Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 17

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 17

 

 

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS20059
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL
ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft
55 Nm (5.5 m•kgf, 40 ft•Ibf)
55 Nm (5.5 m•kgf, 40 ft•Ibf)
LT
1
LS
5
New
2
New
LS
LT
LS
LS
LS
1
4
3
66 Nm (6.6 m•kgf, 48 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS (1)” on page
Front skid plate
4-1.
Refer to “TIE-RODS AND STEERING
Steering knuckles
KNUCKLES” on page 4-61.
Refer to “FRONT ARMS AND FRONT
Front arms
SHOCK ABSORBER ASSEMBLIES” on
page 4-65.
Drain.
Differential gear oil
Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-26.
1
Front constant velocity shaft assembly
2
2
Differential motor coupler
1
Disconnect.
3
Differential case breather hose
1
Disconnect.
4
Differential assembly
1
5
Front drive shaft
1
8-4

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft
55 Nm (5.5 m•kgf, 40 ft•Ibf)
55 Nm (5.5 m•kgf, 40 ft•Ibf)
LT
LS
6
New
10
New
9
8
7
LS
LT
LS
LS
LS
66 Nm (6.6 m•kgf, 48 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
6
Spring
1
7
Damper
1
8
Front drive shaft coupling sleeve
1
9
Dust seal
1
10
Dust seal
1
8-5

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the front constant velocity shaft assemblies
A: Wheel side
B: Differential side
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front constant velocity shaft assemblies.
1
Clip
1
2
Boot band
1
3
Boot band
1
4
Dust boot
1
5
Clip
1
6
Double offset joint
1
7
Circlip
1
8
Ball bearing
1
9
Boot band
1
10
Boot band
1
11
Dust boot
1
12
Constant velocity joint
1
13
Clip
1
14
Constant velocity shaft
1
8-6

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
3
24 Nm (2.4 m•kgf, 17 ft•Ibf)
4
23 Nm (2.3 m•kgf, 17 ft•Ibf)
LS
New
LT
(5)
62 Nm (6.2 m•kgf, 45 ft•Ibf)
New
LS
7
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
New
1
5
2
9
New
8
LS
6
LS
New
New
Order
Job/Parts to remove
Q’ty
Remarks
TIP
Do not disassemble the differential motor or
remove the differential motor pinion gear.
1
Differential motor
1
2
O-ring
1
3
Front drive shaft yoke nut (differential case side)
1
4
Front drive shaft yoke (differential case side)
1
5
Differential case cover
1
6
O-ring
1
7
Differential gear assembly
1
Refer to “ADJUSTING THE DIFFEREN-
8
Differential gear assembly shim
—
TIAL GEAR BACKLASH” on page 8-13.
9
Bearing
1
8-7

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
24 Nm (2.4 m•kgf, 17 ft•Ibf)
11
23 Nm (2.3 m•kgf, 17 ft•Ibf)
12
14
13
15
LS
New
LT
(5)
62 Nm (6.2 m•kgf, 45 ft•Ibf)
16
New
17
10
LS
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
New
New
LS
LS
New
16
New
Order
Job/Parts to remove
Q’ty
Remarks
10
Bearing
1
11
Oil seal
1
12
Clip
1
13
Differential pinion gear
1
14
Bearing
1
15
Bearing
1
16
Oil seal
2
17
Differential case
1
8-8

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS30240
B
DISASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
2
front constant velocity shaft assemblies.
1. Remove:
1
• Boot bands
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
B. Wheel side
• Dust boot “5”
TIP
3. Remove:
• Dust boot
Before removing the clip, slide the dust boot
• Constant velocity joint
away from the double offset joint.
• Clip
A
TIP
5
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
2
B
1
A
4
3
B. Wheel side
EBS30241
CHECKING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
A. Differential side
front constant velocity shaft assemblies.
1. Check:
2. Remove:
• Double offset joint splines
• Boot band “1”
• Constant velocity joint splines
Use the boot band installation tool “2”.
• Constant velocity shaft splines
Boots band installation tool
Wear/damage → Replace.
90890-01526
2. Check:
Boots band installation tool
• Dust boots
YM-01526
Cracks/damage → Replace.
ECB01590
NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
8-9

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS30242
2. Install:
ASSEMBLING THE FRONT CONSTANT
• Dust boot
VELOCITY SHAFT ASSEMBLIES
• Ball bearing “1”
The following procedure applies to both of the
• Circlip “2”
New
front constant velocity shaft assemblies.
• Double offset joint “3”
1. Install:
• Clip “4”
New
• Clip “1”
New
• Constant velocity joint “2”
TIP
• Constant velocity shaft “3”
• Securely install the circlip into the groove in the
• Dust boot
constant velocity shaft.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Securely install the clip into the groove in the
a. Install the clip.
double offset joint.
b. Install the constant velocity joint.
TIP
B
1
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
2 New
then fit the constant velocity shaft into the con-
stant velocity joint using a hammer.
A
New 1
B
3
3
A
4 New
3
B. Differential side
3. Apply:
• Molybdenum disulfide grease
New
1
(into the double offset joint, constant velocity
joint, and dust boots)
2
Molybdenum disulfide grease
70 g (2.5 oz) per dust boot
A
(wheel side)
55 g (1.9 oz) per dust boot (dif-
ferential side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1”
A. Wheel side
• Boot bands “2”, “3”, “4”, “5”
New
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-10

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS30244
TIP
REMOVING THE DIFFERENTIAL GEAR
• The new boot bands may differ from the origi-
ASSEMBLY
nal ones.
1. Remove:
• The dust boots should be fastened with the
• Differential gear assembly “1”
boot bands “3” and “5” at the grooves in the
ECB01570
constant velocity shaft.
NOTICE
The ring gear and differential gear are as-
sembled into a proper unit at the factory by
means of specialized equipment. Do not at-
tempt to disassemble this unit. Disassembly
will result in the malfunction of the unit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the dust boots.
b. Install the dust boot bands “4” and “5”.
Use the boot band installation tool “6”.
Boots band installation tool
EBS30246
90890-01526
CHECKING THE DIFFERENTIAL ASSEMBLY
Boots band installation tool
1. Check:
YM-01526
• Gear teeth
Pitting/galling/wear → Replace differential
pinion gear and differential gear assembly as
a set.
• Bearings
6
Pitting/damage → Replace.
• Oil seals
• O-rings
Damage → Replace.
2. Check:
• Drive shaft splines
• Pinion gear splines
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Wear/damage → Replace.
5. Check:
• Spring
• Thrust movement free play
Fatigue → Replace.
Excessive play → Replace the constant ve-
3. Check:
locity shaft assembly.
• Front drive shaft
Bends → Replace.
EWB03040
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken it.
EBS30247
CHECKING THE DIFFERENTIAL MOTOR
OPERATION
1. Check:
• Differential motor
Does not operate → Replace.
8-11

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
ECB01930
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTICE
a. Slide the shift fork sliding gear “1”, which is in-
Do not disassemble the differential motor or
stalled to the differential case cover, to the left
remove the differential motor pinion gear.
as shown in the illustration to put it into the
2WD mode.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the differen-
tial motor terminals “1” (as shown in the illus-
1
trations).
ECB01940
NOTICE
• Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
• Do not connect the batteries to the differen-
tial motor when it is installed in the differen-
tial case. The differential motor should be
checked when it is removed from the differ-
b. Connect two C-size batteries to the differen-
ential case.
tial motor terminal “2” to operate the differen-
tial motor pinion gear “3”. Operate the
A
differential motor pinion gear until the mark
3V
“4” on the differential motor pinion gear is
aligned with the mark “5” on the differential
motor case.
1
ECB01650
NOTICE
Do not use a 12 V battery to operate the dif-
2
ferential motor pinion gear.
3V
B
3V
3
4
5
2
2
1
c. Insert 6 mm bolts “6” into the differential mo-
tor “7” and use them as a guide to set the mo-
A. Check that the differential motor pinion gear
tor on the differential case cover “8” so that
“2” turns counterclockwise.
the shift fork sliding gear “9” does not move.
B. Check that the differential motor pinion gear
ECB01950
“2” turns clockwise.
NOTICE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
If the position of the shift fork sliding gear is
EBS30249
moved, the position of the differential gear
ASSEMBLING THE DIFFERENTIAL
assembly and the indicator light display may
ASSEMBLY
differ, and the 2WD or differential lock mode
1. Measure:
may not be activated.
• Gear backlash
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-13.
2. Install:
• Differential motor
8-12

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
ECB01250
6
NOTICE
6
Finger tighten the bolt until it holds the ring
7
gear. Otherwise, the ring gear will be dam-
6
9
aged.
4. Attach:
8
• Gear lash measurement tool “2”
• Dial gauge “3”
Gear lash measurement tool
d. Remove the 6 mm bolts, and then install the
90890-01475
motor with the differential motor bolts.
Middle drive gear lash tool
YM-01475
Differential motor bolt
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Differential assembly operation
Unsmooth operation → Replace the differen-
tial assembly.
Insert the double offset joint into the differen-
b
tial assembly, and turn the gears back and
a
forth.
a. Measuring point is 22.5 mm (0.86 in)
b. Measuring point is 28 mm (1.10 in)
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash
0.05-0.25 mm (0.002-0.010 in)
EBS30251
TIP
MEASURING THE DIFFERENTIAL GEAR
Measure the gear backlash at four positions. Ro-
BACKLASH
tate the differential pinion gear 90° each time.
1. Secure the differential case in a vise or anoth-
er supporting device.
EBS30252
2. Remove:
ADJUSTING THE DIFFERENTIAL GEAR
• Drain plug
BACKLASH
• Gasket
1. Remove:
3. Install:
• Differential gear assembly shim(s) “1”
• Ring gear fix bolt (M10) “1”
• Differential gear assembly “2”
(into the drain plug hole)
Ring gear fix bolt (M10)
90890-01527
Ring gear fix bolt (M10)
YM-01527
8-13

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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
2
1
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shims using the following
chart.
Differential gear backlash is
Thinner shim
increased.
Differential gear backlash is
Thicker shim
decreased.
Differential gear assembly shims
Thickness (mm)
0.1 0.2 0.3 0.4
b. Measure the differential gear backlash again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-14

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS20060
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft
B
55 Nm (5.5 m•kgf, 40 ft•Ibf)
3
A
2
3
1
LS
LS
New
New
66 Nm (6.6 m•kgf, 48 ft•Ibf)
LS
LS
1
A: For panel wheel models
B: For cast wheel models
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS (1)” on page
Rear skid plate
4-1.
Refer to “GENERAL CHASSIS (3)” on page
Rear fender
4-8.
Refer to “REAR ARMS AND REAR SHOCK
Rear arms
ABSORBER ASSEMBLIES” on page 4-72.
Drain.
Final gear oil
Refer to “CHANGING THE FINAL GEAR
OIL” on page 3-27.
1
Rear constant velocity shaft assembly
2
2
Final drive case breather hose
1
Disconnect.
3
Trailer hitch
1
8-15

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft
B
55 Nm (5.5 m•kgf, 40 ft•Ibf)
A
LS
LS
6
10
9
5
8
New
7
New
66 Nm (6.6 m•kgf, 48 ft•Ibf)
LS
LS
4
A: For panel wheel models
B: For cast wheel models
Order
Job/Parts to remove
Q’ty
Remarks
4
Final drive assembly
1
5
Rear drive shaft
1
6
Spring
1
7
Damper
1
8
Rear drive shaft coupling sleeve
1
9
Dust seal
1
10
Dust seal
1
8-16

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the rear constant velocity shaft assemblies
A: Wheel side
B: Final drive side
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the rear constant velocity shaft assemblies.
1
Clip
1
2
Boot band
1
3
Boot band
1
4
Dust boot
1
5
Clip
1
6
Double offset joint
1
7
Circlip
1
8
Ball bearing
1
9
Boot band
1
10
Boot band
1
11
Dust boot
1
12
Constant velocity joint
1
13
Clip
1
14
Constant velocity shaft
1
8-17

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the final drive assembly
G
1
New
G
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
(4)
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
New
New
4
G
LT
LS
LS
LS
G
2
9
7
G
4
3
6
New
New
23 Nm (2.3 m•kgf, 17 ft•Ibf)
8
(11)
G
New
5
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
1
Final drive pinion gear assembly
1
Refer to “SELECTING THE FINAL DRIVE
2
Final drive pinion gear shim
—
PINION GEAR SHIM(S)” on page 8-25.
TIP
Working in a crisscross pattern, loosen each
3
Final drive case cover
1
bolt 1/4 of a turn. After all the bolts are loos-
ened, remove them.
4
Dowel pin
2
5
Gasket
1
6
Oil seal
1
7
Bearing
1
8
Bearing
1
Refer to “SELECTING THE WHEEL GEAR
9
Wheel gear shim
—
SHIM(S)” on page 8-28.
8-18

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the final drive assembly
G
New
G
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
(4)
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
16
New
New
New
G
LT
19
LS
17
10
LS
LS
G
G
18
New
15
New
14
13
12
23 Nm (2.3 m•kgf, 17 ft•Ibf)
11
(11)
G
New
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
10
Wheel gear
1
Refer to “SELECTING THE FINAL DRIVEN
Final driven pinion gear shim (final drive case
11
—
PINION GEAR SHIM (FINAL DRIVE CASE
cover side)
COVER SIDE)” on page 8-27.
12
Pinion gear
1
13
Final driven pinion gear
1
Refer to “SELECTING THE FINAL DRIVEN
PINION GEAR SHIM (FINAL DRIVE CASE
14
Thrust washer
—
SIDE) AND THRUST WASHER” on page
8-26.
Refer to “SELECTING THE FINAL DRIVEN
Final driven pinion gear shim (final drive case
PINION GEAR SHIM (FINAL DRIVE CASE
15
—
side)
SIDE) AND THRUST WASHER” on page
8-26.
16
Oil seal
1
17
Bearing
1
18
Bearing
1
19
Final drive case
1
8-19

-------------------------------------------------------------------------------------------------------------------------------------------------------------

REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the final drive assembly
G
23
28
New
29
G
27
26
23 Nm (2.3 m•kgf, 17 ft•Ibf)
25
New
24
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
22
(4)
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
2021
New
New
New
G
LT
LS
LS
LS
G
G
New
New
23 Nm (2.3 m•kgf, 17 ft•Ibf)
(11)
G
New
LS
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
20
Rear drive shaft yoke nut
1
21
Washer
1
22
Rear drive shaft yoke (final drive case side)
1
23
Final drive pinion gear
1
24
Oil seal
1
25
Bearing
1
26
Expander
1
27
Washer
1
28
Bearing
1
29
Final drive pinion gear bearing housing
1
8-20

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS30253
DISASSEMBLING THE REAR CONSTANT
A
VELOCITY SHAFT ASSEMBLIES
4
The following procedure applies to both of the
rear constant velocity shaft assemblies.
3
1. Remove:
• Boot band “1”
Use the boot band installation tool “2”.
Boots band installation tool
90890-01526
Boots band installation tool
A. Final drive side
YM-01526
3. Remove:
• Boot band “1”
A
Use the boot band installation tool “2”.
Boots band installation tool
2
90890-01526
1
Boots band installation tool
YM-01526
B
A. Final drive side
2
2. Remove:
1
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5”
B. Wheel side
TIP
Before removing the clip, slide the dust boot
4. Remove:
away from the double offset joint.
• Dust boot
• Constant velocity joint
A
• Clip
5
TIP
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
2
B
1
B. Wheel side
8-21

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS30254
CHECKING THE REAR CONSTANT
A
3
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
rear constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
New
1
• Constant velocity shaft splines
2
Wear/damage → Replace.
2. Check:
• Dust boots
A
Cracks/damage → Replace.
ECB01590
NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
EBS30255
A. Wheel side
ASSEMBLING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES
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The following procedure applies to both of the
2. Install:
rear constant velocity shaft assemblies.
• Dust boot
1. Install:
• Ball bearing “1”
• Clip “1”
New
• Circlip “2”
New
• Constant velocity joint “2”
• Double offset joint “3”
• Constant velocity shaft “3”
• Clip “4”
New
• Dust boot
TIP
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a. Install the clip.
• Securely install the circlip into the groove in the
b. Install the constant velocity joint.
constant velocity shaft.
• Securely install the clip into the groove in the
TIP
double offset joint.
• Install the clip into the groove in the constant
velocity shaft as shown.
B
• Secure the constant velocity joint in a vise, and
1
then fit the constant velocity shaft into the con-
stant velocity joint using a hammer.
2 New
A
New 1
3
8-22

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
B
Boots band installation tool
90890-01526
Boots band installation tool
YM-01526
3
4 New
6
B. Final drive side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
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Molybdenum disulfide grease
5. Check:
60 g (2.1 oz) per dust boot
• Thrust movement free play
(wheel side)
Excessive play → Replace the constant ve-
70 g (2.5 oz) per dust boot (final
locity shaft assembly.
drive side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1”
• Boot bands “2”, “3”, “4”, “5”
New
TIP
• The new boot bands may differ from the origi-
EBS30256
nal ones.
DISASSEMBLING THE FINAL DRIVE PINION
• The dust boots should be fastened with the
GEAR ASSEMBLY
boot bands “3” and “5” at the grooves in the
1. Remove:
constant velocity shaft.
• Rear drive shaft yoke nut “1”
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a. Place a folded rag as shown.
b. Secure the final drive pinion gear in the vise.
1
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a. Install the dust boots.
b. Install the dust boot bands.
c. Remove the rear drive shaft yoke nut.
Use the boot band installation tool “6”.
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