DS–4 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

REMOVAL
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. DRAIN MANUAL TRANSAXLE OIL (for Manual
Transaxle)
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
2. DRAIN AUTOMATIC TRANSAXLE FLUID (for
Automatic Transaxle)
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
3. REMOVE FRONT WHEEL
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE FRONT AXLE HUB NUT
(a) Using SST and a hammer, pry up the retaining
tab(s) of the hub nut.
SST 09930-00010
NOTICE:
Loosen the staked part of the nut completely,
otherwise the screw of the drive shaft may be
damaged.
SST (b) While applying the brakes, remove the hub nut.
C057565E02

6. DISCONNECT FRONT SPEED SENSOR

LH (a) Remove the bolt and clip, and disconnect the front
speed sensor and flexible hose from the front shock
absorber.
HINT:
The positions of the bolt and clip on the right side
differ from those on the left side.

DS RH

F045754E01
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–5

(b) Remove the bolt and disconnect the front speed

sensor from the steering knuckle.
NOTICE:
• Be careful not to damage the speed sensor.
• Prevent foreign matter from adhering to the
speed sensor.

C057827E01

7. DISCONNECT FRONT STABILIZER BAR

(a) Hold the bolt with a wrench and remove the nut.
(b) Remove the 2 cushion retainers and 2 cushions,
and disconnect the front stabilizer bar.

D028934E01

8. DISCONNECT FRONT NO. 1 SUSPENSION LOWER

ARM SUB-ASSEMBLY
(a) Remove the clip and nut.
(b) Using SST, disconnect the front suspension lower
arm from the steering knuckle.
SST 09628-00011

SST
G022968E07

9. DISCONNECT TIE ROD END SUB-ASSEMBLY

SST (a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the
steering knuckle. DS
SST 09628-62011
10. DISCONNECT FRONT DRIVE SHAFT ASSEMBLY
(a) Using a plastic-faced hammer, tap the drive shaft
and disconnect it.
NOTICE:
D030290E02
• Be careful not to damage the boot.
• Be careful not to damage the speed sensor
rotor.
 DS–6 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

11. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

(a) Using SST, tap out the front drive shaft assembly
LH.
SST SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the oil seal and
boot.
• Be careful not to drop the drive shaft
assembly.
SST
D028937E03

12. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

(a) Using a brass bar and hammer, tap out the front
drive shaft.
NOTICE:
• Be careful not to damage the oil seal and
boot.
• Be careful not to drop the drive shaft
assembly.

C063066E01

13. FIX FRONT AXLE ASSEMBLY LH

NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle's weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
SST is necessary to place the vehicle's weight on the hub
bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)

D028938E02

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

NOTICE:
Keep the drive shaft assembly level during
DS inspection.
(a) Check that there is no remarkable play in the radial
direction of the outboard joint.
(b) Check that the inboard joint slides smoothly in the
thrust direction.
(c) Check that there is no remarkable play in the radial
N000191E01 direction of the inboard joint.
(d) Check the boots for damage.
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–7

DISASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. REMOVE FRONT NO. 2 AXLE INBOARD JOINT
One Touch Clamp Type BOOT CLAMP
(a) One touch clamp type:
Using a screwdriver, remove the inboard joint boot
clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, remove the inboard joint
boot clamp as shown in the illustration.

Claw Engagement Type

D030655E02

2. REMOVE FRONT AXLE INBOARD JOINT BOOT

One Touch Clamp Type CLAMP
(a) One touch clamp type:
Using a screwdriver, remove the inboard joint boot
clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, remove the inboard joint
boot clamp as shown in the illustration.
3. REMOVE FRONT DRIVE SHAFT INBOARD JOINT
BOOT
DS
Claw Engagement Type (a) Disconnect the inboard joint boot from the inboard
joint.

D030656E02
 DS–8 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

4. REMOVE FRONT DRIVE INBOARD JOINT

ASSEMBLY
Matchmark
(a) Remove the old grease from the inboard joint.
(b) Put matchmarks on the inboard joint and outboard
joint shaft.
NOTICE:
Do not use a punch for marking.
(c) Remove the inboard joint from the outboard joint
shaft.
F040222E03

(d) Using a snap ring expander, remove the inner shaft

snap ring.

D028939E01

(e) Put matchmarks on the outboard joint shaft and

Brass Bar
Matchmark tripod joint.
NOTICE:
Do not use a punch for marking.
(f) Using a brass bar and hammer, tap out the tripod
joint from the outboard joint shaft.
NOTICE:
Do not tap the roller.
(g) Remove the No. 2 inboard joint boot clamp, inboard
F040224E03 joint boot and inboard joint boot clamp.

5. REMOVE DRIVE SHAFT DAMPER SETTING CLAMP

One Touch Clamp Type (RH DRIVE SHAFT)
(a) One touch clamp type:
DS Using a screwdriver, remove the damper setting
clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, remove the damper
setting clamp as shown in the illustration.
6. REMOVE FRONT DRIVE SHAFT DAMPER RH (RH
DRIVE SHAFT)
Claw Engagement Type
(a) Remove the drive shaft damper RH.

D030598E02
DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–9

7. REMOVE FRONT NO. 2 AXLE OUTBOARD JOINT

BOOT CLAMP
(a) Using a screwdriver, remove the outboard joint boot
clamp.

C063445E01

8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT

CLAMP
(a) Using a screwdriver, remove the outboard joint boot
clamp.
9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard
joint shaft.
(b) Remove the old grease from the outboard joint.
C063444E01

10. REMOVE FRONT DRIVE INBOARD JOINT HOLE

SNAP RING
(a) Using a screwdriver, pry off the hole snap ring.

C057543E01

11. REMOVE FRONT DRIVE SHAFT DUST COVER

SST (a) Using SST and a press, press out the dust cover.
SST 09950-00020
NOTICE: DS
Be careful not to drop the inboard joint
assembly.

G023850E02
 DS–10 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

REASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT DRIVE SHAFT DUST COVER LH
SST (a) Using SST and a press, press in the dust cover.
SST 09527-10011
NOTICE:
• Be careful not to damage the dust cover.
• Dust cover should be installed completely.
2. INSTALL FRONT DRIVE INBOARD JOINT HOLE
SNAP RING
(a) Install a new hole snap ring.
G023851E02

3. INSTALL FRONT DRIVE SHAFT OUTBOARD BOOT

(a) Wrap the spline of the outboard joint shaft with vinyl
tape to prevent the boot from being damaged.
(b) Install the new parts on the inboard joint shaft in the
following order.
(1) No. 2 outboard joint boot clamp.
(2) Outboard joint boot
(3) Outboard joint boot clamp.
(c) Pack the outboard joint with grease.
Standard grease capacity:
155 to 170 g (5.5 to 6.1 oz.)
(d) Install the outboard joint boot on the outboard joint
shaft.
4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT
BOOT CLAMP
SST (a) Secure the No. 2 outboard joint boot clamp onto the
outboard joint boot.
(b) Place SST onto the No. 2 outboard joint boot clamp.
SST 09521-24010
(c) Tighten the SST so that the No. 2 outboard joint
DS boot clamp is pinched.
NOTICE:
F040235E02 Do not overtighten the SST.
(d) Using SST, measure the clearance of the No. 2
outboard joint boot clamp.
SST 09240-00020 (09242-00080)
Standard clearance:
0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified
value, retighten the clamp.
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–11

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

CLAMP
(a) Mount drive shaft in a soft vise.
SST (b) Secure the outboard joint boot clamp onto the
outboard joint boot.
(c) Place SST onto the outboard joint boot clamp.
SST 09521-24010
(d) Tighten the SST so that the outboard joint boot
clamp is pinched.
F040237E02 NOTICE:
Do not overtighten the SST.
(e) Using SST, measure the clearance of the outboard
joint boot clamp.
SST 09240-00020 (09242-00080)
NOTICE:
When the measured value exceeds the specified
value, retighten the clamp.
SST 6. INSTALL FRONT DRIVE SHAFT DAMPER RH (RH
DRIVE SHAFT)
(a) Install the drive shaft damper RH on the outboard
F040238E02
joint shaft.
7. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP
(RH DRIVE SHAFT)
(a) Install the damper setting clamp to the shaft.
NOTICE:
Be sure to install the clamp in the correct
position.
(b) One touch clamp type:
One Touch Clamp Type Using a screwdriver, install the damper setting
clamp as shown in the illustration.
(c) Claw engagement type:
Using needle nose pliers, install the damper setting
clamp as shown in the illustration.
8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
HINT: DS
Before installing the boot, wrap the spline of the drive
shaft with vinyl tape to prevent the boot from being
Claw Engagement Type damaged.
(a) Install the new parts on the outboard joint shaft in
the following order.
(1) Inboard joint boot clamp
(2) Inboard joint boot
(3) No. 2 inboard joint boot clamp

D030599E02
 DS–12 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

(b) Align the matchmarks and tap in the tripod joint to

the outboard joint.
(c) Using a brass bar and hammer, install the tripod
joint.
NOTICE:
• Do not tap the roller.
• Be sure to install the tripod joint in the correct
direction.
Matchmark
F040227E04

(d) Using a snap ring expander, install a new inner shaft

snap ring.
(e) Apply grease to the inboard joint.
Standard grease capacity:
125 to 135 g (4.5 to 4.8 oz.)

D028939E01

(f) Align the matchmarks and install the inboard joint on

the outboard joint shaft.
Matchmark
9. INSTALL FRONT DRIVE SHAFT INBOARD JOINT
BOOT
(a) Install the inboard joint boot on the inboard joint and
outboard joint shaft.

F040222E03

10. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT

One Touch Clamp Type CLAMP
(a) One touch clamp type:
DS Using a screwdriver, install the inboard joint boot
clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, install the inboard joint
boot clamp as shown in the illustration.

Claw Engagement Type

D030658E02
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–13

11. INSTALL FRONT AXLE INBOARD JOINT BOOT

One Touch Clamp Type CLAMP
(a) One touch clamp type:
Using a screwdriver, install the inboard joint boot
clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, install the inboard joint
boot clamp as shown in the illustration.

Claw Engagement Type

D030657E02

12. INSPECT FRONT DRIVE SHAFT

(a) Check that there is no remarkable play in the
outboard joint.
(b) Check that the inboard joint slides smoothly in the
thrust direction.
(c) Check that there is no remarkable play in the radial
direction of the inboard joint.
(d) Check the boots for damage.

N000191E01

DS
 DRIVE SHAFT – DRIVE SHAFT SYSTEM DS–1

DRIVE SHAFT SYSTEM

PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected Area" column
of the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Drive shaft system
Symptom Suspected area See page
Front wheel shimmy Front drive shaft (worn) DS-12

DS
 DS–14 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Manual transaxle:
Coat the spline of the inboard joint shaft with gear
oil.
(b) Automatic transaxle:
Coat the spline of the inboard joint shaft with ATF.
(c) Align the shaft splines and tap in the drive shaft with
a brass bar and hammer.
HINT:
C063067E01 Whether the inboard joint shaft is in contact with the
pinion shaft or not can be known from the sound or
feeling when driving it in.
NOTICE:
• Set the hole snap ring with the opening side
facing downward.
• Be careful not to damage the boot and oil
seal.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT:
Use the same procedure for the LH side.
3. CONNECT FRONT DRIVE SHAFT ASSEMBLY
(a) Connect the drive shaft to the front axle.
NOTICE:
• Be careful not to damage the outboard joint
boot.
• Be careful not to damage the speed sensor
rotor.
• Do not excessively push the front axle
assembly.

DS 4. CONNECT TIE ROD END SUB-ASSEMBLY

(a) Connect the tie rod end to the steering knuckle with
the nut.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned,
tighten the nut an additional 60°.
5. CONNECT FRONT NO. 1 SUSPENSION LOWER ARM
SUB-ASSEMBLY
(a) Connect the front suspension lower arm to the
steering knuckle with the nut.
Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf)
(b) Install a new clip.
NOTICE:
If the holes for the clip are not aligned, tighten
the nut an additional 60°.
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–15

6. CONNECT FRONT STABILIZER BAR

(a) Connect the front stabilizer bar with the 2 cushion
retainers, 2 cushions and nut, as shown in the
illustration.
NOTICE:
Be sure to install the cushion and retainer in the
correct direction.
(b) Hold the bolt with a wrench and install the nut.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
D027679E01

7. INSTALL FRONT SPEED SENSOR

LH (a) Install the speed sensor and flexible hose on the
shock absorber with the bolt and clip.
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
HINT:
The positions of the bolt and clip on the right side
differ from those of the left side.

RH

F045754E01

(b) Install the speed sensor on the steering knuckle with

the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
NOTICE: DS
• Be careful not to damage the speed sensor.
• Keep the speed sensor clean.
• Do not twist the sensor wire when installing
the speed sensor.

C057827E01

8. INSTALL FRONT AXLE HUB NUT

(a) Install a new hub nut.
Torque: 216 N*m (2,200 kgf*cm, 159 ft.*lbf)
(b) Using a chisel and hammer, stake the hub nut.
9. INSTALL ENGINE UNDER COVER LH
10. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
11. ADD MANUAL TRANSAXLE OIL (for Manual
C057566E01
Transaxle)
 DS–16 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

12. INSPECT AND ADJUST MANUAL TRANSAXLE OIL

LEVEL (for Manual Transaxle)
(a) Inspect and adjust the manual transaxle oil level
(see page MX-2).
13. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic
Transaxle)
14. INSPECT AND ADJUST AUTOMATIC TRANSAXLE
FLUID (for Automatic Transaxle)
(a) Inspect and adjust the automatic transaxle fluid (see
page AX-82).
15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-2).
16. CHECK ABS SPEED SENSOR SIGNAL
(a) Check the ABS speed sensor signal (see page BC-
5).

DS
 DS–2 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY

FRONT DRIVE SHAFT ASSEMBLY

DRIVE SHAFT
LINE

COMPONENTS
FRONT DRIVE SHAFT ASSEMBLY RH

FRONT DRIVE INBOARD

JOINT HOLE SNAP RING

FRONT DRIVE SHAFT

ASSEMBLY LH

8.0 (82, 71 in.*lbf)

FRONT SPEED SENSOR

FLEXIBLE HOSE

29 (300, 22)

TIE ROD END SUB-ASSEMBLY

18 (184, 13)
COTTER PIN

NO. 1 CUSHION
RETAINER 49 (500, 36)

DS CUSHION

216 (2,200, 159)

FRONT STABILIZER BAR
FRONT AXLE HUB NUT
CUSHION

NO. 1 CUSHION RETAINER 98 (1,000, 72)

CLIP

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part FRONT NO. 1 SUSPENSION LOWER ARM SUB-ASSEMBLY

C118311E01
 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–3

FRONT DRIVE SHAFT OUTBOARD JOINT SHAFT ASSEMBLY

FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

FRONT AXLE OUTBOARD

JOINT BOOT CLAMP
Supply Parts

Supply Parts

FRONT AXLE OUTBOARD JOINT BOOT

RH DRIVE SHAFT DAMPER

SETTING CLAMP

FRONT DRIVE
SHAFT DAMPER RH

FRONT AXLE INBOARD JOINT BOOT CLAMP

FRONT DRIVE SHAFT INBOARD JOINT BOOT

FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

DS
INNER SHAFT SNAP RING

TRIPOD JOINT ASSEMBLY

FRONT DRIVE INBOARD JOINT ASSEMBLY

Non-reusable part FRONT DRIVE SHAFT DUST COVER

C118312E01