Driveshaft Installation

Driveshaft Installation

NOTE: Before starting installation, make sure the mating surfaces of the joint and the splined section are not dusty or dirty.

1. Apply about 5 g (0.18 oz) of moly 60 paste (P/N 08734-0001) to the contact area of the outboard joint and the front wheel bearing.

NOTE: The paste helps to prevent noise and vibration.





2. Install a new set ring (A) onto the set ring groove (B) of the left driveshaft.





3. Apply 0.5-1.0 g (0.02-0.04 oz) of grease to the whole splined surface (A) of the right driveshaft. After applying grease, remove the grease from the splined grooves at intervals of 2-3 splines and from the set ring groove (B) so that air can bleed from the intermediate shaft.





4. Clean the areas where the driveshaft contacts the differential thoroughly with solvent or brake cleaner, and dry with compressed air.

NOTE: Do not wash the rubber parts with solvent.

5. Insert the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) until the set ring (D) locks in the groove (E).

NOTE: Insert the driveshaft horizontally to prevent damaging the differential oil seal.





6. Install the outboard joint (A) into the front hub (B).





7. Wipe off any grease contamination from the ball joint tapered section and threads, then install the knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot (C). Torque the new castle nut (D) to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole.

NOTE:
^ Make sure the ball joint boot is not damaged or cracked.
^ Do not align the nut by loosening it.





8. Install the new cotter pin (E) into the ball joint pin hole, and bend the cotter pin as shown.
9. Connect the front stabilizer link (A) to the lower arm. Hold the stabilizer link ball joint pin (B) with a hex wrench (C), and tighten the new flange nut (D).





10. Install the damper fork (A) over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab (B) is aligned with the slot in the damper fork. Loosely install the damper pinch bolt (C).





11. Loosely install the damper fork mounting bolt (D) and a new self-locking nut (E).
12. Install exhaust pipe A.
13. Apply a small amount of engine oil to the seating surface of the new spindle nut (A).





14. Install a new spindle nut, then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (B) against the driveshaft.
15. Install the splash shield.
16. Clean the mating surfaces of the brake discs and the front wheels, then install the front wheels.
17. Turn the front wheels by hand, and make sure there is no interference between the driveshaft and surrounding parts.
18. Lower the vehicle on the lift.
19. Tighten the damper pinch bolt and damper fork mounting bolt with the vehicle's weight on the damper.
20. Refill the transmission with the recommended transmission fluid.
21. Check the front wheel alignment, and adjust it if necessary.
22. Test-drive the vehicle.