Removal and Installation

REMOVAL





1. Loosen the wheel nuts slightly.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations.
3. Remove the wheel nuts and front wheels.
4. Drain the transmission fluid.

NOTE: It is not necessary to drain the transmission fluid when the left driveshaft for the vehicle with intermediate shaft is removed.

5. Raise the locking tab on the spindle nut, then remove the nut.





6. Remove the self-locking nut and flange bolts.
7. Remove the damper fork.





8. Remove the cotter pin from the lower arm ball joint castle nut, and remove the nut.
9. Install a 12 mm hex nut on the ball joint. Be sure that the hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damaged by the special tool.
10. Use the special tool as shown in section 18, to separate the ball joint and lower arm.

CAUTION: Be careful not to damage the ball joint boot.

NOTE: If necessary, apply penetrating type lubricant to loosen the ball joint.





11. Pry the driveshaft assembly with a screwdriver, as shown, to force the set ring at the driveshaft end past the groove.





12. Pull the inboard joint, and remove the driveshaft from the differential case or intermediate shaft as an assembly.

CAUTION:
- Do not pull on the driveshaft; the inboard joint may come apart.
- Use care when prying out the assembly, and pull it straight to avoid damaging the differential oil seal or the intermediate shaft outer seal.





13. Pull the knuckle outward, and remove the driveshaft outboard joint from the front wheel hub using a plastic hammer.

INSTALLATION





1. Install the outboard joint into the knuckle.





2. Apply 0.3 - 1.0 g (0.01 - 0.04 oz) of grease to the whole splined surface of the left driveshaft (for vehicles with intermediate shaft).

NOTE: After applying grease, remove the grease from the splined grooves at intervals of 2 - 3 splines and from the set ring groove so air can bleed from the intermediate shaft.

3. Install the new set ring onto the driveshaft groove.

CAUTION: Always use a new set ring whenever the driveshaft is being installed.

4. Insert the inboard end of the driveshaft into the differential or intermediate shaft until the set ring locks in the groove.

NOTE: Clean the areas where the driveshaft contacts the differential thoroughly with solvent or carburetor cleaner, and dry with compressed air.





5. Install the knuckle on the lower arm, then tighten the castle nut and install a new cotter pin.

NOTE: Wipe off the grease before tightening the nut at the ball joint.

CAUTION:
- Be careful not to damage the ball joint boot.
- Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.





6. Install the damper fork over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab is aligned with the slot in the damper fork.

7. Loosely install the flange bolt and the new self-locking nut.

NOTE: The bolts and nut should be tightened with the vehicle's weight on the damper.





8. Apply oil to the seating surface of the new spindle nut.
9. Install a new spindle nut, then tighten and stake the nut.
10. Install the front wheel with the wheel nuts.

NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and wheel.

11. Tighten the flange bolt and the new self-locking nut with the vehicle's weight on the damper.
12. Refill the transmission with recommended fluid.
13. Check the front wheel alignment, and adjust if necessary.