Disassembly and Reassembly

REMOVE OR DISCONNECT






1. Band (1). Raise the hooked end of the band with a screwdriver or equivalent.
2. Bellows (2).






3. Circlip (3). Pry off with a screwdriver or equivalent.
4. BJ shaft assembly (4).

Fig. 5 Removing balls from joint:

Fig. 11 Replacing ball retainer & guide:

5. Balls (5). Remove the six balls with a screwdriver or equivalent. Rotate the case half a pitch to align the ball guide on the case with the projected portion of the ball retainer, then slide the case toward the bellows. The case can not be removed in the reverse direction.

Fig. 12 Removing or installing snap ring:

6. Snap ring (6). Remove the snap ring fastening the ball retainer to the center shaft.
7. Ball retainer (7).
8. Ball guide (8).






9. Band (9). Raise the hooked end of the band with a screwdriver or equivalent.
10. Bellows (10).
11. Dust seal (11).
12. BJ shaft (12).
13. Bolt (13).
14. DOJ case assembly (14).
15. Snap ring (15).
16. Bearing (16).
17. Snap ring (17).
18. 0-ring (18).
19. Oil seal (19).
20. Bracket (20).
21. DOJ Case (21).
22. Axle case and differential (22).

VISUAL CHECK: Inspect the following parts for wear, damage, or other abnormal conditions.
^ BJ assembly
^ DOJ case, ball, ball guide ball retainer
^ Bellows
^ Bearing
^ Dust seal, oil seal






INSTALL OR CONNECT
1. Axle case and differential. (1).
2. DOJ case (2).
3. Bracket (3).
4. Oil seal (4).
5. O-ring (5).
6. Snap ring (6).
7. Bearing (7).
8. Snap ring (8).
9. DOJ case assembly (9).






1O. Bolt (10). Bolt Torque 8.4 +/- 0.8 kgm ( 60.8 +/- 5.8 lb.ft. / 82.4 +/- 7.8 Nm).
11. BJ shaft (11).
12. Dust seal (12).
13. Bellows (13).
^ Apply a thin coat of grease to the shaft for smooth installation.
^ Apply specified grease to the 1/2 space of the bellows.






14. Band (14). Note the setting direction. After installation, check that the bellows is free from distortion.
15. Ball guide (15).

Fig. 11 Replacing ball retainer & guide:

16. Ball retainer (16). Install the ball guide with the smaller diameter side ahead onto the shaft.

Fig. 12 Removing or installing snap ring:

17. Snap ring (17). Install the snap ring securing the ball retainer to the shaft






18. Ball (18). Bring the ball guide of the cage into alignment with the projected portion of the ring on the ball retainer, then turn the cage 1/2 pitch. Align the track on the ball retainer with the window in the cage and install the six balls into position.






19. BJ shaft assembly (19). Apply specified grease to the half of the space of the DOJ case (Approx. 50g (1.8 oz))






2O. Circlip (20). Install the circlip so that open ends are positioned away from the ball groove.






21. Bellows (21).
^ Before installation, insert the appropriate amount of specified grease into the DOJ case.
^ Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals to the atmospheric pressure.

22. Band (22). After installation, check that the bellows is free from distortion.