Overhaul

DISASSEMBLY





1. Check drive shaft.
a. Check to see that there is no play in the outboard joint shaft.
b. Check to see that the inboard joint shaft slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint shaft.
d. Check for damage to boots.
2. Remove inboard and outboard joint boot clamps.
a. Using pliers, draw the hook together and remove the large inboard joint boot clamp and remove them.
b. Using a side cutter, cut the small inboard and 2 outboard joint boot clamps and remove them.





3. Remove inboard joint shaft from outboard joint shaft.
a. Place matchmarks on the inboard and outboard joint shafts.

NOTICE: Do not punch the marks.

b. Using a snap ring expander, pull out the outboard joint shaft expanding the snap ring.
4. Remove inboard and outboard joint boots.
Slide out the 2 boots.
5. Remove dust cover:

LH Drive Shaft - Using a screwdriver and hammer, remove the dust cover from the inboard joint shaft.





RH Drive Shaft - Using a press, remove the dust cover from the inboard joint shaft.





6. Disassemble inboard joint shaft (RH Drive Shaft).
a. Using Special Service Tool (SST) 09950 - 00020 and a press, remove the dust cover.
b. Using a snap ring expander, remove the snap ring.
c. Using a press, remove the bearing.
d. Remove the snap ring.





7. Remove No.2 dust deflector.
a. Mount outboard joint shaft 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 09309 - 36010, 09316 - 20011 and a press install the No.2 dust deflector.
2. Assemble inboard joint shaft (RH Drive Shaft).
a. Install a new snap ring to the inboard joint shaft.





b. Using SST 09223 - 56010 and a press, install a new bearing.
c. Using a snap ring expander, install a new snap ring.





d. Using SST 09223 - 56010 and a press, install a new dust cover.
3. Install dust cover.





LH Drive Shaft - Using SST 09223 - 56010, 09555 - 55010 and a press, install a dust cover.





RH Drive Shaft - Using SST 09223 - 56010 and a press, install a new dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specification, as shown in the illustration.






4. Temporarily install outboard and in board joint boots and new boot clamps.

HINT:
- Before installing the boot, wrap vinyl tape around the spline of the drive shaft to prevent damaging the boot.
- Before installing the boot, place 3 new clamps to the small boot ends and large end (wheel side) and install its to drive shaft.





5. Install inboard joint shaft to outboard joint shaft.
Align the matchmarks placed at removal, and using a snap ring expander, put in the inboard joint shaft expanding the snap ring.
6. Install boot to outboard joint
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: 105-125 g (3.7-4.4 oz.)
7. Install boot to outboard joint shaft.
a. Pack the inboard joint and boot with grease in the boot kit.
Grease capacity:
Joint side: 120-130 g (4.2-4.6 oz.)
Boot side: 52.5-57.5 g (1.9-2.0 oz.)
b. Install the boot to the inboard joint shaft.
8. Assemble boot clamps to both boots.
a. Make sure that the 2 boots are the shaft groove.





b. Make sure that the 2 boots are not stretched contracted when the drive shaft is at standard length.
Drive Shaft Standard Length:
LH 586.0 ± 2.0 mm (23.071 ± 0.079 inch)
RH 881.6 ± 2.0 mm (34.709 ± 0.079 inch)
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 clamp by drawing the closing hooks together.
e. Secure the clamp onto the boot.





f. Place SST 09521 - 24010 onto the clamp.
g. Tighten the SST so that the clamp is pinched.

CAUTION: Do not overtighten the SST.





h. Using SST 09240-00020, adjust the clearance of the clamp.
Clearance:
A: 1.9 mm (0.075 inch) or less.
B: 1.5-2.5 mm (0.059-0.098 inch)
C: 3.0-4.0 mm (0.118-0.157 inch)
9. Check drive shaft as outlined in step 1 of "DISASSEMBLY".