REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

id031300145100

Special Service Tool (SST)

49 T025 001   Boot clamp crimpers

Replacement Part

Oil and Chemical Type

Caution

•  Do not allow a magnetized tool such as a magnetized screwdriver to come into contact with the ABS sensor rotor. If the ABS sensor rotor becomes magnetized it will be unable to read the ABS wheel speed sensor waveform correctly resulting in an ABS system malfunction to be determined and the inability to perform ABS control. If a magnetized object comes into contact with the ABS sensor rotor, it will be necessary to newly replace the rear drive shaft (ABS sensor rotor).

1.  Disassemble in the order shown in the figure.

2.  Assemble in the reverse order of disassembly.

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1	Boot band (differential side) (See Boot Band (Differential Side) Disassembly Note.) (See Boot Band (Differential Side) Assembly Note.)
2	Outer ring (See Outer Ring Disassembly Note.) (See Outer Ring Assembly Note.)
3	Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
4	Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
5	Boot (differential side) (See Boot (Differential Side) Disassembly Note.) (See Boot (Differential Side) Assembly Note.)
6	Boot band (wheel side) (See Boot (Wheel Side) Disassembly Note.) (See Boot (Wheel Side) Assembly Note.)
7	Boot (wheel side) (See Boot (Wheel Side) Disassembly Note.) (See Boot (Wheel Side) Assembly Note.)
8	Shaft and ball joint component

Boot Band (Differential Side) Disassembly Note

1.  Using a flat chisel and hammer, lightly tap the lever of the boot band to disconnect the lock clip.

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2.  Remove the boot band using pliers.

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Outer Ring Disassembly Note

Caution

•  To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

1.  Place alignment marks on the shaft and outer ring.

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2.  Remove the outer ring from the shaft.

3.  Wipe off grease on the outer ring using a clean rag.

Snap Ring, Tripod Joint Disassembly Note

Caution

•  To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

1.  Place alignment marks on the shaft and tripod joint.

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2.  Remove the snap ring using snap ring pliers.

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Caution

•  When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

•  If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

3.  Remove the tripod joint from the shaft.

4.  Wipe off grease on the shaft and tripod joint using a clean rag.

Boot (Differential Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (differential side).

3.  Wipe off grease on the boot (differential side) using a clean rag.

Boot Band (Wheel Side) Disassembly Note

1.  Remove the boot band using end clamp pliers.

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Boot (Wheel Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (wheel side).

3.  Wipe off grease on the boot (wheel side) and ball joint using a clean rag.

Boot (Wheel Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (wheel side) with vinyl tape wrapped around the spline area of the shaft.

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

2.  Apply the specified grease to the ball joint and boot (wheel side).

3.  Assemble the boot (wheel side) to the ball joint.

Boot Band (Wheel Side) Assembly Note

1.  Adjust opening A of the SST to the standard by rotating the adjustment bolt.

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2.  Crimp the boot band using the SST.

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3.  Verify that crimp B of the boot band is within the standard.

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•  If crimp B exceeds the standard, decrease opening A of the SST and crimp the boot band again.

•  If crimp B is less than the standard, replace the boot band, increase opening A of the SST, and crimp the new boot band.

4.  Verify that the boot band does not protrude from the boot band assembly area.

•  If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.

Boot (Differential Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (differential side) with vinyl tape left wrapped around the spline area of the shaft.

2.  Remove the vinyl tape left wrapped around the spline area of the shaft.

Tripod Joint, Snap Ring Assembly Note

1.  Assemble the tripod joint with the alignment marks on the shaft and tripod joint aligned.

Caution

•  When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

•  If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

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2.  Assemble a new snap ring using snap ring pliers.

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3.  Verify that the snap ring is assembled correctly in the groove of the shaft.

Outer Ring Assembly Note

1.  Apply the specified grease to the outer ring and boot (differential side).

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

2.  Align the shaft and outer ring with the alignment mark and assemble the outer ring.

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3.  Assemble the boot (differential side) to the outer ring.

4.  Set the drive shaft to the standard length.

5.  Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

Note

•  Do not damage the boot.In addition, verify that there is no grease leakage.

•  If the boot is deformed, it may not be possible to perform the full-length adjustment of the shaft.

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6.  Verify that the drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

•  If not within the standard, repeat from Step 4.

Boot Band (Differential Side) Assembly Note

Warning

•  Your hands could be injured while assembling the boot band. Therefore always wear gloves.

1.  Apply rust prevention oil to the inside of the boot band.

2.  Lock the boot band against rotation using an appropriate tool as shown in the figure.

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Caution

•  Do not put the boot band back to its original position after bending it using pliers because it will damage the boot band.

3.  Using a pair of pliers, grip the lever at the base (fulcrum point) and rotate it in the direction of the arrow.

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Caution

•  If the lever flips back by reactive force, press it back again a maximum of only three times to prevent damage to the boot band.

4.  Hold the rotated lever with a finger and temporarily secure the lock clip by squeezing it with a pair of pliers.

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5.  Lightly tap the lock clip with a hammer until the gap in the lock clip is 1 mm {0.04 in} or less.

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6.  After assembling the boot band, perform the following verification.

•  The boot band does not protrude from the band assembly area.

•  The lever is not deformed.

•  The boot and boot band are not damaged.

•  The gap between the boot band and the boot band lever is 1 mm {0.04 in} or less.

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―  If there is any malfunction, replace with a new part.