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Transaxle

D r i v e l i n e / A x l e
Special Tools 16-2
Component Location Index 16-3
Driveshaft Inspection 16-4
Front Driveshaft Removal — 16-4
Front Driveshaft Disassembly 16-6
Front Driveshaft Reassembly 16-10
Front Driveshaft Installation . 16-18
Intermediate Shaft Removal 16-20
Intermediate Shaft Disassembly 16-21
Intermediate Shaft Reassembly 16-23
Intermediate Shaft Installation 16-25
Rear Driveshaft Removal 16-26
Rear Driveshaft Disassembly. 16-29
Rear Driveshaft Reassembly 16-33
Rear Driveshaft Installation 16-41
Propeller Shaft Inspection 16-43
Propeller Shaft Removal 16-44
Propeller Shaft Installation 16-45
Driveline/Axle
Special Tools

Ref.No. Tool Number Description Otv

® 071AF-S3VA000 Ball Joint Thread Protector, 14 m m
® 07746-0010300 Attachment, 42 x 47 m m 1
® 07749-0010000 Driver 1
® 07947-4630100 Fork Seal Driver, 39.2 x 49.5 x 15 m m 1
® 07965-SD90100 Support Base 1
® 07AAD-S9VA000 Driveshaft Remover 1
® 07AAF-SDAA100 Ball Joint Thread Protector, 12 m m 1
® 07JAD-PH80101 Oil Seal Driver Attachment 1
® 07LAD-PW50601 Attachment, 40 x 50 m m 1
® 07LAF-SM40300 Support Base Attachment 1
© 07MAC-SL0A102 Ball Joint Remover, 32 m m 1
© 07MAC-SL0A202 Ball Joint Remover, 28 m m 1

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® 07XAC-001020A Threaded Adapter, 24 x 1.5 m m 1
© 07XAC-001030A Threaded Adapter, 26 x 1.5 m m 1

© © (D © ©

16-2
Component Location Index

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Installation, page 16-25
FRONT DRIVESHAFT
Inspection, page 16-4
Removal, page 16-4
Disassembly, page 16-6
Reassembly, page 16-10
Installation, page 16-18

16-3
Driveline/Axle
Driveshaft Inspection Front Driveshaft Removal

1. Check the inboard boot (A) and the outboard boot (B) Special Tools Required
on the driveshaft (C) for cracks, damage, leaking . Ball Joint Remover, 32 m m 07MAC-SL0A102
grease, and loose boot bands (D). If any damage is • Ball Joint Thread Protector, 14 m m 071AF-S3VA000
f o u n d , replace the boot and the boot bands.
1. Raise the vehicle on a lift.

2. Remove the front wheels.

3. Pry up the locking tab (A) on the spindle nut (B), then
remove the nut.

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2. Check the driveshaft for cracks and damage. If any
damage is f o u n d , replace the driveshaft.

3. Check the inboard joint (E) and the outboard joint (F)
for cracks and damage. If any damage is f o u n d ,
replace the inboard joint or the outboard joint as an
assembly.
4. Drain the transmission f l u i d , then reinstall the drain
4. Hold the inboard joint and turn the front wheel by plug w i t h a new sealing washer (see page 14-209).
hand, then make sure the joint is not excessively
loose. If necessary, replace the inboard joint or the 5. Remove the brake hose m o u n t i n g bolt (A).
outboard joint as an assembly.

16-4
6. Remove the lock pin (A) f r o m the lower arm ball joint, 8. Left driveshaft: Pry the inboard joint (A) f r o m the
then remove the castle nut (B). Separate the knuckle differential using a prybar. Remove the driveshaft as
f r o m the lower arm (C) using the 14 m m ball joint an assembly.
thread protector and the 32 m m ball joint remover
NOTE:
(see page 18-12).
• Do not pull on the driveshaft (B), or the inboard joint
NOTE: may come apart. Pull the inboard joint straight out
• Be careful not to damage the ball joint boot w h e n to avoid damaging the oil seal.
installing the remover. • Be careful not to damage the oil seal w i t h the
• Do not force or h a m m e r on the lower a r m , or pry prybar.
between the lower arm and the knuckle. You could
A
damage the ball joint.

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9. Right driveshaft: Drive the inboard joint (A) off of the
intermediate shaft using a drift and a hammer.
7. Pull the knuckle o u t w a r d , and separate the outboard Remove the driveshaft as an assembly.
joint f r o m the front hub using a plastic hammer.
NOTE: Do not pull on the driveshaft (B), or the inboard
joint may come apart.

(cont'd)

16-5
Driveline/Axle
Front Driveshaft Removal (cont'd) Front Driveshaft Disassembly

10. Remove the set ring (A) f r o m the left driveshaft Special Tools Required
inboard joint. • Threaded Adapter, 26 x 1.5 m m 07XAC-001030A
• Slide Hammer 5/8"-18 UNF, commercially available
• Boot Band Pliers, commercially available
• Bearing Puller, commercially available

Inboard Joint Side

1. Remove the boot bands. Be careful not to damage the
boot.
• If the boot band is a w e l d e d type (A), cut the boot
band.
• If the boot band is a double loop type (B), lift up the
band end (C), and push it into the clip (D).
• If the boot band is a low profile type (E), pinch the

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boot band using commercially available boot band
A pliers (F).

Welded type
11. Remove the set ring (A) f r o m the intermediate shaft.

16-6
 L o w profile t y p e 4. M a k e m a r k s ( A ) o n t h e r o l l e r s (B) a n d t h e s p i d e r (C) t o
identify t h e locations o f the rollers o n t h e spider, t h e n
r e m o v e t h e rollers.

NOTE: Do n o t engrave or scribe any marks o n t h e

rolling surface.

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2. M a k e m a r k s ( A ) o n e a c h r o l l e r (B) a n d t h e i n b o a r d
j o i n t (C) t o i d e n t i f y t h e l o c a t i o n s o f t h e r o l l e r s t o t h e
g r o o v e s in t h e i n b o a r d joint.
A
NOTE: Do not engrave o r scribe any marks o n t h e
rolling surface. 5. R e m o v e t h e c i r c l i p ( D ) .

6. M a k e m a r k s (E) o n t h e s p i d e r a n d t h e d r i v e s h a f t (F) t o
identify t h e position o f the spider o n t h e shaft.

7. R e m o v e t h e s p i d e r .

N O T E : If n e c e s s a r y , u s e a c o m m e r c i a l l y a v a i l a b l e
puller.

8. W r a p t h e s p l i n e s o n t h e d r i v e s h a f t w i t h v i n y l t a p e ( A )
to prevent damaging the boot.

3. R e m o v e t h e i n b o a r d j o i n t o n a c l e a n s h o p t o w e l ( D ) .
Be c a r e f u l n o t t o d r o p t h e r o l l e r s w h e n s e p a r a t i n g
t h e m f r o m the inboard joint.

9. R e m o v e t h e i n b o a r d b o o t . B e c a r e f u l n o t t o d a m a g e
the boot.

10. R e m o v e t h e v i n y l t a p e .

(cont'd)

16-7
Driveline/Axle
Front Driveshaft Disassembly (cont'd)

Outboard Joint Side 4. Make a mark (A) on the driveshaft (B) at the same level
as the outboard joint end (C).
1. Remove the boot bands (A). Lift up the three tabs (B)
using a screwdriver, then release the band. Be careful
not to damage the boot.

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A
5. Securely clamp the driveshaft in a bench vise w i t h a
2. Slide the outboard boot (A) partially t o the inboard shop t o w e l .
joint side. Be careful not to damage the boot.
6. Remove the outboard joint (A) using the 26 x 1.5 m m
threaded adapter (B) and a commercially available
5/8"-18 UNF slide hammer (C).

3. Wipe off the grease to expose the driveshaft and the

outboard joint inner race.

7. Remove the driveshaft f r o m the bench vise.

16-8
 8. Remove the stop ring (A) f r o m the driveshaft.

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

10. Remove the outboard boot. Be careful not to damage

the boot.

11. Remove the vinyl tape.

Driveline/Axle

Front Driveshaft Reassembly

Exploded View

D O U B L E LOOP BANDS
(Replacement parts only)
Replace.

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Use the grease included
in the outboard boot set.

16-10
Special Tools Required 3. Install the spider (A) onto the driveshaft by aligning
• Boot Band Tool KD-3191 or e q u i v a l e n t commercially the marks (B) you made on the spider and the end of
available the driveshaft.
• Seal Clamp Tool Kent-Moore J-35910 or equivalent
commercially available
• Boot Band Pliers, commercially available

NOTE: Refer to the Exploded View, as needed, during

this procedure.

Inboard Joint Side

1. Wrap the splines w i t h vinyl tape (A) to prevent
damaging the inboard boot.

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4. Install a new circlip (C) into the driveshaft groove.
Always rotate the circlip in its groove to make sure it is
fully seated.

5. Fit the rollers (A) onto the spider (B) as s h o w n , and

note these items:
• Reinstall the rollers in their original positions on the
spider by aligning the marks (C) you made.
2. Install the inboard boot onto the driveshaft, then • Hold the driveshaft pointed up to prevent the rollers
remove the vinyl tape. Be careful not to damage the f r o m falling off.
inboard boot.

(cont'd)

16-11
Driveline/Axle

Front Driveshaft Reassembly (cont'd)

6. Pack the inboard joint w i t h the joint grease included in 8. Fit the boot ends (A) onto the driveshaft (B) and the
the new inboard boot set. inboard joint (C).
Grease quantity
Left Inboard joint: 1 9 0 - 2 1 0 g ( 6 . 7 - 7 . 4 oz)
Right Inboard joint: 2 0 5 - 2 2 5 g ( 7 . 2 - 7 . 9 oz)

Use the grease included

in the inboard boot set.

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9. Adjust the length (A) of the driveshafts to the figure as
7. Fit the inboard joint onto the driveshaft, and note s h o w n , then adjust the boots to halfway between full
these items: compression and full extension. Bleed excess air f r o m
• Reinstall the inboard joint onto the driveshaft by the boots by inserting a flat-tipped screwdriver
aligning the marks (A) you made on the inboard between the boot and the joint.
joint and the rollers.
Left driveshaft: 5 7 1 . 2 - 5 7 6 . 2 m m (22.49-22.68 in)
• Hold the driveshaft so the inboard joint is pointing
A
up to prevent it f r o m falling off.

Right driveshaft: 569.5-574.5 mm (22.42-22.62 in)

16-12
10. Install new boot bands. 14. Thread the free end of the band t h r o u g h the nose
• For the double loop type, go to step 11. section of the commercially available boot band tool
• For the l o w profile type, go to step 20. KD-3191 or equivalent (A), and into the slot on the
w i n d i n g mandrel (B).
11. Fit the boot ends onto the driveshaft and the inboard
joint, then install a new double loop band (A) onto the
boot (B).

NOTE: Pass the end of the new double loop band

through the clip (C) twice in the direction of the
forward rotation of the driveshaft.

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15. Using a wrench on the w i n d i n g mandrel of the boot
band tool, tighten the band until the marked spot (C)
on the band meets the edge of the clip.

12. Pull up the slack in the band by hand. 16. Lift up the boot band tool to bend the free end of the
band 90 degrees to the clip. Center-punch the clip,
13. Mark position (A) on the band 10—14 m m (0.4—0.6 in) then fold over the remaining tail onto the clip.
f r o m the clip (B).

(cont'd)

16-13
Driveline/Axle
Front Driveshaft Reassembly (cont'd)

17. U n w i n d the boot band t o o l , and cut off the excess free 20. Install a new low profile band (A) onto the boot (B),
end of the band to leave a 5—10 m m (0.2—0.4 in) tail then hook the tab (C) of the band.
protruding f r o m the clip.

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18. Bend the band end (A) by tapping it d o w n using a
hammer.
21. Close the hook portion of the band using
NOTE: commercially available boot band pliers (A), then
• Make sure the band and clip do not interfere w i t h hook the t a b s ( B ) o f the band.
anything on the vehicle, and the band does not
move.
• Clean any grease remaining on the surrounding
surfaces.

22. Install the boot band on the other end of the boot, and
repeat 20 and 2 1 .

19. Repeat steps 11 through 18 for the band on the other

end of the boot.

16-14
 3®

Outboard Joint Side 4. Install the stop ring (A) into the driveshaft groove (B).

1. Wrap the splines w i t h vinyl tape (A) to prevent

damaging the outboard boot.

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5. Pack about 3 5 g (1.2 oz) grease included in the new
outboard boot set into the driveshaft hole in the
outboard joint.
2. Install new ear clamp bands (B) and the outboard NOTE: If you are installing a new outboard joint, the
boot, then remove the vinyl tape. Be careful not to grease is already installed.
damage the outboard boot.

3. Make sure to check the size of a new stop ring.

NOTICE
To avoid driveshaft and vehicle damage, make sure
y o u install a new stop ring.

Stop Ring Specifications

Overall diameter (A): 31.2 mm (1.23 in)
Wire diameter (B): 2.0 mm (0.08 in)

(cont'd)

16-15
Driveline/Axle
Front Driveshaft Reassembly (cont'd)

6. Insert the driveshaft (A) into the outboard joint (B) 8. Check the alignment of the paint mark (A) y o u made
until the stop ring (C) is close to the joint. w i t h the outboard joint end (B).

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

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7. To completely seat the outboard joint, pick up the
driveshaft and the joint, and tap or hit the assembly
onto a hard surface f r o m a height of about 10 c m (4
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.

9. Pack the outboard joint (A) w i t h the remaining joint

grease included in the new joint boot set.

Total grease quantity

outboard joint: 115—135 g (4.1—4.8 oz)

in the outboard boot set.

16-16
 <3®
10. Fit the boot ends (A) onto the driveshaft (B) and the 12. Close the ear portion (A) of the band using a
outboard joint (C). Bleed any excess air f r o m the boot commercially available seal clamp tool (Kent-Moore
by inserting a flat-tipped screwdriver between the J-35910 or equivalent) (B).
boot and the joint.

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13. Check the clearance between the closed ear portion of
the band. If the clearance is not w i t h i n the standard,
close the ear portion of the band tighter.

6.0 mm
(0.24 in) MAX.
11. Inspect the length (A) of the driveshafts to the figure
as s h o w n , then adjust the boots to halfway between
full compression and full extension.

Left driveshaft: 571.2-576.2 mm (22.49-22.68 in)

A

1 . 0 - 4 . 0 mm (0.04-0.16 in)

14. Repeat steps 12 and 13 for the band on the other end
Right driveshaft: 569.5-574.5 mm (22.42-22.62 in)
of the boot.
A

16-17
Driveline/Axle

Front Driveshaft Installation

NOTE: Before starting installation, make sure the mating 3. Install a new set ring (A) into the set ring groove (B) of
surfaces of the joint and the splined section are clean. the intermediate shaft.
1. A p p l y about 5 g (0.18 oz) of moly 60 paste (P/N
08734-0001) to the contact area (A) of the outboard
joint and the front wheel bearing.

NOTE: The paste helps prevent noise and vibration.

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4. Apply 2 . 0 - 3 . 0 g (0.07—0.10 oz) of super high t e m p
urea grease (P/N 08798-9002) to the w h o l e splined
surface (A) of the right driveshaft. After applying
(P/N 08734-0001)
grease, remove the grease f r o m the splined grooves
at intervals of 2—3 splines and f r o m the set ring
2. Install a new set ring (A) into the set ring groove (B) of groove (B) so that air can bleed f r o m the intermediate
the left driveshaft inboard joint. shaft.

5. Clean the areas where the driveshaft contacts the

differential thoroughly w i t h solvent, and dry t h e m
w i t h compressed air.

NOTE: Do not wash the rubber parts w i t h solvent.

16-18
6. Insert the inboard end (A) of the driveshaft into the 8. Wipe off any grease contamination f r o m the ball joint
differential (B) or the intermediate shaft (C) until the tapered section and threads, then install the knuckle
set ring (D) locks in the groove (E). (A) onto the lower arm (B). Be careful not to damage
the ball joint boot (C). Wipe off the grease before
NOTE: Insert the driveshaft horizontally to prevent
tightening the nut at the ball joint. Torque a new castle
damaging the oil seal.
nut (D) to the lower torque specification, then tighten
it only far enough t o align the slot w i t h the ball joint
pin hole.

NOTE:
• Make sure the ball joint boot is not damaged or
cracked.
• Do not align the nut by loosening it.

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B
A

C E

7. Install the outboard joint (A) into the front hub (B) on
the knuckle.

9. Install the lock pin (E) into the ball joint pin hole as
B shown.

10. Install the brake hose m o u n t i n g bolt (A).

(cont'd)

16-19
Driveline/Axle
Front Driveshaft Installation Intermediate Shaft Removal
(cont'd)
11. Apply a small amount of engine oil to the seating 1. Drain the transmission fluid, then reinstall the drain
surface of a new spindle nut (A). plug w i t h a new sealing washer (see page 14-209).

A 2. Remove the right front driveshaft (see page 16-4).

26 x 1.5 mm
328 N m 3. Remove exhaust pipe A (see step 37 on page 14-223).
(33.5 k g f m , 242 Ibfft)
Replace.
4. Remove the exhaust pipe bracket (A).

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12. Install the spindle nut, then tighten it. After tightening,
use a drift to stake the spindle nut shoulder (B) against
the driveshaft.
5. Remove the flange bolt (A), and t w o dowel bolts (B).
13. Clean the mating surfaces of the brake discs and the
wheels, then install the front wheels.

14. Turn the front wheel by hand, and make sure there is
no interference between the driveshaft and the
surrounding parts.

15. Lower the vehicle on the lift.

16. Refill the transmission w i t h the recommended

transmission fluid (see page 14-209).

17. Check the wheel alignment, and adjust it if necessary

(see page 18-5).

18. Test-drive the vehicle.

B C
6. Remove the intermediate shaft (C) f r o m the
differential. Hold the intermediate shaft horizontal
until it is clear of the differential to prevent damaging
the oil seal (D), then remove the set ring (E) f r o m the
intermediate shaft.

16-20
Intermediate Shaft Disassembly

Special Tools Required 3. Press the intermediate shaft (A) out of the
• Support Base Attachment 07LAF-SM40300 intermediate shaft bearing (B) using the support base
• A t t a c h m e n t 42 x 47 m m 07746-0010300 attachment (C), the support base (D), and a press. Be
• Driver 07749-0010000 careful not to damage the bearing support ring (E) on
• Support Base 07965-SD90100 the intermediate shaft during disassembly.

1. Remove the heat shield (A) f r o m the intermediate PRESS

shaft (B).

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07965-SD90100

4. Remove the internal snap ring (A) f r o m the bearing

2. Remove the outer seal (A) and the external snap ring support (B).
(B) f r o m the intermediate shaft (C).

(cont'd)

16-21
Driveline/Axle
Intermediate Shaft Disassembly (cont'd)

5. Press the intermediate shaft bearing (A) out of the

bearing support (B) using the support base
attachment (C), the support base (D), the driver (E),
the 42 x 47 m m attachment (F), and a press.

07749-0010000

F
07746-0010300
o)

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07965-SD90100

16-22
Intermediate Shaft Reassembly

Exploded View

DOWEL B O L T S

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Pack the interior
of the outer seal.

(cont'd)

16-23
Driveline/Axle

Intermediate Shaft Reassembly (cont'd)

Special Tools Required 4. Press the intermediate shaft (A) into the shaft bearing
• Oil Seal Driver Attachment 07JAD-PH80101 (B) using the 39.2 x 49.5 x 15 m m fork seal driver (C),
• Attachment, 40 x 50 m m 07LAD-PW50601 and a press.
• Support Base Attachment 07LAF-SM40300

*3
• Driver 07749-0010000 PRESS I g

• Fork Seal Driver, 39.2 x 49.5 x 15 m m 07947-4630100

• Support Base 07965-SD90100

NOTE: Refer to the Exploded View, as needed, during

this procedure.

1. Clean the disassembled parts w i t h solvent, and dry

t h e m w i t h compressed air.

NOTE: Do not wash the rubber parts w i t h solvent.

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2. Press a new intermediate shaft bearing (A) into the
bearing support (B) using the driver (C), the oil seal
driver attachment (D), and a press.
PRESS

5. Install the external snap ring (A) into the groove of the
intermediate shaft (B).

3. Install the internal snap ring (A) into the groove (B) of
the bearing support.

16-24
 <3®
Intermediate Shaft Installation

6. Install a new outer seal (A) into the bearing support 1. Clean the areas where the intermediate shaft contacts
(B) using the 40 x 50 m m attachment (C), the support the differential thoroughly w i t h solvent, and dry them
base attachment (D), the support base (E), and a w i t h compressed air.
press. Press the seal until it is 0 ± 0 . 2 m m (0±0.008 in)
NOTE: Do not wash the rubber parts w i t h solvent.
below the surface of the bearing support end.
2. Install a new set ring (A) into the set ring groove (B) of
the intermediate shaft (C).

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7. Install the heat shield (A). 39 N m
(4.0 k g f m , 29 Ibfft)
8 x 1.25 mm
22 N m (2.2 k g f m , 16 Ibfft) 3. Insert the intermediate shaft into the differential
correctly.
NOTE: Insert the intermediate shaft carefully to
prevent damaging the oil seal (D).

4. Install the flange bolt (E) and the t w o dowel bolts (F).

(cont'd)

16-25
Driveline/Axle
Intermediate Shaft Installation Rear Driveshaft Removal
(cont'd)
5. Install the exhaust pipe bracket (A). Special Tools Required
• Driveshaft Remover 07AAD-S9VA000
• Ball Joint Thread Protector, 12 m m 07AAF-SDAA100
. Ball Joint Remover, 28 m m 07MAC-SL0A202

NOTE: Be careful not to damage the brake hose, sensor,

and harness.

1. Raise the vehicle on a lift.

2. Remove the rear wheels.

3. Pry up the locking tab (A) on the spindle nut (B), then
remove the nut.

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8 x 1.25 mm
22 N m (2.2 k g f m , 16 Ibfft)

6. Install exhaust pipe A (see step 47 on page 14-237).

7. Install the right front driveshaft (see page 16-18).

8. Refill the transmission w i t h the recommended

transmission fluid (see page 14-209).

9. Check the wheel alignment, and adjust it if necessary

(see page 18-5).

10. Test-drive the vehicle.

4. Remove the rear wheel speed sensor (A) and harness

stay |B>. —

16-26
5. Remove the lock pin (A) f r o m the upper arm ball joint, 8. Place a transmission jack under lower arm B, and
and remove the castle nut (B). remove the flange bolt (A).

07AAF-SDAA100

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07MAC-SL0A202

9. Pull the knuckle outward, and separate the driveshaft

6. Separate the ball joint f r o m the upper arm (C) using outboard joint f r o m the rear hub using a plastic
the 12 m m ball joint thread protector and the 28 m m hammer.
ball joint remover (see page 18-12).

NOTE:
• Be careful not to damage the ball joint boot w h e n
installing the remover.
• Do not force or hammer on the upper a r m , or pry
between the upper arm and the knuckle. You could
damage the ball joint.
7. Remove the self-locking nut (B), the washer (C), and
the flange bolt (D), then remove lower arm A.

(cont'd)

16-27
Driveline/Axle

Rear Driveshaft Removal (cont'd)

10. Using the driveshaft remover (A) pry out the inboard 12. Remove the set ring (A) f r o m the rear differential.
joint (B) f r o m the rear differential (C).

NOTE: This is a prying tool, do not strike it w i t h a

hammer.

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11. Remove the rear driveshaft (A).

NOTE: W h e n removing the outboard joint, continue

supporting both the knuckle and the lower arm w i t h
the transmission jack. Make sure not to over extend
the brake hose.

16-28
 3®
Rear Driveshaft Disassembly

Special Tools Required 2. Remove the circlip (A).

• Threaded Adapter, 24 x 1.5 m m 07XAC-001020A
• Slide Hammer 5/8"-18 UNF, commercially available B
• Boot Band Pliers, commercially available

Inboard Joint Side

1. Remove the boot bands. Be careful not to damage the
boot.
• If the boot band is a double loop type (A), lift up the
band end (B), and push it into the clip (C).
• Ifthe boot band is a low profile type (D), pinch the
boot band using commercially available boot band
pliers (E).

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Double loop type

B 3. Make marks (B) on the bearing retainer (C) and the

inboard joint (D) to identify the locations of the
bearing retainer to the grooves in the inboard joint.
Then remove the inboard joint on a clean shop towel
(E). Be careful not to drop the steel balls w h e n
separating them f r o m the inboard joint.

4. Remove the snap ring (A).

Low profile type

5. Make marks (B) on the bearing retainer (C), the

bearing race (D), and the driveshaft (E) to identify the
position of the bearing retainer and the bearing race
on the shaft.

6. Remove the bearing race and the steel balls (F).

(cont'd)

16-29
Driveline/Axle
Rear Driveshaft Disassembly (cont'd)

7. Wrap the splines on the driveshaft (A) with vinyl tape Outboard Joint Side
(B) to prevent damaging the boot.
1. Remove the boot bands. Be careful not to damage the
boot.
• If the boot band is a low profile type (A), pinch the
boot band using commercially available boot band
pliers (B).
• If the boot band is an ear clamp type (C), lift up the
three tabs (D) with a screwdriver.

Low profile type

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8. Remove the inboard boot (C). Be careful not to
damage the boot.

9. Remove the vinyl tape.

Ear clamp type

16-30
 0®
2. Slide the outboard boot (A) partially to the inboard 5. Securely clamp the driveshaft in a bench vise with a
joint side. Be careful not to damage the boot. shop t o w e l .

6. Remove the outboard joint (A) using the 24 x 1.5 m m

threaded adapter (B) and a commercially available
5/8"-18 UNF slide hammer (C).

07XAC-001020A

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

4. Make a mark (A) on the driveshaft (B) at the same level

as the outboard joint end (C). 7. Remove the driveshaft f r o m the bench vise.

8. Remove the stop ring (A) f r o m the driveshaft.

(cont'd)

16-31
Driveline/Axle
Rear Driveshaft Disassembly (cont'd)

9. W r a p the splines on the driveshaft w i t h vinyl tape (A)

to prevent damaging the boot.

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10. Remove the outboard boot. Be careful not to damage
the boot.

11. Remove the vinyl tape.

16-32
 <3®
Rear Driveshaft Reassembly

Exploded View
D O U B L E LOOP BANDS
(Replacement parts only)
INBOARD JOINT
Replace.

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EAR CLAMP BAND
Replace.

Use the grease Included

in the outboard boot set.

(cont'd)

16-33
Driveline/Axle
Rear Driveshaft Reassembly (cont'd)

Special Tools Required 6. Pack the inboard joint w i t h the joint grease included in
• Boot Band Tool KD-3191 or equivalent commercially the new inboard boot set.
available
Grease quantity
• Seal Clamp Tool Kent-Moore J-35910 or equivalent Inboard joint: 8 5 — 1 0 5 g (3.0—3.7 oz)
commercially available
• Boot Band Pliers, commercially available

NOTE: Refer to the Exploded View, as needed, during

this procedure.

Inboard Joint Side

1. Wrap the splines w i t h vinyl tape (A) to prevent
damaging the inboard boot.

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7. Install the inboard joint onto the driveshaft by aligning
the marks (A) y o u made on the inboard joint and the
bearing retainer.

A
2. Install the inboard boot onto the driveshaft, then
remove the vinyl tape. Be careful not to damage the
inboard boot.

3. Assemble the steel balls (A), the bearing retainer (B),

and the bearing race (C) by aligning the marks (D) you
made on the bearing retainer and the bearing race.

8. Install a new circlip (B) into the inboard joint groove.

4. Install the bearing onto the driveshaft (E) by aligning

the marks you made on the bearing and the
driveshaft. Be careful not to drop the steel balls w h e n
installing the bearing onto the driveshaft.

5. Install the snap ring (F).

16-34
 9. Fit the boot ends (A) onto the driveshaft (B) and the 12. Fit the boot ends onto the driveshaft and the inboard
inboard joint (C). joint, then install a new double loop band (A) onto the
boot(B).

NOTE: Pass the end of the new double loop band

through the clip (C) twice in the direction of the
forward rotation of the driveshaft.

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10. Adjust the length (A) of the driveshafts to the figure as
s h o w n , then adjust the boots to halfway between full
compression and full extension. Bleed excess air f r o m 13. Pull up the slack in the band by hand.
the boots by inserting a flat-tipped screwdriver
14. Mark position (A) on the band 10—14 m m (0.4—0.6 in)
between the boot and the joint.
f r o m the clip (B).
Left driveshaft: 611.4-616.4 mm (24.07-24.27 in)
Right driveshaft: 640.4-645.4 mm (25.21-25.41 in)

11. Install new boot bands:

• For the double loop type, go to step 12.
• For the low profile type, go to step 2 1 .

(cont'd)

16-35
Driveline/Axle
Rear Driveshaft Reassembly (cont'd)

15. Thread the free end of the band through the nose 18. Unwind the boot band t o o l , and cut off the excess free
section of the commercially available boot band tool end of the band to leave a 5—10 m m (0.2—0.4 in) tail
KD-3191 or equivalent (A), and into the slot on the protruding f r o m the clip.
w i n d i n g mandrel (B).

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19. Bend the band end (A) by tapping it d o w n using a
16. Using a wrench on the w i n d i n g mandrel of the boot hammer.
band tool, tighten the band until the marked spot (C)
on the band meets the edge of the clip. NOTE:
• Make sure the band and the clip do not interfere
17. Lift up the boot band tool to bend the free end of the
w i t h anything, and the band does not move.
band 90 degrees to the clip. Center-punch the clip,
then fold over the remaining tail onto the clip. • Clean any grease remaining on the surrounding
surfaces.

20. Repeat steps 12 through 19 for the band on the other

end of the boot.

16-36
 SJ0

2 1 . Install a new l o w profile band (A) onto the boot (B),

then hook the tab (C) of the band.
Outboard Joint Side
1. Wrap the splines w i t h vinyl tape (A) to prevent
damaging the outboard boot.

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22. Close the hook portion of the band using
commercially available boot band pliers (A), then
hook the tabs (B) of the band. 2. Install a new ear clamp bands (B) and the outboard
boot, then remove the vinyl tape. Be careful not to
damage the outboard boot.

3. Make sure to check the size of a new stop ring.

INQTICEl
To avoid driveshaft and vehicle damage, make sure
y o u install a new stop ring.

Stop Ring Specifications

Overall diameter (A): 28.0 mm (1.10 in)
Wire diameter (B): 1.8 mm (0.07 in)

23. Install the boot band on the other end of the boot, and
repeat steps 21 and 22.

(cont'd)

16-37
Driveline/Axle
Rear Driveshaft Reassembly (cont'd)

4. Install the stop ring (A) into the driveshaft groove (B). 6. Insert the driveshaft (A) into the outboard joint (B)
until the stop ring (C) is close to the joint.

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5. Pack about 35 g (1.2 oz) grease included in the new
outboard boot set into the driveshaft hole in the
outboard joint.

NOTE: If y o u are installing a new outboard joint, the 7. To completely seat the outboard joint, pick up the
grease is already installed. driveshaft and joint, and tap or hit the assembly onto
a hard surface f r o m a height of about 10 c m (4 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.

16-38
8. Check the alignment of the paint mark (A) y o u made 10. Fit the boot ends (A) onto the driveshaft (B) and
with the outboard joint end (B). outboard joint (C). Bleed any excess air f r o m the boot
by inserting a flat-tipped screwdriver between the
NOTICE boot and the joint.
To avoid driveshaft and vehicle damage, the shaft
must be all the w a y into the outboard joint to ensure
the stop ring is properly seated.

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11. Inspect the length (A) of the driveshafts to the figure
as s h o w n , then adjust the boots to halfway between
full compression and full extension.
Left driveshaft: 611.4-616.4 mm (24.07-24.27 in)
Right driveshaft: 640.4-645.4 mm (25.21 - 2 5 . 4 1 in)

9. Pack the outboard joint (A) w i t h the remaining joint

grease included in the new joint boot set.
Total grease quantity
Outboard joint: 80—100 g (2.8—3.5 oz)

Use the grease included

in the outboard boot set.

(cont'd)

16-39
Driveline/Axle
Rear Driveshaft Reassembly (cont'd)

12. Close the ear portion (A) of the band using a 14. Install a new low profile band (A) onto the boot (B),
commercially available seal clamp tool (Kent- Moore then hook the tab (C) of the band.
J-35910 or equivalent) (B).

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15. Close the hook portion of the band using
13. Check the clearance between the closed ear portion of commercially available boot band pliers (A), then
the band. If the clearance is not within the standard, hook the tabs (B) of the band.
close the ear portion of the band tighter.

6.0 mm

1 . 0 - 4 . 0 m m (0.04-0.16 in)

16-40
Rear Driveshaft Installation

NOTE: Before starting installation, make sure the mating 4. Make sure the inboard joint (A) is installed all the way
surfaces of the joint and the splined section are clean. into the rear differential (B) and to ensure the stop ring
(C) is properly seated.
1. Apply 1 . 5 - 2 . 0 g ( 0 . 0 5 - 0 . 0 7 oz) of super high t e m p
urea grease (P/N 08798-9002) to the whole splined
surface (A). After applying grease, remove the grease
f r o m the splined grooves at intervals of 2—3 splines
and f r o m the set ring groove (B) so that air can bleed
f r o m the differential.

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5. Pull the knuckle (A) outward, and insert the outboard
joint (B) into the rear hub.
B
NOTE: When installing the outboard joint continue
supporting both the knuckle and the lower arm with
2. Install a new set ring (A) into the set ring groove of the the transmission jack. Make sure not to over e
differential. the brake hose.

3. Clean the areas where the driveshaft contacts the

differential thoroughly w i t h solvent, and dry t h e m
w i t h compressed air.

NOTE: Do not wash the rubber parts with solvent.

(cont'd)

16-41
Driveline/Axle
Rear Driveshaft installation (cont'd)

6. L o o s e l y install a n e w f l a n g e bolt (A) onto l o w e r a r m B. 8. W i p e off a n y g r e a s e c o n t a m i n a t i o n f r o m t h e ball joint

t a p e r e d s e c t i o n a n d t h r e a d s , t h e n install t h e u p p e r
a r m (A). B e careful not to d a m a g e t h e ball joint boot
(B). W i p e off the g r e a s e before tightening the c a s t l e
nut at t h e ball joint.

A
14 x 1.5 mm
113 N m
(11.5 k g f m ,
83 Ibfft) 12 x 1.25 m m
Replace. 59-69 Nm
B (6.0-7.0 kgfm,

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4 3 - 5 1 Ibfft)
7. Install l o w e r a r m A , t h e n l o o s e l y install a n e w f l a n g e
bolt (B) a n d a n e w s e l f - l o c k i n g nut (C) w i t h the w a s h e r
(D).

9. T o r q u e t h e c a s t l e nut (C) to t h e l o w e r t o r q u e
B s p e c i f i c a t i o n , t h e n tighten it o n l y far e n o u g h to align
14 x 1.5 m m the slot w i t h the ball joint pin hole. Install t h e lock pin
93 N m
(9.5 k g f m , (D) into t h e ball joint pin h o l e a s s h o w n .
69 Ibfft)
Replace. NOTE:
• M a k e s u r e t h e ball j o i n t boot is not d a m a g e d or
cracked.
C
14 x 1.5 m m • Do not align t h e nut by l o o s e n i n g it.
113 N m
(11.5 k g f m , 10. Install the r e a r w h e e l s p e e d s e n s o r (A) a n d h a r n e s s
83 Ibfft) s t a y (B).
Replace.
6 x 1.0 m m
9.8 N m
(1.0 k g f m , 7.2 Ibfft)

16-42
 Propeller Shaft Inspection

11. Place a floor jack under the lower a r m , and raise the Universal Joint and Boots
suspension to load it with the vehicle's weight.
1. Raise the vehicle on a lift.
12. Tighten the lower arm B flange bolt, the lower arm A
self-locking nut, and the lower arm A mounting bolt to 2. Shift the transmission to N.
the specified torque values, then remove the floor 3. Release the parking brake.
jack.
4. Check the center support bearing (A) for excessive
13. A p p l y a small amount of engine oil to the seating play or noise. If the center support has excessive play
surface of a new spindle nut (A). or noise, replace the propeller shaft assembly.
A
24 x 1.5 mm
245 N m
(25.0 k g f m , 181 Ibfft)

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B

5. Check the rubber portion of the m o u n t (B) for damage

14. Install the spindle nut, then tighten it. After tightening, and deterioration. If the rubber portion is damaged or
use a drift to stake the spindle nut shoulder (B) against deteriorated, replace the propeller shaft assembly.
the driveshaft.
6. Check the universal joints for excessive play or noise.
15. Clean the mating surfaces of the brake disc and the If the universal joints have excessive play or noise,
w h e e l , then install the rear wheels. replace the propeller shaft assembly.
16. Turn the rear wheel by hand, and make sure there is
no interference between the driveshaft and
surrounding parts.

17. Lower the vehicle on the lift.

18. Check the wheel alignment, and adjust it if necessary

(see page 18-5).

19. Test-drive the vehicle.

(cont'd)

16-43
Driveline/Axle
Propeller Shaft Inspection (cont'd) Propeller Shaft Removal

1. Raise the vehicle on a lift.

Propeller Shaft Runout
2. Remove the propeller shaft protector.
1. Raise the vehicle on a lift.

2. Shift the transmission to N.

3. Release the parking brake.

4. Install a dial indicator w i t h its needle on the center of

the No. 1 propeller shaft or the No. 2 propeller shaft.

5. Turn the other propeller shaft slowly and check the

runout. Repeat this procedure for the other propeller
shaft.
No. 1 Propeller Shaft Runout
Service Limit: 1.5 mm (0.06 in)

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3. Make a reference mark (A) across the No. 1 propeller
shaft (B) and transfer companion flange (C).

No. 2 Propeller Shaft Runout

Service Limit: 1.5 mm (0.06 in)

C A
4. Remove the flange bolts (D).

6. Ifthe runout on either propeller shaft exceeds the

service limit, replace the propeller shaft assembly.

16-44
 Propeller Shaft Installation

5. Remove the center support bearing mounting bolts. 1. If you are installing a new propeller shaft, go to step 2.

If you are reinstalling the original propeller shaft, go

to step 3.

2. Install a new propeller shaft (A) onto the rear

differential (B), by aligning the reference mark (C) on
the new propeller shaft with the factory reference
mark (D) on the companion flange (E). Do not use the
marks you made on the companion f r o m the removal
procedure. If there are no factory marks on the
companion flange, go to step 4.

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6, Make a reference mark (A) across the No. 2 propeller
shaft (B) and the rear differential companion flange
(C).

3. Reinstall the No. 2 propeller shaft (A) to the rear

differential (B) by aligning the reference marks (C) y o u
made during the removal procedure.
10 x 1.25 mm
72 N m
(7.3 k g f m , 53 Ibfft)
Replace.

7. Remove the flange bolts (D).

B C

4. Attach the No. 2 propeller shaft to the rear differential

w i t h new mounting bolts. Tighten the bolts to the
specified torque.

(cont'd)

16-45
Driveline/Axle
Propeller Shaft Installation (cont'd)

5. Install the center support bearing mounting bolts. 7. Install the propeller shaft protector.

8 x 1.25 m m

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2 2 N m ( 2 . 2 k g f m , 16Ibfft)
10 x 1.25 mm
39 N-m (4.0 k g f m , 29 Ibfft) 8. If you installed a new propeller shaft, test-drive the
vehicle at 55 m p h (88 km/h) and check for noise or
vibration.
6. Install the No. 1 propeller shaft (A) onto the transfer
• If there is no noise or vibration, the repair is
companion flange (B) by aligning the reference mark
complete.
(C). Make sure y o u use new mounting bolts.
• If there is a noise or vibration, go t o step 9.
10x1.25 mm
72 N m (7.3 k g f m , 53 Ibfft) 9. Remove the mounting bolts f r o m the propeller shaft
Replace. at the rear differential companion flange. Note the
current alignment of the propeller shaft t o the rear
differential companion flange.

10. Rotate the propeller shaft 180 degrees f r o m its current

alignment w i t h the rear differential companion flange.

11. Install new mounting bolts and tighten them to the

specified torque.

12. Test-drive the vehicle.

16-46
 NOTES

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 NOTES

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 NOTES

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 NOTES

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cardiagn.com
 cardiagn.com

" Portions of materials contained herein have been reprinted under

license from America Honda Motor Co., Inc. License Agreement AH220 ."
 INTRODUCTION
r - How to Use This Manual
General Inforr
T h i s manual is divided into multiple sections. The first page of
each section is marked with a black tab that lines up with its
corresponding thumb index tab on this page and the back cover. Specifications
Y o u can quickly find the first page of each section without
looking through a full table of contents. T h e s y m b o l s printed at
the top corner of each page c a n also be used a s a quick reference
system. Maintenance
E a c h section includes:
1. A table of contents, or an exploded v i e w index s h o w i n g :
• Parts d i s a s s e m b l y s e q u e n c e .
• Bolt torques and thread sizes. Engine Electrical
• Page references to descriptions in text.
2. D i s a s s e m b l y / a s s e m b l y procedures and tools.
3. Inspection.
Engine Mechanical
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Engine Cooling

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Safety Messages
Y o u r safety, and the safety of others, is very important. T o help
you make informed decisions, w e have provided safety
Fuel and Emissions
m e s s a g e s , and other safety information throughout this manual.
Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle. Y o u must use
your own good judgment. *Transaxle
Y o u will find important safety information in a variety of forms
including:
• Safety L a b e l s — on the vehicle. ^Steering
• Safety M e s s a g e s — preceded by a safety alert symbol ^ and
one of three signal w o r d s , D A N G E R , W A R N I N G , or C A U T I O N .
T h e s e signal w o r d s mean: Suspension(lncluding
Y o u W I L L be KILLED or S E R I O U S L Y H U R T if
TPMS)
ADANGER you don't follow instructions.
Y o u C A N be KILLED or S E R I O U S L Y H U R T if
AWARNING you don't follow instructions. *Brakes(lncluding VSA)
Y o u C A N be H U R T if y o u don't follow
A CAUTION instructions.
Instructions — how to service this vehicle correctly and safely.
Body
All information contained in this manual is based on the latest
product information available at the time of printing. W e reserve
the right to make c h a n g e s at anytime without notice. No part of *Heating, Ventilation,
this publication may be reproduced, or stored in a retrieval
s y s t e m , or transmitted, in any form by any m e a n s , electronic, and Air Conditioning
mechanical, photocopying, recording, or otherwise, without the
prior written permission of the publisher. This includes text,
figures, and tables.
A s you read this manual, you will find information that is
Body Electrical
preceded by a | NOTICE [ s y m b o l . The purpose of this m e s s a g e is to
help prevent d a m a g e to your vehicle, other property, or the
environment. •Audio, Navigation, and
Telematics
First Edition 04/2009
Honda Motor Co., Ltd.
All Rights Reserved
Service Publication Office
Specifications apply to USA and Canada
*Restraints
As sections with * include S R S components;
special precautions are required when servicing.
marked sections are not included in this
manual, see Volume 1.
2009-10 Pilot Vol.2
 cardiagn.com
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If steering maintenance is required)
The Pilot SRS includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above
the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof,
and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this
Service Manual. Items marked with an asterisk (*) on the contents page include or are located near SRS
components. Servicing, disassembling, or replacing these items require special precautions and tools, and
should be done by an authorized Honda dealer.
• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe
frontal or side collision, all SRS service w o r k should be done by an authorized Honda dealer.
• Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal
injury caused by unintentional deployment of the airbags, side airbags, and side curtain airbags.
• Do not b u m p or impact the SRS unit, front impact sensors, side impact sensors, or rear safing sensor,
especially w h e n the ignition switch is in ON (II), or for at least 3 minutes after the ignition switch is turned to
LOCK (0); otherwise, the system may fail in a collision, or the airbags may deploy.
• SRS electrical connectors are identified by yellow color coding. Related components are located in the
steering c o l u m n , center console, dashboard, in the dashboard above the glove box, in the front seats, in the
roof side, and around the floor. Do not use electrical test equipment on these circuits.