Front Drive Shaft Disassembly and Reassembly
Front Drive Shaft Disassembly and Reassembly
Front Drive Shaft Components:Front
Front Drive Shaft Assembly Removal and Installation:Front
Disassembly
NOTE:
Disassembly of the wheel-side joint or the tripod joint spider can cause performance problems.
If anything abnormal (damage, noise, etc.) is found with either of these joints, replace the joint as an assembly.
1) Remove boot bands (1) of differential side, center shaft side or transfer side.
2) Remove joint housing from drive shaft.
3) Wipe off grease from shaft and take off snap ring (1) using snap ring pliers (2).
4) Remove tripod joint spider (1) using 3 arms puller (2).
NOTE:
Except for the housing, washing the tripod joint parts with a washing solution may cause problems with the joint.
Do not use a washing solution to clean any tripod joint parts other than the housing. Use a cloth to remove grease from tripod joints.
5) Pull out boot and small band of differential side, center shaft side or transfer side.
6) Remove damper from shaft, if equipped.
7) Remove wheel side boot big band as follows.
a) Draw hooks of boot big band together and remove band.
8) Undo caulking (1) of wheel side boot small band (2) using flat end rod (3) or the like, then pull out wheel side boot (4) from shaft.
Reassembly
Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
NOTE:
Joints may not perform as designed if proper cleaning and lubrication precautions are not taken.
- Do not wash boots with solvents such as gasoline or kerosene. Washing boots with these solvents causes deterioration of the boots.
- Be sure to lubricate joints with the specified grease in the specified amount. Follow the instructions below to identify the specified grease and specified amount for each joint.
1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare parts.
Grease color
: Tan
Amount
: 90 - 110 g (3.2 - 3.8 oz)
4) Install wheel side boot to drive shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.
7) Fasten boot band (1) securely using special tool as shown in figure.
Distance "a"
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special Tool
(A): 09943-57011
8) Place new wheel side boot big band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.
NOTE:
Squeezing or otherwise distorting the boot will reduce its durability.
Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with bands.
9) Fasten wheel side boot big band (1) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4).
Special Tool
(A): 09943-57021
10) Install damper (1) to specified position on drive shaft, if equipped.
Drive shaft damper installing position (right side)
"a": 208.6 - 214.6 mm (8.213 - 8.448 in,) (2WD-M/T model)
"a": 359.0 - 365.0 mm (14.134 - 14.370 in,) (CVT model and 4WD-M/T model)
Drive shaft damper installing position (left side)
"a": 249.0 - 255.0 mm (9.804 - 10.039 in,) (M/T model)
11) Set new differential side small band and new differential side boot (1) on shaft temporarily, and then apply grease to tripod joint spider (2). Use specified grease in tube included in spare parts.
12) Install tripod joint spider (3) on shaft using snap ring pliers (5) with hammer, directing its chamfered spline toward wheel side, and then fasten it with new snap ring (4).
Special Tool
(A): 09925-98220
13) Apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint.
Grease color
"A": Tan
Amount
"A": 85 - 105 g (3.2 - 3.8 oz)
14) Fit boot (1) to grooves of shaft and housing (2) adjust length to specification below.
Drive shaft boot fixing position (distance between housing end and small boot band)
Left side drive shaft "a": 184.0 - 194.0 mm (7.245 - 7.637 in,)
Right side drive shaft "b": 227.6 - 237.6 mm (8.961 - 9.354 in,) (M/T model)
Right side drive shaft "b": 226.1 - 236.1 mm (8.902 - 9.295 in,) (CVT model)
15) Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
16) Fasten boot bands (1) as shown in figure.
NOTE: - If a boot band is installed with its outer end pointing in the forward rotating direction, the band's end may be caught by something and be raised to loosen the band. This could lead to leakage of grease and eventually to a broken drive shaft.
Be sure to install each boot band with its outer end pointing against the forward rotating direction.
- Squeezing or otherwise distorting the boot will reduce its durability.
Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with its band.
