Front Drive Shaft Assembly

ASSEMBLY OF DRIVE SHAFT





1. INSTALL OUTBOARD JOINT BOOT AND NEW BOOT CLAMP

HINT: Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot. Temporarily install the boot and a new clamp to the outboard joint.





2. ASSEMBLE BOOT TO OUTBOARD JOINT

Before assembling the boot, pack in grease.

HINT: Use the grease supplied in the boot kit.

Grease capacity: 120-130 g(0.26-0.29 lb)





3. INSTALL NEW BOOT CLAMPS AND INBOARD JOINT BOOT
Temporarily install the two new boot clamps and inboard joint.





4. ASSEMBLE NEW INBOARD JOINT COVER
(a) Apply seal packing to the inboard joint cover as shown in the image.

Seal packing: Part No.08826-00801, THREE BOND 1121 or equivalent

HINT: Avoid applying an excess amount to the surface.





(b) Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.

(c) Using a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times.





(d) Use bolts, nuts and washers to keep the inboard joint together.

NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.





5. ASSEMBLE INBOARD JOINT
(a) Align the matchmarks placed before disassembly.

(b) Using a brass bar and hammer, tap the inboard joint onto the drive shaft

NOTICE: Make sure that the brass bar is touching the inner race, and not the cage.

(c) Remove the bolts, nuts and washers.





(d) Using snap ring pliers, install a new snap ring.

NOTICE: Work carefully not to come off the outer race.





6. ASSEMBLE INBOARD JOINT BOOT TO INBOARD JOINT
Pack in grease to the inboard tulip and boot.

HINT: Use the grease supplied in the boot kit.

Grease capacity: 90 - 100 g (0.20-0.22 lb)





7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Be sure the boot is on the shaft groove.

(b) Insure that the boot is not stretched or contracted when the drive shaft is at standard length.

Drive shaft length: 406 mm (15.98 in.)





(c) Bend the band and lock it as shown.





8. CHECK DRIVE SHAFT

(a) Check to see that there is no play in the inboard joint and outboard joint

(b) Check to see that the inboard joint slides smoothly in the thrust direction.