FRONT DRIVE SHAFT ASSEMBLY(for 2NR-FKE) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. A00496MC08
      *1 Press

      Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

      SST
      09527-10011

      Note


      • Install the front drive shaft dust cover in the correct orientation.

      • Do not deform the front drive shaft dust cover.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  2. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


    1. Install a new front drive shaft hole snap ring.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    A0049TBC17
    *1 Protective Tape

    1. Wrap the spline of the outboard joint shaft assembly with protective tape.

    2. Install new parts onto the outboard joint shaft assembly in the following order.


      1. Front No. 2 axle outboard joint boot clamp

      2. Front axle outboard joint boot

      3. Front axle outboard joint boot clamp

    3. Pack the joint portion of the outboard joint shaft assembly and the front axle outboard joint boot with grease.

      Standard Grease Capacity
      for CVT 97 to 107 g (3.42 to 3.77 oz.)
      for Manual Transaxle 91 to 99 g (3.21 to 3.49 oz.)

    4. Install the front axle outboard joint boot onto the outboard joint shaft assembly groove.

      Note

      Keep the groove free of grease.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

    2. Install a new front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.

    3. A004ALLE01

      Place SST onto the front No. 2 axle outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A004B5HE07

      Using SST, adjust the clearance of the front No. 2 axle outboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front No. 2 axle outboard joint boot clamp.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

    2. Install a new front axle outboard joint boot clamp to the front axle outboard joint boot.

    3. A0046QXE06

      Place SST onto the front axle outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the front axle outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0049FLE04

      Using SST, adjust the clearance of the front axle outboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front axle outboard joint boot clamp.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

    2. Install a new front axle outboard joint boot clamp to the front axle outboard joint boot.

    3. A0046QXE06

      Place SST onto the front axle outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the front axle outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0049FLE04

      Using SST, adjust the clearance of the front axle outboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front axle outboard joint boot clamp.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  7. INSTALL FRONT DRIVE SHAFT DAMPER LH (for CVT)


    1. A004AZFC01
      *1 Front Drive Outboard Joint Shaft Assembly LH
      *2 Front Drive Shaft Damper LH
      *3 Front Drive Shaft Damper Clamp

      Install parts to the front drive outboard joint shaft assembly LH in the following order as shown in the illustration.


      1. New front drive shaft damper clamp

      2. Front drive shaft damper LH

      3. New front drive shaft damper clamp

    2. Set the dimension (A) as specified below.

      Dimension (A)
      273.5 to 283.5 mm (0.90 to 0.93 ft.)

    3. Secure the front drive outboard joint shaft assembly LH in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    4. Install the 2 front drive shaft damper clamps to the front drive shaft damper LH.

      Note

      Be sure to install the clamp in the correct position.

    5. Fix the front drive shaft damper LH.


      1. A0047ZGC01
        *a Hold
        *b Turn

        Place SST onto the front drive shaft damper clamp, press it against the front drive shaft damper LH and slightly tighten SST.

        SST
        09521-24010

      2. Tighten SST so that the front drive shaft damper clamp is pinched.

        Note

        Do not overtighten SST.

      3. Remove SST.

      4. A0047KHE02

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

        SST
        09240-00020
        Standard Clearance
        0.8 mm (0.0315 in.) or less

        Note

        If the measured value exceeds the specified value, retighten the front drive shaft damper clamp.

      5. Perform the same procedure for the other front drive shaft damper clamp.

  8. INSTALL FRONT DRIVE SHAFT DAMPER RH (for Manual Transaxle)


    1. A00495FC01
      *1 Front Drive Outboard Joint Shaft Assembly RH
      *2 Front Drive Shaft Damper RH
      *3 Front Drive Shaft Damper Clamp

      Install parts to the front drive outboard joint shaft assembly RH in the following order as shown in the illustration.


      1. Front drive shaft damper RH

        Note

        Install the front drive shaft damper in the correct orientation.

      2. New front drive shaft damper clamp

    2. Secure the front drive outboard joint shaft assembly RH in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Install the front drive shaft damper clamp to the front drive shaft damper RH.

      Note

      Be sure to install the clamp in the correct position.

    4. Set the dimension (A) as specified below.

      Dimension (A)
      459.9 to 463.9 mm (1.51 to 1.52 ft.)

    5. Fix the front drive shaft damper RH.


      1. A004AUKC01
        *a Hold
        *b Turn

        Place SST onto the front drive shaft damper clamp, press it against the front drive shaft damper RH and slightly tighten SST.

        SST
        09521-24010

      2. Remove SST.

      3. A004847E01

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

        SST
        09240-00020
        Standard Clearance
        0.8 mm (0.0315 in.) or less

        Note

        If the measured value exceeds the specified value, retighten the front drive shaft damper clamp.

  9. INSTALL FRONT DRIVE SHAFT DAMPER RH (for CVT)


    1. A0048Z4C01
      *1 Front Drive Outboard Joint Shaft Assembly RH
      *2 Front No. 1 Drive Shaft Damper RH
      *3 Front No. 2 Drive Shaft Damper RH
      *4 Front Drive Shaft Damper Clamp

      Install parts to the front drive outboard joint shaft assembly RH in the following order as shown in the illustration.


      1. Front No. 1 drive shaft damper RH

        Note

        Install the front No. 2 drive shaft damper RH in the correct orientation.

      2. New front drive shaft damper clamp

      3. New front drive shaft damper clamp

      4. Front No. 2 drive shaft damper RH

      5. New front drive shaft damper clamp

    2. Secure the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Install the 3 front drive shaft damper clamps to the front No. 1 drive shaft damper RH and front No. 2 drive shaft damper RH.

      Note

      Be sure to install the clamp in the correct position.

    4. Set the dimension (A), (B) as specified below.

      Dimension (A)
      409.0 to 412.0 mm (1.34 to 1.35 ft.)
      Dimension (B)
      507.0 to 511.0 mm (1.66 to 1.68 ft.)

    5. Fix the front No. 1 drive shaft damper RH.


      1. A004AUKC01
        *a Hold
        *b Turn

        Place SST onto the front drive shaft damper clamp, press it against the front No. 1 drive shaft damper RH and slightly tighten SST.

        SST
        09521-24010

      2. Remove SST.

      3. A004847E01

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

        SST
        09240-00020
        Standard Clearance
        0.8 mm (0.0315 in.) or less

        Note

        If the measured value exceeds the specified value, retighten the front drive shaft damper clamp.

    6. Fix the front No. 2 drive shaft damper RH.


      1. A0047ZGC01
        *a Hold
        *b Turn

        Place SST onto the front drive shaft damper clamp, press it against the front No. 2 drive shaft damper RH and slightly tighten SST.

        SST
        09521-24010

      2. Tighten SST so that the front drive shaft damper clamp is pinched.

        Note

        Do not overtighten SST.

      3. Remove SST.

      4. A0047KHE02

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

        SST
        09240-00020
        Standard Clearance
        0.8 mm (0.0315 in.) or less

        Note

        If the measured value exceeds the specified value, retighten the front drive shaft damper clamp.

      5. Perform the same procedure for the other front drive shaft damper clamp.

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. Install new parts onto the outboard joint shaft assembly in the following order.


      1. Front axle inboard joint boot clamp

      2. Front axle inboard joint boot

      3. Front No. 2 axle inboard joint boot clamp

    2. Fix the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A0047FOC01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the tripod joint assembly onto the outboard joint shaft assembly.

      Note

      Face the serrated side of the tripod joint assembly outward and install it onto the outboard joint shaft assembly end.

    5. Using a brass bar and hammer, install the tripod joint assembly.

      Note


      • Do not hit the rollers.

      • Keep the tripod joint assembly free of foreign matter.

    6. A004BC5

      Using a snap ring expander, install a new snap ring.

    7. Pack the inboard joint with grease.

      Standard Grease Capacity
      for CVT 100 to 113.5 g (3.53 to 4.00 oz.)
      for Manual Transaxle 100 to 110 g (3.53 to 3.88 oz.)
    8. A00488VC23
      *a Matchmark

      Align the matchmarks and install the front drive inboard joint assembly onto the outboard joint shaft assembly.

    9. Install the front axle inboard joint boot into the grooves of the front drive inboard joint assembly and outboard joint shaft assembly.

      Note

      Keep the grooves free of grease.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

    2. Install a new front axle inboard joint boot clamp to the front axle inboard joint boot.

    3. A0047AKE01

      Place SST onto the front axle inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A00490TE01

      Using SST, adjust the clearance of the front axle inboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front axle inboard joint boot clamp.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP


    1. Install a new front No. 2 inboard joint boot clamp onto the front axle inboard joint boot.

    2. A0048NDE01

      Adjust dimension (A) until the drive shaft is within the specified length.

      Dimension (A)
      Drive Type LH Side RH Side
      for CVT 561.1 mm (1.84 ft.) 802.6 mm (2.63 ft.)
      for Manual Transaxle 561.8 mm (1.84 ft.) 803.8 mm (2.64 ft.)
    3. A0049SM

      Using needle-nose pliers, engage the 2 claws and install the front No. 2 inboard joint boot clamp as shown in the illustration.

      Note


      • Do not damage the front axle inboard joint boot.

      • Do not deform the claw of the hook.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  13. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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