FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY [WL-C, WE-C]

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Caution
•  Do not damage and remove the dust cover or the ABS sensor rotor on the drive shaft. These parts cannot be purchased separately. Replace the assembled unit if the dust cover or the ABS sensor rotor is damaged and removed.

1.  Disassemble in the order indicated in the table.

2.  Assemble in the reverse order of disassembly.

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1
Boot band
(See Boot Band Disassembly Note)
(See Boot Band Assembly Note)
2
Clip
3
Outer ring
(See Outer Ring Disassembly Note)
(See Outer Ring Assembly Note)
4
Snap ring
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note)
5
Balls
(See Balls, Inner Ring, Cage Disassembly Note)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note)
6
Inner ring
(See Balls, Inner Ring, Cage Disassembly Note)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note)
7
Cage
(See Balls, Inner Ring, Cage Disassembly Note)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note)
8
Boot
(See Boot Disassembly Note)
(See Boot Assembly Note)
9
Shaft and bell joint component


Boot Band Disassembly Note

Note
•  The wheel side boot band does not need to be removed unless replacing it.

1.  Pry up the locking clips using a screwdriver.

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2.  Remove the band using pliers.

3.  Slide the boot along the shaft to expose the joint.


Outer Ring Disassembly Note

1.  Mark the cage and outer ring for proper assembly.

Caution
•  Mark with paint; do not use a punch.

2.  Remove the clip using a screwdriver.

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3.  Remove the outer ring from the inner ring and the balls.

4.  Clean the grease away.


Balls, Inner Ring, Cage Disassembly Note

1.  Mark the inner ring and cage.

Caution
•  Mark with paint; do not use a punch.

2.  Remove the snap ring using snap‐ring pliers.

3.  Disassemble the balls, inner ring, cage from the drive shaft as component.

4.  Turn the cage approx. 22.5 degree and pull the cage and balls away from the inner ring.

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Boot Disassembly Note

Note
•  The wheel side boot does not need to be removed unless replacing it or the bell joint and shaft component.
•  Do not strip the tape until the boot is assembled.

1.  Wrap the shaft splines with tape.

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2.  Remove the boot.


Boot Assembly Note

1.  Fill the boot (wheel side) with the specified grease from a tube, not by hand.

Caution
•  Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Note
•  The wheel side and differential side boots are different.
•  Use the specified grease supplied in the boot kit.
Grease amount
110—130 g {3.88—4.58 oz}

2.  With the splines of the shaft still wrapped in tape from disassembly, install the boot.

3.  Remove the tape.


Cage, Inner Ring, Balls, Snap Ring Assembly Note

1.  Align the marks and install the balls and cage to the inner ring in the direction shown in the figure.

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Caution
•  Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.

2.  Install a new snap ring.


Outer Ring Assembly Note

1.  Fill the outer ring and boot with the specified grease.

Caution
•  Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Note
•  Use the specified grease supplied in the boot kit.
Grease amount
115—135 g {4.06—4.76 oz}

2.  Align the marks, and install the outer ring on to the shaft.

3.  Install a new clip.

4.  Install the boot.

5.  Set the drive shaft to the standard length.

Front drive shaft standard length
LH: 507.8—517.8 mm {20.00—20.38 in}
RH: 597.2—607.2 mm {23.52—23.90 in}

6.  Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

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Caution
•  Be careful not to allow the grease to leak.
•  Do not damage the boot.

7.  Verify that the drive shaft length is within the specification.


Boot Band Assembly Note


Differential side

1.  Fold the band in the direction opposite to the forward revolving direction of the drive shaft and use pliers to pull it tight.

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2.  Lock the end of the band by bending the locking clips.

Caution
•  Install the band into the groove securely.


Wheel side (small boot band)

1.  Adjust clearance A by turning the adjusting bolt of the SST.

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Clearance A
2.9 mm {0.11 in}

2.  Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.

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•  If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
•  If clearance B is less than the specification, replace the boot band, increase clearance A of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}

3.  Verify that the boot band does not protrude from the boot band installation area.

•  If it does, replace the boot band and repeat Steps 2 and 3.

4.  Fill the boot with the repair kit grease.


Wheel side (big boot band)

1.  Tighten the wheel side big boot band by pinching the tabs shown in the figure.

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Caution
•  If the boot band tabs are damaged, the projection may not hook properly. Therefore, do not apply excessive force to the tabs.
•  If a boot band tab is damaged during the operation, replace it with a new one.

2.  Set the end of the SST (49 T025 001) to the wheel side big boot band tabs at an angle, and tighten the wheel side big boot band.

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3.  Tighten the wheel side big boot band until the projection is hooked.

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4.  If the projection cannot be hooked, press the wheel side big boot band end with a finger to hook the projection.

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5.  After tightening, verify that the wheel side big boot band projection is correctly hooked as shown in the figure.

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6.  Verify that the boot band does not protrude from the boot band installation area.

•  If it does, replace the boot band and repeat Steps 1—6.