Front Drive Shaft Disassembly and Reassembly
Front Drive Shaft Disassembly and ReassemblyDisassembly
CAUTION:
^ Disassembly of wheel side joint is not allowed. If any 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.
1. Remove differential side (or center shaft side) boot big band (1) as follows.
^ For boot big band without joint:
Remove boot big band by tapping boot and band with plastic hammer. If it is hard to remove boot big band, cut it using a nipper or an iron saw with care not to damage joint housing.
^ For boot big band with joint:
Draw hooks of boot big band together and remove band.
2. Wipe off grease from shaft and take off snap ring (1) using snap ring pliers (2).
3. Remove tripod joint spider (1) using 3 arms puller (2).
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.
4. Remove differential side (or center shaft side) boot small band, and then pull out differential side (or center shaft side) boot from shaft.
5. Remove damper from shaft, if equipped.
6. Undo caulking (5) of wheel side boot big band (1) and small band (3) using flat end rod (2) or the like, then pull out wheel side boot (4) from shaft.
Reassembly
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:
^ Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in degreaser causes deterioration of boot.
^ 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 referring to the following for identification of the grease.
1. Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2. Clean boots with cloth.
3. Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare parts.
Grease color: Black
Amount: 70 - 90 g (2.5 - 3.2 oz)
4. Install wheel side boot on shaft.
5. Fill up boot inside with specified grease.
6. Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
7. Fasten boot bands (1) securely using special tool as shown in figure.
CAUTION: Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
Distance "a": 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special Tool (A):09943-57010
8. Install damper (1) to specified position on drive shaft, if equipped.
Drive shaft damper installing position (right side)
"a": 359 mm (14.1 in.) (2WD model)
"a": 362 mm (14.3 in.) (4WD model)
Drive shaft damper installing position (left side)
"a": 252 mm (9.9 in.) (M/T model)
9. Set new differential side (or center shaft side) small band and new differential side (or center shaft side) boot (1) on shaft temporarily, and then apply grease to tripod joint (2). Use specified grease in tube included in spare parts.
10. Install tripod joint spider (3) on shaft using snap ring pliers (5) with hammer, directing its chamfered spline toward wheel side, and then fasten it with new snap ring (4).
Special Tool (A):09925-98220
11. Apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint.
Grease color "A": Dark gray
Amount
"A": 95 - 115 g (3.4 - 4.1 oz) (right side)
"A": 90 - 110 g (3.2 - 3.9 oz) (left side)
12. Fit boot (1) to grooves of shaft and housing (2) adjust length to specification below.
13. Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
Drive shaft boot fixing position (distance between housing end and small boot band)
Left side drive shaft "a": 167.8 mm (6.61 in.) (M/T model)
Left side drive shaft "a": 171.2 mm (6.74 in.) (A/T model)
Right side drive shaft "b": 191.0 mm (7.52 in.)
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.
14. Place differential side (or center shaft side) boot new big band (3) and new small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
15. Fasten differential side (or center shaft side) boot big band (1) and small band (5) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4).
Special Tool (A):09943-57021
