Honda CIVIC 10G 2016 Driveline Axle Page 1

Driveline/Axle Component Location Index
Driveline/Axle Component Location Index 4216 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
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Contents Summary of Driveline Axle

  • Page 1Driveline/Axle Component Location Index cardiagn.com
  • Page 2Ball Joint Boot Replacement and Inspection Special Tool Required Image Description/Tool Number Bearing Driver Attachment, 36 mm 07965-SA50500 cardiagn.com Clip Guide, 45 mm 070AG-SJA0300 1. Ball Joint Boot - Inspect Check the ball joint boot for weakness, damage, cracks, and inner boot grease leaks.
  • Page 3Housing Bracket Ball Joint 1. Vehicle - Lift 2. Front Wheel - Remove 3. Front Suspension Stroke Sensor - Disconnect 1. Disconnect the front suspension stroke sensor from the lower arm. 4. Lower Arm - Disconnect 1. Disconnect the housing bracket ball joint from the lower arm. cardiagn.com 5. Ball Joi
  • Page 41. Pack the interior and lip (A) of a new boot with grease. NOTE: Keep the grease off of the boot-to-lower ball joint housing mating surfaces (B). Use the grease that comes with the ball joint kit, or multi-purpose grease. Do not let dirt or other foreign materials get into the boot. 2. Pack fresh g
  • Page 52. Front Wheel - Remove 3. Knuckle/Hub Bearing Unit Assembly - Remove 4. Ball Joint Boot - Remove 1. Paint an alignment mark (A) at the center point between the boot clip ends (B) on the damper fork (C). 2. Remove the boot clip and the boot. cardiagn.com 5. Ball Joint Boot - Install 1. Pack the inte
  • Page 66. Adjust the depth by turning the clip guide until its base is just above the groove around (A) the bottom of the boot. 7. Slide the clip (B) over the tool and into position on the boot. 8. Align the center of the boot clip ends (C) with the painted alignment mark (D) on the appropriate part. 9. Af
  • Page 7Ball Joint Removal Special Tool Required Image Description/Tool Number Ball Joint Thread Protector, 12 mm 07AAF-SDAA100 cardiagn.com Ball Joint Thread Protector, 14 mm 07AAE-SJAA100 Ball Joint Remover, 32 mm 07MAC-SL00102
  • Page 8Image Description/Tool Number Ball Joint Remover, 28 mm 07MAC-SL00202 cardiagn.com Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it. 1. Ball Joint - Removal 1. Install a hex nut (A) or the ball joint
  • Page 92. Apply grease to the ball joint remover on the areas as shown (A). This will ease the installation of the tool, and prevent damage to the pressure bolt (B) threads. cardiagn.com 3. Loosen the pressure bolt (A), and install the ball joint remover as shown. NOTE: Insert the jaws carefully, making su
  • Page 10Driveshaft Inspection 1. Driveshaft - Inspect 1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking grease, and loose boot bands (D). If any damage is found, replace the boot and the boot bands. 2. Check the driveshaft for cracks and damage. If any
  • Page 11Final Drive Shaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Attachment, 45 mm 07947-6890300 Bearing Separator 07KAF-PS30200 NOTE:
  • Page 12Where icon is shown, click for further information. The final drive shaft bearing and the final drive shaft bearing outer race should be replaced as a set. 1 cardiagn.com Detailed information, notes and precautions Replace 1. Final Drive Shaft Bearing - Remove
  • Page 131. Remove the final drive shaft bearings (A) using the bearing separator, a commercially available spacer (B), and a press. 2. Cotter Retainer - Remove cardiagn.com 3. 29 mm Cotter - Remove 4. Secondary Driven Gear - Remove 1. Remove the secondary driven gear (A) using a press. NOTE: Where icon is s
  • Page 141 cardiagn.com Detailed information, notes and precautions Replace 1. Secondary Driven Gear - Install
  • Page 151. Install the secondary driven gear (A) until it bottoms in the direction shown using a press. 2. 29 mm Cotter - Install cardiagn.com 3. Cotter Retainer - Install 4. Final Drive Shaft Bearing - Install 1. Install the final drive shaft bearings (A) until they bottom using the 15 x 135L driver handle
  • Page 16Final Drive Shaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Attachment, 40 mm 07947-6340300 Attachment, 45 mm 07947-6890300
  • Page 17Image Description/Tool Number Bearing Separator 07KAF-PS30200 cardiagn.com NOTE: Where icon is shown, click for further information. The bearing and the bearing outer race should be replaced as a set. 1
  • Page 18cardiagn.com Detailed information, notes and precautions Replace 1. Final Drive Shaft Tapered Roller Bearing - Remove
  • Page 19Transmission Housing Side 1. Remove the final drive shaft tapered roller bearings (A) using the bearing separator, a commercially available bearing puller (B), and a commercially available spacer (C). Torque Converter Housing Side cardiagn.com 2. Cotter Retainer - Remove 3. 38 mm Cotter - Remove 4.
  • Page 201. Remove the secondary driven gear (A) using a press. NOTE: Where icon is shown, click for further information. cardiagn.com The bearing and the bearing outer race should be replaced as a set. Adjust the final drive shaft tapered roller bearing preload whenever the bearing is replaced. Apply a ligh
  • Page 21cardiagn.com Detailed information, notes and precautions Replace 1. Secondary Driven Gear - Install NOTE: Make sure to assemble the final drive shaft and the final driven gear correctly (Combination A or B) as shown in the chart if either one of them or both are to be replaced. Correct combinations
  • Page 22cardiagn.com 1. Install the secondary driven gear (A) until it bottoms in the direction shown using a press.
  • Page 232. 38 mm Cotter - Install 3. Cotter Retainer - Install 4. Final Drive Shaft Tapered Roller Bearing - Install Transmission Housing Side 1. Install the final drive shaft tapered roller bearing (A) until it bottoms using the 15 x 135L driver handle, the 40 mm attachment, and a press. cardiagn.com Torqu
  • Page 24Final Drive Shaft Tapered Roller Bearing Preload Inspection Special Tool Required Image Description/Tool Number Preload Inspection Tool 070AJ-5T0A100 cardiagn.com Driver Handle, 40 mm I.D. 07746-0030100 NOTE: If the transmission was disassembled, the final drive shaft tapered roller bearing preload
  • Page 251. Install the oil guide plate (A). 2. Install the final drive shaft tapered roller bearing outer race (B) until it bottoms using the 40 mm I.D. driver handle. 3. Final Drive Shaft Tapered Roller Bearing Outer Race - Install (Torque Converter Housing Side) cardiagn.com 1. Install the 51 mm thrust sh
  • Page 265. Torque Converter Housing - Install 1. Install the torque converter housing (A) with the dowel pins (B), and tighten the bolts in a crisscross pattern in at least cardiagn.com two steps. 6. Final Drive Shaft Tapered Roller Bearing Preload - Inspect
  • Page 271. Install the preload inspection tool. 2. Press the preload inspection tool gradually by tightening the bolt (A). 3. Rotate the differential assembly in both directions to seat the bearings. cardiagn.com 4. Measure the starting torque using the preload inspection tool, a torque wrench (A), and a so
  • Page 28NOTE: To increase the starting torque, increase thickness of the 51 mm thrust shim. To decrease the starting torque, decrease the thickness of the 51 mm thrust shim. Do not use more than two thrust shims to adjust the starting torque. 51 mm Thrust Shim No. Thickness A 1.375 mm (0.05413 in) B 1.400 m
  • Page 29Final Drive Shaft Tapered Roller Bearing Preload Inspection Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Bearing Driver Attachment, 62 x 64 mm 07947-6340400 Preload Inspection Tool 07HAJ-PK40201
  • Page 30Image Description/Tool Number Bearing Driver Attachment, 78 x 80 mm 07NAD-PX40100 cardiagn.com NOTE: If the transmission was disassembled, the final drive shaft tapered roller bearing preload must be adjusted. The final drive shaft tapered roller bearing preload must be inspected and adjusted with t
  • Page 311. Install the oil guide plate (A) and the 80 mm thrust shim (B). 2. Install the final drive shaft tapered roller bearing outer race (C) using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment so there is no clearance between the bearing outer race, the 80 mm thrust shim, the
  • Page 32cardiagn.com 2. Install the final drive shaft assembly (B). 3. Install the torque converter housing (C) with the dowel pins (D) and a new gasket (E), and tighten the bolts in a crisscross pattern in at least two steps. 5. Final Drive Shaft Tapered Roller Bearing Preload - Inspect
  • Page 331. Rotate the differential assembly in both directions to seat the bearings using the preload inspection tool. 2. Measure the starting torque using the preload inspection tool, a torque wrench (A), and a socket (B). NOTE: Measure the starting torque at normal room temperature in both directions. Sta
  • Page 34No. Thickness T 1.375 mm (0.05413 in) U 1.400 mm (0.05512 in) V 1.425 mm (0.05610 in) W 1.450 mm (0.05709 in) X 1.475 mm (0.05807 in) Y 1.500 mm (0.05906 in) Z 1.525 mm (0.06004 in) 0A 1.550 mm (0.06102 in) 0B 1.575 mm (0.06201 in) 0C 1.600 mm (0.06299 in) 0D 1.625 mm (0.06398 in) 0E 1.650 mm (0.064
  • Page 35Front Damper/Spring Removal and Installation Special Tool Required Image Description/Tool Number Ball Joint Thread Protector, 12 mm 07AAF-SDAA100 cardiagn.com Ball Joint Remover, 28 mm 07MAC-SL00202 NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the pr
  • Page 364. Damper Items - Remove (With Adaptive Damper System) cardiagn.com 1. Disconnect the connectors (A). 2. Remove the clip (B). 5. Brake Hose Bracket - Remove
  • Page 37Without adaptive damper system With adaptive damper system cardiagn.com 6. Brake Caliper - Remove 1. Remove the caliper assembly without disconnecting the brake hose from the caliper body. NOTE: To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper as
  • Page 389. Tie-Rod End Ball Joint - Disconnect 10.Lower Ball Joint - Disconnect 1. Disconnect the lower ball joint from the lower arm. 11. Knuckle/Hub Assembly - Remove 1. Pull the knuckle (A) outward, and separate the outboard joint (B) from the front hub using a soft face hammer outward. NOTE: Do not pull
  • Page 391. Remove the flange nuts (A). NOTE: Do not let the damper/spring drop down under its own weight. Use the new flange nuts during reassembly. 2. For some models: Remove the damper plate (B). cardiagn.com 3. Remove the damper/spring (A). NOTE: Be careful not to damage the body. During installation, in
  • Page 4014.Wheel Alignment - Check cardiagn.com
  • Page 41Front Damper/Spring Removal and Installation Special Tool Required Image Description/Tool Number Ball Joint Thread Protector, 14 mm 07AAE-SJAA100 cardiagn.com Ball Joint Remover, 32 mm 07MAC-SL00102 NOTE: How to read the torque specifications. 1. Vehicle - Lift 2. Front Wheel - Remove 3. Front Brake
  • Page 424. Brake Disc - Remove 5. Spindle Nut - Remove 6. Damper/Spring Items - Remove 1. Remove the wheel speed sensor (A). 2. Remove the brake hose bracket (B). cardiagn.com 3. Remove the brake hose bracket (A). 4. Disconnect the connector (B) as shown.
  • Page 437. Stabilizer Link - Disconnect cardiagn.com
  • Page 441. Disconnect the stabilizer link from the front damper. 8. Front Suspension Stroke Sensor - Disconnect 1. Disconnect the front suspension stroke sensor from the lower arm. 9. Stopper Link - Remove 1. Disconnect the stopper link from the damper fork. 10.Knuckle/Hub Bearing Unit Assembly - Remove 1.
  • Page 452. Move the lower arm downward and disconnect the knuckle ball joint (A) from the housing bracket (B). 3. Remove the lock pin (A). cardiagn.com NOTE: During installation, install the lock pin as shown after tightening the new castle nut. 4. Remove the castle nut (B). NOTE: During installation, note
  • Page 46Do not pull the driveshaft end outward. The inner driveshaft inboard joint may come apart. During installation, apply specified grease to the contact area (F) of the outboard joint and the hub bearing unit. 11. Damper Fork - Remove NOTE: During installation, note these items. Use new damper fork mou
  • Page 473. Remove the damper/spring (A). NOTE: Be careful not to damage the body. During installation, if the guide pin (B) is equipped, align the guide pin with the body hole (C). cardiagn.com 13.All Removed Parts - Install 1. Install the parts in the reverse order of removal. 14.Brake System - Bleed 15.Wh
  • Page 48Front Driveshaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Pilot, 20 mm 07746-0040500 cardiagn.com Driver Handle, 15 x 135L 07749-0010000 Threaded Adapter, 22 x 1.5 mm 07XAC-001010A
  • Page 49Image Description/Tool Number Threaded Adapter, 24 x 1.5 mm 07XAC-001020A cardiagn.com NOTE: Where icon is shown, click for further information. The following illustrations are examples only. The appearance and structure of the actual parts may vary depending on the model. Be careful not to damage t
  • Page 50cardiagn.com Detailed information, notes, and precautions Replace *1 These parts have inspection items. *2 Right driveshaft (With intermediate shaft) *3 Left driveshaft and Right driveshaft (Without intermediate shaft) 2 Driveshaft Type 2
  • Page 51cardiagn.com Detailed information, notes, and precautions Replace *1 These parts have inspection items. *2 Right driveshaft 1. Boot Band - Remove
  • Page 52Ear Clamp Type Low Profile Type 1 cardiagn.com
  • Page 53Low Profile Type 2 cardiagn.com 2. Outboard Joint - Remove 1. Slide the outboard boot (A) partially toward the inboard joint side. 2. Wipe off the grease to expose the driveshaft and the outboard joint inner race. 3. Make a mark (A) on the driveshaft (B) at the same level as the outboard joint end (
  • Page 544. Securely clamp the driveshaft in a bench vise with a shop towel wrapped around the driveshaft. 5. Remove the outboard joint (A) using the 24 x 1.5 mm threaded adapter (24 mm spindle nut), 22 x 1.5 mm threaded adapter (22 mm spindle nut) and a commercially available 5/8''-18 UNF slide hammer (B).
  • Page 551. Make marks (A) on each roller (B) and the inboard joint (C) to identify the locations of the rollers to the grooves in the inboard joint. NOTE: Do not engrave or scribe any marks on the rolling surface. 2. Remove the inboard joint on a clean shop towel (D). Be careful not to drop the rollers when
  • Page 561. Make a mark (A) on the driveshaft (B) at the same level as the spider end. 2. Make marks (C) on the spider (D) and the driveshaft to identify the position of the spider on the shaft. cardiagn.com 3. Support the roller of the spider (A) seated on wood blocks (B) on a bench vise (C). 4. Remove the
  • Page 57NOTE: Check the inboard boot (A) for cracks and damage. If any damage is found, replace the boot. Wrap the splines on the driveshaft (B) with vinyl tape (C) to prevent damaging the inboard boot. NOTE: cardiagn.com Where icon is shown, click for further information. The following illustrations are ex
  • Page 58cardiagn.com Detailed information, notes, and precautions Replace *1 These parts have inspection items. *2 Right driveshaft (With intermediate shaft) *3 Left driveshaft and Right driveshaft (Without intermediate shaft) 2 Driveshaft Type 2
  • Page 59cardiagn.com Detailed information, notes, and precautions Replace *1 These parts have inspection items. *2 Right driveshaft 1. Outboard Boot - Install
  • Page 60NOTE: Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the outboard boot (C). Install the ear clamp bands (D) with the boot to prevent damaging the bands. 2. Stop Ring - Install 3. Outboard Joint - Install cardiagn.com 1. Fill grease through the driveshaft hole in the o
  • Page 612. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint. 3. To completely seat the outboard joint, pick up the driveshaft and the joint, and tap or hit the assembly onto a hard cardiagn.com surface from a height of about 10 cm (3.9 in). NOTE: Do not use
  • Page 62cardiagn.co
  • Page 635. Pack the outboard joint (A) with the remaining joint grease included in the outboard boot set. Total grease quantity Outboard joint: M/T (1.5 L engine)*1 110-130 g (3.88-4.59 oz) M/T (2.0 L engine)*1 120-140 g (4.23-4.94 oz) CVT (1.5 L engine 120-140 g (4.23-4.94 oz) 2/4-door)*1 CVT (1.5 L engine
  • Page 64NOTE: Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the inboard boot (C). Install the ear clamp bands (D) with the boot to prevent damaging the bands. cardiagn.com
  • Page 655. Spider - Install (Driveshaft Type 1) 1. Install the spider (A) onto the driveshaft (B) by aligning the marks (C) you made on the spider and the end of the driveshaft. cardiagn.com 6. Circlip - Install (Driveshaft Type 1) 7. Inboard Boot Adapter - Install (Driveshaft Type 1) 8. Stop Ring - Install
  • Page 661. Insert the driveshaft (A) into the spider (B) until the stop ring (C) is close to the spider. NOTE: Install the spider onto the driveshaft by aligning the marks (D) you made on the spider and the end of the driveshaft. cardiagn.com 2. Press the spider (A) using commercially available socket (B) a
  • Page 673. Check the alignment of the paint mark (A) you made with the spider end. To avoid driveshaft and vehicle damage, the shaft must be all the way into the spider to ensure the stop ring is properly seated. 10.Inboard Joint - Install cardiagn.com 1. Pack the inboard joint with the joint grease include
  • Page 682. Fit the inboard joint onto the driveshaft, and note these items: Reinstall the inboard joint onto the driveshaft by aligning the marks (A) you made on the inboard joint and the rollers. Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off. 3. Fit the boot ends (A
  • Page 692. Check the clearance (C) and length (D) between the closed ear portions of the band. If the clearance is not within the standard, close the ear portion of the band tighter. cardiagn.com NOTE: Replace the ear clamp band with a new one when the ear portion exceeds the prescribed clearance/length. Ea
  • Page 70cardiagn.co
  • Page 71Low Profile Type 2 1. Install a low profile type 2 band (A) onto the boot (B). 2. Close the hook portion of the band using commercially available clamp pincer SPX 14100134 (C), then hook the tabs (D) of the band. NOTE: Close the low profile type 2 band slowly until a click sound is made. No further
  • Page 72Normal condition 3. Make sure that the band is tightened securely. NOTE: If the tip of the tab (A) is not shown as indicated, replace the low profile type 2 band, then repeat steps 1 through 3. Do not reuse the removed low profile type 2 band. Abnormal condition cardiagn.com 1. Stop Ring - Inspect T
  • Page 73*2: Driveshaft Type 2 cardiagn.com
  • Page 742. Driveshaft Length - Adjust 1. Adjust the length (A) of the driveshafts in the figure as shown. cardiagn.com Driveshaft length: Left/Right Specified length (A) driveshaft 547.07-552.07 mm Left (21.5381-21.7350 in) M/T (1.5 L engine)*1 Right 501.60-506.60 mm (19.7480-19.9448 in) 523.59-528.59 mm Le
  • Page 75*1: Driveshaft Type 1 *2: Driveshaft Type 2 Left/Right Specified length (A) driveshaft 574.00-579.00 mm Left (22.5984-22.7952 in) CVT (1.5 L engine)*2 Right 509.50-514.50 mm (20.0590-20.2559 in) 528.62-533.62 mm Left (20.8118-21.0086 in) CVT (2.0 L engine)*1 Right 822.50-827.50 mm (32.3818-32.5787 i
  • Page 76Front Driveshaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Threaded Adapter, 26 x 1.5 mm 07XAC-001030A cardiagn.com NOTE: Where icon is shown, click for further information. Be careful not to damage the boot. Make marks on the disassembled parts to be able to rea
  • Page 77cardiagn.com Detailed information, notes, and precautions Replace *1 Right driveshaft 1. Boot Band - Remove
  • Page 78Ear clamp type Low profile type cardiagn.com 2. Outboard Joint - Remove 1. Slide the outboard boot (A) partially toward the inboard joint side. 2. Wipe off the grease to expose the driveshaft and the outboard joint inner race.
  • Page 79cardiagn.co
  • Page 803. Make a mark (A) on the driveshaft (B) at the same level as the outboard joint end (C). 4. Securely clamp the driveshaft in a bench vise with a shop towel wrapped around the driveshaft. cardiagn.com 5. Remove the outboard joint (A) using the 26 x 1.5 mm threaded adapter and a commercially availabl
  • Page 81NOTE: Check the outboard boot (A) for cracks and damage. If any damage is found, replace the boot. Wrap the splines on the driveshaft (B) with vinyl tape (C) to prevent damaging the outboard boot. 5. Inboard Joint - Remove 1. Remove the circlip (A). cardiagn.com 2. Make marks (B) on the bearing reta
  • Page 821. Make marks (A) on the bearing retainer (B), the bearing race (C), and the driveshaft (D) to identify the position of the bearing retainer and the bearing race on the shaft. 2. Remove the bearing retainer, the bearing race, and the steel balls (E). NOTE: If necessary, use a commercially available
  • Page 83cardiagn.com Detailed information, notes, and precautions Replace *1 Right driveshaft 1. Outboard Boot - Install
  • Page 84NOTE: Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the outboard boot (C). Install the ear clamp bands (D) with the boot to prevent damaging the bands. 2. Stop Ring - Install 1. Make sure to check the size of a new stop ring. cardiagn.com To avoid driveshaft and vehi
  • Page 85cardiagn.co
  • Page 862. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint. cardiagn.com 3. To completely seat the outboard joint, pick up the driveshaft and the joint, and tap or hit the assembly onto a hard surface from a height of about 10 cm (3.9 in). NOTE: Do not use
  • Page 875. Pack the outboard joint (A) with the remaining joint grease included in the outboard boot set. Total grease quantity Outboard joint: 160-180 g (5.64-6.35 oz) cardiagn.com 6. Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C). 7. Bleed any excess air from the boot by insertin
  • Page 88NOTE: Wrap the splines on the driveshaft (A) with vinyl tape (B) to prevent damaging the inboard boot (C). Install the ear clamp band (D) with the boot to prevent damaging the band. 5. Bearing Retainer and Bearing Race - Install 1. Install the bearing retainer (A) and the bearing race (B) onto cardi
  • Page 892. Install the inboard joint (A) onto the driveshaft by aligning the marks (B) you made on the inboard joint and the bearing retainer. 3. Install a circlip (C) into the inboard joint groove. 4. Fit the boot ends (A) onto the driveshaft (B) and the inboard cardiagn.com joint (C). 5. Bleed excess air
  • Page 901. Inspect the length (A) of the driveshafts in the figure as shown. 2. Adjust the boots to halfway between full compression and full extension. NOTE: Install the joints at exactly the same length. 9. Boot Band - Install cardiagn.com Ear clamp type 1. Close the ear portion (A) of the band using a co
  • Page 91Low profile type 1. Install the low profile band (A) onto the boot (B), than hook the tab (C) of the band. 2. Close the hook portion of the band using commercially available CV Boot Clamp Pliers (30500) (D), then hook the tabs of the band. cardiagn.com
  • Page 92Front Driveshaft Removal and Installation NOTE: Where icon is shown, click for further information. Unless otherwise indicated, illustrations used in the procedure are for left driveshaft. 1 cardiagn.com
  • Page 93cardiagn.com Detailed information, notes, and precautions Replace *1 Intermediate shaft (With intermediate shaft) 1. Vehicle - Lift 2. Front Wheel - Remove
  • Page 943. Spindle Nut - Remove 1. Pry up the stake (A) on the spindle nut (B). 2. Remove the spindle nut. cardiagn.com 4. Transmission Fluid - Drain M/T CVT 5. Lower Arm Ball Joint - Disconnect 6. Outboard Joint - Disconnect
  • Page 957. Inboard Joint - Disconnect (Both Sides) cardiagn.com Left driveshaft and Right driveshaft (Without intermediate shaft) 1. Pry the inboard joint (A) using a pry bar. NOTE: Be careful not to damage the oil seal or the end of the inboard joint with the pry bar. 2. Remove the driveshaft as an assembl
  • Page 96Right driveshaft (With intermediate shaft) 1. Drive the inboard joint (A) off of the intermediate shaft using a drift punch and a hammer. 2. Remove the driveshaft as an assembly. NOTE: Do not pull on the driveshaft (B), or the inboard joint may come apart. Pull the inboard joint straight out. cardia
  • Page 97cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace Engine oil *1 Intermediate shaft (With intermediate shaft) *2 1.5 L engine *3 2.0 L engine 1. Inboard Joint Set Ring - Install
  • Page 982. Inboard Joint - Connect Right driveshaft (With intermediate shaft) 1. Right driveshaft (With intermediate shaft): Apply 0.5-1.0 g (0.018-0.035 oz) of UM246 (P/N 41211-PY5-305) to the whole splined surface (A) of the right driveshaft. 2. Right driveshaft (With intermediate shaft): After applying g
  • Page 991. Apply about 3 g (0.11 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. 4. Lower Arm Ball Joint - Connect cardiagn.com 5. Spindle Nut - Install 1. Use a drift to stake the spindle nut
  • Page 1008. Transmission Fluid - Refill cardiagn.com
  • Page 101M/T CVT 9. Wheel Alignment - Check 10.Test Drive - Check cardiagn.com
  • Page 102Front Driveshaft Removal and Installation NOTE: Where icon is shown, click for further information. The following illustrations are examples only. The appearance and structure of the actual parts may vary depending on the model. 1 cardiagn.com
  • Page 103cardiagn.com Detailed information, notes, and precautions Replace 2
  • Page 1043 cardiagn.com
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  • Page 106cardiagn.com Detailed information, notes, and precautions Replace 1. Vehicle - Lift 2. Front Wheel - Remove (Both Side)
  • Page 107cardiagn.co
  • Page 1083. Spindle Nut - Remove (Both Sides) 1. Pry up the stake (A) on the spindle nut (B). 2. Remove the spindle nut. cardiagn.com 4. Engine Undercover - Remove NOTE: Remove the necessary part(s). 5. Transmission Fluid - Drain 6. Tie-Rod End Ball Joint - Disconnect (Both Sides) 7. Knuckle Mounting Bolt -
  • Page 109cardiagn.com 12.Inboard Joint - Disconnect (Both Sides) Left driveshaft 1. Pry the inboard joint (A) using a pry bar. NOTE: Be careful not to damage the oil seal or the end of the inboard joint with the pry bar. 2. Remove the driveshaft as an assembly. NOTE: Do not pull on the driveshaft (B), or the
  • Page 110Right driveshaft 1. Drive the inboard joint (A) off of the intermediate shaft using a drift punch and a hammer. 2. Remove the driveshaft as an assembly. NOTE: Do not pull on the driveshaft (B), or the inboard joint may come apart. Pull the inboard joint straight out. cardiagn.com 13.Inboard Joint Se
  • Page 111cardiagn.com Detailed information, notes, and precautions Replace Apply 2.0-3.0 g (0.071-0.106 oz) of super high *1 temp urea grease (P/N 08798-9002) or equivalent to the whole splined surface. Apply about 3.0 g (0.106 oz) of Molykote M77 paste *2 (P/N: 08798- 9010) or equivalent to the contact area
  • Page 1123 2 cardiagn.com
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  • Page 114cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace Apply a small amount of engine oil to the seating surface of a new spindle nut. 1. Inboard Joint Set Ring - Install (Both Side)
  • Page 1152. Inboard Joint - Connect 1. Left driveshaft: Clean the areas where the driveshaft contacts the differential thoroughly with solvent, then dry them compressed air. NOTE: Do not wash the rubber parts with solvent. 2. Insert the inboard end (A) of the driveshaft into the differential (B) or the inter
  • Page 116NOTE: Do not use a stake, punch or screwdriver in the brake rotor to keep it from moving. Have an assistant press on the brakes instead while you are tightening. 1. Use a drift to stake the spindle nut shoulder (A) against the driveshaft. 11. Front Wheel - Install (Both Side) cardiagn.com 12.Drivesh
  • Page 117Front Knuckle Ball Joint Inspection When inspecting the ball joint, the vehicle will be shake strongly. Make sure support the front jacking bracket correctly with the suitable jack. Housing Bracket Ball Joint 1. Vehicle - Lift 2. Front Wheel - Remove 3. Housing Bracket Ball Joint - Inspect cardiagn.
  • Page 1183. Check the ball joint boot (A) for weakness, damage, cracks, and inner boot grease leaks. NOTE: If the ball joint boot is damaged with grease leaks, replace the housing bracket ball joint. If the ball joint boot is weakness and cracks without grease leaks, replace the housing bracket ball joint bo
  • Page 119Knuckle Ball Joint cardiagn.com 3. Check the ball joint boot (A) for weakness, damage, cracks, and inner boot grease leaks. NOTE: If the ball joint boot is damaged, weakness, and cracks, replace the knuckle. Damper Fork Ball Joint 4. Check the ball joint boot (A) for weakness, damage, cracks, and in
  • Page 120Front Knuckle/Hub Bearing Unit Removal and Installation Special Tool Required Image Description/Tool Number Ball Joint Thread Protector, 14 mm 07AAE-SJAA100 cardiagn.com Ball Joint Remover, 32 mm 07MAC-SL00102 NOTE: How to read the torque specifications. Do not loosen these bolts (A). 1. Knuckle/Hub
  • Page 121cardiagn.com NOTE: How to read the torque specifications. Refer to the Exploded View as needed during the following procedures. Hub Bearing Unit 1. Vehicle - Lift 2. Front Wheel - Remove
  • Page 1223. Front Brake Caliper - Remove 4. Brake Disc - Remove 5. Spindle Nut - Remove 6. Hub Bearing Unit - Remove NOTE: Keep the wheel bearing/encoder away from any magnetic field. The encoder can be damaged or erased. Do not pull the driveshaft end outward. The inner driveshaft cardiagn.com inboard joint
  • Page 1239. Wheel Speed Sensor and Brake Hose Bracket - Remove cardiagn.com 1. Remove the wheel speed sensor (A) and the brake hose bracket (B). 10.Front Suspension Stroke Sensor - Disconnect 1. Disconnect the front suspension stroke sensor from the lower arm. 11. Knuckle - Remove
  • Page 1241. Remove the mounting bolts (A) and the TORX bolt (B). NOTE: During installation, note these items. Use the new mounting bolts and the TORX bolt. Loosely install the TORX bolt, then tighten the mounting bolts and the TORX bolt in the numbered sequence shown. cardiagn.com 2. Move the lower arm downw
  • Page 1253. Remove the lock pin (A). NOTE: During installation, install the lock pin as shown after tightening the new castle nut. 4. Remove the castle nut (B). NOTE: During installation, note these items. Use a new castle nut. Torque the castle nut to the lower torque specification, then tighten it only far
  • Page 126Front Knuckle/Hub/Wheel Bearing Replacement Special Tool Required Image Description/Tool Number Ball Joint Thread Protector, 12 mm 07AAF-SDAA100 cardiagn.com Ball Joint Remover, 28 mm 07MAC-SL00202 Ball Joint Thread Protector, 14 mm 07AAE-SJAA100
  • Page 127Image Description/Tool Number Ball Joint Remover, 32 mm 07MAC-SL00102 Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Bearing Driver Attachment, 42 x 47 mm 07746-0010300 Pilot, 28 mm 07746-0041100
  • Page 128Image Description/Tool Number Hub Dis/Assembly Pin, 40 mm 07GAF-SE00100 Bearing Driver Attachment, 62 x 68 mm 07746-0010500 cardiagn.com Attachment, 78 x 90 mm 07GAD-SD40101
  • Page 129Image Description/Tool Number Support Base 07965-SD90100 1. Knuckle/Hub/Wheel Bearing - Exploded View cardiagn.com Exploded View
  • Page 130cardiagn.com NOTE: Refer to the Exploded View as needed during the following procedures. Knuckle/Hub 1. Vehicle - Lift
  • Page 1312. Front Wheel - Remove 3. Wheel Speed Sensor - Remove cardiagn.com 4. Brake Hose Bracket - Remove 5. Brake Caliper - Remove 1. Remove the caliper assembly without disconnecting the brake hose from the caliper body. NOTE: To prevent damage to the caliper assembly or brake hose, use a short piece of
  • Page 1326. Spindle Nut - Remove 1. Pry up the stake (A) on the spindle nut (B). 2. Remove the spindle nut. NOTE: Use a new spindle nut during reassembly. Tighten the spindle nut to the specified torque during reassembly. Specified Torque: 1.5 L engine: 245 N·m (25.0 kgf·m, 181 lbf·ft) 2.0 L engine: 181 N·m
  • Page 1331. Disconnect the lower ball joint from the lower arm. 11. Knuckle/Hub Assembly - Remove 1. Pull the knuckle (A) outward, and separate the outboard joint (B) from the front hub using a soft face hammer outward. NOTE: Do not pull the driveshaft end outward. The inner driveshaft inboard joint may come
  • Page 1341. Install the parts in the reverse order of removal. NOTE: Be careful not to damage the ball joint boot when connecting the knuckle. Before connecting the ball joint, degrease the threaded section and the tapered portion of the ball joint pin, the ball joint connecting hole, the threaded section, a
  • Page 1352. Press out the wheel bearing inner race (A) of the hub (B) using the driver handle, the bearing driver attachment, the pilot, a commercially available bearing separator (C), and a hydraulic press. cardiagn.com 2.0 L engine 1. Separate the hub (A) from the knuckle (B) using the hub dis/assembly pin
  • Page 1362. Press out the wheel bearing inner race (A) of the hub (B) using the hub dis/assembly pin, a commercially available bearing separator (C), and a hydraulic press. 2. Splash Guard and Snap Ring - Remove cardiagn.com NOTE: Check for damaged or deformed snap ring, and replace it if damaged. 3. Bearing
  • Page 1374. Bearing - Install 1.5 L engine 1. Wash the knuckle and the hub thoroughly in high flash point solvent before reassembly. 2. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the attachment (1.5 L engine), the support base, and a hydraulic press. NOTE
  • Page 138NOTE: Check for damaged or deformed snap ring, and replace it if damaged. 6. Hub - Install cardiagn.com 1.5 L engine 1. Install the hub (A) onto the knuckle (B) using the bearing driver attachment, the driver handle, the support base, and a hydraulic press. NOTE: Be careful not to damage the splash
  • Page 139cardiagn.co
  • Page 140M/T Differential Backlash Inspection 1. Differential Backlash - Inspect 1. Place the differential assembly on V-blocks (A), and install the intermediate shaft (B) and the left driveshaft (C). 2. Measure the backlash of both pinion gears (D) with a dial indicator (E). If the backlash is not within th
  • Page 141M/T Differential Carrier and Final Driven Gear Removal and Installation 1. Differential Carrier Bearing - Remove 2. Final Driven Gear - Remove 1. Loosen the bolts in a crisscross pattern in several steps, then remove the bolts and the final driven gear (A). 3. All Removed Parts - Install cardiagn.co
  • Page 142M/T Differential Carrier and Final Driven Gear Removal and Installation NOTE: How to read the torque specifications. 1. Differential Carrier Bearing - Remove 2. Final Driven Gear - Remove 1. Loosen the bolts (left-hand threads) in a crisscross pattern in several steps, then remove the bolts and the
  • Page 143M/T Differential Carrier Bearing Preload Adjustment Special Tool Required Image Description/Tool Number Preload Inspection Tool 070AJ-0020101 cardiagn.com NOTE: If any of the items listed below were replaced, the carrier bearing preload must be adjusted. Transmission housing Clutch housing Different
  • Page 1444. At normal room temperature, measure the starting torque of the differential assembly by rotating it in both directions using the preload inspection tool, a torque wrench (A), and a socket (B). 5. If the carrier bearing preload is not within the standard, select an 81 mm shim that will provide the
  • Page 14581 mm Shim Type Thickness A 2.05 mm (0.0807 in) B 2.08 mm (0.0819 in) C 2.11 mm (0.0831 in) D 2.14 mm (0.0843 in) E 2.17 mm (0.0854 in) F 2.20 mm (0.0866 in) G 2.23 mm (0.0878 in) H 2.26 mm (0.0890 in) J 2.29 mm (0.0902 in) K 2.32 mm (0.0913 in) L 2.35 mm (0.0925 in) M 2.38 mm (0.0937 in) N 2.41 mm
  • Page 146M/T Differential Carrier Bearing Replacement Special Tool Required Image Description/Tool Number Remover Installer, 22 x 37/46 x 52 mm 07PAF-0030100 cardiagn.com 1. Differential Carrier Bearing - Remove Clutch housing side 1. Check the carrier bearings for wear and rough rotation. If they rotate smo
  • Page 1472. Remove the carrier bearings (A) with a commercially available bearing puller (B). 2. Differential Carrier Bearing - Install cardiagn.com
  • Page 148Clutch housing side 1. Install the carrier bearings (A) using the 22 x 37/46 x 52 mm remover installer, an attachment and, a press. Press on each bearing until it bottoms. There should be no clearance between the bearings and the differential carrier. NOTE: Place the seal part (B) of the bearing tow
  • Page 149M/T Differential Carrier Bearing Replacement Special Tool Required Image Description/Tool Number Installer Attachment, 50 mm 070AF-RFY0100 cardiagn.com Remover Installer, 22 x 37/46 x 52 mm 07PAF-0030100 NOTE: Where icon is shown, click for further information. The bearing outer race and the tapered
  • Page 150Detailed information, notes, and precautions Replace cardiagn.com Clutch Housing Side 1. 45 x 80 x 21 mm Carrier Bearing - Remove NOTE: When removing the 45 x 80 x 21 mm carrier bearing, do the following procedures. -1. Check the 45 x 80 x 21 mm carrier bearing (A) for wear and rough rotation on the
  • Page 151NOTE for installation Install the 45 x 80 x 21 mm carrier bearing (A) until it bottoms using the 22 x 37/46 x 52 mm remover installer and a press (B). There should be no clearance between the carrier bearing and the differential carrier. cardiagn.com Transmission Housing Side 1. 50 x 81 x 18 mm Carr
  • Page 152NOTE for installation Install the 50 x 81 x 18 mm carrier bearing (A) until it bottoms using the 50 mm installer attachment, an attachment (B), and a press (C). There should be no clearance between the carrier bearing and the differential carrier. cardiagn.com
  • Page 153M/T Differential Component Location Index Si cardiagn.com Type-R
  • Page 154cardiagn.co
  • Page 155M/T Differential Operation Check NOTE: The helical type limited slip differential (LSD) distributes optimum power between the two driving axles according to the difference in torque as demanded by the driving wheels. Under no circumstances should the engine be started with either wheel raised off th
  • Page 156M/T Differential Rotating Torque Check 1. M/T Differential Rotating Torque - Check 1. Turn the vehicle to the OFF (LOCK) mode. 2. Raise the vehicle on a lift. Make sure it is securely supported, and allow all four wheels to rotate freely. 3. Shift the transmission into neutral. 4. Measure the rotati
  • Page 157M/T Differential Thrust Clearance Adjustment Special Tool Required Image Description/Tool Number Driver Handle, 40 mm I.D. 07746-0030100 cardiagn.com 1. Differential Oil Seal (Transmission Housing Side) - Remove 2. Differential Thrust Clearance - Adjust 1. If you removed the 90 mm shim (A) from the
  • Page 1582. Install the differential assembly (A). 3. Tighten the clutch and transmission housings with several 8 mm flange bolts. NOTE: It is not necessary to use sealing agent between the housings for this procedure. cardiagn.com 4. Use the 40 mm I.D. driver handle to bottom the differential assembly in th
  • Page 1595. Measure the clearance between the 90 mm shim and the bearing outer race in the transmission housing. Standard: 0-0.10 mm (0-0.003 in) 6. If the clearance exceeds the standard, select a new 90 mm shim from the following table. If the clearance measured in step 5 is within the standard, go to step
  • Page 160Rear Damper Removal, Installation, and Inspection NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the procedure are for 2/4-door without adaptive damper system. 1. Rear Damper - Exploded View cardiagn.com
  • Page 161cardiagn.co
  • Page 162NOTE: How to read the torque specifications. Refer to the Exploded View as needed during the following procedures. Unless otherwise indicated, illustrations used in the procedure are for 2/4-door without adaptive damper system. 1. Vehicle - Lift 2. Rear Wheel - Remove 3. Damper Items - Remove (With
  • Page 1632. Remove the clip (B). 4. Lower Arm B - Support 1. Position a floor jack under lower arm B. 2. Raise the floor jack until the suspension begins to compress. cardiagn.com 5. Damper - Remove 1. Remove the damper lower mounting bolt (A) and the washer (except Type-R) (B). NOTE: Use the new flange nut
  • Page 1642. Remove the damper upper mounting bolts (A). NOTE: Do not let the damper/spring drop down under its own weight. Use a new flange bolts during reassembly. cardiagn.com 3. Remove the damper unit (A). NOTE: Be careful not to damage the body. During installation, note these items. - Install the damper
  • Page 1651. Rear Damper - Inspect 1. Install the damper mounting base and the self-locking nut. 2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it d