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REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY [MT]

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2016 – MX-5 – DriveLine/Axle

REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY [MT]

Differential Side

1. Disassemble in the order shown in the figure.

2. Assemble in the reverse order of disassembly.

1

Boot band (differential side)

(See Boot band (differential side) disassembly note.)

(See Boot band (differential side) assembly note.)

2

Outer ring

(See Outer ring disassembly note.)

(See Outer ring assembly note.)

3

Snap ring

(See Snap ring, tripod joint disassembly note.)

(See Tripod joint, snap ring assembly note.)

4

Tripod joint

(See Snap ring, tripod joint disassembly note.)

(See Tripod joint, snap ring assembly note.)

5

Boot (differential side)

(See Boot (differential side) disassembly note.)

(See Boot (differential side) assembly note.)

Boot band (differential side) disassembly note

1. Using a flat chisel and hammer, lightly tap the lever of the boot band to disconnect the lock clip.

2. Remove the boot band using pliers.

Outer ring disassembly note

1. Place alignment marks on the shaft and outer ring.

CAUTION:

  • To prevent damage to parts, do not use a punch or similar tool to place alignment marks. Use paint.

2. Secure the shaft in a vise.

3. Lightly tap the outer ring evenly using a hammer and urethane bar or equivalent, and remove the outer ring from the shaft.

CAUTION:

  • When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

4. Wipe off grease on the outer ring using a rag.

Snap ring, tripod joint disassembly note

1. Place alignment marks on the shaft and tripod joint.

CAUTION:

  • To prevent damage to parts, do not use a punch or similar tool to place alignment marks. Use paint.

2. Remove the snap ring using snap ring pliers.

3. Remove the tripod joint from the shaft.

CAUTION:

  • When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

NOTE:

  • If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

4. Wipe off grease on the shaft and tripod joint using a rag.

Boot (differential side) disassembly note

1. Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

2. Remove the boot (differential side).

3. Wipe off grease on the boot (differential side) using a rag.

Boot (differential side) assembly note

NOTE:

  • The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1. Insert the shaft through the boot (differential side) with vinyl tape left wrapped around the spline area of the shaft.

2. Remove the vinyl tape wrapped around the spline of the shaft.

Tripod joint, snap ring assembly note

1. Assemble the tripod joint with the shaft and tripod joint alignment marks aligned.

CAUTION:

  • When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

NOTE:

  • If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

2. Assemble a new snap ring using snap ring pliers.

3. Verify that the snap ring is assembled correctly in the groove of the shaft.

Outer ring assembly note

1. Apply the specified grease to the outer ring and boot (differential side).

NOTE:

  • Apply the grease from the tube. Do not touch the grease directly with your hand.

    Grease amount

  • 90???110 g {3.2???3.8 oz}

2. Secure the outer ring in the vise.

3. After aligning the shaft and outer ring alignment marks, lightly tap the tripod joint area evenly using a hammer and urethane bar or equivalent, and insert the outer ring little by little while maintaining the shaft perpendicular.

CAUTION:

  • When tapping the outer ring lightly using a hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

  • Be careful that dust and dirt do not get on the inside of the outer ring.

4. Assemble the boot (differential side) to the outer ring.

5. Set the rear drive shaft to the standard length. Rear drive shaft (tripod joint) total length (standard)

Total length (standard)

LH

789.1???799.1 mm {31.07???31.46 in}

RH

811.1???821.1 mm {31.94???32.32 in}

6. Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

NOTE:

  • Do not damage the boot. Verify that there is no grease leakage.

  • If the boot is deformed, it may not be possible to perform the full-length adjustment of the shaft.

7. Verify that the rear drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

  • If not within the standard, repeat from Step 5.

Boot band (differential side) assembly note

WARNING:

  • Your hands could be injured while assembling the boot band. Therefore always wear gloves.

1. Apply rust prevention oil to the inside of the boot band.

2. Lock the boot band against rotation using an appropriate tool as shown in the figure.

3. Using a pair of pliers, grip the lever at the base (fulcrum point) and rotate it in the direction of the arrow.

CAUTION:

  • Do not put the boot band back to its original position after bending it using pliers because it will damage the boot band.

4. Hold the bent lever using a hand and secure it temporarily by pinching the lock clip using pliers.

CAUTION:

  • If the lever springs back, press it back in no more 3 times to prevent damage to the boot band.

5. Lightly press the lock clip using a hammer so that the clearance of the lock clip is 1 mm {0.04 in} or less.

  • If there is any malfunction, replace with a new band.

6. Verify that the clearance between the boot band and boot band lever is 1 mm {0.04 in} or less.

  • If there is any malfunction, replace with a new band.

7. After assembling the boot band, perform the following verification.

  • The boot band does not protrude from the band assembly area.

  • The lever is not deformed.

  • The boot and boot band are not damaged.

  • The boot is not damaged.

Wheel Side

1. Disassemble in the order shown in the figure.

2. Assemble in the reverse order of disassembly.

1

Boot band (wheel side)

(See Boot band (wheel side) disassembly note.)

(See Boot band (wheel side) assembly note.)

2

Ball joint

(See Ball joint disassembly note.)

(See Clip, ball joint assembly note.)

3

Clip

(See Clip, ball joint assembly note.)

4

Boot (wheel side)

(See Boot (wheel side) disassembly note.)

(See Boot (wheel side) assembly note.)

Boot band (wheel side) disassembly note

1. Remove the boot band using end clamp pliers.

Ball joint disassembly note

1. Secure the rear drive shaft in a vise.

2. Lightly tap the ball joint evenly using a hammer and urethane bar or equivalent, and remove the ball joint from the rear drive shaft.

CAUTION:

  • When tapping the ball joint lightly using a hammer and urethane bar or equivalent, be careful not to scratch the ball area so as to prevent damage to the part.

3. Wipe off grease on the ball joint using a cloth.

Boot (wheel side) disassembly note

1. Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

2. Remove the boot (wheel side).

3. Wipe off grease on the boot (wheel side) and ball joint using a rag.

Boot (wheel side) assembly note

NOTE:

  • The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1. Insert the shaft through the boot (wheel side) with the vinyl tape left wrapped around the spline area of the shaft.

2. Apply the specified grease to the ball joint and boot (wheel side).

NOTE:

  • Apply the grease from the tube. Do not touch the grease directly with your hand.

    Grease amount

  • 55???75 g {2.0???2.6 oz}

Clip, ball joint assembly note

1. Secure the rear drive shaft in a vise.

2. Install a new clip to the clip groove at the end of the rear drive shaft with the clip opening facing upward.

3. Assemble the ball joint to the rear drive shaft to the position shown in the figure.

4. While pressing the ball joint in the direction of the arrow shown in the figure, compress the clip opening using pincers and insert the clip between the rear drive shaft and ball joint.

5. Lightly tap the ball joint using a copper hammer and assemble the ball joint to the rear drive shaft.

6. Assemble the boot (wheel side) to the ball joint.

Boot band (wheel side) assembly note

1. Adjust opening A of the SST to the standard by rotating the adjustment bolt.

    Standard A

  • Approx. 4.6 mm {0.18 in}

2. Crimp the boot band using the SST.

Large diameter side

Small diameter side

3. Verify that crimp B of the boot band is within the standard.

    Standard B

  • 1.2???4.0 mm {0.05???0.15 in}

  • If crimp B exceeds the standard, decrease opening A of the SST and crimp the boot band again.

  • If crimp B is less than the standard, increase opening A of the SST and crimp a new boot band.

4. Verify that the boot band does not protrude from the band assembly area.

  • If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.

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