Front Drive Shaft Assembly
ASSEMBLYCAUTION: Use specified grease.
EBJ side: NTG2218 (Pan No.28093AA000)
SFJ side: SSG6003 (Pan No.28093TA000)
1) Place the EBJ boot and small boot band on the BJ side of shaft.
CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
2) Place the drive shaft in a vise.
CAUTION: Do not place drive shaft directly in the vise; use wooden blocks.
3) Apply a coat of specified grease [60 to 70 grams (2.12 to 2.47 ounces)] to EBJ.
4) Apply an even coat of specified grease [20 to 30 grams (0.71 to 1.06 ounces)] to the entire inner surface of boot. Also apply the grease to the shaft.
NOTE: The inside of the larger end of BJ boot and the boot groove shall be cleaned so as to be free from grease and other foreign substances.
5) Install the boot projecting portion to the EBJ groove.
6) Set the large boot band in place.
7) Install the boot projecting portion to shaft groove.
8) Tighten the boot bands using ST, torque wrench and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
Tightening torque:
Large boot band 157 Nm (16.0 kgf-m, 116 ft. lbs.) or more
Small boot band 133 Nm (13.6 kgf-m, 98 ft. lbs.) or more
9) Place the SFJ boot at the center of shaft.
10) Align alignment marks and install the trunnion on the shaft.
11) Install the snap ring to the shaft.
CAUTION: Confirm that the snap ring is completely fitted in the shaft groove.
12) Fill 100 to 110 grams (3.53 to 3.88 ounces) of specified grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to the free ring and trunnion.
14) Align alignment marks on free ring and trunnion and install the free ring.
CAUTION: Be careful with the free ring position.
15) Align alignment marks on shaft and outer race, and install outer race.
16) Install the circlip in the groove on the SFJ outer race.
CAUTION: Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
17) Apply an even coat of the specified grease 30 to 40 grams (1.06 to 1.41 ounces) to the entire inner surface of boot.
18) Install the SFJ boot taking care not to twist it.
CAUTION:
^ The inside of the larger end of SFJ boot and the boot groove shall be cleaned so as to be free from grease and other foreign substances.
^ When installing SFJ boot, position outer race of SFJ at center of its travel.
19) Put a band through the clip and wind twice in alignment with band groove of boot.
CAUTION: Use a new band.
20) Pinch the end of band with pliers. Hold the clip and tighten securely.
NOTE: When tightening boot, exercise care so that the air within the boot is appropriate.
21) Tighten the band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE: Tighten the band until it cannot be moved by hand.
22) Tap on the clip with the punch provided at the end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION: Tap to an extent that the boot underneath is not damaged.
23) Cut off band with an allowance of about 10 mm (0.39 inch) left from the clip and bend this allowance over the clip.
CAUTION: Be careful so that the end of the band is in close contact with clip.
24) Fix up boot on the EBJ in the same manner.
NOTE: Extend and retract the SFJ to provide equal grease coating.