Assembly

FRONT DRIVE SHAFT ASSEMBLY:





1. (RH DRIVE SHAFT)
ASSEMBLE CENTER DRIVE SHAFT
- Install a new snap ring to the center drive shaft.
- Using a press and extension bar, press in a new bearing.





- Using a snap ring expander, install a new snap ring.





- Using a press, press in a new drive shaft side dust cover.

HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration.

- Using a press, press in a new transaxle side dust cover.





2. (LH DRIVE SHAFT)
ASSEMBLE SIDE GEAR SHAFT
- Using a press, press in a new dust cover.





3. INSTALL OUTBOARD JOINT BOOT AND NEW BOOT CLAMP

HINT:
- Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.
- Temporarily install the boot and new clamps to the outboard joint.





4. ASSEMBLE BOOT TO OUTBOARD JOINT
- Before assembling the boot, pack in grease.

HINT: Use the grease supplied in the boot kit.

Grease capacity: 135-155 g (4.8-5.5 oz.)





5. INSTALL NEW BOOT CLAMPS AND INBOARD JOINT BOOT
- Temporarily install the two new boot clamps and inboard joint boot.





6. ASSEMBLE NEW INBOARD JOINT COVER
- Clean contacting surfaces of any residual packing material using cleaner.
- Apply seal packing to the inboard joint cover as shown in the illustration.

Seal packing:
Part No. 08826 - 00801, THREE BOND 1122 or equivalent

HINT: Avoid applying an excess amount to the surface.





- Align the bolt holes of the cover with those of the inboard joint,then insert the hexagon bolts.
- Use a plastic hammer to tap the rim of the inboard joint cover into place.
- Do this in the order shown, and repeat several times.





- Use bolts, nuts and washers to keep the inboard joint together.

NOTICE: Tighten the bolts by hand to avoid scratching the flange surface.





7. ASSEMBLE INBOARD JOINT
- Align the matchmarks placed before disassembly.
- Using a brass bar and hammer, tap the inboard joint onto the drive shaft.

NOTICE: Check that the brass bar is touching the inner race. and not the cage.





- Using a snap ring expander, install a new snap ring.

NOTICE: Work carefully so that the outer race does not come off.





8. ASSEMBLE INBOARD JOINT BOOT TO IN BOARD JOINT
- Pack in grease to the inboard tulip and boot.

HINT: Use the grease supplied in the boot kit.

Grease capacity: 140-150 g (4.9-5.3 oz.)





9. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
- Be sure the boots are on the shaft groove.
- Insure that the boot is no stretched or contracted when the drive shaft is at standard length.

Drive shaft standard length:
452.35 ± 2.0 mm (17.8090 ± 0.079 in.)





- Using a boot clamp tool, place pincer jaws in closing hooks of clamps.
- Secure clamp by drawing closing hooks together.





- Check that the clamp at closed position is the same as in the illustration.





- Using a boot clamp tool, tighten the small clamps.





10. PACK IN GREASE TO CENTER DRIVE SHAFT OR SIDE GEAR SHAFT
- Pack grease into the center drive shaft or side gear shaft.

Grease capacity: 43-53 g

HINT: Use the grease supplied in the boot kit.





11. CONNECT DRIVE SHAFT AND CENTER DRIVE SHAFT OR SIDE GEAR SHAFT
- Remove the bolts, nuts and washers.
- Align the matchmarks on the drive shaft and center drive shaft or side gear shaft.
- Place a new gasket on the inboard joint.
- Install the center drive shaft or side gear shaft to the drive shaft.

NOTICE: When moving the drive shaft, do not compress the inboard boot.

- Install the three washers and six hexagon bolts, and using SST,temporarily tighten them.

SST 09923-00020





12. CHECK DRIVE SHAFT
- Check to see that there is no play in the inboard joint and outboard joint.
- Check to see that inboard joint slides smoothly in the thrust direction.