Front

Overhaul - Front Drive Shaft ASSY LH

1. REMOVE FRONT WHEEL
2. DRAIN DIFFERENTIAL OIL





3. REMOVE FRONT AXLE HUB LH NUT
a. Remove the cotter pin and a adjusting cap.
b. Remove the front axle hub LH nut.





4. SEPARATE SPEED SENSOR FRONT LH
a. Using a hexagon wrench, separate the speed sensor front LH.
b. Disconnect the 2 clamp.
c. Remove the bolt and separate the speed sensor wire harness from the steering knuckle.





5. SEPARATE TIE ROD END SUB-ASSY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 0962-62011





6. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 LH
a. Remove the 2 bolts and separate the front suspension arm from the lower ball joint.





7. REMOVE FRONT DRIVE SHAFT ASSY LH
a. Using SST, remove the front drive shaft assy LH.
SST 09520-01010, 09520-24010 (09520-32040)

NOTICE: Be careful not to damage the oil seal.

8. REMOVE FRONT DRIVE SHAFT ASSY RH

HINT: Remove the RH side by the same procedures with LH side.

SST 09520-01010, 09520-24010 (09520-32040)





9. INSPECT SHAFT ASSY, FR DRIVE
a. Check to see that there is no remarkable play in the outboard joint.
b. Check to see that the inboard joint slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.

NOTICE: Move the drive shaft assy keeping it level.





10. SEPARATE FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Using a screwdriver, disclamp the inboard joint boot clamp.
b. Using the same manner to the inboard joint small boot clamp.
11. SEPARATE INBOARD JOINT BOOT





12. REMOVE FRONT DRIVE INBOARD JOINT ASSY LH
a. Place matchmarks on the tripod, inboard and outboard joint shafts.

NOTICE: Do not punch the marks.

b. Remove the inboard joint shaft from the outboard joint shaft.





c. Using a snap ring expander, remove the snap ring.





d. Place matchmarks on the outboard joint shaft and tripod.

NOTICE: Do not punch the marks.

e. Using a brass bar and hammer, remove the tripod from the drive shaft.

NOTICE: Do not tap the roller.





13. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
a. Using a screwdriver, disclamp the inboard joint boot clamps.

HINT: If the outboard joint boot clamp that have been replaced are installed to the drive shaft, use a side cutter to remove them.

b. Using the same manner to the outboard joint small boot clamp.
14. REMOVE OUTBOARD JOINT BOOT





15. REMOVE FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING
a. Using a screwdriver, remove the snap ring.





16. REMOVE FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, remove the dust cover.
SST 09950-00020





17. REMOVE STEERING KNUCKLE LH OIL SEAL
a. Using a screwdriver and a hammer, remove the oil seal.





18. INSTALL STEERING KNUCKLE LH OIL SEAL
a. Using a screwdriver and a hammer, install a new oil seal.

NOTICE: Do not damage the oil seal.





19. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, install a new dust cover.
SST 09527-10011
20. INSTALL FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING
a. Install a new snap ring.





21. 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. Temporarily install a new outboard joint boot with 2 clamps to the drive shaft.
b. Pack the outboard joint assy and boot with grease in the boot kit.
Grease capacity: 260 - 270 g (9.2 - 9.5 oz.)





22. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP
a. Mount drive shaft in a soft vise.
b. Secure the outboard joint boot clamps onto the boot.
c. Place SST onto the outboard joint large boot clamp.
SST 09521-24010
Clearance: 0.8 mm (0.031 inch) or less
d. Tighten the SST so that the large clamp is pinched.

NOTICE: Do not overtighten the SST.





e. Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearances: 0.8 mm (0.031 inch) or less
f. Employ the same manner to the outboard joint small boot clamp.
23. INSTALL INBOARD JOINT BOOT
a. Install a new inboard joint boot to the outboard joint shaft.





24. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
a. Place the beveled side of the tripod axial spline toward the outboard joint.
b. Align the matchmarks placed before removal.
c. Using a brass bar and hammer, tap in the tripod to the drive shaft.

NOTICE: Do not tap the roller.

d. Pack the inboard joint assy and boot with grease in the boot kit.
Grease capacity: 231 - 241 g (8.1 - 8.5 oz.)
e. Using a snap ring expander, install a new snap ring.





25. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Bend the band and lock a new inboard joint large boot clamp with a screwdriver.
b. Using the same manner to the inboard joint small boot clamp.





26. INSPECT FRONT DRIVE SHAFT ASSY LH
a. Check to see that there is no remarkable play in the outboard joint.
b. Check to see that the inboard joint slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.

NOTICE: Move the drive shaft assy keeping it level.





27. INSTALL FRONT DRIVE SHAFT ASSY LH
a. Coat the spline of the inboard joint shaft assy with ATF.
b. Aline the shaft splines and install the drive shaft assy with brass bar and hammer.

NOTICE: Set the snap ring with opening side facing downward Be careful not to damage the oil seal.

HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving it.





28. INSTALL SPEED SENSOR FRONT LH
a. Install the speed sensor wire harness to the steering knuckle with a bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
b. Connect the 2 clips.
c. Using a hexagon wrench, install the speed sensor with the bolt.
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)





29. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 LH
a. Install the lower ball joint to the lower suspension arm with the bolt and nut.
Torque: 225 Nm (2,294 kgf-cm, 166 ft. lbs.)





30. INSTALL TIE ROD END SUB-ASSY LH
a. install the tie rod end to the steering knuckle with the nut.
Torque: 91 Nm (928 kgf-cm, 67 ft. lbs.)
b. Install a new cotter pin.

NOTICE: If the holes for the cotter pin are not aligned, tighten the nut further to 60°.





31. INSTALL FRONT AXLE HUB LH NUT
a. Install the hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Install a new cotter pin and adjusting cap.
32. FILL UP DIFFERENTIAL OIL
33. INSPECT DIFFERENTIAL OIL
34. INSTALL FRONT WHEEL
Torque: 112 Nm (1,142 kgf-cm, 83 ft. lbs.)
35. CHECK ABS SPEED SENSOR SIGNAL