SECTION 4C - DRIVE SHAFT SYSTEM (MY2002)

Service Precaution

General Description

Diagnosis

Front Hub and Disc

Disassembled View

Disassembly

Inspection

Reassembly

Front Drive Shaft Joint

Front Drive Shaft Joints Replacement

Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts

Disassembly

Inspection And Repair

Bushing Replacement

Reassembly

Shift On The Fly System

and Associated Parts

Disassembly

Inspection And Repair

Reassembly

Main Data and Specifications

Special Tools

Propeller Shaft

General Description

Universal Joint

Diagnosis of Propeller Shaft

and Universal Joint

Front Propeller Shaft

Front Propeller Shaft and Associated Parts

Removal

Installation

Slip Joint Disassembly

Universal Joint Disassembly

Inspection and Repair

Universal Joint Reassembly

Slip Joint Reassembly

Main Data and Specifications

Rear Propeller Shaft

Rear Propeller Shaft and Associated Parts

Removal

Installation

Slip Joint Disassembly

Universal Joint Disassembly

Inspection

Universal Joint Reassembly

Slip Joint Reassembly

Main Data and Specifications

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM(SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE REFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING, REFER TO

THE SRS SERVICE INFOMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN POSSIBLE

AIR BAG DEPLOYMENT, PERSONAL INJURY, OR

OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED ,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally,such coatings

adversely affect the fastener torque and the joint

clamping force, and may damage the fastener.

When you install fasteners, use the correct

tightening sequence and specification. Following

these instructions can help you avoid damage to

parts and systems.

General Description

This publication contains essential removal, installation,

adjustment and maintenance procedures.

The front axle utilizes a central disconnect type front

axle/transfer case system.

The drive axles are completely flexible assemblies,

consisting of inner and outer constant velocity (CV)

drive shaft joints connected by an axle shaft.

For description of front propeller shaft and universal

joint, refer to Front Propeller Shaft in this section.

Diagnosis

Condition Possible cause Correction

Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.

Front axle housing cracked. Repair or replace.

Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.

Oil seal worn or defective. Replace the oil seal.

Pinion flange loose or damaged. Tighten or replace.

Noises In Front Axle Drive Shaft

Joint

Broken or worn drive shaft joints and

bellows (BJ and DOJ).

Replace the drive shaft joints and

bellows.

“Clank" When Accelerating From

“Coast"

Loose drive shaft joint to output

shaft bolts.

Tighten.

Damaged inner drive shaft joint. Replace.

Shudder or Vibration During

Acceleration

Excessive drive shaft joint angle. Repair.

Worn or damaged drive shaft joints. Replace.

Sticking spider assembly (inner

drive shaft joint).

Lubricate or replace.

Sticking joint assembly (outer drive

shaft joint).

Lubricate or replace.

Vibration At Highway Speeds Out of balance or out of round tires. Balance or replace.

Front end out of alignment. Align.

Noises in Front Axle Insufficient gear oil. Replenish the gear oil.

Wrong or poor grade gear oil. Replace the gear oil.

Drive pinion to ring gear backlash

incorrect.

Adjust the backlash.

Worn or chipped ring gear, pinion

gear or side gear.

Replace the ring gear, pinion gear or

side gear.

Pinion shaft bearing worn. Replace the pinion shaft bearing.

Hub unit bearing worn. Replace the hub unit bearing.

Differential bearing loose or worn. Tighten or replace.

Wanders and Pulls Incorrect front alignment. Adjust the front alignment.

Steering unit loose or worn. Tighten or replace.

Tire worn or improperly inflated. Adjust the inflation or replace.

Front or rear suspension parts loose

or broken.

Tighten or replace.

Front Wheel Shimmy Hub unit bearing worn. Replace.

Incorrect front alignment. Adjust the front alignment.

Worn ball joint or bush. Replace the ball joint or bush.

Steering unit loose or worn. Tighten or replace.

Tire worn or improperly inflated. Replace or adjust the inflation.

Shock absorber worn. Replace the shock absorber.

Front Hub and Disc

Disassembled View

411R200010

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Disassembly

1.Move the transfer case lever to the 2WD position.

2.Raise the vehicle with a jack. Support the frame with

chassis stands.

3.Remove the brake caliper from the bracket. Secure

the caliper with a wire that it does not interfare with

the work process.

Refer to Front disc caliper assembly in Section 5C of

this Manual.

4. Remove the disk rotor.

Apply penetrating oil to the bearing and disc rotor

contact surfaces if the surfaces are stuck together

because of rust.

5. Inspect the hub unit bearing. Refer to inspection

below.

(1) Disc Rotor

(2) Hub Unit, Bearing

(3) Wheel Pin

(4) ABS Sensor Ring

(5) Bolt

Techline

6. Use a dial gauge to measure the bearing axial rattle.

Bearing axial rattle: 0.05mm (0.002in)max

411R200002

If abnormal conditins are discovered during

inspection, go to Step 7. If there are no abnormal

conditions, reassemble the front discrotor and

caliper.

NOTE: Hub, wheel bearing and spindle is integrated to

the hub unit bearing so it must not be disassembled. If

it has abnormal rattle or noize, replace the hub unit

bearing.

7. Loosen the caulking around the front drive shaft

nuts.

8. Remove the nuts and discard them (they cannot be

reused).

9. Remove the 4 bolts fixing the hub unit bearing to the

knuckle.

Apply penetrating oil to the bearing and knuckle contact

surfaces if the surfaces are stuck together because of

rust.

10. Temporarily install long bolts to 2 of the fixing bolt

holes (the bolts must have the same diameter and

thread width).

411R200012

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11. Strike the long bolts with a hammer to loosen and

remove the hub unit bearing from the knuckle.

• Take care not to strike the front drive shaft.

• Take care not to drop the bearing.

12. Remove the ABS rotor sensor from the bearing.

13. If necessary, replace the wheel pin in the following

manner.

• Place hub on a suitable work surface and remove

wheel studs, as required, using a hammer.

411RS004

(1) Bolt

Inspection

Inspect the parts listed below for abrasion, breakage,

and other abnormal conditions.

Repair or replace the parts as required.

•Disc

•Caliper

•Drive shaft oil seal

•ABS sensor rotor

•Wheel pin

•Hub unit bearing

Reassembly

1.Install the wheel pin.

•Place hub on a wood workbench or a block of

wood approx. 6" by 6" to protect the wheel stud

ends and thresds.

•Install wheel stud, using a hammer.

NOTE: Be sure wheel stud is started squarely and

seats completely.

411RS005

2.Install the ABS rotor sensor to the hub unit bearing.

Tighten the bolts to the specified torque.

ABS rotor sensor bolt

Torque: 19 N·m (1.9 kg·m/14 lb ft)

3.Install the hub unit bearing to the knuckle. Tighten

the bolts to the specified torque.

Hub unit bearing bolt

Torque: 103 N·m (10.5 kg·m/76 lb ft)

If there is rust on the bearing and knuckle contact

surfaces, use sandpaper to remove it before installation.

Take care not to push the front drive shaft and oil seal

out of position.

4.Hand tighten the front drive shaft nuts.

Use new nuts.

5.Install the disc rotor.

6.Install the brake caliper to the bracket.

Refer to Front disc caliper assembly in Section 5C of

this Manual.

7. Tighten the front drive shaft nuts to the specified

torque.

Front drive shaft nut

Torque: 245 N·m (25 kg·m/181 lb ft)

411R200005

8. Caulk the front drive shaft nuts.

The caulking must be free of cracks.

411R200006

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EndOFCalloutFront Drive Shaft Joint

(1) Max 2mm (0.08 in)

Front Drive Shaft Joint

Front Drive Shaft Joints Replacement

• Refer to Front Drive Axle Shaft in

this section, and refer to Front Hub and Disc

in Suspension section.

Front Hub Bearing Preload Check

Check the hub bearing preload at the wheel pin.

New bearing and New oil seal:

24.5N (4.4 – 5.5 lb)

Used bearing and New oil seal:

11.8– 17.7 N(2.6 – 4.0lb)

Inspection Of Shift On The Fly System Gear

Oil

412RY00008

1. Open filler plug and make sure that the oil is up to

the plug port.

If the oil is short, replenish with gear oil GL–5 grade.

2. Tighten the filler plug to specified torque.

Torque:78N·m (8.0 kg·m/58lbin)

Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts

412R200009

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(1) Axle Case and Differential

(2) Snap Ring

(3) Bearing

(4) Snap Ring

(5) Oil Seal

(6) Bracket

(7) DOJ Case

(8) Circlip

(9) Bolt

(10) Drive Shaft Joint Assembly

(11) Ball

(12) Snap Ring

(13) Ball Retainer

(14) Ball Guide

(15) Band

(16) Bellows

(17) Band

(18) Band

(19) Bellows

(20) Band

(21) BJ Shaft

(22) Dust Seal

Disassembly

NOTE: For the left side, follow the same steps as right

side.

1. Raise the hooked end of the band with a

screwdriver or equivalent.

412RS009

2. Remove band(1).

3. Pry off circlip (1) with a screwdriver or equivalent.

412RS010

4. Remove drive shaft joint assembly.

5. Remove the six balls (1) with a screwdriver or

equivalent.

412RS012

6. Using snap ring pliers, remove the snap ring (1)

fastening the ball retainer to the center shaft.

412RS013

7. Remove ball retainer, ball guide and bellows.

8.Use a hammer and chisel to remove the 3 pawls

(above the large and small boot bands on the BJ

side).

CAUTION: Take care not to damage the bellows

during band removal.

412R100009

9. Remove band(1).

10. Remove bellows.

11. Remove dust seal from BJ.

12. Remove BJ shaft assembly.

13. Remove the mounting bracket fixing bolts, and then

remove DOJ case assembly from the axle case.

14. Remove snap ring and bearing.

15. Remove snap ring and oil seal.

16. Remove bracket.

Inspection And Repair

Make necessary correction or parts replacement if wear,

damage, corrosion or any other abnormal condition are

found through inspection.

Check the following parts.

1. Drive shaft joint assembly

2. DOJ case, ball, ball guide, ball retainer

3. Bellows

4. Bearing

5. Dust seal, oil seal

Bushing Replacement

• Remove the bushings using a remover 5–8840–

2309–0 and hammer.

412RW051

• By using installer 5–8840–2309–0, press fit the

bushings into the bracket.

412RW052

Reassembly

1. Install DOJ case to bracket.

2. Install oil seal and fix snap ring.

3. Install bearing and fix snap ring.

4. Install bracket to axle case. Tighten the bracket bolt

to the specified torque.

Torque:116N·m (11.8kg·m/85lbft)

5. Apply 150g of the specified grease in BJ.

6. Install dust seal for BJ.

7.Apply a thin coat of grease to the shaft for smooth

installation then install bellows.

CAUTION: During bellows assembly, be sure to

insert both ends of the bellows into the BJ ASM and

shaft grooves.

412R100007

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412R100013

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8. Install band. Note the setting direction. After

installation, check Standard Caulk Measure. Use

the special tool pliers 5–8840–2745–0 to caulk the

bands to the specified value.

412R100012

Standard Caulk Measure

• 1.2mm (0.05in) <= (1) and (2) <= 4.0mm (0.16in)

• (1) – (2) or (2) – (1) <= 0.4mm (0.016in)

9. Install another bellows and fix band.

10. Install band. Note the setting direction. After

installation, check that the bellows is free from

distortion. (DOJ SIDE ONLY)

412RS017

11. Install another bellows and fix band.

12. Install the ball guide with the smaller diameter side

ahead onto the shaft.

13. Install ball retainer.

(1) Bellows

(2) Shaft

(1) BJ ASM

(2) Bellows

14. Using snap ring pliers, install the snap ring (1)

securing the ball retainer to the shaft.

412RS013

15. Align the track on the ball (1) retainer with the

window in the cage, and install the six balls into

position.

412RS018

16. Pack 150g of the specified grease in DOJ case,

then install drive shaft joint assembly. After

reassembly, move the DOJ longitudinally several

times to get to fit.

17. Install the circlip (1) so that open ends are

positioned away from the ball groove.

412RS019

412RS020

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(1) Outer Case

(2) Circlip

(3) Open Ends

18. Install bellows. Adjust the air pressure within the

bellows by inserting a screwdriver or equivalent, so

that it equals atmospheric pressure.

412RS021

19. Install band. After installation, check that the bellows

is free from distortion.

Shift On The Fly System

Shift On The Fly System and Associated Parts

412RY00007

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Disassembly

1. Remove filler plug and gasket, drain oil.

2. Loosen mounting bracket fitting bolts and remove

front axle drive shaft from front axle case.

3. Remove actuator assembly and draw out actuator

ASM.

4. Remove housing.

5. Remove sleeve.

6. Remove clutch gear.

(1) Filler Plug

(2) Bolt

(3) Oil Seal

(4) Snap Ring(External)

(5) Inner Shaft Bearing

(6) Snap Ring(Internal)

(7) Inner Shaft

(8) Needle Bearing

(9) Clutch Gear

(10) Sleeve

(11) Housing

(12) Front Axle Drive Shaft(LH side) with Bracket

(13) Bolt

(14) Actuator Assembly

(15) Bolt

7. Remove snap ring from front axle case by using

snap ring pliers.

412RW017

8. Take out inner shaft from front axle case.

9. Remove snap ring from inner shaft by using snap

ring pliers.

412RW016

10. Remove inner shaft bearing.

NOTE: Be careful not to damage the shaft.

412RW015

11. Remove needle bearing from inner shaft by using a

remover 5–8840–0027–0 and sliding hammer 5–

8840–0084–0.

412RS045

12. Remove oil seal from front axle case.

NOTE: Be careful not to damage the front axle case.

Inspection And Repair

Inspect the removed parts. If there are abnormalities

such as wear and damage, take corrective action or

replace.

Visual Check

1. Check and see if the inner shaft has such

abnormalities as wear and damage.

412RW014

2. When inspecting the inner shaft, be sure to check

and see if its splined part is twisted, worn, or

cracked. If so, replace with a new shaft. In case

such an abnormality in its gear part (a slide with

sleeve), replace the shaft.

420RS008

Inner Shaft Run–Out

With both end centers supported, rotate the shaft slowly

and measure deflection with a dial gauge.

Limit:0.5mm (0.02in)

NOTE: Do not heat the shaft to correct its bend.

412RS026

Inner Shaft Bearing

412RW006

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1. Inspect the state of inner shaft bearing. If any

abnormality such as smoothlessness is found,

replace with a new inner shaft bearing.

2. Insert a clutch gear and check the state of needle

bearing.

3. If there is an abnormality such as smoothlessness,

replace the needle bearing.

(1) Inner Shaft Bearing

(2) Inner Shaft

(3) Clutch Gear

Sleeve Condition

Check and see that there is not wear damage, or

cracking in the sleeve.

NOTE: Close inspection of the groove and inner gear

are required because those are important parts.

Sleeve Function

412RY00039

Operate the sleeve with the inner shaft combined with

the clutch gear and if smoothlessness is felt, replace the

sleeve.

NOTE: Gear oil should be applied to the contact

surface of gear.

Check the width of sleeve center groove.

Limit:7.1mm (0.28in)

412RW022

Clutch Gear Condition

Check and see that there is not wear, damage, crack, or

any other abnormality in the clutch gear.

Clutch Gear Function

412RY00038

If there is an abnormality such as roughness when

operated in combination with sleeve, replace the clutch

gear.

NOTE: When inspecting, gear oil should be applied to

the contact surface of gear.

Clutch Gear Journal Diameter

Make sure of the size illustrated.

Limit:36.98mm (1.456in)

412RY00037

Actuator

Check and see that there is no damage, cracking, or

other abnormality.

Functional Check

412RY00041

412RY00009

Wake sure of function with boltage (12V) applied to

terminal 3, 4 and set the tester to terminal 1, 2 in

accordance with the table below.

If there is an abnormality, replace the actuator as an

assembly.

NOTE: Be careful not to permit the entry of water or

dust into of the actuator.

Dimentional Check

Measure illustrated sizes 1, 2, and 3.

Limit

1=64.1mm (2.52in)

2=6.7mm (0.26in)

3=6.7mm (0.26in)

412RY00010

Reassembly

1. Install the new oil seal which has been immersed in

differential gear oil, by using an oil seal installer 5–

8840–2407–0 and grip 5–8840–0007–0.

412RW034

State Trminal 3 Trminal 4

Electric

circuit

between

terminal 1

& 2

Function

A +12V Ground OK 2WD

B Ground +12V NONE 4WD

2. Check the oil seal installation position (from shaft

end to oil seal).

Depth:24.2–25.2mm(0.95– 0.99in)

412RS052

3. Force a new needle bearing into inner shaft by

using a Installer 5–8840–2408–0 and grip 5–8840–

0007–0.

412RS051

4. Place a new snap ring(internal) in inner shaft.

Force a new inner shaft bearing into the inner shaft.

412RS044

5. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.

6. Clean the housing contact surface of the front axle

case and insert inner shaft assembly into the front

axle case.

NOTE: Be careful not to damage seal.

7. Install snap ring internal in the groove of front axle

case.

NOTE: Be sure to install the snap ring properly.

412RW017

8. Apply differential gear oil to clutch gear, then install

clutch gear.

9. Apply differential gear oil to sleeve, then install

sleeve.

10. Clean contact surface with the front axle and

actuator mounting surface. Apply liquid gasket to

the contact surface on the front axle case, then

install in the housing.

412RW023

11. Tighten bolts to specified torque.

Torque:75N·m(7.6kg·m/55lbft)

12. Clean the actuator contact surface with the housing

then Install and tighten shift position switch to

specified torque.

Torque:39N·m (4.0kg·m/29lbft)

13. Apply liquid gasket to the contact surface on the

actuator side.

412RW012

14. Align shift arm with the groove of sleeve and install

the actuator.

15. Tighten bolts to specified torque.

Torque:9N·m(0.9kg·m/78lbin)

16. Install front axle drive shaft and mounting bracket.

Tighten fitting bolts to specified torque.

Torque:116N·m (11.8kg·m/85lbft)

17. Pour specified amount of differential gear oil to filler

plug.

Front Differential

Oil Capacity:1.4lit (1.48USqt)

Actuator Housing

Oil Capacity:0.12lit(0.13US qt)

18. Install filler plug through gasket and tighten to

specified torque.

Torque:78N·m (8.0kg·m/58lbft)

Main Data and Specifications

General Specifications

Torque Specifications

412R100003

Front drive axle oil capacity 1.25 liter (1.32 US qt)(Differential)

0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)

Type of lubricant GL–5 (75W–90) Refer to chart in General Information

Axle shaft type Constant velocity joint(Birfield joint type and double offset joint)

E04R200006

Special Tools

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2309–0

(J–39378)

Remover and Installer;

Front Axle mount bushing

5–8840–0027–0

(J– 26941)

Remover; Bearing needle

5–8840–0084–0

(J–2619–01)

Hammer; Sliding

5–8840–2407–0

(J–41693)

Installer; Oil seal

5–8840–2408–0

(J–41694)

Installer; Bearing needle

5–8840–0007–0

(J–8092)

Grip

5–8840–2745–0

(J–35910)

Pliers; Band bellows,

drive shaft

ILLUSTRATION TOOL NO.

TOOL NAME

Propeller Shaft

General Description

401R100003

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(1) Front Propeller Shaft (for Normal Transfer)

(2) Front Propeller Shaft (for TOD)

(3) Rear Propeller Shaft;

Aluminum Tube Type

(for M/T model)

(4) Rear Propeller Shaft;

Steel Tube Type

(for A/T model)

Torque is transmitted from the transmission to the axle

through propeller shaft and universal joint assembles.

All propeller shafts are the balanced tubular type. A

splined slip joint is provided in some drivelines.

• Since the propeller shaft is total balanced carefully,

welding or any other modification are not permitted.

• Alignment marks should be applied to each propeller

shaft before removal.

• Be sure vehicle is stopped, engine is not running,

brake is secured and vehicle is secured to prevent

injury.

• Be careful not to grip the propeller shaft tube too

tightly in the bise as this will be cause deformation.

Phasing

The propeller shaft is designed and built with the yoke

lugs (ears) in line with each other. This design produces

the smoothest running shaft possible, called phasing.

Vibration can be caused by an out-of-phase propeller

shaft. The propeller shaft will absorb vibrations from

speeding up and slowing down each time the universal

joint goes around. This vibration would be the same as

a person snapping rope and watching the "wave"

reaction flow to the end. A propeller shaft working in

phase would be similar to two persons snapping a rope

at the same time, and watching the "waves" meet and

cancel each other out. In comparison, this would be the

same as the universal joints on a propeller shaft. A total

cancellation of vibration produces a smooth flow of

power in the driveline. It is very important to apply a

reference mark to the propeller shaft before removal, to

assure installation alignment.

Universal Joint

401RW015

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A universal joint consists of two Y-shaped yokes

connected by a crossmember called a spider.

The spider is shaped like a cross. Universal joints are

designed to handle the effects of various loadings and

front or rear axle windup during acceleration. Within the

designed angle variations, the universal joint will

operate efficiently and safely. When the design angle is

changed or exceeded the operationallife of the joint may

decrease.

The bearings used in universal joints are of the needle

roller type. The needle rollers are held in place on the

trunnions by round bearing cups. The bearing cups are

held in the yokes by snap rings.

(1) Spider

(2) Yoke

Diagnosis of Propeller Shaft and Universal Joint

Condition Possible cause Correction

Universal Joint Noise. Worn universal joint bearings. Replace.

Improper lubrication. Lubricate as directed.

Loose flange bolts. Tighten to specifications.

Ping, Snap, or Click in Drive Line

(Usually Heard on Initial Load after

the Transmission is in Forward or

Reverse Gear)

Loose bushing bolts on the rear

springs or upper and lower control

arms.

Tighten the bolts to specified torque.

Loose or out-of-phase end yoke. Remove end yoke, turn 180 degrees

from its original position, lubricate

the splines and reinstall. Tighten the

bolts and pinion nut to specified

torque.

Knocking or Clanking Noise in the

Driveline when in High or Neutral

Gear at 16km/h(10mph)

Worn or damaged universal joint Replace the universal joint.

Squeak Lack of lubricant. Lubricate joints and splines. Also

check for worn or brinelled parts.

Shudder on Acceleration (Low

Speed)

Loose or missing bolts at the

flanges.

Replace or tighten bolts to specified

torque.

Incorrectly set front joint angle. Install shim under the transmission

support mount to change the front

joint angle.

Worn universal joint. Replace.

Vibration Incorrect shaft runout. Replace.

Shaft out of balance. Adjust.

Transmission rear housing bushing,

transfer case housing bushing worn.

Replace.

Yoke spline jammed. Replace.

Excessive Leak at the Front Spline

Yoke of Rear Propeller Shaft

Rough surface on splined yoke;

burred nicked or worn.

Replace the seal. Minor burrs can

be Smoothed by careful use of

crocus cloth or fine stone honing.

Replace the yoke if badly burred.

Defective transmission rear oil seal. Replace the transmission rear oil

seal and replenish the transmission

oil.

Front Propeller Shaft

Front Propeller Shaft and Associated Parts

401R100004

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Removal

1. Raise the vehicle on a hoist.

NOTE: Apply alignment marks on the flange at the front

propeller shaft both front and rear side.

401RS020

(1) Bolt, Nut and Washer (Front Axle Side)

(2) Front Propeller Shaft

(3) Bolt, Nut and Washer (Transfer Side)

(4) Bolt and Washer (Front Axle Side)

(5) Front Propeller Shaft (With TOD)

(6) Bolt and Washer (Transfer Side)

401RW053

401RW052

2. Remove bolt, nut and washer (Front axle side).

3. Remove bolt, nut and washer (Transfer side).

4. Remove front propeller shaft.

NOTE: If equipped with torque on demand (TOD),

when removing, installing or carring for front propeller

shaft, be sure to wind a piece of cloth round the part of

the boot with which fittings may interfere so that the

boot can be protected. The boot may be damaged if

bending force is applied to the constant velocity joint of

the shaft.

401RW051

Installation

NOTE: Never install the shaft assembly backwards.

Completely remove the black paint from the connecting

surface of flange coupling on each end of propeller

shaft. Clean so that no foreign matter will be caught in

between.

1. Align the mark which was applied at removal. Install

front propeller shaft and tighten the bolts to the

specified torque.

Torque:63N·m (46lbft)

2. After installing the propeller shaft, be sure to apply

black paint (1) to exposed area (other than

connecting surface) of the entire surface of flange

coupling .

401RS019

Slip Joint Disassembly

401RW032

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1. Lay the shaft horizontally on a bench and secure. 2. Indicate the original assembled position (1) by

marking the phasing of the shaft prior to

disassembly.

(1) Spline Yoke Assembly

(2) Clamp

(3) Boot

(4) Clamp

(5) Tube Assembly

401RW037

3. Using the flat blade of a screwdriver, pry the loose

end of the boot clamp upwards and away from the

propeller shaft boot. Be careful not to damage the

boot.

4. When boot clamps becomes loose, remove by

hand.

5. Repeat for the other boot clamp.

6. Remove the spline yoke assembly from the tube

assembly, by securing the boot with one hand and

pulling on the spline yoke.

7. Remove the boot from the tube assembly.

Universal Joint Disassembly

401RW031

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(1) Flange Yoke

(2) Snap Ring

(3) Spider

(4) Needle Roller Bearing

1. Using a soft drift, tap the outside of the bearing cup

assembly to loosen snap ring. Tap bearing only

hard enough to break assembly away from snap

ring.

Remove snap ring from yoke. Turn joint over, tap

bearing away from snap ring, then remove opposite

snap ring.

Apply alignment marks (1) on the yokes of the

universal joint, then remove snap ring.

401RW018

2. Set the yoke in the arbor press with a piece of tube

stock beneath it.

Place a solid plug on the upper bearing assembly

and press it through to release the lower bearing

assembly.

401RW020

3. If the bearing assembly will not pull out by hand

after pressing, tap the base of the lug near the

bearing assembly to dislodge it.

4. To remove the opposite bearing, turn the yoke over

and straighten the spider in the open hole. Then

carefully press on the end of the spider so the

remaining bearing moves straight out of the bearing

spider hole. If the spider or bearing are cocked, the

bearing will score the walls of the spider hole and

ruin the yoke.

5. Repeat this procedure on the remaining bearing to

remove the spider from the yoke.

6. Make sure of proper position for reinstallation by

applying setting marks, then remove spider .

Inspection and Repair

Make necessary correction or parts replacement if wear,

damage, corrosion or any other abnormal condition is

found through inspection.

NOTE: When any part of the journal assembly (spider,

needle roller bearing) requires replacement, be sure to

replace the entire assembly.

Check the following parts for wear, damage, noise or

any other abnormal conditions.

1. Spider

2. Needle roller bearing

3. Yoke

4. Flange

5. Boot

Spider pin for wear

Spider pin should be smooth and free from fretting or

galling. Visible signs of needle presence is normal, but

wear should not be felt.

401RW038

Propeller shaft runout

Support the propeller shaft on V-blocks (2) and check

for runout by holding the probe of a dial indicator (1) in

contact with the shaft.

Static runout limit:

0.13mm (0.005in)

TIR on the neck of the slip tube shaft (with a

boot).

0.25mm (0.010in)

TIR on the ends of the tubing 3 inch from the

welds.

0.38mm (0.015in)

TIR at the linear center of the tube.

0.38mm (0.015in)

TIR for the full length of tube with 30" or less of

tubing.

(TIR : Total Indicator Reading)

401RS027

Spline

The nylon-coated spline should be free from nicks and

dings and the underlying steel spline should not be

visible.

After cleaning the nylon coating spline, the coating

should exhibit only a slight indication of wear.

Grease volume is approximately 10 grams of grease in

total. Grease should be evenly applied to both the

female and the male slip splines using a small brush.

After assembly of the slip joint, the sliding joint should

be fully worked from the full collapsed to the full

extended position.

Play in the universal joint

Limit:Less than0.15mm (0.006in)

401RW023

Preload of the universal joint

Preload should be 0 to 24.9 kg(0 to11.3 lb). Joints

should rotate smoothly and freely and should exhibit no

rough or ratchety movement.

401RW085

Boot

Check the boot for crack or damage. If necessary,

replace the boot.

If abnormal condition are found on the boot, inspect the

grease for mixing of foreign material.

If the grease is good condition, and slip joint works well,

replace the boot, replenish grease, and reassemble the

slip joint.

If the foreign material is found in the grease, check the

spline for wear and damage.

Universal Joint Reassembly

1. Install spider to flange yoke. Be sure to install the

spider by aligning the setting marks made during

disassembly.

2. Pack the four grease cavities of the spider with a

high quality, extreme pressure N.L.G.I. Grade 2

grease. Do not add additional grease to the bearing

cup assembly.

3. Move one end of the spider to cause a trunnion to

project through the spider hole beyond the outer

machined face of the yoke lug. Place a bearing

over the trunnion diameter and align it to the spider

hole. Using an arbor press, hold the trunnion in

alignment with the spider hole and place a solid plug

on the upper bearing. Press the bearing into the

spider hole enough to install a snap ring.

401RW020

4. Install a snap ring.

Be sure the snap rings are properly seated in the

grooves.

5. Repeat steps 3 and 4 to install the opposite bearing.

If the joint is stiff, strike the yoke ears with a soft

hammer to seat needle bearings.

6. Align setting marks (1) and join the yokes.

401RW018

7. Install snap ring.

Slip Joint Reassembly

401RW032

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EndOFCallout

1.Apply grease evenly to both the female and male

splines.

2.Apply a small amount of grease by finger to the

outer lips of the boot.

3.Slide the boot (smaller diameter side) onto the

spline yoke shaft being careful not to damage the

spline coating or boot.

4.Insert the spline yoke shaft into the tube assembly

being careful to maintain proper phasing. The

spider holes should be in line and as per originally

marked prior to disassembly.

5.Position boot onto tube and yoke shaft in final

position over boot grooves.

6.Attach boot clamps and secure using pliers.

7.Be sure clamp is properly seated and secure.

CAUTION: Use new clamp which is the same parts

as original. Do not use other clamp to avoid bad

balancing of shaft or the grease leakage.

(1) Spline Yoke shaft

(2) Clamp

(3) Boot

(4) Clamp

(5) Tube Assembly

With TOD (Torque On Demand 4´4)

401R100006

Legend

EndOFCallout

Constant Velocity Joint

LJ and BJ constant velocity joints are unremovable

types. Check the joint for play and the boot for damage,

wear, and leak of grease. If abnormality is found,

replace propeller shaft as an assembly.

Play in Constant Velocity Joint

Fix the shaft in a vise throrgh pieces of wood, and try to

move the joint vertically, right and left, and back and

forth to make sure of smooth motions and no

remarkable play.

401RW050

401R100007

Boot of Constant Velocity Joint

Check the boot (2) for crack, damage and grease leak,

and the boot band (1) for loosening and damage. Check

the both sides of the joint and make sure that there is no

leak of grease from the cover press-in parts(3).

401RW048

(1) LJ Constant Velocity Joint

(2) BJ Constant Velocity Joint

401R100008

Front Axle Flange Run-out

1. Set a dial gage at right angle near the outer

circumference of the flange face and check the

run-out of the flange face.

Limit:0.15mm (0.006in)

401RW046

2. Set a dial gage at right angle near the inner

circumference and check the run-out of the flange.

Limit:0.15mm (0.006in)

401RW045

3. If vibration is felt during the 4H AUTO drive,

disconnct the propeller shaft at the front axle.

Reinstall the propeller shaft at 60°, 120°, 180°, 240°,

and 300° and conduct test drive in each position

and check if there is vibration.

401R100009

Main Data and Specifications

General Specifications

Torque Specifications

401R100005

Transmission M/T A/T (Normal Transfer) A/T (With TOD)

Length (between two frange) 467 mm (18.39 in) 632 mm (24.88 in) 626 mm (24.65 in)

Rear Propeller Shaft

Rear Propeller Shaft and Associated Parts

401RX028

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EndOFCallout

Removal

1. Raise the vehicle on a hoist.

NOTE: Apply alignment marks on the flange at the rear

propeller shaft both front and rear side.

2. Remove transfer side bolt, nut and washer.

3. Remove rear axle side bolt, nut and washer.

4. Remove rear propeller shaft.

Installation

NOTE: Never install the shaft assembly backwards.

Never insert bar between yoke lugs when tightening or

removing bolts.

Completely remove the dust or foreign matter from the

connecting surface of flange coupling on each end of

the propeller shaft.

1. Align the mark which is applied at removal.

2. Install rear propeller shaft and tighten the bolts to

the specified torque.

Torque:63N·m(6.4kg·m/46lbft)

(1) Bolt, Nut and Washer (Transfer Side)

(2) Rear Propeller Shaft

(3) Bolt, Nut and Washer (Rear Axle Side)

Slip Joint Disassembly

401RX004

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EndOFCallout

1. Lay the shaft horizontally on a bench and secure.

2. Indicate the original assembled position by marking

the phasing of the shaft prior to disassembly.

3. Using the flat blade of a screwdriver, pry the loose

end of the boot clamp upwards and away from the

propeller shaft boot. Be careful not to damage the

boot.

4. When boot clamps becomes loose, remove by

hand.

5. Repeat for the other boot clamp.

6. Remove the slip yoke assembly from the driveshaft,

by securing the boot with one hand and pulling on

the slip yoke.

7. Remove the boot from the shaft assembly.

(1) Spline Yoke and Universal Joint Assembly

(2) Clamp

(3) Boot

(4) Clamp

(5) Tube and Universal Joint Assembly

Universal Joint Disassembly

401RX022

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EndOFCallout

NOTE: Aluminum is softer than steel. Care must be

taken not to remove excessive material or damage

bearing holes.

If the vehicle has aluminum tube type propeller shaft,

flange yoke, boot kit, journal kit can be replaced. If other

parts are damaged, replace propeller shaft as assembly.

(1) Spider

(2) Flange Yoke

(3) Bearing

(4) Snap Ring

1. Apply alignment marks on the yokes of the universal

joint, then remove the snap ring.

401RW024

If the snap ring is stuck in position, remove paint

from the hole in the yoke or tap around the edge of

the bearing lightly with a soft drift.

401RW025

2. Set the yoke in the arbor press with a piece of tube

stock beneath it.

Place a solid plug on the upper bearing and press it

through to release the lower bearing.

401RW027

3. If the bearing will not pull out by hand after pressing,

tap the base of the lug near the bearing to dislodge

it.

4. To remove the opposite bearing, turn the yoke over

and straighten the spider in the open spider hole.

Then carefully press on the end of the spider so the

remaining bearing moves straight out of the bearing

spider hole. If the spider or bearing are cocked, the

bearing will score the walls of the spider hole and

ruin it.

401RW026

5. Repeat this procedure on the remaining bearing to

remove the spider from the yoke.

Inspection

• Propeller shaft for run-out Aluminum tube type.

Static run-out limit :1.0mm(0.04in)

TIR full length of tubing maximum.

(TIR : Total Indicator Reading)

• Propeller shaft for runout (Steel tube type).

Static runout limit :0.13mm(0.005in)

TIR on the neck of the slip tube shaft (with a

boot).

0.25mm(0.010in)

TIR on the ends of the tubing 3 inch from the

welds.

0.38mm(0.015in)

TIR at the linear center of the tube.

0.38mm(0.015in)

TIR for the full length of tube with 30" or less of

tubing.

(TIR: Total Indicator Reading)

401RW017

• Play in universal joint.

Limit: Less than0.15mm(0.006in)

• Spider pin should be smooth and free from fretting or

galling.

Visible signs of needle presence is normal, but wear

should not be felt.

401RW028

• Preload of the universal joint.

Preload should be 0 to 49 N (0 to 5.0 kg/0 to 11.0 lb).

Joints should rotate smoothly and freely and should

exhibit no rough or ratchety movement.

401RW019

• Inspect splines of slip joint for wear.

The nylon-coated spline should be free from nicks

and dings and the underlying steel spline should not

be visible.

After cleaning the nylon coating spline, the coating

should exhibit only slight indicator of wear.

Grease volume is approximately 10 grams of grease

in total. Grease should be evenly applied to both the

female and the male slip splines using a small brush.

After assembly of the slip joint, the sliding joint should

be fully worked from the full collapsed to the full

extended position.

• Aluminum tube type only: Inspect the aluminum

tubing for surface scratches and dents. These

scratches may not exceed 0.2 mm (0.008 in) in

depth.

401RW022

• Aluminum tube type only: Visually inspect the circle

welds and fittings for any signs of cracks or signs of

deterioration. If there are any cracks that exceed 0.2

mm (0.008 in) in depth, the assembly must be

replaced.

• Aluminum tube type only: Check to be sure there are

no missing balance weights. If balance weights are

missing and void has occurred in the aluminum

tubing greater than 0.2 mm (0.008 in), the assembly

must be replaced.

Universal Joint Reassembly

1. Pack the four grease cavities of the spider with a

high quality, extreme pressure N.L.G.I. Grade 2

grease. Do not add additional grease to bearing

cup assembly.

2. Move one end of the spider to cause a trunnion to

project through the spider hole beyond the outer

machined face of the yoke lug. Place a bearing

over the trunnion diameter and align it to the spider

hole.

Using an arbor press, hold the trunnion in alignment

with the spider hole and place a solid plug on the

upper bearing. Press the bearing into the spider

hole enough to install snap ring.

401RW026

3. Install a snap ring.

NOTE: Be sure the snap rings are properly seated in

the grooves.

4. Repeat steps 2 and 3 to install the opposite bearing.

If the joint is stiff, strike the yoke ears with a soft

hammer to seat the bearing.

5. Align the setting marks and join the yokes.

Slip Joint Reassembly

401RX004

Legend

EndOFCallout

1.Apply grease evenly to both the female and male

splines.

2.Apply a small amount of grease by finger to the

outer lips of the boot.

3.Slide the boot (smaller diameter side) onto the

spline yoke shaft being careful not to damage the

spline coating or boot.

4.Insert the spline yoke shaft spline into the tube

assembly being careful to maintain proper phasing.

The spider holes should be in line and as per

originally marked prior to disassembly.

5.Position boot onto tube and yoke shaft in final

position.

6.Attach boot clamps and secure using pliers.

7.Be sure clamp is properly seated and secure.

CAUTION: Use new clamp which is the same parts

as original. Do not use other clamp to avoid bad

balancing of shaft or the grease leakage.

(1) Spline Yoke and Universal Joint Assembly

(2) Clamp

(3) Boot

(4) Clamp

(5) Tube and Universal Joint Assembly

Main Data and Specifications

General Specifications

Torque Specifications

E04RX013

4WD Model

Engine (Transmission) 6VD1 (M/T) 6VD1 (A/T·Normal

transfer)

6VD1 (A/T·TOD)

Length (between two frange) 1302.2mm (51.27in) 1133.1mm (44.61in) 1121.9mm (44.17in)

Universal joint type Cardan type