From the inner hinge side
1. To prevent damage to the inner boot, wrap the drive shaft splines with vinyl tape (A).
2. Install the inner boot onto the drive shaft, then remove the vinyl tape. Do not damage the inner cover.
3. Install the crosspiece (A) onto the drive shaft, aligning the marks (B) on the crosspiece and on the end of the drive shaft.
4. Place the ring clamp (C) into the groove on the drive shaft. To fully seat the ring clamp in the groove, rotate it.
5. Place the rollers (A) on the crosspiece (B) with the shoulders facing outward, taking into account the following:
- Install the rollers in their original position on the crosspiece, aligning the marks (C).
- To prevent the rollers from falling off, hold the drive shaft vertically.
6. Pack the inner joint with the joint grease supplied with the new drive shaft.
Amount of grease. Inner hinge: 150-160g
7. Place the inner joint onto the drive shaft, taking into account the following:
- Install the inner joint onto the drive shaft, aligning the marks (A) on the inner joint and rollers.
- To prevent the inner joint from falling off, hold the drive shaft vertically.
8. Make sure the ends of the boots fit into the grooves of the drive shaft and joint, then place the clamps on the boots.
- If the clamps are of the two-turn type, proceed to step. 12. (Replacement cover clamps only)
- If the clamps are low-profile type, proceed to step. 9. (UK made only)
9. Place the new low profile clamp (A) onto the boot (B), then hook it onto the tab (C) on the clamp.
10. Compress the slit portion of the clamp using pliers (A) (available for sale), then hook onto the tabs (B) on the clamp.
11. Put the clamp on the other side of the cover and repeat steps. 9 and 10.
12. Place a new two-turn clamp (A) onto the boot with the end of the clamp facing the front of the vehicle.
13. Remove any slack in the clamp by hand.
14. Place a mark (A) 10-14 mm from the bracket (B).
15. Pass the free end of the clamp tape through the nose of the special tool for tightening the clamp of the covers KD-3191 (available for sale) or equivalent (A) and into a slot on the rotating mandrel (B).
16. Place the wrench on the rotating mandrel of the special tool and tighten the clamp until the mark (C) on the band reaches the edge of the bracket.
17. Raise the special tool and bend the free end of the clamp band at an angle of 90° to the bracket. Mark the bracket with a center punch, then wrap the tip onto the bracket.
18. Release the special tool mandrel and trim off the excess tape, leaving a 5-10 mm tip protruding from the bracket.
19. Bend the end of the tape (A) by tapping it with a hammer.
Note:
- Make sure that the tape and clamp do not touch anything and that the tape does not move.
- Remove excess grease from adjacent areas.
20. Put the clamp on the other side of the cover and repeat steps. 12-19.
21. Install a new retaining ring.
From the outer hinge side
1. To prevent damage to the outer boot, wrap the drive shaft splines with vinyl tape (A).
2. Place new clamps (B) on the covers.
3. Put on the outer cover. Do not damage the outer cover.
4. Remove the vinyl tape.
5. Place a new snap ring into the groove (A) on the drive shaft.
6. Insert the drive shaft (A) into the outer joint (B) so that the snap ring (C) fits into the joint.
7. To fully seat the outer joint, grasp the drive shaft and joint and tap them on a hard surface from a height of about 10 cm. Do not use a hammer, otherwise you may damage the drive shaft.
8. Make sure that the paint mark (A) is aligned with the end of the outer hinge (B).
9. Pack the outer joint (A) with the joint grease supplied with the new drive shaft.
Amount of grease. Outer hinge: 140-150g
10. Adjust the length of the drive shafts as shown in the figure below, then set the boots midway between the fully compressed and fully retracted positions. Make sure the ends of the boots fit into the grooves of the drive shaft and hinge.
11. Place the ends of the boot (A) over the drive shaft (B) and outer joint (C).
12. Compress the part of the clamp with the slot (A) using pliers (B) (available for sale).
13. Check the clearance in the compressed (U-shaped) parts of the tape. If the gap differs from the norm, tighten the U-shaped part even more.
14. Repeat steps. 13 and 14 for the clamp on the other side of the cover.