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 BOOT CLAMPS
a. Using a screwdriver, remove the 2 boot clamps.
b. Slide the inboard joint boot toward outboard joint.
3. REMOVE INBOARD JOINT SHAFT





a. Place matchmarks on the outboard joint shaft and inboard joint shaft.

NOTICE: Do not punch the marks.





b. Using a screwdriver, remove the snap ring.
c. Remove the inboard joint shaft from the outboard joint shaft.
4. DISASSEMBLE OUTBOARD JOINT SHAFT





a. Place the matchmarks on the outboard joint shaft, inner race and cage.
b. Remove the 6 balls.
c. Slide the cage toward outboard joint.





d. Using a snap ring expander, remove the snap ring.





e. Using a brass bar and hammer, remove the inner race.

NOTICE: Be careful not to damage the inner race.

f. Remove the cage.
5. REMOVE INBOARD JOINT BOOT
6. REMOVE OUTBOARD JOINT BOOT
a. Using a side cutter or pliers, remove the 2 boot clamps.
b. Remove the outboard joint boot.
7. REMOVE DUST COVER FROM INBOARD JOINT SHAFT
a. LH drive shaft: Using a screwdriver and hammer, remove the dust cover.





b. RH drive shaft: Using SST and a press, remove the dust cover.
SST 09950-00020





8. REMOVE OUTER SNAP RING
Using a snap ring expander, remove the outer snap ring from the inboard joint shaft.
9. REMOVE NO. 2 DUST DEFLECTOR
a. Mount 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 press, install a new No. 2 dust deflector.
SST 09309-36010, 09316-20011
2. INSTALL OUTER SNAP RING
Using a snap ring expander, install a new outer snap ring on the inboard joint shaft.
3. INSTALL DUST COVER
Using a press, install a new dust cover.





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

HINT:
^ Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged.
^ Before installing the boots, place 2 new clamps to outboard joint boot and inboard joint boot.

a. Temporarily install a new outboard joint boot with 2 clamps to the outboard joint shaft.
b. Temporarily install a new inboard joint boot with 2 clamps to the outboard joint shaft.
5. ASSEMBLE OUTBOARD JOINT SHAFT





a. Install the cage to the outboard joint shaft.

NOTICE: The side with smaller diameter must face outboard joint.

b. Align the matchmarks on the inner race and outboard joint shaft.





c. Using a brass bar and hammer, tap in the inner race to the outboard joint shaft.

NOTICE: Be careful not to damage the inner race.





d. Using a snap ring expander, install a new snap ring.





e. Align the matchmarks on the cage and inner race.
f. Install the cage to the inner race.
g. Install the 6 balls.

HINT: Apply grease onto the balls to keep them from failing.





6. INSTALL BOOT TO OUTBOARD JOINT SHAFT
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow) 115 - 135 g (4.1 - 4.8 oz.)
7. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT
a. Before assembling the boot, pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Gray) 95 - 115 g (3.4 - 4.1 oz.)





b. Align the matchmarks on the inboard joint shaft and outboard joint shaft.
c. Install the inboard joint shaft to the outboard joint shaft.





d. Install a new snap ring.
e. Temporarily install the boot to the inboard joint shaft.
8. 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. Place 2 new boot clamps to the inboard joint boot.
d. Using a screwdriver, bend the band and lock the inboard joint boot clamps.
e. Place 2 new boot clamps to the outboard joint boot.





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

NOTICE: Do not overtighten the SST.





h. Using SST, adjust the clearance of the clamp.
SST 09240-00020
Clearance: 1.2 - 4.0 mm (0.047 - 0.157 inch)
9. CHECK DRIVE SHAFT