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Reduction Gear Side




FRONT DRIVE SHAFT

REDUCTION GEAR SIDE : Disassembly and Assembly


DISASSEMBLY

Left Side
1.Fix shaft with a vise.

CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2.Remove boot bands, and then remove boot from housing.
3.Put matching marks on housing and shaft, and then pull out housing from shaft.

CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.





4.Put matching marks (A) on the spider assembly and shaft.

CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.





5.Remove snap ring (1), and then remove spider assembly from shaft.
6.Remove boot from shaft.
7.Remove dust shield from housing.
8.Remove circular clip from housing.
9.Perform inspection after disassembly. Refer to "Inspection" Testing and Inspection.
Right Side
1.Fix shaft with a vise.

CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2.Remove boot bands, and then remove boot from housing.
3.Put matching marks on housing and shaft, and then pull out housing from shaft.

CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.





4.Put matching marks (A) on the spider assembly and shaft.

CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.





5.Remove snap ring (1), and then remove spider assembly from shaft.
6.Remove boot from shaft.
7.Remove support bearing, follow the procedure described below.





a.Remove dust shield from housing.





b.Remove snap ring (1).





c.Press out support bearing from housing.
d.Remove dust shield from housing.
8.Perform inspection after disassembly. Refer to "Inspection" Testing and Inspection.

ASSEMBLY

Left Side
1.Clean the old grease on housing assembly with paper waste.
2.Install dust shield to housing.

CAUTION:
Never reuse dust shield.
3.Install circular clip to housing.

CAUTION:
Never reuse circular clip.
4.Install new boot and boot bands to shaft.

CAUTION:





- Wrap serration on shaft with tape (A) to protect boot from damage.


- Never reuse boot and boot bands.
5.Remove the tape wrapped around the serration on shaft.





6.To install the spider assembly (1), align it with the matching marks (A) on the shaft (2) during the removal, and direct the serration mounting surface (B) to the shaft.





7.Secure spider assembly onto shaft with snap ring (1).

CAUTION:
Never reuse snap ring.
8.Apply the appropriate amount of grease to spider assembly and sliding surface.
9.Assemble the housing onto spider assembly, and apply the balance of the specified amount grease.
Grease amount: Refer to "Drive Shaft" Drive Shaft.
10.Align matching marks put during the removal of housing.





11.Install boot securely into grooves (indicated by "*" marks) shown in the figure.


CAUTION:
If grease adheres to the boot mounting surface (with "*"
marks) on shaft or housing, boot may be removed. Remove all grease from the surface.
12.To prevent the deformation of the boot, adjust the boot installation length to the value by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air.
Boot installation length: Refer to "Drive Shaft" Drive Shaft.

CAUTION:
- If the boot installation length exceeds the standard, it may cause breakage of the boot.
- Be careful not to touch the inside of the boot with the tip of tool.
13.Install boot bands securely.

CAUTION:
Never reuse boot bands.
a.Put boot band in the groove on drive shaft boot. Then fit pawls into holes to temporary installation.
NOTE:





For the large diameter side, fit projection (A) and guide slit (B) at first.
b.Pinch projection on the band with suitable pliers to tighten band.





c.Insert the tip of band into the lower part of pawl (marked with dotted circle) as shown in the figure.
14.Check that displacement does not occur when boot is rotated with the housing assembly fixed.

CAUTION:
- If displacement occurs, reinstall band.
- Never reuse boot band.
Right Side
1.Install support bearing, follow the procedure described below.
a.Install dust shield to housing.

CAUTION:
Never reuse dust shield.





b.Press support bearing (1) onto housing to using the suitable tool (A).

CAUTION:
Never reuse support bearing.





c.Install snap ring (1).

CAUTION:
Never reuse snap ring.





d.Install dust shields.

CAUTION:
Never reuse dust shields.
2.Clean the old grease on housing assembly with paper waste.
3.Install new boot and boot bands to shaft.

CAUTION:





- Wrap serration on shaft with tape (A) to protect boot from damage.


- Never reuse boot and boot bands.
4.Remove the tape wrapped around the serration on shaft.





5.To install the spider assembly (1), align it with the matching marks (A) on the shaft (2) during the removal, and direct the serration mounting surface (B) to the shaft.





6.Secure spider assembly onto shaft with snap ring (1).

CAUTION:
Never reuse snap ring.
7.Apply the appropriate amount of grease to spider assembly and sliding surface.
8.Assemble the housing onto spider assembly, and apply the balance of the specified amount grease.
Grease amount: Refer to "Drive Shaft" Drive Shaft.
9.Align matching marks put during the removal of housing.





10.Install boot securely into grooves (indicated by "*" marks) shown in the figure.


CAUTION:
If grease adheres to the boot mounting surface (with "*"
marks) on shaft or housing, boot may be removed. Remove all grease from the surface.
11.To prevent the deformation of the boot, adjust the boot installation length to the value by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air.
Boot installation length: Refer to "Drive Shaft" Drive Shaft.

CAUTION:
- If the boot installation length exceeds the standard, it may cause breakage of the boot.
- Be careful not to touch the inside of the boot with the tip of tool.
12.Install boot bands securely.

CAUTION:
Never reuse boot bands.
a.Put boot band in the groove on drive shaft boot. Then fit pawls into holes to temporary installation.
NOTE:





For the large diameter side, fit projection (A) and guide slit (B) at first.
b.Pinch projection on the band with suitable pliers to tighten band.





c.Insert the tip of band into the lower part of pawl (marked with dotted circle) as shown in the figure.
13.Check that displacement does not occur when boot is rotated with the housing assembly fixed.

CAUTION:
- If displacement occurs, reinstall band.
- Never reuse boot band.
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