Disassembly and Assembly
FRONT DRIVE SHAFT DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the inboard and outboard joints.
(b) Check to see that the inboard joint slides smoothly in the thrust direction.
(c) Check to see that there is no significant play in the radial direction of the inboard joint.
(d) Check the boot for damage.
2. DISCONNECT CENTER DRIVE SHAFT OR SIDE GEAR SHAFT
(a) Using a 8 mm hexagon wrench, remove the 6 hexagon bolts and 3 washers.
NOTICE:Do not compress the inboard boot.
(b) Remove the joint end cover gasket from the drive shaft.
(c) Use bolts, nuts and washers to keep the inboard joint together.
NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.
3. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS
(a) Using pliers, draw the hooks together and remove the clamps.
(b) Using a side cutter, cut the small boot clamps and remove them.
4. DISASSEMBLE INBOARD JOINT
(a) Place matchmarks on the inboard joint and drive shaft.
(b) Using a snap ring expander, remove the snap ring.
(c) Using SST, a socket wrench and press, remove the inboard joint from the drive shaft.
SST 09726-10011 (09726-00031)
(d) Remove the bolts, nuts and washers.
(e) Using a screwdriver and hammer, pry around the whole perimeter of the inboard joint cover.
(f) Using a screwdriver, remove the inboard joint from the inboard joint cover.
NOTICE: When lifting the inboard joint, hold onto the inner race and outer race.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
6. LH DRIVE SHAFT:
DISASSEMBLE SIDE GEAR SHAFT
Using a screwdriver, remove the dust cover.
7. RH DRIVE SHAFT:
DISASSEMBLE CENTER DRIVE SHAFT
(a) Using a press, remove the transaxle side dust cover.
(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 a press, remove the bearing.
(e) Remove the snap ring.
FRONT DRIVE SHAFT ASSEMBLY
1. RH DRIVE SHAFT:
ASSEMBLE CENTER DRIVE SHAFT
(a) Place the snap ring to the center drive shaft.
(b) Using a press and extension bar, install a new bearing.
(c) Using a snap ring expander, install a new snap ring.
(d) Using a press, install a new bearing side dust cover.
HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the image.
(e) Using a press, install a new transaxle side dust cover.
2. LH DRIVE SHAFT:
ASSEMBLE SIDE GEAR SHAFT
Using a press, install a new dust cover.
3. TEMPORARILY INSTALL BOOTS AND BOOT CLAMPS TO DRIVE SHAFT
HINT:
^ Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.
^ Place new clamps on the small ends of the boots and install the boots to the drive shaft.
4. ASSEMBLE INBOARD JOINT COVER
(a) Clean contacting surfaces of any FIPG material using a cleaner.
(b) Apply FIPG to the inboard joint cover, as shown in the image.
FIPG:
Part No. 08826-00801,THREE BOND 1121 or equivalent
(c) Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
(d) Use a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times.
(e) 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: Check that the brass bar is touching the inner race, and not the cage.
(c) Using a snap ring expander, install a new snap ring.
NOTICE: Work carefully so that the outer race does not come off.
6. ASSEMBLE BOOT TO OUTBOARD JOINT
Before assembling the boot, pack in grease.
HINT: Use the grease supplied in the boot kit.
Grease capacity 135-155 g (4.8-5.5 oz.)
7. ASSEMBLE INBOARD JOINT BOOT TO INBOARD JOINT
Pack the inboard joint and boot with grease.
HINT: Use the grease supplied in the boot kit.
Grease capacity 142-150 g (5.0-5.3 oz.)
8. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure that the boots are in the shaft groove.
(b) Make sure that the boots are not stretched or contracted when the drive shaft is at standard length.
Drive shaft standard length:
452.4 ± 2.0 mm (17.809 ± 0.079 in.)
(c) Holding the clamp near the closing hooks. using pliers, position the holes in the clamp's free end over the closing hooks.
(d) Secure clamps by drawing the closing hooks together.
(e) Secure the clamp onto the boot.
(f) Place SST onto the clamp. SST 09521-24010
(g) Tighten the 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 (09242-00190)
Clearance:
1.9 mm (0.075 in.) or less
9. PACK CENTER DRIVE SHAFT OR SIDE GEAR SHAFT WITH GREASE
Grease capacity 50-60 g (1.8-2.1 oz.)
HINT: Use the grease supplied in the boot kit.
10. TEMPORARILY CONNECT CENTER DRIVE SHAFT OR SIDE GEAR SHAFT TO DRIVE SHAFT
11. CHECK DRIVE SHAFT