Axle Shaft Assembly: Service and Repair

FRONT DRIVE SHAFT
OVERHAUL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed are for the LH side.

1. DRAIN AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
2. DRAIN MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
3. REMOVE FRONT WHEEL
4. REMOVE ENGINE UNDER COVER LH





5. SEPARATE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the nut.
SST 09930-00010

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

b. While applying the brakes, remove the lock axle hub LH nut.





6. SEPARATE 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.





7. DISCONNECT SPEED SENSOR FRONT LH
a. Remove the bolt, and disconnect the speed sensor wire and flexible 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:
- Be careful not to damage the speed sensor.
- Prevent foreign matter from attaching to the speed sensor.





8. SEPARATE TIE ROD END SUB-ASSEMBLY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end sub-assembly LH from the steering knuckle.
SST 09628-00011





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





10. SEPARATE FRONT AXLE ASSEMBLY LH
a. Put matchmarks on the drive shaft and the axle hub.
b. Using a plastic hammer, separate the drive shaft from the axle hub.

NOTICE: Be careful not to damage the boot and speed sensor rotor. Do not excessively push out the drive shaft from the axle assembly LH.





11. 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.





12. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Remove the 2 bolts and pull out the drive shaft together with the drive shaft bearing case.
b. Remove the drive shaft from the transaxle.

NOTICE:
- Be careful not to damage the inboard joint boot and drive shaft dust cover.
- Be careful not to drop the drive shaft assembly.





13. FIX FRONT AXLE ASSEMBLY LH

NOTICE: 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 SST.

SST 09608-16042 (09608-02021, 09608-02041)





14. SEPARATE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP
a. One Touch Type: Using a screwdriver, separate the inboard joint boot LH No.2 clamp, as shown in the illustration.
b. Claw Engagement Type: Using needle-nose pliers, separate the inboard joint boot LH No.2 clamp, as shown in the illustration.





15. SEPARATE FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. One Touch Type: Using a screwdriver, separate the inboard joint boot LH clamp, as shown in the illustration.
b. Claw Engagement Type: Using needle-nose pliers, separate the inboard joint boot LH clamp, as shown in the illustration.
16. REMOVE FR AXLE INBOARD JOINT BOOT
a. Remove the inboard joint boot from the inboard joint assembly LH.





17. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY LH
a. Remove the old grease from the inboard joint.
b. Put matchmarks on the inboard joint assembly LH and outboard joint shaft assembly LH.

NOTICE: Do not punch for the marks.

c. Remove the inboard joint assembly LH from the outboard joint shaft assembly LH.





d. Using a snap ring expander, remove the shaft snap ring.





e. Put matchmarks on the outboard joint shaft assembly LH and tripod joint assembly.

NOTICE: Do not punch for the marks. Using a brass bar and a hammer, remove the tripod joint assembly from the outboard joint shaft assembly LH.

NOTICE: Do not tap the roller.

g. Remove the inboard joint boot and 2 clamps.





18. REMOVE FRONT DRIVE SHAFT DAMPER LH (AUTOMATIC TRANSAXLE)
a. One Touch Type:
1. Using a screwdriver, remove the drive shaft damper clamp, as shown in the illustration.
b. Claw Engagement Type:
1. Using needle nose pliers, remove the drive shaft damper clamp, as shown in the illustration.
c. Remove the front drive shaft damper LH.
19. REMOVE FRONT DRIVE SHAFT DAMPER RH
a. Remove the front drive shaft damper RH using the same procedures as for the front drive shaft damper LH.





20. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP
a. One Touch Type:
1. Using a screwdriver, remove the outboard joint boot LH No.2 clamp, as shown in the illustration.
b. Omega Type:
1. Using pliers, remove the outboard joint boot LH No.2 clamp, as shown in the illustration.





21. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. One Touch Type:
1. Using a screwdriver, remove the outboard joint boot LH clamp, as shown in the illustration.
b. Omega Type:
1. Using pliers, remove the outboard joint boot LH clamp, as shown in the illustration.
22. REMOVE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft assembly LH.
b. Remove the old grease from the outboard joint.





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





24. 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.





25. REMOVE FRONT DRIVE SHAFT DUST COVER RH
a. Using a press, remove the drive shaft dust cover RH.
SST 09950-00020





26. REMOVE DRIVE SHAFT BEARING CASE SUB ASSEMBLY SNAP RING (RH DRIVE SHAFT)
a. Using a screwdriver, remove the bearing case snap ring.





27. REMOVE DRIVE SHAFT BEARING CASE SUB ASSEMBLY (RH DRIVE SHAFT)
a. Using a press, remove the drive shaft bearing case.

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

b. Remove the straight pin.





28. REMOVE FRONT DRIVE SHAFT DUST COVER (RH DRIVE SHAFT)
a. Using SST and a press, remove the drive shaft dust cover.
SST 09950-00020

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





29. REMOVE FRONT DRIVE SHAFT BEARING (RH DRIVE SHAFT)
a. Using a snap ring expander, remove the drive shaft hole snap ring.





b. Using SST and a press, remove the drive shaft bearing.
SST 0952710011
c. Remove the snap ring.





30. INSTALL FRONT DRIVE SHAFT BEARING (RH DRIVE SHAFT)
a. Using SST and a press, install a new drive shaft bearing.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)





31. INSTALL DRIVE SHAFT BEARING CASE SUB ASSEMBLY SNAP RING (RH DRIVE SHAFT)
a. Using a screwdriver, install a new bearing case snap ring.





32. INSTALL DRIVE SHAFT BEARING CASE SUB ASSEMBLY (RH DRIVE SHAFT)
a. Using SST and a press, install the drive shaft bearing case to the inboard joint assembly RH.
SST 09527-10011, 09710-04081

NOTICE: Bearing should be installed completely.





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





33. INSTALL FRONT DRIVE SHAFT DUST COVER (RH DRIVE SHAFT)
a. Using SST and a press, install a new drive shaft dust cover.
SST 09726-40010, 09527-10011
Distance (A): 0 to 1.0 mm (0 to 0.039 inch)

NOTICE: Be careful not to damage the dust cover.

b. Install the straight pin.





34. 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 reaches the specification, as shown in the illustration.
SST 09527-10011
Distance (A): 91.0 to 92.0 mm (3.582 to 3.622 inch)

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





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

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

36. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new hole snap ring.





37. 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. Install new parts to the outboard joint shaft assembly in the following order.
1. Outboard joint boot LH No.2 clamp
2. Outboard joint boot
3. Outboard joint boot LH clamp
b. Pack the outboard joint shaft and boot with grease in the boot kit.
Grease capacity: 190 to 200 g (6.7 to 7.1 oz.)





38. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP
a. Secure the outboard joint boot LH No.2 clamp onto the boot.
b. Place SST onto the outboard joint boot LH No.2 clamp.
SST 09521-24010
c. Tighten the SST so that the outboard joint boot LH No.2 clamp is pinched.

NOTICE: Do not overtighten the SST.





d. Using SST, measure the clearance of the outboard joint boot LH No.2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

NOTICE: When the measured value is greater than the specified value, retighten the clamp.





39. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Secure the outboard joint boot LH clamp onto the boot.
b. Place SST onto the outboard joint boot LH clamp.
SST 09521-24010
c. Tighten the SST so that the outboard joint boot LH clamp is pinched.

NOTICE: Do not overtighten the SST.





d. Using SST, measure the clearance of the outboard joint boot LH clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

NOTICE: When the measured value is greater than the specified value, retighten the clamp.





40. INSTALL FRONT DRIVE SHAFT DAMPER LH (AUTOMATIC TRANSAXLE)

HINT: Install the damper clamp to outboard joint side.

a. Install a new drive shaft damper clamp LH and 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: 202.4 to 206.4 mm (7.969 to 8.126 inch)





d. Hold the front drive shaft lightly in a soft vise.
e. Install the drive shaft damper clamp to the damper.

NOTICE: Be sure to install the clamp in the correct position. One Touch Type:

1. Using a screwdriver, install the drive shaft damper clamp, as shown in the illustration.
g. Claw Engagement Type:
1. Using needle nose pliers, install the drive shaft damper clamp, as shown in the illustration.
41. INSTALL FRONT DRIVE SHAFT DAMPER RH
a. The procedure for the front drive shaft damper RH is the same as for the front drive shaft damper LH.
42. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH
a. Wrap the spline of the outboard joint shaft assembly LH with vinyl tape to prevent the boots from being damaged.
b. Install new parts to the outboard joint shaft assembly LH in the following order.
1. Inboard joint boot LH clamp
2. Inboard joint boot LH No.2 clamp
3. Inboard joint boot





c. Place the beveled side of the tripod axial spline toward the outboard joint.
d. Align the matchmarks placed before removal.
e. Using a brass bar and a hammer, tap in the tripod joint assembly to the drive shaft assembly LH.

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

f. Pack the inboard joint shaft and boot with grease in the boot kit.
Grease capacity: 175 to 185 g (6.2 to 6.5 oz.)





g. Using a snap ring expander, install a new shaft snap ring.





h. Aligning the matchmarks, install the inboard joint assembly LH to the outboard joint shaft assembly LH.
43. INSTALL FR AXLE INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly LH and outboard joint shaft assembly LH.





44. INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP
a. One Touch Type: Using a screwdriver, install the inboard joint boot LH No 2 clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.

b. Claw Engagement Type: Using needle nose pliers, install the inboard joint boot LH No.2 clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.





45. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. One Touch Type: Using a screwdriver, install the inboard joint boot LH clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.

b. Claw Engagement Type: Using needle nose pliers, install the inboard joint boot LH clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.





46. INSPECT FRONT DRIVE SHAFT
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.

NOTICE: Keep the drive shaft assembly level during inspection.





HINT: For dimension (A), refer to the following values.

Reference value
RH: 873.0 to 883.0 mm (34.370 to 34.764 inch)
LH: 556.2 to 566.2 mm (21.898 to 22.291 inch)





47. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Coat the spline of the inboard joint shaft assembly LH with gear oil.
b. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.

NOTICE:
- Set the snap ring with the opening side facing downwards.
- Be careful not to damage the oil seal, boot and dust cover.





48. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Coat the spline of the inboard joint shaft assembly RH with gear oil.
b. Align the shaft splines and install the drive shaft assembly RH with the 2 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)

NOTICE: Do not damage the oil seal, boot and dust cover.





49. INSTALL FRONT AXLE ASSEMBLY LH
a. Align the matchmarks and install the drive shaft assembly LH to the front axle assembly LH.

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





50. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the lower ball joint to the front suspension arm sub-assembly lower No.1 LH with the bolt and 2 nuts.
Torque: 89 Nm (908 kgf-cm, 66 ft. lbs.)
51. INSTALL TIE ROD END SUB-ASSEMBLY LH
a. Install the tie rod end sub-assembly LH 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 60° further.





52. INSTALL SPEED SENSOR FRONT LH
a. Install the speed sensor front LH to the steering knuckle with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





b. Connect the speed sensor wire and flexible hose to the shock absorber with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

NOTICE:
- Be careful not to damage the speed sensor.
- Prevent foreign matter from adhering to the speed sensor.
- Do not twist the sensor wire when installing the speed sensor.





53. 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 wrench (6 mm) to hold the stud.





54. INSTALL FRONT AXLE HUB LH NUT
a. Install a new axle hub LH nut.
Torque: 216 Nm (2,200 kgf-cm, 159 ft. lbs.)
b. Using a chisel and hammer, stake the axle hub LH nut.
55. INSTALL ENGINE UNDER COVER LH
56. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
57. ADD AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
58. INSPECT AND ADJUST AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
59. ADD MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
60. INSPECT MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
61. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
62. CHECK ABS SPEED SENSOR SIGNAL