DISASSEMBLY AND REASSEMBLY



Disassembly steps

>>G<<
 1.
 TJ boot band (large)

>>G<<
 2.
 TJ boot band (small)

>>F<<
 3.
 TJ case and inner shaft assembly <M/T-RH, A/T-RH for GCC, General Export (optional)>
<<A>>
 >>F<<
 4.
 Seal plate
<<B>>
5.
 TJ case
<<C>>
 >>E<<
 6.
 Inner shaft <M/T-RH, A/T-RH for GCC, General Export (optional)>


7.
 Dust cover <M/T-RH, A/T-RH for GCC, General Export (optional)>


8.
 Bracket assembly <M/T-RH, A/T-RH for GCC, General Export (optional)>

>>D<<
 9.
 Dust seal outer <M/T-RH, A/T-RH for GCC, General Export (optional)>

>>D<<
 10.
 Dust seal inner <M/T-RH, A/T-RH for GCC, General Export (optional)>
<<D>>
 >>C<<
 11.
 Centre bearing <M/T-RH, A/T-RH for GCC, General Export (optional)>


12.
 Centre bearing bracket <M/T-RH, A/T-RH for GCC, General Export (optional)>


13.
 Circlip


14.
 Snap ring
<<B>>
 >>B<<
 15.
 Spider assembly
<<E>>
 >>A<<
 16.
 TJ boot


17.
 BJ assembly
note
  • TJ: Tripod Joint
  • BJ: Birfield Joint

LUBRICATION POINTS




DISASSEMBLY SERVICE POINTS

<<A>> SEAL PLATE REMOVAL

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

<<B>> TJ CASE/SPIDER ASSEMBLY REMOVAL
caution Do not disassemble the spider assembly.
1.Wipe off grease from the spider assembly and the inside of the TJ case.
2.Always clean the spider assembly when the grease contains water or foreign material.

<<C>> INNER SHAFT <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> REMOVAL

1.Use special tool inner shaft remover (MB991248 or MD998801) to remove the inner shaft assembly from the TJ case.

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

<<D>> CENTRE BEARING <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> REMOVAL

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

  • Bar (MB990938)
  • Installer adapter (MB990930)

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

REASSEMBLY SERVICE POINTS

>>A<< TJ BOOT INSTALLATION
Wrap plastic tape around the shaft spline, and then install the TJ boot band (small) and TJ boot.

>>B<< SPIDER ASSEMBLY INSTALLATION
1.
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.
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.

>>C<< CENTRE BEARING <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> INSTALLATION

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 <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> /DUST SEAL OUTER <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> INSTALLATION
1.
caution When applying grease, make sure that it does not adhere to anything outside the lip.
Apply the specified grease to the rear surface of all dust seals.
Specified grease: Repair kit grease

    Amount used (Dust seal inner): 14 - 20 g
    Amount used (Dust seal outer): 8 - 12 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 bushing base (MB990890)
  • Bar (MB990938)
  • Installer adapter (MB990934)
3.Apply repair kit grease to the lip of each dust seal.

>>E<< INNER SHAFT <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> INSTALLATION

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

>>F<< SEAL PLATE/TJ CASE AND INNER SHAFT ASSEMBLY <M/T-RH, A/T-RH FOR GCC, GENERAL EXPORT (OPTIONAL)> INSTALLATION

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

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

After applying the specified grease to the TJ case, insert the driveshaft and apply grease one more time.
Specified grease: Repair kit grease

    Amount to use : 145 ± 5 g
note The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

>>G<< TJ BOOT BAND (SMALL)/TJ BOOT BAND (LARGE) INSTALLATION

1.Set the TJ boot bands at the specified distance in order to adjust the amount of air inside the TJ boot, and then tighten the TJ boot band (small) securely.
Standard value (A): 80.9 ± 3 mm



2.Use the pincers for low profile clamps <recommendable tool: OETIKER> to install the TJ boot band (large) by following the next steps.
(1) Use the pincers for low profile clamps to catch the protrusion part of the TJ boot band (large) and tighten it firmly.
(2) After having tightened securely the protrusion part of the TJ boot band (large), hook the end of the TJ boot band (large) as shown in the illustration.