REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

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Special Service Tool (SST)

49 T025 001   Boot clamp crimpers

1.  Disassemble in the order shown in the figure.

2.  Assemble in the reverse order of removal.

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Boot Band (Differential Side) Disassembly Note

Type A

1.  Grasp the boot band at the point shown in the figure using pliers, and remove the band.

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Type B

1.  Remove the boot band using end clamp pliers.

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Outer Ring Disassembly Note

1.  Place alignment marks on the shaft and outer ring.

Caution

•  To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

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2.  Remove the outer ring from the shaft.

3.  Wipe off grease on the outer ring using a clean rag.

Snap Ring, Tripod Joint Disassembly Note

1.  Place alignment marks on the shaft and tripod joint.

Caution

•  To prevent part damage, do not use a punch or similar tool to place alignment marks. Use paint.

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2.  Remove the snap ring using snap ring pliers.

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3.  Remove the tripod joint from the shaft.

Caution

•  When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

•  If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

4.  Wipe off grease on the shaft and tripod joint using a clean rag.

Boot (Differential Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (differential side).

3.  Wipe off grease on the boot (differential side) using a clean rag.

Boot Band (Wheel Side) Disassembly Note

1.  Remove the boot band using end clamp pliers.

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Boot (Wheel Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (wheel side).

3.  Wipe off grease on the boot (wheel side) and ball joint using a clean rag.

Boot (Wheel Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (wheel side) with vinyl tape wrapped around the spline area of the shaft.

2.  Apply the specified grease to the ball joint and boot (wheel side).

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

3.  Assemble the boot (wheel side) to the ball joint.

Boot Band (Wheel Side) Assembly Note

1.  Adjust opening A of the SST to the standard by rotating the adjustment bolt.

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2.  Crimp the boot band using the SST.

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3.  Verify that crimp B of the boot band is within the standard.

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•  If crimp B exceeds the standard, decrease opening A of the SST and crimp the boot band again.

•  If crimp B is less than the standard, replace the boot band, increase opening A of the SST, and crimp the new boot band.

4.  Verify that the boot band does not protrude from the boot band assembly area.

•  If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.

Boot (Differential Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (differential side) with vinyl tape left wrapped around the spline area of the shaft.

2.  Remove the vinyl tape left wrapped around the spline area of the shaft.

Tripod Joint, Snap Ring Assembly Note

1.  Assemble the tripod joint with the alignment marks on the shaft and tripod joint aligned.

Caution

•  When using the hammer and urethane bar or equivalent, be careful not to scratch the roller area so as to prevent damage to the part.

Note

•  If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

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2.  Assemble a new snap ring using snap ring pliers.

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3.  Verify that the snap ring is assembled correctly in the groove of the shaft.

Outer Ring Assembly Note

1.  Apply the specified grease to the outer ring and boot (differential side).

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

2.  Align the shaft and outer ring with the alignment mark and assemble the outer ring.

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3.  Assemble the boot (differential side) to the outer ring.

4.  Set the drive shaft to the standard length.

5.  Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

Note

•  Do not damage the boot.In addition, verify that there is no grease leakage.

•  If the boot is deformed, it may not be possible to perform the full-length adjustment of the shaft.

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6.  Verify that the drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

•  If not within the standard, repeat from Step 4.

Boot Band (Differential Side) Assembly Note

Type A

1.  Grasp the boot band at the point shown in the figure using pliers and tighten the boot band.

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Type B

1.  Adjust opening A of the SST to the standard by rotating the adjustment bolt.

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2.  Crimp the boot band using the SST.

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3.  Verify that crimp B of the boot band is within the standard.

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•  If crimp B exceeds the standard, decrease opening A of the SST and crimp the boot band again.

•  If crimp B is less than the standard, replace the boot band, increase opening A of the SST, and crimp the new boot band.

4.  Verify that the boot band does not protrude from the boot band assembly area.

•  If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.