Front Axle
DISASSEMBLY AND ASSEMBLYCAUTION
As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassembled.
Disassembly Steps 1-10:
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
[A] ETJ CASE REMOVAL
CAUTION
Never disassemble the spider assembly.
[B] ETJ BOOT REMOVAL
1. Wipe off the grease on the shaft spline.
2. When reusing the ETJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.
ASSEMBLY SERVICE POINTS
[A] ETJ BOOT INSTALLATION
Apply a tape to the shaft spline area. Then incorporate the ETJ boot.
[B] SPIDER ASSEMBLY/ETJ CASE INSTALLATION
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 chamfered side.
3. After applying the specified grease to the ETJ case, insert the driveshaft and apply grease one more time.
Specified grease: Repair kit grease
Amount to use: 120 ± 10 g (4.2 ± 0.3 ounce)
NOTE: When using the repair kit grease, Fill the half of the grease into the joint and the other half into the boot as a guideline, and consume the grease completely.
[C] ETJ BOOT BAND (SMALL)/ETJ BOOT BAND (LARGE) INSTALLATION
Adjust the distance (A shown in the illustration) between the boot bands to the standard value to adjust the air volume inside the ETJ boot to the specified value, then be sure to tighten the ETJ boot band (large) and ETJ boot band (small).
Standard value (A): 80 ± 3 mm (3.14 ± 0.12 inches)
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 EBJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and EBJ boot.
4. Align the center groove on the 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)
^ 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 (0.03 inch) for each turn of the adjusting bolt.
^ The adjusting bolt should not be turned more than once.
6. Position the EBJ boot band (small) so that there is even clearance at either end (A and B).
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 special tool MB991561 touches the stopper.
7. Use special tool MB991561 to crimp the boot band (small).
8. Check that the crimping amount (C) of the boot band is at the standard value.
Standard value (C): 2.4 - 2.8 mm (0.10 - 0.11 inch)
If the crimping amount is larger than 2.8 mm (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) C
Example: If C = 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 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 EBJ boot band.
W = 5.5 mm (0.22 inch) -C
Example: If C = 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 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: 105 ± 10 g (3.7 ± 0.3 ounces)
11. Align the center groove on the EBJ boot big end with the EBJ case 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): 3.2 mm (0.13 inch)
13. Position the EBJ boot band (large) so that there is even clearance at either end (D and E).
14. Use special tool MB991561 to crimp the 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 (0.10 - 0.11 inch)
If the crimping amount is larger than 2.8 mm (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)
If the crimping amount is smaller than 2.4 mm (0.10 inch)
Remove the 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 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 is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps 13 to 15, using a new boot band.