TSB : Double Cardan Type

Details

NOTE: The flange yoke can be replaced without removing bearing cups from the tube yoke or ball support yoke. FLANGE YOKE REPLACEMENT Remove the bearing cups in the order indicated (1-4). This is the shortest route to the heart of the centering ball system. Make a close inspection in order to select the correct service method. See Fig 1 . Mark all the yokes before disassembly in order to reassemble the yokes, and in order to retain the driveshaft balance. See Fig 2 . Support the drive shaft in a line horizontal with the table of a press. Place the universal joint so that the lower ear of the yoke is supported on a 1 1/8 in (30 mm) socket. See Fig 3 . In order to shear the plastic retaining ring on the bearing cup, place the U-Joint Bearing Separator (J 9522-3) on the open horizontal bearing cups, and press the lower bearing cup out of the yoke ear. If the bearing cap is not completely removed, lift the cross and insert U-Joint Bearing Spacer Remover (J9522-5) between the seal and the bearing cup being removed and continue pressing the bearing cup out of the yoke. See Fig 4 . Inspect the retaining ring for plastic. Inspect the bearing cup bores for burrs or imperfections. Assemble the flange yoke on inner cross of ball tube yoke. Install bearing cup assemblies. Assemble ball support yoke cross in flange yoke, orienting with tube yoke according to marks made on disassembly. Check for freedom of rotation of all trunnions. If too tight, strike the flange yoke sharply with hammer to aid in seating retaining rings. Fig 1: Bearing Cup Removal Sequence Courtesy of ISUZU MOTOR CO. Fig 2: Marking Double Cardan Joint Courtesy of ISUZU MOTOR CO Fig 3: Supporting Universal Joint Courtesy of ISUZU MOTOR CO. Fig 4: Removing Bearing Cup Courtesy of ISUZU MOTOR CO. CENTERING BALL REPLACEMENT Disassemble the flange yoke assembly. See FLANGE YOKE REPLACEMENT Perform the following inspections: Inspect the ball seat insert bushing for wear. If the bushing is worn, replace the ball support yoke and cross assembly. Inspect the seal and ball seats along with the spring and washers. If any parts show indication of excessive wear or are broken, replace the entire set with a service kit. Always discard the removed seal and replace the seal. Inspect the centering ball surface. If the ball surface shows signs of wear beyond a smooth polish, replace the ball. NOTE: When a centering ball requires replacement, all ball seat components must be replaced also. A separate ball and seat service kit is available. The kit has two seat springs and the longer spring must be discarded. Clean all of the plastic from the grooves of all the yokes. Drive a small pin or punch through the injection holes in order to remove the plastic. Clamp shaft in a bench vice and install C.V. Replaceable Ball Remover (J 23996-2). over ball. See Fig 5 . Tighten the puller nut finger tight. Apply a light coat of multipurpose grease to the jaws of the ball puller tool in order to reduce friction between the jaws and the inside surface of the tool sleeve. Tighten the nut until the ball is removed from the stud. Position a new ball on the stud. Position the Ball Installer Tool (J 23996-1) against the ball and drive the tool with a hammer until the ball bottoms on the stud. See Fig 6 . Fig 5: Installing CV Ball Remover Tool Courtesy of ISUZU MOTOR CO. Fig 6: Installing Ball Onto Stud Courtesy of ISUZU MOTOR CO. BALL SEAT ASSEMBLY REPLACEMENT Remove centering ball. See CENTERING BALL REPLACEMENT . Pry the grease seal from the ball seat housing. Take care not to damage the seal bore when prying the seal. Remove the large washer, the 3 seats, the small washer and the spring from the seat housing. Wash the bore of the housing thoroughly with mineral spirits in order to remove all traces of old lubricant. Dry the bore of the housing thoroughly with compressed air. Obtain a ball and seat kit. Discard the longer of the 2 springs in the kit. Liberally grease the inside diameter of the ball seat housing. Use the grease supplied in the kit. Insert spring, small washer, 3 seats and large washer into housing, thoroughly greasing each part as it is inserted. Position the grease seal on the housing with the seal lip facing down into bore. Place the Seal Installer (J 23694) over the seal and tap the seal into place. The seal is seated when flush with the housing. See Fig 7 . Pack the remaining grease from the ball and seat kit in the seat assembly and on the seal. Make sure the inner surfaces of the seats are liberally lubricated. Position the ball support yoke and cross assembly in the flange yoke. Align the reference marks made at disassembly. Install the bearing cups. Check the ball seat assembly. The ball support yoke snaps over the center and moves to the right or left and up or down freely if the constant velocity joint is correctly assembled. Fig 7: Installing Ball Seat Seal Courtesy of ISUZU MOTOR CO.