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DRIVE SHAFT

AND

FRONT AXLE

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G E N E R A L 2 DRIVE SHAFT 7 FRONT AXLE 14

GENERAL

SPECIFICATIONS

Drive shaft

Joint type

Outer

Inner

Length (Joint to Joint)

Right

Left

Wheel bearing

Type

Dimension O.D x I.D.

B.J (Birfield joint) D.O.J (Double offset joint)

357 mm (14.06 in.)

673 mm (26.50 in.)

Taper roller bearing 65.088 x 38.100 mm (2.56 x 1.5 in.)

SERVICE STANDARD

Setting of D.O.J boot length 75 ± 1 mm (3.0 ± 0.04 in.)

TIGHTENING TORQUE

LUBRICANTS

B.J Boot grease

Recommended lubricant NTN joint grease

or BD-K2 NTN joint grease

or BD-K2 Multipurpose grease SAE J310a, NLGI grade #2 EP

Quantity 90-120 gr (3.2-4.2 oz.)

D.O.J Boot grease

Outer surface of wheel bearing outer race

Wheel bearing and knuckle inside surface

Oil seal lip

60-90 gr (2.1-3.2 oz.)

As required

As required

As required

SPECIAL TOOLS

4 9 - 3

GENERAL

TROUBLESHOOTING

49-5

Wheel bearing troubleshooting

Trouble

Pitting

Flaking

Cracking

Flat spotting

Nicks

Smearing

Rust, corrosion

Wear

Discoloration

Symptom Pitting occurs because of uneven rotation of race and bearing surfaces

The surface peels because of uneven rotation of the race and bearing surfaces

Chipping or cracking of cage or roller edges

When large load is applied, race and roller contact surfaces compress, forming indentations

Instead of rolling along race surface, rollers slide, thus damaging surface

Damage or wear caused by minute particles adhering to surfaces results

in rough movement and such high temperatures that part of surface melt

Appears on various areas of the bearing

Wear of surface areas caused by friction

Grease discoloration results from grease deterioration which causes particles of pigment contained in grease to adhere to surfaces Heat discoloration will appear as a deep brown

on purple

Probable cause Excessive bearing preload Excessive load

End of bearing life Improper bearing assembly Impact when bearing was installed (such as being hit with a hammer)

Excessive bearing preload Excessive load

Vibration when bearings are not used, such as during shipment on freight cars, transport trucks, etc.

Insufficient grease Excessive bearing preload Excessive load

Faulty oil seal Excessive vibration of loads

on bearings Use of grease other than that specified

Insufficient grease Use of grease other than that specified

Faulty oil seal Presence of water or moisture Insufficient grease

Foreign matter Rust or corrosion due to moisture Use of grease other than that specified

Faulty oil seal Use of grease other than that specified

Faulty oil seal Excessive bearing preload Excessive load

DRIVE SHAFT

DRIVE SHAFT

COMPONENTS

TORQUE: Nm (kg.cm, lb.ft)

DRIVE SHAFT REPAIR KITS

KIT NAME

Double offset joint kit

Double offset joint boot kit

Birfield joint and shaft kit

Birfield joint boot kit

Damper kit

o Clip (Retainer ring)

o D.O.J assy

o Circlip

o D.O.J boot

o Snap ring

o D.O.J boot band

o Boot band

o Grease

o Clip (Retainer ring)

o Circlip

o D.O.J boot

o Snap ring

o D.O.J boot band

o Boot band

o Grease

o Clip (Retainer ring)

o Circlip

o Snap ring

o D.O.J boot band

o Boot bands

o Damper band

o B.J boot band

o B.J boot

o B.J assy

o Dust cover

o Grease

o Clip (Retainer ring)

o Circlip

o Snap ring

o D.O.J boot band

o Boot bands

o Damper band

o B.J boot band

o B.J boot

o Grease

o Clip (Retainer ring)

o Circlip

o Snap ring

o D.O.J boot band

o Boot band

o Dynamic damper

o Damper band

o Grease

DRIVE SHAFT

REMOVAL

1 Remove the wheel ornaments, and loosen the drive shaft nut.

2 Lift up the vehicle and remove the tires.

3 Remove the under cover.

4 Remove the lower arm ball joint and strut bar from the lower

arm.

CAUTION

Place the lower arm ball joint on the lower arm to prevent

damage to the ball joint dust boot.

5 Drain the transmission fluid.

6 Insert the pry bar between transmission case and joint case

(D.O.J), and pry the drive shaft from the transmission case.

CAUTIONS:

(a) Be sure to apply pry bar to the rib of transmission case.

(b) Do not insert pry bar too deep to cause damage to the oil

seal [max depth: 7 mm (0.28 in.)

7 Pull out the drive shaft from the transmission case.

CAUTIONS

(a) Put a waste cloth in the hole of the transmission case to

keep out dust.

(b) Hold the drive shaft in the proper position.

(c) Replace retainer ring each time the drive shaft is removed

from the transmission case.

8 Using Special Tool, Axle Shaft Puller (09526-11001), force the

drive shaft out of the hub.

CAUTION

When the drive shaft is forced out, prevent the spacer from

falling out of place.

49-9

DRIVE SHAFT

INSPECTION

1 Check the drive shaft boot for damage and deterioration.

2 Check the ball joints for wear and operating condition.

3 Check the spline part for wear and damage.

DISASSEMBLY

CAUTIONS

(a) Do not disassemble the B.J assembly.

(b) The drive shaft joint uses special grease Do not add another type of grease.

(c) The boot band should be replaced with a new one.

1 Remove the D.O.J boot bands and pull the D.O.J boot from the D.O.J outer race.

CAUTION

Use care to prevent damage to the boot.

2 Remove the circlip with a flat-blade screwdriver.

3 Pull out the drive shaft from the D.O.J outer race.

4 Remove the snap ring and take out the inner race, cage and balls

as an assembly.

DRIVE SHAFT

5 Clean the inner race, cage and balls without disassembly.

6 Removethe B.J boot bands and pull out the D.O.J boot and B.J boot.

CAUTION

If the boot is to be reused, wind a tape around the drive shaft splines to protect the boot.

Inspection after Disassembly

1 Rusted or damaged D.O.J outer race, inner race, cage and balls.

2 Worn splines.

3 Water, foreign matter or rust in B.J boot.

CAUTION

When the B.J assembly is to be reused, do not wide away grease but check for foreign substances in the grease If necessary, clean the B.J assembly and replace grease.

REASSEMBLY

1 Wind a tape around the drive shaft splines (D.O.J side) to prevent damage to the boots.

2 Apply grease to the drive shaft and install the boots.

Recommended grease NTN joint grease

or BD-K2

3 To install the dynamic damper, keep the B.J and shaft in a straight line and secure the dynamic damper using dynamic damper band as shown.

Standard value (A): 383.5 mm (15.0 in.)

DRIVE SHAFT

4 Apply the specified grease to the inner race and cage Install the inner race and cage displaced half a pitch.

CAUTION

Use the grease included in the kit.

5 Apply the specified grease to the cage and fit the balls into the cage.

6 With its chamfered side faced as shown, install the inner race onto the drive shaft, and install the snap ring.

7 Apply 40 to 50 gr (1.4 to 1.8 oz.) of the specified grease to the outer race and install the outer race onto the drive shaft.

8 Apply 20 to 40 gr (0.7 to 1.4 oz.) of the specified grease or equivalent to the outer race and install the clip.

Quantity gr (oz.) Total amount of grease for D.O.J 60-90 (2.1-3.2)

9 Add to the B.J as much specified grease or equivalent as was wiped away at the time of inspection.

10 Install the boots.

11 Tighten the B.J boot bands.

12 To control the air in the D.O.J boot, keep the specified distance between the boot bands when they are tightened.

DRIVE SHAFT

INSTALLATION

1 Tighten the following parts to the specified torque.

Torque Nm (kg.cm, Ib.ft) Drive shaft nut 196-255 (2,000-2,600, 145-188)

Lower arm to ball joint 93-118 (950-1,200, 69-87)

Lower arm to strut bar 93-118 (950-1,200, 69-87)

2 Install new retainer ring every time the drive shaft is removed

from the transmission.

3 Install the washer under the drive shaft nut as shown in

illustration.

49-13

FRONT AXLE

FRONT AXLE

COMPONENTS

TORQUE: Nm (kg.cm, Ib.ft)

REMOVAL

1 Remove the wheel ornaments.

2 Remove the drive shaft nut.

3 Jack up the vehicle and support it with stands.

4 Remove the wheel and tire.

5 Remove the front brake assembly from the knuckle and suspend

it with a wire.

6 Disconnect the lower arm ball joint from the knuckle using special tool.

7 Disconnect the tie rod end ball joint from the knuckle using Special Tool.

FRONT AXLE

8 Disconnect the drive shaft from the hub using the special tool.

9 Remove the hub and knuckle as an assembly from the strut.

INSPECTION

1 Check the hub for cracks and spline for wear.

2 Check the oil seal for cracking or damage.

3 Check the brake disc for scoring and damage.

4 Check the steering knuckle for cracks.

5 Check for defective bearing (Refer to “Wheel bearing trouble-shooting”.)

BEARING REPLACEMENT

1 Set the special tools as illustrated

2 Remove the hub from the knuckle by turning the special tool CAUTIONS

(a) Be sure to use the special tool.

(b) If the hub and knuckle are disassembled by striking with a hammer the bearing will be damaged.

3 Secure the knuckle in a vise.

4 Remove the brake disc from the hub.

FRONT AXLE

5 Remove the outer bearing inner race from the hub using Spe-cial Tools.

6 Remove the oil seal and inner bearing inner race from the knuckle.

7 Drive out the bearing outer races from the knuckle using the special tool.

CAUTION

If either the outer or inner race needs replacement, they must

be replaced as a set.

8 Apply the specified multipurpose grease to the outside surface

of the bearing outer race.

Recommended grease

Multipurpose grease SAE J310a, NLGI grade #2 EP

9 Install the bearing outer race into the knuckle with special tools.

10 Install the disc to the hub and torque to the specification Tightening torque

49-59 Nm (500-600 kg.cm, 36-43 ft.lbs.)

11 Apply the specified multipurpose grease to the bearings and inside surface of the hub.

FRONT AXLE

12 Place the outside bearing inner race into the knuckle.

13 Drive the oil seal (hub side) into the knuckle with the special tool.

14 Apply the specified maltipurpose grease to the lip of the oil seal and to the surfaces of the oil seal which contact the hub Recommended grease

Multipurpose grease SAE J310a,

NLGI grade #2 EP

15 Place the inner bearing into the knuckle.

16 Tighten the hub to the knuckle to 230 Nm (2,350 kg.cm, 167 Ib.ft) with the special tool.

17 Rotate the hub to seat the bearing.

18 Measure the hub bearing starting torque.

Hub bearing starting torque [Limit]

127.4 Ncm (13 kg.cm, 11 Ib.in) or less

19 If the starting torque is 0 Ncm (0 in.lbs.), measure the hub bearing axial play.

20 If the hub axial play exceeds the limit while the nut is tightened

to 230 Nm (2,350 kg.cm, 167 Ib.ft), the bearing, hub and knuckle have probably not been installed correctly Repeat the disassembly and assembly procedure.

Hub bearing axial play [Limit] 0.11 mm (0.0043 in.)

FRONT AXLE

21 Remove the special tool.

22 Apply the specified multipurpose grease to the bearing and to the inside of the knuckle.

Recommended grease

Multipurpose grease SAE J310a,

NLGI grade #2 EP

23 Drive the oil seal (drive shaft side) into the knuckle until it contacts the bearing outer race using special tools.

24 Apply the specified multipurpose grease to the lip of the oil seal.

25 Install the parts by reference to the torque specification.

INSTALLATION

1 Lower the vehicle to the ground and tighten the knuckle to the lower arm ball joint connecting bolt.

2 Install parts by reference to torque specification.