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SECTION 3B

MANUAL TRANSAXLE DRIVE AXLE

DESCRIPTION AND OPERATION

FRONT DRIVE AXLE

Drive axles are flexible shaft assemblies that transmit a rotational force from the transaxle to the front wheel assemblies. Each axle assembly consists of an inner constant-velocity joint and an outer constant-velocity joint connected to an axle shaft. The inner joint is completely The outer joint is also flexible, but it cannot move in and out.
The drive axles use a Rzeppa-style joint on the outboard side and a Tripot-style joint on the inboard side.

COMPONENT LOCATOR

DRIVE AXLE ASSEMBLY


D104B401
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  1. Outer Joint (Rzeppa)
  2. Outer Large Boot Clamp
  3. Outer Boot
  4. Outer Small Boot Clamp
  5. Drive Axle Shaft
  6. Inner Small Boot Clamp
  7. Inner Boot
  8. Inner Large Boot Clamp
  9. Inner Joint (Tripot)
  10. Inner Joint Housing

DIAGNOSTIC INFORMATION AND PROCEDURES

Condition
Probable Cause
Correction
Noise
  • Bent drive axle shaft.
  • Replace drive axle.
  • Worn the spline of drive axle shaft or joint shaft.
  • Replace drive axle.
  • Worn joint by grease leakage.
  • Replace drive axle.
Steering Wheel Vibration
  • Bent drive axle shaft.
  • Replace drive axle.
  • Worn the spline of drive axle shaft or joint shaft.
  • Replace drive axle.
Car Lead/Pull
  • Worn joint by grease leakage.
  • Replace drive axle.
Boot Leak
  • Poor assembly of boot clamp.
  • Replace boot clamp.
  • Torn boot.
  • Replace Boot.

REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE



D106B506
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DRIVE AXLE ASSEMBLY

Tools Required

KM-507-B Tie Rod End Joint Remover

Removal Procedure

  1. Remove the drive axle shaft nut.


  2. D103B505
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  3. Remove the wheels. Refer to Section 2E, Tires and Wheels.
  4. Remove the transaxle under cover.


  5. D104B501
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  6. Drain the transaxle fluid through the drain plug.
  7. Remove the stabilizer bar. Refer to Section 2C, Front Suspension.
  8. Separate the control arm ball joint and the tie rod end from the knuckle. Refer to Section 6D, Manual Steering gear and Section 2C, Front Suspension.
  9. a. Control arm ball joint bolt.
    b. Tie rod end joint castellated nut.

    Notice : Use only the recommended tool for separating the tie rod from the knuckle/strut assembly. Failure to use the recommended tool may cause damage to the knuckle/strut assembly or the tie rod end.



    D104B502
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  10. Pull the drive axle shaft (1) from the wheel hub.
  11. Important : Support the unfastened end of the drive axle. Do not allow the drive axle to dangle freely from the transaxle for any length of time after it has been removed from the wheel hub.



    D104B503
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  12. Remove the drive axle from the transaxle.
  13. Important : Cap the transaxle drive opening after the drive axle has been removed to keep any contamination out.



D104B504
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Inspection Procedure

  1. Inspect for worn or damaged spline of drive axle (1).
  2. Inspect for a leaking boot (2).
  3. Inspect for a bent shaft (3).


D14B502A
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Installation Procedure

  1. Clean the transaxle seal.
  2. Install the drive axle into the transaxle.
  3. Install the wheel hub onto the drive axle shaft.
  4. Mount the knuckle onto the control arm ball joint.


  5. D14B505B
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  6. Install the control arm ball joint bolt.
  7. Tighten
    Tighten the control arm ball joint bolt to 50-70 N·m (36-52 lb-ft).

    a. Control arm ball joint bolt
  8. Install the tie rod into the knuckle and install the tie rod end joint castellated nut.
  9. Tighten
    Tighten the tie rod end joint castellated nut to 30-55 N•m (21-41 lb-ft).

    b. Tie rod end joint castellated nut.


    D14B506A
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  10. Install the stabilizer bar.
  11. Tighten
    • Tighten the stabilizer bar mounting bolts 33-53 N·m (24-39 lb-ft).
    • Tighten the stabilizer bar castellated nut to 40-50 N·m (30-36 lb-ft).
    • a. Stabilizer bar mounting bolt.
      b. Stabilizer bar castellated nut.



    D14B507A
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  12. Install the drive axle shaft nut.
  13. Tighten
    Tighten the drive axle shaft nut to 210 N·m (155 lb-ft)

    Notice : Always use a new nut. Always peen the caulking nut with a punch and a hammer until the nut is locked into place on the wheel hub.

  14. Install the wheels. Refer to Section 2E, Tires and wheels.


  15. D13BB520A
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  16. Refill the transaxle fluid to the proper level.
  17. Classification
    75W-85 (GL-4)
    Capacity
    2.1L (2.21 gt)


    D13B521A
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  18. Install the transaxle under cover.
  19. Tighten
    Tighten the transaxle under cover bolts to 35-55 N•m (25-41 lb-ft)

UNIT REPAIR



D104B701
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INNER JOINT (TRANSAXLE SIDE)

Tools Required

J-35566 Boot Clamp Pliers

Disassembly Procedure

  1. Remove the drive axle. Refer to "Drive Axle Assembly" in this section.
  2. Remove the clamps on the joint boot.


  3. D104B702
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  4. Remove the joint housing from boot.
  5. a. Boot.
    b. Joint housing.


    D104B703
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  6. Degrease the joint assembly.
  7. Remove the tripot joint.


  8. D104B704
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  9. Remove the drive axle shaft boot.


D104B705
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Fill the joint housing with recommended grease when installing.
  3. Capacity
    90-100 g (3.2-3.5 ounces)

    Notice : Always use the recommended grease. If not, joint and boot can be damaged.

    Important : Always use new clamps.

Inspection Procedure

  1. Inspect the operation of joint.
  2. Inspect for a leaking boot through the clamp side.


D104B706
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OUTER JOINT (WHEEL SIDE)

Disassembly Procedure

  1. Remove the drive axle. Refer to "Drive Axle Assembly" in this section.
  2. Remove the clamps on the joint boot.


  3. D104B707
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  4. Degrease the joint assembly.
  5. Remove the joint assembly.


  6. D104B704
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  7. Remove the drive axle shaft boot.


D104B708
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Install the joint assembly.


  3. D104B709
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  4. Fill the joint housing with recommended grease when installing.
  5. Capacity
    80-90 g (2.8-3.2 ounces)

    Notice : Always use the recommended grease. If not, joint and boot can be damaged.

    Important : Always use new clamps.



D104B710
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Inspection Procedure

  1. Inspect the operation of joint.
  2. Inspect for a leaking boot through the clamp side.
  3. Important : Do not disassemble the outer joint assembly. Parts are match fit and can not be serviced separately. Improper reassembly will adversely affect both performance and safety.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Drive Axle
Type
Inner
-
Tripot Joint
-
Outer
-
Rzeppa Joint
-
Length
Right
mm (in.)
553.5(21.79)
-
Left
mm (in.)
386.5(15.22)
-
Shaft Diameter
mm(in.)
22(0.87)
-
Grease Capacity
Inner
g(ounce)
90-100 (3.2-3.5)
-
Outer
g(ounce)
80-90 (2.8-3.2)
-

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
Control Arm Ball Joint Bolt
50 - 70
36 - 52
-
Tie Rod End Joint castellated Nut
30 - 55
21 - 41
-
Stabilizer Bar Bolt
33 - 53
24 - 39
-
Stabilizer Bar Castellated Nut
40 - 50
30 - 36
-
Drive Axle Shaft Nut
210
155
-
Wheel Nut
90 - 110
66 - 81
-
Transaxle Under Cover Bolt
35 - 55
25 - 41
-
Oil Drain Plug
25 - 30
18 - 22
-
Oil Level Plug
36 - 54
26 - 40
-

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE


D104B101
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KM-507-B Tie Rod End Joint Remover

D105B101
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J-35566 Boot Clamp Pliers


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