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. If any noise or damage exists in it, replace it as assembly.
^ Do not disassemble tripod joint. If any malcondition is found in it, replace it as differential side joint 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 (1) using 3 arms puller (2).
CAUTION:
To prevent any problem caused by washing solution, do not wash tripod joint except its housing. Degreasing of tripod joint with cloth is allowed.
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).
CAUTION:
^ Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in degreaser causes deterioration of boot.
^ To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint referring to the followings for identification of the grease.
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.
CAUTION:
Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
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 (2). Use specified grease in tube included in spare parts.
12) Install tripod joint (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.
CAUTION:
Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
