Front Axels & CV Joints Overhaul (4WD)

Note: see Hub & Knuckle Overhaul for hub & knuckle removal details — this section covers the drive axles and CV joints themselves.

Component removal

1. Castle Nut
2. Washer
3. Hub, Knuckle, and Tie Rod End
4. Wheel Speed Sensor (ABS vehicles)
5. Hub & Knuckle Assembly
6. Lower Arm & Cross Member Attachment Bolts
7. Drive Shaft Axels
8. Circle Clip

Fastener torques

Torque	Nm (kgf·m)
T = 108–127	(11.0–13.0; 80–94 ft-lb)
T = 105	(10.5; 77 ft-lb)
T = 15–33	(1.5–3.4; 11–24 ft-lb)
Castle Nut Torque: T = 196–255	(20.0–26.0; 145–188 ft-lb)

Note: see following pages for removal and installation key points.

Tie rod removal

Tools: MB990635 (Linkage Press), plus a second tool printed as “MB:99:113” (verify printed p.208 — same illegible tool number as the Hub & Knuckle section).

1. Attach a piece of string as shown to prevent the tie rod press from dropping after removing the tie rod.
2. Press out tie rod. Ball joint tools: MB990244 (or “MB9990244” as printed), MB990767 (Hub Placement Holder).

Drive axle removal

3. Attach the tools listed in the diagram: MB991354 (Puller Plate), MB990242 (as printed; likely MB990241 Axel Shaft Puller — verify printed p.208).
4. Press out drive axle.
5. Once the axle has been pressed, use a pry bar to back out the unit.

Note: never use a hammer to knock out shafts — damage will occur.

6. For on-vehicle bearing removal, use tools MB991000/MB990998 (Spacer) and MB991017 (Front Hub Reamer & Installer).

BJ/DOJ boot repair kits — component disassembly

Right-side and left-side BJ and DOJ boot repair kits are shown separately in the source diagram.

BJ kit:

1. Boot Band (BJ)
2. BJ Boots
3. BJ (outer race/joint — label ambiguous, see flag below)
4. C-Clip
5. Dust Cover

DOJ kit:

1. Boot Band (DOJ)
2. DOJ Outer Race
3. Snap Ring
4. Inner Race Cage/Ball Assembly
5. DOJ Boots
6. Boot Band

(verify printed p.209) — the numbered component list (1-13 in the source) interleaves BJ and DOJ parts against a two-panel diagram; several stray OCR tokens (“N12”, “N1”, “2006”) could not be resolved to labels and are omitted. Item 11 (“BJ”) is ambiguous — likely “BJ Outer Race” or “BJ Joint” by analogy with the DOJ side, but not confirmed.

Note: optional boot kits are available for both BJ & DOJ axle types.

Boot type & length inspection

Boot	Size code (as printed)
DOJ / BJ — Large	20-112#BJ75L
DOJ / BJ — Small	20-113#BJ75L

(verify printed p.210) — the boot type/size table and the phrase printed as “Boot Type Differential ties” did not resolve cleanly; the two size codes above could not be confidently attributed to BJ vs. DOJ specifically. Do not order boot kits by these codes without confirming against a clean copy or the parts catalogue.

Note: boots must be tight to prevent air from entering the internal area and ballooning. Ballooning can cause early boot failure.

DOJ boot length inspection

DOJ boot length must be 80 ± 3 mm (3.150 ± 0.118 in), or failure may occur.