Repair Procedures

Replacement

1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.





CAUTION:
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).

3. Remove the split (A), then remove the castle nut (B) and washer (C) from the front hub under applying the brake.

Tightening torque:
215.7 N.m(22.0 Kgf.m, 159.1lb.ft)





CAUTION:
- Have the convex side of washer (C) facing the outside, and then install castle nut (B) and split pin (A) to the driveshaft.
- After fastening castle nut to the initial tightening torque (22.0 Kgf.m), fit the closest hole in the direction of fastening.




4. Remove the brake caliper mounting bolts and then place the brake caliper assembly (A) with wire.

Tightening torque:
78.4 - 98.0 N.m(8.0 - 10.0 Kgf.m, 57.8 - 72.3lb.ft)




5. Remove the tie rod end ball joint (A) from the knuckle.
(1) Remove the split pin.
(2) Remove the castle nut.

Tightening torque:
23.5 - 33.3 N.m(2.4 - 3.4 Kgf.m, 17.3 - 24.5lb.ft)




6. Remove the wheel speed sensor (A) from the knuckle.

Tightening torque:
6.8 - 10.8 N.m( 0.7 - 1.1 Kgf.m, 5.1 - 7.9lb.ft)




7. Remove the lower arm (A) mounting bolts and nut from the knuckle.

Tightening torque:
98.0 - 117.6 N.m(10.0 - 12.0 Kgf.m, 72.3 - 86.7 lb.ft)




8. Loosen the knuckle mount bolts from strut assembly then remove the knuckle assembly (A).

Tightening torque:
156.9 - 176.5 N.m(16.0 - 18.0 Kgf.m, 115.7 - 130.1lb.ft)




9. Disconnect the drive shaft end (A).




10. Loosen the side cover mounting blots then remove the side covet (A).




11. Inner shaft mounting bolts and then disconnect the inner shaft (A).
[RHD]




[LHD]




12. Install in the reverse order of removal.

CAUTION:
- Use a pry bar (B) being careful not to damage the transaxle and joint.
- Do not insert the pry bar (B) too deep, as this may cause damage to the oil seal.
- Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
- Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
- Support the driveshaft properly.
- Replace the retainer ring whenever the driveshaft is removed from the transaxle case.

Inspection

1. Check the driveshaft boots for damage and deterioration.
2. Check the ball joint for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks, wear and position.




5. Check the driveshaft for cracks and wears.

Disassembly

CAUTION:
- Do not disassemble the BJ assembly.
- Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
- The boot band should be replaced with a new one.

1. Remove the circlip (B) from driveshaft splines (A) of the transaxle side PTJ case.




2. Remove the both boot clamps from the transaxle side PTJ case.




3. Pull out the boot from the transaxle side joint(PTJ).
4. Remove the clip (C) from the PTJ case (B).
5. While dividing joint(PTJ) boot (A) of the transaxle side, wipe the grease in PTJ case (B) and collect them respectively.





CAUTION:
- Be careful not to damage the boot.
- According to below the illustrated, put marks (D) on roller of trunnion assembly (A), PTJ case (B) and spline part (C), for providing assembly.





6. Using a snap ring plier or flat-tipped (-) screwdriver, remove the circlip (A).




7. Remove the trunnion assembly (B) from the driveshaft (A) using the special tool (09495-33000).




8. Clean the trunnion assembly.
9. Remove the boot (A) of the transaxle side joint(PTJ).

CAUTION:
For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).




10. Using a plier or flat-tipped (-) screwdriver, remove the both side of clamp (B) of the dynamic damper (A).




11. Fix the driveshaft (A) with a vice (B) as illustrated.




12. Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper when the dynamic damper is removed.
13. Separate the dynamic damper (A) from the shaft (B) carefully.




14. Using a plier or flat-tipped (-) screwdriver, remove the clamp on the side of wheel.




15. Pull out the joint(BJ) on the side of wheel the direction of the transaxle.
Be careful not to damage the boot.

Reassembly

1. Wrap tape around the driveshaft splines (PTJ. side) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the BJ boots.
3. Install the bands to both BJ boots.




4. Using the SST(09495-3K000), secure the boot bands.

Clearance (A): 2.0 mm (0.079 in.) or less




5. To reassemble the dynamic damper, keep the shaft in the straight, line and tighten the dynamic damper with dynamic damper band, as per the illustration.

Distance (L): 219.7 ± 2mm (8.64 ± 0.07in)




6. Install the PTJ boot bands and PTJ boot.
7. Install the trunnion assembly (A) and the circlip (E) to the spline (C) on the driveshaft.
At this time align the marks (D) each other.








8. Install the clip to the PTJ case (B).
9. Add the specified grease to the PTJ as much as wiped away at inspection.
10. Install the PTJ boots.
11. To control the air in the PTJ boot, keep the specified distance between the boot bands when they are tightened.









12. Install the bands to both PTJ boots.