Axle Shaft Assembly: Service and Repair
FRONT DRIVE SHAFTComponents:
Components Front Drive Shaft Assembly LH:
Components Front Drive Shaft Assembly RH:
REMOVAL
1. REMOVE ENGINE UNDER COVER NO.1
2. REMOVE ENGINE UNDER COVER NO.2
3. DRAIN HYBRID VEHICLE TRANSAXLE FLUID
4. REMOVE FRONT WHEEL
5. REMOVE FRONT AXLE HUB NUT
6. SEPARATE FRONT SPEED SENSOR
a. Remove the 2 bolts and clip, and separate the sensor wire and hose from the shock absorber.
NOTICE: Be careful not to damage the speed sensor.
7. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY
8. REMOVE FRONT DISC
9. SEPARATE TIE ROD ASSEMBLY
10. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1
a. Remove the bolt and 2 nuts, and separate the front suspension arm sub-assembly lower No.1 from the lower ball joint.
11. REMOVE FRONT AXLE ASSEMBLY
12. SEPARATE FRONT STABILIZER LINK ASSEMBLY
13. REMOVE COWL TOP SILENCER PAD
14. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING
15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
a. Using SST, remove the front drive shaft assembly LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
^ Be careful not to damage the transaxle case oil seal and inboard joint boot.
^ Be careful not to drop the drive shaft assembly.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Using pliers, remove the bearing bracket hole snap ring.
b. Remove the bolt from the drive shaft bearing bracket.
c. Using SST, remove the front drive shaft assembly RH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
^ Be careful not to damage the transaxle case oil seal and inboard joint boot.
^ Be careful not to drop the drive shaft assembly.
DISASSEMBLY
1. REMOVE INBOARD JOINT BOOT NO.2 CLAMP
a. Using pliers, remove the inboard joint boot No.2 clamp, as shown in the illustration.
2. REMOVE INBOARD JOINT BOOT CLAMP
a. Remove the inboard joint boot clamp perform the same procedures as for the inboard joint boot No.2 clamp.
3. SEPARATE INBOARD JOINT BOOT
a. Separate the inboard joint boot from the inboard joint assembly.
4. REMOVE INBOARD JOINT SHAFT ASSEMBLY
a. Remove the grease from the inboard joint.
b. Put matchmarks on the inboard joint shaft assembly and outboard joint shaft.
NOTICE: Do not use a punch for the marks.
c. Remove the inboard joint shaft assembly from the outboard joint shaft.
d. Using a snap ring expander, remove the snap ring.
e. Put matchmarks on the outboard joint shaft and tripod.
NOTICE: Do not use a punch for the marks.
f. Using a brass bar and hammer, remove the tripod from the outboard joint shaft.
NOTICE: Do not tap the roller.
5. REMOVE INBOARD JOINT BOOT
a. Remove the inboard joint boot and inboard joint boot clamp.
6. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP
a. Using pliers, remove the front drive shaft damper clamp, as shown in the illustration.
7. REMOVE FRONT DRIVE SHAFT DAMPER
a. Remove the drive shaft damper.
8. REMOVE OUTBOARD JOINT BOOT NO.2 CLAMP
a. Using pliers, remove the outboard joint boot No.2 clamp, as shown in the illustration.
9. REMOVE OUTBOARD JOINT BOOT CLAMP
a. Remove the outboard joint boot clamp perform the same procedures as for the outboard joint boot No.2 clamp.
10. REMOVE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft.
b. Remove the grease from the outboard joint.
11. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using a screwdriver, remove the front drive shaft LH hole snap ring.
12. REMOVE FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, remove the drive shaft dust cover LH.
SST 09950-00020
NOTICE: Be careful not to drop the inboard joint assembly.
13. REMOVE FRONT DRIVE SHAFT DUST COVER RH
a. Using SST and a press, remove the drive shaft dust cover RH.
SST 09950-00020
NOTICE: Be careful not to drop the inboard joint assembly.
14. REMOVE FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, remove the drive shaft dust cover.
SST 09950-00020
NOTICE: Be careful not to drop the inboard joint assembly.
15. REMOVE FRONT DRIVE SHAFT RH HOLE SNAP RING
a. Using a snap ring expander, remove the drive shaft RH hole snap ring.
16. REMOVE FRONT DRIVE SHAFT BEARING
a. Using SST and a press, remove the front drive shaft bearing.
SST 09527-10011
REASSEMBLY
1. INSTALL FRONT DRIVE SHAFT BEARING
a. Using SST and a press, install a new front drive shaft bearing.
SST 09726-40010, 09527-10011
NOTICE: Bearing should be completely installed.
2. INSTALL FRONT DRIVE SHAFT RH HOLE SNAP RING
a. Using a snap ring expander, install a new front drive shaft RH hole snap ring.
3. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, install a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover meets the specification, as shown in the illustration.
SST 09726-40010,09527-10011
Distance (A): 26.8 to 27.4 mm (1.0551 to 1.0787 inch)
4. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new drive shaft dust cover LH.
SST 09527-10011
NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.
5. INSTALL FRONT DRIVE SHAFT DUST COVER RH
a. Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.
SST 09527-10011
Distance (A): 109.5 mm (4.311 inch)
6. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new hole snap ring to the inboard joint shaft assembly.
7. INSTALL OUTBOARD JOINT BOOT
HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.
a. Install new parts to the outboard joint shaft assembly in the following order.
1 Outboard joint boot No.2 clamp (A)
2 Outboard joint boot (B)
3 Outboard joint boot clamp (c)
b. Pack the outboard joint shaft and boot with grease.
Grease capacity: 205 to 225 g (7.2 to 7.9 oz.)
8. INSTALL OUTBOARD JOINT BOOT NO.2 CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.
NOTICE: Do not overtighten the vise.
b. Install the outboard joint boot No.2 clamp onto the boot.
c. Place SST onto the outboard joint boot No.2 clamp.
SST 09521-24010
d. Tighten the SST so that the outboard joint boot No.2 clamp is pinched.
SST 09521-24010
NOTICE: Do not overtighten the SST.
e. Using SST, measure the clearance of the outboard joint boot No.2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less
NOTICE: When the measured value is greater than the specified value, retighten the clamp.
9. INSTALL OUTBOARD JOINT BOOT CLAMP
a. Install the outboard joint boot clamp perform the same procedures as for the outboard joint boot No.2 clamp.
10. INSTALL FRONT DRIVE SHAFT DAMPER
a. Install the drive shaft damper to the drive shaft.
b. Make sure that the damper is on the shaft groove.
c. Set the distance, as specified.
Distance (A): 225.5 to 229.5 mm (8.8779 to 9.0354 inch)
11. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.
NOTICE: Do not overtighten the vise.
b. Install the drive shaft damper clamp to the damper.
NOTICE: Be sure to install the clamp in the correct position.
c. Place SST onto the drive shaft damper clamp.
SST 09521-24010
d. Tighten the SST so that the clamp is pinched.
SST 09521-24010
NOTICE: Do not overtighten the SST.
e. Using SST, measure the clearance of the drive shaft damper clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less
NOTICE: Using SST, measure the clearance of the drive shaft damper clamp.
12. INSTALL INBOARD JOINT SHAFT ASSEMBLY
a. Install new parts to the inboard joint shaft assembly in the following order.
1 Inboard joint boot clamp (A)
2 Inboard joint boot (B)
3 Inboard joint boot No.2 clamp (c)
b. Hold the outboard joint shaft assembly between aluminum plates in a vise.
NOTICE: Do not overtighten the vise.
c. Place the beveled side of the tripod axial spline toward the outboard joint shaft.
d. Align the matchmarks.
e. Using a brass bar and hammer, tap in the tripod to the outboard joint shaft.
NOTICE:
^ Do not tap the roller.
^ Be sure to install the tripod in the correct direction.
f. Using a snap ring expander, install a new front inner shaft snap ring.
g. Pack the inboard joint shaft and boot with grease.
Grease capacity: 155 to 175 g (5.5 to 6.2 oz.)
h. Align the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.
13. INSTALL INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly.
14. INSTALL INBOARD JOINT BOOT NO.2 CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.
NOTICE: Do not overtighten the vise.
b. Install the inboard joint boot No.2 clamp onto the boot.
c. Place SST onto the inboard joint boot No.2 clamp.
SST09521-24010
d. Tighten the SST so that the inboard joint boot No.2 clamp is pinched.
SST 09521-24010
NOTICE: Do not overtighten the SST.
e. Using SST, measure the clearance of the inboard joint boot No.2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less
NOTICE: When the measured value is greater than the specified value, retighten the clamp.
15. INSTALL INBOARD JOINT BOOT CLAMP
a. Install the outboard joint boot clamp perform the same procedures as for the inboard joint boot No.2 clamp.
16. INSPECT FRONT DRIVE SHAFT ASSEMBLY
a. Check that there is no excessive play in the outboard joint.
b. Check that the inboard joint slides smoothly in the thrust direction.
c. Check that there is no excessive play in the radial directions of the inboard joint.
d. Check the boots for damage.
INSTALLATION
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Install a new drive shaft hole snap ring.
b. Coat the spline of the inboard joint shaft assembly with ATF.
c. Align the shaft splines and install the drive shaft assembly with a brass bar and hammer.
NOTICE:
^ Set the snap ring with the opening side facing down.
^ Be careful not to damage the drive shaft dust cover, boot and oil seal.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Coat the spline of the inboard joint shaft assembly with ATF.
b. Align the shaft splines and install the drive shaft assembly.
NOTICE: Be careful not to damage the drive shaft dust cover, boot and oil seal.
c. Using pliers, install a new bearing bracket hole snap ring.
d. Install a new bolt to the drive shaft bearing bracket.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)
3. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
4. INSTALL COWL TOP SILENCER PAD
5. INSTALL FRONT STABILIZER LINK ASSEMBLY
6. INSTALL FRONT AXLE ASSEMBLY
7. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1
a. Install the lower ball joint to the front suspension arm sub-assembly lower with the bolt and 2 nuts.
Torque: 127 Nm (1,300 kgf-cm, 94 ft. lbs.)
8. CONNECT TIE ROD ASSEMBLY
9. INSTALL FRONT DISC
10. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY
11. INSTALL FRONT AXLE HUB NUT
a. Using a socket wrench (30 mm), install a new axle hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, stake the axle hub nut.
12. INSTALL FRONT SPEED SENSOR
a. Install the speed sensor to the steering knuckle with the bolt.
Torque: Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
NOTICE:
^ Be careful not to damage the speed sensor.
^ Prevent foreign matter from adhering to the speed sensor.
^ Do not twist the sensor wire when installing the speed sensor.
b. Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on knuckle.
Torque: Bolt B 19 Nm (192 kgf-cm, 14 ft. lbs.)
13. ADD HYBRID VEHICLE TRANSAXLE FLUID (w/Oil Cooler)
14. ADD HYBRID VEHICLE TRANSAXLE FLUID (w/o Oil Cooler)
15. INSTALL ENGINE UNDER COVER NO.2
16. INSTALL ENGINE UNDER COVER NO.1
17. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
18. ADJUST FRONT WHEEL ALIGNMENT
19. CHECK SPEED SENSOR SIGNAL