FRONT DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

id031300802600

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
—
—

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.

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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 (2WD)
(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


Boot Band (Transaxle Side) Disassembly Note

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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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 the SST.

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Snap Ring, Tripod Joint Disassembly Note

Caution
•  To prevent damage to parts, use paint instead of a punch or similar tool to place alignment marks.

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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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.
Caution
•  Be careful not to scratch the roller area when using a hammer and urethane bar or equivalent. Otherwise, the part could be damaged.

3.  Remove the tripod joint from the shaft.

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


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 cloth.


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 cloth.


Boot (Wheel Side) Assembly Note

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

1.  Install the boot 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 from the tube. Do not touch the grease directly with your hand.

Boot (wheel side) grease amount

Engine type

Grease amount
SKYACTIV-G 2.5
90—110 g {3.2—3.8 oz}
SKYACTIV-D 2.2
110—130 g {3.89—4.58 oz}

3.  Remove the vinyl tape.


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
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
1.2—4.0 mm {0.05—0.15 in}
•  If width B of the crimp exceeds the standard, reduce opening width A of the SST and crimp the boot band again.
•  If crimp B is less than the standard, increase opening A of the SST and crimp a new boot band.

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
•  Be careful not to scratch the roller area when using a hammer and urethane bar or equivalent. Otherwise, the part could be damaged.
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.  Install 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 standard.

Dust cover thickness: 0.8 mm {0.031 in}

Engine type

Installation position
SKYACTIV-G 2.5
87.7—88.9 mm {3.46—3.50 in}
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 2.5
88.1—89.3 mm {3.47—3.51 in}
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 2.5
LH
140—160 g {4.94—5.64 oz}
RH
135—155 g {4.77—5.46 oz}
SKYACTIV-D 2.2
LH
190—210 g {6.71—7.40 oz}
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 2.5
LH
672.5—682.5 mm {26.48—26.87 in}
RH
1036.4—1046.4 mm {40.804—41.196 in}
SKYACTIV-D 2.2
LH
661.8—671.8 mm {26.06—26.44 in}
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

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 springs back, press it back in no more than 3 times to prevent damage to the boot band.

4.  Hold the bent lever using a hand and secure it temporarily by pinching the lock clip using pliers.

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5.  Lightly press the lock clip using a hammer so that the clearance of the lock clip is 1 mm {0.04 in} or less.

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•  If there is any malfunction, replace with a new band.

6.  Verify that the clearance between the boot band and boot band lever is 1 mm {0.04 in} or less.

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•  If there is any malfunction, replace with a new boot band.

7.  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 boot is not damaged.