FRONT DRIVE SHAFT ASSEMBLY(for 4WD/AWD) 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


    1. A01CWXDN01

      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 bearing is completely installed.

    2. A01CY7K

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01CXZEN01

      Using SST and a press, install a new front drive shaft dust cover LH.

      SST
      09527-10011

      Note


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

      • Be careful not to damage the front drive shaft dust cover LH.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01CX1AN04

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

      SST
      09527-10011
      Standard Distance (A)
      103.5 to 104.5 mm (4.075 to 4.114 in.)

      Note

      Be careful not to damage the front drive shaft dust cover RH.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01CW1IC05
      *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. 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 2AD-FTV, 2AD-FHV (Automatic Transaxle) 205 to 215 g (7.3 to 7.5 oz)
      for 1AD-FTV, 2AD-FTV, 2AD-FHV (Manual Transaxle)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle)
      for 3ZR-FE, 3ZR-FAE (Manual Transaxle)
      for 3ZR-FE, 3ZR-FAE (CVT) 171 to 181 g (6.1 to 6.3 oz)

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

    A01CXUD

    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. A01CW5G

      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. A01CXBP

      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.

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

    Tech Tips

    Use the same procedure described for the LH side.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

    A01CXJ4

    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. A01CXDM

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

    3. A01CXK8

      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 AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

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


    1. A01CWL5C03
      *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 2AD-FTV, 2AD-FHV (Automatic Transaxle) 158.0 to 162.0 mm (6.221 to 6.377 in.)
      for 1AD-FTV, 2AD-FTV, 2AD-FHV (Manual Transaxle)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle) -
      for 3ZR-FE, 3ZR-FAE (Manual Transaxle) -
      for 3ZR-FE, 3ZR-FAE (CVT) 161.0 to 165.0 mm (6.339 to 6.496 in.)

  10. INSTALL FRONT DRIVE SHAFT DAMPER RH


    1. A01CWL5C03
      *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)
      161.0 to 165.0 mm (6.339 to 6.496 in.)

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


    1. A01CWI6C01
      *A for One Touch Type
      *B for Claw Engagement Type

      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.

  12. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  13. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH


    1. 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. A01CXM1C02
      *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.

    4. 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. A01CW9O

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

    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. A01CY2PC05
      *a Matchmark

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

  14. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  15. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A01CXD2C01
      *A for LH Side
      *B for RH Side

      Check that the 2 joint boots are not stretched or contracted when the front drive shaft is at the standard length.

      Length (A)
      Item Length
      for 2AD-FTV, 2AD-FHV (Automatic Transaxle) LH Side 565.6 mm (1.86 ft.)
      RH Side 928.4 mm (3.05 ft.)
      for 1AD-FTV, 2AD-FTV, 2AD-FHV (Manual Transaxle) LH Side 553.6 mm (1.82 ft.)
      RH Side 933.9 mm (3.06 ft.)
      for 2AR-FE (Automatic Transaxle) LH Side 577.6 mm (1.89 ft.)
      RH Side 922.4 mm (3.03 ft.)
      for 2AR-FE (Manual Transaxle) LH Side 583.6 mm (1.91 ft.)
      RH Side 909.4 mm (2.98 ft.)
      for 3ZR-FE, 3ZR-FAE (Manual Transaxle) LH Side 594.6 mm (1.95 ft.)
      RH Side 896.4 mm (2.94 ft.)
      for 3ZR-FE, 3ZR-FAE (CVT) LH Side 591.2 mm (1.94 ft.)
      RH Side 881.9 mm (2.89 ft.)

      Note

      Keep the drive shaft assembly level during inspection.

      If the boots are stretched or contracted, correct them.

  16. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

    A01CYCEC01
    *A for One Touch Type
    *B for Claw Engagement Type

    1. for One Touch Type:

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

      Note

      Be careful not to damage the boot.

    2. for Claw Engagement Type:

      Using needle-nose pliers, install the front axle inboard joint boot clamp LH as shown in the illustration.

      Note

      Be careful not to damage the boot.

  17. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  18. 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.

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

    Tech Tips

    Use the same procedure described for the LH side.

  20. INSPECT FRONT DRIVE SHAFT

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