Front Axle
DISASSEMBLY AND REASSEMBLY
Lubricant Points
Disassembly Service Points
T.J. Case Removal
After removing the T.J. case from the B.J. assembly, wipe off the grease on the T.J. case
Inner Shaft Removal
1. Use the special tool to remove the inner shaft assembly, together with the seal plate, from the T.J. case.
2. Use the special tools to remove the inner shaft from the bracket.
1. Remove the snap ring from the drive shaft with the snap ring pliers.
2. Take out the spider assembly from the drive shaft.
3. Clean the spider assembly.
CAUTION:
1. Do not disassemble the spider assembly.
2. Use care in handling so as not to damage the drive shaft.
1. Wipe the grease off of the spline portion.
2. Remove the T.J. boot.
NOTE: If the boot is reused, wrap plastic tape around the drive shaft spline so that the boot is not damaged when it is removed.
Reassembly Service Points
>A< B.J. Boot/B.J. Boot Band (Large)/B.J. Boot Band (Small) Installation
1. Wrap plastic tape around the spline part on the drive shaft, and then install the B.J. boot band (small) and B.J. boot.
2. Install the smaller side of the BJ boot band so that one shaft groove can be seen.
3. Turn the adjusting bolt of the special tool to adjust the opening dimension (W) to the standard value.
Standard value (W): 2.9 mm (0.114 inch)
NOTE:
1. The dimension (W) is adjusted by approximately 0.7 mm (0.028 inch) per one turn.
2. Do not turn the adjusting bolt more than one turn.
4. Place the boot band (small) along the protruding portion, and install it so that there is some clearance (A) along the other side.
5. Use the special tool to crimp the B.J. boot band (small).
CAUTION:
1. Hold the drive shaft perpendicularly, and use the special tool to crimp the B.J. boot band securely.
2. Crimp the B.J. boot band until the special tool touches the stopper.
6. Check that the crimped width (B) is within the standard value.
Standard value (113): 2.4 - 2.8 mm (0.094 - 0.110 inch)
W = 5.5 mm (0.217 inch) - B
Example: If (B) is 2.9 mm (0.114 inch), (W) is 2.6 mm (0.102 inch).
W = 5.5 mm (0.217 inch) - B
Example: If (B) is 2.3 mm (0.091 inch), (W) is 3.2 mm (0.126 inch).
7. Check that the B.J. boot band is secured correctly. If the band is secured incorrectly, repeat steps 4 to 6 to replace it.
8. Apply the specified amount of grease to the boot.
Specified grease: Repair kit grease 95 g (3.35 oz.)
9. Install the B.J. boot to adjust the clearance (c) between the B.J. boot end and the stepped phase of the B.J. housing is within the standard value.
Standard value (c): 0.1 - 1.55 mm (0.004 - 0.061 inch)
10. Adjust the opening dimension (W) to the standard value as mentioned at the step (3).
Standard value (W): 3.2 mm (0.126 inch)
11. Place the B.J. boot band (large) along the protruding portion, and install it so that there is some clearance (D) along the other side.
12. Use the special tool to crimp the BJ. boot band (large) in the same way as the step (5).
13. Check that the crimped width (E) is within the standard value.
Standard value (E): 2.4 - 2.8 mm (0.094 - 0.110 inch)
W = 5.8 mm (0.228 inch) - E
Example: If (E) is 2.9 mm (0.114 inch), (W) is 2.9 mm (0.114 inch).
W = 5.8 mm (0.228 inch) - E
Example: If (E) is 2.3 mm (0.091 inch), (W) is 3.5 mm (0.138 inch).
14. Check that the boot band is secured correctly. If the band is secured incorrectly, repeat steps (11) to (13) to replace it.
>B< Spider Assembly Installation
Install the spider assembly to the shaft from the direction of the spline beveled section.
>C< Center Bearing Installation
>D< Dust Seal Installation
1. Apply multi-purpose grease to the rear surfaces of all dust seals.
Inner dust seal 7 - 10 g (0.25 - 0.35 oz.)
Outer dust seal 4 - 6 g (0.14 - 0.21 oz.)
2. Use the special tools to install the dust seal so that its surface runs even with that of the center bearing bracket.
3. Apply multi-purpose grease to the lip of each dust seal.
NOTE: When applying grease, make sure that it does not adhere to anything outside the lip.
>E< Inner Shaft Installation
>F< T.J. Case And Inner Shaft Assembly Installation
1. Apply multi-purpose grease to the inner shaft spline, then press fit into the T.J. case.
2. Use the special tool to support the T.J. case.
3. Use a pipe [0.30 mm (1.18 inch)] to press the seal plate into the TJ. case.
4. Fill the specified grease to the T.J. case.
Specified grease: Repair kit grease 105 g (3.70 oz.)
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
CAUTION: The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
>G< T.J. Boot Band (Small)/T.J. Boot Band (Large) Installation
Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot band securely.
Standard value (A): 80 ± 3 mm (3.15 ± 0.12 inch)
INSPECTION
- Check the drive shaft for damage, bending or corrosion.
- Check the inner shaft for damage, bending or corrosion.
- Check the drive shaft splines for wear or damage.
- Check the inner shaft splines for wear or damage.
- Check the spider assembly for roller rotation, wear or corrosion.
- Check the groove inside T.J. case for wear or corrosion.
- Check the boots for deterioration, damage or cracking.
- Check the center bearing for seizure, discoloration or roughness of rolling surface.
- Check the dust cover for damage or deterioration.