Front Axle

DISASSEMBLY

NOTE: For the left side, follow the same steps as right side.





1. Raise the hooked end of the band (1) with a screwdriver or equivalent.

2. Remove band.





3. Pry off circlip (1) with a screwdriver or equivalent.

4. Remove drive shaft joint assembly.





5. Using snap ring pliers, remove the snap ring.
6. Remove spacer.





7. Remove the six balls (1) with a screwdriver or equivalent.





8. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft.
9. Remove ball retainer, ball guide and bellows.





10. Raise the hooked end of the band (1) with a screwdriver or equivalent.
11. Remove band.
12. Remove bellows.
13. Remove dust seal.
14. Remove BJ shaft assembly.
15. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case.
16. Remove snap ring and bearing.
17. Remove snap ring and oil seal.
18. Remove bracket.

INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection.
Check the following parts:
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal

BUSHING REPLACEMENT





- Remove the bushings using a remover J-39378-1 and hammer.





- By using installer J-39378-2 and base J-39378-3, press fit the bushings into the bracket.

REASSEMBLY
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to the specified torque.

Torque: 116 Nm (85 ft. lbs.)

5. Apply 150g of the specified grease in BJ.
6. Install dust seal.
7. Apply a thin coat of grease to the shaft for smooth installation then install bellows.





8. Install band. Note the setting direction. After installation, check that the bellows is free from distortion.
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side ahead onto the shaft.
11. Install ball retainer.





12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft.





13. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position.
14. Install spacer.
15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit.








17. Install the circlip (1) so that open ends are positioned away from the ball groove.





18. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure.
19. Install Band. After installation, check that the bellows is free from distortion.