FRONT DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

id031300802600

Special Service Tool (SST)

49 H027 002

Bearing remover

49 UB71 525

Bearing installer

49 W032 310

Support block

1. Disassemble in the order shown in the figure.

2. Assemble in the reverse order of disassembly.

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1	Boot band (transaxle side larger diameter) (See Boot Band (Transaxle Side) Disassembly Note.) (See Boot Band (Transaxle Side) Assembly Note.)
2	Outer ring (See Outer Ring Disassembly Note.) (See Outer Ring Assembly Note.)
3	Dust cover (2WD) (See Dust Cover Disassembly Note.) (See Dust Cover Assembly Note.)
4	Snap ring
5	Bearing (See Bearing Disassembly Note.) (See Bearing Assembly Note.)
6	Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
7	Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
8	Boot (transaxle side) (See Boot (Transaxle Side) Disassembly Note.) (See Boot (Transaxle Side) Assembly Note.)
9	Boot band (dynamic damper)
10	Dynamic damper (See Dynamic Damper Assembly Note.)
11	Outer joint component

Boot Band (Transaxle Side) Disassembly Note

Large diameter side

1. Grasp the boot band at the point shown in the figure using pliers, and remove the band.

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Small diameter side

1. Grasp the boot band at the point shown in the figure using pliers, and remove the band.

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Outer Ring Disassembly Note

1. Place alignment marks on the shaft and outer ring.

Caution

• To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

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2. Secure the shaft in a vise.

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3. Lightly tap the outer ring evenly using a hammer and urethane bar or equivalent, and remove the outer ring from the shaft.

Caution

• When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

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4. Wipe off grease on the outer ring using a clean rag.

Dust Cover Disassembly Note

1. Remove the dust cover using a press and the SST.

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Bearing Disassembly Note

1. Remove the bearing using a press and SST.

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Snap Ring, Tripod Joint Disassembly Note

1. Place alignment marks on the shaft and tripod joint.

Caution

• To prevent damage to parts, do not use a punch or similar tool to place alignment marks. Use paint.

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2. Remove the snap ring using snap ring pliers.

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3. Remove the tripod joint from the shaft.

Caution

• When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

• If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

4. Wipe off grease on the shaft and tripod joint using a clean rag.

Boot (Transaxle Side) Disassembly Note

1. Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2. Remove the boot (transaxle side).

3. Wipe off grease on the boot (transaxle side) using a clean rag.

Dynamic Damper Assembly Note

1. Verify that the assembly position of the dynamic damper is within the standard.

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Standard

227—233 mm {8.94—9.17 in}

Boot (Transaxle Side) Assembly Note

Note

• The boot shapes on the wheel side and the transaxle side are different. Do not assemble the wrong boot by mistake.

1. Insert the shaft through the boot (transaxle side) with the vinyl tape left wrapped around the spline area of the shaft.

2. Remove the vinyl tape wrapped around the spline of the shaft.

Tripod Joint, Snap Ring Assembly Note

1. Assemble the tripod joint with the shaft and tripod joint alignment marks aligned.

Caution

• When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

• If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

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2. Assemble a new snap ring using snap ring pliers.

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3. Verify that the snap ring is assembled correctly in the groove of the shaft.

Bearing Assembly Note

1. Assemble the new bearing using the SST and the press.

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Dust Cover Assembly Note

1. Assemble a new dust cover using the SST and the press.

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2. Verify that the installation position of the dust cover is within the specification.

Specification

Dust cover thickness:0.8 mm {0.031 in}

93.2—94.4 mm {3.67—3.71 in}

Dust cover thickness:1.2 mm {0.047 in}

93.6—94.8 mm {3.68—3.73 in}

Outer Ring Assembly Note

1. Apply the specified grease to the outer ring and boot (transaxle side).

Note

• Apply the grease from the tube. Do not touch the grease directly with your hand.

Grease amount

155—175 g {5.47—6.17 oz}

2. Secure the outer ring in the vise.

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3. After aligning the shaft and outer ring alignment marks, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and insert the outer ring little by little while maintaining the shaft perpendicular.

Caution

• When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

• Be careful that dust and dirt do not get on the inside of the outer ring.

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4. Assemble the boot (transaxle side) to the outer ring.

5. Set the drive shaft to the standard length.

Front drive shaft (tripod joint) full length (standard)

LH	694.3—704.3 mm {27.34—27.72 in}
RH	1075.3—1085.3 mm {42.335—42.728 in}

6. Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

Note

• Do not damage the boot. Verify that there is no grease leakage.

• If the boot is deformed, it may not be possible to perform the full-length adjustment of the shaft.

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7. Verify that the drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

• If not within the standard, repeat from Step 5.

Boot Band (Transaxle Side) Assembly Note

1. Grasp the boot band at the point shown in the figure using pliers and tighten the boot band.

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