Front Axle
DISASSEMBLY AND REASSEMBLY
CAUTION: Never disassemble the BJ assembly except when replacing the BJ boot.
Lubrication Points
DISASSEMBLY SERVICE POINTS
BALL REMOVAL
Remove the balls from the DOJ cage.
DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction shown in the illustration.
Wrap plastic tape around the spline part on the DOJ side of the driveshaft so that DOJ boot is not damaged when removed.
ASSEMBLY SERVICE POINTS
>A< D0J INNER RACE/SNAP RING/DOJ CAGE/BALLS INSTALLATION
Install the cage, balls and inner race to the driveshaft, and fit the snap ring securely to the groove in the driveshaft.
>B< DOJ OUTER RACE INSTALLATION
CAUTION: The driveshaft joint use special grease. Do not mix old and new or different types of grease.
1. Fill the inside of the DOJ outer race and DOJ boot with the specified grease.
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
Specified grease: Repair kit grease 140 g (4.9 oz.)
CAUTION: Do not secure the boot band (large).
2. Install the circlip onto the DOJ outer race. Place the DOJ boot over the DOJ outer race, and then use a boot band (small) to secure the boot.
>C< DOJ BOOT/DOJ BOOT BAND INSTALLATION
1. Position the DOJ outer race so that the distance between the boot bands is at the standard value.
Standard value (A):
<3.0L> 92 - 98 mm (3.6 - 3.9 inches)
<3.5L> 87 - 93 mm (3.4 - 3.7 inches)
2. Remove part of the DOJ boot from the DOJ outer race to release the air pressure inside the boot.
CAUTION: Be sure that the installation direction of the boot bands is correct.
3. Secure the boot band (large) on DOJ boot.
BJ BOOT (RESIN BOOT) REPLACEMENT
1. Remove the boot bands (large and small).
NOTE: The BJ boot bands cannot be re-used.
2. Remove the BJ boot.
3. Turn the adjusting bolt on special too[ MB991561 so that the size of the opening (W) is at the standard value.
NOTE:
- The value of W will change by approximately 0.7 mm, (0.03 inch) for each turn of the adjusting bolt.
- The adjusting bolt should not be turned more than once.
Standard value (W): 2.9 mm (0.12 inch)
4. Place the BJ boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.
CAUTION:
- Secure the driveshaft in an upright position and clamp the part of the BJ boot band to be crimped securely in the jaws of the special tool.
- Crimp the BJ boot band until the special tool touches the stopper.
5. Use special tool MB991561 to crimp the BJ boot band (small).
6. Check that crimping amount (B) of the BJ boot band is at the standard value.
Standard value (113): 2.4 - 2.8 mm (0.10 - 0.11 inch)
Readjust the value of (W) in step 3 according to the following formula, and then repeat the operation in step 5.
W = 5.5 mm (0.22 inch) - B
Example: If B = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).
Remove the BJ boot band, readjust the value of (W) in step 3 according to the following formula, and then repeat the operations in steps 4 and 5 using a new BJ boot band.
W = 5.5 mm (0.22 inch) - B
Example: If B = 2.3 mm (0.10 inch) then W = 3.2 mm (0.13 inch).
7. Check that the BJ boot band is not protruding past the place where it has been installed.
If so, remove it and then repeat the operations in steps 4 to 6 using a new BJ boot band.
CAUTION: The driveshaft joint uses special grease. Do not mix old and new grease or different types of grease.
8. Fill the inside of the BJ boot with the specified amount of the specified grease.
Specified grease: Repair kit grease 120 g (4.2 oz.)
9. Install the BJ boot band (large) so that there is the clearance (C) between it and the BJ housing is at the standard value.
Standard value (C): 0.1 - 1.55 mm (0.004 - 0.061 inch)
10. Follow the same procedure as in step 3 to adjust the size of the opening (W) shown on P.26-26 on special tool MB991561 so that it is at the standard value.
Standard value (W): 3.2 mm (0.13 inch)
11. Place the BJ boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration.
12. Use special tool MB991561 to crimp the BJ boot band (large) in the same way as in step 5.
13. Check that the crimping amount (E) of the BJ boot band is at the standard value.
Standard value (E): 2.4 - 2.8 mm (0.10 - 0.11 inch)
Readjust the value of (W) in step 10 according to the following formula, and then repeat the operation in step 12.
W = 5.8 (0.23 inch) mm - E
Example: If E = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).
Remove the BJ boot band, readjust the value of (W) in step 10 according to the following formula, and then repeat the operating in steps 11 and 12 using a new BJ boot band.
W = 5.8 (0.23 inch) mm - E
Example: If E = 2.3 mm (0.10 inch), then W = 3.5 mm (0.14 inch).
14. Check that the BJ boot band is not protruding past the place where it has been installed.
If so, remove it and repeat the operations in steps 11 to 13 using a new BJ boot band.