DRIVE SHAFT (TRIPOD JOINT) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

.

Boot Band (Wheel Side, Transaxle Side: Smaller Diameter) Disassembly Note

Note

• Remove the boot band only if there is a malfunction.

1. Remove the boot band using end clamp pliers.

Boot Band (Transaxle Side Larger Diameter) Disassembly Note

1. Pry up the boot band at the points indicated in the figure using pliers and remove the band.

Outer Ring Disassembly Note

1. Place an alignment mark on the drive shaft and outer ring.

2. Remove the outer ring.

Snap Ring, Tripod Joint Disassembly Note

1. Place an alignment mark on the shaft and tripod joint.

2. Remove the snap ring using snap ring pliers.

3. Remove the tripod joint from the shaft.

Caution

• Do not tap the tripod joint with a hammer.

Boot Disassembly Note

Note

• Remove the wheel side boot only if there is any malfunction.

1. Wrap the shaft splines with tape.

2. Remove the boot.

Boot Assembly Note

Note

• The boot shapes on the wheel side and the differential side are different. Do not install the wrong boot by mistake.

1. Fill the inside of the new dust boot (wheel side) with grease.

Caution

• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

ZJ, Z6, and LF (ATX): 93-103 g {3.29-3.63 oz}

LF (MTX): 110-120 g {3.89-4.23 oz}

2. Install the boot with the drive shaft spline still wrapped with vinyl tape.

3. Remove the vinyl tape.

Tripod Joint, Snap Ring Assembly Note

1. While aligning the marks on the shaft and the tripod joint, insert the tripod joint using a bar and a hammer.

Caution

• Do not tap the roller with a hammer.

2. Insert a new snap ring using snap ring pliers.

Caution

• Be sure the snap ring engages correctly in the groove of the shaft.

Outer Ring Assembly Note

1. Fill the outer ring and boot (transaxle side) with the specified grease.

Caution

• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

ZJ, Z6: 127-141 g {4.49-4.97 oz}

LF (ATX) : 109-123 g {3.85-4.34 oz}

LF (MTX) : 153-167 g {5.41-5.89 oz}

2. Assemble the outer ring.

3. Set the drive shaft to the standard length.

Standard

Z6 (ATX/LH): 598.5-608.5 mm {23.57-23.95 in}

Z6 (ATX/RH): 526.8-536.8 mm {20.75-21.13 in}

ZJ, Z6 (MTX/LH): 629.2-639.2 mm {24.78-25.16 in}

LF (ATX/LH): 599.5-609.5 mm {23.61-23.99 in}

LF (ATX/RH): 527.9-537.9 mm {20.79-21.17 in}

LF (MTX/LH): 611.7-616.7 mm {24.09-24.27 in}

4. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

Caution

• Do not let the grease leak.

• Do not damage the boot.

5. Verify that the drive shaft length is within the specification under atmospheric pressure inside the boot.

• If not within the specification, repeat from Step 3.

Boot Band (Transaxle Side Larger Diameter) Assembly Note

1. Pry up the boot band at the points indicated in the figure using pliers and tighten the boot band.

Caution

• Verify that the boot band is installed securely to the boot slot.

Boot Band (Wheel Side, Transaxle Side Smaller Diameter) Assembly Note

1. Adjust opening width A by turning the adjusting bolt of the SST.

Standard A

1.6 mm {0.063 in}

2. Crimp the wheel side small boot band completely closed so there is no gap using the SST.

3. Verify that the boot band does not protrude from the boot band installation area.

• If the boot band protrudes from the boot band installation area, replace the boot band and repeat Step 2.

4. Fill the boot with the repair kit grease.

5. Adjust opening width A of the SST to the specification.

Standard A

2.0 mm {0.079 in}

6. Crimp the wheel side large boot band completely closed so there is no gap using the SST.

7. Verify that the boot band does not protrude from the boot band installation area.

• If the boot band protrudes from the boot band installation area, replace the boot band and repeat Step 6.