Disassembly and Assembly

AUTOMATIC FREEWHEEL UNIT DISASSEMBLY





- Disassemble in the order indicated in the table.

Hub Disassembly Note





- Remove the hub by using the SST.

Ball Bearing Disassembly Note





1. Remove the ball bearing and the joint shaft by using a press.





2. Remove the ball bearing by using a press.

Bearing Disassembly Note





1. Remove the dust seal and bearing by using the SST.





2. Remove the bearing by using a press.

Oil Seal Disassembly Note





- Remove the oil seal by using the SST.

AUTOMATIC FREEWHEEL UNIT ASSEMBLY

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- Assembly in the order indicated in the table.


Oil Seal Assembly Note
1. Apply front differential oil to the new oil seal.





2. Install the oil seal by using the SST

Adjustment Shim, Ball Bearing Assembly Note





1. Set the removed shim(s) into the housing and install the ball bearing by using the SST
2. Install the retaining ring.





3. Measure the clearance between the ball bearing and the retaining ring.

Maximum clearance 0.15 mm (0.0059 inch)

4. If not as specified, adjust by adding or removing shims. Use no more than two shims on either side.

Available shim thickness:
0.15 mm (0.0059 inch) 0.30 mm (0.0118 inch), 0.35 mm (0.0 138 inch) 0.40 mm (0.0157 inch), 0.50 mm (0.0197 inch)

Bearing Assembly Note





- Install the bearing by using the SST

Joint Shaft Assembly Note
1. Remove the retaining ring.





2. Using the SSTs, install the joint shaft and bearing, with the seal facing upward.
3. Install the retaining ring.

Spacer, Hub Assembly Note





1. Install the spacer removed during disassembly and the hub by using a suitable pipe and the SST.
2. Install a new clip.





3. Measure the clearance between the hub and the new clip.

Maximum clearance 0.15 mm (0.0059 inch)

4. If not as specified, adjust by adding or removing spacers. Use no more than two spacers on either side.

Available shim thickness:
0.15 mm (0.0059 inch), 0.30 mm (0.0118 inch), 0.35 mm (0.0138 inch), 0.40 mm (0.0157 inch), 0.50 mm (0.0197 inch)

Dust Seal Assembly Note





- Install a new dust seal by using the SST.

Oil Seal Assembly Note





- Install a new oil seal by using the SST

Boot Assembly Note





- Install the boot as shown in the figure.

Roll Pin Assembly Note





- Install a new roll pin as shown in the figure.

JOINT SHAFT INSPECTION





1. Measure the joint shaft runout.

Maximum runout 0.03 mm (0.0012 inch)

2. If not as specified, replace the joint shaft.

SHIFT FORK INSPECTION





1. Measure the clearance between the gear sleeve and shift fork.

Standard clearance 0.1-0.4 mm (0.0040-0.0157 inch)
Maximum clearance 0.5 mm (0.0197 inch)

2. If not as specified, replace the gear sleeve or shift fork.