Intermediate Shaft Removal and Installation
Intermediate Shaft Removal and Installation
Removal
1. Vehicle Lift
1. Raise the vehicle on a lift, and make sure it is securely supported.
2. Engine Undercover
1. Remove the engine undercover (A).
3. MTF Replacement (M/T)
1. Remove the drain plug (A) and the sealing washer (B), and drain the MTF.
2. Reinstall the drain plug with a new sealing washer.
4. Tire and Wheel-Removal, Front Right
1. Remove the right front wheel.
5. Right Lower Ball Joint Lower Arm Side Disconnection
1. Remove the flange bolt (A).
2. Remove the flange nuts (B).
3. Disconnect the lower ball joint (C) from the lower arm.
6. Right Front Driveshaft Inboard Side - Disconnection (With Intermediate Shaft)
1. Drive the inboard joint (A) off of the intermediate shaft using a drift punch and a hammer.
NOTE: Do not pull on the driveshaft or the inboard joint may come apart.
2. Remove the set ring (A).
7. Floor Jack Support (Except K24Z7 Engine)
1. Lift and support the engine with a jack and a wood block under the oil pan.
8. Lower Torque Rod (Except K24Z7 Engine)
1. Remove the lower torque rod mounting bolts.
9. Lower Torque Rod Bracket (Except K24Z7 Engine)
1. Remove the lower torque rod bracket (A).
10. Intermediate Shaft Assembly
1. Remove the crankshaft position (CKP) sensor cover (A).
Except K24Z7 engine
K24Z7 engine
2. Remove the dowel bolts (A) and the flange bolt (B).
3. Remove the intermediate shaft (A) from the differential.
NOTE: Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal (B).
Installation
1. Intermediate Shaft Assembly
1. Insert the intermediate shaft (A) into the differential correctly.
NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal (B).
Except K24Z7 engine
K24Z7 engine
2. Install the dowel bolts (A) and the flange bolt (B).
3. Install the crankshaft position (CKP) sensor cover (A).
2. Lower Torque Rod Bracket (Except K24Z7 Engine)
1. Install the lower torque rod bracket (A) using new flange bolts.
3. Lower Torque Rod (Except K24Z7 Engine)
1. Connect the lower torque rod (A) and the lower torque rod bracket (B) using new bolts.
4. Floor Jack Support (Except K24Z7 Engine)
1. Remove the jack and the wood block.
5. Right Front Driveshaft Inboard Side - Reconnection (With Intermediate Shaft)
1. Install a new set ring (A).
2. Apply 0.5-1.0 g (0.018-0.035 oz) of super high temp urea grease (P/N 08798-9002) to the whole splined surface (A) of the right driveshaft.
3. After applying grease, remove the grease from the splined grooves at intervals of 2-3 splines and from the set ring groove (B) so that air can bleed from the intermediate shaft.
4. Insert the inboard end (A) of the driveshaft onto the intermediate shaft (B) until the set ring (C) locks in the groove (D).
6. Right Lower Ball Joint Lower Arm Side Reconnection
1. Connect the lower ball joint (A) to the lower arm.
2. Install new flange nuts and a new flange bolt in the sequence shown.
7. Tire and Wheel-Installation, Front Right
1. Install the right front wheel.
NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.
8. MTF Replacement (M/T)
1. Remove the filler plug (A) and the sealing washer (B).
2. Refill the transmission with MTF to the proper level (C). Always use Honda Manual Transmission Fluid (MTF).
3. Reinstall the filler plug with a new sealing washer.
9. Engine Undercover
1. Install the engine undercover (A).
10. Pre-Alignment Checks
For proper inspection and adjustment of the wheel alignment, do these checks:
1. Release the parking brake to avoid an incorrect measurement.
2. Make sure the suspension is not modified.
3. Make sure the fuel tank is full, and that the spare tire, the jack, and the tools are in place on the vehicle.
4. Check the tire size and tire pressure according to tire information.
11. Caster - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Check the caster angle.
* If the measurement is within specifications, measure the front camber angle.
* If the measurement is not within specifications, check for bent or damaged suspension components.
12. Camber - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Check the camber angle.
* If the measurement is within specification, measure the toe-in.
* If the measurement for the front camber is not within the specification, go to front camber adjustment.
* If the measurement for the rear camber is not within the specification, check for bent or damaged suspension components.
13. Front Toe - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Set the steering column to the middle tilt position and telescopic positions.
2. Center the steering wheel spokes, and install a steering wheel holder tool.
3. Check the toe with the wheels pointed straight ahead.
Front toe-in: 0±2 mm (0±0.08 in)
* If adjustment is required, go to the front toe adjustment.
* If no adjustment is required, remove the alignment equipment.
14. Turning Angle - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.
2. If the measurement is not within the specifications, even up both sides of the tie-rod threaded section length while adjusting the front toe.
3. If it is correct, but the turning angle is not within the specifications, check for bent or damaged suspension components.
15. Test Drive
1. Test-drive the vehicle.
16. Maintenance Minder Reset
1. After doing all procedures, select the individual maintenance item you wish to reset with the HDS (See the Maintenance Minder General Information).