Front
Front Drive Shaft Disassembly and ReassemblyReference: Front Drive Shaft Components: Front
Reference: Front Drive Shaft Assembly Removal and Installation: Front
Disassembly
CAUTION:
^ Disassembly of wheel side joint is not allowed. Replace drive shaft assembly if noise or damage exists in it.
^ Do not disassemble tripod joint. Replace drive shaft assembly if any faulty conditions are found in it.
1) Remove boot bands (1) of differential side.
2) Remove differential side joint housing from tripod joint.
3) Wipe off grease from shaft and use snap ring pliers (2) to take off snap ring (1).
4) Use 3 arms puller (2) to remove tripod joint (1).
CAUTION:
To prevent any problem caused by washing solution, do not wash tripod joint except its housing. It is acceptable to use a shop cloth to degrease tripod joint.
5) Pull out differential side boot from shaft.
6) Remove damper band (1). (6M/T model)
7) Remove damper from shaft. (6M/T model)
8) Use flat end rod (1) or the like to undo caulking (2) of wheel side boot big band and small band (3), and then pull out wheel side boot from shaft.
NOTE:
Use nippers to cut the boot band if it is a welded type. Give care so as not to damage the boot while cutting the band.
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 housing of tripod joint (2) are washed thoroughly and air dried.
CAUTION:
^ To prevent any problem caused by washing solution, do not wash tripod joint except its housing. It is acceptable to use a shop cloth to degrease tripod joint.
Degreasing of tripod joint with shop cloth is allowed.
^ Do not wash boots in degreaser such as gasoline or kerosene, etc. Washing in degreaser causes boot deterioration.
^ To ensure full performance of joint as originally designed, apply the specified amount of grease to respective joint according to the following procedures.
Wheel side joint
1) Wash disassembled parts (except boots). After washing parts, blow dry until completely dry.
2) Clean boots with shop cloth.
3) Apply grease from the service kit to wheel side joint.
Amount
: 90 - 110 g (3.17 - 3.88 oz)
4) Install wheel side boot on shaft.
5) Fill boot inside with specified grease.
6) Insert flat-end screwdriver into boot (2) and allow air to enter boot so that air pressure in boot becomes the same as the atmospheric pressure.
7) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
CAUTION:
^ Be sure to use new boot bands.
^ Do not squeeze or distort boot when fastening it with boot bands. Distorted boot caused by squeezing air may reduce its durability.
8) Use special tool as shown in figure to securely fasten boot bands (1).
CAUTION:
Do not squeeze or distort boot when fastening it with boot bands. Distorted boot caused by squeezing air may reduce its durability.
Distance "a"
: 1.2 - 4.0 mm (0.1 - 0.2 in.)
Special Tool
(A): 09943-57011
9) Place new damper band onto damper putting band outer end (1) against forward rotation (2) as shown in figure. (6M/T model)
CAUTION:
Be sure to use new damper band.
10) Install damper to specified position on drive shaft. (6M/T model)
Drive shaft damper installing position
"a": 286 - 292 mm (11.3 - 11.5 in.)
11) Fasten damper band (1) as shown in figure. (6M/T model)
Differential side joint
1) Place new boot bands onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
CAUTION:
Be sure to use new boot bands.
2) Install boot bands and boot to shaft temporarily.
3) Install the chamfered spline (3) of the tripod joint to the shaft.
4) Use snap ring pliers (2) to fasten new snap ring (1).
5) Apply specified grease included in spare parts to tripod joint, differential side joint housing and boot.
Grease amount
6M/T model (right side drive shaft): 150 - 170 g (5.29 - 6.00 oz)
6M/T model (left side drive shaft): 165 - 185 g (5.82 - 6.53 oz)
CVT model (right side drive shaft): 150 - 170 g (5.29 - 6.00 oz)
CVT model (left side drive shaft): 155 - 175 g (5.47 - 6.17 oz)
6) Install the differential side joint housing to the tripod joint.
7) Fit boot (3) to grooves (2) of shaft and differential side joint housing (1).
8) Insert flat-end screwdriver into boot (2) and allow air to enter boot so that air pressure in boot becomes the same as the atmospheric pressure.
Drive shaft boot fixing position (distance between differential side joint end and small boot band center) "a"
6M/T model (right side drive shaft): 201.2 mm (7.921 in.)
6M/T model (left side drive shaft): 190.6 - 191.1 mm (7.504 - 7.524 in.)
CVT model (right side drive shaft): 201.2 mm (7.921 in.)
CVT model (left side drive shaft): 184.7 mm (7.272 in.)
9) Fasten differential boot bands (1) as shown in figure.
CAUTION:
Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
