Axle Shaft Assembly: Service and Repair

FRONT DRIVE SHAFT (2ZZ-GE)

COMPONENTS

OVERHAUL

HINT: Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side.

1. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER LH

4. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the hub LH nut.
SST 09930-00010
b. While applying the brakes, remove the hub LH nut.

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

5. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
a. Remove the nut and separate the front stabilizer link assembly LH from the shock absorber assembly front LH.

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, and separate the speed sensor front LH and flexible hose from the shock absorber assembly front LH.

b. Remove the bolt, and separate the speed sensor front LH from the steering knuckle.

7. SEPARATE TIE ROD END SUB-ASSEMBLY LH
a. Remove the cotter pin and nut.
b. Using SST, separate the tie rod end sub-assembly LH from the steering knuckle.
SST 09628-62011

8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Remove the bolt and 2 nuts, and separate the front suspension arm sub-assembly lower No.1 LH from the lower ball joint.

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

NOTICE: Be careful not to damage the boot and speed sensor rotor.

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

NOTICE: Be careful not to damage the dust cover, boot or oil seal.

HINT: In case of not being able to remove the drive shaft by hooking the SST claw to the position (A) in the illustration, hook it to the position (13) and remove.

11. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Remove the 2 bearing lock bolts, and pull out the front drive shaft assembly RH.

NOTICE: Be careful not to damage the dust cover, boot or oil seal.

12. 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, make sure to support the hub bearing with SST when the vehicle weight is applied.

SST 09608-16042 (09608-02021, 09608-02041)

13. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH
a. Check that there is no remarkable play in the outboard joint.
b. Check that the inboard joint slides smoothly in the thrust direction.
c. Check that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.

NOTICE: Keep the drive shaft assembly level during inspection.

14. REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP
a. Using pliers, remove the inboard joint boot LH No.2 clamp, as shown in the illustration.
15. REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Remove the inboard joint boot LH clamp by the same procedures as for the inboard joint boot LH No.2 clamp.
16. SEPARATE INBOARD JOINT BOOT
a. Separate the inboard joint boot from the inboard joint assembly LH.

17. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY LH
a. Remove the old grease from the inboard joint sub-assembly LH.
b. Put matchmarks on the inboard joint sub-assembly LH and outboard joint shaft assembly.

NOTICE: Do not punch for the marks.

c. Remove the inboard joint sub-assembly LH from the outboard joint shaft assembly.

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

e. Put matchmarks on the outboard joint shaft assembly and tripod joint assembly.

NOTICE: Do not punch for the marks.

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

NOTICE: Do not tap the roller.

g. Remove the inboard joint boot LH No.2 clamp, inboard joint boot and inboard joint boot LH clamp.

18. REMOVE DRIVE SHAFT DAMPER

HINT: Perform the procedure below only when disassembling the RH side.

a. Using pliers, remove the damper clamp, as shown in the illustration.
b. Remove the drive shaft damper.

19. 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.
20. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Remove the outboard joint boot LH clamp by the same procedures as for the outboard joint boot LH No.2 clamp.
21. REMOVE OUTBOARD JOINT BOOT
a. Remove the outboard joint boot from the outboard joint shaft.
b. Remove the old grease from the outboard joint.

22. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Using a screwdriver, remove the LH hole snap ring.

23. REMOVE FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, remove the dust cover LH.
SST 09950-00020

NOTICE: Be careful not to drop the inboard joint.

24. REMOVE FRONT DRIVE SHAFT DUST COVER RH
a. Using a press, remove the dust cover RH.

NOTICE: Be careful not to drop the inboard joint.

25. REMOVE DRIVE SHAFT BEARING CASE SUB-ASSEMBLY SNAP RING (RH DRIVE SHAFT)
a. Using a screwdriver, remove the drive shaft bearing snap ring.

26. REMOVE DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (RH DRIVE SHAFT)
a. Using a press, remove the bearing case sub-assembly.

NOTICE: Be careful not to drop the inboard joint.

b. Remove the straight pin.

27. REMOVE FRONT DRIVE SHAFT DUST COVER (RH DRIVE SHAFT)
a. Using SST and a press, remove the dust cover.
SST 09950-00020

NOTICE: Be careful not to drop the inboard joint.

28. REMOVE FRONT DRIVE SHAFT BEARING (RH DRIVE SHAFT)
a. Using a snap ring expander, remove the inner RH shaft snap ring.

b. Using SST and a press, remove the drive shaft bearing.
SST 09527-21011

NOTICE: Be careful not to drop the inboard joint.

c. Remove the drive shaft bearing snap ring.

29. INSTALL FRONT DRIVE SHAFT BEARING (RH DRIVE SHAFT)
a. Using SST and a press, install a new drive shaft bearing.
SST 09950-60010 (09951-00650), 09950-70010 (09951-07100)

30. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY SNAP RING (RH DRIVE SHAFT)
a. Using a screwdriver, install a new drive shaft bearing snap ring.

31. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (RH DRIVE SHAFT)
a. Using SST and a press, install the bearing case sub-assembly to the inboard joint.
SST 09527-10011, 09710-04081

b. Using a snap ring expander, install a new inner RH shaft snap ring.
c. Install the straight pin.

32. INSTALL FRONT DRIVE SHAFT DUST COVER (RH DRIVE SHAFT)
a. Using SST and a press, install a new dust cover until the distance (A) from the tip of the bearing case sub-assembly to the dust cover reaches the specification, as shown in the illustration.
SST 09726-40010, 09527-10011
Distance (A): 1.0 mm (0.039 inch)

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

33. INSTALL FRONT DRIVE SHAFT DUST COVER RH
a. Using SST and a press, install a new dust cover RH until the distance (A) from the tip of center drive shaft to the dust cover RH reaches the specification, as shown in the illustration.
SST 09527-10011
Distance (A): 86.0 to 87.0 mm (3.386 to 3.425 inch)

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

34. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new dust cover LH as shown in the illustration.
SST 09527-10011

NOTICE:
^ Dust cover should be installed completely.
^ Be careful not to damage the dust cover.
35. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new LH hole snap ring.

36. INSTALL OUTBOARD JOINT BOOT

HINT: Before installing the boot, wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.

a. Install new parts to the outboard joint shaft assembly in the following order.
(1) Outboard joint boot LH No.2 clamp
(2) Outboard joint boot
(3) Outboard joint boot LH clamp
b. Pack the outboard joint shaft and boot with grease in the boot kit.
Grease capacity: 152 to 162 g (5.4 to 5.7 oz.)

37. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP
a. Mount the drive shaft in a soft vise.
b. Secure the clamp onto the boot.
c. Place SST onto the clamp.
SST 09521-24010
d. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.

e. Using SST, measure the clearance of the clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.032 inch) or less

NOTICE: When the measured value exceeds the specified value, retighten the clamp.

38. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. Mount the drive shaft in a soft vise.
b. Secure the clamp onto the boot.
c. Place SST onto the clamp.
SST 09521-24010
d. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.

39. INSTALL DRIVE SHAFT DAMPER

HINT: Perform the procedure below only when reassembling the RH side.

a. Set the distance (A), as described below.
Distance (A): 198 to 202 mm (7.795 to 7.953 inch)
b. Install the damper setting clamp to the shaft.

NOTICE: Be sure to install the clamp in the correct position.

c. Mount the drive shaft in a soft vise.
d. Secure the damper setting clamp onto the damper.
e. Place SST onto the damper setting clamp.
SST 09521-24010
f. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.

g. Using SST, measure the clearance of the damper setting clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.032 inch) or less

NOTICE: When the measured value exceeds the specified value, retighten the clamp.

40. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

HINT: Before installing the boot, wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.

a. Install new parts to the outboard joint shaft assembly in the following order.
(1) Inboard joint boot LH clamp
(2) Inboard joint boot LH No.2 clamp
(3) Inboard joint boot

b. Align the matchmarks, and install the tripod joint assembly to the outboard joint assembly.
c. Using a brass bar and a hammer, install the tripod joint assembly.

NOTICE: Do not tap the roller.

d. Using a snap ring expander, install a new inner LH shaft snap ring.
e. Pack the inboard joint sub-assembly LH with grease.
Grease capacity: 160 to 180 g (5.6 to 6.3 oz.)

f. Align the matchmarks, and install the inboard joint sub-assembly LH to the outboard joint shaft assembly.
41. INSTALL INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly and outboard joint shaft assembly.

42. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Mount the drive shaft in a soft vise.
b. Secure the clamp onto the boot.
c. Place SST onto the clamp.
SST 09521-24010
d. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.

43. INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP
a. Mount the drive shaft in a soft vise.
b. Secure the clamp onto the boot.
c. Place SST onto the clamp.
SST 09521-24010
d. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.

44. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

NOTICE: Keep the drive shaft assembly level during inspection.

a. Check that there is no remarkable play in the outboard joint.
b. Check that the inboard joint slides smoothly in the thrust direction.
c. Check that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.

HINT: For dimension (A), refer to the table.

45. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Coat the spline of the inboard joint shaft assembly with gear oil.
b. Align the shaft splines, and install the drive shaft assembly LH with brass bar and a hammer.

NOTICE:
^ Set the hole snap ring with opening side facing downwards.
^ Be careful not to damage the oil seal, boot or dust cover.

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 in.

46. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
a. Coat the spline of the inboard joint shaft assembly with gear oil.
b. Align the shaft splines, and install the drive shaft assembly RH with the 2 bearing lock bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)

NOTICE: Be careful not to damage the oil seal, boot or dust cover.

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

NOTICE: Be careful not to damage the outboard joint boot or speed sensor rotor.

48. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the lower ball joint to the front suspension arm sub-assembly lower No.1 LH with the bolt and 2 nuts.
Torque: 89 Nm (908 kgf-cm, 66 ft. lbs.)
49. INSTALL TIE ROD END SUB-ASSEMBLY LH
a. Install the tie rod end sub-assembly LH 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 600.

50. INSTALL SPEED SENSOR FRONT LH
a. Install the speed sensor front LH and flexible hose to the shock absorber assembly front LH with the bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)

b. Install the speed sensor front LH 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. Keep the speed sensor clean.
^ Do not twist the sensor wire when installing the sensor.

51. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Install the front stabilizer link assembly LH with the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)

HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

52. INSTALL FRONT AXLE HUB LH NUT
a. Install a new hub LH nut.
Torque: 216 Nm (2,200 kgf-cm, 159 ft. lbs.)
b. Using a chisel and a hammer, stake the hub LH nut.
53. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
54. ADD MANUAL TRANSAXLE OIL
55. INSPECT AND ADJUST MANUAL TRANSAXLE OIL
56. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
57. CHECK ABS SPEED SENSOR SIGNAL