Overhaul
TOOL REQUIRED- ST 925091000 Band Tightening Tool
DISASSEMBLE
1. Straighten bent claw of larger end of DOJ boot.
2. Loosen band by means of screwdriver or pliers with care of not damaging boot.
3. Remove boot band on the small end of DOJ boot in the same manner.
4. Remove the larger end of DOJ boot from DOJ outer race.
5. Pry and remove round circlip located at the neck of DOJ outer race with a screwdriver.
6. Take out DOJ outer race from shaft assembly.
7. Wipe off grease and take out balls.
(1) Outer race
(2) Grease
CAUTION: The grease is a special grease (grease for constant velocity joint). Do not confuse with other greases.
NOTE: Disassemble exercising care not to lose balls (6 pcs).
8. To remove the cage from the inner race, turn the cage by a half pitch to the track groove of the inner race and shift the cage.
9. Remove snap ring, which fixes inner race to shaft, by using pliers.
10. Take out DOJ inner race.
11. Take off DOJ cage from shaft and remove DOJ boot.
CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
12. Remove UFJ/BJ boot in the same procedure as steps 1 to 3.
13. Thus, disassembly of axle is completed, but UFJ/BJ is unable to be disassembled.
INSPECTION
NOTE: Check the removed parts for damage, wear, corrosion and etc. If faulty, repair or replace.
1. DOJ (Double Offset Joint): Check seizure, corrosion, damage, wear and excessive play.
2. Shaft: Check excessive bending, twisting, damage and wear.
3. UFJ (Under cut Free Joint): Check seizure, corrosion, damage and excessive play.
4. Boot: Check for wear, warping, breakage or scratches.
5. Grease: Check for discoloration or fluidity.
ASSEMBLE
NOTE: Use specified grease:
UFJ/BJ side:
- UFJ (Front)-NTG2218 (Part No. 28093AA020)
- BJ (Rear)-Molylex No. 2 (Part No. 723223010) or Sunlight TB2-A
DOJ side:
- AT model (Front and Rear) and MT model (Rear) -VU-3A702 (Yellow) (Part No. 23223GA050)
- MT model (Front)-Molylex No. 2 (Part No. 723223010) or Sunlight TB2-A
1. Install BJ boot in specified position. and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease.
2. Place DOJ boot at the center of shaft.
CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
3. Insert DOJ cage onto shaft.
NOTE: Insert the cage with the cut-out portion facing the shaft end, since the cage has an orientation.
4. Install DOJ inner race on shaft and fit snap ring with pliers.
NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
5. Install cage, which was previously fitted, to inner race fixed upon shaft.
(1) Inner race
(2) Cage
NOTE: Fit the cage with the protruded part aligned with the track on the inner race and then turn by a half pitch.
6. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the interior of DOJ outer race.
7. Apply a coat of specified grease to the cage pocket and six balls.
8. Insert six balls into the cage pocket.
9. Align the outer race track and ball positions and place in the part where shaft. inner race, cage and balls are previously installed, and then fit outer race.
(1) Outer race
(2) Grease
10. Install circlip in the groove on DOJ outer race.
NOTE:
- Assure that the balls. cage and inner race are completely fitted in the outer race of DOJ.
- Exercise care not to place the matched position of circlip in the ball groove of outer race.
- Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
11. Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft.
12. Install DOJ boot taking
NOTE:
- The inside of the larger end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances.
- When installing DOJ boot, position outer race of DOJ at center of its travel.
13. Put a band through the clip and wind twice in alignment with band groove of boot.
CAUTION: Use a new band.
14. Pinch the end of band with pliers. Hold the clip and tighten securely.
NOTE: When tightening boot, exercise care so that the air within the boot is appropriate.
15. Tighten band by using ST.
NOTE: Tighten band until it cannot be moved by hand.
16. Tap on the clip with the punch provided at the end of ST.
CAUTION: Tap to an extent that the boot underneath is not damaged.
17. Cut off band with an allowance of about 10 mm (0.39 inch) left from the clip and bend this allowance over the clip.
CAUTION: Be careful so that the end of the band is in close contact with clip.
18. Fix up boot on BJ and UFJ in the same manner.
NOTE: Extend and retract DOJ to provide equal grease coating.