Front Driveshaft Reassembly

Front Driveshaft Reassembly

Exploded View





Special Tools Required

- Boot Band Tool KD-3191 or equivalent, commercially available
- Boot Band Clamp Tool Kent-Moore J-35910 or equivalent, commercially available
- Boot Band Pliers, commercially available

NOTE: Refer to the Exploded View, as needed, during this procedure.

Inboard Joint Side

1. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the inboard boot.

Double loop type/Low profile type





Locking tab type





2. Install a new locking tab type band (B) and the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.

3. Install the spider (A) onto the driveshaft by aligning the marks (B) you made on the spider and the end of the driveshaft.





4. Install a new circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to make sure it is fully seated.

5. Fit the rollers (A) onto the spider (B) and note these items:

- Reinstall the rollers in their original positions on the spider by aligning the marks (C) you made.
- Hold the driveshaft pointed up to prevent the rollers from falling off.





6. Pack the inboard joint with the joint grease included in the new inboard boot set.

Grease quantity










7. Fit the inboard joint onto the driveshaft, and note these items:

- Reinstall the inboard joint onto the driveshaft by aligning the marks (A) you made on the inboard joint and the rollers.
- Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.





8. Fit the boot ends (A) onto driveshaft (B) and the inboard joint (C).






9. Adjust the length (A) of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension. Bleed excess air from the boots by inserting a flat-tipped screwdriver between the boot and the joint.






10. Install new boot bands.

- For the double loop type, go to step 11.
- For the low profile type, go to step 20.
- For the locking tab type, go to step 23.

11. Fit the boot ends onto the driveshaft and the inboard joint, then install a new double loop band (A) onto the boot (B).

NOTE: Pass the end of the new double loop band through the clip (C) twice in the direction of the forward rotation of the driveshaft.





12. Pull up the slack in the band by hand.

13. Mark a line (A) on the band 10-14 mm (0.4-0.6 in) from the clip (B).






14. Thread the free end of the band through the nose section of the commercially available boot band tool (KD-3191 or equivalent) (A), and into the slot on the winding mandrel (B).





15. Using a wrench on the winding mandrel of the boot band tool, tighten the band until the marked line (C) on the band meets the edge of the clip.

16. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.






17. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5-10 mm (0.2-0.4 in) tail protruding from the clip.






18. Bend the band end (A) by tapping it down using a hammer.

NOTE:

- Make sure the band and the clip do not interfere with anything on the vehicle and the band does not move.
- Clean any grease remaining on the surrounding surfaces.





19. Repeat steps 11 through 18 for the band on the other end of the boot.

20. Install a new low profile band (A) onto the boot (B), then hook the tab (C) of the band.






21. Close the hook portion of the band using commercially available boot band pliers (A), then hook the tabs (B) of the band.





22. Repeat steps 20 and 21 for the band on the other end of the boot.

23. Install a new locking tab type boot band (A) on the inboard joint side of the inboard boot. Fold down the locking tabs.





24. Lightly tap on the doubled-over portions to flatten them.

25. Install the boot band on the other end of the boot, and repeat steps 23 and 24.

Outboard Joint Side

1. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the outboard boot.

Ear clamp type





Locking tab type





2. Install new bands (B) and the outboard boot on to the driveshaft, then remove the vinyl tape. Be careful not to damage the outboard boot.

3. Make sure to check the size of a new stop ring.

NOTICE
To avoid driveshaft and vehicle damage, make sure you install a new stop ring.










4. Install the stop ring (A) into the driveshaft groove (B).






5. Pack about 35 g (1.2 oz) of grease included in the new outboard boot set into the driveshaft hole in the outboard joint.

NOTE: If you are installing a new outboard joint, the grease is already installed.






6. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.






7. To completely seat the outboard joint, pick up the driveshaft and joint, and tap or hit the assembly onto a hard surface from a height of about 10 cm (4 in).

NOTE: Do not use a hammer, as excessive force may damage the driveshaft. Be careful not to damage the threaded section (A) of the outboard joint.






8. Check the alignment of the paint mark (A) you made with the outboard joint end (B).

NOTICE
To avoid driveshaft and vehicle damage, the shaft must be all the way into the outboard joint to ensure the stop ring is properly seated.






9. Pack the outboard joint (A) with the remaining joint grease included in the new outboard boot set.










10. Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C). Bleed any excess air from the boot by inserting a flat-tipped screwdriver between the boot and the joint.






11. Inspect the length (A) of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension.





12. Install new boot bands.

- For the ear clamp type, go to step 13.
- For the locking tab type, go to step 16.

13. Close the ear portion (A) of the band using commercially available boot band clamp tool (Kent-Moore J-35910 or equivalent) (B).






14. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band tighter.





15. Repeat steps 13 and 14 for the band on the other end of the boot.

16. Install a new locking tab type boot band (A) on the inboard joint side of the inboard boot. Fold down the locking tabs.





17. Lightly tap on the doubled-over portions to flatten them.

18. Repeat steps 16 and 17 for the band on the other end of the boot.