DRIVE SHAFT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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Boot Band (Wheel Side) Disassembly Note

Note

• The boot band does not need to be removed unless it is being replaced.

1. Remove the boot clamp with end clamp pliers as shown and discard the clamp.

Boot Band (Transaxle Side) Disassembly Note

1. Pry up the locking clips using a screwdriver.

2. Pull back the end of the band.

Clip Disassembly Note

1. Mark the drive shaft and outer ring for proper assembly.

Caution

• Mark with paint; do not use a punch.

2. Remove the clip.

Balls, Inner Ring, Cage Disassembly Note

1. Mark the inner ring and cage.

Caution

• Mark with paint; do not use a punch.

2. Turn the cage approximately 30 ° and pull the cage and balls away from the inner ring.

ABS Sensor Rotor Disassembly Note

Caution

• Do not remove the sensor rotor unless it is necessary.

• Do not reuse the sensor rotor if removed.

1. Tap the ABS sensor rotor off the drive shaft using a chisel.

ABS Sensor Rotor Assembly Note

1. Set a new ABS sensor rotor on the drive shaft and press it on using the SSTs.

Dynamic Damper Assembly Note

1. Install the dynamic damper as shown in the figure.

L3: 281.7-287.7 mm {11.10-11.32 in}

MZR-CD (RF Turbo): 288.7-294.7 mm {11.37-11.60 in}

2. Install the new boot band on the dynamic damper.

Boot Assembly Note

1. Fill the boot (wheel side) with the specified grease.

Caution

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

Note

• The wheel side and transaxle side boots are different.

• Use the specified grease supplied in the boot kit.

L3: 130-150 g {4.59-5.29 oz}

MZR-CD (RF Turbo): 160-180 g {5.65-6.35 oz}

2. With the splines of the shaft still wrapped in tape from the disassembly procedure, install the boot.

3. Remove the tape.

Cage, Inner Ring, Balls, Snap Ring Assembly Note

1. Align the marks and install the balls and cage on the inner ring in the direction shown in the figure.

Caution

• Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.

2. Install a new snap ring.

Outer Ring, Clip Assembly Note

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

Caution

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

Note

• Use the specified grease supplied in the boot kit.

L3: 140-160 g {4.95-5.64 oz}

MZR-CD (RF Turbo): 160-180 g {5.65-6.35 oz}

2. Align the marks, and install the outer ring on the shaft.

3. install a new clip.

4. Install the boot.

5. Set the drive shaft to the standard length.

Standard length

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

Caution

• Be careful not to leak the grease.

• Do not damage the boot.

7. Verify that the drive shaft length is within the standard.

Boot Band (Transaxle Side) Assembly Note

1. Fold the band in the direction opposite to the forward revolving direction of the drive shaft and pull it tight using pliers.

2. Lock the end of the band by bending the locking clips.

Caution

• Install the band into the groove securely.

Boot Band (Wheel Side) Assembly Note

1. Adjust clearance A by turning the adjusting bolt of the SST.

2.9 mm {0.11 in}

2. Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.

• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.

• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST, and crimp the new boot.

2.4-2.8 mm {0.095-0.110 in}

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

• If it does, replace the boot band and repeat steps 2 and 3.

4. Fill the boot with the repair kit grease.

5. Adjust clearance A by turning the adjusting bolt of the SST.

3.2 mm {0.13 in}

6. Crimp the wheel side big boot band using the SST.

7. Verify that clearance B is within the specification.

• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.

• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and crimp the new boot.

2.4-2.8 mm {0.095-0.110 in}

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

• If it does, replace the boot band and repeat steps 7 and 8.