Overhaul
DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
<> TJ CASE/SPIDER ASSEMBLY REMOVAL
1. Wipe off grease from the spider assembly and the inside of the TJ case.
CAUTION: Do not disassemble the spider assembly.
2. Always clean the spider assembly when the grease contains water or foreign material
<> TJ BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the TJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot
REASSEMBLY SERVICE POINTS
>>A<< DYNAMIC DAMPER/DAMPER BAND/TJ BOOT INSTALLATION
1. Install the dynamic damper in the position shown in the illustration.
CAUTION:
^ There should be no grease adhered to the rubber part of the dynamic damper.
^ Be careful not to confuse the damper band with the TJ boot band (small). Locate the identification colors and numbers stamped on the band levers.
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and then install the TJ boot band (small) and TJ boot.
CAUTION:
^ The driveshaft joint use special grease. Do not mix old and new or different types of grease.
^ If the spider assembly has been cleaned, take special care to apply the specified grease.
1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease
2. Install the spider assembly to the shaft from the direction of the spline bevelled section.
CAUTION: The driveshaft joint use special grease. Do not mix old and new or different types of grease.
3. After applying the specified grease to the T.J. case, insert the driveshaft and apply grease one more time.
Specified grease: Repair kit grease
Amount to use:
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
>>C<< TJ BOOT BAND (SMALL)/TJ 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 bands securely.
Standard value (A): 85 ± 3 mm (3.3 ± 0.12 inch)
INSPECTION
^ Check the driveshaft for damage, bending or corrosion.
^ Check the driveshaft spline part for wear or damage.
^ Check the spider assembly for roller rotation, wear or corrosion.
^ Check the groove inside TJ case for wear or corrosion.
^ Check the dynamic damper for damage or cracking.
^ Check the boots for deterioration, damage or cracking.
^ Check the dust cover for damage or deterioration.
RJ BOOT OR BJ BOOT (RESIN BOOT) REPLACEMENT
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the R.J. boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and resin boot.
4.
Install the RJ boot with the part with the smallest diameter in a position such that the shaft groove can be seen.
Align the center groove on the BJ boot small end with the shaft groove.
5. Turn the adjusting bolt on special tool MB991561 so that the size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
If it is larger than 2.9 mm (0.11 inch)>
Tighten the adjusting bolt.
If it is smaller than 2.9 mm (0.11 inch)>
Loosen the adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than once.
6.
Place the RJ boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.
Position the BJ boot band (small) so that there are even clearance at either end (B and C).
CAUTION:
^ Secure the driveshaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of the special tool MB991561.
^ Crimp the boot band until the special tool MB991561 touches the stopper.
7. Use the special MB991561 tool to crimp the boot band (small)
8. Check that the crimping amount (D) of the boot band is at the standard value.
Standard value (D):
If the crimping amount is larger than 1.5 mm (0.06 inch)>
Readjust the value of (W) in step 5 according to the following formula, and then repeat the operation in step 7.
W = 3.0 mm (0.12 inch) - D
Example: If D = 1.6 mm (0.06 inch), then W = 1.4 mm (0.055 inch).
If the crimping amount is smaller than 1.0 mm (0.04 inch)>
Remove the RJ boot band, readjust the value of (W) in step 5 according to the following formula, and then repeat the operations in steps 6 and 7 using a new RJ boot band.
W = 3.0 mm (0.12 inch) - D
Example: If D = 0.9 mm (0.035 inch), then W = 2.1 mm (0.08 inch).
Readjust the value of (W) in step 5 according to the following formula, and then repeat the operation in step 7.
W = 5.5 mm (0.22 inch) - D
Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).
If the crimping amount is smaller than 2.4 mm (0.10 inch)>
Remove the BJ boot band, readjust the value of (W) in step 5 according to the following formula, and then repeat the operations in steps 6 and 7 using a new BJ boot band.
W = 5.5 mm (0.22 inch) - D
Example: If D = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch).
9. Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat the operations in steps 6 to 8 using a new boot band.
CAUTION: The driveshaft joint uses special grease. Do not mix old and new or different types of grease.
10. Fill the inside of the boot with the specified amount of the specified grease.
Specified grease: Repair kit grease
Amount to use:
11.
Install the RJ boot band (large) so that there is the clearance (E) between it and the RJ housing is at the standard value
Standard value (E): 0.10 - 1.55 mm (0.004 - 0.061 inch)
Align the center groove on the BJ boot big end with the shaft groove.
12. Follow the same procedure as in step 5 to adjust the size of the opening (W) on the special tool so that it is at the standard value.
Standard value (W):
13.
Place the RJ boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (F) in the illustration.
Position the BJ boot band (large) so that there are even clearance at either end (G and H).
14. Use the special tool MB991561 to crimp the R.J. boot band (large) in the same way as in step 7.
15. Check that the crimping amount (I) of the boot band is at the standard value.
Standard value (I):
If the crimping amount is larger than 1.5 mm (0.06 inch)>
Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14.
W = 3.0 mm (0.12 inch) - I
Example: I = 1.6 mm (0.06 inch), then W = 1.4 mm (0.055 inch).
If the crimping amount is smaller than 1.0 mm (0.04 inch)>
Remove the RJ boot band, readjust the value of (W) in step 12 according to the following formula, and then repeat the operations in steps 13 and 14 using a new RJ boot band.
W = 3.0 mm (0.12 inch) - I
Example: If I = 0.9 mm (0.035 inch), then W = 2.1 mm (0.08 inch).
W = 5.5 mm (0.22 inch) - I
Example: If I = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).
If the crimping amount is smaller than 2.4 mm (0.10 inch)> Remove the BJ boot band, readjust the value of (W) in step 12 according to the following formula, and then repeat the operations in steps 13 and 14 using a new BJ boot band.
W = 5.5 mm (0.22 inch) - I
Example: If I = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch).
16. Check that the boot band is not sticking out past the place where it has been installed If the boot band is sticking out, remove it and then repeat the operations in steps 13 to 15 using a new boot band.