Front
OVERHAULHINT: Overhaul the RH side by the same procedures with LH side.
1. DRAIN AUTOMATIC TRANSAXLE FLUID
2. DRAIN TRANSFER OIL (4WD)
3. REMOVE FRONT WHEEL
4. 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.
5. SEPARATE FRONT STABILIZER LINK ASSY 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.
6. SEPARATE SPEED SENSOR FRONT LH
a. Remove the bolt, separate the speed sensor from the steering knuckle.
7. SEPARATE TIE ROD ASSY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 09628-62011
8. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
9. SEPARATE FRONT AXLE ASSY 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.
10. REMOVE FRONT DRIVE SHAFT ASSY LH
a. Remove the front fender apron seal LH.
b. 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.
11. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD)
a. Remove the front fender apron seal RH.
b. Remove the 2 bolts and pull out the drive shaft together with the center bearing bracket.
c. Remove the drive shaft.
12. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD)
HINT: Overhaul the RH side by the same procedures with LH side.
13. FIX FRONT AXLE ASSY 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 (09600-02021, 09608-02041)
14. 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.
15. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Using a screwdriver, unstake the 2 inboard joint boot clamps.
16. SEPARATE FRONT AXLE INBOARD JOINT BOOT
17. 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.
18. REMOVE DRIVE SHAFT DAMPER
a. Using a screwdriver, unstake the damper clamp.
b. Remove the damper clamp.
19. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
a. Using a screwdriver, unstake the 4 joint boot clamps.
HINT: If the outboard joint boot clamps that have been replaced are installed to the drive shaft, use a side cutter or pliers to remove then.
20. REMOVE OUTBOARD JOINT BOOT
21. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using a screwdriver, remove the snap ring.
22. REMOVE FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, remove the dust cover.
SST 09950-00020
23. REMOVE FRONT DRIVE SHAFT DUST COVER RH (2WD)
a. Using a press, remove the dust cover.
24. REMOVE FRONT DRIVE SHAFT DUST COVER RH (4WD)
a. Using SST and a press, remove the dust cover
SST 09950-00020
25. REMOVE CASE SUB ASSY, DRIVE SHAFT BEARING SNAP RING (2WD)
a. Using a screwdriver, remove the snap ring
26. REMOVE DRIVE SHAFT BEARING CASE SUB ASSY (2WD)
a. Using a press, remove the bearing case
27. REMOVE FRONT DRIVE SHAFT DUST COVER (2WD)
a. Using SST and a press, remove the dust cover.
SST 09950-00020
28. REMOVE FRONT DRIVE SHAFT BEARING (2WD)
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the bearing.
SST 09527-10011
c. Remove the snap ring.
29. INSTALL FRONT DRIVE SHAFT BEARING (2WD)
a. Using SST and a press, install a new bearing.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
30. INSTALL CASE SUB ASSY, DRIVE SHAFT BEARING SNAP RING (2WD)
a. Using a screwdriver, install a new snap ring.
31. INSTALL DRIVE SHAFT BEARING CASE SUB ASSY (2WD)
a. Using SST and a press, install the bearing case to the inboard joint.
SST 09527-10011, 09710-04081
b. Using snap ring expander, install a new snap ring.
32. INSTALL FRONT DRIVE SHAFT DUST COVER (2WD)
a. Using SST and a press, install a new dust cover.
SST 09726-00010, 09527-10011
33. INSTALL FRONT DRIVE SHAFT DUST COVER RH (2WD)
a. Using SST and a 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.
SST 09527-10011
Distance: 91.5 ± 0.5 mm (3.6 ± 0.02 inch)
34. INSTALL FRONT DRIVE SHAFT DUST COVER RH (4WD)
a. Using SST and a press, install a new dust cover.
SST 09527-10011
35. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new dust cover.
SST 09527-10011
36. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new snap ring.
37. 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 inboard joint shaft and boot with grease in the boot kit.
Grease capacity: 262 - 277 g (9.2 - 9.7 oz.)
38. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP
a. Mount drive shaft in a soft vise.
b. Secure the 2 outboard joint boot clamps onto the boot.
c. Place SST onto the outboard joint large boot clamp.
SST 09521-24010
Clearance: 0.8 mm or less
d. Tighten the SST so that the large clamp is pinched.
NOTICE: Do not over-tighten the SST.
e. Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm or less
f. Employ the same manner to the outboard joint small boot clamp.
39. INSTALL DRIVE SHAFT DAMPER
a. Make sure that the damper is on the shaft groove.
b. Set the distance, as described.
Distance: 204.4 ± 2.0 mm (8.047 ± 0.079 inch)
40. 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 outboard joint shaft and boot with grease in the boot kit.
Grease capacity: 185 - 195 g (6.5 - 6.9 oz.)
e. Using a snap ring expander, install a new snap ring.
41. INSTALL FRONT AXLE INBOARD JOINT BOOT
a. Install the inboard joint boot to the outboard joint shaft.
42. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP
a. Bend the band and lock the inboard joint boot clamps with a screwdriver.
43. INSPECT FRONT DRIVE SHAFT
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. 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.
44. INSTALL FRONT DRIVE SHAFT ASSY LH
a. Coat the spline of the inboard joint shaft assy with AT F.
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.
c. Install fender apron seal LH.
45. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD)
a. Coat the spline of the inboard joint shaft assy with gear oil.
b. Aline the shaft splines and install the drive shaft assy with the 2 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
NOTICE: Do not damage the oil seal.
46. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD)
HINT: Install the RH side by the same procedures with LH side.
47. INSTALL FRONT AXLE ASSY LH
a. Install the drive shaft assy LH to the front axle assy LH.
NOTICE:
^ Be careful not to damage the outboard joint boot.
^ Be careful not to damage the speed sensor rotor.
48. 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: 127 Nm (1,300 kgf-cm, 94 ft. lbs.)
49. INSTALL TIE ROD ASSY 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°.
50. 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.
51. INSTALL FRONT STABILIZER LINK ASSY LH
a. Install the stabilizer bar link with the nut.
Torque: 74 Nm (760 kgf-cm, 55 ft. lbs.)
HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
52. 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.
53. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
54. ADD AUTOMATIC TRANSAXLE FLUID
55. INSPECT AUTOMATIC TRANSAXLE FLUID
56. ADD TRANSFER OIL (4WD)
57. INSPECT TRANSFER OIL (4WD)
58. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
59. CHECK ABS SPEED SENSOR SIGNAL