Drive/Propeller Shaft: Service and Repair

OVERHAUL
1. REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and brace.
2. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH
a. Remove the 2 bolts and brace.
3. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH
a. Remove the 2 bolts and brace.
4. DISCONNECT HEATED OXYGEN SENSOR
5. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the 4 bolts, 4 nuts and 2 gaskets from the exhaust manifold.
b. Remove the exhaust pipe.
6. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 4 bolts and heat insulator.
7. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
a. Remove the 4 bolts and heat insulator.





8. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
a. Using SST, loosen the adjusting nut until it can be turned by hand.
SST 09922-10010

HINT: Use 2 of the same type of SST.





b. Place matchmarks on the transmission companion flange, flexible coupling and intermediate shaft.
c. Remove the 3 nuts, 3 washers and 3 bolts from the transmission side.

NOTICE: The propeller shaft should not be disconnected from the flexible coupling.





d. Place matchmarks on the differential companion flange, flexible coupling and propeller shaft.
e. Remove the 3 nuts, 3 washers and 3 bolts from the differential side.

NOTICE: The propeller shaft should not be disconnected from the flexible coupling.





f. Remove the 2 center support bearing set bolts and adjusting washers.

NOTICE: When removing the set bolts, support the center support bearing by hand so that the transmission and intermediate shaft, and propeller shaft and differential remain in a straight line.

Maximum joint angle: 5°

HINT: Some vehicles are not equipped with an adjusting washer.





g. Push the propeller shaft straight forward to compress the propeller shaft and pull out the propeller shaft from the centering pin of the differential.

NOTICE: Press the propeller shaft straight ahead to keep the transmission and intermediate shaft aligned straight.

h. Pull the propeller shaft outward the vehicle's rear.

NOTICE: The intermediate shaft and propeller shaft should not be disconnected.





HINT: If the flexible coupling cannot be easily disconnected by hand, insert a screwdriver into the bolt hole of the flexible coupling as shown in the illustration, then pry the coupling out.

NOTICE: Do not bring the screwdriver blade in direct contact with the flexible coupling's rubber portion.





9. INSPECT FLEXIBLE COUPLING
a. Check that the front and rear flexible couplings are not cracked or damaged.
If the flexible coupling is damaged, replace the propeller shaft assembly.
b. Inspect the flexible coupling centering bush.
1. Check for damage to the bush.
If the bush is damaged, replace the propeller shaft assembly.





10. REMOVE FLEXIBLE COUPLING
a. Remove the 3 nuts, 3 washers and 3 bolts from the flexible coupling.





11. REMOVE PROPELLER INTERMEDIATE SHAFT ASSEMBLY
a. Place matchmarks on the intermediate shaft and propeller shaft.
b. Separate the intermediate shaft and propeller shaft.
c. Remove the dust boot from the propeller shaft.





NOTICE: If planning to reuse the dust boot, wrap tape around the spline to prevent the spline from damaging the dust boot.





12. REMOVE CENTER SUPPORT BEARING ASSEMBLY NO.1
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, press out the center support bearing and No. 1 dust deflector.
SST 09950-00020





c. Using SST and a press, press out the No. 2 dust deflector.





13. INSPECT PROPELLER INTERMEDIATE SHAFT ASSEMBLY
a. Using a dial indicator, measure the intermediate shaft run out.
Maximum runout: 0.8 mm (0.031 inch)
If the shaft runout is greater than the maximum, replace the shaft.
14. INSPECT PROPELLER SHAFT ASSEMBLY
a. Using a dial indicator, measure the propeller shaft runout.
Maximum runout: 0.8 mm (0.031 inch)
If the shaft runout is greater than the maximum, replace the shaft.





15. INSPECT SPIDER BEARING
a. Check if the spider bearing rotates smoothly.
b. Check if there is any play in the spider bearing. If necessary, replace the propeller shaft.





16. INSTALL CENTER SUPPORT BEARING ASSEMBLY NO.1
a. Using SST and a press, press in a new No. 2 dust deflector.
SST 09506-35010, 09316-60011 (09316-00011)





b. Using SST and a press, press in the center support bearing.
SST 09330-50010





c. Using SST and a press, press in a new No. 1 dust deflector until SST almost touches the rubber of the center support bearing.
SST 09608-00071, 09608-06041





d. Using SST and a press, press in the No. 1 dust deflector until it contacts the bearing.
SST 09330-50010
e. Using a snap ring expander, install a new snap ring.





17. INSTALL PROPELLER INTERMEDIATE SHAFT ASSEMBLY
a. Install the dust boot.

NOTICE: Before installing the new shaft, wrap tape around the spline to prevent the spline from damaging the dust boot.

b. Apply grease to the spline.
Grease: Molybdenum disulphide lithium base, NLGI No. 2





c. Align the matchmarks and assemble the intermediate shaft and propeller shaft.
d. Cover the adjusting nut with the dust boot.





NOTICE: The directions of the intermediate shaft companion flange and the propeller shaft companion flange should differ by 180°.

e. Fully tighten the adjusting nut by hand.





18. INSTALL FLEXIBLE COUPLING
a. Align the matchmarks on the shaft flange and flexible coupling.
b. Install and torque the 3 bolts, 3 washers and 3 nuts.
Torque: 79 Nm (805 kgf-cm, 58 ft. lbs.)





19. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
a. Apply grease to the flexible coupling centering bush.
Grease: Molybdenum disulphide lithium base, NLGI No. 2
b. Install the propeller shaft from the vehicle's rear.

NOTICE: Support the center support bearing by hand so that the transmission and intermediate shaft, and propeller shaft and differential remain in a straight line.

Maximum joint angle: 5°





c. Align the matchmarks and connect the propeller shaft to the transmission and differential.
d. Install and torque the 6 bolts, 6 washers and 6 nuts.
Torque: 79 Nm (805 kgf-cm, 58 ft. lbs.)

NOTICE: The bolts should be installed from the propeller shaft side.





e. Temporarily install the 2 center support bearing set bolts with the adjusting washers.

HINT: Use the adjusting washers which were removed.





f. If using a new propeller shaft (w/ phase marks):
1. Install the propeller shaft phase marks and differential/transmission phase marks so that their phase marks match.
If the propeller shaft phase marks and differential/transmission phase marks do not align, install the propeller shaft and differential so that their phase marks are as close together as possible.
g. If using a new propeller shaft (w/o phase marks): Install the propeller shaft.





h. Adjust the center bearing assembly in relation to the front and rear of the vehicle. Make sure that the distance between the center bearing housing's rear end and cushion's rear end is 12.5 ± 1 mm (0.492 ± 0.04 inch), as shown in the illustration.
i. While performing the adjustment above in (h), make sure the center bearing housing's center line is at a right angle to the propeller's axial direction.
j. Tighten the 2 center support bearing set bolts.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)





k. Using SST, tighten the adjusting nut.
SST 09922-10010
Torque: 50 Nm (515 kgf-cm, 37 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 34.5 cm (13.6 inch).

20. INSPECT AND ADJUST NO.2 AND NO.3 JOINT ANGLE

NOTICE: When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary.





a. Stabilize the propeller shaft and differential.
1. Turn the propeller shaft several times by hand to stabilize the center support bearing and flexible couplings.





2. Using a jack, raise and lower the differential to stabilize the differential mounting cushion.





b. Check the No. 2 and No. 3 joint angle.
1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
SST 09370-50010

HINT: The SST should be directly underneath the shaft tube.





2. Using SST, measure the installation angle of the differential.
SST 09370-50010

HINT: Measure the installation angle by placing SST in the position shown in the illustration.





3. Calculate the No. 2 joint angle.
No. 2 joint angle: A - B = -1°01' ± 37'
A: Intermediate shaft installation angle
B: Propeller shaft installation angle
4. Calculate the No. 3 joint angle.
No. 3 joint angle: B - C = 1°14' ± 42'
B: Propeller shaft installation angle
C: Differential installation angle
If the measured angle is not within the specification, adjust it with the center support bearing adjusting washer.





c. Adjust the joint angle.
1. Select the propeller shaft center support bearing adjusting washer so that the joint angles become specifications.





Thickness of adjusting washer

NOTICE:
^ The left and right washers should be the same thick ness.
^ The 2 washers should not be assembled together.

2. Install the selected adjusting washer.
21. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
a. Install the heat insulator with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
22. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the heat insulator with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
23. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe, 4 bolts, 4 nuts and 2 new gaskets to the exhaust manifold. Torque the bolts.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
24. INSTALL HEATED OXYGEN SENSOR
a. Connect the heated oxygen sensor.
Torque: 44 Nm (448 kgf-cm, 33 ft. lbs.)

HINT:
^ Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3.5 turns.
^ After installing the heated oxygen sensor, check that the heated oxygen sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.

25. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH
a. Install the brace with the 2 bolts.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
26. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH
a. Install the brace with the 2 bolts.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
27. INSTALL FRONT FLOOR BRACE CENTER
a. Install the brace with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
28. CHECK FOR EXHAUST GAS LEAKS