Unit Overhaul

Disassembly





1) Remove boot band of differential side joint.





2) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, then take shaft out of outer race.





3) Remove circlip (1) and then cage (2).
4) Remove inside and outside boots from shaft.

CAUTION:
^ Do not disassemble wheel side joint (outboard joint). If any malcondition is found in joint, replace it as assembly.
^ Do not disassemble ball joint of differential side joint. If any malcondition is found in ball joint, replace differential side joint assembly.

Reassembly

CAUTION:
^ To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed.
^ For M/T vehicle with H25 engine:
To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint. i.e. yellow grease to wheel side joint and black one to differential side.
^ Bend each boot band against forward rotation.
^ Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.





1) Fully apply joint grease to wheel side joint. Use joint grease in the tube included in spare part.
"A": Joint Grease (about 85 - 90g (3.0 - 3.2 oz)) 99000-25120
2) Fit wheel side boot (1) on shaft. Fill up inside of boot (1) with joint grease. Before fixing boot band (2), insert screwdriver into boot (1) on joint side and allow air to enter boot (1) so that air pressure in boot (1) becomes the same as atmospheric pressure.
3) Fixing boot band (2).





4) Install boot (1) onto drive shaft till its small diameter side fits to shaft groove and fix there with boot band (2).





5) Install cage (1) to shaft.

CAUTION: Install cage (1) directing smaller outside diameter side to shaft end.





6) Install circlip (1) by using snap ring plier.





7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part or joint grease (99000-25120).





8) Insert cage into outer race and fit circlip (1) into groove of outer race.

CAUTION: Position opening of circlip "a" so that it will not be lined up with a ball.

9) Apply grease to inside of outer race, and fit boot to outer race. Fill up inside of boot with joint grease.
"A": Joint Grease (about 90 - 95g (3.2 - 3.4 oz)) 99000-25120





10) Fitting boot to outer race, adjust so that measurements "b" and "c" become as shown in the figure.
Differential side (RH) boot installation position (Length "b"):
"b": 203.2 - 213.2 mm (8.00 - 8.40 inch)
"b": 196.8 - 206.8 mm (7.75 - 8.14 inch) for M/T vehicle with H25 engine
Differential side (LH) boot installation position (Length "c"):
"c": 125.5 - 135.5 mm (4.94 - 5.33 inch)
"c": 127.5 - 137.5 mm (5.02 - 5.41 inch) for M/T vehicle with H25 engine
1) Before fixing boot band, insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
2) Clamp boot band. Check boots for distortion or dent.