Outboard Joint Side

WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.

Wrap the splines with vinyl tape (A) to prevent damaging the outboard boot.

Fig 1: Wrapping Splines With Vinyl Tape
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install new ear clamp bands (B) and the outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.
Make sure to check the size of a new stop ring.
NOTE: To avoid driveshaft and vehicle damage, make sure you install a new stop ring.

Stop ring specifications

Overall diameter (A): 23.5 mm (0.93 in)

Wire diameter (B): 2.0 mm (0.08 in)

Fig 2: Identifying Stop Ring Diameter
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the stop ring (A) into the driveshaft groove (B).

Fig 3: Identifying Stop Ring Into Driveshaft Groove
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Pack about 35 g (1.2 oz.) 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.

Fig 4: Filling Joint Grease In Inboard Boot Set
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.

Fig 5: Inserting Driveshaft Into Outboard Joint
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 (4 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.

Fig 6: Tapping Driveshaft Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Check the alignment of the paint mark (A) you made with the outboard joint end (B).
NOTE: 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.

Fig 7: Checking Alignment Of Paint Mark With Outboard Joint End
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Pack the outboard joint (A) with the remaining joint grease included in the new outboard boot set.
Total grease quantity

Outboard joint: 90-100 g (3.2-3.5 oz.)

Fig 8: Filling Joint Grease In Outboard Boot Set
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fit the boot ends (A) onto the driveshaft (B) and the outboard joint (C). Bleed any excess air from the boot by inserting a flat-tipped screwdriver between the boot and the joint.

Fig 9: Fitting Boot Ends Onto Driveshaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the length (A) of the driveshafts to the figure as shown, then adjust the boots to halfway between full compression and full extension.
Left driveshaft: 494-499 mm (19.45-19.65 in)

Right driveshaft: 814-819 mm (32.05-32.24 in)

Fig 10: Identifying Driveshafts Length
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Close the ear portion (A) of the band using a commercially available seal clamp tool (Kent-Moore J-35910 or equivalent) (B).

Fig 11: Closing Ear Portion Of Band Using Commercially Available Seal Clamp Tool
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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.

Fig 12: Checking Clearance Between Closed Ear Portion Of Band
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Repeat steps 12 and 13 for the band on the other end of the boot.