Drive Intermediate Shaft Assembly Disassembly and Reassembly (Diesel - 2WD Model)
Precautions: General safety (00)
Disassembly
1)Remove snap ring (1) from drive intermediate shaft (2).
2)Using hydraulic press (1) and special tool, remove drive intermediate shaft (2) from intermediate shaft bearing.
3)Remove dust seal (1) from intermediate shaft bearing support using special tool.
4)Remove bearing support circlip (1) using snap ring pliers (2).
5)Using hydraulic press and special tool, remove intermediate shaft bearing from intermediate shaft bearing support (1) by pushing the bearing from transaxle side.
6)Remove deflector (1) and/or bearing shield from drive intermediate shaft using flat-bladed screwdriver or the like, if necessary.
Reassembly
1)Install new deflector (1) onto drive intermediate shaft, if removed, by tapping flat-surface of deflector indicated by arrow in figure, along the circle little by little using flat-bladed screwdriver covered with cloth (2) to protect it from damage.
NOTICE:
•Denting or scratching the oil seal contact surface of drive intermediate shaft will cause oil leakage.
Do not damage the contact surface when installing the deflector.
•Incomplete installation of the deflector will damage the oil seal and result in oil leakage.
Check that the deflector end (3) contacts the shoulder (4) of the shaft evenly.
Do not damage the contact surface when installing the deflector.
•Incomplete installation of the deflector will damage the oil seal and result in oil leakage.
Check that the deflector end (3) contacts the shoulder (4) of the shaft evenly.
2)Install new bearing shield (1) to drive intermediate shaft using special tool, if removed.
3)Using hydraulic press and special tools, install new intermediate shaft bearing to intermediate shaft bearing support (1) by pushing the bearing from drive shaft side.
4)Install new circlip (1) in groove (2) of intermediate shaft bearing support.
5)Apply grease (2 – 3 g (0.07 – 0.10 oz)) to space on bearing as shown in figure.
6)Install new dust seal (1) to specified position on drive shaft side of intermediate shaft bearing support (2) in specified direction shown in figure using special tools.
Distance between bearing support surface and dust seal
“a”: 1.5 – 2.5 mm (0.06 – 0.09 in.)
7)Press-fit drive intermediate shaft (2) into inner race (1) of intermediate shaft bearing from transaxle side using hydraulic press and special tool.
8)Install new snap ring (1) to drive intermediate shaft (2).