Front Drive Shaft Assembly

Front Drive Shaft

ASSEMBLY

AC + AAR TYPE

NOTE:
Use specified grease.

AAR side:
One-Luber C
1) Pass the AAR boot through the shaft.
2) Install the trunnion to the shaft.
(1) Match the alignment marks, and attach the trunnion onto the shaft.
(2) Attach the snap ring to the shaft.

CAUTION:
Confirm that the snap ring is completely fitted in the shaft groove.





3) Fill 50 to 60 g (1.76 to 2.12 oz) of specified grease into the interior of AAR outer race.
4) Install the trunnion to the roller kit.
(1) Apply a thin coat of specified grease to the roller kit and trunnion.
(2) Place the axle shaft between wooden blocks and fix it on a vise.

CAUTION:
Do not set the axle shaft directly on a vise.

5) Align the alignment marks on the shaft and outer race.
6) Tap the insertion upper part of the outer race alternately using a plastic or wood bar shown in the figure, and then insert the roller one by one.

CAUTION:
^ Do not use a metal bar as the outer race may deform.
^ Do not tap on the end of outer race (shaft part).
^ Be careful not to deform the baffle plate.





7) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot.
8) Install the AAR boot taking care not to twist it.

CAUTION:
Do not let grease get on groove of the outer race side.





9) Insert a flat tip screwdriver, etc. between outer race and boot to make pressure inside of boot as high as barometric pressure.
10) Tighten the boot band.
(1) Install the new large boot band and small boot band at the required positions.
(2) Connect the torque wrench and socket flex handle to the ST.

Preparation tool:
ST: BOOT BAND PLIER (28099AC000)
Torque wrench
Socket flex handle
(3) Use a prepared tool, tighten the boot band.





Clearance at the crimped section of the boot band:
Large boot band: 1 mm (0.04 in) or less
Small boot band: 1 mm (0.04 in) or less

Tightening torque:
Large boot band: 178 Nm (18.15 kgf-m, 131.3 ft-lb)
Small boot band: 145 Nm (14.79 kgf-m, 106.9 ft-lb)

11) Extend and retract the AAR repeatedly to provide an equal coating of grease.

EBJ + PTJ TYPE

1) Roll up a thick piece of paper to a size where the shaft can pass through, and affix with tape to form a cylinder.
2) Attach a new O-ring on this cylinder.

CAUTION:
^ Always use a new O-ring.
^ Be careful that the O-ring does not become scratched and that there are no foreign objects attached to it.
^ Make sure to install the O-ring so that it does not twist as much as possible.
^ Do not stretch the O-ring to 30 mm (1.18 in) inner diameter or more.





3) Pass the cylinder material onto the shaft, and slide in the direction of the shaft axis.





4) Clean the shaft boot groove, and wipe off the grease.
5) Slide the cylinder material near the shaft boot groove, and move the O-ring from the cylinder material onto the shaft boot groove.

CAUTION:
^ Attach the O-ring to the shaft boot groove center.
^ Be careful that the O-ring does not become scratched and that there are no foreign objects attached to it.
^ Make sure to install the O-ring so that it does not twist as much as possible.
^ With the O-ring attached, do not wash with kerosene, gasoline, etc.





6) Pass the PTJ small diameter boot band through the shaft.
7) Wrap vinyl tape around the splines of the shaft.

CAUTION:
To prevent damage to the boots, make sure to always wrap with vinyl tape for protection.

8) Install a new PTJ boot.

CAUTION:
Make sure to fit securely on the boot groove of the shaft.





9) Match the alignment marks, and attach the trunnion onto the shaft.





10) Attach the snap ring to the shaft.

CAUTION:
Confirm that the snap ring is completely fitted in the shaft groove.

11) Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of the PTJ outer race.
Grease:
NKG302
12) Apply a thin coat of specified grease to the roller kit and trunnion.
13) Match the alignment marks of the roller kit and trunnion, and attach the roller kit.

CAUTION:
Be careful with the roller kit position.





14) Match the alignment marks of the shaft and outer race, and attach the outer race.





15) Install the snap ring in the groove of the PTJ outer race.

CAUTION:
Pull the shaft lightly and make sure that the snap ring is completely fitted in the groove.

16) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot.
17) Attach the PTJ boot taking care not to twist it.

CAUTION:
^ Clean the large end of PTJ boot and the boot groove well, and remove the grease and other substances.
^ When installing the PTJ boot, position the outer race of the PTJ at center of the stroke.

18) Set the new boot band at the specified position.
19) Tighten the boot bands using ST, torque wrench and socket flex handle.

CAUTION:
The large boot band is to be tightened so that the omega shaped part is at the position indicated in the figure below.





ST 28099AC000 BOOT BAND PLIER





Tightening torque:
Large boot band
178 Nm (18.15 kgf-m, 131.3 ft-lb)
Small boot band
145 Nm (14.79 kgf-m, 106.9 ft-lb)

20) Extend and retract the PTJ repeatedly so that grease is spread evenly.