Inboard Constant Velocity Joint and Boot
Except 5 Speed Manual Transaxle Inboard Constant Velocity Joint & BootHalfshaft Assemblies:
Fig. 6 Separating Constant Velocity Joint From Shaft:
1. Place halfshaft in suitable vise. Use caution not to damage boot or clamp.
2. Cut large boot clamp and remove from boot, Fig. 5, then position boot upward on shaft. If boot only is being replaced due to damage, check joint grease for contamination. If joints were operating satisfactorily and grease is not contaminated, add grease and install new boot. If grease is contaminated, joint must be completely disassembled.
3. Place interconnecting shaft in a suitable vise and angle constant velocity joint so that inner bearing race is exposed, Fig. 6.
4. Using suitable drift and hammer, tap inner bearing race to dislodge internal circlip and separate constant velocity joint from interconnecting shaft, being careful not to drop joint.
5. Remove boot from shaft, cutting remaining clamp as necessary.
6. Remove circlip from end of shaft and discard. Inspect stop ring for damage and replace as necessary.
Inboard Constant Velocity Joint & Boot, 5 Speed Manual Transaxle
1. Remove large boot clamp, roll boot back, and wipe away excess grease.
2. Remove wire ring bearing retainer from outer race, then remove outer race.
3. Pull inner race and bearing assembly out until it rests on circlip, then, using suitable pliers, spread stop ring and move it back on shaft.
4. Slide inner race and bearing assembly down shaft to expose circlip, then remove circlip.
5. Remove inner race and bearing assembly and, if necessary, remove boot.
INSTALLATION
Joints Except 5 Speed Manual Transmission Inboard Constant Velocity Joint & Boot
1. Install new stop ring, if removed. Ensure that stop ring is properly seated in groove.
2. Install new circlip in groove nearest end of shaft. To avoid over-expansion or twisting of circlip, start one end in groove and work circlip over stub shaft end and into groove. Interconnecting shafts are different depending on application. These shafts are non-symmetrical. Outboard end is approximately 1/4 inch longer, from end of shaft to end of boot groove, than inboard end. Be careful to install inboard and outboard constant velocity joints to proper ends of shaft.
3. Install constant velocity joint boot, if removed, ensuring that boot is seated in groove. Tighten clamp securely, but not too tight.
4. Before positioning boot over constant velocity joint, pack joint and boot as follows:
a. On inboard constant velocity joint, fill boot with 45 grams of grease and pack joint with 90 grams of grease.
b. On outboard constant velocity joint, fill boot with 45 grams of grease and pack joint with 45 grams of grease. Use only lubricant E2FZ-19590-A or equivalent.
5. Position boot upward toward end of shaft, then position constant velocity joint onto shaft and tap into position using plastic mallet. Joint is fully seated when circlip locks in groove cut into joint bearing inner race. Check for proper seating by trying to pull joint from shaft.
Fig. 7 Halfshaft Assembled Lengths:
6. Remove all excess grease from external surfaces of constant velocity joint, then position boot over constant velocity joint and move joint in or out to adjust to proper length, Fig. 7.
7. Before installing boot clamp, insert dulled screwdriver blade between boot and outer bearing race to allow trapped air to escape.
8. Ensure that boot is seated in groove, then install clamp securely but not too tight.
Inboard Constant Velocity Joint & Boot, 5 Speed Manual Transmission
Fig. 8 Interconnecting Shaft. 1989-90:
Fig. 9 Interconnecting Shaft.:
1. Move circlip and stop ring back into their respective grooves on shaft. Lefthand interconnecting shaft is symmetrical and inboard and outboard constant velocity joints may be installed on either end. Righthand interconnecting shaft is non-symmetrical and care must be taken so that inboard and outboard constant velocity joints are correctly installed, Fig. 8 and 9.
2. Install constant velocity joint boot, if removed. Ensure that boot is seated in groove, then install clamp securely but not too tight.
3. Install new circlip in groove nearest end of shaft. To avoid over-expansion or twisting of circlip, start one end in groove and work circlip over stub shaft end and into groove.
4. Fill boot with 45 grams of grease and fill outer race with 90 grams of grease. Use only lubricant E2FZ-19590-A or equivalent.
5. Push inner race and bearing assembly into outer race by hand.
6. Install ball retainer into groove inside outer race.
7. With boot positioned upward toward end of shaft, install constant velocity joint using suitable hammer. Ensure that splines are aligned before hammering constant velocity joint onto shaft.
8. Remove all excess grease from external surfaces of constant velocity joint, then position boot over constant velocity joint and move joint in or out to adjust to proper length, Fig. 7.
9. Before installing boot clamp, insert dulled screwdriver blade between boot and outer bearing race to allow trapped air to escape.
10. Ensure that boot is seated in groove, then install clamp securely but not too tight.