Drive Shaft Disassembly and Assembly (2WD Models)

Disassembly

Note: disassembly is carried out in the order of the numbers indicated in the figure "Disassembly and assembly of the drive shaft". When removing parts, pay attention to the following operations.

Note: the drive shaft is fitted with an external hinge type (RJ and BJ) and inner hinge type (TJ).

Caution: Do not disassemble the outer hinge.

1. Remove the inner joint race.

Remove the inner joint race and remove the grease from the interior of the race.

Note: Keep water and dirt out of the inner joint cage.

2. Remove the inner hinge cover.

A) Remove grease from the splines of the wheel drive shaft.

b) Remove the inner hinge cover.

Note: When reusing the inner pivot boot, wrap tape around the spline of the shaft to prevent damage to the boot.

Examination

1. Check the drive shaft for damage, deformation or corrosion.

2. Check the spline of the drive shaft for excessive wear or damage.

3. Check the triple joint for binding, excessive wear or corrosion.

4. Check the inner joint race groove for wear or corrosion.

5. Check the damper for damage or cracks.

6. Check up covers of hinges on absence of damages, cracks.

Assembly

Note: Assembly is in the reverse order of disassembly. Pay attention to the following operations when assembling.

1. Install damper.

A) Set the damper to the position shown in the figure.

Sedan models:

since 05.2000 (2WD):

with 4G15 engines:

• "A" - 236 mm
• "IN" - 469 mm

with 4G93 engines:

• "A" - 239.5 mm
• "IN" - 470.5 mm

since 07.2000

(4WD, with 4G93 engines):

• "A" — 245±3 mm
• "IN" — 220±3 mm

Station wagon models:

from 11.2000:

2WD:

• "A" - 470.5 mm
• "IN" - 239.5 mm

4WD:

• "WITH" - 220 mm
• "D" —

from 05.2001, with 4G93 engines:

• "WITH" - 230 mm
• "D" - 415 mm

since 05.2002 (Sport Edition):

2WD:

• "IN" - 415 mm
• "WITH" - 230 mm

4WD:

• "IN" - 254 mm
• "WITH" - 230 mm

b) Tighten damper clamps.

Attention:

• - Do not allow grease to come into contact with the rubber surface of the damper.
• - Damper clamps and inner pivot boot clamps are distinguished by identification numbers printed on the clamp arms. Be especially careful when installing the appropriate clamps.

Clamp identification marks:

2WD sedan models from 05.2000:

• for damper - 31.3 (blue)
• for the cover of the internal hinge - 33 (another)

4WD models, station wagon models (with 4G93 engine (since 05.2001)) and models since 2002 (Sport Edition):

• for damper - 8382
• for the cover of the inner hinge - E687

2. Installing the protective cover of the inner hinge.

Wrap tape around the spline of the driveshaft, and then install the small collar of the inboard joint boot and the inboard joint boot.

3. Install the triple pivot and inner pivot race.

A) Install the triple joint.



b) Apply the special grease from the repair kit between each axle and the inner pivot roller.


Recommended grease: from rem. kit.

Attention:

• A special grease is used to lubricate the drive shaft joints. Do not mix old and new grease or different types of grease.
• If the triple joint has been cleaned of grease, take extra care to apply only the specified grease.

V) After filling the inner joint race with special grease, install the drive shaft into it and apply the grease from the repair kit again.

Amount of lubricant:

Sedan models:

• 2WD - 125±10g

4WD:

• with engines 4G15 - 95±10g
• with 4G93 engines - 105± 10g

Station wagon models:

from 11.2000:

• 2WD - 125±10g
• 4WD - 105+ 10g

from 05.2001, with 4G93 engines:

• left shaft - 115 + 10 g
• right shaft - 120 +10 g

since 05.2002 (Sport Edition):

2WD:

• left shaft - 115 +10 g
• right shaft - 120 +10 g

4WD:

• left shaft - 115 + 10 g
• right shaft - 130±10 g

Note: the grease from the repair kit should be divided equally to lubricate the hinge and lay it inside the boot.

Attention: a special grease is used to lubricate the drive shaft joints. Do not mix old and new grease or different types of grease.

4. Install the small and large collars of the inner hinge boot.


Install the inner hinge boot clamps at an appropriate distance apart (to provide the necessary amount of air inside the case) and then tighten the clamps securely.

Rated value (A):

Sedan models:

• 2WD - 85 + 3 mm

4WD:

• with 4G15 motors - 85±3 mm
• with 4G93 engines - 90 +3 mm

Station wagon models:

until 05.2001:

• 2WD - 85+Gmm
• 4WD - 90 + 3 mm

since 05.2001

• with 4G93 engine - 90 +3 mm

Replacement of collars of a cover of the internal hinge

1. Remove the small and large clamps.

Note: when installing, replace the removed clamp with a new one.

2. Remove the inner hinge cover.

3. Install the cover.

A) Fit the boot into the groove on the shaft as shown.







b) Apply special grease from the repair kit to the inside of the boot.

Nominal quantity of grease:

Sedan models:

• 2WD models - 110 + 10 g

4WD Models:

• Model 1500 - 85 +10 g
• Model 1800 - 95 +10 g

Station wagon models:

• 2WD models - 110 +10 g
• 4WD models - 95 +10 g

4. Turn the adjusting bolt to adjust the special tool to the size "A".

Distance "A":

Sedan models:

• Small collar - 2.9 mm
• Large collar - 3.2 mm

Station wagon models:

Small collar:

• 2WD Models - 1.6mm
• 4WD Models - 2.9mm

Large collar:

• 2WD Models - 1.6mm
• 4WD Models - 3.2mm

Note:

• - One turn of the adjusting bolt is approximately 0.7 mm.
• - Do not turn the adjusting screw more than 1 turn.

5. Install the clamp as shown.







6. Using the special tool, fix the clamp as shown in the figure.

Note:

• - Mount the drive shaft vertically.
• - Compress the covers with a special tool until the stopper hits.

7. Measure the distance "IN", as it shown on the picture.

Rated distance:

• 2WD models - 1.0 - 1.5 mm
• 4WD Models - 2.4-2.8mm