Driveshaft Reassembly

Reassembly





'01 model





'02-03 models

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.
2. Install the new inboard boot on the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.





3. Install the spider (A) on the driveshaft by aligning the marks (B) on the spider and end of the driveshaft.
4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to make sure it is fully seated.





5. Fit the rollers (A or B) onto the spider (C) with their high shoulders facing outward, and note these items:
- Reinstall the rollers in their original positions on the spider by aligning the marks (D).
- Hold the driveshaft pointed up to prevent the rollers from falling off.
- Roller (A) is used on '02-03 models.
- Roller (B) is used on '01 model.





6. Pack the inboard joint with the joint grease included in the new driveshaft set.
Grease quantity
Inboard joint:
120 - 130 g (4.2 - 4.6 oz.) ('01 model)
150 - 160 g (5.3 - 5.6 oz.) ('02-03 models)





7. Fit the inboard joint onto the driveshaft, and note these items:
- Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the rollers.
- Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.
8. Install the boot bands.
- For the double loop type, go to step 11. (Boot band replacement only)
- For the low profile type, go to step 9.





9. Install the new low profile band (A) onto the boot (B) and dynamic damper, then hook the tab (C) of the band.





10. Close the hook portion of the band with a commercially available boot band pincers (A), then hook the tabs (B) of the band.





11. Fit the boot ends onto the driveshaft and the inboard joint, then install the new double loop band (A) onto the boot.
12. Pull up the slack in the band by hand.





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





14. 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).
15. 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.





16. Lift 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.





17. Unwind the boot band 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.





18. 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

19. Repeat steps 11 through 18 for the band on the other end of the boot.





20. Install the new set ring.

Outboard Joint Side:





1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.
2. Install the new ear clamp bands (B) and new outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.





3. Seat the new stop ring into the driveshaft groove (A).





4. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.





5. 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. Be careful not to damage the threaded section (A) of the outboard joint.





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
Outboard joint: 140 - 150 g (4.9 - 5.3 oz.)





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 groove of the driveshaft and joint.
Left Driveshaft: 554 - 559 mm (21.8 - 22.0 inch)
Right Driveshaft: 544 - 549 mm (21.4 - 21.6 inch)





9. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).





10. Close the ear portion (A) of the band with a commercially available boot band pincers KentMoore J-35910 or equivalent (B).





11. Check the clearance between the closed ear portion of the bands. If the clearance is not within the standard, close the ear portion of the bands further.
12. Repeat steps 10 and 11 for the band on the other end of the boot.