Disassembly and Reassembly
Part 1 0f 2:
Part 2 Of 2:
DISASSEMBLY SERVICE POINTS
T.J. CASE REMOVAL
After removing the T.J. case from the B.J. assembly, wipe off the grease on the T.J. case.
INNER SHAFT REMOVAL
1. Use the special tool to remove the inner shaft assembly, together with the seal plate, from the T.J. case.
2. Use the special tools to remove the inner shaft from the bracket.
1. Remove the snap ring from the drive shaft with the snap ring plier.
2. Take out the spider assembly from the drive shaft.
3. Clean the spider assembly.
CAUTION:
1. Do not disassemble the spider assembly.
2. Use care in handling so as not to damage the drive shaft.
1. Wipe the grease off of the spline portion.
2. Remove the T.J. boot.
NOTE: If the boot is reused, wrap plastic tape around the drive shaft spline so that the boot is not damaged when it is removed.
REASSEMBLY SERVICE POINTS
>A< T.J. BOOT INSTALLATION
Wrap plastic tape around the spline part on the drive shaft, and then install the T.J. boot band and T.J. boot.
>B< SPIDER ASSEMBLY/T.J. CASE INSTALLATION
1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease
CAUTION:
1. The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
2. If the spider assembly has been cleaned, take special care to apply the specified grease.
2. Install the spider assembly to the shaft from the direction of the spline bevelled section.
3. After applying specified grease to the T.J. case, insert the drive shaft and apply grease one more time.
Specified grease: Repair kit grease 120 g (4.23 oz.)
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
CAUTION: The drive shaft Joint uses special grease. Do not mix old and new or different types of grease.
>C< CENTER BEARING INSTALLATION
>D< DUST SEAL INSTALLATION
1. Apply the specified grease to the rear surfaces of all dust seals.
Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent
Inner dust seal 7 - 10 g (0.25 - 0.35 oz.)
Outer dust seal 4 - 6 g (0.14 - 0.21 oz.)
2. Use the special tools to install the dust seal so that its surface runs even with that of the center bearing bracket.
3. Apply the specified grease to the lip of each dust seal.
Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent
NOTE: When applying grease, make sure that it does not adhere to anything outside the lip.
>E< INNER SHAFT INSTALLATION
>F< INNER SHAFT ASSEMBLY INSTALLATION
1. Apply specified grease to the inner shaft spline, then press fit into the T.J. case.
Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent
2. Use the special tool secure the T.J. case
3. Use a pipe [0 30 mm (1.18 inch)] to press the seal plate into the T.J. case.
4. Fill the specified grease furnished in the repair kit to the T.J. case.
Specified grease: Repair kit grease 105 g (3.70 oz.)
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
CAUTION: The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
>G< T.J. BOOT BAND INSTALLATION
Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot band securely.
Standard value (A) : 8013 mm (3.151.12 inch)
INSPECTION
- Check the drive shaft for damage, bending or corrosion.
- Check the inner shaft for damage, bending or corrosion.
- Check the drive shaft splines for wear or damage.
- Check the inner shaft splines for wear or damage.
- Check the spider assembly for roller rotation, wear or corrosion.
- Check the groove inside T.J. case for wear or corrosion.
- Check the boots for deterioration, damage or cracking.
- Check the center bearing for seizure, discoloration or roughness of rolling surface.
- Check the dust cover for damage or deterioration.
B.J. BOOT (RESIN BOOT) REPLACEMENT
1. Remove the large and small boot bands.
NOTE: Do not reuse the boot bands.
2. Remove the B.J. boot.
3. Install the small diameter end of the B.J. boot by so locating it as to expose only one of the grooves provided on the shaft.
4. Turn the adjusting bolt of the special tool to obtain a standard value of the opening width (W).
Standard value (W): 2.9 mm (0.114 inch)
When width is above 2.9 mm (0.114 inch)> Tighten the adjusting bolt.
When width is below 2.9 mm (0.114 inch)> Loosen the adjusting bolt.
NOTE:
1. One complete turn of the adjusting bolt will change the width by approx. 0.7 mm (0.028 inch).
2. Do not give more than one turn to the adjusting bolt.
5. Install the boot band (small) against the projection at the boot end to provide clearance A as shown in the illustration.
6. Using the special tool, crimp the boot band.
CAUTION:
1. With the drive shaft secured vertically, pinch positively the portion to be crimped of the band between the tips of the special tool.
2. Be sure to compress the boot band until the special tool handle comes in contact with the stopper.
7. Make sure that the amount of boot band crimping (B) is of the standard value.
Standard value (B): 2.4 - 2.8 mm (0.094 - 0.110 inch)
Readjust W given in (4) above to the value calculated by the following formula, and repeat work described in (6).
W = 5.5 mm (0.217 inch) - B
[Example: When B = 2.9 mm (0.114 inch) , W = 2.6 mm (0.102 inch)]
Remove the boot band, readjust W given in (4) to the value calculated by the following formula and repeat work described in (5) and (6) by using a new boot band.
W = 5.5 mm (0.217 inch) - B
[Example: When B = 2.3 mm (0.091 inch), W = 3.2 mm (0.126 inch)]
8. Make sure that the boot band does not protrude from the band mounting area. If the band protrude, replace it with a new band and repeat work described in (5) through
9. Pack the boot with specified amount of grease to specification.
Specified grease: Grease in repair kit
Amount applied: 155 g (5.47 oz.)
10. lnstall the boot with a clearance of standard value (C) provided between the large diameter end of the boot and the shoulder of B.J. housing.
Standard value (C) : 0.1 -1.55 mm (0.004-.061 inch).
11. Adjust the width of opening in the special tool (W) to standard value in the same manner as described in (4).
Standard value (W.: 3.2 mm (0.126 inch)
12. Install the boot band (large) against the projection at the boot end to provide clearance D as shown in the illustration.
13. Crimp the boot band (large) with the special tool in the same manner as described in (6) above.
14. Make sure that the amount of boot band crimping is within the range of standard value (E).
Standard value (E): 2.4 - 2.8 mm (0.094 - 0.110 inch)
When amount of crimping is above 2.8 mm (0.110 inch)>
Readjust W given in (11) to a value obtained by the following formula and repeat work described in (13) above.
W = 5.8 mm (0.228 inch) - E
[Example: When E = 2.9 mm (0.114 inch), W = 2.9 mm (0.114 inch)]
When amount of crimping is below 2.4 mm (0.094 inch)>
Remove the boot band, readjust W given in step 11 to a value calculated by the following formula and repeat work described in (12) and (13) by using a new boot band.
W = 5.8 mm (0.228 inch) - E
[Example: When E = 2.3 mm (0.091 inch), W = 3.5 mm (0.138 inch)]
15. Make sure that the boot band does not protrude from its mounting area. If the band protrudes, replace it with a new band and repeat work described in (12) through (14).