FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY[L3]

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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 (differential side)
(See Boot Band (Differential Side) Disassembly Note.)
(See Boot Band (Differential Side) Assembly Note.)
3
Outer ring
(See Outer Ring Disassembly Note.)
(See Outer Ring Assembly Note.)
4
Snap ring
(See Snap Ring, Tripod Joint Disassembly Note.)
(See Tripod Joint, Snap Ring Assembly Note.)
5
Tripod joint
(See Snap Ring, Tripod Joint Disassembly Note.)
(See Tripod Joint, Snap Ring Assembly Note.)
6
Boot
(See Boot Disassembly Note.)
(See Boot Assembly Note.)
7
Dynamic damper
(See Dynamic Damper Assembly Note.)
8
Shaft, bell joint component


Boot Band (Wheel Side) Disassembly Note

Note
•  Remove the boot band only if there is a malfunction.

1.  Remove the boot band using end clamp pliers.

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Boot Band (Differential Side) Disassembly Note

1.  Press the lock clip upward using a flathead screwdriver.

2.  Remove the boot band using pliers.

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Outer Ring Disassembly Note

1.  Place an alignment mark on the outer ring (tripod side) and the drive shaft.

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2.  Remove the outer ring.


Snap Ring, Tripod Joint Disassembly Note

1.  Place an alignment mark on the shaft and tripod joint.

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2.  Remove the snap ring from the shaft using snap ring pliers.

3.  Remove the tripod joint.

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


Boot Disassembly Note

Note
•  Remove the wheel side boot only if there is any malfunction.

1.  Wrap the shaft splines with tape and remove the boot.

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Dynamic Damper Assembly Note

1.  Install the dynamic damper with the length shown in the figure within the specification.

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Standard
291.0—297.4 mm {11.46—11.70 in}


Boot Assembly Note

1.  Fill the inside of the new dust boot (wheel side) with grease.

Warning
•  Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Note
•  The boot shapes on the wheel side and the differential side are different. Do not install the wrong boot by mistake.
•   Apply the repair kit grease
Grease amount
105—125 g {3.7—4.4 oz}

2.  Assemble the boot with the shaft spline wrapped with tape.

3.  Remove the tape.


Tripod Joint, Snap Ring Assembly Note

1.  While aligning the marks on the shaft and the tripod joint, insert the tripod joint.

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Caution
•  Do not tap the roller with a hammer.

2.  Insert a 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.  Apply the outer ring and boot (differential side) with the repair kit grease.

Warning
•  Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Grease amount
200—220 g {7.1—7.7 oz}

2.  Assemble the outer ring.

3.  Set the drive shaft to the standard length.

Standard
Left side: 648.2—658.2 mm {25.52—25.91 in}
Right side: 601.2—611.2 mm {23.67—24.06 in}

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

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

5.  Verify that the drive shaft length is within the specification under atmospheric pressure inside the boot.

•  If not within the specification, readjust.


Boot Band (Differential Side) Assembly Note

1.  Set a new boot band to the boot slot.

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Caution
•  Remove grease from the boot slot.
•  Bend the boot band to the opposite direction of drive shaft forward rotation direction.

2.  After pulling the tip of the boot band with pliers, crimp it.

3.  Fold back the clip to secure the boot band.

Caution
•  Verify that the boot band is installed securely to the boot slot.


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 C by turning the adjusting bolt of the SST.

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Clearance C
3.2 mm {0.13 in}

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

7.  Verify that clearance D is within the specification.

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•  If clearance D is more than the specification, reduce clearance C of the SST and crimp the boot again.
•  If clearance D 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}

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.