ES300 1992-1997

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable to the battery.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the front wheel(s).
  8.  
  9. Remove the front fender apron seal.
  10.  
  11. Drain the transaxle.
  12.  
  13. Disconnect the tie rod end from the steering knuckle by removing the cotter pin and nut. Using tool SST 09628-62011 or equivalent, separate the tie rod from the steering knuckle.

    Click image to see an enlarged view

    Fig. Remove the cotter pin and nut



    Click image to see an enlarged view

    Fig. Separate the tie rod from the steering knuckle

  14.  
  15. Disconnect the stabilizer bar link from the lower control arm. Make note of the washers and cushions positions.

    Click image to see an enlarged view

    Fig. Disconnect the stabilizer bar link from the lower control arm

  16.  
  17. Disconnect the lower ball joint from the steering knuckle by removing the bolt and two nuts. Push down on the lower control arm and separate the steering knuckle from the ball joint.

    Click image to see an enlarged view

    Fig. Disconnect the lower ball joint from the steering knuckle

  18.  
  19. Place matchmarks on the halfshaft.

    Click image to see an enlarged view

    Fig. Place matchmarks on the halfshaft

  20.  
  21. Using SST (SST 09923-00020), loosen the six hexagon bolts while depressing the brake pedal. Do not remove the bolts, finger tighten them not to drop down the halfshaft.
  22.  
  23. Using a plastic hammer, disconnect the halfshaft from the axle hub. Push the front axle hub toward the outside of the vehicle, and separate the halfshaft from the axle hub.

    Click image to see an enlarged view

    Fig. Separate the halfshaft from the axle hub

  24.  
  25. Remove the left halfshaft from the transaxle as follows:
    1. Use a brass bar and hammer to tap the inner joint out of the transaxle.
    2.  
    3. Remove the halfshaft.

      Click image to see an enlarged view

      Fig. Remove the halfshaft

    4.  
    5. Once the halfshaft is removed from the vehicle, remove the snapring from the halfshaft.

      Click image to see an enlarged view

      Fig. Remove the snapring

    6.  

  26.  
  27. Remove the right halfshaft from the transaxle as follows:
    1. Remove the bearing lockbolt. The lockbolt is located in the center of the halfshaft, near the dampener.

      Click image to see an enlarged view

      Fig. Remove the bearing lockbolt

    2.  
    3. Using snapring pliers, remove the snapring and pull the halfshaft from the transaxle.

      Click image to see an enlarged view

      Fig. Remove the snapring and the halfshaft

    4.  

  28.  

To install:

  1. To install the left halfshaft to the transaxle:
    1. Install a new snapring.
    2.  
    3. Coat the side gear shaft and differential case sliding surface with gear oil.
    4.  
    5. Using a brass bar and hammer, tap in the drive shaft until it makes contact with the pinion shaft.
    6.  
    7. Install the halfshaft to the transaxle with the snapring opening facing down. The halfshaft should click into place when installing.
    8.  
    9. After installation of the halfshaft, check that there is 0.08-0.12 in. (2-3 mm) of play in axial direction, and check that the halfshaft cannot be removed by hand.
    10.  

  2.  
  3. Connect the halfshaft to the steering knuckle and then install the locknut. Torque the locknut to 217 ft. lbs. (294 Nm).
  4.  
  5. To install the right halfshaft to the transaxle:
    1. Coat the side gear shaft and differential case sliding surface with gear oil.
    2.  
    3. Install the halfshaft to the transaxle through the bearing bracket.
    4.  
    5. Using snapring pliers, install the snapring.
    6.  
    7. Install the bearing lockbolt. Torque the lockbolt to 24 ft. lbs. (32 Nm).
    8.  

  6.  
  7. Install the outboard joint side of the halfshaft to the axle hub.
  8.  
  9. Connect the steering knuckle to the lower ball joint. Install the two nuts and bolt. Torque the nuts and bolt to 94 ft. lbs. (127 Nm).
  10.  
  11. Using SST (SST 09043-88010), tighten the six hexagon bolts to 48 ft. lbs. (65 Nm).
  12.  
  13. Connect the stabilizer bar link to the lower control arm. Torque the nut to 47 ft. lbs. (64 Nm).
  14.  
  15. Connect the tie rod to the steering knuckle and torque the nut to 36 ft. lbs. (49 Nm). Install a new cotter pin to the tie rod end.
  16.  
  17. Install the bearing lock nut and tighten to 217 ft. lbs. (294 Nm). Install the lock nut cap and secure it with a new cotter pin.
  18.  
  19. Install the front fender apron seal.
  20.  
  21. Install the wheel(s) and lower the vehicle.
  22.  
  23. Refill the transaxle and check for leaks.
  24.  
  25. Connect the negative battery cable to the battery.
  26.  

 
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