Front
TOOL REQUIRED^ 925091000 Band Tightening Tool
^ 925090000 Band Tightening Tool
DISASSEMBLE
1. Place alignment marks on shaft and outer race.
2. Remove Free-ring tripod joint (FTJ) boot band and boot. Be careful not to damage boot.
3. Remove circlip from FTJ outer race using screwdriver.
4. Remove FTJ outer race from shaft assy.
5. Wipe off grease. The grease is a special grease. Do not confuse with other greases.
6. Place alignment mark on free ring and trunnion.
7. Remove free ring from trunnion.
8. Place alignment mark on trunnion and shaft.
9. Remove snap ring and trunnion. Be sure to wrap shaft splices with vinyl tape to prevent boot from scratches.
10. Remove FTJ boot.
11. Remove BJ boot band and boot.
INSPECTION
1. Check the removed parts for damage, wear, corrosion, etc. If faulty, repair or replace.
2. FTJ and Bell Joint (BJ): Check seizure, corrosion, damage, wear and excessive play.
3. Shaft: Check excessive bending, twisting damage and wear.
4. Boot: Check for wear, warping, breakage or scratches.
5. Grease: Check for discoloration or fluidity.
ASSEMBLE
NOTE: Use specified grease. BJ side: Molylex No. 2 (P/N 723223010) or Sunlight TB2-A FTJ side: SSG 6003. Be sure to wraps shaft splines with vinyl tape to prevent boot from scratches.
1. Install BJ boot in specified position and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease. The inside of the larger end of BJ boot and the boot groove must be cleaned so as to be free from grease and other substances.
2. Place FTJ boot at the center of shaft.
3. Align alignment marks and install trunnion on shaft.
4. install snap ring to shaft. Confirm that the snap ring is completely fitted in the shaft groove.
5. Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of FTJ outer race.
6. Apply a coat of specified grease to free ring and trunnion.
7. Align alignment marks on free ring and trunnion and install free ring.
8. Align alignment marks on shaft and outer race, and install outer race.
9. Install circlip in the groove on FTJ outer race. Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
10. Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot.
11. Install FTJ boot taking care not to twist it.
a. The inside of the larger end of FTJ boot and the boot groove shall be cleaned so as to be free from grease and other substances.
b. When installing FTJ boot, position outer race of FTJ at center of its travel.
12. Put a band through the clip and wind twice in alignment with band groove of boot. Use a new band.
13. Pinch the end of band with pliers. Hold the clip and tighten securely. When tightening boot, exercise care so that the air within the boot is appropriate.
14. Tighten band by using band tightening tool.
a. Tighten band until it cannot be moved by hand.
b. Former band tightening tool is interchangeable with this 925091000
15. Tap on the clip with the punch provided at the end of band tightening tool. Tap to an extent that the boot underneath is not damaged.
16. Cut off band with an allowance of about 10 mm (0.39 inch) left from the clip and bend this allowance over the clip. Be careful so that the end of the band is in close contact with clip.
17. Fix up boot on BJ in the same manner. Extend and retract FTJ to provide equal grease.