DRIVE SHAFT (DOUBLE OFFSET JOINT) DISASSEMBLY/ASSEMBLY

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1.  Disassemble in the order indicated in the table.

2.  Assemble in the reverse order of disassembly.

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1
Boot band (wheel side)
(See DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY.)
2
Boot band (transaxle side)
(See DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY.)
3
Clip
(See Clip Disassembly Note.)
4
Outer ring
(See Outer Ring Assembly Note.)
5
Snap ring
(See Snap Ring Disassembly Note.)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
6
Balls, inner ring, cage
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
7
Boot
(See Boot Assembly Note.)
8
Dynamic damper
(See Dynamic Damper Assembly Note.)
9
Shaft and ball joint component


Clip Disassembly Note

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

1.  Mark the drive shaft and outer ring for proper assembly.

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Snap Ring Disassembly Note

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

1.  Mark the drive shaft end and inner ring for proper assembly.

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Dynamic Damper Assembly Note

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

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Standard length
MZR 1.8, MZR 2.0, MZR 2.0 DISI, MZR 2.5: 245—251 mm {9.65—9.88 in}
MZR-CD 2.2: 198—204 mm {7.80—8.03 in}

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


Boot Assembly Note

Note
•  The wheel-side and transaxle-side boots are different.

1.  Fill the boot (wheel side) with the specified grease.

Caution
•  Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
MZR 1.8, MZR 2.0, MZR 2.0 DISI: 85—105 g {3.0—3.7 oz}
MZR 2.5: 95—115 g {3.4—4.0 oz}
MZR-CD 2.2: 110—130 g {3.89—4.58 oz}

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

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.

Caution
•  Install the cage so that the major diameter is at the same side as the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.

2.  Align the marks and install the inner ring to the shaft.

3.  Install a new snap ring.


Outer Ring Assembly Note

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

Caution
•  Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
MZR 1.8, MZR 2.0, MZR 2.0 DISI: 105—125 g {3.71—4.40 oz}
MZR 2.5: 115—135 g {4.06—4.76 oz}
MZR-CD 2.2: 135—155 g {4.77—5.46 oz}

2.  Install the outer ring on to the shaft.

3.  Install the boot.

4.  Set the drive shaft to the standard length.

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Drive shaft standard length
LH
―  MZR 1.8, MZR 2.0, MZR 2.0 DISI,
MZR 2.5:
688.7—698.7 mm {27.12—27.50 in}
―  MZR-CD 2.2:
647.7—657.7 mm {25.51—25.89 in}
RH
―  MZR 1.8, MZR 2.0, MZR 2.0 DISI,
MZR 2.5:
638.7—648.7 mm {25.15—25.53 in}
―  MZR-CD 2.2:
591.7—601.7 mm {23.30—23.68 in}

5.  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.

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