Disassembly and Reassembly

Disassembly

NOTE:
^ Due to the amount of work required to replace one damaged boot, it is best to replace both boots at the same time.
^ These instructions are for the inboard joint. The same procedure applies to the outboard joint.





1. Remove the set ring (A) from the inboard joint.











2. Remove the boot bands. Be careful not to damage the boot and dynamic damper.
^ If the boot band is a welded type (A), cut the boot band (B).
^ If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E).
^ If the boot band is a low profile type (F), pinch the boot band using a commercially available boot band pincers (G).





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 idiot





4. Make a mark (A) on the rollers (B) and spider (C) to identify the locations of the rollers on the spider, them remove the rollers.
5. Remove the circlip (D).
6. Mark the spider (C) and driveshaft (E) to identify the position of the spider on the shaft.
7. Remove the spider (C).





8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
9. Remove the inboard boot. Be careful not to damage the boot.
10. Remove the vinyl tape.

Reassembly

Special Tools
^ Required Boot band tool, KD-3191 or equivalent, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.





1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.
2. Install the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.





3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the end of the d rives h aft.
4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to make sure it is fully seated.





5. Fit the rollers (A) onto the spider (B) with their high shoulders facing outward, and note these items:
^ Reinstall the rollers in their original positions on the spider by aligning the marks (C).
^ Hold the driveshaft pointed up to prevent the rollers from falling off.





6. Pack the inboard joint with the joint grease included in the new driveshaft set.
Grease quantity
Inboard joint: 80 - 90 g (2.8 - 3.2 oz.)





7. Fit the inboard joint onto the driveshaft, and note these items:
^ Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the rollers.
^ Hold the driveshaft so the inboard joint points up to prevent it from falling off.





8. Adjust the length of the driveshafts to the figure, 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.
Left driveshaft: 633 - 637 mm (24.9 - 25.1 inch)
Right driveshaft: 690 - 694 mm (27.2 - 27.3 inch)





9. Fit the boot ends onto the driveshaft and the inboard joint, then install the new double loop band (A) onto the boot.
10. Pull up the slack in the band by hand.





11. Mark a position (A) on the band 10 - 14 mm (0.406 inch) from the clip (B).





12. Thread the free end of the band through the nose section of the commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
13. 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.





14. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.





15. Unwind the boot band tool, and cut off the excess free end of the band to leave 5 - 10 mm (0.2 - 0.4 inch) from the clip.





16. 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.

17. Install the boot band on the other end of the boot, and repeat steps 9 through 15.





18. Install the new set ring (A).