Disassembly and Reassembly

Disassembly

Special Tools Required
- Threaded adapter, 22 x 1.5 mm 07XAC-001010A Threaded adapter, 24 x 1.5 mm 07XAC-001020A
- Boot band pincers, commercially available

Inboard Joint Side:





1. Remove the set ring (A) from the inboard joint.
2. Remove the boot bands. Take care not to damage the boot and dynamic damper.
- If the boot band is welded type (A), cut the boot band (B).
- If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E).
- If the boot band is a low profile type (F), pinch the boot band using the commercially available boot band pincers (G).





Welded Type





Double Loop Type





Low Profile Type





3. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint.





4. Make a mark (A) on the rollers (B) and spider (C) to identify the locations of rollers on the spider, them remove the rollers.
5. Remove the circlip (D).
6. Mark (E) the spider (C) and driveshaft (F) to identify the position of the spider on the shaft.
7. Remove the spider (C).





8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the 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. Remove the boot bands. Take care not to damage the boot and dynamic damper.
- If the boot band is an ear clamp type (A), lift up the three tabs (B) with a screwdriver.





Ear Clamp Type





2. Slide the outboard boot (A) 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 (A) on the driveshaft (B) at the same position of the outboard joint end (C).





5. Carefully clamp the driveshaft in a vise.
6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B).
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 (A) to prevent damage to the boot.
10. Remove the outboard boot. Take care not to damage the boot.
11. Remove the vinyl tape.

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 and dynamic damper.
2. Install the dynamic damper and inboard boot onto the driveshaft, then remove the vinyl tape. Take care not to damage the inboard boot and dynamic damper.





3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the 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) onto the spider (B) with their high shoulders facing outward, and note these items:
- Reinstall the rollers in their original positions on the spider by aligning the marks (C).
- 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 (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. Adjust the inboard joint until the rollers are in the middle of the joint.





9. Fit the boot ends onto the driveshaft and the inboard joint, then install the band (A) onto the boot (B).
10. Pull up the slack in the band by hand.





11. Mark a position (A) on the band 10 - 14 mm (0.40 - 0.6 inch) from the clip (B).





12. Thread the free end of the band through the nose section of the commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
13. 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.





14. 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.





15. 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.





16. 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

17. Repeat steps 9 through 16 for the band on the other end of the boot.





18. 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 outboard boot, then remove the vinyl tape. Take care not to damage the outboard boot.





3. Install 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.








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.





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





11. Close the ear portion (A) of the band with a commercially available boot band pincers (B).





12. 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.