For 1990-2009 cars

## Wheel Drive Shaft Replacement Diesel - Automatic and Manual

#### Tools Required

• | KM-507-C Ball Joint Remover

• | KM-460-B Axle Shaft Remover

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the wheels. Refer to Tire and Wheel Removal and Installation .
3. Remove the axle shaft caulking nut. Discard the nut.
4. Remove the lower ball joint nut and bolt.

Notice: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal.

5. Separate the steering knuckle from the lower ball joint.
6. Remove the tie rod nut.

Notice: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal.

7. Separate the tie rod end using the KM-507-C (1).

Notice: Refer to Drive Axle Notice in the Preface section.

8. Remove the drive axle from the intermediate axle using the KM-460-B (1).

### Installation Procedure

Important: Do not damage the seals.

1. Clean the hub seal and transaxle seal.
2. Install the drive axle into the intermediate axle shaft.
3. Install the wheel hub onto the axle shaft.
4. Mount the steering knuckle onto the lower ball joint.
5. 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).

6. Install the lower ball joint nut and bolt.

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

7. Loosely install a new axle shaft caulking nut. Always use a new nut.

Tighten
Tighten the axle shaft caulking nut to 320 N·m (236 lb ft).

8. Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
9. Install the wheels. Loosely install the nuts. Refer to Tire and Wheel Removal and Installation .
10. Lower the vehicle to the floor.

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

11. Refill the transaxle fluid to the proper level.

## Wheel Drive Shaft Replacement Gasoline - Automatic Transaxle

#### Tools Required

• | DT 47539 (DW340-110) Axle Shaft Remover

• | KM-507-C Ball Joint Remover

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the wheels. Refer to Tire and Wheel Removal and Installation.
3. Remove the axle shaft caulking nut. Discard the nut.
4. Remove the lower ball joint pinch bolt and 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 of the tie rod end.

5. Separate the steering knuckle from the lower ball joint using the KM-507-C (1).
6. Remove the tie rod nut.
7. Separate the tie rod end using the KM-507-C .
8. Remove the damping block connection nut and bolt.
9. Remove the rear mounting bracket bolts and the bracket.

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.

10. Push the drive axle shaft 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.

11. Remove the drive axle from the transaxle using the DT 47539 (1).

### Installation Procedure

Important: Do not damage the seals.

1. Clean the hub seal and the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the axle shaft.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the rear mounting bracket bolts and the bracket.

Tighten
Tighten the rear mounting bracket bolts to 62 N·m (45 lb ft).

5. Install the damping block connection nut and bolt.

Tighten
Tighten the damping block connection nut and bolt to 68 N·m (50 lb ft).

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

Tighten
Tighten the tie rod nut to 55 N·m (41 lb ft).

7. Install the lower ball joint pinch bolt and nut.

Tighten
Tighten the lower ball joint pinch bolt and nut to 60 N·m (44 lb ft).

8. Loosely install a new axle shaft caulking nut. Always use a new nut.
9. Install the wheels. Loosely install the nuts. Refer to Tire and Wheel Removal and Installation.
10. Lower the vehicle to the floor.
11. Tighten the wheel nuts.

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

12. Tighten the axle shaft caulking nut.

Tighten
Tighten the axle shaft caulking nut to 300 N·m (221 lb ft).

13. Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
14. Refill the transaxle fluid to the proper level. Refer to Transmission Fluid Level Inspection.

## Wheel Drive Shaft Replacement Gasoline - Manual Transaxle

#### Tools Required

• | KM-460-B Axle Shaft Remover

• | KM-507-C Ball Joint Remover

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the wheels. Refer to Tire and Wheel Removal and Installation.
3. Remove the axle shaft caulking nut. Discard the nut.
4. Remove the lower ball joint pinch bolt and nut.
5. Separate the steering knuckle from the lower ball joint using the KM-507-C (1).
6. Remove the tie rod nut.
7. Separate the tie rod end using the KM-507-C .

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.

8. Push the drive axle shaft 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.

9. Remove the drive axle from the transaxle using the KM-460-B (1).

### Installation Procedure

Important: Do not damage the seals.

1. Clean the hub seal and the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the axle shaft.

Notice: Refer to Fastener Notice in the Preface section.

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

Tighten
Tighten the tie rod nut to 55 N·m (41 lb ft).

5. Install the lower ball joint pinch bolt and nut.

Tighten
Tighten the lower ball joint pinch bolt and nut to 60 N·m (44 lb ft).

6. Loosely install a new axle shaft caulking nut. Always use a new nut.
7. Install the wheels. Loosely install the nuts. Refer to Tire and Wheel Removal and Installation.
8. Lower the vehicle to the floor.
9. Install the wheel nuts.

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

10. Tighten the axle shaft caulking nut.

Tighten
Tighten the axle shaft caulking nut to 300 N·m (221 lb ft).

11. Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
12. Refill the transaxle fluid to the proper level. Refer to Transmission Fluid Level Inspection.