CAUTION- For vehicles with ABS, be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly and reassembly.
- Never disassemble the BJ assembly except when replacing the BJ boot.
)
| Disassembly steps |
|||
|---|---|---|---|
>>G<< |
1. |
PTJ boot band (large) |
|
| >>G<< |
2. |
PTJ boot band (small) |
|
| 3. |
PTJ case and inner shaft assembly <2WD-RH> |
||
| <<A>> |
>>F<< |
4. |
PTJ case |
| <<B>> |
>>E<< |
5. |
Inner shaft <2WD-RH> |
| 6. |
Dust cover <2WD-RH> |
||
| 7. |
Bracket assembly <2WD-RH> |
||
| >>D<< |
8. |
Dust seal outer <2WD-RH> |
|
| >>D<< |
9. |
Dust seal inner <2WD-RH> |
|
| <<C>> |
>>C<< |
10. |
Centre bearing <2WD-RH> |
| 11. |
Centre bearing bracket <2WD-RH> |
||
| 12. |
Circlip |
||
| 13. |
Snap ring |
||
| <<A>> |
>>B<< |
14. |
Spider assembly |
| <<D>> |
>>A<< |
15. |
PTJ boot |
| >>A<< |
16. |
Damper band <LH> |
|
| >>A<< |
17. |
Dynamic damper <LH> |
|
| 18. |
BJ assembly |
||
| 19. |
BJ boot band (small) |
||
| 20. |
BJ boot band (large) |
||
| 21. |
BJ boot |
NOTE:
- PTJ: Pillow Tripod Joint
- BJ: Birfield Joint
)
)
- Use special tool inner shaft remover (MB991248 or MD998801) to remove the inner shaft assembly from the PTJ case.
)
- Use special tool side bearing puller (MB990810) to remove the centre bearing bracket from the inner shaft.
)
Use the following special tools to remove the centre bearing from the centre
bearing bracket.
- Bar (MB990938)
- Installer adapter (MB990930)
)
- Install the dynamic damper in the position (L) shown in the figure .
- L: 237 ± 3 mm <2000-Non-Turbo-LH>
- L: 227 ± 3 mm <2000-Turbo-LH>
- L: 231 ± 3 mm <2400-LH>, 222 ± 3 mm <2400-RH>
- Secure the damper bands.
- Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small) and PTJ boot.
>>B<<
SPIDER ASSEMBLY INSTALLATION
- 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.
CAUTIONSpecified grease: Repair kit grease
)
- Install the spider assembly to the shaft from the direction of the spline chamfered side.
)
Use the following special tools to press-fit the centre bearing into the centre bearing
bracket.
- Bar (MB990938)
- Installer adapter (MB990932)
>>D<<DUST SEAL INNER <2WD-RH>
/DUST SEAL
OUTER <2WD-RH>
INSTALLATION
- Apply the specified grease to the rear surface of all dust seals.
CAUTIONSpecified grease: Repair kit grease
Amount used:
Dust seal inner: 14 - 20 g
Dust seal outer: 8 - 12 g
Amount used:
Dust seal inner: 14 - 20 g
Dust seal outer: 8 - 12 g
)
)
- Use the following special tools to press the dust seals into the centre bearing bracket until they are flush with each other.
- Rear suspension bushing base (MB990890)
- Bar (MB990938)
- Installer adapter (MB990934)
- Apply repair kit grease to the lip of each dust seal.
)
- Use special tool inner shaft installer base (MB991172) to hold the centre bearing inner race, and then press-in the inner shaft.
)
- 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.
)
After applying the specified grease to the PTJ case, insert the drive shaft and apply
grease one more time.
- Specified grease: Repair kit grease
- Amount to use:
- <2WD>: 215 ± 10 g
- <4WD>: 220 ± 10 g <2000-Turbo>, 150 ± 10 g <2400>
NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint
and inside the boot.
)
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):
- <2WD>: 90 ± 3 mm
- <4WD>: 90 ± 3 mm <2000-Turbo>, 85 ± 3 mm <2400>