Axle Shaft Assembly: Service and Repair

INSPECTION





Driveshaft Boot
Check the boots on the driveshaft for cracks, damage, leaking grease or loose boot bands. If any damage is found, replace the boot and boot bands.

Loose Splines
Turn the driveshaft by hand, and make sure the splines and joint are not excessively loose. If damage is found, replace the inboard joint.

Twisted or Cracked
Make sure the driveshaft is not twisted or cracked. Replace it, if necessary.

REMOVAL
1. Loosen the wheel nuts slightly.
2. Raise the front of 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 differential oil when the left driveshaft is removed.

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





6. Remove the self-locking nut and flange bolt.
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 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 on the inboard joint, and remove the driveshaft from the differential case or bearing support as an assembly.

CAUTION:
^ Do not pull on the driveshaft, as 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.





Left driveshaft:
Remove the left driveshaft from the bearing support by tapping on the inboard joint of the driveshaft with a plastic hammer.





13. Pull the knuckle outward, and remove the driveshaft outboard joint from the front wheel hub by tapping on the end of outboard joint with a plastic hammer.

DISASSEMBLY
1. Carefully clamp the driveshaft in a rise with soft jaws.
2. Remove the set ring from the inboard joint.
3. To remove the boot band.

NOTE: Take care not to damage the boot.





- If the boot band is the welded type, cut it off as shown.





- If the boot band is a double loop type, raise the band bend as shown.





- If the boot band is an ear clamp type (for outboard joint on the Canada model only), raise the three tabs with a screwdriver.





4. Mark each roller and inboard joint to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel.

NOTE: Be careful not to drop the rollers when separating them from the inboard joint.

5. Mark the rollers and spider to identify the locations of rollers-on the spider, then remove the rollers.





6. Remove the circlip.
7. Mark the spider and driveshaft to identify the position of the spider on the shaft.
8. Remove the spider using a commercially-available bearing remover.





9. Wrap the splines on the driveshaft with vinyl tape to prevent damage to the boots.
10. Remove the inboard boot and outboard boot, then remove the vinyl tape.

CAUTION: Take care not to damage the boot.





11. Inspect the outboard joint for faulty movement and wear. If any roughness or excess play is felt, replace the outboard joint.

REASSEMBLY





NOTE:
^ Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent.
^ GREASE: Thoroughly pack the inboard joint and both joint boots with the joint grease included in the new driveshaft set.
^ The Canada model uses a Thermoplastic Polyester Elastomer (TPE) outboard joint boot. Use the ear clamp type boot band in the outboard joint boot set.

Grease quantity:
Inboard Joint
All models: 120 - 130 g (4.2 - 4.6 oz)
Outboard Joint
USA model: 130 - 140 9 (4.6 - 4.9 oz)
Canada model: 140 - 150 g (4.9 - 5.3 oz)





1. Wrap the splines with vinyl tape to prevent damage to the boots. When installing the TPE outboard boot on a Canada model, coat the surface of the vinyl tape with the engine oil.
2. Install the outboard boot and inboard boot to the driveshaft, then remove the vinyl tape.

CAUTION: Take care not to damage the boots.





3. Install the spider on the driveshaft by aligning the marks on the spider and end of the driveshaft.
4. Fit the circlip into the driveshaft groove.

NOTE: Always rotate the circlip in its groove to be sure it is fully seated.





5. Pack the outboard joint with the joint grease included in the new driveshaft set.

Grease quantity:
USA model 130 - 140 g (4.6 - 4.9 oz)
Canada model 140 - 150 g (4.9 - 5.3 oz)





6. Fit the rollers to the spider with their high shoulders facing outward.

NOTE:
^ Reinstall the rollers in their original positions on the spider by aligning the marks.
^ Hold the driveshaft pointed up to prevent the rollers from falling off.





7. Pack the inboard joint with the joint grease included in the new driveshaft set.

Grease quantity: 120 - 130 g (4.2 - 4.6 oz)





8. Install the inboard joint onto the driveshaft.

NOTE:
^ Reinstall the inboard joint onto the driveshaft by aligning the marks on the inboard joint and the rollers.
^ Hold the driveshaft so the inboard joint points up to prevent it from failing off.





9. Fit the joint boot ends onto the driveshaft and joints.
When installing the TPE outboard joint boot on a Canada model, be sure the end of the boot is seated in the grooves of the driveshaft and outboard joint.





10. Adjust the length of the driveshafts to the specifications below, then adjust the boots to halfway between full compression and full extension.

NOTE: The ends of boots; seat in the groove of the driveshaft and joint.

11. Install the boot bands following procedure.

Double Loop Boot Band Installation:
USA model: all bands
Canada model: inboard joint bands only





-1. Set the double loop band onto the boot with the band end toward the front of the vehicle.
-2. Pull up the slack in band by hand.





-3. Make a mark on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip.
-4. Thread the free end of the band through the nose section of the commercially available boot band tool (KD-3191 or equivalent), and into the slot on the winding mandrel.





-5. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot on the band meets the edge of the clip.





-6. Raise 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.





-7. Unwind the boot banding 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.





-8. Bend the band end by tapping it down with a hammer.

NOTE:
- Make sure the band does not move.
- Remove any grease remaining in the surrounding surfaces.

Ear Clamp Type Boot Band Installation:
Canada model outboard joint bands





-1. Set the ear clamp boot band by aligning the tabs with holes in the band.





-2. Close the ear portion of the band with a commercially available boot band pincers.





-3. Measure the clearance between the closed ear portion of the band.

Standard: 0 - 3 mm (0 - 0.12 inch)

If the bands, clearance is not within the standard, close the ear portion of the band further.

NOTE:
^ Make sure the band does not move.
^ Remove any grease remaining in the surrounding surfaces.

INSTALLATION





1. Install the outboard joint into the knuckle,





2. Apply 0.5 - 1.0 g (0.02 - 0.04 oz) of specified grease to the whole splined surface of the 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 inboard joint.

3. Install a new set ring onto the driveshaft or intermediate shaft groove.





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





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. Install a new spindle nut, then tighten and stake the nut.
9. Clean the mating surfaces of the brake disc and wheel, then install the front wheel with the wheel nuts.
10. Rotate the driveshaft by hand to make sure the closed portion of outboard boot band does not interfere with the knuckle or ABS wheel sensor.
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.