Axle Shaft Assembly: Service and Repair
REAR DRIVE SHAFT REMOVAL/INSTALLATIONCaution:
^ Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Drain the rear differential oil.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Add rear differential oil.
5. After installation, inspect the rear wheel alignment.
Locknut Removal Note
1. Lock the disc plate by applying the brakes.
2. Knock the crimped portion of the locknut outward using a chisel and a hammer.
3. Remove the locknut.
Brake Caliper Component Removal Note
1. Suspend the brake caliper component using a cable.
2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.
Rear Drive Shaft Removal Note
1. Temporarily install a spare nut to the end of the rear drive shaft.
2. Knock the nut with copper hammer lightly and remove the rear drive shaft from the wheel hub.
3. Separate the rear drive shaft from the wheel hub.
4. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and then remove the rear drive shaft.
Caution:
^ The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when removing the drive shaft from the differential.
5. Pull the rear drive shaft to the outer side of the vehicle and disconnect it from the rear differential.
6. To hold the rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after disconnecting the rear drive shaft.
Clip Installation Note
1. Point the opening of the new drive shaft clip upward, install it to the clip groove at the end of the rear drive shaft with the installation width within the specification.
Standard 32 mm (1.3 inch)
2. After installing the clip, measure the outer diameter. If it exceeds the specification, reinstall the new clip.
Rear Drive Shaft Installation Note
1. Apply differential oil to the differential oil seal lip.
Caution:
^ The sharp edges of the rear drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when installing the rear drive shaft from the rear differential.
2. Insert the rear drive shaft into the rear differential with the clip opening facing upward.
3. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle.
Locknut Installation Note
1. Tighten a new locknut.
2. Crimp the locknut, using a chisel and hammer.
Rear Drive Shaft Disassembly/Assembly
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Boot Band (Axle Side) Disassembly Note
Note:
^ Remove the boot band only if there is an abnormality.
1. Remove the boot band using end clamp pliers.
Boot Band (Differential Side) Disassembly Note
1. Remove the crimp of the clip using a flathead screwdriver.
Outer Ring Disassembly Note
1. Place an alignment mark on the drive shaft and the outer ring.
2. Remove the outer ring.
Snap Ring, Tripod Joint Disassembly Note
1. Place an alignment mark on the shaft and tripod joint.
2. Remove the snap ring using a snap ring pliers.
3. Remove the tripod joint from the shaft.
Caution:
^ To prevent damage to the component, do not use a hammer when removing it.
Boot Disassembly Note
Note:
^ Remove the axle side boot only if there is an abnormality.
1. Wrap the shaft spline with vinyl tape.
2. Remove the boot.
Boot Assembly Note
Note:
^ The boot shapes on the axle side and the differential side are different so do not misinstall them.
1. Fill the inside of the new dust boot (wheel side) with grease.
Note:
^ Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
MT: 115 - 135 g (4.06 - 4.76 oz)
AT: 90 - 110 g (3.18 - 3.88 oz)
2. Install the boot with the drive shaft spline still wrapped with vinyl tape.
3. Remove the vinyl tape.
Tripod Joint, Snap Ring Assembly Note
1. Align the tripod joint with the shaft mark and insert it using a brass bar.
Caution:
^ To prevent damage to the component, do not tap the roller part when installing.
2. Install the new snap ring to the shaft installation slot securely using a snap ring pliers.
Outer Ring Assembly Note
1. Fill the outer ring and boot (differential side) with the repair kit grease.
Note:
^ Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
MT: 175 - 195 g (6.18 - 6.87 oz)
AT: 135 - 155 g (4.77 - 5.46 oz)
2. Assemble the outer ring.
3. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.
Caution:
^ Do not let the grease leak.
^ Do not damage the boot.
4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.
Standard
5. After installation, verify that there is no boot damage or grease leakage.
Boot Band (Differential Side) Assembly Note
1. Using pliers, pull the boot band around the boot slot in opposite direction of drive shaft forward rotation direction and tighten.
2. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead screwdriver to secure the boot band.
3. Verify that the boot band is installed to the boot slot securely.
Boot Band (Axle Side) Assembly Note
1. Turn the adjusting bolt of the SST and adjust the opening size to the specification A.
Specification A 2.9 mm (0.11 inch)
2. Crimp the boot band (small-size) using the SST.
3. Verify that the crimp value B is within the specification.
^ If the crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.
^ If the crimp value B is less than the specification, increase opening length A of the SST and crimp the new boot band.
Specification B 2.4 - 2.8 mm (0.095 - 0.110 inch)
4. Verify that the boot band does not protrude from the boot band installation area.
^ If the boot band protrudes from the installation area, replace it with a new band and repeat Step 2-4.
5. Fill the boot with the repair kit grease.
6. Adjust opening length A of the SST to the specification.
Specification A 3.2 mm (0.13 inch)
7. Crimp the boot band (large-size) using the SST.
8. Verify that the boot band crimp value B is within the specification.
^ If crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.
^ If the crimp value B is less than the specification, replace the boot band, increase opening length A of the SST, and then recrimp the new boot band.
Specification B 2.4 - 2.8 mm (0.095 - 0.110 inch)
9. Verify that the boot band does not protrude from the boot band installation area.
^ If the boot band protrudes from the installation area, replace it with a new band and repeat Step 7-9.