Front Drive Shaft Disassembly and Reassembly
Front Drive Shaft Disassembly and Reassembly
Front Drive Shaft Components:Front
Front Drive Shaft Assembly Removal and Installation:Front
Disassembly
NOTE:
Disassembly of the wheel-side joint or the tripod joint can cause performance problems.
If anything abnormal (damage, noise, etc.) is found with either of these joints, replace the joint as an assembly.
1) Remove boot bands (1) of differential side.
2) Remove differential side joint housing from tripod joint.
3) Wipe off grease from shaft and use snap ring pliers (2) to take off snap ring (1).
4) Use 3-arms puller (2) to remove tripod joint (1).
NOTE:
Except for the housing, washing the tripod joint parts with a washing solution may cause problems with the joint.
Do not use a washing solution to clean any tripod joint parts other than the housing. Use a cloth to remove grease from tripod joints.
5) Pull out differential side boot from shaft.
6) Remove damper band(s) (1).
7) Remove damper from shaft.
8) Use flat end rod (1) or the like to undo caulking (2) of wheel side boot big band and small band (3), and then pull out wheel side boot from shaft.
NOTE:
Use nippers to cut the boot band if it is a welded type. Give care so as not to damage the boot while cutting the band.
Reassembly
Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and housing of tripod joint (2) are washed thoroughly and air dried.
NOTE:
Joints may not perform as designed if proper cleaning and lubrication precautions are not taken.
- Do not wash boots with solvents such as gasoline or kerosene. Washing boots with these solvents causes deterioration of the boots.
- Be sure to lubricate joints with the specified grease in the specified amount. Follow the instructions below to identify the specified grease and specified amount for each joint.
Wheel side joint
1) Wash disassembled parts (except boots). After washing parts, blow dry until completely dry.
2) Clean boots with shop cloth.
3) Apply grease from the service kit to wheel side joint.
Amount
: 90 - 110 g (3.17 - 3.88 oz)
4) Install wheel side boot on shaft.
5) Fill boot inside with specified grease.
6) Insert flat-bladed screwdriver into boot (2) and allow air to enter boot so that air pressure in boot becomes the same as the atmospheric pressure.
7) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
NOTE:
Squeezing or otherwise distorting the boot will reduce its durability.
Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with bands.
8) Use special tool as shown in figure to securely fasten boot bands (1).
NOTE:
Squeezing or otherwise distorting the boot will reduce its durability.
Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with bands.
Distance "a"
: 1.2 - 4.0 mm (0.1 - 0.2 in.)
Special Tool
(A): 09943-57011
9) Place new damper band(s) onto damper putting band outer end (1) against forward rotation (2) as shown in figure.
10) Install damper to specified position on drive shaft.
Drive shaft damper installing position
6M/T model "a": 286 - 292 mm (11.3 - 11.5 in.)
CVT model "b": 281 - 287 mm (11.1 - 11.3 in.)
11) Fasten damper band(s) (1) as shown in figure. (6M/T model)
Differential side joint
12) Place new boot bands onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
13) Install boot bands and boot to shaft temporarily.
14) Install the chamfered spline (3) of the tripod joint to the shaft.
15) Use snap ring pliers (2) to fasten new snap ring (1).
16) Apply specified grease included in spare parts to tripod joint, differential side joint housing and boot.
Grease amount
6M/T model (right side drive shaft): 150 - 170 g (5.29 - 6.00 oz)
6M/T model (left side drive shaft): 165 - 185 g (5.82 - 6.53 oz)
CVT model (right side drive shaft): 150 - 170 g (5.29 - 6.00 oz)
CVT model (left side drive shaft): 155 - 175 g (5.47 - 6.17 oz)
17) Install the differential side joint housing to the tripod joint.
18) Fit boot (3) to grooves (2) of shaft and differential side joint housing (1).
19) Insert flat-bladed screwdriver into boot (2) and allow air to enter boot so that air pressure in boot becomes the same as the atmospheric pressure.
Drive shaft boot fixing position (distance between differential side joint end and small boot band center) "a"
6M/T model (right side drive shaft): 201.2 mm (7.921 in.)
6M/T model (left side drive shaft): 190.6 - 191.1 mm (7.504 - 7.524 in.)
CVT model (right side drive shaft): 201.2 mm (7.921 in.)
CVT model (left side drive shaft): 184.7 mm (7.272 in.)
20) Fasten differential boot bands (1) as shown in figure.
NOTE: - If a boot band is installed with its outer end pointing in the forward rotating direction, the band's end may catch a piece of rope, rag, wire, etc. on the road. These things may tangle with the band and cause the band to open. This could lead to leakage of grease and eventually to a broken drive shaft.
Be sure to install each boot band with its outer end pointing against the forward rotating direction.
- Squeezing or otherwise distorting the boot will reduce its durability.
Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with its band.