Disassembly and Reassembly

FRONT DRIVESHAFT (G.I - A.C TYPE)






DISASSEMBLY

NOTE:
^ Do not disassemble the tripod assembly.
^ Special grease must be applied to the driveshaft joint.
^ The boot clamp should be replaced with a new one.
^ The boot should be replaced with a new one.

1. Using a side cutter, cut the G.I. and A.C. big clamps and remove them.
2. Using a brass bar and hammer, remove the G.I. and A.C. small clamps.
3. Place matchmarks on the tripod and tulip.

NOTE: Do not punch the mark.





4. Remove the tulip assembly from the driveshaft.





5. Using a snap ring expander, remove the snap ring.
6. Place matchmarks on the tripod and joint shaft.





7. Using a brass bar and hammer, remove the tripod from the joint shaft.





8. Remove the A.C boot clamps and pullout the G.I. boot and A.C. boot.

INSPECTION AFTER DISASSEMBLY
1. Check the driveshaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into A.C.
3. Check the tripod assembly for roller rotation, wear or corrosion.





4. Check the groove inside tulip for wear or corrosion.

REASSEMBLY
1. Wrap tape around the driveshaft splines (G.I. side) to prevent damage to the boots as they are installed.





2. Place new clamps in the small boot ends and then install the boots on to the driveshaft.
3. After aligning the matchmark, place the beveled side of the tripod axial spline toward the A.C. joint.





4. Using a 19 mm socket and hammer, tap the tripod of the driveshaft.
5. Install a new snap ring.
6. Add the specified grease to the A.C. joint and boot as much as was wiped away at inspection.





7. Apply the specified grease to the G.I. joint and boot.
8. Align the matchmarks and install the G.I. joint to the shaft.
9. Install the boots.

NOTE:
^ Make sure that 2 boots are on the shaft groove.
^ Make sure that the 2 boots are not stretched.





10. Position the holes in the clamp's free end to the closing hooks.





11. Using pliers, secure the clamps.
Clearance (A):
A.C. big clamp: 2.0 mm (0.079 inch) or less
A.C. small clamp: 1.8 mm (0.071 inch) or less





12. To control the volume of air in the G.I. boot, keep the specified distance between the boot clamps when they are tightened.
Standard value (A, B)
3.5L A/T
LH side: 517.8 ± 2 mm (20.4 ± 0.08 inch)
RH side: 533.6 ± 2 mm (21.01 ± 0.08 inch)
13. Holding the G.I. big clamp near the closing hook, using long nose plier, position the hole in the clamps free end on the closing hook.





14. Secure the clamp by drawing the closing hooks together.
15. Using pliers, secure the G.I. small clamp.
Clearance (A):
G.I. small clamp: 1.6 mm (0.063 inch) or less