From the side of the inner hinge
1. To prevent damage to the inner boot, wrap the splines of the drive shaft with vinyl tape.
2. Install the inner boot on the drive shaft, then remove the vinyl tape. Do not damage the inner case.
3. Press the bearing cage with the large diameter side toward the end of the drive shaft, then press the bearing race onto the drive shaft.
4. Align the mark on the bearing race with the mark on the drive shaft, then press the bearing race onto the drive shaft.
5. Place the ring clamp in the groove of the drive shaft. To fully seat the ring clamp in the groove, turn it.
6. Press the bearing retainer onto the bearing ring, aligning the marks.
7. Insert steel balls into the holes in the bearing cage.
8. Pack the inner joint with the joint grease supplied with the new drive shaft.
9. Slide the inner joint onto the drive shaft, aligning the marks on the inner joint with the marks on the bearing retainer.
10. Install the circlip into the groove on the inner pivot.
11. 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.
12. 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.
13. Remove any slack in the clamp by hand.
14. Place a mark 10-14mm from the clamp.
15. Pass the free 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.
16. 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.
17. Lift the special tool and bend the loose 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.
18. Release the mandrel of the special tool and cut off the excess tape, leaving a 5-10 mm tip protruding from the clamp.
19. 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.
20. 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.
9. Put the ends of the boot on the drive shaft and the outer hinge (Drawing in the middle ko-onka at the top).
10. 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 degree 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.
