• HEADINGS
  • Special Tools
  • Component Location Index
  • Driveshaft Inspection
  • Driveshaft Removal
  • Driveshaft Disassembly
    • Inboard Joint Side
    • Outboard Joint Side
  • Dynamic Damper Replacement
  • Driveshaft Reassembly
    • Exploded View
    • Inboard Joint Side
    • Outboard Joint Side
  • Driveshaft Installation
  • Intermediate Shaft Removal
  • Intermediate Shaft Disassembly
  • Intermediate Shaft Reassembly
    • Exploded View
  • Intermediate Shaft Installation
• FIGURES
  • Fig. 1: Identifying Special Tools
  • Fig. 2: Identifying Driveline/Axle Component Location
  • Fig. 3: Checking Inboard Boot And Outboard Boot On Driveshaft
  • Fig. 4: Identifying Locking Tab On Spindle Nut
  • Fig. 5: Holding Stabilizer Ball Joint Pin With Hex Wrench
  • Fig. 6: Identifying Self-Locking Nut Damper Fork Mounting Bolt
  • Fig. 7: Tapping Driveshaft
  • Fig. 8: Tapping Inboard Joint
  • Fig. 9: Prying Inboard Joint From Transmission Housing
  • Fig. 10: Identifying Set Ring
  • Fig. 11: Pinching Boot (Welded Type)
  • Fig. 12: Pushing Boot Band Clip (Double Loop Type)
  • Fig. 13: Pinching Boot Band Using Boot Band Pliers (Low Profile Type)
  • Fig. 14: Identifying Mark Location
  • Fig. 15: Identifying Rollers And Spider With Circlip
  • Fig. 16: Wrapping Splines On Driveshaft With Vinyl Tape
  • Fig. 17: Lifting Up Three Tabs
  • Fig. 18: Identifying Outboard Boot
  • Fig. 19: Wiping Grease To Expose Driveshaft And Outboard Joint Inner Race
  • Fig. 20: Removing Outboard Joint
  • Fig. 21: Identifying Stop Ring From Driveshaft
  • Fig. 22: Wrapping Splines On Driveshaft With Vinyl Tape
  • Fig. 23: Identifying Right Driveshaft
  • Fig. 24: Identifying Left Driveshaft
  • Fig. 25: Identifying Right Driveshaft Length
  • Fig. 26: Identifying Left Driveshaft Length
  • Fig. 27: Exploded View Of Driveshaft
  • Fig. 28: Wrapping Splines With Vinyl Tape
  • Fig. 29: Identifying Spider Onto Driveshaft
  • Fig. 30: Identifying Mark Location
  • Fig. 31: Identifying Grease Applying Area
  • Fig. 32: Fitting Inboard Joint Onto Driveshaft
  • Fig. 33: Fitting Boot Onto Driveshaft And Inboard Joint
  • Fig. 34: Identifying Driveshafts Length - Right
  • Fig. 35: Identifying Driveshafts Length - Left
  • Fig. 36: Identifying Low Profile Band Onto Boot
  • Fig. 37: Closing Hook Portion Of Band With Commercially Available Boot Band Pliers
  • Fig. 38: Passing End Of Double Loop Band Through Clip
  • Fig. 39: Identifying Boot Band Position
  • Fig. 40: Tightening Boot Band
  • Fig. 41: Punching Boot Band
  • Fig. 42: Cutting Off Excess Free End Of Band
  • Fig. 43: Tapping Boot Band
  • Fig. 44: Wrapping Splines With Vinyl Tape
  • Fig. 45: Identifying Stop Ring Into Driveshaft Groove
  • Fig. 46: Applying Grease In Driveshaft Hole
  • Fig. 47: Inserting Driveshaft Into Outboard Joint
  • Fig. 48: Tapping Outboard Joint Into Hard Surface
  • Fig. 49: Checking Alignment Of Paint Mark With Outboard Joint Rim
  • Fig. 50: Applying Grease To Outboard Joint
  • Fig. 51: Fitting Boot Onto Driveshaft And Outboard Joint
  • Fig. 52: Closing Portion Of Band
  • Fig. 53: Identifying Clearance Between Closed Portion Of Band
  • Fig. 54: Applying Grease In Outboard Joint And Front Wheel Bearing
  • Fig. 55: Identifying Set Ring
  • Fig. 56: Applying Grease To Splined Surface
  • Fig. 57: Inserting Inboard Of Driveshaft Into Differential
  • Fig. 58: Installing Outboard Joint Into Front Wheel Hub
  • Fig. 59: Identifying Knuckle Onto Lower Arm (with Torque Specifications)
  • Fig. 60: Aligning Tab With Slot In Damper Fork (with Torque Specifications)
  • Fig. 61: Holding Stabilizer Link Ball Joint Pin With Hex Wrench (with Torque Specifications)
  • Fig. 62: Applying Small Amount Of Engine Oil To Seating Surface Of Spindle Nut (with Torque Specifications)
  • Fig. 63: Identifying Flange Bolt And Dowel Bolts
  • Fig. 64: Identifying Intermediate Shaft And Differential Oil Seal
  • Fig. 65: Identifying Set Ring, Outer Seal And External Snap Ring
  • Fig. 66: Pressing Intermediate Shaft Out Of Intermediate Shaft Bearing
  • Fig. 67: Identifying Internal Snap Ring
  • Fig. 68: Pressing Intermediate Shaft Bearing Out Of Bearing Support
  • Fig. 69: Exploded View Of Intermediate Shaft (with Torque Specifications)
  • Fig. 70: Pressing Intermediate Shaft Bearing Into Bearing Support
  • Fig. 71: Identifying Internal Snap Ring
  • Fig. 72: Pressing Intermediate Shaft Into Shaft Bearing
  • Fig. 73: Identifying External Snap Ring Into Groove
  • Fig. 74: Pressing Outer Seal Into Bearing Support
  • Fig. 75: Identifying Set Ring
  • Fig. 76: Identifying Intermediate Shaft And Differential Oil Seal
  • Fig. 77: Identifying Flange Bolt And Dowel Bolts (with Torque Specifications)
• TABLES

2004-08 DRIVELINE/AXLES

Driveline/Axle - TSX

Special Tools

Fig. 1: Identifying Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Component Location Index

Fig. 2: Identifying Driveline/Axle Component Location
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Driveshaft Inspection

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 boot bands.

   Fig. 3: Checking Inboard Boot And Outboard Boot On Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Check the driveshaft for cracks and damage. If any damage is found, replace the driveshaft.
3. Check the inboard joint (E) and the outboard joint (F) for cracks and damage. If any damage is found, replace the inboard joint or the outboard joint as an assembly.
4. Hold the inboard joint and turn the front wheel by hand, then make sure the joint is not excessively loose. If necessary, replace the inboard joint or the outboard joint as an assembly.

Driveshaft Removal

1. Raise the vehicle on the lift.
2. Remove the front wheels.
3. Lift up the locking tab (A) on the spindle nut (B), then remove the nut.

   Fig. 4: Identifying Locking Tab On Spindle Nut
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Drain the transmission fluid. Reinstall the drain plug with a new washer:
   • Manual transmission (see MANUAL TRANSMISSION )
   • Automatic transmission (see step 3 on ATF REPLACEMENT )
5. Hold the stabilizer ball joint pin (A) with a hex wrench (B), and remove the flange nut (C). Separate the front stabilizer link (D) from the lower arm.

   Fig. 5: Holding Stabilizer Ball Joint Pin With Hex Wrench
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Remove self-locking nut (A), 12 mm damper fork mounting bolt (B), and 10 mm damper pinch bolt (C), then remove the damper fork (D).

   Fig. 6: Identifying Self-Locking Nut Damper Fork Mounting Bolt
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the cotter pin from the lower arm ball joint castle nut, and remove the nut, then separate the ball joint from the lower arm using the ball joint thread protector and the ball joint remover (see step 11 on KNUCKLE/HUB/WHEEL BEARING REPLACEMENT ).

   NOTE:

   To avoid damaging the ball joint, install the ball joint thread protector onto the threads of the ball joint. Be careful not to damage the ball joint boot when installing the remover. Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint.

8. Pull the knuckle outward, and remove the outboard joint from the front hub using a plastic hammer.

   Fig. 7: Tapping Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Right driveshaft: Drive the inboard joint (A) off of the intermediate shaft using a drift and hammer. Remove the driveshaft as an assembly.

   NOTE:

   Do not pull on the driveshaft (B) or the inboard joint may come apart.

   Fig. 8: Tapping Inboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Left driveshaft: Pry the inboard joint (A) from the transmission housing using a prybar. Remove the driveshaft as an assembly.

    NOTE:

    Do not pull on the driveshaft (B) or the inboard joint may come apart. Pull the driveshaft straight out to avoid damaging the oil seal.

    Fig. 9: Prying Inboard Joint From Transmission Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Driveshaft Disassembly

Special Tools Required

• Threaded adapter, 24 x 1.5 mm 07XAC-001020A
• Slide hammer, 5/8"-18 UNF, commercially available

Inboard Joint Side

1. Remove the set ring from the inboard joint (left driveshaft).

   Fig. 10: Identifying Set Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the boot bands. Be careful not to damage the boot.
   • If the boot band is a welded 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 boot band using commercially available boot band pliers (F).

   Welded type

   Fig. 11: Pinching Boot (Welded Type)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Double loop type

   Fig. 12: Pushing Boot Band Clip (Double Loop Type)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Low profile type

   Fig. 13: Pinching Boot Band Using Boot Band Pliers (Low Profile Type)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Make a marks (A) on each rollers (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.

   NOTE:

   Do not engrave or scribe marks on the rolling surface. C

   Fig. 14: Identifying Mark Location
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Make a marks (A) on the rollers (B) and spider (C) to identify the locations of the rollers on the spider, then remove the rollers.

   NOTE:

   Do not engrave or scribe marks on the rolling surface.

   Fig. 15: Identifying Rollers And Spider With Circlip
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the circlip (D).
6. Mark the spider and driveshaft (E) to identify the position of the spider on the shaft.
7. Remove the spider.
8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.

   Fig. 16: Wrapping Splines On Driveshaft With Vinyl Tape
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Remove the inboard boot. Be careful not to damage the boot.
10. Remove the vinyl tape.

Outboard Joint Side

1. Remove the boot bands (A). Lift up the three tabs (B) with a screwdriver. Be careful not to damage the boot.

   Fig. 17: Lifting Up Three Tabs
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Slide the outboard boot (A) partially to the inboard joint side. Be careful not to damage the boot.

   Fig. 18: Identifying Outboard Boot
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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 rim (C).

   Fig. 19: Wiping Grease To Expose Driveshaft And Outboard Joint Inner Race
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Securely clamp the driveshaft in a bench vise with a shop towel.

   Fig. 20: Removing Outboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Remove the outboard joint (A) using the 24 x 1.5 mm threaded adapter (B) and a commercially available 5/8"-18 UNF, slide hammer (C).
7. Remove the driveshaft from the bench vise.
8. Remove the stop ring from the driveshaft.

   Fig. 21: Identifying Stop Ring From Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

   Fig. 22: Wrapping Splines On Driveshaft With Vinyl Tape
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Remove the outboard boot. Be careful not to damage the boot.
11. Remove the vinyl tape.

Dynamic Damper Replacement

1. Remove the inboard joint (see INBOARD JOINT SIDE ).
2. Remove the dynamic damper bands (see step 2 ).
   • If the band is a welded type, cut the band.
   • If the band is a double loop type, lift up the band end, and push it into the clip.
   • If the band is a low profile type, pinch the band using commercially available boot band pliers.
3. Remove the dynamic damper.

   Right driveshaft

   Fig. 23: Identifying Right Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Left driveshaft

   Fig. 24: Identifying Left Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Adjust the position of the new dynamic damper to these measurements.

   NOTE:

   Be careful not to swap the dynamic dampers. The right and left dynamic dampers are different.

   Right driveshaft: 268-272 mm (10.55-10.71 in.)

   Fig. 25: Identifying Right Driveshaft Length
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Left driveshaft: 288-292 mm (11.34-11.50 in.)

   Fig. 26: Identifying Left Driveshaft Length
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Install the double loop band (see step 14 ).
6. Install the inboard joint (see INBOARD JOINT SIDE ).

Driveshaft Reassembly

Exploded View

Fig. 27: Exploded View Of Driveshaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

• Boot band tool, KD-3191 or equivalent, commercially available
• Boot band pliers, Kent-Moore J-35910 or equivalent, commercially available

NOTE:

Refer to the EXPLODED VIEW, as needed, during this procedure.

Inboard Joint Side

1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.

   Fig. 28: Wrapping Splines With Vinyl Tape
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Install the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.
3. Install the spider (A) onto the driveshaft by aligning the marks (B) you mode on the spider and the end of the driveshaft.

   Fig. 29: Identifying Spider Onto Driveshaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the circlip (C) into the driveshaft groove. Rotate the circlip in its groove to make sure it is fully seated.
5. Fit the rollers (A) onto the spider (B) with their high shoulders facing outward, and note these items:
   • Reinstall the rollers in their original positions on the spider by aligning the marks (C) you mode.
   • Hold the driveshaft pointed up to prevent the rollers from falling off.

     Fig. 30: Identifying Mark Location
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Pack the inboard joint with the joint grease included in the new inboard boot set.

   Grease quantity

   Inboard joint: 150-160 g (5.3-5.6 oz)

   Fig. 31: Identifying Grease Applying Area
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Fit the inboard joint onto the driveshaft and note these items:
   • Reinstall the inboard joint onto the driveshaft by aligning the marks (A) you mode on the inboard joint and the rollers.
   • Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.

     Fig. 32: Fitting Inboard Joint Onto Driveshaft
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Fit the boot (A) ends onto the driveshaft (B) and the inboard joint (C).

   Fig. 33: Fitting Boot Onto Driveshaft And Inboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Adjust the length of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension. Doing this prevents a vacuum or too much air in the boot, preventing it from compressing or extending properly.

   Right driveshaft

   Fig. 34: Identifying Driveshafts Length - Right
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Left driveshaft

   Fig. 35: Identifying Driveshafts Length - Left
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Install new boot bands.
    • For the low profile type, go to step 11.
    • For the double loop type, go to step 14. (Boot band replacement only)
11. Install the new low profile band (A) onto the boot (B), then hook the tabs (C) of the band.

    Fig. 36: Identifying Low Profile Band Onto Boot
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Close the hook portion of the band with commercially available boot band pliers (A), then hook the tabs (B) of the band.

    Fig. 37: Closing Hook Portion Of Band With Commercially Available Boot Band Pliers
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Install the boot band on the other end of the boot, and repeat steps 11 and 12.
14. Fit the boot ends onto the driveshaft and the inboard joint, then install the 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.

    Fig. 38: Passing End Of Double Loop Band Through Clip
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

15. Pull up the slack in the band by hand.
16. Mark a position (A) on the band 10-14 mm (0.4-0.6 in.) from the clip (B).

    Fig. 39: Identifying Boot Band Position
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Thread the free end of the band through the nose section of the commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).

    Fig. 40: Tightening Boot Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Using a wrench on the winding mandrel of the boot band tool, tighten the band until the marked spot (C) on the band meets the edge of the clip.
19. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.

    Fig. 41: Punching Boot Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5-10 mm (0.2-0.4 in.) tail protruding from the clip.

    Fig. 42: Cutting Off Excess Free End Of Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Bend the band end (A) by tapping it down with a hammer.

    NOTE:

    Make sure the band and clip do not interfere with anything on the vehicle and the band does not move. Clean any grease remaining on the surrounding surfaces. Fig. 43: Tapping Boot Band Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Repeat steps 14 through 21 for the band on the other end of the boot.

Outboard Joint Side

1. Wrap the splines with vinyl tape (A) to prevent damaging the outboard boot.

   Fig. 44: Wrapping Splines With Vinyl Tape
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Install the new ear clamp bands (B) and the outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.
3. Install a new stop ring into the driveshaft groove (A).

   Fig. 45: Identifying Stop Ring Into Driveshaft Groove
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

   Fig. 46: Applying Grease In Driveshaft Hole
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is closed.

   Fig. 47: Inserting Driveshaft Into Outboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. To completely seat the outboard joint, pick up the driveshaft and joint, and tap or hit them from a height of about 10 cm (4 in.) onto a hard surface. 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.

   Fig. 48: Tapping Outboard Joint Into Hard Surface
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Check the alignment of the paint mark (A) you made with the outboard joint rim (B).

   Fig. 49: Checking Alignment Of Paint Mark With Outboard Joint Rim
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Pack the outboard joint (A) with the remaining grease included in the new outboard boot set.

   Total grease quantity

   Outboard joint: 140-150 g (4.9-5.3 oz)

   Fig. 50: Applying Grease To Outboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Fit the boot (A) ends onto the driveshaft (B) and the outboard joint (C).

   Fig. 51: Fitting Boot Onto Driveshaft And Outboard Joint
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Close the ear portion (A) of the band with commercially available boot band pliers Kent-Moore J-35910 or equivalent (B).

    Fig. 52: Closing Portion Of Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band tighter.

    Fig. 53: Identifying Clearance Between Closed Portion Of Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Repeat steps 10 and 11 for the band on the other end of the boot.

Driveshaft Installation

NOTE:

Before starting installation, make sure the mating surfaces of the joint and the splined section are not dusty or dirty.

1. Apply grease to the contact area (A) of the outboard joint and the front wheel bearing.

   Fig. 54: Applying Grease In Outboard Joint And Front Wheel Bearing
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   NOTE:

   Failure to apply grease may cause excessive noise and vibration.

2. Install a new set ring onto the set ring groove of the driveshaft (left driveshaft).

   Fig. 55: Identifying Set Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Apply 0.5-1.0 g (0.02-0.04 oz) of grease to the whole splined surface (A) of the right driveshaft. After applying grease, remove the grease from the splined grooves at intervals of 2-3 splines and from the set ring groove (B) so that air can bleed from the intermediate shaft.

   Fig. 56: Applying Grease To Splined Surface
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Clean the areas where the driveshaft contacts the differential thoroughly with solvent or brake cleaner, and dry with compressed air.

   NOTE:

   Do not wash the rubber parts with solvent.

5. Install the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) until the set ring (D) locks in the groove (E).

   NOTE:

   Insert the driveshaft horizontally to prevent damaging the differential oil seal.

   Fig. 57: Inserting Inboard Of Driveshaft Into Differential
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Install the outboard joint (A) into the front hub (B).

   Fig. 58: Installing Outboard Joint Into Front Wheel Hub
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Wipe off any grease contamination from the ball joint tapered section and threads, then install the knuckle (A) onto the lower arm (B). Torque the new castle nut (C) to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the nut by loosening it.

   NOTE:

   Make sure the ball joint boot is not damaged or cracked.

   Fig. 59: Identifying Knuckle Onto Lower Arm (with Torque Specifications)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Install the new cotter pin (D) into the ball joint pin hole, and bend the cotter pin as shown.
9. Install the damper fork (A) over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab (B) is aligned with the slot in the damper fork. Loosely install the damper pinch bolt (C).

   Fig. 60: Aligning Tab With Slot In Damper Fork (with Torque Specifications)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Loosely install a new damper fork mounting bolt (D) and a new self-locking nut (E).
11. Connect the front stabilizer link (A) to the lower arm. Hold the stabilizer link ball joint pin (B) with a hex wrench (C), and tighten the new flange nut (D).

    Fig. 61: Holding Stabilizer Link Ball Joint Pin With Hex Wrench (with Torque Specifications)
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Apply a small amount of engine oil to the seating surface of the new spindle nut (A).

    Fig. 62: Applying Small Amount Of Engine Oil To Seating Surface Of Spindle Nut (with Torque Specifications)
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Install a new spindle nut, then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (B) against the driveshaft.
14. Place a jack under the lower arm, and raise the suspension to load it with the vehicle's weight.
15. Clean the mating surfaces of the brake disc and the front wheel, then install the front wheel.
16. Turn the front wheel by hand, and make sure there is no interference between the driveshaft and surrounding parts.
17. Tighten the damper pinch bolt and damper fork mounting bolt with the vehicle's weight on the damper.
18. Lower the vehicle on the lift.
19. Refill the transmission with the recommended transmission fluid:
    • Manual transmission (see MANUAL TRANSMISSION )
    • Automatic transmission (see step 4 on ATF REPLACEMENT )
20. Check the front wheel alignment, and adjust it if necessary (see WHEEL ALIGNMENT ).
21. Test-drive the vehicle.

Intermediate Shaft Removal

1. Drain the transmission fluid. Reinstall the drain plug with a new washer:
   • Manual transmission (see MANUAL TRANSMISSION )
   • Automatic transmission (see step 3 on ATF REPLACEMENT )
2. Remove the right driveshaft (see DRIVESHAFT REMOVAL ).
3. Remove the flange bolt (A) and two dowel bolts (B).

   Fig. 63: Identifying Flange Bolt And Dowel Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontally until it is clear of the differential to prevent damaging the differential oil seal (B).

   Fig. 64: Identifying Intermediate Shaft And Differential Oil Seal
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Intermediate Shaft Disassembly

Special Tools Required

• Half shaft base 07NAF-SR30101
• Oil seal driver 07947-SB00100

1. Remove the set ring (A), outer seal (B), and external snap ring (C).

   Fig. 65: Identifying Set Ring, Outer Seal And External Snap Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using a press. Be careful not to damage the bearing support ring (C) on the intermediate shaft during disassembly.

   Fig. 66: Pressing Intermediate Shaft Out Of Intermediate Shaft Bearing
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the internal snap ring.

   Fig. 67: Identifying Internal Snap Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Press the intermediate shaft bearing (A) out of the bearing support (B) using the half shaft base (C), oil seal driver (D), and a press.

   Fig. 68: Pressing Intermediate Shaft Bearing Out Of Bearing Support
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Intermediate Shaft Reassembly

Exploded View

Fig. 69: Exploded View Of Intermediate Shaft (with Torque Specifications)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

• Oil seal driver 07GAD-PH70201
• Attachment, 52 x 55 mm 07746-0010400
• Attachment, 35 mm I.D. 07746-0030400
• Driver 07749-0010000

NOTE:

Refer to the Exploded View, as needed, during this procedure.

1. Clean the disassembled parts with solvent, and dry them with compressed air. Do not wash the rubber parts with solvent.
2. Press the intermediate shaft bearing (A) into the bearing support (B) using the 52 x 55 mm attachment (C), driver (D), and a press.

   Fig. 70: Pressing Intermediate Shaft Bearing Into Bearing Support
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Seat the internal snap ring into the groove of the bearing support.

   Fig. 71: Identifying Internal Snap Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Press the intermediate shaft (A) into the new shaft bearing (B) using the 35 mm I.D. attachment (C) and a press.

   Fig. 72: Pressing Intermediate Shaft Into Shaft Bearing
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

   Fig. 73: Identifying External Snap Ring Into Groove
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Install the new outer seal (A) into the bearing support (B) using the oil seal driver (C) and a press.

   Fig. 74: Pressing Outer Seal Into Bearing Support
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Intermediate Shaft Installation

1. Install the new set ring.

   Fig. 75: Identifying Set Ring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or brake cleaner, and dry with compressed air.

   NOTE:

   Do not wash the rubber parts with solvent.

3. Insert the intermediate shaft assembly (A) into the differential until the set ring locks in the groove.

   NOTE:

   Insert the intermediate shaft horizontally to prevent damaging the differential oil seal (B).

   Fig. 76: Identifying Intermediate Shaft And Differential Oil Seal
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the flange bolt (A) and two dowel bolts (B). B

   Fig. 77: Identifying Flange Bolt And Dowel Bolts (with Torque Specifications)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Install the right driveshaft (see DRIVESHAFT INSTALLATION ).
6. Refill the transmission with the recommended transmission fluid:
   • Manual transmission (see MANUAL TRANSMISSION )
   • Automatic transmission (see step 4 on ATF REPLACEMENT )
7. Test-drive the vehicle.