DRIVE SHAFT / PROPELLER SHAFT  PROPELLER SHAFT ASSEMBLY(for Standard Roof)  REASSEMBLY  

1.458,3.625 0.792,3.208 0.792,3.208 1.448,2.781 true 2.135,3.635 2.781,3.219 2.781,3.219 2.125,2.792 true 2.958,1.802 3.125,1.802 true 2.958,0.135 3.125,0.135 true 1.24,0.156 1.552,0.354 0.313,0.198 10 false *a 0.594,3.115 0.906,3.313 0.313,0.198 10 false *b 2.844,3.104 3.156,3.302 0.313,0.198 10 false *b 3.198,0.063 3.385,0.271 0.188,0.208 10 false *c 3.177,1.698 3.406,1.917 0.229,0.219 10 false *c

*a	Front Side
*b	Seal
*c	Cutout

Install the center No. 1 support bearing assembly to the intermediate shaft.

NOTICE:

·

Carefully insert the part so that the seal does not invert.

·

Make sure to install the part so that the cutouts face the rear of the vehicle.

1.708,1.323 2.573,1.729 2.573,1.729 1.698,1.177 true 2.656,1.688 2.969,1.844 0.313,0.156 10 false *a

*a

Matchmark

Align the matchmarks on the flange coupling and intermediate shaft, and then install the flange coupling to the intermediate shaft.

2.365,1.635 2.208,1.635 2.208,1.635 2.208,1.167 true 1.125,0.698 1.438,0.854 0.313,0.156 10 false *a 1.552,1.635 1.865,1.792 0.313,0.156 10 false *b 2.458,1.531 2.917,1.729 0.458,0.198 10 false SST

*a	Turn
*b	Hold

Using SST to hold the flange coupling, install a new lock nut.

SST

09330-00021  

Torque:

101.5 N*m (1035 kgf*cm, 75 ft.*lbf)

Using a chisel and hammer, stake the lock nut.

NOTICE:

·

Fully stake the lock nut along the entire groove.

·

Do not damage the threads of the intermediate shaft.

Apply grease to a new spider and new spider bearings.

Grease:

Lithium base chassis grease NLGI No. 2

NOTICE:

Do not apply too much grease.

1.083,0.917 1.083,0.167 1.083,0.167 1.25,0.167 true 2.5,1 3.167,1 true 1.688,1.656 2,1.854 0.313,0.198 10 false *a 0.063,1.229 0.375,1.427 0.313,0.198 10 false *b 1.292,0.083 1.75,0.281 0.458,0.198 10 false SST 3.219,0.927 3.396,1.229 0.177,0.302 10 false A

*a	Turn
*b	Hold

Using SST, install 2 of the spider bearings to the spider.

SST

09332-25010  

HINT:

Before installing SST, sufficiently raise the part labeled A. If the part labeled A is too low, it may be difficult to install SST.

Install 2 new snap rings to the installed spider bearings. The snap rings must have equal thickness and allow 0 to 0.05 mm (0 to 0.00196 in.) of axial play.

NOTICE:

While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

HINT:

Do not reuse the snap rings.

Standard Snap Ring Thickness:

Part No.	Thickness
90520-29039	1.98 to 2.00 mm (0.0780 to 0.0787 in.)
90520-29040	2.00 to 2.02 mm (0.0788 to 0.0795 in.)
90520-29041	2.02 to 2.04 mm (0.0796 to 0.0803 in.)
90520-29042	2.04 to 2.06 mm (0.0804 to 0.0811 in.)
90520-29043	2.06 to 2.08 mm (0.0812 to 0.0818 in.)
90520-29044	2.08 to 2.10 mm (0.0819 to 0.0826 in.)
90520-29045	2.10 to 2.12 mm (0.0827 to 0.0834 in.)
90520-29046	2.12 to 2.14 mm (0.0835 to 0.0842 in.)
90520-29047	2.14 to 2.16 mm (0.0843 to 0.0850 in.)
90520-29048	2.16 to 2.18 mm (0.0851 to 0.0858 in.)

NOTICE:

·

While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

·

Use a new snap ring.

·

Use a snap ring with as close to the same thickness as possible on both ends.

2.365,0.656 1.656,0.302 1.656,0.302 1.333,0.302 true 1.115,0.198 1.427,0.354 0.313,0.156 10 false *a

*a	Hammering Point

Using a hammer, tap the flange yoke until there is no clearance between the spider bearing outer race and snap ring.

HINT:

Install the spider bearing on the sleeve side using the procedure described above.

1.583,1.021 0.979,0.469 0.979,0.469 1.74,0.833 true 0.813,0.375 1.125,0.573 0.313,0.198 10 false *a

*a

Matchmark

Align the matchmarks on the flange yoke and propeller shaft.

1.729,1.094 2.552,0.51 2.552,0.51 1.927,1.167 true 2.604,0.365 2.917,0.521 0.313,0.156 10 false *a

*a

Matchmark

Align the matchmarks on the flange yoke and propeller shaft.

1.521,1.292 2.635,1.823 2.635,1.823 1.688,1.083 true 2.677,1.781 2.99,1.938 0.313,0.156 10 false *a

*a

Matchmark

Align the matchmarks on the sleeve yoke and intermediate shaft.

1.167,1 1.167,0.417 1.167,0.417 1.25,0.417 true 2.5,1.333 2.865,1.323 true 1.323,1.573 1.635,1.771 0.313,0.198 10 false *a 0.979,0.125 1.292,0.323 0.313,0.198 10 false *b 1.292,0.333 1.75,0.531 0.458,0.198 10 false SST 2.948,1.25 3.167,1.469 0.219,0.219 10 false A

*a	Turn
*b	Hold

Using SST, install the 2 spider bearings to the spider.

SST

09332-25010  

HINT:

Before installing SST, sufficiently raise the part labeled A. If the part labeled A is too low, it may be difficult to install SST.

Install 2 new snap rings to the installed spider bearings. The snap rings must have equal thickness and allow 0 to 0.05 mm (0 to 0.00196 in.) of axial play.

NOTICE:

While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

HINT:

Do not reuse the snap rings.

Standard Snap Ring Thickness:

Part No.	Thickness
90520-29039	1.98 to 2.00 mm (0.0780 to 0.0787 in.)
90520-29040	2.00 to 2.02 mm (0.0788 to 0.0795 in.)
90520-29041	2.02 to 2.04 mm (0.0796 to 0.0803 in.)
90520-29042	2.04 to 2.06 mm (0.0804 to 0.0811 in.)
90520-29043	2.06 to 2.08 mm (0.0812 to 0.0818 in.)
90520-29044	2.08 to 2.10 mm (0.0819 to 0.0826 in.)
90520-29045	2.10 to 2.12 mm (0.0827 to 0.0834 in.)
90520-29046	2.12 to 2.14 mm (0.0835 to 0.0842 in.)
90520-29047	2.14 to 2.16 mm (0.0843 to 0.0850 in.)
90520-29048	2.16 to 2.18 mm (0.0851 to 0.0858 in.)

NOTICE:

·

While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

·

Use a new snap ring.

·

Use a snap ring with as close to the same thickness as possible on both ends.

1.646,2.031 1.896,2.031 1.896,2.031 2.344,1.792 false 1.458,1.938 1.667,2.125 0.208,0.188 10 *a

*a	Hammering Point

Using a hammer, tap the propeller shaft until there is no clearance between the spider bearing outer race and snap ring.

HINT:

Install the spider bearing on the sleeve side using the procedure described above.

1.385,1.031 2.51,0.302 2.51,0.302 1.469,1.094 true 2.573,0.229 2.885,0.385 0.313,0.156 10 false *a

*a

Matchmark

Align the matchmarks on the flange yoke and flange coupling, and connect them with the 4 washers and 4 nuts.

Torque:

88.2 N*m (899 kgf*cm, 65 ft.*lbf)

NOTICE:

If any parts with matchmarks are replaced during inspection, reassemble them so that the sleeve yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are at right angles to each other.