Nissan Frontier D40. Manual - part 680

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< DISASSEMBLY AND ASSEMBLY >

DRIVE SHAFT

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

Disassembly and Assembly

INFOID:0000000005272965

DISASSEMBLY

Final Drive Side

1.

Mount the drive shaft in a vise.

CAUTION:

When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.

2.

Remove boot bands and slide the boot back.

3.

Put matching marks on housing and shaft before separating joint assembly.

CAUTION:

Use paint or similar substance for matching marks. Do not scratch the surfaces.

4.

Remove the stopper ring using a suitable tool as shown, and pull
the housing off.

1.

Circlip

2.

Dust cover

3.

Housing

4.

Snap ring

5.

Ball cage, steel ball and inner race assembly

6.

Stopper ring

7.

Boot band

8.

Boot

9.

Shaft

10.

Joint sub-assembly

WDIA0342E

SFA476

DRIVE SHAFT

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5.

Remove the snap ring using a suitable tool, then remove the ball
cage, steel ball, and inner race assembly from the shaft.

6.

Remove the boot from the shaft.

7.

Remove circlip and dust cover from the housing.

8.

Clean the old grease off of the housing using paper towels.

Wheel Side

1.

Mount the drive shaft in a vise.

CAUTION:

When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.

2.

Remove the boot bands and slide the boot back.

3.

Screw a sliding hammer or suitable tool 30 mm (1.18 in) or more
into threaded part of joint sub-assembly. Pull joint sub-assembly
off of shaft as shown.
NOTE:
Align the sliding hammer and shaft and remove the joint sub-
assembly by pulling directly.

CAUTION:

• If the joint sub-assembly cannot be removed after five or

more unsuccessful attempts, replace the entire drive shaft
assembly.

4.

Remove boot from the shaft.

5.

Remove circlip from the shaft.

6.

While rotating the ball cage, clean the old grease off of the joint sub-assembly using paper towels.

INSPECTION AFTER DISASSEMBLY

Shaft

• Replace the shaft if there is any bending, cracking, or other damage.

Joint Sub-assembly

• Check for any rough rotation or unusual axial looseness.
• Clean any foreign material from inside the joint sub-assembly.
• Check for any compression scars, cracks, or fractures.

CAUTION:

If any irregular conditions are found in the joint sub-assembly components, replace the entire joint
sub-assembly.

Housing

NOTE:
Housing, ball cage, steel ball, and inner race are in a set.
• Check for any compression scars, cracks, fractures, or unusual wear on the ball rolling surface.
• Check for any deformation of the boot installation components.

Ball Cage

• Check the sliding surface for any compression scars, cracks, or fractures of sliding surface.

Steel Ball

SFA514A

SDIA0606E

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< DISASSEMBLY AND ASSEMBLY >

DRIVE SHAFT

• Check for any compression scars, cracks, fractures, or unusual wear.

Inner Race

• Check the ball sliding surface for any compression scars, cracks, or fractures.
• Check for any damage to the serrated part.

ASSEMBLY

Final Drive Side

1.

Wrap the serrated part of the shaft with tape. Install the boot
band and boot to shaft.
NOTE:
Discard the old boot band and boot and use a new one for
assembly.

2.

Remove the tape wound around the serrated part of the shaft.

3.

Install the ball cage, steel ball, and inner race assembly on the
shaft, and secure them using the snap ring.
NOTE:
Discard the old snap ring and use a new one for assembly.

4.

Insert the specified quantity of Genuine NISSAN Grease or
equivalent, into the housing. Refer to 

MA-16, "For North Amer-

ica: Fluids and Lubricants"

.

CAUTION:

If grease adheres to the boot mounting surface (indicated
by * marks) on shaft and housing, boot may come off.
Remove all grease from surfaces.

5.

Install the stopper ring onto the housing.

CAUTION:

• Do not reuse stopper rings.
• Make sure that housing and stopper ring are fully engaged.

6.

Install the boot securely into the grooves (indicated by * marks)
as shown.

CAUTION:

If there is grease on boot mounting surfaces (indicated by *
marks) of shaft and housing, boot may come off. Remove
all grease from surfaces.

7.

Check that the boot installation length (L) is the length indicated
below. Insert a flat-tip screwdriver or similar tool into the large
end of the boot. Bleed air from boot to prevent boot deformation.

SFA800

SDIA1125E

Grease capacity

: 120 

−

 140 g (4.23 

−

 4.94 oz)

SDIA1446E

SDIA2493E

DRIVE SHAFT

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CAUTION:

• The boot may break if the boot installation length is less than the specified value.
• Do not to touch the tip of the screwdriver to the inside of the boot.

8.

Secure the big and small ends of the boot with the new boot
bands as shown. 
NOTE:
Discard not reuse boot bands.

9.

Secure housing and shaft and then make sure that they are in the correct position when rotating boot. Use
a new boot band if the boot band needs to be loosened to reposition the boot.

10. Install circlip and dust cover to housing.

NOTE:
Do not reuse circlip and dust cover.

Wheel Side

1.

Insert the Genuine NISSAN Grease or equivalent, into the joint
sub-assembly serration hole until the grease begins to ooze
from the ball groove and serration hole. Refer to 

MA-16, "For

North America: Fluids and Lubricants"

. After inserting the

grease, use a shop cloth to wipe off the grease that has oozed
out.

2.

Wrap the serrated part of the shaft with tape. Install the boot
band and boot onto the shaft. Do not damage the boot.
NOTE:
Discard the old boot band and boot and use a new one for
assembly.

3.

Remove the protective tape wound around the serrated part of
the shaft.

Boot installation length (L) 

: 163.9 - 164.3 mm 
(6.45 - 6.47 in)

SFA395

SDIA1127E

SFA800