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DRIVE SHAFT (AJ) REMOVAL/INSTALLATION

BME031325500204

  Caution

  • Performing the following procedures without first removing the ABS wheel-speed sensor could cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
  • Removing the right side drive shaft with the shaft bracket installed may cause the deformation of the joint shaft bracket. Therefore, remove or install the right side drive shaft and joint shaft as a component.

1. Drain the transaxle oil.

2. Remove the steering knuckle, wheel hub and dust cover component. (Right side)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

1 | Locknut
2 | Tie-rod end (See Tie-rod End Ball Joint Removal Note.)
3 | Lower arm ball joint (See Lower Arm Ball Joint Removal Note.)
4 | Nut (stabilizer control link)
5 | Drive shaft (left side) (See Drive Shaft (Left Side) Removal Note.) (See Drive Shaft (Left Side) Installation Note.)
6 | Nut (joint shaft bracket)
7 | Drive shaft (right side) and joint shaft (See Drive Shaft (Right Side) and Joint Shaft Removal Note.) (See Drive Shaft (Right Side) and Joint Shaft Installation Note.)
8 | Drive shaft (right side) (See Drive Shaft (Right Side) Removal Note.)
9 | Clip (drive shaft (left side)) (See Clip (Drive Shaft (Left Side)) Installation Note.)
10 | Joint shaft (See Joint Shaft Installation Note.)
11 | Clip (joint shaft) (See Clip Installation Note.)

## Drive Shaft (Left Side) Removal Note

1. Remove the clinch bolt and nut.

2. Wrap a rag around the ball joint dust boot.

3. Pry the lower arm out of the knuckle.

4. Install a spare nut on the drive shaft so that the nut is flush with the end of the drive shaft.

5. Tap the nut with a copper hammer to loosen the drive shaft from the front wheel hub.

6. Separate the drive shaft from the wheel hub.

7. Separate the left side drive shaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle, as shown in the figure.

  Caution

  • The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when removing the drive shaft from the transaxle.

## Drive Shaft (Right Side) and Joint Shaft Removal Note

1. Remove the drive shaft (right side) and joint shaft component.

2. Install the SST (49 G030 455) into the transaxle to hold the side gears after the drive shaft (right side) ad the joint shaft component are removed.

## Drive Shaft (Right Side) Removal Note

1. Secure the shaft portion of the joint shaft in a vise.

2. As shown in the figure, insert a pry bar between the drive shaft and the joint shaft and tap on the bar to uncouple them.

## Joint Shaft Installation Note

1. Secure the shaft portion of the drive shaft in a vise.

2. Install the joint shaft using a plastic hammer as shown in the figure.

## Clip (Drive Shaft (Left Side)) Installation Note

1. Install a new clip on the drive shaft (left side) with the opening facing upward. Ensure that the diameter of the clip does not exceed the specification on installation.

2. After installation, measure the outer diameter. If it exceeds the specification, repeat steps 1-2 using a new clip.

Outer diameter

  32.5-33.2 mm {1.28-1.30 in}

## Drive Shaft (Right Side) and Joint Shaft Installation Note

1. Apply ATF to the oil seal lip.

2. Push the drive shaft and joint shaft into the transaxle.

  Caution

  • The sharp edges of the joint shaft can slice or puncture the oil seal. Be careful when installing the joint shaft to the transaxle.

## Drive Shaft (Left Side) Installation Note

1. Insert the drive shaft into the wheel hub.

2. Apply ATF to the oil seal lip.

3. Push the drive shaft into the transaxle.

  Caution

  • The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the drive shaft to the transaxle.
  • The oil seals are damaged easily if this procedure is not done correctly.

4. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held by the clip.