DISASSEMBLY AND REASSEMBLY <2WD>


caution As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassembled.




Disassembly steps

>>I<<
 1.
 PTJ boot band (large)

>>I<<
 2.
 PTJ boot band (small)


3.
 Circlip
<<A>>
 >>H<<
 4.
 PTJ case/Inner shaft assembly
<<B>>
 >>H<<
 5.
 Seal plate
<<C>>
6.
 PTJ case
<<D>>
 >>G<<
 7.
 Inner shaft


8.
 Dust cover


9.
 Bracket assembly

>>F<<
 10.
 Dust seal outer

>>F<<
 11.
 Dust seal inner


12.
 Snap ring
<<E>>
 >>E<<
 13.
 Centre bearing


14.
 Centre bearing bracket


15.
 Circlip


16.
 Snap ring

>>D<<
 17.
 Spider assembly
<<F>>
 >>C<<
 18.
 PTJ boot

>>B<<
 19.
 Damper band

>>B<<
 20.
 Dynamic damper (LH)


21.
 EBJ assembly


22.
 EBJ boot band (small)


23.
 EBJ boot band (large)

>>A<<
 24.
 EBJ boot

LUBRICATION POINTS




DISASSEMBLY SERVICE POINTS

<<A>>PTJ CASE/INNER SHAFT ASSEMBLY REMOVAL
caution When removing the PTJ case and inner shaft assembly, be careful not to drop off the roller part of spider assembly, because it easily departs from the spider assembly.

<<B>> SEAL PLATE REMOVAL

Use a slotted screwdriver to make a hole in the seal plate inside the PTJ case, and remove it.

<<C>> PTJ CASE REMOVAL

Use special tool bar (MD998801) to remove the PTJ case from the inner shaft assembly.

<<D>>INNER SHAFT REMOVAL

Use special tool side bearing puller (MB990810) to remove the inner shaft from the centre bearing bracket.

<<E>>CENTRE BEARING REMOVAL

Use the following special tools to remove the centre bearing from the centre bearing bracket.

  • Installer bar (MB990938)
  • Installer adapter (MB990930)

<<F>> PTJ BOOT REMOVAL
1.Wipe off grease from the shaft spline.
2.When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

REASSEMBLY SERVICE POINTS

>>A<< EBJ BOOT INSTALLATION
Wrap plastic tape around the shaft spline, and then install the EBJ boot.

>>B<< DYNAMIC DAMPER/DAMPER BAND 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: 221 ± 3 mm
2.Secure the damper band.
3.Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small) and PTJ boot.

>>C<< PTJ BOOT INSTALLATION
Wrap plastic tape around the shaft spline, and then install the PTJ boot.

>>D<< SPIDER ASSEMBLY INSTALLATION
1.
caution
  • The drive shaft 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.
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.

>>E<<CENTRE BEARING INSTALLATION

Use the following special tools to press-fit the centre bearing into the centre bearing bracket.

  • Installer bar (MB990938)
  • Installer adapter (MB990932)

>>F<<DUST SEAL INNER/DUST SEAL OUTER INSTALLATION
caution When applying grease, make sure that it does not adhere to anything outside the lip.
1.Apply the specified grease to the rear surface of all dust seals.
Specified grease: Repair kit grease

    Amount used (Dust seal inner): 6 - 10 g
    Amount used (Dust seal outer): 3 - 7 g


2.Use the following special tools to press the dust seals into the centre bearing bracket until they are flush with each other.

  • Rear suspension bush base (MB990890)
  • Installer bar (MB990938)
  • Installer adapter (MB990934)
3.Apply repair kit grease to the lip of each dust seal.

>>G<<INNER SHAFT INSTALLATION

Use special tool inner shaft installer base (MB991172) to hold the centre bearing inner race, and then press-in the inner shaft.

>>H<<SEAL PLATE/PTJ CASE/INNER SHAFT ASSEMBLY INSTALLATION

1.Apply repair kit grease to the inner shaft spline, then press fit it into the PTJ case.
note When press-fitting the inner shaft into the PTJ case, apply a thin coat of repair kit grease to the dust seal outer lip part and the outside edge of the PTJ axial part.

2.Use special tool bearing installer (MD998369) to press in the seal plate.
caution The driveshaft joint uses special grease. Do not mix old and new or different types of grease.

3.After applying the specified grease to the PTJ case, insert the driveshaft and apply grease again.
Specified grease: Repair kit grease

    Amount to use: 210 ± 10 g <LH>, 225 ± 10 g <RH>
note The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

>>I<< PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION

Set the PTJ boot bands at the specified distance in order to adjust the amount of air inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band (large) securely.
Standard value (A): 85 ± 3 mm