Front Drive Shaft Assembly (For Hatchback) Reassembly

Using SST and a press, install a new dust cover into the inboard joint until it is flush with the end.

SST

09527-10011

NOTICE:

1. Install the dust cover in the correct orientation.
   
2. Do not deform the dust cover.
   

HINT:

Use the same procedure for the RH side as for the LH side.

Install a new snap ring.

Wrap the spline of the outboard joint shaft with protective tape.

Install new parts onto the outboard joint shaft in the following order.

Pack the joint portion of the outboard joint shaft and the outboard joint boot with grease.

Standard Quantity:

116 to 126 g (4.1 to 4.4 oz.)

Install the outboard joint boot onto the outboard joint shaft groove.

NOTICE:

Keep the groove free of grease.

HINT:

Use the same procedure for the RH side as for the LH side.

Install a new boot clamp onto the outboard joint boot and provisionally fold back the lever.

NOTICE:

1. Set the lever into the guide groove correctly and install the clamp as far into the inner side of the vehicle as possible.
   
2. Check the band and the lever for any deformation before folding back the lever.
   

Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.

NOTICE:

1. Do not damage the deflector.
   
2. Make sure that the outboard joint is in direct contact with the work plane.
   

Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

NOTICE:

Do not damage the outboard joint boot.

HINT:

Use the same procedure for the RH side as for the LH side.

Install a new boot clamp onto the outboard joint boot and provisionally fold back the lever.

NOTICE:

1. Set the lever into the guide groove correctly.
   
2. Check the band and the lever for any deformation before folding back the lever.
   

Using water pump pliers, pinch the boot clamp to provisionally fix it.

Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

NOTICE:

Do not damage the outboard joint boot.

HINT:

Use the same procedure for the RH side as for the LH side.

Install the drive shaft damper onto dimension (A) shown in the illustration.

Dimension (A):

425.6 to 429.6 mm (16.76 to 16.91 in.)

NOTICE:

Install the damper in the correct orientation.

One touch type:

1. Install a new damper clamp onto the front drive shaft damper and fix the damper clamp with a screwdriver.
   

Claw engagement type:

1. Using needle-nose pliers, install a new damper clamp as shown in the illustration.
   

   Text in Illustration

   *a	One Touch Type
   *b	Claw Engagement Type

Install a new parts onto the outboard joint shaft in the following order.

Fix the outboard joint shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Remove the protective tape.

Align the matchmarks and install the tripod joint onto the outboard joint shaft.

NOTICE:

Face the serrated side of the tripod joint outward and install it onto the outboard joint end.

Using a brass bar and hammer, install the tripod joint.

NOTICE:

1. Do not hit the rollers.
   
2. Keep the tripod joint free of foreign matter.
   

Using a snap ring expander, install a new snap ring.

Pack the inboard joint with grease.

Standard Quantity:

125 to 135 g (4.4 to 4.8 oz.)

Align the matchmarks and install the inboard joint onto the outboard joint shaft.

HINT:

Use the same procedure for the RH side as for the LH side.

Install the inboard joint boot into the grooves of the inboard joint and outboard joint shaft.

NOTICE:

Keep the grooves free of grease.

HINT:

Use the same procedure for the RH side as for the LH side.

One touch type:

1. Install a new boot clamp onto the inboard joint boot and provisionally fold back the lever.
   

   NOTICE:

   1. Set the lever into the guide groove correctly.
      
   2. Check the band and the lever for any deformation before folding back the lever.
      




2. Using water pump pliers, pinch the boot clamp to provisionally fix it.
   

   Text in Illustration

   *a	Place the tip near the center of the lever.





3. Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.
   

   NOTICE:

   Do not damage the inboard joint boot.

Claw engagement type:

1. Using needle-nose pliers, install a new clamp as shown in the illustration.
   

   NOTICE:

   1. Do not damage the boot.
      
   2. Do not deform the claw of the hook.
      

   HINT:

   Use the same procedure for the RH side as for the LH side.

Install a new boot clamp onto the inboard joint boot.

Adjust dimension (A) until the drive shaft is within the specified length.

Dimension (A):

LH	RH
584.3 mm (23.00 in.)	826.3 mm (32.53 in.)

One touch type:

1. Install a new boot clamp onto the inboard joint boot and provisionally fold back the lever.
   

   CAUTION:

   Wear protective gloves to avoid injuries to your hands.

   NOTICE:

   1. Set the lever into the guide groove correctly.
      
   2. Check the band and the lever for any deformation before folding back the lever.
      




2. Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.
   

   Text in Illustration

   *a	Weight
   *b	Contact

   NOTICE:

   1. Do not damage the deflector.
      
   2. Make sure that the inboard joint is in direct contact with the work plane.
      




3. Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.
   

   NOTICE:

   Do not damage the boot.

Claw engagement type:

1. Using needle-nose pliers, engage the 2 claws and install the boot clamp as shown in the illustration.
   

   NOTICE:

   1. Do not damage the boot.
      
   2. Do not deform the claw of the hook.
      

   HINT:

   Use the same procedure for the RH side as for the LH side.

Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction.

Check for cracks, damage and grease leakage on the boot joint.

HINT:

Keep the drive shaft level while moving it.

Check dimension (A).

Dimension (A):

LH	RH
584.3 mm (23.00 in.)	826.3 mm (32.53 in.)