOVE EXHAUST PIPE ASSEMBLY CENTER
a. Remove the 2 bolts, 2 nuts, gasket and disconnect the center exhaust pipe from front exhaust pipe.
b. Remove the 4 O-rings, 2 exhaust pipe supports and exhaust pipe center (with exhaust tail pipe).
5. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH
a. Remove the 2 bolts and RR suspension member brace rear lower LH.
6. REMOVE RR END BODY MOUNTING SET PLATE
a. Remove the 4 bolts and set plate.
7. REMOVE REAR SUSPENSION MEMBER BRACE LH
a. Remove the 2 bolts and brace.
8. DISCONNECT SPEED SENSOR REAR LH
9. DISCONNECT TOE CONTROL LINK SUB-ASSEMBLY LH
10. DISCONNECT UPPER CONTROL ARM ASSEMBLY REAR LH
11. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
a. Place matchmarks on the drive shaft and side gear shaft.
NOTICE: Do not punch the matchmarks.
b. Using a 10 mm hexagon wrench, remove the 6 bolts and 2 washers with depressing the brake pedal.
c. Hold the inboard joint side of the drive shaft so that the outboard joint side does not bend too much.
d. Using a brass bar and hammer, lightly tap the end of the drive shaft, disengage the axle hub and remove the drive shaft.
NOTICE: Be careful not to damage the boots, end cover, drive shaft's speed sensor rotor or axle hub's oil seal.
HINT: With the drive shaft removed, do not lower the vehicle to the ground as damage may occur to the axle bearing. If the vehicle must be moved, use SST to lock the axle bearing.
SST 09608-16042 (09608-02021, 09608-02041)
12. INSPECT REAR DRIVE SHAFT ASSEMBLY LH
a. Check that operation of the joint is smooth within the sliding range in the axial direction.
HINT: If a large angle is used for the cross-groove type joint, the joint will feel like it is catching, but this is not a defect.
b. Check that the boots are not cracked, damaged or leaking.
c. Check that there are no scratches on the speed sensor rotor.
If necessary, replace the boots and/or outboard joint shaft.
13. REMOVE REAR AXLE INBOARD JOINT END COVER
a. Using a screwdriver, pry out the end cover.
b. Use bolts, nuts and washers to keep the inboard joint together.
NOTICE: Tighten the bolts and nuts by hand to avoid scratching the flange surface.
14. REMOVE REAR DRIVE SHAFT INBOARD JOINT BOOT NO.2 CLAMP
a. Using a side cutter or pliers, remove the boot clamp.
15. REMOVE REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP
a. Using a side cutter or pliers, remove the boot clamp.
16. DISCONNECT INBOARD JOINT BOOT
17. REMOVE REAR DRIVE SHAFT CROSS GROOVE JOINT SUB-ASSEMBLY
a. Place matchmarks on the inboard joint and outboard joint shaft.
NOTICE: Do not punch the matchmarks.
b. Using a snap ring expander, remove the snap ring.
c. Using SST, an extension bar and press, press out the cross groove joint from the outboard joint shaft.
SST 09726-12023 (09726-01031)
18. REMOVE REAR AXLE INBOARD JOINT COVER
a. Mount the inboard joint in a soft jaw vise.
b. Using a screwdriver and hammer, tap out the inboard joint cover from the cross groove joint.
NOTICE: Make sure the cage and inner race are not positioned too much to one side of the outer race.
19. REMOVE REAR DRIVE SHAFT OUTBOARD JOINT BOOT NO. 2 CLAMP
a. Using a side cutter or pliers, remove the boot clamp.
20. REMOVE REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP
a. Using a side cutter or pliers, remove the boot clamp.
21. REMOVE INBOARD JOINT BOOT
22. REMOVE OUTBOARD JOINT BOOT
23. REMOVE REAR WHEEL BEARING DUST DEFLECTOR NO.1 LH
a. Mount the outboard joint in a soft jaw vise.
b. Using a screwdriver and hammer, tap out the dust deflector.
NOTICE: Be careful not to damage the ABS speed sensor rotor.
24. INSTALL REAR WHEEL BEARING DUST DEFLECTOR NO.1 LH
a. Using SST and a press, press in a new dust deflector.
SST 09309-36010, 09502-12010
NOTICE: Be careful not to damage the ABS speed sensor rotor.
25. INSTALL OUTBOARD JOINT BOOT
a. Before installing the boot, pack the boot with grease.
Grease capacity: 100 to 105 g (3.5 to 3.7 oz.)
HINT: Use the grease supplied in the boot kit.
b. Install the boot to the outboard joint.
NOTICE:
^ Keep grease off the joint connection groove of the boot.
^ Apply grease on the entire ball contact surface inside the joint.
26. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT NO. 2 CLAMP
a. Position the clamp onto the boot.
b. Place SST onto the clamp.
SST 09521-24010
c. Tighten SST so that the clamp is pinched as shown in the illustration.
NOTICE: Do not overtighten SST.
d. Using SST, adjust the clearance of the clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.031 inch) or less
27. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP
HINT: Use the same procedures described for the No. 2 clamp.
28. INSTALL REAR AXLE INBOARD JOINT COVER
HINT:
^ If the groove joint comes apart, reassemble it in step (a).
^ If the groove joint does not come apart, start from step (c).
a. Align the matchmarks placed before the removal.
HINT: When the matchmarks have disappeared, perform the following procedures.
1. Install the inner race to the cage so that the indented part of the inner race is on the opposite side of the bevelled surface of the cage.
2. Install the outer race so that the indented part of the outer race is facing the same side as the bevelled surface of the cage.
3. Match the narrow projections of the inner race with the wide projections of the outer race.
b. Tilt the cage and inner race to the side and insert the balls one by one.
NOTICE: When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out.
c. Apply FIPG to the inboard joint cover as shown in the illustration.
FIPG: Part No.08826-00801, THREE BOND 1121 or equivalent
Seal width: 1.0 to 1.8 mm (0.039 to 0.071 inch)
HINT: Avoid applying an excessive amount to the surface.
d. Remove grease from the surface of the cross groove joint facing to the cover.
e. Align the bolt holes of the cover with those of the cross groove joint, then insert the hexagon bolts.
f. Using a plastic hammer, tap the rim of the inboard joint cover into place. Tap the rim uniformly in several passes in the order shown in the illustration.
g. Insert the inboard joint boot clamp, inboard joint boot and inboard joint boot clamp No. 2 to the outboard joint shaft (in that order).
29. INSTALL REAR DRIVE SHAFT CROSS GROOVE JOINT SUB-ASSEMBLY
a. Install the inboard joint boot clamp.
b. Align the matchmarks placed before removal.
c. Using a brass bar and hammer, tap the cross groove joint onto the drive shaft.
NOTICE: Check that the brass bar is touching the inner race, not the cage.
30. INSTALL INBOARD JOINT BOOT
a. Before assembling the boots, pack the boot with grease.
Grease capacity: 100 to 105 g (3.5 to 3.7 oz.)
HINT: Use the grease supplied in the boot kit.
NOTICE:
^ Keep grease off the joint connection groove of the boot.
^ Apply grease on the entire ball contact surface inside the joint.
b. Install the boot to the inboard joint.
31. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT NO.2 CLAMP
a. Make sure that the inboard joint boot is not stretched or contacted when the drive shaft is at standard length.
HINT: The drive shaft is designed to move ± 20 mm (0.79 inch) from the normal position.
Drive shaft standard length
RH 598.5 mm (23.563 inch)
LH 553.5 mm (21.791 inch)
b. Install the inboard joint boot No. 2 clamp.
HINT: Use the same procedures described for the outboard joint boot No. 2 clamp in step 26.
32. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP
HINT: Use the same procedures described for the outboard joint boot No. 2 clamp in step 26.
33. INSTALL REAR AXLE INBOARD JOINT END COVER
a. Pack grease into the end cover.
Grease capacity: 50 to 55 g (1.8 to 1.9 oz.)
b. Remove grease from the surface of the cross groove joint facing to the cover.
c. Install a new gasket with the adhesive part facing the outer race side of the cross groove joint.
d. Align the bolt holes of the cover with those of the cross groove joint.
e. Temporarily install the 6 hexagon bolts and 6 washers to the end cover side.
f. Temporarily install the 6 nuts to the boot side.
g. Using a 10 mm hexagon wrench, tighten the bolts. Tighten the bolts uniformly and in several passes in the order shown in the illustration.
h. Check that the claw of the end cover touches the cross groove joint.
i. Remove the 6 hexagon bolts, 6 washers and 6 nuts in steps (e) and (f).
34. INSPECT REAR DRIVE SHAFT ASSEMBLY LH
a. Check that operation of the joint is smooth within the sliding region in the axial direction.
HINT: If a large angle is used for the cross-groove type joint, the joint will feel like it is catching, but this is not a defect.
b. Check that the boots are not cracked, damaged or leaking.
c. Check that there are no scratches on the speed sensor rotor.
If necessary, replace the boots and/or outboard joint shaft.
35. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
a. Align the matchmarks and drive shaft to the side gear shaft.
NOTICE: Be careful not to damage the boots and end cover.
b. Using a 10 mm hexagon wrench, install the 2 washers and 6 hexagon bolts while applying the brakes.
HINT: Apply a light coat of engine oil on the threads of the bolts.
36. CONNECT UPPER CONTROL ARM ASSEMBLY REAR LH
37. CONNECT TOE CONTROL LINK SUB-ASSEMBLY LH
38. CONNECT SPEED SENSOR REAR LH
39. INSTALL REAR SUSPENSION MEMBER BRACE LH
a. Install the brace with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
40. INSTALL RR END BODY MOUNTING SET PLATE
a. Install the set plate with the 4 bolts.
41. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH
a. Install the brace with the 2 bolts.
42. INSTALL EXHAUST PIPE ASSEMBLY CENTER
a. Install the exhaust pipe with a new gasket and the 2 exhaust pipe supports.
b. Install the 2 bolts, 2 nuts and 4 O-rings.
43. INSTALL FRONT FLOOR BRACE CENTER
a. Install the brace with the 4 bolts.
44. INSTALL REAR WHEEL
a. Install the wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
45. CHECK ABS SPEED SENSOR SIGNAL