DISASSEMBLY AND REASSEMBLY <2WD: 1500, 1800, 2000-LH>


caution
  • As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassembled.
  • The EBJ boot for 1800-RH is not replaceable.




Disassembly steps


1.
 Circlip

>>C<<
 2.
 TJ/ETJ boot band (large)

>>C<<
 3.
 TJ/ETJ boot band (small)
<<A>>
 >>B<<
 4.
 TJ/ETJ case


5.
 Snap ring
<<A>>
 >>B<<
 6.
 Spider assembly
<<B>>
 >>A<<
 7.
 TJ/ETJ boot

>>A<<
 8.
 Damper band A <1500-A/T>, Damper band B <1500-M/T, 1800>

>>A<<
 9.
 Dynamic damper (LH)

>>A<<
 10.
 Dynamic damper (RH)


11.
 EBJ boot band (large)


12.
 EBJ boot band (small)


13.
 EBJ boot


14.
 EBJ assembly




Disassembly steps


1.
 Circlip

>>C<<
 2.
 PTJ boot band (large)

>>C<<
 3.
 PTJ boot band (small)


4.
 Circlip
<<A>>
 >>B<<
 5.
 PTJ case


6.
 Snap ring
<<A>>
 >>B<<
 7.
 Spider assembly
<<B>>
 >>A<<
 8.
 PTJ boot

>>A<<
 9.
 Damper band

>>A<<
 10.
 Dynamic damper


11.
 EBJ boot band (large)


12.
 EBJ boot band (small)


13.
 EBJ boot


14.
 EBJ assembly

LUBRICATION POINTS




DISASSEMBLY SERVICE POINTS

<<A>> TJ/ETJ CASE/PTJ CASE/SPIDER ASSEMBLY REMOVAL
caution
  • Do not disassemble the spider assembly.
  • When removing the PTJ case, be careful not to drop off the roller part of spider assembly, because it easily departs from the spider assembly.
1.Wipe off grease from the spider assembly and the inside of the TJ/ETJ case or PTJ case.
2.Always clean the spider assembly when the grease contains water or foreign material.

<<B>> TJ/ETJ BOOT/PTJ BOOT REMOVAL
1.Wipe off the grease on the shaft spline.
2.When reusing the TJ/ETJ boot or PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

REASSEMBLY SERVICE POINTS

>>A<< DYNAMIC DAMPER/DAMPER BAND/TJ/ETJ BOOT/PTJ BOOT INSTALLATION

1.
caution There should be no grease adhered to the rubber part of the dynamic damper.
Install the dynamic damper in the position (A) shown in the figure .

    A: 241 ± 3 mm <1500-A/T-LH>
    A: 221 ± 3 mm <1800-M/T-LH>
    A: 231 ± 3 mm <2000-LH>
    A: 421 ± 3 mm <1500-RH>
    A: 426 ± 3 mm <1800-RH>
2.Secure the damper band.
3.Wrap plastic tape around the shaft spline, and then install the TJ/ETJ boot band (small) or PTJ boot band (small) and TJ/ETJ boot or PTJ boot.

>>B<< SPIDER ASSEMBLY/TJ/ETJ CASE/PTJ CASE INSTALLATION
caution
  • The driveshaft joint use special grease. Do not mix old and new or different types of grease.
  • If the spider assembly has been cleaned, take special care to apply the specified grease.
1.Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease

2.Install the spider assembly to the shaft from the direction of the spline chamfered side.

3.After applying the specified grease to the TJ/ETJ case or PTJ case, insert the driveshaft and apply grease one more time.
Specified grease: Repair kit grease
Amount to use:

    110 ± 10 g <1500-M/T>
    115 ± 10 g <1500-A/T>
    120 ± 10 g <1800-M/T-LH, 1800-CVT>
    130 ± 10 g <1800-M/T-RH>
    255 ± 10 g <2000-LH>
note When using the repair kit grease, fill the half of the grease into the joint and the other half into the boot as a guideline, and consume the grease completely.

>>C<< TJ/ETJ BOOT BAND (SMALL)/TJ/ETJ BOOT BAND (LARGE)/PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION

Adjust the distance (A shown in the illustration) between the boot bands to the standard value to adjust the air volume inside the TJ/ETJ boot or PTJ boot to the specified value, then be sure to tighten the TJ/ETJ boot band (large) or PTJ boot (large) and TJ/ETJ boot band (small) or PTJ boot band (small).
Standard value (A):

    85 ± 3 mm <1500>
    80 ± 3 mm <1800>
    95 ± 3 mm <2000-LH>