Overhaul
DISASSEMBLY AND ASSEMBLYCAUTION
^ Be careful not to damage the ABS rotor, which is attached to the EBJ outer race during disassembly and reassembly.
^ Never disassemble the EBJ assembly except when replacing the EBJ boot.
Disassembly Steps 1-22:
Required Special Tools:
LUBRICATION POINTS:
DISASSEMBLY SERVICE POINTS
<> SEAL PLATE REMOVAL
Use a slotted screwdriver to make a hole in the seal plate inside the PTJ case, and remove it.
<> PTJ CASE/SPIDER ASSEMBLY REMOVAL
CAUTION: Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the inside of the PTJ case.
2. Clean the spider assembly if water or foreign material is observed.
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1. Use special tool MB991248 to remove the inner shaft assembly from the PTJ case.
2. Use special tool MB990810 to remove the center bearing bracket from the inner shaft.
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Use special tools MB990938 and MB990930 to remove the center bearing from the center bearing bracket.
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1. Wipe off grease from the shaft spline.
2. When reusing the TJ boot or PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.
ASSEMBLY SERVICE POINTS
>>A<< DYNAMIC DAMPER/DAMPER BAND/PTJ BOOT INSTALLATION
CAUTION: There should be no grease adhered to the rubber part of the dynamic damper.
1. Install the dynamic damper in the position shown in the illustration.
L: 260.5 ± 3 mm (10.3 ± 0.12 inches)
L: 226 ± 3 mm (8.9 ± 0.12 inches)
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small) and PTJ boot.
>>B<< SPIDER ASSEMBLY INSTALLATION
CAUTION:
^ The drive shaft 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 chamfered side.
>>C<< CENTER BEARING INSTALLATION
Use special tools MB990938 and MB990932 to press-fit the center bearing into the center bearing bracket.
>>D<< DUST SEAL INNER/DUST SEAL OUTER INSTALLATION
CAUTION: When applying grease, make sure that it does not adhere to anything outside the lip.
1. Apply the specified grease to the rear surface of all dust seals.
Specified grease: Repair kit grease
Amount used (Dust seal inner): 14 - 20 g (0.5 - 0.7 ounce)
Amount used (Dust seal outer): 8 - 12 g (0.3 - 0.4 ounce)
2. Use special tools MB990890, MB990938, and MB990934 to press the dust seals into the center bearing bracket until they are flush with each other.
3. Apply repair kit grease to the lip of each dust seal.
>>E<< INNER SHAFT INSTALLATION
Use special tool MB991172 to hold the center bearing inner race, and then press-in the inner shaft.
>>F<< SEAL PLATE/PTJ CASE AND INNER SHAFT ASSEMBLY INSTALLATION
1. Apply repair kit grease to the inner shaft spline, then press fit it into the PTJ case.
NOTE: When press-fitting the inner shaft into the PTJ case, apply a thin coat of repair kit grease to the dust seal outer lip part and the outside edge of the PTJ axial part.
2. Use special tool MD998369 to press in the seal plate.
>>G<< PTJ CASE INSTALLATION
CAUTION: The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
After applying the specified grease to the PTJ case, insert the drive shaft and apply grease again.
Specified grease: Repair kit grease
Amount to use
Amount to use : 245 ± 10 g (8.6 ± 0.3 ounces)
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
>>H<< PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION
Set the PTJ boot bands at the specified distance in order to adjust the amount of air inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band (large) securely.
Standard value (A): 85 ± 3 mm (3.35 ± 0.12 inches)
INSPECTION
^ Check the drive shaft for damage, bending or corrosion.
^ Check the inner shaft for damage, bending or corrosion.
^ Check the drive shaft spline part for wear or damage.
^ Check the inner shaft spline part for wear or damage.
^ Check the spider assembly for roller rotation, wear or corrosion.
^ Check the groove inside TJ case or PTJ 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.
BJ/EBJ BOOT REPLACEMENT
Required Special Tool
^ MB991561: Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ/EBJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ/EBJ boot.
4. Align the center groove on the BJ/EBJ 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)
NOTE: The value of W will change by approximately 0.7 mm (0.03 inch) for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than once.
6. Position the BJ/EBJ boot band (small) so that there is even clearance at either end (A and B).
CAUTION:
^ Secure the drive shaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of special tool M991561.
^ Crimp the boot band until the special tool touches the stopper.
7. Use special tool MB991561 to crimp the boot band (small).
8. Check that the crimping amount of the boot band is at the standard value.
Standard value (D): 2.4 - 2.8 mm (0.09 - 0.11 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).
Remove the BJ/EBJ 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/EBJ 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 does not stick out past the place where it has been installed. If the boot band sticks out, remove it and then repeat steps 6 to 8, using a new boot band.
CAUTION: The drive shaft 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 (BJ) <2.4L>: 120 ± 10 g (4.2 ± 0.3 ounces)
Amount to use (EBJ) <3.8L>: 155 ± 10 g (5.5 ± 0.3 ounces)
11. Align the center groove on the BJ/EBJ boot big end with the BJ/EBJ case groove.
12. Follow the same procedure as in step 5 to adjust the size of the opening (W) on special tool so that it is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
13. Position the BJ/EBJ boot band (large) so that there is even clearance at either end (D and E).
14. Use special tool to crimp the BJ/EBJ boot band (large) in the same way as in step 7.
15. Check that the crimping amount (F) of the boot band is at the standard value.
Standard value (F): 2.4 - 2.8 mm (0.09 - 0.11 inch)
Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14.
W = 5.8 mm (0.23 inch) - F
Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).
Remove the EBJ/EBJ 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 EBJ/EBJ boot band.
W = 5.8 mm (0.23 inch) - F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm (0.14 inch).
16. Check that the boot band does not stick out past the place where it has been installed. If the boot band sticks out, remove it and then repeat steps 13 to 15, using a new boot band.