Constant Velocity Joint Boot: Service and Repair

Rear Drive Shaft / Inboard-Outboard Joints:

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, damaged 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 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, remove the inboard joint cover from the inboard joint.

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

5. Remove boots from drive shaft. Remove the inboard joint boot and outboard boot.

ASSEMBLY
1. 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, do the following procedure.

1. Install the inner race to the cage so that the indented bevelled part of the inner race is on the opposite side to the bevelled 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 bevelled 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.





2. Temporarily install new boots and new boot clamps, as follows:
a. Place four new boot clamps to boots.

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

b. Install two boots to the drive shaft.

3. Install inboard joint cover, as follows:





a. Apply Formed In Place Gasket (FIPG) to the inboard joint cover as shown in the illustration.

FIPG: Part No. 08826 - 00801, THREE BOND 1121 or equivalent.
- Install a nozzle that is cut to 1 mm (0.04 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

b. Clean 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-faced hammer to tap the rim of the inboard joint cover in place. Do this in the order shown, and repeat several times.

4. Install inboard joint, as follows:





a. Align the matchmarks placed before removal.
b. Using a brass bar and a hammer, install 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.





5. Assemble boots to joints. Before assembling the boot, pack with only the same amount of grease that was wiped off.

Grease capacities:
Outer joint: 100 - 105 g (3.5 - 3.7 oz.).
Inner joint: 100 - 105 g (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.

6. Install new boot clamps to both of the 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 Special Service Tool (SST) 09521 - 24010 or equivalent, onto the clamp.
c. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the clamp by 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 from the standard position.

Drive shaft standard length:
Right hand side (AT,MT): 598.5 mm (23.602 inch).
Left Side:
MT: 547.5 mm (21.555 inch).
AT: 553.5 mm (21.791 inch).

7. Install new end cover, as follows:
a. Pack grease into the end cover.

Grease capacity: 50 - 55 g (1.8 - 1.9 oz.).

b. Clean 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 two washers to 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.

8. Check drive shaft.