Front Drive Shaft Assembly
ASSEMBLYEBJ+PTJ TYPE
NOTE:
Use specified grease.
EBJ side: NTG2218-M (Part No. 28395AGO10)
PTJ side: NKG302 (Part No. 28495AE00)
1. Place the EBJ boot and small boot band on EBJ side of shaft.
CAUTION:
Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches.
2. Place the drive shaft in a vise.
CAUTION:
Do not place the drive shaft directly in a vise; use wooden blocks.
3. Apply a coat of specified grease [60 to 70 g (2.12 to 2.47 ounces)] to El3J.
4. Apply an even coat of specified grease [20 to 30 g (0.71 to 1.06 ounces)] to entire inner surface of boot. Also apply grease to shaft.
NOTE:
EBJ installation surface of EBJ boot shall be cleaned so as to be free from grease and other substances.
5. Install the boot projecting portion to 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 the 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 PTJ boot at the center of shaft.
10. Align the alignment marks, and then install the trunnion on shaft.
11. Install the snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted in shaft groove.
12. Fill 100 to 110 g (3.53 to 3.88 ounces) of specified grease into the interior of PTJ outer race.
13. Apply a coat of specified grease to roller kit and trunnion.
14. Align the alignment marks on roller kit and trunnion, and then install the free ring.
CAUTION:
Be careful with the roller kit position.
15. Align the alignment marks on shaft and outer race, and then install the outer race.
16. Install the circlip in the groove on PTJ outer race.
CAUTION:
Pull the shaft lightly and assure the circlip is completely fitted in groove.
17. Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 ounces) to the entire inner surface of boot.
18. Install the PTJ boot taking care not to twist it.
CAUTION:
^ PTJ installation surface of PTJ boot shall be cleaned so as to be free from grease and other substances.
^ When installing the PTJ boot, position the outer race of PTJ at center of its travel.
19. Put a new band through the clip and wind twice in alignment with band groove of boot.
20. Tighten the band by using the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
21. Tap on the clip with punch provided at the end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not damaged.
22. Cut off the band with an allowance of about 10 mm (0.39 inch) left from clip, and bend this allowance over clip.
CAUTION:
Be careful so that the end of band is in close contact with clip.
23. Extend and retract the PTJ to provide equal grease coating.
BJ+DOJ TYPE
NOTE:
Use specified grease.
BJ side: NTG2218-M (Part No. 28395AG030)
DOJ side: NKG205 (Part No. 28495AGO10)
1. Install the BJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 ounces) of specified grease.
2. Place the DOJ boot at the center of shaft.
3. Wrap the shaft splines with vinyl tape.
4. Insert the DOJ cage onto shaft.
NOTE:
Insert the cage with cut-out portion facing the shaft end, since the cage has an orientation.
5. Install the DOJ inner race on shaft, and fit the snap ring with pliers.
NOTE:
Confirm the snap ring is completely fitted in shaft groove.
6. Install the cage, which was previously fitted, to inner race fixed upon shaft.
NOTE:
Fit the cage with protruded part aligned with the track on inner race, and then turn by a half pitch.
7. Fill 80 to 90 g (2.82 to 3.17 ounces) of specified grease into the interior of DOJ outer race.
8. Apply a coat of specified grease to cage pocket and six balls.
9. Insert six balls into cage pocket.
10. Align the outer race track and ball positions and place in the part where shaft, inner race, cage and balls are previously installed, and then fit the outer race.
11. Install the circlip in the groove on DOJ outer race.
NOTE:
^ Assure the balls, cage and inner race are completely fitted in the outer race of DOJ.
^ Exercise care not to place the matched position of circlip in ball groove of outer race.
^ Pull the shaft lightly and assure that the circlip is completely fitted in groove.
12. Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 ounces)] to the entire inner surface of boot. Also apply grease to shaft.
13. Install the DOJ boot taking care not to twist it.
NOTE:
^ Inside of the larger end of DOJ boot and boot groove shall be cleaned so as to be free from grease and other substances.
^ When installing the DOJ boot, position the outer race of DOJ at center of its travel.
14. Put a new band through the clip and wind twice in alignment with band groove of boot.
NOTE:
When tightening the boot, exercise care so that air within boot is appropriate.
15. Tighten the band using the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
16. Tap on the clip with the punch provided at the end of ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tap to an extent that the boot underneath is not damaged.
17. Cut off the band with an allowance of about 10 mm (0.39 inch) left from clip, and bend this allowance over the clip.
NOTE:
Be careful so that the end of band is in close contact with clip.
18. Fix up the boot on BJ in the same manner.
19. Extend and retract the DOJ to provide equal grease coating.