Axle Shaft: Service and Repair
REMOVAL
1. Remove the rear wheel.
NOTE: When installing the rear wheel, tighten it to 103 Nm (76 ft. lbs.).
2. Disconnect the exhaust pipe.
NOTE: Support the exhaust pipe securely.
3. Remove the cotter pin and lock cap and, while depressing the brake pedal, remove the nut.
NOTE: When installing the nut, tighten it to 289 Nm (213 ft. lbs.).
4. Remove the rear drive shaft by doing the following.
a. Place matchmarks on the drive shaft and side gear shaft.
NOTE: Do not use a punch to mark the matchmarks. Use paint etc.
b. Using a 10 mm hexagon wrench, remove the six hexagon bolts and two washers with depressing the brake pedal.
Installation Hint: Apply a light coat of engine oil on the threads of the bolts.
NOTE: When installing the nuts and bolts, tighten them to 83 Nm (61 ft. lbs.).
c. Hold the inboard joint side of the drive shaft so that the outboard joint side does not bend too much.
d. Using a brass bar and hammer, lightly tap the end of the drive shaft, disengage the axle hub and remove the drive shaft.
NOTE: Be careful not to damage the boots, end cover, speed sensor rotor of the drive shaft and oil seal of the axle hub.
DISASSEMBLY
1. Check the drive shaft, doing the following.
a. Check that operation of the joint is smooth within the sliding region in the axial direction.
NOTE: If a large angle is used for the cross-groove type joint, the joint will feel like it is catching, but this does not indicate an abnormality.
b. Check that the boots are not cracked, damaged or leaking.
c. Check that there are no scratches on the speed sensor rotor.
2. Remove the end cover after doing these steps.
a. Using a screwdriver, remove the end cover.
b. Use bolts, nuts and washers to keep the inboard join together.
NOTE: Tighten the bolt by hand to avoid scratching the flange surface.
3. Using a side cutter or pliers, remove the four boot clamps
4. Remove the inboard joint after doing the following.
a. Place matchmarks on the inboard joint and drive shaft.
NOTE: Do not punch the marks.
b. Using a snap ring expander, remove the snap ring.
c. Using the 09726 - 12023 (09726 - 01031) SST, an extension bar and a press, remove the inboard joint from the drive shaft.
d. Mount the inboard joint in a soft jaw vise.
e. Using a screwdriver and hammer, remove the inboard joint cover from the inboard joint.
NOTE: Make sure that the cage and inner race are not positioned too much to one side of the outer race.
5. Remove the inboard joint boot and outboard boot.
6. Remove the No.2 dust deflector, doing the following.
a. Mount the outboard joint in a soft jaw vise.
b. Using a screwdriver and hammer, remove the No.2 dust deflector.
NOTE: Be careful not to damage the ABS speed sensor rotor.
ASSEMBLY
1. Using the 09309 - 36010, 09502 - 12010 SST and a press, install a new No.2 dust deflector.
NOTE: Be careful not to damage the ABS speed sensor rotor.
2. Assemble the inboard joint by doing the following. If the joint has come apart, reassemble it in the following order.
a. Align the matchmarks placed before removal.
NOTE: When the matchmarks have disappeared, do the following procedure.
1. Install the inner race to the cage so that the indented bevelled part of the inner race is on the opposite side to the bevelled top of the cage.
2. Install the outer race so that the indented side of the outer race is facing the same side as the bevelled surface of the cage.
3. Match the narrow projections of the inner race with the wide projections of the outer race.
b. Tilt the cage and inner race to the side and insert the balls one by one.
NOTE: When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out.
3. Temporarily install the new boots and the new boot clamps by doing the steps.
a. Place four new boot clamps to two new boots.
NOTE: Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boots.
b. Install the two boots to the drive shaft.
4. Install the inboard joint cover by doing these procedures.
a. Apply Part No.08826 - 00801, THREE BOND 1121 or equivalent FIPG to the inboard joint cover, as shown in the illustration. Install a nozzle that has been cut to a 1 mm (0.04 inch) opening.
NOTE: Avoid applying an excessive amount to the surface.
b. Remove grease from the surface of the inboard joint facing the cover.
c. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
d. Use a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat it several times.
5. Install the inboard joint, doing these steps.
a. Align the matchmarks placed before removal.
b. Using a brass bar and hammer, tap the inboard joint onto the drive shaft.
NOTE: Check that the brass bar is touching the inner race, and not the cage.
c. Using a snap ring expander, install a new snap ring.
6. Before assembling the boots, pack with only the same amount of grease that was wiped off, then assemble the boots. The boot grease capacity is 100 - 105 g (0.22 - 0.23 lb. 3.5 - 3.7 oz.).
NOTE:
- Use the grease supplied in the boot kit.
- Keep grease off the joint connection groove of the boot.
- Pack with grease all over the ball contact surface inside the Joint.
7. Install the boot clamps to both of the boots by doing the following.
a. Position the clamp onto the boot.
NOTE: Pinch the inboard side of the boot clamp, as shown in the illustration.
b. Place the 09521 - 24010 Special Service Tool (SST) onto the clamp.
c. Tighten the SST so that the clamp is pinched.
NOTE: Do not overtighten the SST.
d. Using the 09240 - 00020 (09240 - 00080) SST, adjust the clearance of the clamp. The clearance should be 0.8 mm (0.031 inch) or less.
e. The drive shaft is designed to move +20 mm (0.79 inch) from the normal position. The drive shaft standard lengths are as follows. The right hand side should be 598.5 mm (23.563 inch) and the left hand side should be 553.5 mm (21.791 inch).
8. Install a new end cover after doing these procedures.
a. Pack grease into the end cover. The grease capacity is 50 - 55 (0.11 - 0.12 lb, 1.8 - 1.g oz.).
b. Remove grease from the surface of the inboard joint facing the cover.
c. Glue on a new gasket, with the side with adhesive on it facing toward the outer race side of the inboard joint.
d. Align the bolt holes of the cover with those of the inboard joint.
e. Install the six hexagon bolts and washer from the end cover side.
f. Install the six nuts to the boot side.
g. Using a 10 mm hexagon wrench, tighten the bolts. Do this in the order shown, and repeat several times.
h. Check that the claw of the end cover touches the inboard joint.
9. Check the drive shaft.
INSTALLATION
Install in the reverse order of removal, noting the following:
- check ABS speed sensor signal.