Disassembly and Reassembly
Disassembly
Special Tools Required
^ Threaded adapter, 24 x 1.5 mm 07XAC-001020A
^ Slide hammer, commercially available
Inboard Joint Side:
1. Remove the boot bands. Take care not to damage the boot.
^ If the boot band is a double loop type (A), lift up the band bend (B), and push it into the clip (C).
^ If the boot band is a low profile type (D), pinch the boot band using a commercially available boot band pincers (E).
2. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.
3. Make a mark (A) on the rollers (B) and spider (C) to identify the locations of rollers on the spider, then remove the rollers.
4. Remove the circlip (D).
5. Make a mark (E) on the spider and driveshaft to identify the position of the spider on the shaft.
6. Remove the spider using a commercially available bearing remover (F).
7. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
8. Remove the inboard boot. Take care not to damage the boot.
9. Remove the vinyl tape.
Outboard Joint Side:
1. Pry up the three tabs (A) with a screwdriver, then lift up the end of the band. Take care not to damage the boot.
2. Slide the outboard boot to the inboard joint side. Take care not to damage the boot.
3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.
4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C).
5. Carefully clamp the driveshaft in a vise.
6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B).
7. Remove the driveshaft from the vise.
8. Remove the stop ring from the driveshaft.
9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
10. Remove the outboard boot and boot band (B). Take care not to damage the boot.
11. Remove the vinyl tape.
Reassembly
Special Tools Required
^ Boot band tool, KD-3191 or equivalent, commercially available
^ Boot band pincers, Kent-Moore J-35910 or equivalent, commercially available
NOTE: Refer to the Exploded View as needed during this procedure.
Inboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.
2. Install the inboard boot to the driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot.
3. Install the spider (A) onto the driveshaft (B) by aligning the marks (C) on the spider and the end of the driveshaft.
4. Fit the circlip (D) 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) as shown, and note these items;
^ Reinstall the rollers in their original positions on the spider by aligning the marks (C).
^ 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 driveshaft set.
Grease quantity
Inboard joint: 150 - 160 grams (5.3 - 5.6 ounces)
7. Fit the inboard joint onto the driveshaft, and note these items:
^ Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the rollers.
^ Hold the driveshaft so the inboard joint points up to prevent it from falling off.
8. Adjust the inboard joint until the rollers are in the middle of the joint.
9. Fit the boot (A) ends onto the driveshaft (B) and the inboard joint (C).
10. Install the boot bands with the band end toward to front of the vehicle.
11. Pull up the slack in the band by hand.
12. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).
13. 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).
14. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.
15. Lift up the boot band tool to bend the free end of the band 90° to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.
16. 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 inch) tail protruding from the clip.
17. Bend the band end (A) by tapping it down with a hammer.
NOTE:
^ Make sure the band and clip do not interfere with anything and the band does not move.
^ Remove any grease remaining on the surrounding surfaces.
Outboard Joint Side:
1. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the outboard boot.
2. Install the new ear clamp band (B) and outboard boot. Take care not to damage the outboard boot.
3. Remove the vinyl tape.
4. Install the new stop ring into the driveshaft groove (A).
5. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.
6. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 inch) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.
7. Check the alignment of the paint mark (A) with the outboard joint end (B).
8. Pack the outboard joint with the joint grease included in the new joint boot set:
Grease quantity
Outboard joint: 119 - 129 grams (4.2 - 4.5 ounces)
9. Adjust the length of the driveshafts to the figure, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.
Left Driveshaft: 579 - 584 mm (22.8 - 23.0 inch)
Right Driveshaft: 624 - 629 mm (24.6 - 24.8 inch)
10. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).
11. Set the new ear clamp band (A) by threading the tab (B) into holes (C) of the band.
12. Close the ear portion (A) of the band with a commercially available boot band pincers Kent-Moore J-35910 or equivalent (B).
13. 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 further.