Constant Velocity Joint Boot: Service and Repair

Rear Drive Shaft:

DISASSEMBLY
1. Check drive shaft, as follows:





a. Check that operation of the joint is smooth within the sliding region in the axial direction.

NOTE: If a large angle is used for the cross-groove type joint, the joint will feel like it is catching, but this does not indicate an abnormality.

b. Check that the boots are not cracked, damage or leaking.
c. Check that there are no scratches on the speed sensor rotor.





2. Remove end cover, as follows:
a. Using a screwdriver, remove the end cover.
b. Use bolts, nuts and washers to keep the inboard joint together.

NOTICE: Tighten the bolt by hand to avoid scratching the flange surface.

3. Remove boot clamps. Using a side cutter or pliers, remove the four boot clamps.
4. Remove inboard joint, as follows:
a. Place matchmarks on the inboard joint and drive shaft.





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





c. Using Special Service Tool (SST) 09726 - 12023 (09726 - 01031) or equivalent, an extension bar and a press, remove the inboard joint from the drive shaft.
d. Mount the inboard joint in a soft jaw vise.





e. Using a screwdriver and hammer, tap out the inboard joint cover from the inboard joint.

NOTICE: Make sure that the cage and inner race are not positioned too much to one side of the outer race.

5. Remove boots. Remove the inboard joint boot and outboard boot.
6. Remove No. 3 dust deflector, as follows:
a. Mount the outboard joint in a soft jaw vise.





b. Using a screwdriver and hammer, remove the No. 3 dust deflector.

NOTICE: Be careful not to damage the Anti-Lock Brake System (ABS) speed sensor rotor.

ASSEMBLY





1. Install new No. 3 dust deflector. Using SST 09309 - 36010, 09502 - 12010 or equivalent, and a press, install a new No. 3 dust deflector.

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

2. Assemble inboard joint. If the joint has come apart, reassemble it in the following order.





a. Align the matchmarks placed before removal.

NOTE: When the matchmarks have disappeared, perform the following procedure.
1) Install the inner race to the cage so that the indented beveled part of the inner race is on the opposite side to the beveled top of the cage.
2) Install the outer race so that the indented side of the outer race is facing the same side as the beveled surface of the cage.





3) Match the narrow projections of the inner race with the wide projections of the outer race.





b. Tilt the cage and inner race to the side and insert the balls one by one.

NOTICE: When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out.

3. Temporarily install new boots and new boot clamps, as follows:





a. Place four new boot clamps to the two new boots, as shown.

NOTE: Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boots.

b. Install the two boots to the drive shaft.
4. Install inboard joint cover, as follows:





a. Apply Formed In Place Gasket (FIPG) to a new inboard joint cover, as shown in the illustration. Install a nozzle that has been cut to 1 mm (0.04 inch) opening.
FIPG: Part No. 08826 - 00801, THREE BOND 1121 or equivalent.

NOTE: Avoid applying an excessive amount to the surface.

b. Remove grease from the surface of the inboard joint facing the cover.





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 it several times.
5. Install inboard joint, as follows:





a. Align the matchmarks placed before removal.
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.
6. Assemble boots to joints. Before assembling the boot, pack with only the same amount of grease that was wiped off.
Grease capacity: 100 - 105 g (0.22 - 0.23 lb., 3.5 - 3.7 oz.).

NOTE Use the grease supplied in the boot kit.

NOTICE:
- Keep grease off the joint connection groove of the boot.
- Pack with grease all over the ball contact surface inside the joint.

7. Install boot clamps to both boots, as follows:
a. Position the clamp onto the boot.





NOTE: Pinch the inboard side of the boot clamp, as shown in the illustration.

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

NOTICE: Do not overtighten the SST.





d. Using SST 09240 - 00020 or equivalent, adjust the clearance of the clamp.
Clearance: 0.8 mm (0.031 inch) or less.





e. The drive shaft is designed to move +/- 20 mm (0.79 inch) from the normal position.
Drive shaft standard length:
Right Side: 598.5 mm (23.563 inch).
Left Side: 553.5 mm (21.791 inch).
8. Install end cover, as follows:
a. Pack grease into a new end cover.
Grease capacity: 50 - 55 g (0.11 - 0.12 lb., 1.8 - 1.9 oz.)
b. Remove grease from the surface of the inboard joint facing the cover.
c. Glue on a new gasket, with the side with adhesive on it facing toward the outer race side of the inboard joint.
d. Align the bolt holes of the cover with those of the inboard joint.
e. Install the six hexagon bolts and washer from the end cover side.
f. Install the six nuts to the boot side.





g. Using a 10 mm hexagon wrench, tighten the bolts. Do this in the order shown, and repeat several times.
h. Check that the claw of the end cover touches the inboard joint.
9. Check drive shaft.