Drive/Propeller Shaft: Service and Repair

REAR PROPELLER SHAFT ASSEMBLY

COMPONENTS:

REMOVAL
1. REMOVE EXHAUST PIPE ASSEMBLY FRONT
2. REMOVE FRONT FLOOR HEAT INSULATOR NO. 1
a. Remove the 4 nuts, grommet and front floor heat insulator No. 1.
3. REMOVE REAR PROPELLER SHAFT ASSEMBLY

a. Put matchmarks on both flanges.
b. Remove the 4 nuts, bolts and washers.

HINT: If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.

c. Remove the 2 bolts, 2 center support bearing washers and center support bearing.

d. Insert SST in the transmission to prevent oil leakage.
SST 09325-40010

NOTICE: Be careful not to damage the oil seal.

DISASSEMBLY

1. REMOVE PROPELLER SHAFT ASSEMBLY
a. Put matchmarks on both flanges.

b. Remove the 4 nuts, bolts, washers and propeller shaft assembly.

2. REMOVE CENTER SUPPORT BEARING ASSEMBLY NO. 1
a. Hold the intermediate shaft assembly in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b. Using a chisel and a hammer, release the staked part of the nut.

NOTICE: Release the staked part of the nut completely, otherwise the threads of the intermediate shaft may be damaged.

c. Using SST to hold the universal joint flange, remove the nut and intermediate shaft washer.
SST 09330-00021

d. Put matchmarks on the intermediate shaft assembly and universal joint flange.

e. Using SST, remove the universal joint flange from the intermediate shaft assembly.
SST 09950-00020, 09950-00030, 09330-00021

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

f. Remove the center support bearing assembly No. 1 and 2 center support bearing washers from the intermediate shaft assembly.
g. Hold the intermediate shaft assembly in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

h. Using a screwdriver and a hammer, remove the sliding shaft dust cover.

3. INSPECT PROPELLER SHAFT ASSEMBLY
a. Using a dial indicator, inspect the runout of the propeller shaft.
Maximum runout: 0.8 mm (0.031 inch)

NOTICE: The dial indicator must be set at a right angle to the center of the propeller shaft.

HINT: If the shaft runout exceeds the maximum, replace the propeller shaft.

4. INSPECT INTERMEDIATE SHAFT
a. Using a dial indicator, inspect the runout of the intermediate shaft.
Maximum runout: 0.8 mm (0.031 inch)

NOTICE: The dial indicator must be set at a right angle to the center of the propeller shaft.

HINT: If the shaft runout exceeds the maximum, replace the intermediate shaft.

5. INSPECT SPIDER BEARING
a. Check that the spider bearing rotates smoothly.
b. Check that there is no play in the spider bearing.

HINT: If necessary, replace the intermediate shaft.

6. INSPECT CENTER SUPPORT BEARING ASSEMBLY NO. 1
a. Turn the center support bearing by hand in the rotating direction. Check the center support bearing turns smoothly.
b. Check that the seals are not cracked or damaged.

HINT: If the center support bearing is damaged, worn, or does not turn smoothly, replace it.

REASSEMBLY
1. INSTALL CENTER SUPPORT BEARING ASSEMBLY NO. 1

a. Using SST and a press, install a new sliding shaft dust cover.
SST 09316-60011 (09316-00011)

NOTICE: Be careful not to damage the sliding shaft dust cover.

b. Set the center support bearing assembly No. 1 and 2 center support bearing washers on the intermediate shaft assembly, as shown in the illustration.

NOTICE: Be sure to install the bearing in the correct direction.

c. Align the matchmarks on the universal joint flange and intermediate shaft assembly, and place the universal joint flange on the intermediate shaft assembly.
d. Install the intermediate shaft washer to the intermediate shaft assembly.
e. Hold the intermediate shaft assembly in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

f. Using SST to hold the universal joint flange, press the center support bearing assembly No. 1 into position by tightening down a new nut.
SST 09330-00021
Torque: 182 Nm (1,850 kgf-cm, 134 ft. lbs.)
g. Loosen the nut.
h. Tighten the nut again.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

i. Using a chisel and a hammer, stake the nut.

2. INSTALL PROPELLER SHAFT ASSEMBLY
a. Align the matchmarks on the intermediate shaft flange and the propeller shaft flange, and install the shaft with the 4 bolts, washers and nuts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)

INSTALLATION
1. INSTALL REAR PROPELLER SHAFT ASSEMBLY

a. Remove the SST from the transmission.
SST 09325-40010
b. Insert the yoke of the intermediate shaft into the transmission.

HINT: Be careful not to damage the oil seal.

c. Install the 2 center support bearing washers and center support bearing, and temporarily tighten the 2 bolts.

d. Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)

e. Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 inch) respectively as shown in illustration.

f. Check that the center line of the bracket is at right angles to the shaft axial direction.

g. Tighten the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

2. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE
a. Stabilize the propeller shaft and differential.
1. Turn the propeller shaft several times by hand to stabilize the center support bearing.
b. Check the No. 2 and No. 3 joint angles.
1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
SST 09370-50010

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

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

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

3. Calculate the No. 2 joint angle.
No. 2 joint angle: A - B = -1°36' to -0°36'
A: Intermediate shaft installation angle
B: Propeller shaft installation angle
4. Calculate the No. 3 joint angle.
No. 3 joint angle: B - C = 1°09' to 2°09'
B: Propeller shaft installation angle
C: Differential installation angle

HINT: If the measured angle is not within the specified range, adjust it with the center support bearing washers.

c. Adjust the No. 2 joint angle.

1. Select the center support bearing washers for adjustment.

Adjustment Washer:

NOTICE: The 2 washers should be of the same thickness.

3. INSTALL FRONT FLOOR HEAT INSULATOR NO. 1
a. Install the heat insulator No. 1 with the 4 nuts and grommet.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

4. INSTALL EXHAUST PIPE ASSEMBLY FRONT
5. CHECK FOR EXHAUST GAS LEAKS