Disassembly and Assembly

DISASSEMBLY





1. CHECK DRIVE SHAFT
a. Check to see that there is no remarkable play in the outboard joint.
b. Check to see that the inboard joint slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.





2. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS
a. Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it.
b. Using a side cutter, cut the small inboard joint boot clamp and remove it.
c. Using a side cutter, cut the 2 outboard joint boot clamps and remove them.





3. REMOVE INBOARD JOINT SHAFT
a. Place matchmarks on the tripod, inboard and outboard joint shafts.

NOTICE: Do not punch the marks.

b. Remove the inboard joint shaft from the outboard joint shaft.





4. REMOVE TRIPOD
a. Using a snap ring expander, remove the snap ring.
b. Place matchmarks on the outboard joint shaft and tripod.

NOTICE: Do not punch the marks.

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

NOTICE: Do not tap the roller.

5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
Slide out the 2 boots.

NOTICE: Do not disassemble the outboard joint.





6. LH drive shaft: REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard joint shaft.
SST 09950-00020
7. RH drive shaft: DISASSEMBLE INBOARD JOINT SHAFT





a. Using a press, remove the transaxle side dust cover from the inboard joint shaft.





b. Using SST and a press, remove the bearing side dust cover.
SST 09950-00020
c. Using a snap ring expander, remove the snap ring.





d. Using SST and a press, remove the bearing.
SST 09950-00020
e. Remove the snap ring.





8. REMOVE NO. 2 DUST DEFLECTOR
a. Mount the outboard joint shaft in a soft jaw vise.
b. Using a screwdriver and hammer, remove the No. 2 dust deflector.

NOTICE: Be careful not to damage the ABS speed sensor rotor.

REASSEMBLY





1. INSTALL NO. 2 DUST DEFLECTOR
Using SST and a press, install a new No. 2 dust deflector.
SST 09309-36010, 09316-20011
2. RH drive shaft: ASSEMBLE INBOARD JOINT SHAFT
a. Install a new snap ring to the inboard joint shaft.





b. Using a steel plate and press, install a new bearing.
c. Using a snap ring expander, install a new snap ring.





d. Using SST, an extension bar and press, install a new bearing side dust cover.
SST 09506-35010

HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration.





e. Using a steel plate and press, install a new transaxle side dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specified value, as shown in the illustration.
Distance: 109.5 - 110.5 mm (4.31 - 4.35 inch)





3. LH drive shaft: INSTALL DUST COVER
Using a press, install a new dust cover.





4. TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS

HINT:
^ Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
^ Before installing the boots, place 3 new clamps to the small boot ends and large boot end (outboard joint side).

5. INSTALL TRIPOD
a. Place the beveled side of the tripod axial spline toward the outboard joint.
b. Align the matchmarks placed before removal.
c. Using a brass bar and hammer, tap in the tripod to the outboard joint shaft.

NOTICE: Do not tap the roller.

d. Using a snap ring expander, install a new snap ring.
6. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity (Color = Gray): 105 - 125 g (3.7 - 4.4 oz.)
7. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT
a. Pack the inboard joint and boot with grease in the boot kit.
Grease capacity (Color = Yellow ocher): 170 - 190 g (6.0 - 6.7 oz.)
b. Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft.
c. Temporarily install the boot to the inboard joint shaft.





8. CHECK DRIVE SHAFT LENGTH
a. Make sure that the 2 boots are on the shaft groove.
b. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.





Drive shaft standard length





9. Large inboard joint boot clamp: INSTALL BOOT CLAMP TO INBOARD JOINT SHAFT BOOT
a. Place the large inboard joint boot clamp.
b. Using pliers, pinch the claws to compress the clamp and engage the other claws.
10. Others: INSTALL BOOT CLAMPS TO BOTH BOOTS
a. Secure the preplaced 3 clamps onto the boots.





b. Place SST onto the clamp.
SST 09521-24010
c. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.





d. Using SST, adjust the clearance of the clamp.
SST 09240-00020
Clearance:
A: 1.9 mm (0.075 inch) or less
B: 1.5 - 2.5 mm (0.059 - 0.098 inch)
C: 3.0 - 4.0mm (0.118 - 0.157 inch)
11. CHECK DRIVE SHAFT