Reassembly

DRIVE SHAFT: REAR DRIVE SHAFT (for 4WD):

REASSEMBLY

1. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT
HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.





(a) Install new parts to the outboard joint shaft assembly in the following order.
(1) Rear drive shaft outboard joint boot No.2 clamp (A)
(2) Rear drive shaft outboard joint boot (B)
(3) Rear drive shaft outboard joint boot clamp (C)
(b) Pack the outboard joint shaft and boot with grease.
Grease capacity:
71 to 81 g (2.5 to 2.9 oz.)
2. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP






(a) Install the outboard joint boot clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT NO.2 CLAMP






(a) Install the outboard joint boot No.2 clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

4. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY






(a) Install new parts to the outboard joint shaft assembly in the following order.
(1) Rear drive shaft inboard joint boot clamp (A)
(2) Rear drive shaft inboard joint boot (B)
(3) Rear drive shaft inboard joint boot No.2 clamp (C)
(b) Install the cage to the rear drive outboard joint shaft assembly.
NOTE: Face the smaller inside diameter side to the outboard joint shaft assembly and insert.

(c) Hold the rear drive outboard joint shaft assembly between aluminium plates in a vise.
NOTE: Do not overtighten the vise.

(d) Align the matchmarks.






(e) Using a brass bar and hammer, tap in the inner race to the rear drive outboard joint shaft.






(f) Using a snap ring expander, install a new rear drive shaft snap ring.






(g) Align the matchmarks and install the cage to the inner race.
(h) Apply grease to the 6 balls.
(i) Install the 6 balls.
NOTE: Be careful not to drop the balls.

(j) Pack the inboard joint assembly and boot with grease.
Grease capacity:
132 to 142 g (4.7 to 5.0 oz.)






(k) Align the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.
5. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assembly.
6. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP






(a) Install the inboard joint boot clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

7. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT NO.2 CLAMP






(a) Install the inboard joint boot No.2 clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

8. INSPECT REAR DRIVE SHAFT ASSEMBLY






(a) Check that there is no excessive play in the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust direction.
(c) Check that there is no excessive play in the radial directions of the inboard joint.
(d) Check the boots for damage.