Reassembly

DRIVE SHAFT / PROPELLER SHAFT: REAR DRIVE SHAFT ASSEMBLY (for AWD): REASSEMBLY

1. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT

(a) Hold the drive shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.





Text in Illustration





(c) Install new parts to the outboard joint shaft in the following order:

(1) Rear drive shaft outboard joint boot clamp

(2) Outboard joint boot

(3) No. 2 rear drive shaft outboard joint boot clamp

(d) Pack the outboard joint shaft assembly and outboard joint boot with grease from the boot kit.

Grease capacity:

71 to 81 g (2.5 to 2.9 oz.)

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

(a) Hold the drive shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) One touch type:

(1) Using a screwdriver, install the No. 2 rear drive shaft outboard joint clamp as shown in the illustration.





NOTICE:
Do not damage the outboard joint boot.

(c) Claw engagement type:

(1) Using needle-nose pliers, install the No. 2 rear drive shaft outboard joint boot clamp as shown in the illustration.





NOTICE:
Do not damage the outboard joint boot.

3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

(a) One touch type:

(1) Using a screwdriver, install the rear drive shaft outboard joint clamp as shown in the illustration.





NOTICE:
Do not damage the outboard joint boot.

(b) Claw engagement type:

(1) Using needle-nose pliers, install the rear drive shaft outboard joint boot clamp as shown in the illustration.





NOTICE:
Do not damage the outboard joint boot.

4. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY

(a) Wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.





Text in Illustration





(b) Install new parts to the outboard joint shaft in the following order:

(1) No. 2 rear drive shaft inboard joint boot clamp

(2) Inboard joint boot

(3) Rear drive shaft inboard joint boot clamp

(c) Align the matchmarks placed before removal and install the inner race to the rear drive outboard joint shaft assembly using a brass bar and a hemmer.





Text in Illustration





NOTICE:
Be careful not to damage the inner race.

(d) Using a snap ring expander, install a new shaft snap ring.





(e) Align the matchmarks placed before removal and install the cage to the inner race.





Text in Illustration





(f) Install the 6 balls with grease to the inner race.

NOTICE:
Be careful not to drop the balls.

HINT
Apply grease onto the balls to keep them from falling.

(g) Pack the outboard joint shaft and boot with grease.

Grease capacity:

132 to 142 g (4.6 to 5.0 oz.)

(h) Align the matchmarks and install the inboard joint assembly to the outboard joint shaft assembly.





Text in Illustration





5. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT

(a) Install the inboard joint boot to the outboard joint shaft.

(b) Check whether the drive shaft dimension (A) is within the following specification.





Dimension (A):

619.6 mm (2.03 ft.)

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

(a) Using needle-nose pliers, install the No. 2 rear drive shaft inboard joint boot clamp as shown in the illustration.





NOTICE:
Do not damage the inboard joint boot.

7. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(a) Using needle-nose pliers, install a new rear drive shaft inboard joint boot clamp as shown in the illustration.





NOTICE:
Do not damage the inboard joint boot.

8. INSPECT REAR DRIVE SHAFT ASSEMBLY Rear Drive Shaft Assembly