TJ Gasket Repair Procedures

DISASSEMBLY

1. 1
   Remove the front drive shaft. (Refer to Propeller Shaft - Front Propeller Shaft)
2. 2
   Remove the snap ring (B) from the spline of the drive shaft (B).

   

3. 3
   Remove the two rings from the TJ housing bellows.

   

   

4. 4
   Remove the TJ cover (A).

   

   

5. 5
   Remove the snap ring (A) from the shaft.

   

6. 6
   Remove the cross (B) from the drive shaft (A) using the special service tool (09495-33000).

   

7. 7
   Clean the entire cross assembly.
8. 8
   Remove the TJ bellows (A).

   

Inspection

1. 1
   Check that the drive shaft boots are not damaged or deteriorated.
2. 2
   Check the drive shaft splines for wear or damage.
3. 3
   Make sure there is no water or foreign matter in the joint.
4. 4
   Check the cross assembly to make sure the rollers are not worn or corroded and rotate smoothly.
5. 5
   Make sure the splines in the seal housing have no signs of wear or corrosion.
6. 6
   Make sure the dynamic damper is not damaged or cracked.

Installation

1. 1
   Wrap insulation tape around all splines of the drive shaft (TJ) to prevent damage to the bellows seal.
2. 2
   Using the alignment marks (D) made during disassembly to facilitate installation, install the cross assembly (A) and elastic ring (B) onto the splines of the transmission shaft (C).

   

   

3. 3
   Add the specified grease to the bellows in the amount removed for inspection.
4. 4
   Install two sealing bands.
5. 5
   Using the special service tool (09495-39100), tighten the TJ bellows seal clamps. [Hook Type]

   

   [Ear Type]

   

6. 6
   Install the front propeller shaft. (Refer to Propeller Shaft - Front Propeller Shaft)
7. 7
   Check the front alignment. (Refer to Suspension System - "Front Wheel Alignment")