Note:
- Thoroughly clean disassembled parts with solvent and dry with compressed air. Do not wash rubber parts in solvent.
- Thoroughly pack both joints and both joints with the grease supplied with the new drive shaft.
- Driveshaft outer joint cover made of polyester thermoplastic elastomer (TRE). Secure the outer pivot boot assembly with a slotted clip.
Amount of lubricant:
- Inner hinge: 130-140g
- External hinge: 105-115g
Slot (A) inner hinge: 0.5-1.0 g (drawing on the right)
From the side of the inner hinge
1. To prevent damage to the inner boot and dynamic damper, wrap the splines of the drive shaft with vinyl tape.
2. Install the dynamic damper and inner boot to the drive shaft, then remove the vinyl tape. Be careful not to damage the inner cover and dynamic damper.
3. Install the cross on the drive shaft, aligning the marks on the cross and the end of the drive shaft.
4. Place the ring clamp in the groove of the drive shaft. To fully seat the ring clamp in the groove, turn it.
5. Slide the casters onto the cross with the shoulders facing out, keeping the following in mind:
- Install the rollers in their original position on the cross, aligning the marks.
- Keep the drive shaft vertical to keep the rollers from falling off.
6. Pack the inner joint with the joint grease supplied with the new drive shaft.
7. Slide the inner joint onto the drive shaft as shown in the figure, taking into account the following:
- Install the inner joint on the drive shaft, aligning the marks on the inner joint and rollers.
- To prevent the inner pivot from falling off, hold the drive shaft vertically.
8. Adjust the length of the drive shafts as shown below, then install the boots midway between the fully compressed and fully retracted positions. Make sure that the ends of the covers sit in the grooves of the drive shaft and hinge.
Standard:
- Left drive shaft: 487-492mm
- Right drive shaft: 506-511mm
9. Install the dynamic damper as shown below.
Standard:
- Left drive shaft: 251-255mm
- Right Drive Shaft: 242-246mm
10. Put the ends of the boot on the drive shaft and the inner joint, then put the clips on the covers so that the end of the clip looks towards the front of the car.
11. Remove any slack in the clamp by hand.
12. Place a mark 10-14mm from the clamp.
13. Pass the loose end of the clip band through the nose of the KD-3191 Boot Clip Tightening Tool (available for sale) or equivalent and into a slot on a rotating mandrel.
14. Place a wrench on the rotating arbor of the special tool and tighten the clamp until the mark on the tape reaches the edge of the clamp.
15. Lift the special tool and bend the free end of the clamp band at a 90°angle to the clamp. Pin the clip with a center punch, then wrap the tip over the clip.
16. Release the mandrel of the special tool and cut off the excess tape, leaving a 5-10 mm tip protruding from the clamp.
17. Bend the end of the tape by tapping it with a hammer.
Note:
- Make sure that the tape and clip do not interfere with anything and that the tape does not move.
- Remove excess grease from adjacent areas.
18. Install a new circlip.
From the side of the outer hinge
1. To prevent damage to the outer boot, wrap the splines of the drive shaft with vinyl tape.
2. Put on the outer cover. Do not damage the outer cover.
3. Remove the vinyl tape.
4. Install a new circlip into the groove of the drive shaft.
5. Insert the drive shaft into the outer joint so that the circlip fits against the joint.
6. 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 the drive shaft may be damaged.
7. Make sure the paint mark lines up with the end of the outer hinge.
8. Pack the outer joint with the joint grease supplied with the new drive shaft.
Grease quantity: Outer joint: 105-110 g.
9. Put the ends of the boot on the drive shaft and outer hinge.
10. Attach the new slotted clip by sliding the tabs through the slots in the tape.
11. Crimp the U-shaped part of the clamp band with clamp pliers (available for sale).
12. Check the gap in the U-shaped part of the tape. If the gap is large, tighten the U-shaped part further.