Service Manual2005 MANUAL TRANSAXLE DRIVE AXLE

SECTION 3B

MANUAL TRANSAXLE DRIVE AXLE

SPECIFICATIONS

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Axle Shaft Caulking Nut Initial Torque	320	236	-
Lower Ball Joint Nut and Bolt	105	77	-
Tie Rod Nut	50	37	-
Wheel Nuts	100	74	-
Intermediate Axle Shaft Mounting Bolts	52	38	-

SPECIAL TOOLS

Special Tools Table

	J-8059 Snap Ring Pliers
	KM-507-B Ball Joint Separator

	KM-460-A Axle Shaft Remover
	J-35566 Seal Clamp Pliers

COMPONENT LOCATOR

Front Drive Axle

Caulking Nut
C/V Joint
Snap Ring
Axle Shaft (right-hand shown, left-hand similar)
Seal Retaining Clamp
Drive Axle Outboard Seal
Seal Retaining Clamp
Seal Retaining Clamp
Drive Axle Inboard Seal
Seal Retaining Clamp
Tripot Joint Retaining Ring
Tripot Joint
Shaft Retaining Ring
Tripot Housing

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Drive Axle Assembly

Tools Required

KM-507-B Ball Joint Separator

KM-460-A Axle Shaft Remover

Removal Procedure

Raise and suitably support the vehicle.
Remove the wheels. Refer to Section 2E, Tires and Wheels.
Remove the axle shaft caulking nut. Discard the nut.

Remove the lower ball joint nut and bolt.

Notice : Use only the recommended tool for separating the lower ball joint. Failure to use the recommended tool may cause damage to the ball joint and the seal.

Separate the steering knuckle from the lower ball joint.

Remove the tie rod 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.

Separate the tie rod end using the ball joint separator KM-507-B.

Remove the drive axle from the intermediate axle shaft remover KM-460-A.

Push the drive axle shaft from the wheel hub.

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.

Important : Place a drain pan below the transaxle to catch the escaping fluid. Cap the transaxle drive opening after the drive axle has been removed to keep the fluid in and any contamination out.

Remove the intermediate axle shaft mounting bolts and the shaft from the transaxle.

Installation Procedure

Notice : Do not damage the seals.

Clean the hub seal and the transaxle seal.
Install the intermediate axle shaft into the transaxle.

Tighten

Tighten the intermediate axle shaft mounting bolts to 52 N•m (38 lb-ft).

Install the drive axle into the intermediate axle shaft.
Install the wheel hub onto the axle shaft.

Mount the steering knuckle onto the lower ball joint.

Install the tie rod into the knuckle/strut and install the tie rod nut.

Tighten

Tighten the tie rod nut to 50 N•m (37 lb-ft).

Install the lower ball joint nut and bolt.

Tighten

Tighten the lower ball joint nut and bolt to 105 N•m (77 lb-ft).

Loosely install a new axle shaft caulking nut. Always use a new nut.
Tighten the axle shaft caulking nut to 320 N•m (236 lb-ft).
Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
Install the wheels. Loosely install the nuts. Refer to Section 2E, Tires and Wheels.
Lower the vehicle to the floor.

Tighten

Tighten the wheel nuts to 100 N•m (74 lb-ft).

Refill the transaxle fluid to the proper level. Refer to Section 5B, Five-Speed Manual Transaxle.

UNIT REPAIR

Outer Joint Seal

Tools Required

J-8059 Snap Ring Pliers

J-35566 Seal Clamp Pliers

Removal Procedure

Remove the drive axle from the vehicle. Refer to "Drive Axle Assembly" in this section.
Remove the large seal retaining clamp. Discard the clamp.
Remove the small seal retaining clamp. Discard the clamp.

Degrease the joint.
Spread the snap ring using the snap ring pliers J-8059 and remove the outer joint from the axle shaft.

Caution : Do not disassemble the outer joint assembly. Parts are match fit and cannot be serviced separately. Improper reassembly will adversely affect both performance and safety.

Remove the seal from the joint assembly.

Installation Procedure

Install the seal onto the axle shaft.
Spread the snap ring using the snap ring pliers J-8059 and install the outer joint onto the axle shaft.
Fill the joint seal with 200 to 220 g (7.1 to 7.8 ounces) of the recommended grease. Repack the joint with 200 to 220 g (7.1 to 7.8 ounces) of the recommended grease.

Install a new large seal retaining clamp and a new small seal retaining clamp.

Crimp the new small seal retaining clamp and the new large seal retaining clamp using the seal clamp pliers J-35566.
Install the drive axle shaft to the vehicle. Refer to "Drive Axle Assembly" in this section.

Inner Tripot Seal

Tools Required

J-8059 Snap Ring Pliers

J-35566 Seal Clamp Pliers

Removal Procedure

Remove the drive axle from the vehicle. Refer to "Drive Axle Assembly" in this section.
Remove the large seal retaining clamp. Discard the clamp.
Remove the small seal retaining clamp. Discard the clamp.

Pry the tripot joint retaining ring from the tripot housing.

Remove the tripot housing from the seal.

Degrease the tripot assembly.
Remove the shaft retaining ring using the snap ring pliers J-8059.

Remove the tripot and the tripot joint retaining ring from the axle shaft.
Remove the tripot joint seal from the axle shaft.

Installation Procedure

Install a new small seal retaining clamp onto the seal. Do not crimp the seal retaining clamp.
Install the seal onto the axle shaft.
Install the tripot joint retaining ring and the tripot onto the axle shaft.

Install the shaft retaining ring onto the axle shaft using the snap ring pliers J-8059.

Fill the tripot housing with 150 to 170 g (5.3 to 6.0 ounces) of the recommended grease. Repack the tripot with 150 to 170 g (5.3 to 6.0 ounces) of the recommended grease.
Install the tripot housing onto the tripot assembly.

Install the tripot joint retaining ring into the tripot housing.

Install a new large seal retaining clamp. Crimp the large seal retaining clamp using the seal clamp pliers J-35566.
Crimp the new small seal retaining clamp using the seal clamp pliers J-35566.
Install the drive shaft onto the vehicle. Refer to "Drive Axle Assembly" in this section.

GENERAL DESCRIPTION AND SYSTEM OPERATION

Front Drive Axle

General Description

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 flexible and has the ability to move in and out. 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.