Acura TSX / Honda Accord CL. Manual — part 297

Fig. 5: Removing Cotter Pin From Lower Arm Ball Joint
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2004 Acura TSX

2004 DRIVE AXLES Axle Shafts - Front - TSX

Fig. 6: Removing Axle Shaft Outboard Joint From Wheel Hub
Courtesy of AMERICAN HONDA CO., INC.

2004 Acura TSX

2004 DRIVE AXLES Axle Shafts - Front - TSX

Fig. 7: Removing Intermediate Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Installation

2004 Acura TSX

2004 DRIVE AXLES Axle Shafts - Front - TSX

1. Install a new set ring into the set ring groove of the axle shaft (left axle shaft). See Fig. 8 .

2. Apply .02-.04 oz. (.5-1 g) of specified grease to the whole splined surface (A) of the right axle shaft. See

Fig. 9 . 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.

3. Clean the areas where the axle shaft contacts the differential thoroughly with solvent or carburetor

cleaner, and dry with compressed air. Insert the inboard end (A) of the axle shaft into the differential (B)
or intermediate shaft (C) until the set ring (D) locks in the groove (E). See Fig. 10 .

4. Install the outboard joint (A) into the front hub (B). See Fig. 11 .

5. Clean off any grease contamination from the ball joint tapered section and threads, then install the

knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot (C). Wipe off the grease
before tightening the nut at the ball joint. Tighten the castle nut (D) to the lower torque specification, then
tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening. See Fig.
12 and TORQUE SPECIFICATIONS .

6. Install the new cotter pin (D) into the hole, and bend the center pin.

7. Install the damper fork (A) over the axle shaft and onto the lower arm. See Fig. 13 . Install the damper in

the damper fork so the aligning tab (B) is aligned with the slot in the damper fork. Loosely install the
flange bolt (C).

8. Loosely install the flange bolt (D) and a new self-locking nut (E).

9. Connect the front stabilizer link (B) to the lower arm. See Fig. 3 . Hold the stabilizer link ball point pin

(A) with a hex wrench (C), and tighten the new flange nut (C).

10. Install a new spindle nut (A), then tighten the nut. See Fig. 2 . After tightening, use a drift to stake the

spindle nut shoulder (B) against the axle shaft.

11. Clean the mating surfaces of the brake disc and the front wheel, then install the front wheel with the

wheel nuts.

12. Turn the front wheel by hand, and make sure there is no interference between the axle shaft and

surrounding parts.

13. Tighten the flange bolt and the self-locking nut with the vehicle's weight on the damper.

14. Refill the transmission with transmission fluid:

z

Manual transmission. See appropriate SERVICING in MANUAL TRANSMISSIONS.

z

Automatic transmission. See appropriate SERVICING in AUTOMATIC TRANSMISSIONS.

15. Check the front wheel alignment, and adjust it if necessary. See appropriate WHEEL ALIGNMENT

article in SUSPENSION.

2004 Acura TSX

2004 DRIVE AXLES Axle Shafts - Front - TSX