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Front Wheel Drive Shaft Outer Joint and Boot Replacement > < Front Wheel Drive Intermediate Shaft Bearing Replacement

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Front Wheel Drive Shaft and Intermediate Shaft Assembly Replacement - Right Side (1.7L Diesel)

Special Tools

•  EN-956-1   Extension
•  CH-49376   Holding Wrench
•  CH-49400   Hub Spindle Remover
•  DT-6332   Seal Protector

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.

Caution: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

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3. Using the CH-49376   wrench (1) with EN-956-1   extension (2).

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4. Remove and DISCARD the wheel drive shaft nut (2) from the wheel drive shaft (1).

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5. Using the CH-49400   remover (2), separate the brake rotor and wheel bearing/hub assembly (1).
6. Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .
7. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement .

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8. Remove the 3 bolts (1) from the intermediate flange.
9. Remove the wheel drive shaft and intermediate shaft assembly (2) through bracket.
10. If necessary replace inner joint and boot. Refer to Front Wheel Drive Shaft Inner Joint and Boot Replacement , otherwise discard complete assembly.

Installation Procedure


Note:  It is not possible to install the intermediate shaft bearing after the bonding is made.
1. Replace intermediate shaft bearing. Refer to Front Wheel Drive Intermediate Shaft Bearing Replacement .

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2. Replace retaining ring (1).
3. Replace O-ring (2).
4. Clean the mating faces of the intermediate shaft and the drive shaft with solvent.

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5. Apply Loctite 262 only to the drive shaft in the position shown (1). Container and brush have to be free from metal if used more than once.
6. Assemble drive shaft and intermediate shaft.
  The bonding process takes 12 hours at room temperature. Let the bonding age either prior reinstallation into the car or after reinstallation. The car must not be driven or moved during the aging/bonding. The completed car may be pushed to a parking place (for aging).

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7. Install the DT-6332   protector into the differential output shaft seal.

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8. Carefully install the intermediate shaft assembly (2) into the differential until the splines are past the DT-6332   protector
9. Remove the DT-6332   protector from the differential output shaft seal. Install the intermediate shaft assembly (2) into the differential until it is fully seated.

Caution: Refer to Fastener Caution .
10. Install the 3 bolts to the intermediate flange and tighten to 22 N·m (16 lb ft) .
11. Install the front wheel drive shaft into the front wheel bearing/hub.
12. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement .
13. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .
Warning:  Refer to Torque-to-Yield Fastener Warning .

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14. Install the NEW wheel drive shaft nut (2) on the wheel drive shaft (1) in 3 passes.

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15. Using the CH-49376   wrench (1) with EN-956-1   extension (2).
  •  Using a torque wrench and the appropriate size socket (1), tighten the wheel drive shaft nut (2) to 150 N·m 111 (lb ft) .
  •  Release the wheel drive shaft nut (2) trough 45° .
  •  Retighten the wheel drive shaft nut (2) to 250 N·m 184 (lb ft) .
16. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
17. Lower the vehicle.
18. Inspect the transaxle fluid level. Refer to Transmission Fluid Level Inspection .

Front Wheel Drive Shaft Outer Joint and Boot Replacement > < Front Wheel Drive Intermediate Shaft Bearing Replacement