FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY [DOUBLE OFFSET JOINT]

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1.  Disassemble in the order indicated in the table.

2.  Assemble in the reverse order of disassembly.

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1
Boot band (wheel side)
(See Boot Band (Wheel Side) Disassembly Note.)
(See Boot Band (Wheel Side) Assembly Note.)
2
Boot band (transaxle side)
(See Boot Band (Transaxle Side) Disassembly Note.)
(See Boot Band (Transaxle Side) Assembly Note.)
3
Clip
(See Clip Disassembly Note.)
(See Outer Ring, Clip Assembly Note.)
4
Outer ring
(See Outer Ring, Clip Assembly Note.)
5
Snap ring
(See Snap Ring Disassembly Note.)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
6
Balls
(See Balls, Inner Ring, Cage Disassembly Note.)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
7
Inner Ring
(See Balls, Inner Ring, Cage Disassembly Note.)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
8
Cage
(See Balls, Inner Ring, Cage Disassembly Note.)
(See Cage, Inner Ring, Balls, Snap Ring Assembly Note.)
9
Boot
(See Boot Assembly Note.)
(See Boot Disassembly Note.)
10
Dynamic damper
(See Dynamic Damper Assembly Note.)
11
Shaft and ball joint component


Boot Band (Wheel Side) Disassembly Note

Note
•  The boot band does not need to be removed unless it is being replaced.

1.  Remove the boot clamp with end clamp pliers as shown and discard the clamp.

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Boot Band (Transaxle Side) Disassembly Note

1.  Pry up the locking clips using a screwdriver.

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2.  Pull back the end of the band.


Clip Disassembly Note

1.  Mark the drive shaft and outer ring for proper assembly.

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Caution
•  Mark with paint; do not use a punch.

2.  Remove the clip.


Snap Ring Disassembly Note

1.  Mark the drive shaft end, inner ring and cage for proper reassembly.

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Caution
•  Mark with paint; do not use a punch.

2.  Remove the snap ring using snap‐ring pliers.


Balls, Inner Ring, Cage Disassembly Note

1.  Turn the cage approx. 22.5°and pull the cage and balls from the inner ring.

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Boot Disassembly Note

Note
•  The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft component.
•  Do not strip the tape until the boot is assembled.

1.  Wrap the shaft splines with tape.

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2.  Remove the boot.


Dynamic Damper Assembly Note

1.  Install the dynamic damper as shown in the figure.

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Standard length
290.7—298.7 mm {11.45—11.75 in}

2.  Install the new boot band onto the dynamic damper.


Boot Assembly Note

Note
•  The wheel side and transaxle side boots are different.

1.  Fill the boot (wheel side) with the specified grease.

Caution
•  Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
110—130 g {3.89—4.58 oz}

2.  With the splines of the shaft still wrapped in tape from disassembly, install the boot.

3.  Remove the tape.


Cage, Inner Ring, Balls, Snap Ring Assembly Note

1.  Align the marks and install the balls and cage to the inner ring in the direction shown in the figure.

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Caution
•  Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.

2.  Install a new snap ring.


Outer Ring, Clip Assembly Note

1.  Fill the outer ring and boot (differential side) with the specified grease.

Caution
•  Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
135—155 g {4.77—5.46 oz}

2.  Align the marks, and install the outer ring on to the shaft.

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3.  Install a new clip to the outer ring clip groove.

4.  Install the boot.

5.  Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

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Caution
•  Do not let grease leak.
•  Do not damage the boot.

6.  Set the drive shaft to the standard length.

Front drive shaft length (double offset joint)
LH: 679.9—689.9 mm {26.77—27.16 in}
RH: 623.6—633.6 mm {24.56—24.94 in}

7.  Verify that the drive shaft length is within the standard.

•  If not, repeat from Step 5.


Boot Band (Transaxle Side) Assembly Note

1.  Fold the band in the direction opposite to the forward revolving direction of the drive shaft and use pliers to pull it tight.

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2.  Lock the end of the band by bending the locking clips.

Caution
•  Install the band into the groove securely.


Boot Band (Wheel Side) Assembly Note

1.  Adjust clearance A by turning the adjusting bolt of the SST.

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Clearance A
2.9 mm {0.11 in}

2.  Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.

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•  If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
•  If clearance B is less than the specification, replace the boot band, increase clearance A of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}

3.  Verify that the boot band does not protrude from the boot band installation area.

•  If it does, replace the boot band and repeat Steps 2 and 3.

4.  Fill the boot with the repair kit grease.

5.  Adjust clearance A by turning the adjusting bolt of the SST.

Clearance A
3.2 mm {0.13 in}

6.  Crimp the wheel side big boot band using the SST.

7.  Verify that clearance B is within the specification.

•  If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
•  If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}

8.  Verify that the boot band does not protrude from the boot band installation area.

•  If it does, replace the boot band and repeat Steps 7 and 8.