Rear Driveshaft Disassembly & Reassembly(AWD/4WD): Reassembly
NOTE:
- Be careful not to damage the boot.
- Refer to the Exploded View as needed during this procedure.
Inboard Joint
- 1. Inboard Boot - Install
1. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the outboard boot
2. Install a new ear clamp bands (B) and the outboard boot (C) onto the driveshaft
3. Remove the vinyl tape.
- 2. Spider - Install
1. Install the spider (A) onto the driveshaft by aligning the marks (B) you made on the spider and the end of the driveshaft
2. Install a new circlip (C)
3. Always rotate the circlip in its groove to make sure it is fully seated.
- 3. Inboard Joint - Install
1. Pack the inboard joint with the joint grease included in the new inboard boot set.
Grease quantity inboard joint:
Type Left/Right driveshaft Quantity AWD Left and right 100-116 g(3.53-4.09 oz) Type Left/Right driveshaft Quantity 4WD Left and right 96-124 g(3.39-4.37 oz) 2. Fit the inboard joint onto the driveshaft, and note these items: - Reinstall the inboard joint onto the driveshaft by aligning the marks (A) you made on the inboard joint and the rollers.
- Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.
3. Fit the boot ends (A) onto the driveshaft (B) and the inboard joint (C). 4. Adjust the length (A) of the driveshafts in the figure as shown, then adjust the boots to halfway between full compression and full extension. Driveshaft length:
Type Left/Right driveshaft Specified length (A) AWD Left 662.6-667.6 mm(26.087-26.283 in) Right 705.6-710.6 mm(27.780-27.976 in) 4WD Left 650-655 mm(25.591-25.787 in) Right 705.6-710.6 mm(27.559-27.756 in) 5. Bleed excess air from the boots by inserting a flat-tipped screwdriver between the boot and the joint.
- 4. Boot Band - Install
1. Install new boot bands:
- For the double loop type, go to step 2.
- For the ear clamp type, go to step 12.
- For the low profile type, go to step 14.
2. Fit the boot ends onto the driveshaft and the inboard joint, then install a new double loop band (A) onto the boot (B).
NOTE: Pass the end of the double loop band through the clip (C) twice in the direction of the forward rotation of the driveshaft.
3. Pull up the slack in the band by hand.
4. Mark a line (A) on the band 10-14 mm (0.39-0.55 in) from the clip (B). 5. 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) 6. Using a wrench on the winding mandrel of the boot band tool, tighten the band until the marked line (C) on the band meets the edge of the clip.
7. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip 8. Center-punch the clip
9. Fold over the remaining tail onto the clip.
10. 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 in) tail protruding from the clip. 11. Bend the band end (A) by tapping it down using a hammer. NOTE:
- Make sure the band and the clip do not interfere with anything on the vehicle, and the band does not move.
- Clean any grease remaining on the surrounding surfaces.
12. Close the ear portion (A) of the band using a commercially available boot band clamp tool (Kent-Moore J-35910 or equivalent) (B). 13. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band tighter. 14. Fit the boot ends onto the driveshaft and the inboard joint, then install a new low profile band type (A) onto the boot (B) 15. Hook the tab (C) of the band
16. Close the hook portion of the band using commercially available CV boot clamp pliers (30500) (D), then hook the tabs (E) of the band
17. Install the boot band on the other end of the boot, and repeat steps 4 and 6.
Outboard Joint
- 1. Outboard Boot - Install
1. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the outboard boot (B)
2. Install new ear clamp bands (C) and the outboard boot onto the driveshaft
3. Remove the vinyl tape.
- 2. Outboard Joint - Install
1. Make sure to check the size of a new stop ring.
To avoid driveshaft and vehicle damage, make sure you install a new stop ring.
Stop ring specifications:
Type Overall diameter (A) Wire diameter (B) AWD 20.89 mm (0.822 in) 1.44 mm (0.057 in) 4WD 20.16 mm (0.794 in) 2. Install the stop ring (A). 3. Pack about 35 g (1.2 oz) of grease included in the new outboard boot set into the driveshaft hole in the outboard joint. NOTE: If you are installing a new outboard joint, the grease is already installed.
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 the joint, and tap or hit the assembly onto a hard surface from a height of about 10 cm (3.9 in). NOTE: 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) you made with the outboard joint end (B). To avoid driveshaft and vehicle damage, the shaft must be all the way into the outboard joint to ensure the stop ring is properly seated.
7. Pack the outboard joint (A) with the remaining joint grease included in the outboard boot set. Total grease quantity outboard joint:
Type Left/Right driveshaft Quantity AWD Left and right 67-87 g(2.36-4.37 oz) 4WD Left and right 70-90 g(2.47-3.18 oz) 8. Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C) 9. Bleed any excess air from the boot by inserting a flat-tipped screwdriver between the boot and the joint.
10. Adjust the length (A) of the driveshafts in the figure as shown, then adjust the boots to halfway between full compression and full extension. Driveshaft length:
Type Left/Right driveshaft Specified length (A) AWD Left 662.6-667.6 mm(26.087-26.283 in) Right 705.6-710.6 mm(27.780-27.976 in) 4WD Left 650-655 mm(25.591-25.787 in) Right 705.6-710.6 mm(27.559-27.756 in) 11. Bleed excess air from the boots by inserting a flat-tipped screwdriver between the boot and the joint.
- 3. Boot Band - Install
1. Close the ear portion (A) of the band using a commercially available boot band clamp tool (Kent-Moore J-35910 or equivalent) (B).
2. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band tighter.
