Disassembly and Assembly
Front Drive Shaft Disassembly and AssemblyDisassembly
For tripod joint type drive shaft
1. Remove differential side boot band, then take out tripod joint housing (1).
2. Remove grease from shaft and take off snap ring (1) by using special tool, then pull out spider (2) from shaft.
Special Tool (A): 09900-06107
CAUTION: To prevent needle bearing of joint from being degreased, do not wash it if it is to be reused.
3. Remove boot band, then pull out differential side boot from shaft.
4. Pull out damper through shaft. (if equipped)
5. Using chisel (1) and hammer, raise claw (4) and remove big band (2) and small band (3).
6. Pull out wheel side boot from shaft.
CAUTION:
^ Disassembly of wheel side joint is not allowed. If noise or damage exists in it, replace it as assembly.
^ Do not disassemble tripod joint spider. If any malcondition is found in it, replace it as differential side joint assembly.
For DOJ type drive shaft
1. Remove boot band (1) of differential side joint.
2. Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, then take shaft out of outer race (3).
3. Wipe off grease and remove circlip (1) used to fix cage by using special tool (A).
Special Tool (A): 09900-06107
4. Draw away cage (1) by using bearing puller (2), and remove boot (3) from shaft.
5. Remove boot band, then pull out differential side boot from shaft.
6. Pull out damper through shaft. (if equipped)
7. Undo boot bands of wheel side joint boot, then pull out boot through shaft.
CAUTION: Do not disassemble wheel side joint. If any malcondition is found in any joint, replace it as assembly.
For center shaft and center bearing support
1. By using hydraulic press (1), draw out center shaft (2) from center shaft support (3).
2. Remove oil seals (4) from center shaft support.
3. Remove circlip (1).
Special Tool (A): 09900-06108
4. Remove center shaft support bearing from center shaft support bracket (2).
Assembly
For tripod joint type drive shaft
Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried. Replace boot(s) (3) with new one(s).
CAUTION: To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint. Refer to the following for identification of the grease.
"A": Grease (Gray)
"B": Grease (Yellow)
Grease volume to be applied
"A": 90 - 100 g (3.2 - 3.5 oz)
"B": 110 - 120 g (3.9 - 4.2 oz)
1. Wash disassembled parts. After washing, dry parts completely by blowing air.
2. Install wheel side boot by positioning it so that one groove (1) in shaft shows.
3. Place new wheel side small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.
4. Install wheel side small band (1), putting its lower edge against projected end (4) of boot (3) so that clearance "a" is provided as shown in figure.
5. Fasten small band by using special tool.
NOTE:
^ Small band must not come out of its installation section.
^ Be sure to caulk small band securely until complete contact "b" is obtained.
Special Tool (A): 09943-57010
6. Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set.
7. Install wheel side boot so that its projected section (2) fits in dent section (1) in wheel side joint.
8. Place new wheel side big band onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
9. Install wheel side big band (1), putting its upper edge against projected end (2) of boot (4) so that clearance "a" is provided as shown in figure.
10. Fasten boot big band (1) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4).
Special Tool (A): 09943-57020
11. Install dynamic damper (1) on drive shaft according to dimension specified as follows. (if equipped)
Drive shaft dynamic damper installing position (distance "a" between reference position and damper) 154.5 - 160.5 mm (6.1 - 6.3 inch)
12. Set new differential side small band and new differential side boot (1) on shaft temporarily. Apply grease to tripod joint (2). Use specified grease in tube included in spare parts.
13. Install tripod joint spider (3) on shaft, facing its chamfered spline inward (wheel side), then fasten it with new snap ring (4).
Special Tool (A): 09900-06107
14. Apply grease to inside of tripod joint housing (1), joint it with tripod joint and fit boot (2) to tripod joint housing.
After fitting boot, insert screwdriver into boot on tripod joint housing side and allow air to enter boot so that air pressure in boot at the joint position shown in next step becomes the same as atmospheric pressure.
15. When fixing boot (1) to tripod joint housing (2) with differential side big band (3), adjust so that measured dimensions become as indicated in the following.
Joint set position when fixing boot (distance between reference position and small boot band)
LH shaft "a": 151.5 - 161.5 mm (5.96 - 6.36 inch)
RH shaft "b": 177.0 - 187.0 mm (6.97 - 7.36 inch)
CAUTION: To prevent any problem caused by washing solution, do not wash tripod joint except its housing. Degreasing of tripod joint with cloth is allowed.
CAUTION:
^ Bend each boot band against forward rotation.
^ Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
For DOJ type drive shaft
Judging from abnormality noted before disassembly and what is found though visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and DOJ housing (2) are washed thoroughly and air dried. Replace boot(s) (3) with new one(s).
CAUTION: To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint.
"A": Grease (Black)
"B": Grease (Black (rather light than "A"))
Grease volume to be applied
"A": 80 - 100 g (2.8 - 3.5 oz)
"B": 100 - 120 g (3.5 - 4.2 oz)
1. Wash disassembled parts. After washing, dry parts completely by blowing air.
2. Apply grease to wheel side joint. Use specified grease in tube included in wheel side boot set.
3. Install wheel side boot on shaft, fill up boot inside with grease and then fasten boot with bands (1).
CAUTION:
^ Bend each boot band against forward rotation (A).
^ Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
4. Install dynamic damper (1) on LH drive shaft according to dimension specified as follows.
LH Drive shaft dynamic damper installing position (distance "a" between reference position and damper) 187 - 193 mm (7.4 - 7.6 inch)
5. Set new differential side small band and new differential side boot on shaft temporarily.
6. Drive in the cage (1) by using a pipe (2).
Drive shaft joint cage installing pipe diameter "a": 26.0 mm (1.024 inch) or more "b": 32.0 mm (1.260 inch) or less
CAUTION: Install cage directing smaller outside diameter side to wheel side.
7. Install circlip (1) by using special tool (A).
Special Tool (A): 09900-06107
8. Apply grease to entire surface of cage. Use specified grease in tube included in spare parts.
9. Insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2).
CAUTION: Position opening of snap ring "c" so that it will not be lined up with a ball.
10. Apply grease to inside of joint housing (1), and fit boot (2) to joint housing. After fitting boot, insert screwdriver into boot on joint housing side and allow air to enter boot so that air pressure in boot at the joint position shown in next step becomes the same as atmospheric pressure.
11. When fixing boot (1) to joint housing (2) with differential side big band (3), adjust so that measurements become as indicated in the following.
Joint set position when fixing boot (distance between reference position and small boot band)
LH drive shafted: 167.5 - 177.5 mm (6.59 - 6.99 inch)
RH drive shaft "e": 188 - 198 mm (7.40 - 7.80 inch)
CAUTION:
^ Bend each boot band against forward rotation (A).
^ Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
For center shaft and center shaft support
Install center shaft by reverse removal procedure noting the following points.
^ When installing circlips (1), make sure that they fit in circlip grooves in center shaft support bracket (2) securely.
^ When installing oil seals, use care so that they are in proper direction as shown.
^ Fill the space between oil seals and center shaft support bearing (3) with grease.
"A": Grease 99000-25010
^ Press-fit center shaft (1) from LH oil seal side.