Rear
Rear Propeller Shaft
Removal
1. Raise the vehicle on a hoist.
Note: Apply alignment marks on the flange at the rear propeller shaft both front and rear side.
2. Remove transfer side bolt, nut and washer (except spline yoke type).
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
Note: Plug the hole of the transmission rear end to prevent oil leakage (spline yoke type only).
Installation
Note: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or removing bolts.
Completely remove the dust or foreign matter from the connecting surface of flange coupling on each end of the propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
Slip Joint Disassembly
1. Lay the shaft horizontally on a bench and secure.
2. Indicate the original assembled position by marking the phasing of the shaft prior to disassembly.
3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the propeller shaft boot. Be careful not to damage the boot.
4. When boot clamps becomes loose, remove by hand.
5. Repeat for the other boot clamp.
6. Remove the slip yoke assembly from the driveshaft, by securing the boot with one hand and pulling on the slip yoke.
7. Remove the boot from the shaft assembly.
Universal Joint Disassembly
Note: Aluminum is softer than steel. Care must be taken not to remove excessive material or damage bearing holes.
If the vehicle has aluminum tube type propeller shaft, yoke, boot kit, journal kit can be replaced. If other parts are damaged, replace propeller shaft as assembly.
1. Apply alignment marks on the yokes of the universal joint, then remove the snap ring.
If the snap ring is stuck in position, remove paint from the hole in the yoke or tap around the edge of the bearing lightly with a soft drift.
2. Set the yoke in the arbor press with a piece of tube stock beneath it.
Place a solid plug on the upper bearing and press it through to release the lower bearing.
3. If the bearing will not pull out by hand after pressing, tap the base of the lug near the bearing to dislodge it.
4. To remove the opposite bearing, turn the yoke over and straighten the spider in the open spider hole. Then carefully press on the end of the spider so the remaining bearing moves straight out of the bearing spider hole. If the spider or bearing are cocked, the bearing will score the walls of the spider hole and ruin it.
5. Repeat this procedure on the remaining bearing to remove the spider from the yoke.
Inspection
^ Propeller shaft for run-out Aluminum tube type.
Static run-out limit: 1.0 mm (0.04 inch)
TIR full length of tubing maximum. (TIR: Total Indicator Reading)
^ Propeller shaft for runout (Steel tube type).
Static runout limit: 0.13 mm (0.005 inch)
TIR on the neck of the slip tube shaft (with a boot). 0.25 mm (0.010 inch)
TIR on the ends of the tubing 3 inch from the welds. 0.38 mm (0.015 inch)
TIR at the linear center of the tube. 0.38 mm (0.015 inch)
TIR for the full length of tube with 30" or less of tubing. (TIR: Total Indicator Reading)
^ Play in universal joint.
Limit: Less than 0.15 mm (0.006 inch)
^ Spider pin should be smooth and free from fretting or galling.
Visible signs of needle presence is normal, but wear should not be felt.
^ Preload of the universal joint.
Preload should be 0 to 49 N (0 to 11.0 lbs.).
Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement.
^ Inspect splines of slip joint for wear.
The nylon-coated spline should be free from nicks and dings and the underlying steel spline should not be visible.
After cleaning the nylon coating spline, the coating should exhibit only slight indication of wear.
Grease volume is approximately 10 grams of grease in total. Grease should be evenly applied to both the female and the male slip splines using a small brush. After assembly of the slip joint, the sliding joint should be fully worked from the full collapsed to the full extended position.
^ Aluminum tube type only: Inspect the aluminum tubing for surface scratches and dents.
These scratches may not exceed 0.2 mm (0.008 inch) in depth.
^ Aluminum tube type only: Visually inspect the circle welds and fittings for any signs of cracks or signs of deterioration. If there are any cracks that exceed 0.2 mm (0.008 inch) in depth, the assembly must be replaced.
^ Aluminum tube type only: Check to be sure there are no missing balance weights. If balance weights are missing and void has occurred in the aluminum tubing greater than 0.2 mm (0.008 inch), the assembly must be replaced.
Universal Joint Reassembly
1. Pack the four grease cavities of the spider with a high quality, extreme pressure N.L.G.I. Grade 2 grease. Do not add additional grease to bearing cup assembly.
2. Move one end of the spider to cause a trunnion to project through the spider hole beyond the outer machined face of the yoke lug. Place a bearing over the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment with the spider hole and place a solid plug on the upper bearing. Press the bearing into the spider hole enough to install snap ring.
3. Install a snap ring.
Note: Be sure the snap rings are properly seated in the grooves.
4. Repeat steps 2 and 3 to install the opposite bearing. If the joint is stiff, strike the yoke ears with a soft hammer to seat the bearing.
5. Align the setting marks and join the yokes.
Slip Joint Reassembly
1. Apply grease evenly to both the female and male splines.
2. Apply a small amount of grease by finger to the outer lips of the boot.
3. Slide the boot (smaller diameter side) onto the spline yoke shaft being careful not to damage the spline coating or boot.
4. Insert the spline yoke shaft spline into the tube assembly being careful to maintain proper phasing. The spider holes should be in line as originally marked prior to disassembly.
5. Position boot onto tube and yoke shaft in its assembled position.
6. Attach boot clamps and secure using pliers.
7. Be sure clamp is properly seated and secure.
Caution: Only use a similar type or same as the original type clamp. Using any other clamp may create an imbalances shaft or lead to grease leakage.