Disassembly and Assembly
FRONT DRIVE SHAFT
Disassembly and Assembly
DISASSEMBLY
Front Final Drive Side
1. Fix shaft with a vise.
CAUTION:
Protect shaft when fixing with a vise using aluminum or copper plates.
2. Remove boot bands, and then remove boot from housing.
3. Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or similar substance for matching marks. Never scratch the surfaces.
4. Put matching marks (A) on the spider assembly and shaft.
CAUTION:
Use paint or similar substance for matching marks. Never scratch the surfaces.
5. Remove snap ring (1), and then remove spider assembly from the shaft.
6. Remove boot from the shaft.
7. Remove dust shield from housing. (right side)
8. If plug needs to be removed, move boot to wheel side, and take it out with a plastic hammer. (left side)
Wheel Side
1. Fix shaft with a vise.
CAUTION:
Protect shaft when fixing with a vise using aluminum or copper plates.
2. Remove boot bands, and then remove boot from joint sub-assembly.
3. Screw the drive shaft puller (A) 30 mm (1.18 in) or more into the thread of joint sub-assembly, and pull joint sub-assembly with a sliding hammer (B) from shaft.
CAUTION:
- If joint sub-assembly cannot be removed after five or more unsuccessful attempts, replace shaft and joint sub assembly as a set.
- Align sliding hammer and drive shaft and remove them by pulling directory.
4. Remove circular clip from shaft.
5. Remove boot from shaft.
6. Clean old grease on joint sub-assembly with paper waste while rotating ball cage.
ASSEMBLY
Front Final Drive Side
1. Clean old grease on housing with paper waste.
2. If plug (1) has been removed, use a drift to press in a new one.
(left side)
Black arrow: Press
A: Drift [SST: KV38100500 ( - )]
B: Drift [SST: KV38102200 ( - )]
3. Install new boot and boot bands to shaft.
CAUTION:
- Wrap serration on shaft with tape to protect boot from damage.
- Never reuse boot and boot band.
4. Remove the tape wrapped around the serration on shaft.
5. To install the spider assembly (1), align it with the matching marks (A) on the shaft (2) during the removal, and direct the serration mounting surface (B) to the shaft.
6. Secure spider assembly onto shaft with snap ring (1).
7. Apply the appropriate amount of grease to spider assembly and sliding surface.
8. Assemble the housing onto spider assembly, and apply the balance of the specified amount grease.
Standard
Grease amount : Refer to FAX-29, "Drive Shaft". Drive Shaft
9. Align matching marks painted when housing was removed.
10. Install boot securely into grooves (indicated by "*" marks) shown in the figure.
CAUTION:
If grease adheres to the boot mounting surface (with "*" mark) on shaft or housing, boot may come off. Remove all grease from the surface.
11. To prevent the deformation of the boot, adjust the boot installation length (L) to the value shown below by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air.
Standard
Boots installed length (L) : Refer to FAX-29, "Drive Shaft". Drive Shaft
CAUTION:
- If the boot installation length is outside the standard, it may cause breakage of boot.
- Be careful not to touch the inside of the boot with the tip of tool.
12. Install new larger and smaller boot bands securely.
a. For one-touch clamp band i. Secure the large and small ends of a boot with new boot bands as shown in the figure.
b. For low profile type band i. Put boot band in the groove on drive shaft boot. Then fit pawls
( ) into holes to temporary installation.
NOTE:
For the large diameter side, fit projection (A) and guide slit (B) at first.
ii. Pinch projection on the band with suitable pliers to tighten band.
iii. Insert tip of band below end of the pawl.
13. Secure housing and shaft, and then make sure that they are in the correct position when rotating boot. Install them with new boot band when the mounting positions become incorrect.
14. Install dust cover to housing. (right side)
CAUTION:
Never reuse dust cover.
Wheel Side
For further details on the installation procedure, refer to the installation procedure of "Replacement" for the drive shaft boot.