Part 2

FRONT DRIVE SHAFT(continued)

Components:

11. INSTALL FRONT DRIVE INNER SHAFT INNER LH SHAFT SNAP RING
a. Install a new hole snap ring.
12. INSTALL FRONT DRIVE INNER SHAFT INNER RH SHAFT SNAP RING (for 4WD)
a. Install a new hole snap ring.
13. 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. Install new parts to the outboard joint shaft assembly in the following order.
1. Outboard joint boot No. 2 clamp (A)
2. Outboard joint boot (B)
3. Outboard joint boot clamp (C)

b. Pack the outboard joint shaft and boot with grease.
14. INSTALL OUTBOARD JOINT BOOT NO. 2 CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.

NOTICE: Do not overtighten the vise.

b. Install the outboard joint boot No. 2 clamp onto the boot.
c. Place SST onto the outboard joint boot No. 2 clamp.
SST 09521-24010

d. Tighten the SST so that the outboard joint boot No. 2 clamp is pinched.
SST 09521-24010

NOTICE: Do not overtighten the SST.

e. Using SST, measure the clearance of the outboard joint boot No. 2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

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

15. INSTALL OUTBOARD JOINT BOOT CLAMP
a. Install the outboard joint boot clamp perform the same procedures as for the outboard joint boot No. 2 clamp.

16. INSTALL FRONT DRIVE SHAFT DAMPER
a. Install the drive shaft damper to the drive shaft.
b. Make sure that the damper is on the shaft groove.

c. Set the distance, as specified below.
17. INSTALL FRONT DRIVE SHAFT DAMPER RH CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.

NOTICE: Do not overtighten the vise.

b. Install the drive shaft damper clamp to the damper.

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

c. Place SST onto the drive shaft damper clamp.
SST 09521-24010

d. Tighten the SST so that the clamp is pinched.
SST 09521-24010

NOTICE:: Do not overtighten the SST.

e. Using SST, measure the clearance of the drive shaft damper clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

NOTICE: Using SST, measure the clearance of the drive shaft damper clamp.

18. INSTALL FRONT DRIVE SHAFT DAMPER RH CLAMP
a. Set a new damper clamp to the drive shaft damper RH and install the damper clamp with a screwdriver.

19. INSTALL FRONT DRIVE SHAFT DAMPER RH CLAMP
a. Set a new damper clamp to the drive shaft damper RH and install the damper clamp with needle-nose pliers.

20. INSTALL INBOARD JOINT SHAFT ASSEMBLY
a. Install new parts to the inboard joint shaft assembly in the following order.
1. Inboard joint boot clamp (A)
2. Inboard joint boot (B)
3. Inboard joint boot No. 2 clamp (C)
b. Hold the outboard joint shaft assembly between aluminum plates in a vise.

NOTICE: Do not overtighten the vise.

c. Place the beveled side of the tripod axial spline toward the outboard joint shaft.

d. Align the matchmarks.

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

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

f. Using a snap ring expander, install a new front inner shaft snap ring.

g. Pack the inboard joint shaft and boot with grease.

h. Align the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.
21. INSTALL INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly.
22. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Hold the outboard joint shaft assembly between aluminum plates in a vise.

NOTICE: Do not overtighten the vise.

b. Install the inboard joint boot No. 2 clamp onto the boot.
c. Place SST onto the inboard joint boot No. 2 clamp.
SST 09521-24010

d. Tighten the SST so that the inboard joint boot No. 2 clamp is pinched.
SST 09521-24010

NOTICE: Do not overtighten the SST.

e. Using SST, measure the clearance of the inboard joint boot No. 2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

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

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

24. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP
a. Using a screwdriver, install the inboard joint boot LH No. 2 clamp, as shown in the illustration.
25. INSTALL INBOARD JOINT BOOT CLAMP
a. Install the outboard joint boot clamp perform the same procedures as for the inboard joint boot No. 2 clamp.

26. INSPECT FRONT DRIVE SHAFT ASSEMBLY
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 boots for damage.

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

INSTALLATION
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
a. Coat the spline of the inboard joint shaft assembly with ATF.

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

NOTICE:
^ Set the snap ring with the opening side facing down.
^ 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 (for 2WD)
a. Using a screwdriver, install a new bearing bracket hole snap ring.

NOTICE: Do not damage the oil seal and boot.

b. Install the bolt.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2AZ-FE)
a. Coat the spline of the inboard joint shaft assembly RH with gear oil.

b. Align the shaft splines and install the drive shaft assembly RH with the 2 bolts.

NOTICE: Do not damage the oil seal, boot and dust cover.

4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

HINT: Install the RH side using the same procedures as for the LH side.

NOTICE:
- Set the snap ring with the opening side facing downward.
- Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.

5. 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.
^ Be careful not to damage the speed sensor rotor.

6. INSTALL NO. 1 FRONT SUSPENSION ARM SUB ASSEMBLY LOWER LH
a. Install the lower ball joint to the front suspension arm sub-assembly lower with the bolt and nuts.
Torque: 127 Nm (1,300 kgf-cm, 94 ft. lbs.)
7. INSTALL TIE ROD END SUB-ASSEMBLY 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 are not aligned, tighten the nut up to 60° further.

8. INSTALL SPEED SENSOR FRONT LH
a. Install the speed sensor to the steering knuckle with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

NOTICE: Prevent foreign matter from adhering to the speed sensor.

b. Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on knuckle.
Torque: 19 Nm (192 kgf-cm, 14 ft. lbs.)

NOTICE:
^ Be careful not to damage the speed sensor.
^ Prevent foreign matter from adhering to the speed sensor.
^ Do not twist the sensor wire when installing the speed sensor.

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

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

10. INSTALL FRONT AXLE HUB LH NUT
a. Using s socket wrench (30 mm), install a new axle hub LH nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, stake the axle hub LH nut.
11. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
12. ADD AUTOMATIC TRANSAXLE FLUID
13. ADD TRANSFER OIL (for 4WD)
14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
15. CHECK ABS SPEED SENSOR SIGNAL