Rear Driveshaft Reassembly

Rear Driveshaft Reassembly

Rear Driveshaft:

Special Tools Required
- Boot band tool, KD-3191 or equivalent, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.

Inboard Joint Side
1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot.








2. Install the inboard boot and boot band (B) on the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.
3. Install the steel balls (A) and the bearing retainer (B) onto the bearing race (C) by aligning the marks (D) on the bearing retainer and the bearing race.





4. Install the bearing onto the driveshaft (E) by aligning the marks on the bearing and the driveshaft.
5. Install the snap ring (F).
6. Pack the inboard joint with the joint grease included in the new driveshaft set.





7. Install the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and driveshaft.





8. Install the circlip (B).
9. Adjust the length of the driveshafts to these measurements, bleed excess air from the boot, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.
Left driveshaft: 480 - 485 mm (18.9 - 19.1 inch)
Right driveshaft: 515 - 520 mm (20.3 - 20.5 inch)





10. Install the boot bands. Double loop type, do steps 11 through 19. Locking tab type, do steps 20 and 21.
11. Fit the boot ends onto the driveshaft and the inboard joint, then install the new double loop band (A) onto the boot.





12. Pull up the slack in the band by hand.
13. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B).





14. 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).





15. Using a wrench on the winding mandrel of the boot band tool, tighten the band until the marked spot (C) on the band meets the edge of the clip.
16. Lift up the boot band tool to bend the free end of the band 90° to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.





17. Unwind the boot band tool, and cut off the excess free end of the band to leave 5 - 10 mm (0.2 - 0.4 inch) from the clip.





18. Bend the band end (A) by tapping it down with a hammer.

NOTE:
- Make sure the band and clip do not interfere with anything, and the band does not move.
- Remove any grease remaining on the surrounding surfaces.





19. Install the boot band on the other end of the boot, and repeat steps 11 through 18.
20. Install a new locking tab type boot band on the inboard joint side of the inboard boot. Fold down the locking tabs.





21. Lightly tap on the doubled-over portions to flatten them.

Outboard Joint Side
1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.





2. Install a new ear clamp band (B) and the outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.
3. Install a new stop ring in the driveshaft groove (A).





4. Pack about half of the grease included in the new joint boot set into the driveshaft hole in outboard joint. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is closed.





5. To completely seat the outboard joint, pick up the driveshaft and joint, and tap them on a hard surface. 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) with the outboard joint end (B).





7. Pack the outboard joint (A) with the remaining joint grease included in the new joint boot set.





8. Adjust the length of the driveshafts to these measurements, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the groove of the driveshaft and joint.
Left driveshaft: 480 - 485 mm (18.90 - 19.09 inch)
Right driveshaft: 515 - 520 mm (20.28 - 20.47 inch)





9. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).





10. Close the ear portion (A) of the band with commercially available boot band pincers Kent-Moore J-35910 or equivalent (B).





11. 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.





12. Install the new low profile band (A) onto the boot (B), then hook the tab (C) of the band.





13. Close the hook portion of the band with a commercially available boot band pincers (A), then hook the tabs (B) of the band.