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
Using a screwdriver, remove the 4 boot clamps.





3. REMOVE INBOARD JOINT TULIP
a. Place matchmarks on the inboard joint tulip and outboard joint shaft.

NOTICE: Do not punch the marks.

b. Remove the inboard joint tulip 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 AND CLAMPS
Slide out the 2 boots and 4 clamps.

NOTICE: Do not disassemble the outboard joint.





6. 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 NEW NO. 2 DUST DEFLECTOR
Using SST and a press, install a new No. 2 dust deflector.
SST 09309-36010, 09316-20011

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





2. TEMPORARILY INSTALL NEW OUTBOARD AND INBOARD JOINT BOOTS AND 4 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.

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 INBOARD JOINT TULIP
a. Pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow) 180 - 190 g (6.35 - 6.70 oz.)
b. Align the matchmarks placed before removal, and install the inboard joint tulip to the outboard joint shaft.





5. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
a. Before assembling the boots, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Gray) 107 - 117 g (3.77 - 4.13 oz.)
b. Make sure that the 2 boots are on the shaft groove.
c. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
Standard length: 607.7 ± 5.0 mm (23.93 ± 0.20 inch)
d. Place 4 new boot clamps to the 2 boots.
e. Bend the band and lock it with a screwdriver.