Disassembly and Assembly
REAR DRIVE SHAFT
Disassembly and Assembly
DISASSEMBLY
Rear 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.
CAUTION:
Use paint or similar substance for matching marks. Never scratch the surface.
4.Remove stopper ring with suitable tool, and pull out housing.
5.Put matching marks on ball cage/steel ball/inner race assembly and shaft.
CAUTION:
Use paint or similar substance for matching marks. Never scratch the surface.
6.Remove snap ring, then remove ball cage/steel ball/inner race assembly from shaft.
7.Remove boot from shaft.
Wheel Side
1.Remove dust shield from drive shaft.
2.Fix shaft with a vise.
CAUTION:
Protect shaft when fixing with a vise using aluminum or copper plates.
3.Remove boot bands. Then remove boot from joint sub-assembly.
4.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.
5.Remove circular clip from shaft.
6.Remove boot from shaft.
ASSEMBLY
Rear Final Drive Side
1.Remove old grease on housing with paper paste.
2.Install new boot and boot band to shaft.
CAUTION:
- Wrap serrated part of shaft with tape to protect from damage.
- Never reuse boot and boot band.
3.Remove the tape wrapped around the serrated on shaft.
4.Install ball cage/steel ball/inner race assembly (1) to shaft (2), and secure them tightly with a snap ring (3).
CAUTION:
Never reuse snap ring.
NOTE:
Align matching marks painted when ball cage/steel ball/inner race assembly were removed.
5.Apply the appropriate amount of grease onto housing and slid surface.
NOTE:
Align matching marks painted when housing were removed.
Standard
Grease amount: Rear Axle.
6.Install stopper ring to housing.
7.After installed, pull shaft to check engagement between housing and stopper ring.
8.Install boot securely into grooves (indicated by "*" marks) shown in the figure.
CAUTION:
If there is grease on boot mounting surfaces (indicated by
"*" marks) of shaft or housing, boot may come off. Remove all grease from the surfaces.
9.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 : Refer to {LINK_TO_MANY:0000000007470193}{LINK_TO_MANY:0000000007470194}, "Drive
length (L)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.
10.Install new boot bands securely.
CAUTION:
Never reuse boot band.
a.For one-touch clamp band i.Secure large and small ends of 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 (black arrow) 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.
11.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.
Wheel Side
1.Clean old grease on joint sub-assembly with paper waste.
2.Apply the specified amount of grease into joint sub-assembly serration hole until grease begins to ooze from ball groove and serration hole.
CAUTION:
After applying grease, use a paper waste to wipe off old grease that has oozed out.
3.Install new boot and boot band to shaft.
CAUTION:
- Wrap serrated part of shaft with tape to protect from damage.
- Never reuse boot and boot band.
4.Remove the tape wrapped around the serrated on shaft.
5.Position circular clip on groove at the shaft edge.
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip.
6.Align both center axles of the shaft edge and joint sub-assembly. Then assemble shaft with circular clip joint sub-assembly.
7.Install joint sub-assembly to shaft using plastic hammer.
CAUTION:
Confirm that joint sub-assembly is correctly engaged while rotating drive shaft.
8.Apply the balance of the specified amount of grease into the boot inside from large diameter side of boot.
Standard
Grease amount: Rear Axle.
9.Install the boot securely into grooves (indicated by "*" marks)
shown in the figure.
CAUTION:
If grease adheres to the boot mounting surface (with "*"
mark) on the shaft or housing, boot may come off. Remove all grease from the surfaces.
10.To prevent the deformation of the boot, adjust the boot installation length (L) to the specified value shown below by inserting the suitable tool into inside of the boot from the large diameter side of boot and discharging the inside air.
Standard
Boots installed : Refer to {LINK_TO_MANY:0000000007470193}{LINK_TO_MANY:0000000007470194}, "Drive
length (L)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.
11.Secure the large and small ends of the boot with boot bands using the boot band crimping tool (A) [SST: KV-40107300 (-)].
NOTE:
Secure boot band so that dimension (M) meets the specification as shown in the figure.
Dimension "M": 1.0 - 4.0 mm (0.039 - 0.157 in)
12.Secure joint sub-assembly and shaft, and then make sure that they are in the correct position when rotating boot. Install them with boot band when boot installation positions become incorrect.
13.Install dust shield to drive shaft.