Axle Shaft Assembly: Service and Repair

Part 1 Of 2:

Part 2 Of 2:

FRONT DRIVE SHAFT
OVERHAUL

HINT: Overhaul the RH following the same procedures as for the LH.

1. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
2. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
3. REMOVE FRONT WHEEL
4. REMOVE ENGINE UNDER COVER LH





5. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, pry up the retaining tab of the hub LH 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 hub LH nut.





6. SEPARATE SPEED SENSOR FRONT LH
a. Remove the bolt and the clip, and separate the speed sensor front LH and the flexible hose from the shock absorber assembly front LH.

HINT: The positions of the bolt and clip on the right side differ from those on the left side.





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 adhering to the speed sensor.





7. SEPARATE STABILIZER BAR FRONT
a. Hold the bolt with the spanner (10 mm) and remove the nut.
b. Remove the 2 cushion retainers No.1, the 2 cushions and separate the stabilizer bar front.





8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Remove the clip and the nut.
b. Using SST, separate the front suspension arm embassy lower No.1 LH from the steering knuckle.
SST 09620-00011





9. SEPARATE TIE ROD END SUB-ASSEMBLY LH
a. Remove the cotter pin and the nut.
b. Using SST, separate the tie rod end summary LH from the steering knuckle.
SST 09628-62011
10. SEPARATE FRONT AXLE ASSEMBLY LH
a. Using a plastic hammer, separate the front drive shaft assembly LH from the front axle assembly LH.

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





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 oil seal and the boot.
^ Be careful not to drop the drive shaft assembly.





12. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (RH DRIVE SHAFT)
a. Using a brass bar and a hammer, remove the front drive shaft assembly RH.

NOTICE:
^ Be careful not to damage the oil seal and the boot.
^ 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's weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is necessary to place the vehicle's weight on the hub bearing, first support it with SST.

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





14. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

NOTICE: Keep the drive shaft assembly level during inspection.

a. Check that there is no remarkable play in the radial direction of the outboard joint.
b. Check if 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.





15. REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP
a. One Touch Clamp Type: Using a screwdriver, unclamp the inboard joint boot LH No.2 clamp as shown in the illustration.
b. Claw Engagement Type: Using needle nose pliers, remove the inboard joint boot LH No.2 clamp as shown in the illustration.





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





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

NOTICE: Do not use a punch for marking.

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





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





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

NOTICE: Do not use a punch for marking.

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

NOTICE: Do not tap the roller.

g. Remove the inboard joint boot LH No.2 clamp, the inboard joint boot and the inboard joint boot LH clamp.





19. REMOVE DRIVE SHAFT DAMPER SETTING CLAMP (RH DRIVE SHAFT)

HINT: Use the procedure for RH disassembly only.

a. One Touch Clamp Type: Using a screwdriver, unclamp the damper setting clamp as shown in the illustration.
b. Claw Engagement Type: Using needle nose pliers, remove the damper setting clamp as shown in the illustration.
20. REMOVE DRIVE SHAFT DAMPER (RH DRIVE SHAFT)

HINT: Use the procedure for RH disassembly only.

a. Remove the drive shaft damper RH.





21. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP
a. Using a screwdriver, unclamp the outboard joint boot LH No.2 clamp.





22. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Using a screwdriver, unclamp the outboard joint boot LH clamp.
23. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft assembly.
b. Remove the old grease from the outboard joint.





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





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

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





26. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install the dust cover LH.
SST 09527-10011

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

27. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new LH hole snap ring.
28. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
a. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
b. Install the new parts on the inboard joint shaft assembly.
1. Outboard joint boot LH No.2 clamp
2. Outboard joint boot
3. Outboard joint boot LH clamp
c. Pack the outboard joint assembly LH with grease.
Grease capacity: 155 to 170 g (5.5 to 6.1 oz.)
d. Install the outboard joint boot on the outboard joint shaft assembly.





29. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP
a. Secure the outboard joint boot LH No.2 clamp onto the outboard joint 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 (09242-00080)
Clearance: 0.8 mm (0.031 in.) or less

NOTICE: When the measured value exceeds the specified value, retighten the clamp.





30. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Mount drive shaft in a soft vise.
b. Secure the outboard joint boot LH clamp onto the outboard joint boot.
c. Place SST onto the outboard joint boot LH clamp.
SST 09521-24010
d. Tighten the SST so that the outboard joint boot LH clamp is pinched.

NOTICE: Do not overtighten the SST.





e. Using SST measure the clearance of the outboard joint boot LH clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.031 in.) or less

NOTICE: When the measured value exceeds the specified value, retighten the clamp.

31. INSTALL DRIVE SHAFT DAMPER (RH DRIVE SHAFT)

HINT: Use the procedure for RH disassembly only.

a. Install the drive shaft damper RH on the outboard joint shaft assembly.
32. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP (RH DRIVE SHAFT)

HINT: Use the procedure for RH disassembly only.

a. Install the damper setting clamp to the shaft.

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





b. One Touch Clamp Type: Using a screwdriver, install the damper setting clamp as shown in the illustration.
c. Claw Engagement Type: Using needle nose pliers, install the damper setting clamp as shown in the illustration.
33. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

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

a. Install the new parts on the outboard joint shaft assembly in the following order.
1. Inboard joint boot LH clamp
2. Inboard joint boot
3. Inboard joint boot LH No.2 clamp





b. Align the matchmarks, install the tripod joint assembly to the outboard joint assembly.
c. Using a brass bar and a hammer, install the tripod joint assembly.

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





d. Using a snap ring expander, install a new inner LH shaft snap ring.
e. Apply grease to the inboard joint assembly LH.
Grease capacity: 125 to 135 g (4.5 to 4.8 oz.)





f. Align the matchmarks, install the inboard joint assembly LH on the outboard joint shaft assembly.
34. INSTALL FR AXLE INBOARD JOINT BOOT
a. Install the inboard joint boot on the inboard joint assembly and the outboard joint shaft assembly.





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





36. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. One Touch Clamp Type: Using screwdriver, install the inboard joint boot LH clamp as shown in the illustration.
b. Claw Engagement Type: Using needle nose pliers, install the inboard joint boot LH clamp as shown in the illustration.





37. INSPECT FRONT DRIVE SHAFT

NOTICE: Keep the drive shaft assembly level during inspection.

a. Check that there is no remarkable play in the outboard joint.
b. Check if 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.





38. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. M/T: Coat the spline of the inboard joint shaft assembly with gear oil.
b. A/T: Coat the spline of the inboard joint shaft assembly with ATF.
c. Align the shaft splines, install the drive shaft assembly LH with a brass bar and a hammer.

NOTICE:
^ Set the hole snap ring with the opening side facing down.
^ Be careful not to damage the boot and the oil seal.

HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving it in.

39. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (RH DRIVE SHAFT)

HINT: Apply the same procedure to the RH

NOTICE:
^ Set the hole snap ring with the opening side facing down.
^ Be careful not to damage the boot and the oil seal.

40. INSTALL FRONT AXLE ASSEMBLY LH
a. Install the 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.
^ Do not excessively push the front axle assembly LH.

41. 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°.

42. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the tie front suspension arm sub-assembly lower No.1 LH to the steering knuckle with the nut.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
b. Install a new clip.

NOTICE: If the holes for the clip are not aligned, tighten the nut up to 60°.





43. INSTALL STABILIZER BAR FRONT
a. Install the stabilizer bar front with 2 cushion retainers No.1, 2 cushions and the nut, as shown in the illustration.

NOTICE: Be sure to install the cushion and retainer in the correct direction.

b. Torque the nut with the spanner (10 mm).
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





44. INSTALL SPEED SENSOR FRONT LH
a. Install the speed sensor front LH and the flexible hose on the shock absorber assembly front LH with the bolt and clip.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

HINT: The positions of the bolt and clip on the right side differ from those of the left side.





b. Install the speed sensor front LH on the steering knuckle with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in. lbs.)

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





45. INSTALL FRONT AXLE HUB LH NUT
a. Install a new hub LH nut.
Torque: 216 Nm (2,200 kgf-cm, 159 ft. lbs.)
b. Using a chisel and a hammer, stake the hub LH nut.
46. INSTALL ENGINE UNDER COVER LH
47. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
48. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
49. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
50. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
51. INSPECT AND ADJUST AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
52. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
53. CHECK ABS SPEED SENSOR SIGNAL