FRONT DRIVE SHAFT (RH SIDE) : Removal & Installation

AWD models with PR25DD engine 

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 hammer (A) and Tool (B) release staked area (C) of wheel hub lock nut (D).

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   Tool number (B)

   : KV40108800 (J-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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   WARNING: To avoid risk of death or severe personal injury:

   • 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.
8. Remove the lower transverse link. Refer to Removal and Installation .
   CAUTION: Do not reuse pinch bolt nut.
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. Using a suitable tool, remove the transfer cover oil seal.
    CAUTION:

    • When removing transfer cover oil seal with suitable tool, do not damage the transfer cover.
    • Do not reuse transfer cover oil seal.
13. 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)	: -- (J-52390)
   Tool (B)	: -- (J-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. Tighten the bearing retainer bolts in the numerical order shown.
   • Refer to the following for installation.

     M8 bolt

     : No. 1 and No. 2

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

     Fig 1: Bearing Retainer Bolts Tightening Sequence

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6. Tighten support bearing bracket bolts in the numerical order as shown.
   • Refer to the following for the installation positions of bolts.
     Fig 2: Bearing Bracket Bolts Tightening Sequence

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     1. Temporarily tighten bolts No. 1 and No. 2.
     2. Tighten bolts No. 3 - 4 to specified torque.
     3. Tighten bolts No. 1 and No. 2 to specified torque.

     M10 bolt

     : No. 1 - 5

     50.0 N.m (5.1 kg-m, 37 ft-lb)

7. Install new circular clip on drive shaft in circular clip groove on transaxle side. Refer to FRONT DRIVE SHAFT : Disassembly and Assembly .
   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 driveshaft damage, which may cause a crash and serious injury or damage the drive shaft.
   CAUTION:

   • Do not reuse circular clip.
   • Make sure new circular clip on drive shaft is securely fastened.
   • 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.
     WARNING: To avoid risk of death or severe personal injury:

     • Do not reuse wheel stud.
     • Do not reuse wheel hub lock nut.
   • Place a washer (A) as shown to install wheel studs (1) by using tightening force of nut (B).
     WARNING: To avoid risk of death or severe personal injury:

     • Do not apply lubricating oil to these mating surfaces.
     • Check that there is no clearance between wheel stud and wheel hub and bearing.
     • Do not use a power tool to tighten the wheel hub lock nut.
     • Align the marks made on the rotor and the front wheel hub during disassembly.
     • Do not reuse lower strut nut.
     • Do not reuse the wheel hub lock nut.
     • Do not apply lubricating oil to these matching surfaces.
   • Clean the matching surface of drive shaft and wheel hub assembly. And then apply paste [service parts (440037S000)] to surface (A) of joint sub-assembly of drive shaft.

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

     • Clean mating surfaces of wheel hub lock nut and wheel hub and bearing.
     • Do not apply lubricating oil to these matching surface.
     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.

     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 the wheel hub lock nut.
   • Using hammer (A) and cold chisel (B) stake the wheel hub lock nut (C) as shown.

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     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)

8. Installation of the remaining components is in the reverse order of removal.

INSPECTION AND ADJUSTMENT AFTER INSTALLATION 

• Check CVT fluid level and leakage. Refer to CVT FLUID : Inspection (RE0F10D), or CVT FLUID : Inspection (RE0F10H).
• Check wheel alignment. Refer to WHEEL ALIGNMENT : Inspection .
• Adjust the neutral position of the steering angle sensor. Refer to Work Procedure .