Drive Shaft & Axle

Workshop Manual
1996 - 2000
http://www.hmaservice.com/viewer/content.asp?vehicletype=Pass...HY%5ERD13%5E1998%5Eall%5E0%5Enone%5Enone%5E34577%5Eshop%5E%24
SPECIFICATIONS
Drive shaft
Joint type 1.8 M/T 1.8 A/T

a.Outer a.B.J. a.B.J.
b.Inner b.D.O.J. b.T.J.
Length (Joint to joint) mm (in.) - -

a.Left a.399 (15.70) a.398.1 (15.67)
b.Right b.654 (26.93) b.679.1 (26.74)
Maximum permissible joint angle - -

a.B.J. a.45.3° or more^ a.45° or more^
b.D.O.J. b.22° or more b.--
c.T.J. c.-- c.23° or more
B.J.: Birfield joint

D.O.J.: Double offset joint
T.J.: Tripod joint
http://www.hmaservice.com/viewer/content.asp?vehicle...%5E1998%5Eall%5E0%5Enone%5Enone%5E34577%5Eshop%5E%2412/03/2009 3:23:11 PM
SPECIFICATIONS
Drive shaft
Joint type 1.8 M/T 1.8 A/T

a.Outer a.B.J. a.B.J.
b.Inner b.D.O.J. b.T.J.
Length (Joint to joint) mm (in.) - -

a.Left a.399 (15.70) a.398.1 (15.67)
b.Right b.684 (26.93) b.679.1 (26.74)
Maximum permissible joint angle - -

a.B.J. a.45.3° or more a.45° or more
b.D.O.J. b.22° or more b.--
c.T.J. c.-- c.23° or more
B.J.: Birfield joint

D.O.J.: Double offset joint
T.J.: Tripod joint
COMPONENTS
INSPECTION
a.Check the drive shaft boots for damage and deterioration.
b.Check the ball joints for wear and operating condition.
c.Check the splines for wear and damage.
REMOVAL
1. Lift up the vehicle and remove the tires.
2. Remove the drive shaft nuts from the front hubs.
3. Remove the lower arm ball joint from the knuckle.
Be sure to tie the cord of the special tool to a nearby part.
4. Detach the tie rod end ball joint connection.

5. Remove the stabilizer bar self locking nut and stabilizer bar connection.
6. Drain the transaxle fluid.
7. Insert a pry bar between the transaxle case and joint case (T.J or D.O.J), and pry the drive shaft from the
transaxle case.
a.Be sure to apply the pry bar to the rib of the transaxle case.
b.Do not insert the pry bar too deep, as this may cause damage to the oil seal. [max. depth:].
http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34589%5Eshop%5E%24 (1 of 2)12/03/2009 3:29:52 PM

8. Pull out the drive shaft from the transaxle case.

a.Place a shop towel in the hole of the transaxle case.
b.Properly support the drive shaft.
c.Replace the retainer ring each time the drive shaft is removed from the transaxle case.
For Auto Transaxle Type

1. Insert a pry bar into the groove of the drive shaft to remove the drive shaft from the transaxle.
Do not pull on the drive shaft; doing so will damage the D.O.J. Use the pry bar.
2. Using special tool (09526-11001) force the drive shaft out of the hub.
When the drive shaft is forced out, keep the spacer from falling out of place.

ASSEMBLY
1. Wrap tape around the drive shaft splines (T.J side) to prevent damage to the boots.
2. Apply grease to the drive shaft and install the boots.
3. To install the dynamic damper, keep the B.J. and shaft in a straight line and secure the dynamic damper in the
direction as shown in the illustration and install the small boot band.
4. Apply grease into the T.J. boot and install the boot.
5. Tighten the T.J boot bands.

6. Add to the B.J. as much specified grease as was wiped away at the time of inspection.
7. Install the boots.
8. Tighten the B.J. boot bands.
9. To control the air in the T.J. boot, keep the specified distance between the boot bands when they are tightened.
10. Tighten the following parts to the specified torque.
11. Install a new retainer ring each time the drive shaft is removed from the transaxle.

12. Install the washer under the drive shaft nut as shown in the illustration.

ASSEMBLY
1. Wrap tape around the drive shaft splines (D.O.J side) to prevent damage to the boots.
2. Apply grease to the drive shaft and install the boots.
3. Apply the specified grease to the inner race and cage. Install the cage so that it is offset on the race as shown.
Use the grease included in the repair kit.
4. Apply the specified grease to the cage and fit the balls into the cage.
5. Install the chamfered side as shown, and then install the inner race onto the drive shaft, and install the snap
ring.

6. Apply 60±3 gr. (2.1±0.1 oz.) of specified grease to the outer race and install the outer race onto the drive shaft.
7. Apply 40±3 gr. (1.4±0.1 oz.) of specified grease into the D.O.J. boot and install the boot.
8. Tighten the D.O.J boot bands.
9. Add to the B.J. as much specified grease as was wiped away at the time of inspection.
10. Install the boots.
11. Tighten the B.J. boot bands.
12. To control the air in the D.O.J. boot, keep the specified distance between the boot bands when they are
tightened.

Components (D.O.J-B.J TYPE)

DRIVE SHAFT (D.O.J-B.J)
Kit name Illustration Contents

Double offset joint kit a.Clip (Retainer ring)

b.D.O. J assy
c.Circlip
d.D.O.J boot
e.Snap ring
f.D.O.J boot band
g.Boot band
h.Grease
Double offset joint boot kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot
e.D.O.J boot band
f.Boot band
g.Grease
Birfield joint and shaft kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot bands
f.B.J boot band
g.B.J boot
h.B.J assy
i.Dust cover
j.Grease
Birfield joint boot kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot bands
f.B.J boot band
g.B.J boot
h.Grease

Damper kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot band
f.Dynamic damper band
g.Dynamic damper
h.grease

Components (DOJ-BJ TYPE)

DRIVE SHAFT (DOJ-BJ)

Double offset joint kit a.Clip (Retainer ring)

b.D.O. J assy
c.Circlip
d.D.O.J boot
e.Snap ring
f.D.O.J boot band
g.Boot band
h.Grease
Double offset joint boot kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot
e.D.O.J boot band
f.Boot band
g.Grease
Birfield joint and shaft kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot bands
f.B.J boot band
g.B.J boot
h.B.J assy
i.Dust cover
j.Grease
Birfield joint boot kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot bands
f.B.J boot band
g.B.J boot
h.Grease

Damper kit a.Clip (Retainer ring)

b.Circlip
c.Snap ring
d.D.O.J boot band
e.Boot band
f.Dynamic damper band
g.Dynamic damper
h.grease

Purchased
from Ebay seller
Reveleus1
Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
COMPONENTS (T.J. - B.J. Type)

T.J. boot kit a.Cirlip

b.Snap ring
c.T.J. boot band
d.Boot band
e.Grease
T.J. joint kit a.Circlip

b.Snap ring
c.T.J. boot band
d.Boot band
e.Dynamic damper band
f.Boot band
g.B.J. boot
h.Grease
B.J. boot kit a.Circlip

b.T.J. case
c.Spider assembly
d.T.J. boot
e.T.J. boot band
f.Boot band
g.Grease
B.J. joint and shaft kit a.Circlip

b.Snap ring
c.T.J boot band
d.Boot band
f.Boot band
g.B.J. boot
h.Grease

Damper kit a.Circlip

b.Snap ring
c.T.J. boot band
d.Boot bands
f.Dynamic damper
g.grease

DISASSEMBLY
1. Do not disassemble the B.J. assembly. The drive shaft joint uses special grease. Do not substitute another
type of grease. The boot band should be replaced with a new one. Remove the D.O.J. boot bands and pull the
D.O.J boot from the D.O.J outer race.
Be careful not to damage the boot.
2. Remove the circlip with a flat-blade screwdriver.
3. Pull out the drive shaft from the D.O.J outer race.

4. Remove the snap ring and take out the inner race, cage and balls as an assembly.
5. Clean the inner race, cage and balls without disassembling.

6. Remove the B.J boot bands and pull out the D.O.J boot and B.J boot.
If the boot is to be reused, wrap tape around the D.O.J. boot and B.J. boot.

INSPECTION AFTER DISASSEMBLY

1. Check the drive shaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into B.J.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside T.J. case for wear or corrosion.
5. Check the dynamic damper for damage or cracking.
COMPONENTS
DISASSEMBLY
1. Remove the snap ring.
2. Attach the special tools to the knuckle and hub.
3. Secure the knuckle in a vise.

4. Tighten the nut of the special tool and remove the hub from the knuckle.
When removing wheel hub or wheel bearing from knuckle, replace wheel bearing assembly (outer race, inner
races and grease seals) with a new one.
5. Using the special tool, remove the wheel bearing inner race (outside) from the front hub.

6. Install the inner race (outside) that was removed from the hub to the wheel bearing, and then use the special
tool to remove the wheel bearing.

REASSEMBLY
1. Fill the wheel bearing with multipurpose grease.
2. Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces.
3. Use the special tool to press in the bearing.
Do not press inner race of wheel bearing assembly.
4. Install snap ring into groove of knuckle.

5. Measure the hub bearing starting torque.
6. If the starting torque is, measure the hub bearing axial play.
7. If the hub axial play exceeds the limit while the nut is tightened to, the bearing, hub and knuckle have not been
installed correctly. Repeat the disassembly and assembly procedure.
8. Remove the special tool.
INSTALLATION
1. Install parts to the torque specifications.
2. Be sure to install the washer and wheel bearing nut in the specified direction.
3. After installing the wheel, lower the vehicle to the ground and tighten the wheel bearing nut.
4. If the position of the split pin holes does not match, tighten the nut up tomaximum.
5. Install the split pin in the first matching holes and bend it over.

REMOVAL
Before removing the front axle assembly, disconnect the ABS wheel sensor from the assembly and move it away
from the front axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor
becoming inoperative.
Remove the drive shaft nut. Jack up the vehicle and support it with jack stands. Remove the wheel and tire.
Remove the front brake assembly from the knuckle and suspend with a wire.
Brake hose does not need to be disconnected from brake caliper. Be careful not do depress brake pedal, or
piston will pop out.
Disconnect the lower arm ball joint from the knuckle using the special tool.
1. Using the special tool, remove the drive shaft nut.

2. Disconnect the tie rod and ball joint from the knuckle using the special tool.
a.Be sure to tie a cord to the special tool and to a nearby part.
b.Loosen the nut, but do not remove it.
3. Disconnect the drive shaft from the hub using the special tool.
4. Remove the hub and knuckle as an assembly from the strut.


LUBRICANTS
D.O.J.- B.J. type drive shaft(For 1.8 M/T)
Recommended lubricants Quantity

B.J. boot grease CENTOPLEX 278M/136K 110±6gr.
(Joint: 55±3 gr., Boot: 55±3 gr.)
D.O.J. boot grease AMBLYGON TA 10/2A 100±6 gr.
(Joint: 60±3 gr., Boot: 40±3 gr.)
T.J. - B.J. type drive shaft (For 1.8 A/T)
Recommended lubricants Quantity

B.J. boot grease CENTOPLEX 278M/136K 110±6gr.
(Joint: 55±3 gr., Boot: 55±3 gr.)
T.J. boot grease KLK TJ41-182 (MS511-50 KOREA KLUBER) 120±6 gr.
(Joint: 75±3 gr., Boot: 45±3 gr.)
SPECIAL TOOLS
Tool (Number and Name) Illustration Use

09500-21000Bar Removal of front wheel
bearing.
09517-21000Hub bearing Removal of front wheel

remover bearing. (Use with 09500-
21000.)
09216-21300Hub bearing Installation of front wheel

installer bearing.
09495-33000Puller Removal of the front

wheel bearing inner race.
09517-21500Front hub remover Removal & installation of

and installer the front hub. (Use with
09517-29000.)

09517-29000Knuckle arm bridge Removal of the front

hub. (Use with 09517-
21500.)
09532-11600Pre-load socket Measuring of front wheel

bearing preload. (Use
with 09517-21500, 30
mm socket and torque
wrench.)
09526-11001Axle shaft puller Removal of the drive

shaft from the front hub.
09568-34000Ball joint remover Removal of the front

lower arm ball joint and
tie rod end ball joint.

TROUBLESHOOTING
Symptom Probable cause Remedy

Vehicle pulls to one side Scoring of drive shaft ball joint Replace
Wear, rattle or scoring wheel bearing Replace
Defective front suspension and steering Adjust or replace
Vibration Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Wear, rattle or sintering of wheel bearing Replace
Shimmy Defective wheel balance Adjust or replace
Excessive noise Wear, damage or bending of drive shaft Replace
Rattle of drive shaft and hub serration Replace
Rattle of drive shaft and side gear serration Replace
Wear, rattle of scoring of wheel bearing Replace
Loose hub nut Adjust or replace
Bent cage Cage damage due to improper handling or Replace bearing

tool usage
Galling Metal smears on roller end due to Check seals, check for proper
overheating, lubricant problem or lubrication
overloading
Cracked inner race Race cracked due to improper fit, cooking or Replace bearing
poor bearing seats
Etching Bearing surfaces appear gray or grayish Replace bearing

black in color with related etching away of
material usually at roller spacing
Brinelling Surface indentations on race surface Check seals, check for proper
caused by rollers either under impact lubrication
loading or vibration while the bearing is not
rotating

Heat discoloration Heat discoloration is dark blue resulting Replace bearing

from overload or no lubricant (Yellow or Check seals and other parts
brown color is normal)
Fatigue spalling Flaking of surface metal resulting from Replace bearing

fatigue Clean all related parts

Drive Shaft &amp; Axle

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Drive Shaft &amp; Axle

Uploaded by

Copyright:

Available Formats

Workshop Manual

Joint type 1.8 M/T 1.8 A/T

Length (Joint to joint) mm (in.) - -

Maximum permissible joint angle - -

B.J.: Birfield joint

Joint type 1.8 M/T 1.8 A/T

Length (Joint to joint) mm (in.) - -

Maximum permissible joint angle - -

B.J.: Birfield joint

4. Detach the tie rod end ball joint connection.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34589%5Eshop%5E%24 (1 of 2)12/03/2009 3:29:52 PM

8. Pull out the drive shaft from the transaxle case.

For Auto Transaxle Type

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34589%5Eshop%5E%24 (2 of 2)12/03/2009 3:29:52 PM

5. Tighten the T.J boot bands.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34604%5Eshop%5E%24 (1 of 2)12/03/2009 3:30:21 PM

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34604%5Eshop%5E%24 (2 of 2)12/03/2009 3:30:21 PM

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34592%5Eshop%5E%24 (1 of 2)12/03/2009 3:30:39 PM

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34592%5Eshop%5E%24 (2 of 2)12/03/2009 3:30:39 PM

Components (D.O.J-B.J TYPE)

Kit name Illustration Contents

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33941%5Eshop%5E%24 (1 of 3)12/03/2009 3:30:58 PM

Double offset joint kit a.Clip (Retainer ring)

Double offset joint boot kit a.Clip (Retainer ring)

Birfield joint and shaft kit a.Clip (Retainer ring)

Birfield joint boot kit a.Clip (Retainer ring)

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33941%5Eshop%5E%24 (2 of 3)12/03/2009 3:30:58 PM

Damper kit a.Clip (Retainer ring)

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33941%5Eshop%5E%24 (3 of 3)12/03/2009 3:30:58 PM

Components (DOJ-BJ TYPE)

Kit name Illustration Contents

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36115%5Eshop%5E%24 (1 of 3)12/03/2009 3:31:20 PM

Double offset joint kit a.Clip (Retainer ring)

Double offset joint boot kit a.Clip (Retainer ring)

Birfield joint and shaft kit a.Clip (Retainer ring)

Birfield joint boot kit a.Clip (Retainer ring)

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36115%5Eshop%5E%24 (2 of 3)12/03/2009 3:31:20 PM

Damper kit a.Clip (Retainer ring)

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36115%5Eshop%5E%24 (3 of 3)12/03/2009 3:31:20 PM

Thank-you for purchasing from me, it

COMPONENTS (T.J. - B.J. Type)

Kit name Illustration Contents

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34595%5Eshop%5E%24 (1 of 3)12/03/2009 3:31:34 PM

T.J. boot kit a.Cirlip

T.J. joint kit a.Circlip

B.J. boot kit a.Circlip

B.J. joint and shaft kit a.Circlip

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34595%5Eshop%5E%24 (2 of 3)12/03/2009 3:31:34 PM

Damper kit a.Circlip

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34595%5Eshop%5E%24 (3 of 3)12/03/2009 3:31:34 PM

2. Remove the circlip with a flat-blade screwdriver.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33942%5Eshop%5E%24 (1 of 2)12/03/2009 3:31:47 PM

5. Clean the inner race, cage and balls without disassembling.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33942%5Eshop%5E%24 (2 of 2)12/03/2009 3:31:47 PM

INSPECTION AFTER DISASSEMBLY

2. Attach the special tools to the knuckle and hub.

3. Secure the knuckle in a vise.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34613%5Eshop%5E%24 (1 of 2)12/03/2009 3:32:54 PM

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34613%5Eshop%5E%24 (2 of 2)12/03/2009 3:32:54 PM

4. Install snap ring into groove of knuckle.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33933%5Eshop%5E%24 (1 of 2)12/03/2009 3:33:13 PM

5. Measure the hub bearing starting torque.

8. Remove the special tool.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E33933%5Eshop%5E%24 (2 of 2)12/03/2009 3:33:13 PM

Drive Shaft & Axle

Drive Shaft & Axle