Axle Shaft Assembly: Service and Repair
OVERHAULHINT: Overhaul the RH side by the same procedures with LH side.
NOTICE: Do not disassemble the outboard joint.
1. DRAIN AUTOMATIC TRANSAXLE FLUID
2. REMOVE FRONT WHEEL
3. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the nut.
SST 09930-00010
b. While applying the brakes, remove the lock nut.
4. SEPARATE SPEED SENSOR FRONT LH
a. Remove the bolt, separate the sensor wire and hose from the shock absorber.
HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
b. Remove the bolt, separate the speed sensor from the steering knuckle.
5. SEPARATE TIE ROD ASSEMBLY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 09620-62011
6. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
7. SEPARATE FRONT AXLE ASSEMBLY LH
a. Using a plastic hammer, separate the drive shaft from the axle hub.
NOTICE: Be careful not to damage the boot and speed sensor rotor.
8. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
a. Remove the front fender apron seal LH.
b. Using SST, remove the front drive shaft assembly LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE: Be careful not to damage the oil seal.
9. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Using pliers, remove the snap ring.
b. Remove the bolt and front drive shaft RH from the bearing bracket.
c. Using brass bar and hummer, remove the drive shaft from transaxle.
NOTICE: Be careful not to damage the dust cover and oil seal.
10. FIX FRONT AXLE ASSEMBLY LH
NOTICE: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
11. INSPECT FRONT DRIVE SHAFT ASSEMBLY 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 assembly keeping it level.
12. REMOVE FRONT DRIVE FLANGE SHAFT SUB-ASSEMBLY
a. Mount drive shaft in a soft vise.
b. Using a hexagon wrench, remove the 6 hexagon bolts and 3 joint washers.
NOTICE: Do not compress the inboard boot.
c. Remove the gasket from the drive shaft.
d. Use bolts, nuts and washers to keep the inboard joint together.
NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.
13. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY LH
a. Mount drive shaft in a soft vise.
b. Using a hexagon wrench, remove the 6 hexagon bolts and 3 joint washers.
NOTICE: Do not compress the inboard boot.
c. Remove the gasket from the drive shaft.
d. Use bolts, nuts and washers to keep the inboard joint together.
NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.
14. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using screwdriver, remove the snap ring.
15. REMOVE FRONT DRIVE SHAFT DUST COVER LH
a. Mount inboard joint shaft in a soft vise.
b. Using screwdriver, remove the dust cover.
16. REMOVE FRONT DRIVE SHAFT DUST COVER RH
a. Using a press, remove the dust cover from the inboard joint shaft.
17. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Using screwdriver, remove the 2 boot clamps.
18. REMOVE FRONT DRIVE SHAFT CROSS GROOVE JOINT SUB-ASSEMBLY LH
a. Place matchmarks on the inboard joint and drive shaft.
b. Using a snap ring expander, remove the snap ring.
c. Using SST, a socket wrench and press, remove the inboard joint from the drive shaft.
SST 09726-10011 (09726-00031)
19. REMOVE FRONT AXLE INBOARD JOINT COVER LH
a. Mount inboard joint shaft in a soft vise.
b. Using a screwdriver, remove the cover.
20. REMOVE FRONT DRIVE SHAFT DUST COVER
a. Using a screwdriver, pry off the dust cover until the SST can be installed.
b. Using SST and a press, remove the dust cover.
SST 09950-00020
21. REMOVE FRONT DRIVE SHAFT BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the bearing from the inboard joint.
SST 09527-21011
c. Remove the snap ring.
22. REMOVE BOOT,FR AXLE INBOARD JOINT
a. Remove the 2 clamps and boots.
23. REMOVE DRIVE SHAFT DAMPER
a. Using a screwdriver, unstake the damper clamp.
b. Remove the damper from the outboard joint.
24. INSTALL DRIVE SHAFT DAMPER
a. Make sure that the damper is on the shaft groove.
b. Set the distance, as described.
Distance: 189.5 ± 2.0 mm (7.46 ± 0.079 inch)
25. INSTALL FRONT DRIVE SHAFT CROSS GROOVE JOINT SUB-ASSEMBLY LH
If the joint has come apart, reassemble it in the following order.
a. Align the matchmarks placed before removal.
If the matchmarks have disappeared, do the following procedure.
1 Install the inner race to the cage.
2 Install the outer race so that the wide indented part is at the same as the indented part of the inner race.
HINT: The cage does not have the specified attachment direction.
3 Match the narrow projections of the inner race with the wide projections of the outer race.
b. Tilt the cage and inner race to the side and insert the balls one by one.
NOTICE: When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out.
26. INSTALL FRONT AXLE INBOARD JOINT COVER LH
a. Clean contacting surfaces of any FIPG material using a cleaner.
b. Apply FIPG to the inboard joint cover, as shown in the illustration.
FIPG: 08826-00801, THREE BOND 1121 or equivalent
c. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
d. Use a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times.
e. Use bolts, nut and washers to keep the inboard joint together.
NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.
27. INSTALL FRONT DRIVE SHAFT BEARING
a. Install the snap ring.
b. Using SST and a press, install the new bearing.
SST 09527-21011
c. Using a snap ring expander, install a new snap ring.
28. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, install a new dust cover.
SST 09527-21011
Clearance: 0.6 mm (0.024 inch)
29. INSTALL FRONT AXLE INBOARD JOINT BOOT
a. Pack the inboard joint shaft and boot with grease in the boot kit.
Grease capacity: 103 - 113 g (3.6 - 4.0 oz.)
30. INSTALL FRONT DRIVE SHAFT CROSS GROOVE JOINT SUB-ASSEMBLY LH
a. Align the matchmarks placed before disassembly.
b. Using a brass bar and hammer, tap the inboard joint onto the drive shaft.
NOTICE: Check that the brass bar is touching the inner race, and not the cage.
c. Using a snap ring expander, install a new snap ring.
NOTICE: Work carefully so that the outer race does not come off.
31. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Make sure that the 2 boots are on the shaft groove.
b. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
Drive shaft standard length:
c. Bend the band and lock the inboard joint boot clamps with a screwdriver.
32. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using a press, install a new dust cover.
NOTICE: Do not damage the dust cover.
33. INSTALL FRONT DRIVE SHAFT DUST COVER RH
a. Using a steel plate and press, install a new dust cover until the distance from the tip of center drive shaft to the dust cover reaches the specification, as shown in the illustration.
Distance: 3MZ-FE 110 (4.33 inch)
Distance: 2AZ-FE 91.5 (3.6 inch)
34. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install the new snap ring.
35. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY LH
a. Pack the cross groove joint and side gear shaft with grease in the boot kit.
Grease capacity: 30 - 40 g (1.1 - 1.4 oz.)
b. Using a hexagon wrench, install the 6 hexagon bolts and 3 joint washers.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
36. INSTALL FRONT DRIVE FLANGE SHAFT SUB-ASSEMBLY
a. Pack the cross groove joint and side gear shaft with grease in the boot kit.
Grease capacity: 30 - 40 g (1.1 - 1.4 oz.)
b. Using a hexagon wrench, install the 6 hexagon bolts and 3 joint washers.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
37. INSPECT FRONT DRIVE SHAFT ASSEMBLY 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 assembly keeping it level.
38. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Coat the spline of the inboard joint shaft assembly with ATF.
b. Aline the shaft splines and install the drive shaft assembly 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.
c. Install fender apron seal LH.
39. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Coat the spline of the inboard joint shaft assembly with ATF.
b. Aline the shaft splines and install the drive shaft assembly.
NOTICE: Be careful not to damage the oil seal.
c. Using pliers, install the snap ring.
d. Install the bolt to the bearing bracket.
Torque: 32.4 Nm (330 kgf-cm, 24 ft. lbs.)
40. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
NOTICE: Be careful not to damage the outboard joint boot. Be careful not to damage the speed sensor rotor.
41. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the lower ball joint to the lower suspension arm with the bolt and nut.
Torque: 127 Nm (1,300 kgf-cm, 94 ft. lbs.)
42. INSTALL TIE ROD ASSEMBLY LH
a. Install the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 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°.
43. INSTALL SPEED SENSOR FRONT LH
a. Install the flexible hose to shock absorber with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
b. Install the speed sensor to the steering knuckle with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
NOTICE:
^ Be careful not to damage the speed sensor.
^ Prevent foreign matter from being attached.
^ Do not twist the sensor wire when installing the sensor.
44. INSTALL FRONT AXLE HUB LH NUT
a. Install the hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using chisel and hammer, stake the hub nut.
45. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
46. ADD AUTOMATIC TRANSAXLE FLUID
47. INSPECT AND ADJUST AUTOMATIC TRANSAXLE FLUID
48. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
49. CHECK ABS SPEED SENSOR SIGNAL