FRONT DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

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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 larger diameter)
(See Boot Band (Transaxle Side Larger Diameter) Disassembly Note.)
(See Boot Band (Transaxle Side Larger Diameter) Assembly Note.)
2
Boot band (transaxle side smaller diameter)
(See Boot Band (Transaxle Side Smaller Diameter) Disassembly Note.)
(See Boot Band (Transaxle Side Smaller Diameter) Assembly Note.)
3
Outer ring
(See Outer Ring Disassembly Note.)
(See Outer Ring Assembly Note.)
4
Dust cover
(See Dust Cover Disassembly Note.)
(See Dust Cover Assembly Note.)
5
Bearing
(See Bearing Disassembly Note.)
(See Bearing Assembly Note.)
6
Snap ring
(See Snap Ring, Tripod Joint Disassembly Note.)
(See Tripod Joint, Snap Ring Assembly Note.)
7
Tripod joint
(See Snap Ring, Tripod Joint Disassembly Note.)
(See Tripod Joint, Snap Ring Assembly Note.)
8
Boot (transaxle side)
(See Boot (Transaxle Side) Disassembly Note.)
(See Boot (Transaxle Side) Assembly Note.)
9
Boot band (wheel side)
(See Boot Band (Wheel Side) Disassembly Note.)
(See Boot Band (Wheel Side) Assembly Note.)
10
Boot (wheel side)
(See Boot (Wheel Side) Disassembly Note.)
(See Boot (Wheel Side) Assembly Note.)
11
Shaft and ball joint component


Boot Band (Transaxle Side Larger Diameter) Disassembly Note

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

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Boot Band (Transaxle Side Smaller Diameter) Disassembly Note


SKYACTIV-G 2.0, SKYACTIV-G 2.5

1.  Remove the boot band using end clamp pliers.

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SKYACTIV-D 2.2

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

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Outer Ring Disassembly Note

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

Caution
•  To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.
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2.  Secure the shaft in a vise.

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3.  Lightly tap the outer ring evenly using a hammer and urethane bar or equivalent, and remove the outer ring from the shaft.

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.
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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

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

Caution
•  To prevent damage to parts, do not use a punch or similar tool to place alignment marks. Use paint.
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2.  Remove the snap ring using snap ring pliers.

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3.  Remove the tripod joint from the shaft.

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.

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.


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.
Grease amount
SKYACTIV-G 2.0, SKYACTIV-G 2.5: 96—106 g {3.4—3.7 oz}
SKYACTIV-D 2.2: 160—180 g {5.65—6.34 oz}

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


Boot Band (Wheel Side) Assembly Note


SKYACTIV-G 2.0, SKYACTIV-G 2.5

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

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Standard A
Large diameter side: Approx. 3.2 mm {0.13 in}
Small diameter side: Approx. 2.6 mm {0.10 in}

2.  Crimp the boot band using the SST.

Large diameter side

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Small diameter side

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

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Standard B
Large diameter side: 1.2 mm {0.047 in} or less
Small diameter side: 1.0 mm {0.039 in} or less
•  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.


SKYACTIV-D 2.2

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

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Standard A
Approx. 4.5 mm {0.18 in}

2.  Crimp the boot band using the SST.

Large diameter side

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Small diameter side

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

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Standard B
2.0—3.0 mm {0.08—0.11 in}
•  If crimp B exceeds the standard, decrease opening 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

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

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.
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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.

Specification

Engine type

Installation position
SKYACTIV-G 2.0, 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}


Outer Ring 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.
Grease amount
SKYACTIV-G 2.0, SKYACTIV-G 2.5: 89—99 g {3.2—3.4 oz}
SKYACTIV-D 2.2: 155—175 g {5.47—6.17 oz}

2.  Secure the outer ring in the vise.

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3.  After aligning the shaft and outer ring alignment marks, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and insert the outer ring little by little while maintaining the shaft perpendicular.

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.
•  Be careful that dust and dirt do not get on the inside of the outer ring.
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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 full length (standard)
LH
―  SKYACTIV-G 2.0: 675.5—685.5 mm {26.60—26.98 in}
―  SKYACTIV-G 2.5: 675.5—685.5 mm {26.60—26.98 in}
―  SKYACTIV-D 2.2: 672.5—682.5 mm {26.48—26.87 in}
RH
―  SKYACTIV-G 2.0: 1038.95—1048.95 mm {40.9036—41.2972 in}
―  SKYACTIV-G 2.5: 1040.95—1050.95 mm {40.9824—41.3760 in}
―  SKYACTIV-D 2.2: 1052.50—1062.50 mm {41.4371—41.8307 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 Smaller Diameter) Assembly Note


SKYACTIV-G 2.0, SKYACTIV-G 2.5

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

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Standard C
Approx. 2.0 mm {0.079 in}

2.  Crimp the boot band using the SST.

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

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Standard D
0.8 mm {0.03 in} or less
•  If crimp D exceeds the standard, decrease opening C 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.


SKYACTIV-D 2.2

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

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Boot Band (Transaxle Side Larger Diameter) Assembly Note

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

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