Removal and Installation (RH)

REMOVAL 

1. Remove front disc brake rotor. Refer to Removal and Installation .
2. Remove wheel sensor bolt and position wheel sensor aside. Refer to Exploded View .
   WARNING: To avoid risk of death or severe personal injury:

   • Do not pull on wheel sensor harness.
3. Using suitable tool (A) and Tool (B) release staked area (C) of wheel hub lock nut (D).

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   Tool (B)

   : (NI-52982)

4. Visually verify that staked area (A) of wheel hub lock nut (B) is completely released from front drive shaft (1) or damage to drive shaft can occur.

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   (C)	: Fully released
   (D)	: Not fully released
   (E)	: Fully released (sectional view)
   (F)	: Not fully released (sectional view)

   WARNING: To avoid risk of death or severe personal injury:

   • Be sure that staked area of wheel hub lock nut is fully released or damage to drive shaft can occur.
   • Do not damage front drive shaft threads.
5. Loosen wheel hub lock nut from drive shaft.
   WARNING: To avoid risk of death or severe personal injury:

   • Do not use power tool.
   • Do not damage front drive shaft threads.
   • Do not reuse drive shaft lock nut.
   • When loosening lock nut, if it does not turn smoothly, verify that staked area is completely released.
6. Using a piece of wood and a suitable tool, tap on the lock nut to disengage drive shaft from wheel hub.

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   CAUTION:

   • Do not place drive shaft joint at an extreme angle. Be careful not to over extend slide joint.
   • Do not allow drive shaft to hang without support.
   NOTE: Use suitable puller if drive shaft cannot be separated from wheel hub and bearing assembly.
7. Remove wheel hub lock nut.
   WARNING: To avoid risk of death or severe personal injury:

   • Do not reuse wheel hub lock nut.
   • Do not reuse pinch bolt nut.
8. Remove the lower transverse link. Refer to Removal and Installation .
9. Remove bearing retainer to support bearing bracket bolts.
10. Insert suitable tool (A) between the drive shaft and the transaxle. Remove the drive shaft from the transaxle.

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    CAUTION:

    • Confirm that the circular clip is attached to the drive shaft.
    • Do not place the drive shaft joint at an extreme angle when removing the drive shaft. Also be careful not to overextend the slide joint.

    Tool (A)

    : Drive shaft joint puller (Commercially available)

11. If necessary, remove support breaking bracket bolts and support bearing bracket.
12. Remove the drive shaft oil seal (1) using suitable tool (A).
    CAUTION:

    Do not reuse drive shaft oil seal.

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INSPECTION AFTER REMOVAL 

• Move joint up/down, left/right, and in axial direction. Check for any rough movement or significant looseness.
• Check boot for cracks or other damage, and for grease leakage.

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• If damaged, disassemble drive shaft to verify damage, and repair or replace as necessary.

INSTALLATION 

1. Install drive shaft oil seal (1) onto Tool (A) before installing into transfer case assembly using Tool (B).
   CAUTION:

   Do not reuse drive shaft oil seal.

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   Tool (A)	: - (NI-52390)
   Tool (B)	: - (NI-8092)

2. Using two people, install the drive shaft oil seal (1) to the specified depth (A).

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   Dimension (A)

   : 2.0 - 2.6 mm (0.079 - 0.102 in)

3. Using two people, install the transfer cover oil seal (1) using suitable tool (A).

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   CAUTION:

   Do not reuse transfer cover oil seal.

4. Verify the transfer cover oil seal (2) is installed to the correct depth (A).

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   Dimension (A)

   : 0.0 - 0.6 mm (0.000 - 0.024 in)

   (1)	: Drive shaft oil seal
   (B)	: Drive shaft oil seal installation depth

5. Lubricate the transfer cover oil seal and drive shaft oil seal lips before installing front drive shaft (RH).
6. Tighten the bearing retainer bolts in the numerical order shown in the illustration.

   M8 bolt

   : No. 1 and No. 2

   25.0 N.m (2.6 kg-m, 18 ft-lb)

   Fig 1: Bearing Retainer Bolt Tightening Sequence - AWD

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7. Tighten support bearing bracket bolts in the numerical order as shown in the illustration.
   • Refer to the following for the installation positions of bolts.
     Fig 2: Support Bearing Bracket Bolt Tightening Sequence - AWD

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     1. Temporarily tighten bolts No. 1 and No. 2.
     2. Tighten bolts No. 3 - 5 to specified torque.
     3. Tighten bolts No. 1 and No. 2 to specified torque.

     M10 bolt

     : No. 1 - 5

     48.0 N.m (4.9 kg-m, 35 ft-lb)

8. Install new circular clip on drive shaft in circular clip groove on transaxle side. Refer to Disassembly and Assembly .
   CAUTION:

   • Do not reuse circular clip.
   • Make sure new circular clip on drive shaft is securely fastened.
   WARNING: Ensure that the circular clip is properly engaged, otherwise the joint sub-assembly could pull away from transaxle during vehicle operation resulting in loss of drive force and possible drive shaft damage, which may cause a crash and serious injury or damage the drive shaft.
   • To ensure the circular clip is properly engaged, grasp the housing (1) and pull back and forth in axial direction while listening for clicking sounds.

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   • Pull the joint sub-assembly in the axial direction away from the transaxle assembly ( ). Confirm that the joint sub assembly cannot be pulled out.
   • Apply a moderate coat of paste [service parts (440037S000)] to bearing surface (A) as shown in the illustration.

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     NOTE: Always check with the Parts Department for the latest parts information.
     NOTE: To avoid damage to the vehicle:

     • Apply paste to cover entire flat surface of joint sub-assembly of drive shaft.

       Paste amount

       : 1.0 - 3.0 g (0.04 - 0.10 oz)

   • Hold wheel hub and bearing using a suitable tool. Tighten wheel hub lock nut.

     110 N.m (11 kg-m, 81 ft-lb)

     WARNING: To avoid risk of death or severe personal injury:

     • Since drive shaft is assembled by press-fitting, use a torque wrench to tighten wheel hub lock nut. Do not use a power tool.
     • Too much torque causes axle noise. Too little torque causes wheel bearing looseness.
     • Do not reuse wheel hub lock nut.
   • Using suitable tool (A) and Tool (B) stake the wheel hub lock nut (C) as shown in the illustration.

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     Tool (B)

     : (NI-52982)

     WARNING: To avoid the risk of death or severe personal injury:

     • Use the following range when staking the wheel hub lock nut.

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     (A)	: 6.2 mm (0.244 in)
     (B)	: 26.4 - 27.8 mm (1.039 - 1.094 in)

9. Remainder of installation is in the reverse order of removal.

INSPECTION AND ADJUSTMENT AFTER INSTALLATION 

• Check CVT fluid level and leakage. Refer to Fluids and Lubricants .
• Check wheel alignment. Refer to Wheel Alignment (Unladen1)1 .
• Adjust the neutral position of the steering angle sensor. Refer to Description .