Front Driveshaft Disassembly and Reassembly (Except K20C1)

Front Driveshaft Disassembly and Reassembly

Special Tools Required

Image	Description/Tool Number
	Pilot, 20 mm 07746-0040500
	Driver Handle, 15 x 135L 07749-0010000
	Threaded Adapter, 22 x 1.5 mm 07XAC-001010A
	Threaded Adapter, 24 x 1.5 mm 07XAC-001020A

NOTE:

Where icon is shown, click for further information.

The following illustrations are examples only. The appearance and structure of the actual parts may vary depending on the model.

Be careful not to damage the boot.

Make marks on the disassembled parts to be able to reassemble them in their original positions.

Unless otherwise indicated, illustrations used in the procedure are for the left driveshaft.

Driveshaft Type 1

	Detailed information, notes, and precautions
	Replace
*1	These parts have inspection items.
*2	Right driveshaft (With intermediate shaft)
*3	Left driveshaft and Right driveshaft (Without intermediate shaft)

Driveshaft Type 2

	Detailed information, notes, and precautions
	Replace
*1	These parts have inspection items.
*2	Right driveshaft

1.	Boot Band - Remove

Ear Clamp Type

Low Profile Type 1

Low Profile Type 2

2.	Outboard Joint - Remove

Slide the outboard boot (A) partially toward the inboard joint side.

Wipe off the grease to expose the driveshaft and the outboard joint inner race.

Make a mark (A) on the driveshaft (B) at the same level as the outboard joint end (C).

Securely clamp the driveshaft in a bench vise with a shop towel wrapped around the driveshaft.

Remove the outboard joint (A) using the 24 x 1.5 mm threaded adapter (24 mm spindle nut), 22 x 1.5 mm threaded adapter (22 mm spindle nut) and a commercially available 5/8''-18 UNF slide hammer (B).

NOTE: Check inside of the outboard joint and on the serrations for wear and tear.

Remove the driveshaft from the bench vise.

3.	Stop Ring - Remove

4.	Outboard Boot - Remove

NOTE:

Check the outboard boot (A) for cracks and damage. If any damage is found, replace the boot.

Wrap the splines on the driveshaft (B) with vinyl tape (C) to prevent damaging the outboard boot.

5.	Inboard Joint - Remove

Make marks (A) on each roller (B) and the inboard joint (C) to identify the locations of the rollers to the grooves in the inboard joint.

NOTE: Do not engrave or scribe any marks on the rolling surface.

Remove the inboard joint on a clean shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.

NOTE: Check inside of the inboard joint and on the serrations for wear and tear.

6.	Inboard Boot Adapter - Remove (Driveshaft Type 1)

7.	Circlip - Remove (Driveshaft Type 1)

8.	Spider - Remove (Driveshaft Type 1)

Make marks (A) on the spider (B) and the driveshaft (C) to identify the position of the spider on the shaft.

Remove the spider.

NOTE: If necessary, use a commercially available bearing puller while being careful not to damage the spider.

9.	Spider - Remove (Driveshaft Type 2)

Make a mark (A) on the driveshaft (B) at the same level as the spider end.

Make marks (C) on the spider (D) and the driveshaft to identify the position of the spider on the shaft.

Support the roller of the spider (A) seated on wood blocks (B) on a bench vise (C).

Remove the driveshaft (D) from the spider using the 20 mm pilot and the 15 x 135L driver handle.

NOTE:

Be careful not to damage the rollers.

Do not directly hit the driveshaft with the hammer.

10.	Stop Ring - Remove (Driveshaft Type 2)

11.	Inboard Boot - Remove

NOTE:

Check the inboard boot (A) for cracks and damage. If any damage is found, replace the boot.

Wrap the splines on the driveshaft (B) with vinyl tape (C) to prevent damaging the inboard boot.

NOTE:

Where icon is shown, click for further information.

The following illustrations are examples only. The appearance and structure of the actual parts may vary depending on the model.

Make marks on the disassembled parts to be able to reassemble them in their original positions.

Be careful not to damage the boot.

Use the grease included in the inboard/outboard boot set.

Be careful not to get grease on the boots attachment grooves.

Unless otherwise indicated, illustrations used in the procedure are for the left driveshaft.

Driveshaft Type 1

	Detailed information, notes, and precautions
	Replace
*1	These parts have inspection items.
*2	Right driveshaft (With intermediate shaft)
*3	Left driveshaft and Right driveshaft (Without intermediate shaft)

Driveshaft Type 2

	Detailed information, notes, and precautions
	Replace
*1	These parts have inspection items.
*2	Right driveshaft

1.	Outboard Boot - Install

NOTE:

Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the outboard boot (C).

Install the ear clamp bands (D) with the boot to prevent damaging the bands.

2.	Stop Ring - Install

3.	Outboard Joint - Install

Fill grease through the driveshaft hole in the outboard joint before installing the driveshaft.
Inject enough grease so that it seeps out from the gap around the bearing when the driveshaft is inserted.

NOTE: If you are installing a new outboard joint, the grease is already installed.

Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.

To completely seat the outboard joint, pick up the driveshaft and the joint, and tap or hit the assembly onto a hard surface from a height of about 10 cm (3.9 in).

NOTE: Do not use a hammer, as excessive force may damage the driveshaft. Be careful not to damage the threaded section (A) of the outboard joint.

Check the alignment of the paint mark (A) you made with the outboard joint end (B).

To avoid driveshaft and vehicle damage, the shaft must be all the way into the outboard joint to ensure the stop ring is properly seated.

Pack the outboard joint (A) with the remaining joint grease included in the outboard boot set.

Total grease quantity Outboard joint:
M/T (1.5 L engine)^*1	110?130 g (3.88?4.59 oz)
M/T (2.0 L engine)^*1	120?140 g (4.23?4.94 oz)
CVT (1.5 L engine 2/4-door)^*1	120?140 g (4.23?4.94 oz)
CVT (1.5 L engine 4-door)^*2	105?115 g (3.70?4.06 oz)
CVT (1.5 L engine 5-door)^*1	88?108 g (3.10?3.81 oz)
CVT (2.0 L engine)^*1	85?105 g (3.00?3.70 oz)

*1: Driveshaft Type 1
*2: Driveshaft Type 2

Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C).

Bleed any excess air from the boot by inserting a flat-tipped screwdriver between the boot and the joint.

4.	Inboard Boot - Install

NOTE:

Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the inboard boot (C).

Install the ear clamp bands (D) with the boot to prevent damaging the bands.

5.	Spider - Install (Driveshaft Type 1)

Install the spider (A) onto the driveshaft (B) by aligning the marks (C) you made on the spider and the end of the driveshaft.

6.	Circlip - Install (Driveshaft Type 1)

7.	Inboard Boot Adapter - Install (Driveshaft Type 1)

8.	Stop Ring - Install (Driveshaft Type 2)

9.	Spider - Install (Driveshaft Type 2)

Insert the driveshaft (A) into the spider (B) until the stop ring (C) is close to the spider.

NOTE: Install the spider onto the driveshaft by aligning the marks (D) you made on the spider and the end of the driveshaft.

Press the spider (A) using commercially available socket (B) and the press.

Check the alignment of the paint mark (A) you made with the spider end.

To avoid driveshaft and vehicle damage, the shaft must be all the way into the spider to ensure the stop ring is properly seated.

10.	Inboard Joint - Install

Pack the inboard joint with the joint grease included in the new inboard boot set.

Total grease quantity Inboard joint:
M/T (1.5 L engine)^*1	137?157 g (4.83?5.54 oz)
M/T (2.0 L engine)^*1	115?135 g (4.06?4.76 oz)
CVT (1.5 L engine 2/4-door)^*1	115?135 g (4.06?4.76 oz)
CVT (1.5 L engine 4-door)^*2	100?110 g (3.53?3.88 oz)
CVT (1.5 L engine 5-door)^*1	110?130 g (3.88?4.59 oz)
CVT (2.0 L engine) Left^*1	120?130 g (4.23?4.59 oz)
CVT (2.0 L engine) Right^*1	125?135 g (4.41?4.76 oz)

*1: Driveshaft Type 1
*2: Driveshaft Type 2

Fit the inboard joint onto the driveshaft, and note these items:

Reinstall the inboard joint onto the driveshaft by aligning the marks (A) you made on the inboard joint and the rollers.

Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.

Fit the boot ends (A) onto the driveshaft (B) and the inboard boot adapter (Driveshaft type 1) (C)/inboard joint (Driveshaft type 2) (D).

Bleed excess air from the boots by inserting a flat-tipped screwdriver between the boot and the joint.

11.	Boot Band - Install

Ear Clamp Type

Close the ear portion (A) of the band using a commercially available boot band clamp tool (Kent-Moore J-35910 or equivalent) (B).

Check the clearance (C) and length (D) between the closed ear portions of the band. If the clearance is not within the standard, close the ear portion of the band tighter.

NOTE: Replace the ear clamp band with a new one when the ear portion exceeds the prescribed clearance/length.

Ear position	Small band	Large band
C^*1	0.7?3.5 mm (0.028?0.138 in)	1.0?3.6 mm (0.039?0.142 in)
D^*1	8.0 mm (0.315 in) max.	8.4 mm (0.331 in) max.
C^*2	3.0 mm (0.118 in) max.	3.0 mm (0.118 in) max.
D^*2	6.0 mm (0.236 in) max.	6.0 mm (0.236 in) max.

*1: Driveshaft Type 1
*2: Driveshaft Type 2

Low Profile Type 1

Install a low profile type 1 band (A) onto the boot (B), than hook the tab (C) of the band.

Close the hook portion of the band using commercially available CV Boot Clamp Pliers (30500) (D), then hook the tabs of the band.

Low Profile Type 2

Install a low profile type 2 band (A) onto the boot (B).

Close the hook portion of the band using commercially available clamp pincer SPX 14100134 (C), then hook the tabs (D) of the band.

NOTE:

Close the low profile type 2 band slowly until a click sound is made.

No further closure movement should be made after the click sound or a leak will occur.

Normal condition

Abnormal condition

Make sure that the band is tightened securely.

NOTE:

If the tip of the tab (A) is not shown as indicated, replace the low profile type 2 band, then repeat steps 1 through 3.

Do not reuse the removed low profile type 2 band.

1.	Stop Ring - Inspect

To avoid driveshaft and vehicle damage, make sure you install a new stop ring.

Stop ring specifications	Overall diameter (A)	Wire diameter (B)
M/T (1.5 L engine)^*1	29.80 mm (1.1732 in)	1.8 mm (0.071 in)
M/T (2.0 L engine)^*1	24.30 mm (0.9567 in)	1.6 mm (0.063 in)
CVT (1.5 L engine)^*1	24.30 mm (0.9567 in)	1.6 mm (0.063 in)
CVT (1.5 L engine)^*2	26.45 mm (1.0413 in)	2.0 mm (0.079 in)
CVT (2.0 L engine)^*1	25.35 mm (0.9980 in)	1.6 mm (0.063 in)

*1: Driveshaft Type 1
*2: Driveshaft Type 2

2.	Driveshaft Length - Adjust

Adjust the length (A) of the driveshafts in the figure as shown.

Driveshaft length:

	Left/Right driveshaft	Specified length (A)
M/T (1.5 L engine)^*1	Left	547.07?552.07 mm (21.5381?21.7350 in)
M/T (1.5 L engine)^*1	Right	501.60?506.60 mm (19.7480?19.9448 in)
M/T (2.0 L engine)^*1	Left	523.59?528.59 mm (20.6137?20.8106 in)
M/T (2.0 L engine)^*1	Right	447.16?452.16 mm (17.6047?17.8015 in)
CVT (1.5 L engine)^*1	Left	571.86?576.86 mm (22.5141?22.7110 in)
CVT (1.5 L engine)^*1	Right	505.89?510.89 mm (19.9169?20.1137 in)
CVT (1.5 L engine)^*2	Left	574.00?579.00 mm (22.5984?22.7952 in)
CVT (1.5 L engine)^*2	Right	509.50?514.50 mm (20.0590?20.2559 in)
CVT (2.0 L engine)^*1	Left	528.62?533.62 mm (20.8118?21.0086 in)
CVT (2.0 L engine)^*1	Right	822.50?827.50 mm (32.3818?32.5787 in)

*1: Driveshaft Type 1
*2: Driveshaft Type 2

Adjust the boots to halfway between full compression and full extension.

NOTE: Install the joints at exactly the same length.