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D2 DRIVE SHAFT/PROPELLER SHAFT/AXLE

AXLE SYSTEM --------------------------------- D2 - 1

BASIC CHECK AND ADJUSTMENT -- D2 - 1
FRONT AXLE ----------------------------------- D2 - 2
REMOVAL AND INSTALLATION ------- D2 - 2
FRONT DRIVE SHAFT----------------------- D2 - 8
REMOVAL AND INSTALLATION ------- D2 - 8
DISASSEMBLING AND
ASSEMBLING ------------------------------ D2 - 12
REAR AXLE BEARING ( 2WD ) --------- D2 - 17
REMOVAL AND INSTALLATION(VEHICLES
NOT EQUIPPED WITH ABS) ---------- D2 - 17
REMOVAL AND INSTALLATION(ABS-
EQUIPPED VEHICLES) ----------------- D2 - 17

D2
D2–1
1 AXLE SYSTEM
1-1 BASIC CHECK AND ADJUSTMENT
1-1-1 CHECK OF WHEEL BEARING FOR EXCESSIVE
PLAY
(1) Check of wheel bearing for excessive play
1.Move the tire by holding the tire at the upper and lower
parts by hands. Check to see if the wheel bearing has
excessive play.
If there is excessive play, perform the check again while
L2NK5002T10
depressing the brake pedal and confirm whether it is
excessive play of the wheel bearing or not.
2.Turn the wheel and check to see if abnormal noise is emit-
ted.
3.If necessary, set a dial gauge at the circumference of the
forward end of the drive shaft and check for excessive
play in the bearing axial direction.
If the allowable limit is exceeded, replace the axle hub
and radial ball bearing.
ALLOWABLE LIMIT: 0.05mm

M21K5169T10

(2) Check of boot for cracks and damage

1.Visually check the boot of the universal joint section of the drive shaft for any cracks or damage.
2.Visually check to see if any boot rupture or boot band looseness is present.
 D2–2
2 FRONT AXLE
2-1 REMOVAL AND INSTALLATION
2-1-1 ARTICLES TO BE PREPARED
SST
Shape Part No. Part name

09628-00011-000
Puller,tie-rod end
(09611-87701-000)

09511-87202-000 Wrench rear axle bearing lock nut

09520-00031-000
Puller,rear axle shaft
(09520-00030-000)

09550-10013-000
set,replacer B
(09550-10012-000)

09950-97201-000
Puller,universal
(09950-20017-000)

09510-87301-000 Puller,axle shaft

09506-87301-000 Replacer,differential drive pinion bearing corn,rear

09527-87301-000 Remover,rear axle shaft bearing

09950-70010-000 Set,handle

09951-07200-000
Handle
(09631-00020-000)
D2–3
Tool
Snap ring pliers

Instrument
Dial gauge,Torque wrench

2-1-2 OPERATION BEFORE REMOVAL

1.Lift up the vehicle.
2.Remove the front wheel.
3.Remove the front wheel speed sensor.(ABS equipped vehicles)
Refer to Page E3-4.

4.Remove the front disc brake caliper assembly and hang it, using a wire or the like.
Refer to Page E1-53.

CAUTION
• Be very careful not to damage the flexible hose.

5.Remove the brake disc.

2-1-3 INSPECTION
(1) Check of bearing for axial play
1.Set a dial gauge to a point on the periphery at the tip-end
of the drive shaft. Check the bearing for axial play.
If the play exceeds the limit, replace the axle hub and
radial ball bearing.
ALLOWABLE LIMIT: 0.05mm

M21K5169T10

(2) Check of front axle runout

1.Set a dial gauge to the outer periphery of the axle hub.
Turn the axle hub to check the runout.
If the runout exceeds the limit, replace the axle hub and
radial ball bearing.
ALLOWABLE LIMIT: 0.05mm

M21K5170T10
 D2–4
2-1-4 REMOVAL AND INSTALLATION PROCEDURES
(1) Components

d T:95.7&12.2 {975&124}

N T:51.5&7.4 {525&75}
N

a T:41.7&12.2 {425&124}
~N
T:8.3&1.5 {85&15}
~
S e

~h

g
~

c T:196.1&29.4 {2000&299}

T11K5016S28

~:Non - reusable parts

Unit:N;m{kgf;cm}
(2) Removal and installation procedures
j i 1 a Shaft Ay, front drive,RH/LH j 6 e Hub S/A, front axle
j 2 b End S/A, tie rod,RH/LH 7 f Knuckle, steering,RH/LH
j i 3 c Arm S/A, suspension lower W/bush,RH/LH 8 g Rotor, skid control, sensor front
j 4 a Shaft Ay, front drive,RH/LH j i 9 h Bearing, Radial ball
5 d Absorber Ay, shock front,RH/LH

2-1-5 POINTS OF REMOVAL

(1) Shaft Ay, front drive,RH/LH
1.Remove the nut.
(1) Release the staked portion, using a chisel or the like.
D2–5
(2) Remove the nut, using the SST.
SST: 09511-87202-000

SST

M21K5173T10

(2) End S/A, tie rod,RH/LH SST

1.Separate the RH/LH steering knuckles from the end S/A,
using the SST.
(1) Suspend the SST with a rope.
(2) Install a dummy nut to the threaded section of the end
S/A. Set the SST and remove the end S/A.
SST: 09628-00011-000
Retention
A11C5045ET10

(3) Arm S/A, suspension lower W/bush,RH/LH

1.Remove the ball joint section of the arm S/A, using the SST.
(1) Suspend the SST with a rope.
(2) Install a dummy nut to the threaded section of the arm
S/A. Set the SST and remove the arm S/A.
SST: 09628-00011-000

M21C5007T10
(4) Shaft Ay, front drive,RH/LH
1.Separate the shaft Ay from the front axle hub S/A and
RH/LH steering knuckle, using the SST.
SST: 09510-87301-000 SST
CAUTION
• Hang the drive shaft by means of wire or the like.

M21K5172T10
(5) Hub S/A, front axle
1.Remove the hub S/A and RH/LH steering knuckle from the RH/LH front shock absorber Ay.
2.Remove the front axle hub S/A.
(1) Secure the hub S/A and RH/LH steering knuckle in a vice, using the bolts that retain the RH/LH
steering knuckles in the RH/LH front shock absorber Ay.
 D2–6
(2) Remove the hub S/A from the RH/LH steering knuckle,
using the SST.
SST
SST: 09520-00031-000
(3) Remove the skid control sensor rotor.(ABS-equipped
vehicles)

L11K5128T10

(4) Remove the radial ball bearing inner race, using the
SST.
SST
SST: 09950-97201-000

L11K5129T10

(6) Bearing, radial ball

1.Detach the hole snap ring, using a snap ring expander.
2.Remove the bearing, using the SST in combination with a
press.
SST: 09527-87301-000(A) SSTB SSTC
SST: 09554-10011-000 [09554-10011-000](B)
SST: 09951-07200-000 [09951-07200-000](C)
SSTA

L11K5130T10

2-1-6 POINTS OF INSTALLATION

(1) Bearing, radial ball SSTC
1.Press the radial ball bearing to the steering knuckle S/A,
SSTB
using the SST in combination with a press. Install the hole
snap ring. SSTA
SST: 09506-87301-000(A)
SST: 09554-10011-000 [09554-10011-000](B)
SST: 09951-07200-000 [09951-07200-000](C)
L11K5131T10
2.Install the skid control sensor rotor.(ABS-equipped vehi-
cles)
3.Press the front axle hub S/A into the steering knuckle,
using the SST in combination with a press. SSTB

SST: 09556-10011-000 [09556-10011-000](A)

SSTA
SST: 09951-07200-000 [09551-07200-000](B)

L11K5132T10
D2–7
(2) Arm S/A, suspension lower W/bush,RH/LH
1.Install the RH/LH steering knuckle to the arm S/A.
CAUTION
• During the assembly, ensure that no lubricant, such as
grease, is adhered to the threaded portion, tapered
section, and RH/LH steering knuckle installation sec-
tions of the ball stud of the arm S/A. If any lubricant is
adhered, be certain to wipe it off.
No grease has adhered.
2.Install the front axle hub S/A and RH/LH steering knuckle
to the shock absrober, while inserting the RH/LH front
drive shaft Ay.
CAUTION
• Do not pull out the drive shaft beyond the required
extent.
M21C5011ET16

(3) ShaftAy, front drive,RH/LH

1.Install the nut.
(1) Tighten the nut to the specified torque, using the SST.
SST: 09511-87202-000

SST

M21K5174T10
(2) Using a chisel, firmly stake the tip-end of the front drive
shaft and nut, as indicated in the right figure. Tool
Depth of staking
CAUTION
• Ensure that the staked section of the nut and the
threaded portion of the shaft Ay exhibit no crack.
(Peeling off of the plating of the nut is permissible.)
NOTE
• The staking should be carried out in the center direc-
Good Bad Bad
tion of the shaft Ay. The staking depth must be 3.5-0.5 +1.5

L11K5135ET10
mm
2-1-7 OPERATION AFTER INSTALLATION
1.Install the brake disc.
2.Install the front disc brake caliper assembly.
Refer to Page E1-53.

3.Install the front wheel speed sensor.(ABS-equipped vehicles)

Refer to Page E3-4.

4.Install the front wheel.

TIGHTENING TORQUE: 103.0&14.7N;m {1050&150kgf;cm}

5.Check the front alignment.

Refer to Page C1-1.

6.Lift down the vehicle.

 D2–8
3 FRONT DRIVE SHAFT
3-1 REMOVAL AND INSTALLATION
WARNING
• Do not carry out the operation while the exhaust pipe is still hot, for there is a pssibility of getting
scalded.

3-1-1 ARTICLES TO BE PREPARED

SST
Shape Part No. Part name

09511-87202-000 Wrench rear axle bearing lock nut

09628-00011-000
Puller,tie-rod end
(09611-87701-000)

09912-87301-000 Puller,slide hammer

09510-87301-000 Puller,axle shaft

Instrument
Torque wrench

Lubricant,adhesive,others
MP grease,ATF DexronOA,Transmission gear oil SAE75W(90 or SAE75W(85 or SAE75W(80 (API Classification GL3 or
GL4)

3-1-2 OPERATION BEFORE REMOVAL

1.Lift up the vehicle.
2.Remove the front wheel.
3.Drian the transaxle oil.
D2–9
3-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) Components

c T:95.7&12.2 {975&124}

N T:51.5&7.4 {525&75}
a
~d
N
T:41.7&12.2 {425&124}

~N

T:196.1&29.4 {2000&299}

T11K5057S28

k: MP grease
~: Non-reusable parts
Unit: N;m{kgf;cm}
(2) Removal and installation procedures
j i 1 a Shaft Ay, front drive,RH/LH
j 2 b End S/A, tie rod,RH/LH
3 c Absorber Ay, shock front,RH/LH
j i 4 a Shaft Ay, front drive,RH/LH
5 d Ring, shaft snap

3-1-4 POINTS OF REMOVAL

(1) Shaft Ay, front drive,RH/LH
1.Remove the lock nut.
(1) Release the staked portion, using a chisel or the like.
(2) Remove the nut by using the SST to prevent turning.
SST
SST: 09511-87202-000

M21K5173T10
 D2–10
(2) End S/A, tie rod,RH/LH
SST
1.Remove the end S/A from the RH/LH steering knuckles,
using the SST.
(1) Suspend the SST with a rope.
(2) Install a dummy nut to the threaded section of the end
S/A. Set the SST and remove the end S/A.
SST: 09628-00011-000

Retention
A11C5045ET10

(3) Shaft Ay, front drive,RH/LH

1.Separate the shaft Ay from the RH/LH steering knuckles,
using the SST. SST
SST: 09510-87301-000

T11K5062T10

2.Turn over the dust cover, while paying attention not to

scratch the dust cover. Remove the shaft Ay by applying
the arrow edge of the hub nut wrench to the edge surface
of the shaft Ay.

T11K5049T10

3-1-5 INSPECTION
Check the boot for brekage or damage. Replace any faulty part.
3-1-6 POINTS OF INSTALLATION
(1) Shaft Ay, front drive,RH/LH SST
1.Insert the front drive shaft assembly to the differential car-
rier assembly, using the SST.
SST: 09912-87301-000
CAUTION
• The insertion should be carried out in such a way that
the lip section of the oil seal may not be damaged.
• Apply MP grease to the oil seal contact surface of the T11K5058T10
shaft Ay and its serration section.
(2) Shaft Ay, front drive,RH/LH
1.Install the nut.
(1) Tighten the nut to the specified torque, using the SST.
SST: 09511-87202-000

SST

M21K5174T10
D2–11
(2) Using a chisel, firmly stake the tip-end of the front drive
Tool
shaft and nut, as indicated in the right figure. Depth of staking
CAUTION
• Ensure that the staked section of the nut and the
threaded portion of the shaft Ay exhibit no crack.
(Peeling off of the plating of the nut is permissible.)
NOTE
• The staking should be carried out in the center direc- Good Bad Bad
tion of the shaft Ay. The staking depth must be 3.5-0.5 +1.5
L11K5135ET10
mm
3-1-7 OPERATION AFTER INSTALLATION
1.Fill transaxle fluid.
(1) M/T vehicle
Refer to Page F2-1.

(2) A/T vehicle

Refer to Page F3-1.

2.Install the front wheel.

TIGHTENING TORQUE: 103.0&14.7N;m {1050&150kgf;cm}

3.Lift down the vehicle.

4.Check and adjust the front wheel alignment.
Refer to Page C1-1.
 D2–12
3-2 DISASSEMBLING AND ASSEMBLING
3-2-1 ARTICLES TO BE PREPARED
Tool
Snap ring expander

SST
Shape Part No. Part name

09648-97202-000 pliers B,drive shaft boots band

3-2-2 DISASSEMBLY AND ASSEMBLY PROCEDURES

(1) Components

j
~h

~a

~d e

~b

M21K5067S33

~:Non - reusable parts

D2–13
(2) Disassembling and assembling procedure
1 a Ring, shaft snap j 6 f Boot, front axle inboard joint
2 b Clamp, rear drive shaft boot j i 7 g Damper, drive shaft
j i 3 c Joint S/A, front axle inboard 8 h Clamp, Rear drive shaft boot
4 d Ring, drive shaft snap j i 9 i Boot, front axle outboard joint
j i 5 e Tripod Ay, Inboard joint 10 j Shaft,front axle,RH/LH

3-2-3 POINTS OF DISASSEMBLY

(1) Joint S/A, front axle inboard
1.Remove the rear drive shaft boot clamp (At the inboard
side).
(1) Using a flat screwdriver, release the locking at the bent
section of the boot band (At the inboard side).

C11K5059T10

2.Displace the front axle inboard joint boot. Wipe off grease.
Put mate marks on the joint S/A and RH/LH front axle Mating mark

shaft.
CAUTION
• As for the mate marks, use paint. (Do not use punch-
ing.
3.Remove the front axle inboard joint S/A

C11K5060ET10

(2) Tripod Ay, Inboard joint

1.Remove the drive shaft snap ring, using a snap ring expander.
TOOL: Snap ring expander

2.Put mating marks on the tripod Ay and RH/LH front axle

shaft.

Mating mark

T02K5006ET10
 D2–14
3.Remove the inboard joint tripod Ay, using a brass bar.
CAUTION
• Be sure to apply a brass bar to the boss section of the
tripod, not at the roller section.

T02K5007T10
(3) Boot, front axle inboard joint
1.Wind a tape on the spline section at the inboard side.
Remove the boot (At the inboard side). Tape

L11K5144ET10

(4) Damper, drive shaft

1.Put mate marks on the damper and drive shaft. (These
mate marks are used as a guide during the press-fitting.)
2.Remove the damper, using a press.

Mark
T02K5008ET10

(5) Boot, front axle outboard joint

1.Remove the boot band (At the outboard side).
(1) Using a flat screwdriver, release the locking at the
bent section of the boot band (at the outboard side).

C11K5061T10

2.Remove the boot (At the outboard side).

3-2-4 POINTS OF ASSEMBLY
(1) Boot, front axle outboard joint
1. Assemble the boot (At the outboard side).
(1) Wind a tape on the spline section at the inboard side. .
(2) Fill the outboard joint section and the inside of the boot with the grease furnished in the boot set.
Assemble the boot (At the outboard side).
NOTE
• Filling amount: 1KR engine mounted vehicles: 70&10g
K3 engine mounted vehicles: 95&10g
D2–15
2.Assemble the rear drive shaft boot clamp by bending it in
the sequence specified in the right figure.
(Type 1KR engine mounted vehicles)

L11K5147T10
3.Positively stake the rear drive shaft boot clamp, using the
SST.
(Type K3 engine mounted vehicles)
SST
SST: 09648-97202-000
NOTE
• Dimensions B 1.0 - 4.0mm

T11K5053T16

(2) Damper, drive shaft

1.The press-fitting should be made up to the mark position
that was put during the disassembly.
CAUTION
• The press-fitting should be with the joint section in a
straight condition.

T02K5010T10

(3) Tripod Ay, inboard joint

1.Assemble the front axle inboard joint boot and rear drive shaft boot clamp to the RH/LH front axle
shafts.
2.Assemble the tripod Ay, aligning with the mating marks on
the RH/LH front axle shaft.
CAUTION
• Assemble the tripod Ay to the RH/LH front axle shaft
from the chamfered side of the spline.
• When the brass bar is used for driving, be sure to
apply the brass bar to the boss section of the tripod,
not to the roller section. Mating mark

T02K5006ET10
 D2–16
3.Install the drive shaft snap ring, using a snap ring
expander.
TOOL: Snap ring expander

N11K5041T10

(4) Joint S/A, front axle inboard

1.Fill the joint S/A with the grease furnished in the boot set. Mating mark
Assemble the joint S/A, aligning with the mate marks on
the RH/LH front axle shafts. .
NOTE
• Filling amount:1KR engine mounted vehicles: 65&10g
K3 engine mounted vehicles: 80&10g

C11K5060ET10

2.Bend and assemble the boot band, as indicated in the

right figure.

L11K5147T10
D2–17
4 REAR AXLE BEARING ( 2WD )
4-1 REMOVAL AND INSTALLATION (VEHICLES NOT EQUIPPED WITH ABS)
Refer to Page E1-65.
4-3 REMOVAL AND INSTALLATION (ABS-EQUIPPED VEHICLES)
Refer to Page E1-65.

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