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REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

BHE031325600W04

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

1 | Boot band (axle side) (See Boot Band (axle side) Disassembly Note.) (See Boot Band (Axle Side) Assembly Note.)
2 | Boot band (differential side) (See Boot Band (Differential Side) Disassembly Note.) (See Boot Band (Differential Side) Assembly Note.)
3 | Outer ring (See Outer Ring Disassembly Note.) (See Outer Ring Assembly Note.)
4 | Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
5 | Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
6 | Boot (See Boot Disassembly Note.) (See Boot Assembly Note.)
7 | Shaft and ball joint component

## Boot Band (axle side) Disassembly Note

  Note

  • Remove the boot band only if there is an abnormality.

1. Remove the boot band using end clamp pliers.

## Boot Band (Differential Side) Disassembly Note

1. Remove the crimp of the clip using a flathead screwdriver.

## Outer Ring Disassembly Note

1. Place an alignment mark on the drive shaft and the outer ring.

2. Remove the outer ring.

## Snap Ring, Tripod Joint Disassembly Note

1. Place an alignment mark on the shaft and tripod joint.

2. Remove the snap ring using a snap ring plier.

3. Remove the tripod joint from the shaft.

  Caution

  • To prevent damage to the component, do not use a hammer when removing it.

## Boot Disassembly Note

  Note

  • Remove the axle side boot only if there is an abnormality.

1. Wrap the shaft spline with vinyl tape.

2. Remove the boot.

## Boot Assembly Note

  Note

  • The boot shapes on the axle side and the differential side are different so do not misinstall them.

1. Fill the inside of the new dust boot (wheel side) with grease.

  Note

  • Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

  Grease amount
  MT: 115-135 g {4.06-4.76 oz}
  AT: 90-110 g {3.18-3.88 oz}

2. Install the boot with the drive shaft spline still wrapped with vinyl tape.

3. Remove the vinyl tape.

## Tripod Joint, Snap Ring Assembly Note

1. Align the tripod joint with the shaft mark and insert it using a brass bar.

  Caution

  • To prevent damage to the component, do not tap the roller part when installing.

2. Install the new snap ring to the shaft installation slot securely using a snap ring pliers.

## Outer Ring Assembly Note

1. Fill the outer ring and boot (differential side) with the repair kit grease.

  Note

  • Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

  Grease amount
  MT: 175-195 g {6.18-6.87 oz}
  AT: 135-155 g {4.77-5.46 oz}

2. Assemble the outer ring.

3. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

  Caution

  • Do not let the grease leak.
  • Do not damage the boot.

4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.

  Standard

  | Drive shaft length (mm {in})
  --- | ---
  MT | Left side | 792.6-802.6 {31.21-31.59}
  Right side | 832.6-842.6 {32.78-33.17}
  AT | Left side | 791.1-801.1 {31.15-31.53}
  Right side | 831.1-841.1 {32.71-33.11}

5. After installation, verify that there is no boot damage or grease leakage.

## Boot Band (Differential Side) Assembly Note

1. Using pliers, pull the boot band around the boot slot in opposite direction of drive shaft forward rotation direction and tighten.

2. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead screwdriver to secure the boot band.

3. Verify that the boot band is installed to the boot slot securely.

## Boot Band (Axle Side) Assembly Note

1. Turn the adjusting bolt of the SST and adjust the opening size to the specification A.

  Specification A
  2.9 mm {0.11 in}

2. Crimp the boot band (small-size) using the SST.

3. Verify that the crimp value B is within the specification.

  • If the crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.
  • If the crimp value B is less than the specification, increase opening length A of the SST and crimp the new boot band.

  Specification B
  2.4-2.8 mm {0.095-0.110 in}

4. Verify that the boot band does not protrude from the boot band installation area.

  • If the boot band protrudes from the installation area, replace it with a new band and repeat Step 2-4.

5. Fill the boot with the repair kit grease.

6. Adjust opening length A of the SST to the specification.

  Specification A
  3.2 mm {0.13 in}

7. Crimp the boot band (large-size) using the SST.

8. Verify that the boot band crimp value B is within the specification.

  • If crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.
  • If the crimp value B is less than the specification, replace the boot band, increase opening length A of the SST, and then recrimp the new boot band.

  Specification B
  2.4-2.8 mm {0.095-0.110 in}

9. Verify that the boot band does not protrude from the boot band installation area.

  • If the boot band protrudes from the installation area, replace it with a new band and repeat Step 7-9.