FRONT DRIVE SHAFT REMOVAL/INSTALLATION

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Caution

•  Performing the following procedures could cause an open circuit in the front ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

1.  Remove the wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

2.  Disconnect the front ABS wheel-speed sensor wiring harness installed to the steering knuckle and set it aside.

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3.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

5.  Drain the manual transaxle oil or ATF. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].) (See MANUAL TRANSAXLE OIL REPLACEMENT [D66M-R, D66MX-R].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

6.  Remove the locknut with the brake pedal depressed. (See Locknut Installation Note.)

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Caution

•  When removing the locknut, remove it manually without using an electric or pneumatic tool. Otherwise, the locknut may seize.

•  When removing the locknut, do not apply load at the ground to the axle. Otherwise, it could damage the wheel hub.

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  After installation, add the specified manual transaxle oil or ATF. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].) (See MANUAL TRANSAXLE OIL REPLACEMENT [D66M-R, D66MX-R].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

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1	Tie-rod end (See TIE-ROD END REPLACEMENT.)
2	Stabilizer control link upper nut
3	Dynamic damper
4	Brake hose clip
5	Front lower arm ball joint (See FRONT LOWER ARM REMOVAL/INSTALLATION.)
6	Front drive shaft (LH) (See Front Drive Shaft Removal Note.) (See Front Drive Shaft (LH) Installation Note.)
7	Front drive shaft clip (See Front Drive Shaft Clip Installation Note.)
8	Bracket No.2 (See Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.0, SKYACTIV-G 2.5, SKYACTIV-D 2.2].)
9	Front drive shaft (RH) (See Front Drive Shaft Removal Note.) (See Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.0, SKYACTIV-G 2.5, SKYACTIV-D 2.2].) (See Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.5T].)
10	Bracket No.1 (See Bracket No.1 Removal Note [SKYACTIV-G 2.5T].) (See Bracket No.1 Removal Note [SKYACTIV-D 2.2].) (See Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.0, SKYACTIV-G 2.5, SKYACTIV-D 2.2].) (See Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.5T].)
11	Transfer oil seal (RH) No.1 (See TRANSFER OIL SEAL REPLACEMENT [GW6AX-EL].)
12	Transfer oil seal (RH) No.3 (See TRANSFER OIL SEAL REPLACEMENT [GW6AX-EL].)

Front Drive Shaft Removal Note

Caution

•  The oil seal at the front end of the front drive shaft could be damaged. When removing the front drive shaft, be careful not to damage the oil seal.

1.  Install a spare nut onto the front drive shaft.

2.  Tap the nut with a copper hammer and separate the front drive shaft from the axle.

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3.  Separate the front drive shaft from the wheel hub.

4.  Separate the front drive shaft (LH) from the transaxle using the SSTs.

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5.  Remove the front drive shaft.

6.  If the front drive shaft for 4WD vehicles is removed, replace transfer oil seals (RH) No.1 and No.3 with new ones. (See TRANSFER OIL SEAL REPLACEMENT [GW6AX-EL].)

Bracket No.1 Removal Note [SKYACTIV-G 2.5T]

1.  Remove the bolt.

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2.  Remove the bracket No.1.

Bracket No.1 Removal Note [SKYACTIV-D 2.2]

1.  Remove the catalytic converter lower bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the bracket No.1.

Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.0, SKYACTIV-G 2.5, SKYACTIV-D 2.2]

Caution

•  The oil seal could be damaged at the end area of the front drive shaft. When installing the front drive shaft to the transaxle, be careful not to damage the oil seal. If the oil seal is damaged, replace it with a new one.

•  Retighten the bracket No.1 stud bolts when the bracket No.2 nuts are loosened.

1.  Tighten the bracket No.1 stud bolts.

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2.  Temporarily tighten the bolts A and B.

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3.  Tighten the bolts A, then tighten the bolt B to the specified torque.

4.  Apply transaxle oil or ATF to the oil seal lip.

5.  Insert the front drive shaft into the transaxle until the front drive shaft bearing contacts the bracket stopper.

6.  Temporarily tighten the nuts C, then tighten the nuts C to the specified torque.

7.  Apply grease (D4Y0 33247 or equivalent) to the wheel bearing inner race and front drive shaft contact surface (Area A in figure).

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8.  Insert the front drive shaft into the wheel hub.

Bracket, Front Drive Shaft (RH) Installation Note [SKYACTIV-G 2.5T]

Caution

•  Retighten the bracket No.1 stud bolts when the bracket No.2 nuts are loosened.

1.  Tighten the bracket No.1 stud bolts.

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2.  Insert the drive shaft into the transaxle until the drive shaft bearing contacts the bracket stopper.

3.  Temporarily tighten the bolts A and B.

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4.  Temporarily tighten the nuts, then tighten the nuts to the specified torque.

5.  Apply ATF to the oil seal lip.

6.  Insert the front drive shaft into the transaxle until the front drive shaft bearing contacts the bracket stopper.

7.  Temporarily tighten the nuts C, then tighten the nuts C to the specified torque.

8.  Install the bolt.

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9.  Apply grease (D4Y0 33247 or equivalent) to the wheel bearing inner race and drive shaft contact surface (Area A in figure).

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Front Drive Shaft Clip Installation Note

1.  Install a new clip to the clip groove at the end of the front drive shaft with the clip opening facing upward.

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2.  Verify that the outer diameter of the clip is within the specification.

•  If it exceeds the specification, repeat installation using a new clip.

Front Drive Shaft (LH) Installation Note

Caution

•  The sharp edges of the front drive shaft can slice or puncture the oil seal. Be careful when installing the front drive shaft to the transaxle.

1.  Apply transaxle oil or ATF to the oil seal lip.

2.  Apply grease (D4Y0 33247 or equivalent) to the wheel bearing inner race and front drive shaft contact surface (Area A in figure).

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3.  Insert the front drive shaft into the wheel hub.

4.  Install the front drive shaft to the transaxle.

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5.  After installation, pull the transaxle side outer ring forward to confirm that the front drive shaft is securely held by the clip.

Locknut Installation Note

Caution

•  When installing the locknut, install it manually without using an electric or pneumatic tool. Otherwise, the locknut may seize and the tightening force of the wheel hub may decrease and cause excessive play or abnormal noise.

•  When installing the locknut, do not apply load at the ground to the axle. Otherwise, it could damage the wheel hub.

1.  If dust or grease is on the drive shaft thread area, wipe it off with a cloth.

2.  Tighten the locknut using the following procedure and with the brake pedal depressed.

(1)  Tighten locknut to 100—150 N·m {11—15 kgf·m, 74—110 ft·lbf} torque.

(2)  Loosen locknut to 180°.

(3)  Tighten locknut to 236—274 N·m {25—27 kgf·m, 175—202 ft·lbf} torque.