Driveshaft

Driveshaft Overhaul





'98-00 models





'01-02 models


Driveshafts Removal

Special Tool Required
Ball joint remover, 28 mm 07MAC-SL00200

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. Lift up the locking tab (A) on the spindle nut (B), then remove the nut.
5. If the right driveshaft is removed, drain the MTF or the ATF. It is not necessary to drain the transmission fluid when the left driveshaft is removed (for vehicles with intermediate shaft).





6. Remove the self-locking nut (A) and 10 mm flange bolts (B and C) then remove the damper fork (D).





7. Remove the cotter pin (A) from the lower arm ball joint castle nut (B), and remove the nut.
8. Separate the ball joint from the lower arm (C) with the special tool.





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





10. Pry out the inboard joint (A) with a prybar, and remove the driveshaft from the differential case or bearing support as an assembly. Do not pull on the driveshaft (B), because the inboard joint may come apart. Draw the driveshaft straight out to avoid damaging the differential oil seal or the intermediate shaft outer seal.





Left driveshaft with intermediate shaft


Driveshafts Disassembly

Special Tools Required
- Threaded adapter, 24 x 1.5 mm 07XAC-001020A
- Slide hammer, commercially available
- Boot band pincer, commercially available

Inboard Joint Side:





1. Remove the set ring (A) from the inboard joint.











2. Remove the boot bands. Take care not to damage the boot and dynamic damper.
- If the boot band is welded type (A), cut the boot band (B).
- If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E). If the boot band is a low profile type (F), pinch and remove the boot band with a commercially available boot band pincer (G).





3. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.





4. Make a mark (A) on the rollers (B or C) and spider (D) to identify the locations of rollers on the spider, them remove the rollers.

NOTE:
- Roller (B) is used on '98-00 A/T models and all '01-02 models.
- Roller (C) is used on '98-00 M/T models.

5. Remove the circlip (E).
6. Mark the spider (D) and driveshaft (F) to identify the position of the spider on the shaft.
7. Remove the spider.





8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot and dynamic damper (for left driveshaft on A/T models and all right driveshafts).
9. Remove the inboard boot and dynamic damper. Take care not to damage the boot and dynamic damper.
10. Remove the vinyl tape.

Outboard Joint Side:











1. Remove the boot bands. Take care not to damage the boot and dynamic damper.
- If the boot band is a welded type (A), cut the boot band (B).
- If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E).
- If the boot band is an ear clamp type (F), lift up the three tabs (G) with a screwdriver. If the boot band is the locking tabs type, pry up the tabs with a screwdriver, and lift up the end of the band.





2. Slide the outboard boot (A) to the inboard joint side. Take care not to damage the boot.
3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.





4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C).





5. Carefully clamp the driveshaft in a vise.
6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B).
7. Remove the driveshaft from the vise.





8. Remove the stop ring from the driveshaft.


Driveshafts Reassembly

Special Tools Required
- Boot band tool, KD-3191 or equivalent commercially available
- Boot band pincers, Kent-Moore J-35910 or equivalent commercially available
- Boot band pincer, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.

Inboard Joint Side





1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.
2. Install the inboard boot to the driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot.





3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the end of the driveshaft.
4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to be sure it is fully seated.





5. Fit the rollers (A or B) onto the spider (C) with their high shoulders facing outward, and note these items:
- Reinstall the rollers in their original positions on the spider by aligning the marks (D).
- Hold the driveshaft pointed up to prevent the rollers from falling off.
- Roller (A) is used on '98-00 A/T models and all '01-02 models. Roller (B) is used on '98-00 M/T models.





6. Pack the inboard joint with the joint grease included in the new driveshaft set.
Grease quantity
Inboard joint:
120 - 130 g (4.2 - 4.6 oz) ('98-00 models)
150 - 160 g (5.3 - 5.6 oz) ('01-02 models)





7. Fit the inboard joint onto the driveshaft, and note these items:
- Reinstall the inboard joint (A) onto the driveshaft by aligning the marks (B) on the inboard joint and the rollers.
- Hold the driveshaft so the inboard joint points up to prevent it from falling off.
- For M/T models, align the roller holders (C) with the grooves in the inboard joint ('98-00 models).





8. Adjust the length of the driveshafts to the figure, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.
Left driveshaft: 554 - 559 mm (21.8 - 22.0 inch)
Right driveshaft: 544 - 549 mm (21.4 - 21.6 inch)
9. Install the boot bands.
- For the double loop type, go to step 13.
- For the low profile type, go to step 11.





10. Install the new low profile band (A) onto the boot (B) and dynamic damper, then hook the tab (C) of the band.





11. Close the hook portion of the band with a commercially available boot band pincers (A) then hook the tabs (B) of the band.





12. Fit the boot ends onto the driveshaft and the inboard joint, then install the band (A) onto the boot (B).
13. Pull up the slack in the band by hand.





14. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).
15. Thread the free end of the band through the nose section of the commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).





16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.





17. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.





18. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5 - 10 mm (0.2 - 0.4 inch) tail protruding from the clip.





19. Bend the band end (A) by tapping it down with a hammer.

NOTE:
- Make sure the band and clip do not interfere with anything and the band does not move.
- Remove any grease remaining on the surrounding surfaces





20. Install the new set ring.

Outboard Joint Side:








1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.
2. Install the new boot band (B) (TPE type).
3. Install the outboard boot. Take care not to damage the outboard boot.
4. Remove the vinyl tape.





5. Install the new stop ring (A) into the driveshaft groove (B).





6. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close on the joint.





7. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about, 10 cm (4 inch) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.





8. Check the alignment of the paint mark (A) with the outboard joint end (B).





9. Pack the outboard joint with the joint grease included in the new joint boot set.
Grease quantity
Outboard joint (Rubber): 130 - 140 g (4.6 - 4.9 oz)
Outboard joint (TPE): 140 - 150 g (4.9 - 5.3 oz)
10. Install the outboard boot and boot bands.
- For TPE type boot, go to step 20.
- For rubber type boot, go to step 11.





11. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).





12. Set the new double loop band (A) onto the boot.
13. Pull up the slack in the band by hand.





14. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).





15. Thread the free end of the band through the nose section of a commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.





17. Lift up the boot band tool to bend the free end of the band 90° to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.





18. Unwind the boot band tool, and cut off the excess free end of the bend to leave a 5 - 10 mm (0.2 - 0.4 inch) tail protruding from the clip.





19. Bend the band end (A) by tapping it down with a hammer.

NOTE:
- Make sure the band and clip do not interfere with anything, and the band does not move.
- Remove any grease remaining on the surrounding surfaces.





20. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).





21. Close the ear portion (A) of the band with a commercially available boot band pincers (B).





22. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band further.


Driveshafts Installation





1. Apply 0.3 - 1.0 g (0.01 - 0.04 oz) of specified grease to the whole splined surface (A) of the left driveshaft (for vehicles with intermediate shaft). 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.
2. Install a new set ring onto the set ring groove of the driveshaft.





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





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





5. Install the knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot (C). Wipe off the grease before tightening the nut at the ball joint. Torque the castle nut (D) 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 new cotter pin (E) into the pin hole, and bend the cotter pin.





7. 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 flange bolt (C).
8. Loosely install the flange bolt (D) and a new self locking nut (E).





9. Install a new spindle nut (A), then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (B) against the driveshaft.
10. Clean the mating surfaces of the brake disc and the front wheel, then install the front wheel with the wheel nuts.
11. Tighten the flange bolts and the self-locking nut with the vehicles weight on the damper.
12. Refill the transmission with recommended MTF or ATF.
13. Check the front wheel alignment and adjust if necessary.