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 JOINT SHAFT
a. Using a screwdriver, disclamp the 2 inboard joint boot clamps.
b. Slide the inboard joint boot toward the outboard joint.
c. Place matchmarks on the inboard joint shaft and tripod.

NOTICE: Do not punch the marks.

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





3. 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, tap out the tripod from the outboard joint shaft.

NOTICE: Do not tap the roller.

4. REMOVE INBOARD JOINT BOOT AND 2 CLAMPS
5. RH drive shaft: REMOVE DYNAMIC DAMPER
a. Using a screwdriver, remove the dynamic damper clamp.
b. Remove the dynamic damper.
6. REMOVE OUTBOARD JOINT BOOT
a. Using a side cutter, cut the 2 outboard joint boot clamps and remove them.
b. Remove the outboard joint boot from the outboard joint shaft.

NOTICE: Do not disassemble the outboard joint.





7. REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard joint shaft.
SST 09950-00020

REASSEMBLY





1. INSTALL DUST COVER
Using a press, install a new dust cover to the inboard joint shaft.





2. TEMPORARILY INSTALL BOOTS, CLAMPS AND DYNAMIC DAMPER (RH DRIVE SHAFT)

HINT: Before installing the boots (and dynamic damper), wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged.

a. Place 2 new clamps on a new outboard joint boot and install them to the outboard joint shaft.
b. RH drive shaft: Place a new clamp on the dynamic damper and install them to the outboard joint shaft.
c. Place 2 new clamps on a new inboard joint boot and install them to the outboard joint shaft.
3. 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.
4. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Black) 155 - 170 g (5.5 - 6.0 oz.)
5. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT
Pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow ocher) 125 - 135 g (4.4 - 4.8 oz.)
b. Align the matchmarks placed before removal.
c. Install the inboard joint shaft to the outboard joint shaft.
d. Temporarily install the boot to the inboard joint shaft.
6. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
a. Make sure that the 2 boots are on the shaft grooves.





b. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.





Drive shaft standard length

c. Bend the band and lock the inboard joint boot clamps with a screwdriver.
d. Secure the 2 outboard joint boot clamps onto the boot.





e. Place SST onto the outboard joint large boot clamp.
SST 09521-24010
f. Tighten the SST so that the large clamp is pinched.

NOTICE: Do not overtighten the SST.





g. Using SST, adjust the clearance of the large clamp.
SST 0924-00020
Clearance: 0.8 mm (0.031 inch) or less
h. Employ the same manner to the outboard joint small boot clamp.





7. RH drive shaft: ASSEMBLE DYNAMIC DAMPER CLAMP
a. Set the distance, as described.
Distance: 427.6 ± 2.0 mm (16.835 ± 0.079 inch)
b. Bend the band and lock the dynamic damper clamp with a screwdriver.
8. CHECK DRIVE SHAFT