Disassembly and Assembly
DISASSEMBLY1. Careful clamp the driveshaft in a vise with soft jaws, then remove the set ring from the inboard joint.
2. Remove the boot bands on the inboard joint and outboard joint.
CAUTION: Take care not to damage the boot.
- If the boot band is a welded type or a low profile type boot band, carefully cut it off with a pair of diagonal cutters.
- If the boot band is a double loop band type, raise the band bend as shown.
- If the boot band is an ear clamp type (for outboard joint on the Canada model, raise the three tabs with a screwdriver.
3. Mark each roller and inboard joint to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel.
NOTE: Be careful not to drop the rollers when separating them from the inboard joint.
4. Mark the rollers and spider to identify the locations of rollers on the spider, then remove the rollers.
5. Remove the circlip.
6. Mark the spider and driveshaft to identify the position of the spider on the shaft.
7. Remove the spider using a bearing remover.
8. Wrap the splines on the driveshaft with vinyl tape to prevent damage to the boots.
9. Remove the inboard boot.
CAUTION: Take care not to damage the boot.
10. Remove the dynamic damper and outboard boot, then remove the vinyl tape.
CAUTION: Take care not to damage the dynamic damper and boot.
11. Inspect the outboard joint for faulty movement and wear. If any roughness or excess play is felt, replace the outboard joint.
REASSEMBLY
NOTE:
- Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent.
- Thoroughly pack the inboard joint and both joint boots with the joints boots with the joint grease included in the new driveshaft set.
Grease quantity:
Inboard Joint
All models: 120 - 130 g (4.2 - 4.6 ounce)
Outboard Joint
USA model: 90 - 100 g (3.2 - 3.5 ounce)
Canada model: 105 - 115 g (3.7 - 4.1 ounce)
- The Canada model uses a Thermoplastic Polyester Elastomer (TPE) outboard joint boot. Use the ear clamp type boot band in the outboard joint boot set.
1. Wrap the splines with vinyl tape to prevent damage to the boots and dynamic damper.
2. Install the outboard boot, dynamic damper and inboard boot to the driveshaft, then remove the vinyl tape.
CAUTION: Take care not to damage the boots and dynamic damper.
3. Pack the outboard joint with the joint grease included in the new driveshaft set.
4. Install the spider on the driveshaft by aligning the marks on the spider and end of the driveshaft.
5. Fit the circlip into the driveshaft groove.
NOTE: Always rotate the circlip in its groove to be sure it is fully seated.
6. Fit the rollers to the spider with their high shoulders facing outward.
Note these items during reassembly:
- Reinstall the rollers in their original positions on the spider by aligning the marks.
- Hold the driveshaft pointed up to prevent the rollers from failing off.
7. Pack the inboard joint with the joint grease included in the new driveshaft set.
8. Fit the inboard joint onto the driveshaft.
NOTE:
- Reinstall the inboard joint onto the driveshaft by aligning the marks on the inboard joint and the rollers.
- Hold the driveshaft so the inboard joint points up to prevent it from falling off.
9. Fit the joint boot ends onto the driveshaft and joints.
When installing the outboard joint boot on a Canada model, be sure the end of the boot is seated in the grooves of the driveshaft and outboard joint.
10. Adjust the length of the driveshafts to the specifications below, then adjust the boots to halfway between full compression and full extension.
NOTE: The ends of boots seat in the groove of the driveshaft and joint.
11. Position the dynamic damper as shown below.
12. Install the boot bands following procedure.
Double Loop Boot Band Installation:
USA models: all bands
Canada model: inboard joint and dynamic damper bands
-1. Set the double loop band onto the boot with the band end toward the front of the vehicle.
-2. Pull up the slack in band by hand.
-3. Make a mark on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip.
-4. Thread the free end of the band through the nose section of the commercially available boot band tool (KD-3191 or equivalent), and into the slot on the winding mandrel.
-5. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot on the band meets the edge of the clip.
-6. Raise up the boot band tool to bend the free end of the band 90 degrees to the clip.
Center punch the clip, then fold over the remaining tail onto the clip.
-7. Unwind the boot banding tool, and cut off the excess free end of the band to leave a 5 - 10 mm (0.2 - 0.4 inch) tail protruding from the clip.
-8. Bend the band end by tapping it down with a hammer.
NOTE:
- Make sure the band does not move.
- Remove any grease remaining in the surrounding surfaces.
Ear Clamp Type Boot Band Installation: Canada model outboard joint bands
-1. Install the ear clamp boot band by aligning the tabs with holes in the band.
-2. Close the ear portion of the band with a commercially available boot band pincers.
-3. Measure the clearance between the closed ear portion of the band.
Standard: 0 - 3 mm (0 - 0.12 inch)
If the band's, clearance is not within the standard, close the ear portion of the band further.
NOTE:
-Make sure the band does not move.
- Remove any grease remaining in the surrounding surfaces.