Front Drive Shaft Assembly (For 2Az-Fe) Installation

Install a new front drive shaft hole snap ring LH to the front drive inboard joint assembly.

Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

NOTICE:

1. Face the end gap of the front drive inboard joint hole snap ring downward.
   
2. Do not damage the oil seal.
   
3. Do not damage the inboard joint boot.
   

HINT:

Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

Install the front drive shaft assembly RH.

Using a screwdriver, install a new bearing bracket hole snap ring.

NOTICE:

1. Do not damage the boot or oil seal.
   
2. Move the drive shaft assembly while keeping it level.
   

Install a new bolt.

Torque:

32 N*m{330 kgf*cm, 24 ft.*lbf}

Install the manual transmission case protector with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Push the front axle assembly LH out of the vehicle to align the spline of the drive shaft with the front axle assembly LH and insert the front axle assembly LH.

NOTICE:

1. Do not push out the front axle further than necessary.
   
2. Do not damage the outboard joint boot.
   
3. Check for any foreign matter on the speed sensor rotor and insertion part.
   
4. Do not damage the speed sensor rotor.
   

Install the front lower suspension arm to the lower ball joint with the bolt and 2 nuts.

Torque:

89 N*m{908 kgf*cm, 66 ft.*lbf}

Connect the tie rod end sub-assembly LH to the steering knuckle with the nut.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

NOTICE:

Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

Install a new cotter pin.

Install the front stabilizer link assembly to the front shock absorber with coil spring with the nut.

Torque:

74 N*m{755 kgf*cm, 55 ft.*lbf}

NOTICE:

If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

Install the front speed sensor and front flexible hose to the front shock absorber with the bolt.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

NOTICE:

Do not twist the front speed sensor when installing it.

HINT:

Install the speed sensor harness bracket first, and then the front flexible hose.

Install the front speed sensor and front flexible hose to the front shock absorber with the bolt.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

NOTICE:

Do not twist the front speed sensor when installing it.

HINT:

Install the speed sensor harness bracket first, and then the front flexible hose.

Install the front speed sensor with the clamp to the front shock absorber.

Clean the threaded parts on the drive shaft and axle shaft nut using a non-residue solvent.

NOTICE:

1. Be sure to perform this work for a new drive shaft.
   
2. Keep the threaded parts free of oil and foreign matter.
   

Using a socket wrench (30 mm), install a new axle shaft nut.

Torque:

216 N*m{2203 kgf*cm, 160 ft.*lbf}

Using a chisel and hammer, caulk the axle shaft nut.

Install a new gasket and the drain plug.

Torque:

49 N*m{499 kgf*cm, 36 ft.*lbf}

Add manual transaxle oil.

Install the transmission filler plug and a new gasket.

Torque:

49 N*m{499 kgf*cm, 36 ft.*lbf}

Stop the vehicle in a level place.

Remove the transmission filler plug and the gasket.

Check that the oil surface is within 5 mm (0.197 in.) of the bottom of the transmission filler plug opening.

NOTICE:

1. Excessively large or small amounts of oil may cause problems.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Check for oil leakage when the oil level is low.

Install the transmission filler plug and a new gasket.

Torque:

49 N*m{499 kgf*cm, 36 ft.*lbf}

Park the vehicle on a level surface and set the parking brake.

With the engine idling and the brake pedal depressed, move the shift lever to all positions from P to S. Then return it to P.

Pull out the dipstick and wipe it clean.

Push the dipstick back fully into the pipe.

Pull the dipstick out again and check that the fluid level is within the HOT range. If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add a proper amount of new fluid and recheck the fluid level.