Disassembly and Assembly: Assembly

Front Final Drive Side

1. Clean old grease on housing with paper waste.
2. If plug (1) has been removed, use a drift to press in a new one. (left side)

   : Press

   Fig 1: Pressing Plug Using Drift

   
3. Install new boot and boot bands to shaft.
   CAUTION:

   • Wrap serration on shaft with tape to protect boot from damage.
   • Never reuse boot and boot band.
4. Remove the tape wrapped around the serration on shaft.
5. To install the spider assembly (1), align it with the matching marks (A) on the shaft (2) during the removal, and direct the serration mounting surface (B) to the shaft.
   Fig 2: Aligning Spider Assembly With Matching Marks On Shaft

   
6. Secure spider assembly onto shaft with snap ring (1).
7. Apply the appropriate amount of grease to spider assembly and sliding surface.
8. Assemble the housing onto spider assembly, and apply the balance of the specified amount grease.

   Standard 

   Grease amount:  Refer to "DRIVE SHAFT ".

   Fig 3: Securing Spider Assembly Onto Shaft With Snap Ring

   
9. Align matching marks painted when housing was removed.
10. Install boot securely into grooves (indicated by "*" marks) shown in the figure.
    CAUTION: If grease adheres to the boot mounting surface (with "*" mark) on shaft or housing, boot may come off. Remove all grease from the surface.
    BOOT MOUNTING SURFACE REFERENCE CHART
    
    

    Right side	Left side

11. To prevent the deformation of the boot, adjust the boot installation length (L) to the value shown below by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air.

    Standard 

    Boots installed length (L):  Refer to "DRIVE SHAFT ".

    CAUTION:

    • If the boot installation length is outside the standard, it may cause breakage of boot.
    • Be careful not to touch the inside of the boot with the tip of tool.
12. Install new larger and smaller boot bands securely.
    1. For one-touch clamp band
       1. Secure the large and small ends of a boot with new boot bands as shown in the figure.
          Fig 4: Securing Large And Small Ends Of Boot With New Boot Bands

          
    2. For low profile type band
       1. Put boot band in the groove on drive shaft boot. Then fit pawls into holes to temporary installation.
          NOTE: For the large diameter side, fit projection (A) and guide slit (B) at first.
          Fig 5: Fitting Projection And Guide Slit

          
       2. Pinch projection on the band with suitable pliers to tighten band.
       3. Insert tip of band below end of the pawl.
13. Secure housing and shaft, and then make sure that they are in the correct position when rotating boot. Install them with new boot band when the mounting positions become incorrect.
14. Install dust cover to housing. (right side)
    CAUTION: Never reuse dust cover.
    Fig 6: Inserting Tip Of Band Below End Of Pawl

    

    Wheel Side