FRONT DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

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Special Service Tool (SST)

49 H027 002 Bearing remover		49 W032 310 Support block		49 T025 001 Boot clamp crimpers
49 UB71 525 Bearing installer		49 0710 520 Bearing puller		—

Replacement part

Boot band (transaxle side) Quantity: 2 Location of use: Boot (transaxle side)	Dust cover Quantity: 1 Location of use: Outer ring	Snap ring Quantity: 1 Location of use: Outer ring
Clip Quantity: 1 Location of use: Outer ring	Bearing Quantity: 1 Location of use: Outer ring	Snap ring Quantity: 1 Location of use: Tripod joint
Boot (transaxle side) Quantity: 1 Location of use: Front drive shaft (transaxle side)	Boot band (wheel side) Quantity: 2 Location of use: Boot (wheel side)	Boot (wheel side) Quantity: 1 Location of use: Front drive shaft (wheel side)

Oil and Chemical Type

Grease

Type: Maintenance parts

1. Disassemble in the order shown in the figure.

2. Assemble in the reverse order of disassembly.

ATX

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MTX

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Boot Band (Transaxle Side) Disassembly Note

Type A

1. Using a flat chisel and hammer, lightly tap the lever of the boot band to disconnect the lock clip.

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2. Remove the boot band using pliers.

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Type B

1. Grasp the boot band at the point shown in the figure using pliers, and remove the band.

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Clip, Outer Ring Disassembly Note

Caution

• To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

1. Place alignment marks on the shaft and outer ring.

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2. Remove the clip using a screwdriver.

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3. Remove the outer ring from the shaft.

4. Wipe off grease on the outer ring using a clean rag.

Dust Cover Disassembly Note

1. Remove the dust cover using a press and the SST.

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Bearing Disassembly Note

1. Remove the bearing using a press and SST.

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Snap Ring, Tripod Joint Disassembly Note

Caution

• To prevent damage to parts, do not use a punch or similar tool to place alignment marks. Use paint.

1. Place alignment marks on the shaft and tripod joint.

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2. Remove the snap ring using snap ring pliers.

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Caution

• When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

• If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

3. Remove the tripod joint from the shaft.

4. Wipe off grease on the shaft and tripod joint using a clean rag.

Boot (Transaxle Side) Disassembly Note

1. Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2. Remove the boot (transaxle side).

3. Wipe off grease on the boot (transaxle side) using a clean rag.

Boot Band (Wheel Side) Disassembly Note

1. Remove the boot band using end clamp pliers.

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Boot (Wheel Side) Disassembly Note

1. Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2. Remove the boot (wheel side).

3. Wipe off grease on the boot (wheel side) and ball joint using a clean rag.

Dynamic Damper (No.1) Disassembly Note

1. Remove the dynamic damper using the SST, spacers (such as spare nuts), and a press.

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Dynamic Damper (No.1) Assembly Note

1. Apply soapy water to the inside of the dynamic damper.

2. Assemble the dynamic damper using the SST, spacers (such as spare nuts), and a press.

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3. Verify that the installation position of the dynamic damper is within the specification.

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Specification

Engine type		Installation position
SKYACTIV-G 2.0	LH	288—294 mm {11.4—11.5 in}
SKYACTIV-G 2.0	RH	188—194 mm {7.41—7.63 in}
SKYACTIV-D 2.2	LH	273—279 mm {10.8—10.9 in}
SKYACTIV-D 2.2	RH	183—189 mm {7.21—7.44 in}

Dynamic Damper (No.2) Assembly Note

1. Verify that the assembly position of the dynamic damper is within the standard.

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Standard

250.7—256.7 mm {9.88—10.10 in}

Boot (Wheel Side) Assembly Note

Note

• The boot shapes on the wheel side and the transaxle side are different. Do not assemble the wrong boot by mistake.

1. Insert the shaft through the boot (wheel side) with the vinyl tape left wrapped around the spline area of the shaft.

2. Apply the specified grease to the ball joint and boot (wheel side).

Note

• Apply the grease directly from the tube. Do not touch the grease directly with your hand.

Boot (wheel side) grease amount

Engine type	Grease amount
SKYACTIV-G 2.0 [MTX]	95—115 g {3.4—4.0 oz}
SKYACTIV-G 2.0 [ATX]	90—110 g {3.2—3.8 oz}
SKYACTIV-G 2.5	90—110 g {3.2—3.8 oz}
SKYACTIV-G 2.5T, SKYACTIV-D 2.2	110—130 g {3.89—4.58 oz}

3. Assemble the boot (wheel side) to the ball joint.

Boot Band (Wheel Side) Assembly Note

1. Adjust opening A of the SST to the standard by rotating the adjustment bolt.

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Standard A

Approx. 4.6 mm {0.18 in}

2. Crimp the boot band using the SST.

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3. Verify that crimp B of the boot band is within the standard.

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Standard B

1.2—4.0 mm {0.05—0.15 in}

• If crimp B exceeds the standard, decrease opening A of the SST and crimp the boot band again.

4. Verify that the boot band does not protrude from the band assembly area.

• If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.

Boot (Transaxle Side) Assembly Note

Note

• The boot shapes on the wheel side and the transaxle side are different. Do not assemble the wrong boot by mistake.

1. Insert the shaft through the boot (transaxle side) with the vinyl tape left wrapped around the spline area of the shaft.

2. Remove the vinyl tape wrapped around the spline of the shaft.

Tripod Joint, Snap Ring Assembly Note

Caution

• When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

• If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

1. Assemble the tripod joint with the shaft and tripod joint alignment marks aligned.

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2. Assemble a new snap ring using snap ring pliers.

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3. Verify that the snap ring is assembled correctly in the groove of the shaft.

Bearing Assembly Note

1. Assemble the new bearing using the SST and the press.

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Dust Cover Assembly Note

1. Assemble a new dust cover using the SST and the press.

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2. Verify that the installation position of the dust cover is within the specification.

Dust cover thickness: 0.8 mm {0.031 in}

Engine type	Installation position
SKYACTIV-G 2.0, SKYACTIV-G 2.5	87.7—88.9 mm {3.46—3.50 in}
SKYACTIV-G 2.5T, SKYACTIV-D 2.2	93.2—94.4 mm {3.67—3.71 in}

Dust cover thickness: 1.2 mm {0.047 in}

Engine type	Installation position
SKYACTIV-G 2.0, SKYACTIV-G 2.5	88.1—89.3 mm {3.47—3.51 in}
SKYACTIV-G 2.5T, SKYACTIV-D 2.2	93.6—94.8 mm {3.69—3.73 in}

Outer Ring, Clip Assembly Note

1. Apply the specified grease to the outer ring and boot (transaxle side).

Note

• Apply the grease from the tube. Do not touch the grease directly with your hand.

Boot (transaxle side) grease amount

Engine type	Grease amount
SKYACTIV-G 2.0 [MTX]	LH	170—190 g {6.00—6.70 oz}
SKYACTIV-G 2.0 [MTX]	RH	170—190 g {6.00—6.70 oz}
SKYACTIV-G 2.0 [ATX]	LH	140—160 g {4.94—5.64 oz}
SKYACTIV-G 2.0 [ATX]	RH	135—155 g {4.77—5.46 oz}
SKYACTIV-G 2.5	LH	140—160 g {4.94—5.64 oz}
SKYACTIV-G 2.5	RH	135—155 g {4.77—5.46 oz}
SKYACTIV-G 2.5T, SKYACTIV-D 2.2	LH	190—210 g {6.71—7.40 oz}
SKYACTIV-G 2.5T, SKYACTIV-D 2.2	RH	190—210 g {6.71—7.40 oz}

Caution

• Be careful that dust and dirt do not get on the inside of the outer ring.

2. Insert the outer ring to the shaft.

3. Assemble a new clip using a screwdriver.

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4. Assemble the boot (transaxle side) to the outer ring.

5. Set the drive shaft to the standard length.

Drive shaft (tripod joint) full length (standard)

Engine type	Full length (standard)
SKYACTIV-G 2.0 [MTX]	LH	675.5—685.5 mm {26.60—26.98 in}
SKYACTIV-G 2.0 [MTX]	RH	1039.8—1049.8 mm {40.938—41.330 in}
SKYACTIV-G 2.0 [ATX]	LH	672.5—682.5 mm {26.48—26.87 in}
SKYACTIV-G 2.0 [ATX]	RH	1036.6—1046.6 mm {40.812—41.204 in}
SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)	LH	672.5—682.5 mm {26.48—26.87 in}
SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)	RH	1036.4—1046.4 mm {40.804—41.196 in}
SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)	LH	663.5—673.5 mm {26.13—26.51 in}
SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)	RH	1045.5—1055.5 mm {41.162—41.555 in}
SKYACTIV-G 2.5T	LH	661.8—671.8 mm {26.06—26.44 in}
SKYACTIV-G 2.5T	RH	1043.3—1053.3 mm {41.075—41.468 in}
SKYACTIV-D 2.2 [MTX]	LH	661.9—671.9 mm {26.06—26.45 in}
SKYACTIV-D 2.2 [MTX]	RH	1043—1053 mm {41.07—41.45 in}
SKYACTIV-D 2.2 [ATX]	LH	661.8—671.8 mm {26.06—26.44 in}
SKYACTIV-D 2.2 [ATX]	RH	1043.3—1053.3 mm {41.075—41.468 in}

6. Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

Note

• Do not damage the boot. Verify that there is no grease leakage.

• If the boot is deformed, it may not be possible to perform the full-length adjustment of the shaft.

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7. Verify that the drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

• If not within the standard, repeat from Step 5.

Boot Band (Transaxle Side) Assembly Note

Type A

Warning

• Your hands could be injured while assembling the boot band. Therefore always wear gloves.

1. Apply rust prevention oil to the inside of the boot band.

2. Lock the boot band against rotation using an appropriate tool as shown in the figure.

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Caution

• Do not put the boot band back to its original position after bending it using pliers because it will damage the boot band.

3. Using a pair of pliers, grip the lever at the base (fulcrum point) and rotate it in the direction of the arrow.

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Caution

• If the lever flips back by reactive force, press it back again a maximum of only three times to prevent damage to the boot band.

4. Hold the rotated lever with a finger and temporarily secure the lock clip by squeezing it with a pair of pliers.

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5. Lightly tap the lock clip with a hammer until the gap in the lock clip is 1 mm {0.04 in} or less.

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6. After assembling the boot band, perform the following verification.

• The boot band does not protrude from the band assembly area.

• The lever is not deformed.

• The boot and boot band are not damaged.

• The gap between the boot band and the boot band lever is 1 mm {0.04 in} or less.

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― If there is any malfunction, replace with a new part.

Type B

1. Grasp the boot band at the point shown in the figure using pliers and tighten the boot band.

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1	Boot band (transaxle side) (See Boot Band (Transaxle Side) Disassembly Note .) (See Boot Band (Transaxle Side) Assembly Note)
2	Clip (See Clip, Outer Ring Disassembly Note.) (See Outer Ring, Clip Assembly Note.)
3	Outer ring (See Clip, Outer Ring Disassembly Note.) (See Outer Ring, Clip Assembly Note.)
4	Dust cover (With dust cover) (See Dust Cover Disassembly Note.) (See Dust Cover Assembly Note.)
5	Snap ring
6	Bearing (See Bearing Disassembly Note.) (See Bearing Assembly Note.)
7	Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
8	Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
9	Boot (transaxle side) (See Boot (Transaxle Side) Disassembly Note.) (See Boot (Transaxle Side) Assembly Note.)
10	Boot band (wheel side) (See Boot Band (Wheel Side) Disassembly Note.) (See Boot Band (Wheel Side) Assembly Note.)
11	Boot (wheel side) (See Boot (Wheel Side) Disassembly Note.) (See Boot (Wheel Side) Assembly Note.)
12	Shaft and ball joint component
13	Outer joint component