Overhaul

DISASSEMBLY AND REASSEMBLY

Lubricant Points

Disassembly Service Points
T.J. Case Removal
Remove the T.J. case from the BJ assembly, and wipe off the grease inside the T.J. case.

Snap Ring/Spider Assembly Removal

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.

T.J. Boot Removal

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.

B.J. Boot Band (Small)/B.J. Boot Band (Large) Removal

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 13J. boot band (small) and B.J. boot.
2. Install the smaller side of the 13J. 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)
Screw in the adjusting bolt.
Loosen the adjusting bolt.

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 BA 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 BA boot band until the special tool touches the stopper.

6. Check that the crimped width (B) is within the standard value.

Standard value (13): 2.4 - 2.8 mm (0.094 - 0.110 inch)
Readjust the dimension (W) of step 3 to the value calculated by the following equation, and repeat step 5.
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).
Remove the B.J. boot band, readjust the dimension (W) of step 3 to the value calculated by the following equation, and use a new BA boot band to repeat steps 4 to 5.
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
<2.0L Engine (Non-turbo)> 110 g (3.88 oz.)
<2.0L Engine (Turbo) and 2.4L Engine> 130 g (4.59 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 BJ. 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 B.J. 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)
Readjust the dimension (W) of step 10 to the value calculated by the following equation, and repeat step 12.
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).
Remove the B.J. boot band, readjust the dimension (W) of step 10 to the value calculated by the following equation, and use a new B.J. boot band to repeat steps 11 to 12.
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< Dynamic Damper Installation

Install the dynamic damper in the position shown in the illustration.

>C< Spider Assembly/T.J. Case Installation

1. Install the spider assembly to the shaft from the direction of the spline beveled section.
2. After applying specified grease to the T.J. case, insert the drive shaft and apply grease one more time.

Specified grease: Repair kit grease
<2.0L Engine (Non-turbo)> 105 g (3.70 oz.)
<2.0L Engine (Turbo) and 2.4L Engine> 120 g (4.23 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.

>D< 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 TJ boot bands securely.

Standard value (A): 80 ± 3 mm (3.15 ± 0.12 inch)

INSPECTION
- Check the drive shaft for damage, bending or corrosion.
- Check the drive shaft spline part for wear or damage.
- Check the spider assembly for roller rotation, wear or corrosion.
- Check the groove inside T.J. case for wear of corrosion.
- Check the dynamic damper for damage or cracking.
- Check the boots for deterioration, damage or cracking.