Disassembly and Reassembly

DISASSEMBLY
1. DISASSEMBLE DRIVE SHAFT

NOTICE: Do not disassemble the outboard shaft.

(a) Check the drive shaft.
(1) Check that there is no remarkable play in the outboard joint.
(2) Check that the inboard joint slides smoothly in the thrust direction.
(3) Check that there is no remarkable play in the radial direction of the inboard joint.
(4) Check the boots for damage.
(b) Remove the inboard and outboard joint boot clamps.
Using a screwdriver, disclamp the boot clamps.
(c) w/ Dynamic damper:
Remove the dynamic damper clamps.
Using a screwdriver, disclamp the clamps.

(d) Remove the inboard shaft.
(1) Slide the inboard boot toward the outboard joint.
(2) Place matchmarks on the inboard joint shaft, tripod and outboard joint shaft, and then remove the inboard joint shaft.

NOTICE: Do not punch the marks.

(e) Remove the tripod.
(1) Using a snap ring expander, remove the snap ring.
(2) Place matchmarks on the outboard joint shaft and tripod.
(3) Using a brass bar and a hammer, remove the tripod.

NOTICE: Do not tap the roller.

(f) Remove the inboard joint boot, (dynamic damper), outboard joint boot and boot clamps.
2. RH for 2WD:
DISASSEMBLE INBOARD JOINT SHAFT

(a) Remove the No. 1 dust cover.
Using a press, remove the dust cover.

(b) Remove the bearing case.
(1) Using a screwdriver, remove the snap ring (large).
(2) Using a press, remove the bearing case.
(3) Using a pin punch and a hammer, remove the straight pin from the bearing case.

(d) Remove the bearing.
(1) Using a snap ring expander, remove the snap ring (small).
(2) Using a press, remove the bearing.

3. Except RH for 2WD:
REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard joint shaft.
SST 09950-00020

REASSEMBLY
1. RH for 2WD:
REASSEMBLE INBOARD JOINT SHAFT
(a) Assemble the bearing case.

(1) Using a pin punch and a hammer, install the straight pin into the bearing case.

(2) Using SST and a press, install a new bearing into the bearing case.
SST 09950-60020 (09951-00720), 09950-70010 (09951-07150)
(3) Using a screwdriver, install a new snap ring (large).

(b) Install the bearing case.
(1) Using SST and a press, install the bearing with the bearing case assembly to the inboard shaft.
SST 09710-04081
(2) Using a snap ring expander, install a new snap ring (small).
(c) Install the dust covers.

(1) Using SST and a press, install a new No. 2 dust cover.
SST 09710-04081

(2) Using a press, install a new No. 1 dust cover, as shown in the illustration.

2. Except RH for 2WD:
INSTALL NEW DUST COVER
Using a press, install a new dust cover.
3. REASSEMBLE DRIVE SHAFT
(a) Temporarily install a new outboard joint boot (dynamic damper), a new inboard joint boot and new boot clamps.

HINT: Before installing the boots, wrap vinyl tape around the spline of the drive shaft to prevent damaging the boots.

(1) Install a new outboard joint boot to the outboard joint shaft, and place new boot clamps on the outboard joint boot.
(2) w/ dynamic damper:
Install the dynamic damper to the outboard joint shaft, and place a new boot clamp on it.

HINT: The dynamic damper direction is shown in the illustration.

(3) Place new boot clamps on a new inboard boot, and install them to the outboard joint shaft.

(b) Install the tripod.
(1) Place the beveled side of the tripod axial spline toward the outboard joint.
(2) Align the matchmarks placed before removal procedure.
(3) Using a brass bar and a hammer, tap the tripod to the drive shaft.

NOTICE: Do not tap the roller.

(4) Using a snap ring expander, install a new snap ring.
(c) Cover the outboard joint boot.
Pack the outboard joint and boot with grease in the boot kit, and cover the outboard joint with the boot.
Grease capacity: (Color= yellow) 190 - 200 g (6.8 - 7.1 oz.)

(d) Cover the inboard joint boot.
(1) Pack the inboard joint shaft and boot with grease in the boot kit.
Grease capacity: (Color= ocher yellow) 185 - 195 g (6.6 - 7.0 oz.)
(2) Align the matchmarks placed before removal procedure, and install the inboard joint shaft to the outboard joint shaft.
(3) Cover the inboard joint shaft with the boot.
(e) Tighten the boot clamps.

(1) Make sure that the 2 boots are on the shaft groove.
(2) Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.

Drive shaft standard length:

(3) w/ dynamic damper:
Slide the dynamic damper by the distance, as shown in the illustration.
Distance: 155.9 - 159.9 mm (6.14 - 6.30 inch)
(4) Bend the band and tighten the boot clamps (and dynamic damper clamp) with a screwdriver.