Front Drive Shaft

FRONT DRIVE SHAFT ASSEMBLY (FOR 4WD)

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. SEPARATE SPEED SENSOR FRONT

3. REMOVE FRONT AXLE HUB NUT
a. Using SST and a hammer, release the staked part of the front axle hub nut.
SST 09930-00010

NOTICE: Release the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

b. While applying the brakes, remove the front axle hub nut.

4. SEPARATE LOWER BALL JOINT ASSEMBLY FRONT
a. Remove the 2 bolts and steering knuckle from the lower ball joint.

5. SEPARATE TIE ROD ASSEMBLY

a. Remove the clip and nut.

b. Using SST, separate the tie rod end from the steering knuckle.
SST 09628-00011

NOTICE:
^ Pay careful attention not to damage the steering knuckle because it is made of aluminum and may be damaged easily.
^ Do not damage the ball joint dust cover.
^ Make sure that the SST is securely set to the steering knuckle spacer.
^ If the steering knuckle spacer has come off, replace the steering knuckle with a new one.
^ Make sure that the string of the SST is securely tied to the vehicle.

6. SEPARATE FRONT AXLE ASSEMBLY
a. Using a plastic hammer, separate the front axle assembly from the drive shaft assembly

NOTICE: Be careful not to damage the drive shaft boot.

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

NOTICE:
^ Be careful not to damage the drive shaft boot, dust cover and oil seal.
^ Be careful not to drop the drive shaft assembly.

8. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Using water pump pliers, remove the bearing bracket hole snap ring.
b. Remove the bolt and front drive shaft assembly from the drive shaft bearing bracket.

NOTICE:
^ Be careful not to damage the drive shaft boot, dust cover and oil seal.
^ Be careful not to drop the drive shaft assembly.

9. FIX FRONT AXLE ASSEMBLY
SST 09608-16042 (09608-02021, 09608-02041)

NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle's full weight, such as moving the vehicle with the drive shaft removed.
If it is necessary to place the vehicle's weight on the hub bearing, first support it with SST.

10. INSPECT FRONT DRIVE SHAFT
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 boot for damage.

DISASSEMBLY

1. REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO. 2 CLAMP
a. Using a screwdriver, remove the inboard joint boot No. 2 clamp as shown in the illustration.

2. REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Remove the inboard joint boot clamp using 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 FRONT DRIVE INBOARD JOINT ASSEMBLY LH

a. Put matchmarks on the inboard joint assembly and outboard joint shaft.

NOTICE: Do not use a punch for the marks.

b. Remove the inboard joint assembly from the outboard joint shaft.
c. Put matchmarks on the outboard joint shaft and tripod joint.

NOTICE: Do not use a punch for the marks.

d. Using a snap ring expander, remove the shaft snap ring.

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

NOTICE: Do not tap the roller.

5. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO. 2 CLAMP
a. Using pliers, remove the outboard joint boot LH No. 2 clamp as shown in the illustration.

6. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Remove the inboard joint boot clamp using the same procedures as for the inboard joint boot No. 2 clamp.

7. REMOVE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft.
b. Remove the grease from the outboard joint.

8. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using a screwdriver, remove the front drive shaft snap ring.

9. REMOVE FRONT DRIVE SHAFT DUST COVER LH
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.

10. REMOVE FRONT DRIVE SHAFT BEARING

a. Using a snap ring expander, remove the drive shaft hole snap ring.

b. Using SST and a press, remove the bearing.
SST 09527-10011

NOTICE: Be careful not to drop the inboard joint assembly.

11. REMOVE FRONT WHEEL BEARING DUST DEFLECTOR NO. 1 LH
a. Using a screwdriver and hammer, remove the front wheel bearing dust deflector No. 1.

REASSEMBLY

1. INSTALL FRONT WHEEL BEARING DUST DEFLECTOR NO. 1 LH
a. Using SST and a press, install a new front wheel bearing dust deflector No. 1.
SST 09309-36010, 09316-20011

NOTICE:
^ Dust deflector should be completely installed.
^ Be careful not to damage the dust deflector.

2. INSTALL FRONT DRIVE SHAFT BEARING

a. Using SST and a steel plate, install a new front drive shaft bearing.
SST 09710-22042 (09710-02051)

NOTICE: Bearing should be completely installed.

b. Using a snap ring expander, install a new drive shaft hole snap ring.

3. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new drive shaft dust cover.
SST 09527-10011

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.

4. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new hole snap ring.

5. 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. Hold the drive shaft lightly in a soft vise.
b. Temporarily install a new outboard joint boot to the drive shaft with the 2 clamps.
c. Pack the outboard joint and boot with grease.
Grease capacity: 105 to 125 g (3.5 to 4.4 oz.)

6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Hold the drive shaft lightly in a soft vise.
b. Install the 2 outboard joint boot clamps onto the boot.
c. Place SST onto the outboard joint small boot clamp.

d. Tighten the SST so that the outboard joint small boot clamp is pinched.
SST 09521-24010

NOTICE: Do not overtighten the SST.

e. Using SST, measure the clearance of the outboard joint small boot clamp.
SST 09240-00020
Clearance: 1.2 to 4.0 mm (0.0472 to 0.1575 inch)

NOTICE: When the measured value is greater than the specified value, retighten the clamp.

7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO. 2 CLAMP
a. Hold the drive shaft lightly in a soft vise.
b. Install the 2 outboard joint boot clamps onto the boot.
c. Place SST onto the outboard joint large boot clamp.

d. Tighten the SST so that the outboard joint large boot clamp is pinched.
SST 09521-24010

NOTICE: Do not overtighten the SST.

e. Using SST, measure the clearance of the outboard joint large boot clamp.
SST 09240-00020
Clearance: 1.2 to 4.0 mm (0.0472 to 0.1575 inch)

NOTICE: When the measured value is greater than the specified value, retighten the clamp.

8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH
a. Temporarily install a new inboard joint boot with the 2 clamps to the drive shaft.

b. Align the matchmarks and place the beveled side of the tripod joint axial spline toward the outboard joint shaft.

c. Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.

NOTICE:
^ Do not tap the roller.
^ Be sure to install the tripod joint assembly in the correct direction.

d. Using a snap ring expander, install a new shaft snap ring.
e. Pack the outboard joint and boot with grease.
Grease capacity: 145 to 165 g (5.1 to 5.8 oz.)

f. Align the matchmarks and install the inboard joint assembly to the outboard joint shaft assembly.

9. INSTALL INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly.

10. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Using a screwdriver, install the inboard joint boot clamp as shown in the illustration.

11. INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO. 2 CLAMP
a. Using a screwdriver, install the inboard joint boot clamp No. 2 as shown in the illustration.

12. INSPECT DRIVE SHAFT
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.

INSTALLATION
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Coat the spline of the inboard joint shaft assembly with gear oil.
b. Set the shaft snap ring with the opening side facing down.

c. Align the shaft splines and install the drive shaft assembly with a brass bar and hammer.

NOTICE:
^ Be careful not to damage the drive shaft dust cover, boot and oil seal.
^ Move the drive shaft assembly while keeping it level.

2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Coat the spline of the inboard joint shaft assembly with gear oil.
b. Install the drive shaft assembly.

c. Using a water pump pliers, install a new bearing bracket hole snap ring.

NOTICE:
^ Do not damage the boot and oil seal.
^ Move the drive shaft assembly while keeping it level.

d. Install a new bolt.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)

3. INSTALL FRONT AXLE ASSEMBLY
a. Install the front drive shaft assembly to the front axle assembly.

NOTICE: Be careful not to damage the drive shaft boot.

4. INSTALL TIE ROD ASSEMBLY
a. Install the tie rod end to the steering knuckle with the nut.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
b. Install a new clip.

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

5. INSTALL LOWER BALL JOINT ASSEMBLY FRONT
a. Install the steering knuckle to the lower ball joint with the 2 bolts.
Torque: 120 Nm (1,224 kgf-cm, 89 ft. lbs.)

6. INSTALL FRONT AXLE HUB NUT
a. Using a socket wrench (30 mm), install a new axle hub nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)

b. Using a chisel and hammer, stake the front axle hub nut.

7. INSTALL SPEED SENSOR FRONT
8. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

9. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
10. CHECK ABS SPEED SENSOR SIGNAL