Front Drive Shaft (Plunging Tripod Joint (DOJ) and Birfield Joint (BJ)) - Installation

1. Wrap the splined portion of the drive shaft on the inner CV joint side with (plastic) insulation tape to prevent damage to the boot.

2. Apply grease to the drive shaft and install the CV joint boots.

Recommended grease:

Outer CV joint (BJ): CENTOPLEX 278M/136K Inner CV joint (DOJ): AMBLYGON TA 10/2A

3. To install the dynamic damper, hold the outer CV joint and drive shaft in a straight line, and secure the dynamic damper with a clamp at the locations shown in the illustration.

Standard value: mm 1.6L M/T 1.8L M/T 2.0L M/T Left shaft (LH) 467.5 +2 -0 469 +2 -0 469 +2 -0 Right shaft (RH) 205 ± 2 209 ± 2 208 ± 2

4. Apply the specified grease to the inner race and cage of the CV joint. Install the cage so that the distance between the cage and the inner race matches the value shown in the illustration.

Use the special grease from the repair kit.

5. Apply the specified grease to the cage of the inner CV joint and install the balls into the cage.

6. Position side (A) of the inner CV joint as shown in the illustration. Install the inner race of the CV joint onto the drive shaft and secure it with the snap ring.

7. Apply the specified grease to the outer race of the inner CV joint, install it onto the drive shaft and secure it with the snap ring.

8. Fill the inner CV joint boot with the specified grease and install it in place.

Amount of grease for the inner CV joint (DOJ): g.

1.6L M/T 1.8L M/T 2.0L M/T Total 95 ± 6 100 ± 6 100 ± 6 In CV joint 60 ± 3 60 ± 3 60 ± 3 In boot 35 ± 3 40 ± 3 40 ± 3 9. Secure the inner CV joint boot with clamps.

10. Add the specified grease to the outer CV joint housing in an amount equal to the grease removed during inspection.

11. Install the outer CV joint boot.

12. Secure the outer CV joint boot with clamps.

13. Position the outer CV joint boot clamps at the proper distance from each other (to provide the required air volume inside the boot), then tighten the clamps securely.

Standard value (A): mm 1.6L M/T 1.8L M/T 2.0L M/T Left shaft (LH) 512.7 ± 2 513.2 ± 2 513.2 ± 2 Right shaft (RH) 795.7 ± 2 795.2 ± 2 796.2 ± 2