Reassembly

Reassembly

Special Tools Required
- Boot band tool, KD-3191 or equivalent, commercially available
- Boot band pincers, Kent-Moore J-35910 or equivalent, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.

Inboard Joint Side:





1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot (B).
2. Install the inboard boot to the driveshaft (C), then remove the vinyl tape.





3. Install the steel bail (A) and the bearing retainer (B) onto the bearing race (C) by aligning the marks (D) on the bearing retainer and the bearing race.
4. Install the bearing onto the driveshaft (E) by aligning the marks (D) on the bearing and the driveshaft.
5. Install the snap ring (F).





6. Pack the inboard joint with the joint grease included in the new driveshaft set.
Grease quantity





7. Install the inboard joint (A) onto the driveshaft (B) by aligning the marks (C) on the inboard joint and driveshaft.
8. Install the circlip (D).





9. Adjust the length of the driveshafts to the figure, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.






10. Fit the boot ends onto the driveshaft and the inboard joint, then install the boot band.
11. Pull up the slack in the band by hand.





12. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).





13. Thread the free end of the band through the nose section of a commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
14. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.





15. Lift up the boot band tool to bend the free end of the band 900 to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.





16. Unwind the boot band tool, and cut off the excess 5 - 10 mm (0.2 - 0.4 inch) from the clip.





17. Bend the band end (A) by tapping it down with a hammer.

NOTE:
- Make sure the band and clip do not interfere with anything, and the band does not move.
- Remove any grease remaining on the surrounding surfaces.

18. Install the boot band on the other end of the boot, and repeat steps 11 through 17.

Outboard Joint Side:





1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot (B).
2. Install the new locking tab type boot band (C) and the outboard boot on the driveshaft (D), then remove the vinyl tape.





3. Install the new circlip (A) into the driveshaft groove (B).





4. Insert the driveshaft (A) into the outboard joint (B) until the circlip (C) is close on the joint.





5. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 inches) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.





6. Check the alignment of the paint mark (A) with the outboard joint end (B).





7. Pack the outboard joint (A) with the joint grease included in the new joint boot set.
Grease quantity





8. Install a new locking tab type boot band on the outboard joint side of the outboard boot. Fold down the locking tabs.
9. Lightly tap on the double-over portions to reduce their height.
10. Install a double loop type boot band on the front driveshaft side of inboard boot.