Disassembly and Assembly

Disassembly
Inboard Joint Side





1. Remove the set ring from the inboard joint.
2. Remove the boot bands. Take care not to damage the boot and dynamic damper.
- If the boot band is a welded type, cut the boot band.
- If the boot band is a double loop type, lift up the band bend.

Welded Type:

Double Loop Type:

3. Make a mark on 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. Be careful not to drop the rollers when separating them from the inboard joint.
4. Make a mark on 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 commercially available bearing remover.
8. Wrap the splines on the driveshaft with vinyl tape to prevent damage to the inboard boot and dynamic damper.
9. Remove the inboard boot and dynamic damper. Take care not to damage the boot and dynamic damper.





10. Remove the vinyl tape.

Outboard Joint Side:





1. Lift up the three tabs with a screwdriver, then remove the boot bands. Take care not to damage the boot and dynamic damper.





2. Slide the outboard boot to the inboard joint side. Take care not to damage the boot.
3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.





4. Make a mark on the driveshaft at the same position of the outboard joint end with paint.
5. Carefully clamp the driveshaft in a vise.





6. Remove the outboard joint using the special tools.
7. Remove the driveshaft from the vise.





8. Remove the stop ring from the driveshaft.
9. Wrap the splines on the driveshaft with vinyl tape to prevent damage to the outboard boot.
10. Remove the outboard boot. Take care not to damage the boot.





11. Remove the vinyl tape.

Reassembly
Note these items during reassembly:
- Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent.
- Thoroughly pack both joints and both joint boots with the joint grease included in the new driveshaft set.
- The joint uses a Thermoplastic Polyester Elastomer (TPE) outboard joint boot. Use the ear clamp type boot band in the outboard joint boot set.

Inboard Joint Side:
1. Wrap the splines with vinyl tape to prevent damage to the inboard boot and dynamic damper.





2. Install the dynamic damper and inboard boot to the driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot and dynamic damper.
3. Install the spider onto the driveshaft by aligning the marks on the spider and end of the driveshaft.





4. Fit the circlip into the driveshaft groove. Always rotate the circlip in its groove to be sure it is fully seated.





5. Fit the rollers to the spider with their high shoulders facing outward, and note these items:
- Reinstall the rollers in their original positions on the spider by aligning the marks.
- Hold the driveshaft pointed up to prevent the rollers from falling off.





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





7. Fit the inboard joint onto the driveshaft, and note these items:
- 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 failing off.





8. 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.





9. Position the dynamic damper as shown.





10. Fit the boot ends onto the driveshaft and the inboard joint, then install the boot bands with the band end toward the front of the vehicle.
11. Pull up the slack in the band by hand.





12. Mark a position on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip.
13. 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.





14. 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.





15. Lift up the boot band tool to bend the free end of the band 90° 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 free end of the band to leave a 5 - 10 mm (0.2 - 0.5 inch) tail protruding from the clip.





17. Bend the band end 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 new set ring.

Outboard Joint Side:
1. Wrap the splines with vinyl tape to prevent damage to the outboard boot.
2. Install the outboard boot. Take care not to damage the outboard boot.





3. Remove the vinyl tape.





4. Install the new stop ring into the driveshaft groove.





5. Insert the driveshaft into the outboard joint until the stop ring is close on the joint.





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





7. Check the alignment of the paint mark with the outboard joint end.





8. Pack the outboard joint with the joint grease included in the new joint boot set.





9. Fit the boot ends onto the driveshaft and outboard joint.





10. Set the new ear clamp band by threading the tabs into holes of the band.





11. Close the ear portion of the band with a commercially available boot band pincers.





12. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band further.