Axle Shaft: Service and Repair

FRONT DRIVE SHAFT (From July, 2003)
OVERHAUL
1. DRAIN AUTOMATIC TRANSAXLE FLUID
2. REMOVE FRONT WHEEL





3. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the front axle hub LH nut.
SST 09930-00010

NOTICE: Loosen the staked part of the lock nut completely, otherwise the screw of the drive shaft may be damaged.

b. While applying the brake, remove the front axle hub LH nut.





4. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
a. Remove the nut, and separate the stabilizer link assembly LH.

HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

5. DISCONNECT SPEED SENSOR FRONT LH





a. Remove the bolt and clip, and separate the sensor wire and hose from the shock absorber.

NOTICE: Be careful not to damage the speed sensor.





b. Remove the bolt, and separate the speed sensor front LH from the steering knuckle.

NOTICE: Prevent foreign matter from adhering to the speed sensor.





6. DISCONNECT TIE ROD ASSEMBLY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 09628-62011





7. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Remove the bolt and 2 nuts, and disconnect the front suspension arm sub-assembly lower No. 1 LH from the lower ball joint.





8. DISCONNECT FRONT AXLE ASSEMBLY LH
a. Using a plastic hammer, separate the drive shaft from the axle hub.

NOTICE: Be careful not to damage the boot and speed sensor rotor.





9. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
a. Using SST, remove the front drive shaft assembly LH.
SST 09520-01010, 09520-24010 (09520-32040)

NOTICE:
^ Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
^ Be careful not to drop the drive shaft assembly.





10. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Using pliers, remove the drive shaft bearing bracket hole snap ring.
b. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.





11. FIX FRONT AXLE ASSEMBLY LH
SST 09608-16042 (09608-02021, 09608-02041)

NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle's full 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 SST.





12. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

NOTICE: Move the drive shaft assembly keeping it level.

a. Check that there is no remarkable play in the radial direction of the outboard joint.
b. Check that the inboard joint slides smoothly in the thrust direction.
c. Check that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.
13. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP





a. One touch type
1. Using a screwdriver, remove the front axle inboard joint boot LH clamp and front axle inboard joint boot LH No.2 clamp, as shown in the illustration.





b. Claw Engagement type
1. Using pliers, remove the front axle inboard joint boot LH clamp and front axle inboard joint boot LH No.2 clamp, as shown in the illustration.
14. DISCONNECT FR AXLE INBOARD JOINT BOOT
a. Separate the inboard joint boot from the inboard joint assembly.
15. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY LH





a. Put matchmarks on the inboard joint assembly and outboard joint shaft.

NOTICE: Do not use a punch for the marks.

b. Remove the inboard joint assembly from the outboard joint shaft.





c. Using a snap ring expander, remove the front drive inner shaft inner RH shaft snap ring.





d. Put matchmarks on the outboard joint shaft and tripod joint.

NOTICE: Do not use a punch for the marks.

e. Using a brass bar and hammer, remove the tripod joint from the outboard joint shaft.

NOTICE: Do not tap the roller.

16. REMOVE FRONT DRIVE SHAFT DAMPER LH
a. Using a screwdriver, remove the front drive shaft damper LH clamp.
b. Remove the front drive shaft damper LH.
17. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
a. Using a screwdriver, remove the front axle outboard joint boot LH clamp and front axle outboard joint boot LH No.2 clamp.
18. REMOVE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft.
b. Remove the old grease from the outboard joint.





19. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using a screwdriver, remove the hole snap ring.





20. REMOVE FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, remove the front drive shaft dust cover LH.
SST 09950-00020

NOTICE: Be careful not to drop the inboard joint assembly.





21. REMOVE FRONT DRIVE SHAFT DUST COVER RH
a. Using a press, remove the front drive shaft dust cover RH.





22. REMOVE FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, remove the front drive shaft dust cover.
SST 09950-00020
23. REMOVE FRONT DRIVE SHAFT BEARING





a. Using a snap ring expander, remove the front drive shaft hole snap ring RH.





b. Using SST and a press, remove the bearing.
SST 09527-10011

NOTICE: Be careful not to drop the inboard joint assembly.

24. INSTALL FRONT DRIVE SHAFT BEARING





a. Using SST and a steel plate, install a new front drive shaft bearing.
SST 09527-30010, 09527-10011

NOTICE: Bearing should be completely installed.





b. Using a snap ring expander, install a new front drive shaft hole snap ring RH.





25. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, install a new front drive shaft dust cover until the distance from the tip of the center drive shaft to the front drive shaft dust cover meets the specification, as shown in the illustration.
SST 09527-10011, 09726-40010
Distance: 42.1 ± 0.5 mm (1.7 ± 0.02 inch)





26. INSTALL FRONT DRIVE SHAFT DUST COVER RH
a. Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.
SST 09527-10011
Distance: 110.5 ± 0.5 mm (4.4 ± 0.02 inch)

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.





27. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new front drive shaft dust cover LH.
SST 09527-10011

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.

28. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new front drive shaft LH hole snap ring.





29. INSTALL OUTBOARD JOINT BOOT

HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.

a. Hold the drive shaft lightly in a soft vise.
b. Temporarily install a new outboard joint boot with 2 new clamps to the drive shaft.
c. Pack the outboard joint shaft and boot with grease.
Grease capacity: 205 - 215 g (7.2 - 7.6 oz.)
30. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP





a. Hold the drive shaft lightly in a soft vise.
b. Install the 2 outboard joint boot clamps onto the boot.
c. Place SST onto the outboard joint large boot clamp.
SST 09521-24010
d. Tighten the SST so that the large clamp is pinched.

NOTICE: Do not overtighten the SST.





e. Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm (0.032 inch) or less
f. Employ the same manner to the outboard joint small boot clamp.





31. INSTALL FRONT DRIVE SHAFT DAMPER LH
a. Install the drive shaft damper LH to the drive shaft.
b. Make sure that the damper is on the shaft groove.
c. Set the distance, as described.
Distance: 225.4 ± 2.0 mm (8.87 ± 0.079 inch)
d. Install a new front drive shaft damper LH clamp to the front drive shaft damper LH.
32. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH





a. Temporarily install a new inboard joint boot with 2 new clamps to the drive shaft.
b. Place the beveled side of the tripod joint axial spline toward the outboard joint shaft.
c. Align the matchmarks.
d. Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.

NOTICE:
^ Do not tap the roller.
^ Be sure to install the tripod joint assembly in the correct direction.





e. Using a snap ring expander, install a new shaft snap ring.
f. Pack the outboard joint shaft and boot with grease.
Grease capacity: 175 to 185 g (6.25 to 6.61 oz.)





g. Aligning the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.
33. INSTALL FR AXLE INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly.
34. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP





a. One touch type
1. Using a screwdriver, install the front axle inboard joint boot LH clamp and front axle inboard joint boot LH No.2 clamp, as shown in the illustration.





b. Claw Engagement type
1. Using pliers, install the front axle inboard joint boot LH clamp and front axle inboard joint boot LH No.2 clamp, as shown in the illustration.
35. INSPECT FRONT DRIVE SHAFT

NOTICE: Move the drive shaft assembly keeping it level.





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





e. Make sure that the 2 boots are on the shaft groove.
f. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.





Drive shaft standard length: mm (in.)





36. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Install a new front drive shaft LH hole snap ring.
b. Coat the spline of the inboard joint shaft assembly with ATF.
c. Align the shaft splines and install the drive shaft assembly with a brass bar and hammer.

NOTICE:
^ Set the snap ring with the opening side facing down ward.
^ Be careful not to damage the oil seal, boot and dust cover.
^ Move the drive shaft assembly while keeping it level.





37. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Using a screwdriver, install a new bearing bracket hole snap ring.

NOTICE: Do not damage the oil seal and boot.

b. Install the bolt.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)
38. INSTALL FRONT AXLE ASSEMBLY LH
a. Install the front drive shaft assembly LH to the front axle assembly LH.

NOTICE: Be careful not to damage the outboard joint boot. Be careful not to damage the speed sensor rotor.





39. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the lower ball joint to the front suspension arm sub assembly lower with the bolt and nuts. Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
40. INSTALL TIE ROD ASSEMBLY LH
a. Install the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Install a new cotter pin.

NOTICE: If the holes for the cotter pin are not aligned, tighten the nut up to 600 further.

41. INSTALL SPEED SENSOR FRONT LH





a. Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on knuckle.
Torque: 19 Nm (192 kgf-cm, 14 ft. lbs.)

NOTICE:
^ Be careful not to damage the speed sensor.
^ Do not twist the sensor wire when installing the speed sensor.





b. Install the speed sensor to the steering knuckle with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

NOTICE: Prevent foreign matter from adhering to the speed sensor.





42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Install the front stabilizer link assembly LH with the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.





43. INSTALL FRONT AXLE HUB LH NUT
a. Using a socket wrench (30 mm), install a new axle hub LH nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, stake the front axle hub LH nut.
44. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
45. ADD AUTOMATIC TRANSAXLE FLUID
46. INSPECT AUTOMATIC TRANSAXLE FLUID
47. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
48. CHECK ABS SPEED SENSOR SIGNAL