REMOVAL AND INSTALLATION

CAUTION

For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged.

For vehicles with ABS, be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work.

Pre-installation Operation

Transmission Fluid Draining (Refer to GROUP 23A, On-vehicle Service-Transmission Fluid Replacement.)

Transfer Oil Draining <4WD>
(Refer to GROUP 23A, On-vehicle Service-Transfer Oil Replacement .)

Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Muffler .)

Post-installation Operation

Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Muffler .)

Check the Ball Joint Dust Cover for cracks or damage by pushing it with your finger.

Transfer Oil Filling<4WD> (Refer to GROUP 23A, On-vehicle Service-Transfer Oil Replacement .)

Transmission Fluid Filling (Refer to GROUP 23A, On-vehicle Service-Transmission Fluid Replacement.)

			Removal steps
<<A>>	>>C<<	1.	Drive shaft nut
	>>C<<	2.	Washer
		3.	Front ABS sensor <Vehicles with ABS>
		4.	Brake hose clamp
		5.	Front ABS sensor bracket <Vehicles with ABS>
		6.	Brake hose bracket
	>>B<<	7.	Self-locking nut
		8.	Stabilizer rubber
		9.	Collar
		10.	Stabilizer link assembly
		11.	Lower arm ball joint connection
<<B>>		12.	Self-locking nut (tie rod end connection)
<<C>>	>>A<<	13.	Drive shaft
<<C>>	>>A<<	14.	Drive shaft and inner shaft assembly <2WD-RH>
<<D>>	>>A<<	15.	Output shaft <4WD>
		16.	Circlip

REMOVAL SERVICE POINTS

<<A>> DRIVE SHAFT NUT REMOVAL

CAUTION

Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft nut is loosened.

Use special tool front hub and flange yoke holder (MB990767) to fix the hub and remove the drive shaft nut.

<<B>>SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL

CAUTION

Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads.

Hang special tool with cord to prevent it from falling.

Install special tool ball joint remover (MB991897) as shown in the figure.

Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.

Tighten the bolt with a wrench to disconnect the tie rod end.

<<C>> DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY <2WD-RH> REMOVAL

Use the following special tools to push out the drive shaft or the drive shaft and inner shaft assembly from the hub.

Puller shaft (MB990242)

Puller bar (MB990244)

Puller body (MB991354)

Front hub and flange yoke holder (MB990767)

Remove the drive shaft from the hub by pulling the bottom of the brake disc towards you.

CAUTION

Do not pull on the drive shaft; doing so will damage the PTJ; be sure to use the pry bar.

When pulling the drive shaft out from the transmission, be careful that the spline part of the drive shaft does not damage the oil seal.

Insert a pry bar between the transmission case and the drive shaft, and then pry and remove the drive shaft from the transmission.

If the inner shaft is hard to remove from the transmission, strike the bracket assembly lightly with a plastic hammer and remove the inner shaft.

Use special tool plug (MB991460) to prevent the entry of foreign material into the transmission case.

CAUTION

Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools.

Spacer (MB991000)

Front hub remover and installer (MB991017)

<<D>>OUTPUT SHAFT <4WD> REMOVAL

CAUTION

When pulling the output shaft out from the transmission, be careful that the spline part of the output shaft does not damage the oil seal.

Use special tool sliding hammer (MB991721) to remove the output shaft.

INSTALLATION SERVICE POINTS

>>A<< OUTPUT SHAFT <4WD>/DRIVE SHAFT AND INNER SHAFT ASSEMBLY <2WD-RH>/DRIVE SHAFT INSTALLATION

CAUTION

When installing the output shaft, the drive shaft or the drive shaft and inner shaft assembly, be careful that the spline part of the output shaft, the drive shaft or the drive shaft and inner shaft assembly do not damage the oil seal.

>>B<< SELF-LOCKING NUT INSTALLATION

<2000-Non-Turbo>

Install the stabilizer bar and collar as shown in the figure, and tighten the self-locking nut so that the protruding length of the stabilizer link protruding part meets its standard value (A).

Standard value (A): 22 ± 1.5 mm

<2000-Turbo, 2400>

Tighten the self-locking nut so that the protruding length of the stabilizer link protruding part meets its standard value (A).

Standard value (A): 9.4 ± 0.4 mm

>>C<< WASHER/DRIVE SHAFT NUT INSTALLATION

Be sure to install the drive shaft washer in the specified direction.

CAUTION

Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged.

Using special tool front hub and flange yoke holder (MB990767), tighten the drive shaft nut to the specified torque.

Tightening torque: 245 ± 29 N·m