FRONT DRIVE SHAFT ASSEMBLY(for 2WD) REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When using a vise, place aluminum plates between the part and vise.

  • When using a vise, do not overtighten it.

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)


    1. w/o Drive Shaft Bearing Case:


      1. A01GBGUN01

        Using SST and a press, install a new front drive shaft bearing to the front drive inboard joint assembly RH.

        SST
        09527-10011
        09710-30012   ( 09710-04081 )

        Note


        • Make sure the front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.

        • Do not apply weight to the dust cover and outer race of the front drive shaft bearing.

      2. A01GB4J

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

        Note

        The Snap ring should be installed completely.

  2. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (for RH Side)


    1. w/ Drive Shaft Bearing Case:


      1. A01GBQRN04

        Using SST and a press, install a new drive shaft bearing case sub-assembly to the front drive inboard joint assembly RH.

        SST
        09527-10011
        09710-30012   ( 09710-04081 )

        Note


        • Make sure the front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.

        • Do not apply weight to the dust cover and outer race of the front drive shaft bearing.

      2. A01GAZJ

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

        Note

        The Snap ring should be installed completely.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)


    1. w/o Drive Shaft Bearing Case:


      1. A01GCLEN01

        Using SST and a press, install a new drive shaft dust cover to the front drive inboard joint assembly RH.

        SST
        09527-10011
        09726-40010
        Standard distance (A)
        41.6 to 42.6 mm (1.638 to 1.677 in.)

        Note


        • Make sure to install the front drive shaft dust cover in the correct direction.

        • Do not damage the front drive shaft dust cover.

        • The front drive shaft dust cover should be installed completely.

    2. w/ Drive Shaft Bearing Case:


      1. A01GB1WN01

        Using SST and a press, install a new drive shaft dust cover to the front drive inboard joint assembly RH.

        SST
        09527-10011
        09726-40010
        Standard distance (A)
        41.6 to 42.6 mm (1.638 to 1.677 in.)

        Note


        • Make sure to install the front drive shaft dust cover in the correct direction.

        • Do not damage the front drive shaft dust cover.

        • The front drive shaft dust cover should be installed completely.

  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01GB66N01

      Using SST and a press, press in the front drive inboard joint assembly LH until the new front drive shaft dust cover LH contacts the edge of the front drive inboard joint assembly LH.

      SST
      09527-10011

      Note


      • Make sure to install the front drive shaft dust cover LH in the correct direction.

      • Do not damage the front drive shaft dust cover LH.

      • The front drive shaft dust cover LH should be installed completely.

  5. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01GAHEN05

      Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint assembly RH until the distance from the tip of the front drive inboard joint assembly RH to the front drive shaft dust cover RH onto reaches the specification as shown in the illustration.

      SST
      09527-10011
      Standard Distance (A)
      Item Length
      for 1AD-FTV (Manual Transaxle) 110.0 to 111.0 mm (4.331 to 4.370 in.)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle) 91.0 to 92.0 mm (3.583 to 3.622 in.)
      for 3ZR-FE (Manual Transaxle)
      for 3ZR-FE (CVT)

      Note


      • Make sure to install the front drive shaft dust cover RH in the correct direction.

      • Do not damage the front drive shaft dust cover RH.

      • Front drive shaft dust cover RH should be installed completely.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    Tech Tips

    Use the same procedure for the RH and LH sides.


    1. A01GBLSC05
      *a Protective Tape

      Before installing the front axle outboard joint boot, wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the front axle outboard joint boot from being damaged.

    2. A01GANLC02
      *1 Front No. 2 Axle Outboard Joint Boot Clamp
      *2 Front Axle Outboard Joint Boot
      *3 Front Axle Outboard Joint Boot Clamp
      A01GAQ1 Outboard Joint Side
      A01GBFL Inboard Joint Side

      Install new parts to the front drive 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. Install the front axle outboard joint boot so that it is between the front No. 2 axle outboard joint boot clamp and front drive outboard joint shaft assembly.

    4. Temporarily install the front axle outboard joint boot clamp to the front axle outboard joint boot.

    5. Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.

      Standard Grease Capacity
      Item Grease Capacity
      for 1AD-FTV (Manual Transaxle) 205 to 215 g (7.3 to 7.5 oz)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle)
      for 3ZR-FE (Manual Transaxle)
      for 3ZR-FE (CVT) 171 to 181 g (6.1 to 6.3 oz)

    6. Install the front axle outboard joint boot to the groove of the front drive outboard joint shaft assembly.

      Note


      • Do not apply grease to the part of the front axle outboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the front axle outboard joint boot.

  7. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH

    A01GAAT

    CAUTION:

    Wear protective gloves to avoid injuries to your hands.


    1. Install the front No. 2 axle outboard joint boot clamp LH onto the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly and install the front No. 2 axle outboard joint boot clamp LH as close to the inside of the vehicle as possible.

      • Check the band and lever for any deformation before folding back the lever.

    2. A01GCQJ

      Lean your weight on your hand and roll the front drive outboard joint shaft assembly LH forward while pressing the front drive outboard joint shaft assembly LH against a surface until a click sound is heard.

      Note


      • Do not damage the deflector.

      • Make sure that the front drive outboard joint shaft assembly LH is in direct contact with the surface.

    3. A01GDHX

      Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

      Note

      Do not damage the front axle outboard joint boot.

  8. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  9. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

    A01GCAQ

    CAUTION:

    Wear protective gloves to avoid injuries to your hands.


    1. Install the front axle outboard joint boot clamp LH to the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and lever for any deformation before folding back the lever.

    2. A01GD5P

      Using water pump pliers, pinch the front axle outboard joint boot clamp LH to temporarily fix it in place.

    3. A01GCXM

      Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

      Note

      Do not damage the front axle outboard joint boot.

  10. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  11. INSTALL FRONT DRIVE SHAFT DAMPER LH (w/ Drive Shaft Damper)


    1. w/ 1 Clamp:


      1. A01GCR5C02
        *A for 3ZR-FE
        *B except 3ZR-FE
        *1 Front Drive Shaft Damper Clamp LH
        *2 Front Drive Shaft Damper LH

        Install a new front drive shaft damper clamp LH and front drive shaft damper LH onto the front drive outboard joint shaft assembly LH.

        Tech Tips

        Make sure the front drive shaft damper clamp LH is on the outboard joint side.

      2. Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.

        Standard Distance (A)
        Item Length
        for 3ZR-FE 199.0 to 203.0 mm (7.835 to 7.992 in.)
        except 3ZR-FE 212.5 to 216.5 mm (8.367 to 8.523 in.)

    2. w/ 2 Clamps:


      1. A01GD01C02
        *A for 3ZR-FE
        *B except 3ZR-FE
        *1 Front Drive Shaft Damper Clamp LH
        *2 Front Drive Shaft Damper LH

        Install 2 new front drive shaft damper clamp LH and the front drive shaft damper LH onto the front drive outboard joint shaft assembly LH.

      2. Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.

        Standard Distance (A)
        Item Length
        for 3ZR-FE 199.0 to 203.0 mm (7.835 to 7.992 in.)
        except 3ZR-FE 212.5 to 216.5 mm (8.367 to 8.523 in.)

  12. INSTALL FRONT DRIVE SHAFT DAMPER RH (w/ Drive Shaft Damper)


    1. w/ 1 Clamp:


      1. A01GD0SC01
        *1 Front Drive Shaft Damper Clamp RH
        *2 Front Drive Shaft Damper RH

        Install a new front drive shaft damper clamp RH and front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

        Tech Tips

        Make sure the front drive shaft damper clamp RH is on the outboard joint side.

      2. Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.

        Standard Distance (A)
        199.0 to 203.0 mm (7.835 to 7.992 in.)

    2. w/ 2 Clamps:


      1. A01GAXZC01
        *1 Front Drive Shaft Damper Clamp RH
        *2 Front Drive Shaft Damper RH

        Install 2 new front drive shaft damper clamp RH and the front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

      2. Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.

        Standard Distance (A)
        199.0 to 203.0 mm (7.835 to 7.992 in.)

  13. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH (w/ Drive Shaft Damper)


    1. A01GBNZC02
      *A for One Touch Type
      *B for Claw Engagement Type
      *a Claw Engagement

      w/ 1 Clamp:

      Install the front drive shaft damper clamp LH.

      Note

      Be sure to install the front drive shaft damper clamp LH in the correct position.


      1. for One Touch Type:

        Using a screwdriver, install the front drive shaft damper clamp LH as shown in the illustration.

      2. for Claw Engagement Type:

        Using needle-nose pliers, install the front drive shaft damper clamp LH as shown in the illustration.

        Note

        Do not deform the claw engagement of the front drive shaft damper clamp LH.

    2. A01GBNZC02
      *A for One Touch Type
      *B for Claw Engagement Type
      *a Claw Engagement

      w/ 2 Clamps:

      Install the 2 front drive shaft damper clamp LH.

      Note

      Be sure to install the front drive shaft damper clamp LH in the correct position.


      1. for One Touch Type:

        Using a screwdriver, install the 2 front drive shaft damper clamp LH as shown in the illustration.

      2. for Claw Engagement Type:

        Using needle-nose pliers, hold the 2 front drive shaft damper clamp LH at the claw engagement.

        Note

        Do not deform the claw engagement of the front drive shaft damper clamp LH.

  14. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (w/ Drive Shaft Damper)

    Tech Tips

    Use the same procedure described for the LH side.

  15. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH


    1. A01GAF1C02
      *1 Front Axle Inboard Joint Boot Clamp LH
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp LH
      *a Protective Tape
      A01GAQ1 Outboard Joint Side
      A01GBFL Inboard Joint Side

      Install new parts to the front drive outboard joint shaft assembly LH in the following order.


      1. Front axle inboard joint boot clamp LH

      2. Front axle inboard joint boot

      3. Front No. 2 axle inboard joint boot clamp LH

    2. Remove the protective tape from the front drive outboard joint shaft assembly LH.

    3. A01GAGGC02
      *a Matchmark

      Align the matchmarks and place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly LH.

      Note

      Face the cut edge of the spline toward the inboard joint side and insert the spline onto the outboard joint shaft assembly LH.

    4. A01GASR

      Using a brass bar and hammer, tap the tripod joint onto the front drive outboard joint shaft assembly LH.

      Note


      • Do not tap the rollers.

      • Be sure to install the tripod in the correct direction.

    5. A01GC3C

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

      Note

      The Snap ring should be installed completely.

    6. Pack the front drive inboard joint assembly LH and front axle inboard joint boot with grease from the boot kit.

      Standard grease capacity
      175 to 185 g (6.2 to 6.5 oz)
    7. A01GDENC05
      *a Matchmark

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

  16. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  17. INSTALL FRONT AXLE INBOARD JOINT BOOT

    Tech Tips

    Use the same procedure for the RH and LH sides.


    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.

      Note


      • Do not apply grease to the part of the front axle inboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the front axle inboard joint boot.

    2. A01GDA6C01
      *A for LH Side
      *B for RH Side

      Check that the front axle inboard joint boot and front axle outboard joint boot are not stretched or contracted when the rear drive shaft assembly is at the standard length.

      Length (A)
      Item Length
      for 1AD-FTV (Manual Transaxle) LH Side 553.6 mm (1.82 ft.)
      RH Side 932.4 mm (3.06 ft.)
      for 2AR-FE (Automatic Transaxle) LH Side 577.6 mm (1.89 ft.)
      RH Side 914.4 mm (3.00 ft.)
      for 2AR-FE (Manual Transaxle) LH Side 583.6 mm (1.91 ft.)
      RH Side 906.4 mm (2.97 ft.)
      for 3ZR-FE (Manual Transaxle) LH Side 594.6 mm (1.95 ft.)
      RH Side 893.4 mm (2.93 ft.)
      for 3ZR-FE (CVT) LH Side 591.2 mm (1.94 ft.)
      RH Side 890.0 mm (2.92 ft.)

      Note

      Keep the drive shaft assembly level during inspection.

      If the front axle inboard joint boot and front axle outboard joint boot are stretched or contracted, correct them.

  18. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


    1. A01GBJ9C03
      *A for One Touch Type
      *B for Claw Engagement Type
      *a Claw Engagement

      for One Touch Type:

      Using a screwdriver, install the front axle inboard joint boot clamp LH as shown in the illustration.

      Note


      • Correctly set the front axle inboard joint boot clamp LH to the guide groove.

      • Do not damage the front axle inboard joint boot.

    2. for Claw Engagement Type:


      1. Install the front axle inboard joint boot clamp LH to the drive shaft inboard joint boot.

        Note

        Correctly set the front axle inboard joint boot clamp LH to the guide groove.

      2. Using needle-nose pliers, hold the front axle inboard joint boot clamp LH at the claw engagement.

        Note


        • Do not damage the front axle inboard joint boot.

        • Do not deform the claw engagement of the front axle inboard joint boot clamp LH.

  19. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  20. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP LH

    Tech Tips

    Use the same procedure described for the front axle inboard joint boot clamp LH.

  21. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  22. INSPECT FRONT DRIVE SHAFT

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