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DRIVE SHAFT DISASSEMBLY/ASSEMBLY

id031300144200

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

1 | Boot band (wheel side, transaxle side smaller diameter) (See Boot Band (Wheel Side, Transaxle Side Smaller Diameter) Disassembly Note) (See Boot Band (Wheel Side, Transaxle Side Smaller Diameter) Assembly Note)
2 | Boot band (transaxle side larger diameter) (See Boot Band (Transaxle Side Larger Diameter) Disassembly Note) (See Boot Band (Transaxle Side Larger Diameter) Assembly Note)
3 | Outer ring (See Outer Ring Disassembly Note) (See Outer Ring Assembly Note)
4 | Snap ring (See Snap Ring And Tripod Joint Disassembly Note) (See Tripod Joint And Snap Ring Assembly Note)
5 | Tripod joint (See Snap Ring And Tripod Joint Disassembly Note) (See Tripod Joint And Snap Ring Assembly Note)
6 | Boot (See Boot Disassembly Note) (See Boot Assembly Note)
7 | Shaft and ball joint component
8 | Dynamic damper (See Dynamic Damper Assembly Note)

## Boot Band (Wheel Side, Transaxle Side Smaller Diameter) Disassembly Note

  Note

  • The boot band does not need to be removed unless it is being replaced.

1. Remove the boot band using an end clamp plier.

## Boot Band (Transaxle Side Larger Diameter) Disassembly Note

1. Pry up the points indicated in the figure using a plier, and remove the boot band.

## Outer Ring Disassembly Note

1. Mark the drive shaft and outer ring.

2. Remove the outer ring.

## Snap Ring And Tripod Joint Disassembly Note

1. Mark the shaft and tripod joint.

2. Remove the snap ring using a snap ring plier.

3. Remove the tripod joint from the shaft.

  Caution

  • Do not tap the tripod joint with a hammer.

## Boot Disassembly Note

  Note

  • The wheel side boot do not need to be removed unless they are being replaced.

1. Wrap the shaft splines with tape.

2. Remove the boot.

## Dynamic Damper Assembly Note

1. Install the dynamic damper as shown in the figure.

Length

  ZJ: 227.5 mm {8.957 in}
  ZY: 228.4 mm {9.354 in}

2. Install a new boot band to the dynamic damper.

## Boot Assembly Note

  Note

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

1. Fill the inside of the new dust boot (wheel side) with grease.

  Caution

  • Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

  ZJ: 70-90 g {2.5-3.1 oz}
  ZY: 75-95 g {2.7-3.3 oz}

2. Install the boot with the splines of the shaft still wrapped in tape from disassembly.

3. Remove the tape.

## Tripod Joint And Snap Ring Assembly Note

1. Align the marks and insert the tripod joint using a bar and a hammer.

  Caution

  • Do not damage the roller.

2. Insert a new snap ring using a snap ring plier.

  Caution

  • Be sure the snap ring engages correctly in the groove of the shaft.

## Outer Ring Assembly Note

1. Fill the outer ring and boot (transaxle side) 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.

Grease amount

  ZJ: 109-125 g {3.85-4.40 oz}
  ZY: 120-136 g {4.24-4.79 oz}

2. Assemble the outer ring.

3. Set the drive shaft to the standard length.

Drive shaft length

  ZJ (MTX, LH): 645.1-655.1 mm
  ZJ (MTX, RH): 538.5-648.5 mm
  ZY (MTX, LH): 645.0-655.0 mm
  ZY (MTX, RH): 538.5-648.5 mm
  ZY (ATX, LH): 630.0-640.0 mm
  ZY (ATX, RH): 537.6-547.6 mm

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

  Caution

  • Do not let the grease leak.
  • Do not damage the boot.

5. Verify that the drive shaft length is within the standard under atmospheric pressure inside the boot.

  • If not within the specification, repeat the Steps 3-5.

## Boot Band (Transaxle Side Larger Diameter) Assembly Note

1. Pry up the points indicated in the figure using a plier, and tighten the boot band.

  Caution

  • Verify that the boot band is installed into the groove securely.

## Boot Band (Wheel Side, Transaxle Side Smaller Diameter) Assembly Note

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

Clearance A

  1.6 mm {0.06 in}

2. Crimp the wheel side small boot band completely using the SST.

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

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

4. Fill the boot with the repair kit grease.

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

Clearance A

  2.0 mm {0.08 in}

6. Crimp the wheel side large boot band completely using the SST.

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

  • If it does, replace the boot band and repeat Step 6.