Disassembly and Reassembly
Driveshafts Disassembly
^ Special Tools Required
- Threaded adapter, 24 x 1.5 mm 07XAC-001020A
- Slide hammer, commercially available
Inboard Joint Side:
1. Remove the set ring (A) from the inboard joint.
2. Remove the boot bands. Take care not to damage the boot.
^ If the boot band is a locking tab type (A), pry up the locking tabs (B) with a screwdriver, and lift up the end of the band.
^ If the boot band is a double loop type (C), lift up the band bend (D).
3. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.
4. Remove the snap ring (A).
5. Make a mark (B) on the spider (C or D) and driveshaft (E) to identify the position of the spider on the shaft.
NOTE: The spider (C) is left driveshaft; spider (D) is right driveshaft.
6. Remove the spider.
7. Wrap the splices on the driveshaft with vinyl tape (A) to prevent damage to the boot.
8. Remove the boot band and the inboard boot. Take care not to damage the boot.
9. Remove the vinyl tape.
Outboard Joint Side:
1. Lift up the three tabs (A) with a screwdriver, then remove the boot bands (B). Take care not to damage the boot.
2. Slide the outboard boot (A) to the inboard joint side. Take care not to damage the boot.
3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.
4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C).
5. Carefully clamp the driveshaft (A) in a vise (B).
6. Remove the outboard joint (C) using the special tool and a commercially available 5/8" x 18 slide hammer (D).
7. Remove the driveshaft from the vise.
8. Remove the circlip (A) from the driveshaft (B).
9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
10. Remove the outboard boot. Take care not to damage the boot.
11. Remove the vinyl tape.
Driveshafts Reassembly
^ Special Tools Required
- Boot band tool, KD-3191 or equivalent, commercially available
- Boot band pincers, Kent-Moore J-35910 or equivalent, commercially available
NOTE: Refer to the Exploded View as needed during this procedure.
Inboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.
2. Install the inboard boot to the driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot.
3. Install the spider (A or B) onto the driveshaft (C) by aligning the marks (D) on the spider and the end of the driveshaft.
NOTE: The spider (A) is for the left driveshaft; spider (B) is for the right driveshaft.
4. Install the snap ring (E).
5. Pack the inboard joint with the joint grease included in the new driveshaft set.
Grease quantity
Inboard joint:
Left Driveshaft: 180 - 200 g (6.3 - 7.1 oz.)
Right Driveshaft: 165 - 185 g (5.8 - 6.5 oz.)
6. Fit the inboard joint (A) onto the driveshaft (B), and note these items:
^ Reinstall the inboard joint onto the driveshaft by aligning the marks (C) on the inboard joint and the rollers (D).
^ Hold the driveshaft so the inboard joint points up to prevent it from falling off.
7. Adjust the length of the driveshafts to the figure shown, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.
8. Fit the boot ends onto the driveshaft and the inboard joint, then install the boot band.
9. Pull up the slack in the band by hand.
10. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).
11. Thread the free end of the band through the nose section of a commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
12. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.
13. Lift up the boot band tool to bend the free end of the band 90° to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.
14. Unwind the boot band tool, and cut off the excess 5 - 10 mm (0.2 - 0.4 inch) from the clip.
15. Bend the band end (A) by tapping it down with a hammer.
NOTE:
^ Make sure the band and clip do not interfere with anything, and the band does not move.
^ Remove any grease remaining on the surrounding surfaces.
16. Install the boot band on the other end of the boot, and repeat steps 9 through 15.
17. Install the new set ring.
Outboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.
2. Install the new ear clamp bands (B) and outboard boot, then remove the vinyl tape. Take care not to damage the boot.
3. Install the new circlip (A) into the driveshaft groove (B).
4. Insert the driveshaft (A) into the outboard joint (B) until the circlip (C) is close on the joint.
5. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 inch) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.
6. Check the alignment of the paint mark (A) with the outboard joint end (B).
7. Pack the outboard joint (A) with the joint grease included in the new joint boot set.
Grease quantity
Outboard Joint: 110 - 130 g (3.9 - 4.6 oz.)
8. Fit the boot ends (A) onto the driveshaft (B) and outboard joint (C).
9. Close the ear portion (A) of the band with a commercially available boot band pincers Kent-Moore J-35910 or equivalent (B).
10. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band further.
11. Repeat steps 9 and 10 for the band on the other end of the boot.