Driveshaft Reassembly

Driveshaft Reassembly

Driveshaft:

Special Tools Required
^ Boot band tool, KD-3191 or equivalent, commercially available
^ Boot band pliers, Kent-Moore J-35910 or equivalent, commercially available
^ Boot band pliers, 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 damaging the inboard boot.





2. Double loop type/Low profile type: Install the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.
3. Locking tab type: Install the new boot band (B) and the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.
4. Install the spider (A) onto the driveshaft by aligning the marks (B) you made on the spider and the end of the driveshaft.





5. Install the snap ring (C).
6. Pack the inboard joint with the joint grease included in the new boot set.





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





8. Fit the boot ends (A) onto the driveshaft (B) and the inboard joint (C).





9. Adjust the length of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension. Bleed excess air from the boots by inserting a flat-tipped screwdriver between the boot and the joint.





10. Install new boot bands.

^ For the locking tab type, go to step 11.
^ For the double loop type, go to step 13. (Replacement part only)
^ For the low profile type, go to step 22.

11. Install a new locking tab band on the inboard joint side of the inboard boot. Fold down the locking tabs.





12. Lightly tap on the doubled-over portions to reduce their height.
13. Fit the boot ends onto the driveshaft and the inboard joint, then install a new double loop band (A) onto the boot (B).





14. Pull up the slack in the band by hand.
15. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 in.) from the clip (B).





16. 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).





17. Using a wrench on the winding mandrel of the boot band tool, tighten the band until the marked spot (C) on the band meets the edge of the clip.
18. 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.





19. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5 - 10 mm (0.2 - 0.4 in.) tail protruding from the clip.





20. Bend the band end (A) by tapping it down with a hammer.

NOTE:
^ Make sure the band and the clip do not interfere with anything on the vehicle and the band does not move.
^ Clean any grease remaining on the surrounding surfaces.





21. Repeat steps 13 through 20 for the band on the other end of the boot.
22. Install the new low profile band (A) onto the boot (B), then hook the tab (C) of the band.





23. Close the hook portion of the band with a commercially available boot band pliers (A), then hook the tabs (B) of the band.





24. Install the boot band on the other end of the boot, and repeat steps 22 and 23.

Outboard Joint Side
1. Wrap the splines with vinyl tape (A) to prevent damaging the outboard boot.





2. Install the new ear clamp bands (B) and the outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.
3. Install a new stop ring (A) into the driveshaft groove (B).





4. Pack about 35 g (1.2 oz) grease included in the new outboard boot set into the driveshaft hole in the outboard joint.





5. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.





6. To completely seat the outboard joint, pick up the driveshaft and joint, and tap or hit them from a height of about 10 cm (4 in.) onto a hard surface.





7. Check the alignment of the paint mark (A) with the outboard joint rim (B).





8. Pack the outboard joint (A) with the remaining joint grease included in the new joint boot set.





9. Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C). Bleed any excess air from the boot by inserting a flat-tipped screwdriver between the boot and the joint.





10. Adjust the length of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension.





11. Close the ear portion (A) of the band with a commercially available boot band pliers Kent-Moore J-35910 or equivalent (B).





12. 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 tighter.





13. Repeat steps 11 and 12 for the band on the other end of the boot.