Disassembly and Assembly

DISASSEMBLY





1. CHECK DRIVE SHAFT
a. Check to see that the joints slide smoothly in the axial direction.
If a large angle is applied for the cross-groove type joint, the joint will be felt like it is catching, but this does not indicate an abnormality.
b. Check the boots for damage or crack.
c. Check the ABS speed sensor rotor for damage.





2. REMOVE END COVER
a. Using a screwdriver, remove the end cover.
b. Using bolts, nuts and washers, keep the inboard joint assembly not to take apart.

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

3. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS
Using a side cutter, cut the boot clamps and remove them.
4. REMOVE INBOARD JOINT





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

NOTICE: Do not punch the marks.

b. Using a snap ring expander, remove the snap ring.
c. Slide the inboard joint boot toward the outboard joint.





d. Using SST, an extension bar and press, remove the inboard joint from the outboard joint shaft.
SST 09726-12023 (09726-01031)
e. Remove the bolts, nuts and washers.





f. Clamp the inboard joint in a soft jaw vise.
g. Using a screwdriver and hammer, pry around the whole perimeter of the inboard joint cover and remove the inboard joint.

NOTICE: To prevent the balls from falling, remove the inboard joint by holding the inner and outer races.

5. REMOVE BOOTS
Remove the inboard and outboard joint boots.





6. REMOVE NO. 2 DUST DEFLECTOR
a. Clamp the outboard joint 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 a press, install a new No. 2 dust deflector.
SST 09309-36010, 09502-12010

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.





If the matchmarks have disappeared, do the following procedure.
1 Install the inner race to the cage.
2 Install the outer race so that the wide indented part is at the same side as the indented part of the inner race.

HINT: The cage does not have the specified attachment direction.

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 BOOTS AND BOOT CLAMPS
a. Place 4 new boot clamps to each new boot.

HINT: Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent boots from being damaged.

b. Install the 2 boots with clamps to the drive shaft.
4. INSTALL INBOARD JOINT COVER





a. Remove any packing material on the inboard joint.
b. Apply FIPG to a new inboard joint cover as shown in the illustration.

HINT:
^ Use FIPG supplied with a new end cover.
^ Do not apply too much.

c. Remove grease from the surface of the inboard joint facing to the cover.
d. Align the bolt holes in the cover with those of the inboard joint, then insert the hexagon bolts.





e. Using a plastic hammer, tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times.





5. INSTALL INBOARD JOINT
a. Align the matchmarks placed before removal.
b. Using a brass bar and hammer, install the inboard joint to outboard joint shaft.

NOTICE: Check that the brass bar is not touching the cage, but inner race.

c. Using a snap ring expander, install a new snap ring.
6. ASSEMBLE BOOTS TO JOINTS
Before assembling the boots, pack with only the same amount of grease that was wiped off.





Grease capacity:

HINT: 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. CHECK DRIVE SHAFT STANDARD LENGTH





Drive shaft standard length:

HINT: The drive shaft is designed to move ±20 mm (0.79 inch) from the normal position.

8. INSTALL NEW BOOT CLAMPS TO BOTH BOOTS





a. Place SST onto the inboard joint large boot clamp.
SST 09521-24010
b. Tighten SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.





c. Using SST, adjust the clearance of the clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less
d. Employ the same manner to the other clamps.





9. INSTALL END COVER
a. Remove grease from the surface of the inboard joint facing to the cover.
b. Apply FIPG supplied with a new end cover.
c. Align the bolt holes in the cover with those of the inboard joint.
d. Install the 6 hexagon bolts and 3 washers from the end cover side.
e. Install 6 nuts to the boot side.
f. Using a 8 mm hexagon wrench, tighten the bolts. Do this in the order shown, and repeat several times.
g. Check that the claw of the end cover touches the inboard joint.
10. CHECK DRIVE SHAFT