FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY

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


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.


Outer Ring Disassembly Note

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

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2.  Remove the clip.

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3.  Remove the outer ring.


Snap Ring, Tripod Joint Disassembly Note

1.  Mark the shaft and tripod joint for proper assembly.

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

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3.  Remove the tripod joint from the shaft.

Caution
•  Do not tap the tripod joint with a hammer.


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.


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 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.


Boot Band (Wheel Side) Assembly Note


Boot band (small diameter side)

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 1 and 2.


Boot band (Large diameter side)

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

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Clearance C
3.2 mm {0.13 in}

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

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•  If clearance B is more than the specification, reduce clearance C of the SST and crimp the boot again.
•  If clearance B is less than the specification, replace the boot band, increase clearance C of the SST, and crimp the new boot.
Clearance D
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 1 and 2.


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.


Tripod Joint, Snap Ring Assembly Note

1.  Align the marks and install the tripod joint using a bar and a hammer.

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2.  Install the new snap ring using snap-ring pliers.

Caution
•  Be sure the snap ring engages correctly in the groove of the shaft.


Outer Ring Assembly Note

1.  Fill the outer ring and boot (transaxle 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
240—260 g {8.48—9.17 oz}

2.  Install the roller cassettes.

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

4.  Install a new clip.

5.  Install the boot.

6.  Set the drive shaft to the standard length.

Front drive shaft standard length
LH: 658.7—668.7 mm {25.92—26.30 in}
RH: 630.7—640.7 mm {24.82—25.20 in}

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

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

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


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.