1991 LEXUS SC300 boot

REAR DRIVE SHAFT INSTALLATION
SA0S4±02
1. INSTALL DRIVE SHAFT
(a) Insert the outboard joint side of the drive shaft to the axle hub.
NOTICE:
wBe careful not to damage the boots, end cover and speed
sensor rotor of the drive shaft, and oil seal of the axle hub.
w Make sure the outboard joint side of the drive shaft does
not bend too much.
(b) Align the matchmarks on the side gear shaft and drive shaft.
(c) Apply a light coat of engine oil on the threads of the bolt.
(d) Install the 6 hexagon bolts and 2 washers.
(e) Using a 10 mm hexagon wrench, torque the bolts.
Torque: 83 N Vm (850 kgf Vcm, 64 ft Vlbf)
2. INSTALL EXHAUST PIPE
3. INSTALL LOCK NUT, LOCK CAP AND NEW COTTER PIN
Torque: 289 N Vm (2,950 kgf Vcm, 213 ft Vlbf)
4. INSTALL REAR WHEEL AND LOWER VEHICLE
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±67
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REAR DRIVE SHAFT DISASSEMBLY
SA0UY±05
1. CHECK DRIVE SHAFT
(a) Check that operation of the joint is smooth within the slidingregion in the axial direction.
HINT: If a large angle is used for the cross±groove type joint,
the joint will feel like it is catching, but this does not indicate
an abnormality.
(b) Check that there are no cracks, damage or grease leaks with
the boots.
(c) Check that there are no scratches on the speed sensor rotor.
2. REMOVE END COVER
(a) Using a screwdriver, remove the end cover.
(b) Use bolts, nuts and washers to keep the i nboard joint
together.
NOTICE: Tighten the bolt by hand to avoid scratching the
flange surface.
3. REMOVE BOOT CLAMPS Using a side cutter or pliers, remove the clamps.
SA±68
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SUSPENSION AND AXLE REAR DRIVE SHAFT
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4. REMOVE INBOARD JOINT
(a) Place matchmarks on the inboard joint and drive shaft.
NOTICE: Do not punch the marks.
(b) Using a snap ring expander, remove the snap ring.
(c) Using SST, an extension bar and a press, press out theinboard joint from the drive shaft.
SST 09726±12022 (09726±01030)
(d) Mount the inboard joint in a soft jaw vise.
(e) Using a screwdriver and hammer, tap out the inboard joint cover from the inboard joint.
NOTICE: Make sure the cage and inner race are not positioned
too much to one side of the outer race.
5. REMOVE BOOTS Remove the inboard joint boot and outboard boot.
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±69
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REAR DRIVE SHAFT ASSEMBLY
SA0UZ±05
1. ASSEMBLE INBOARD JOINTIf the joint has come apart, reassemble it in the following or-
der.
(a) Align the matchmarks placed before removal.
HINT: When the matchmarks have disappeared, perform the
following procedure.
(1) Install the inner race to the cage so that the indented bev-elled part of the inner race is on the opposite side to the
bevelled top of the cage.
(2) Install the outer race so that the indented side of the outer race is facing the same side as the bevelled surface of
the cage.
(3) Match the narrow projections of the inner race with the wide projections of the outer race.
(b) Tilt the cage and inner race to the side and insert the balls one
by one.
NOTICE: When the cage and inner race are tilted over, support
the joint with your hand to prevent the balls from falling out.
2. TEMPORARILY INSTALL NEW BOOTS AND NEW BOOT CLAMPS
(a) Place 4 new boot clamps to each boots.
HINT: Before installing the boots, wrap vinyl tape around the
spline of the shaft to prevent damaging the boots.
(b) Install the 2 boots to the drive shaft.
3. INSTALL INBOARD JOINT COVER
(a) Apply seal packing to the inboard joint cover as shown in the illustration.
Seal packing:
Part No.08826±00801, THREE BOND 1121 or equivalent
wInstall a nozzle that has been cut to a 1 mm (0.04 in.)
opening.
SA±70
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HINT: Avoid applying an excessive amount to the surface.
(b) Remove grease from the surface of the inboard joint facing the cover.
(c) Align the bolt holes of the cover with those of the inboard joint,
then insert the hexagon bolts.
(d) Use a pl astic±faced hammer to tap the rim of the inboard joint
cover into place. Do this in the order shown, and repeat
several times.
4. INSTALL INBOARD JOINT
(a) Align the matchmarks placed before removal.
(b) Using a brass bar and hammer, tap the inboard joint onto the drive shaft.
NOTICE: Check that the brass bar is touching the inner race,
and not the cage.
(c) Using a snap ring expander, install a new snap ring.
5. ASSEMBLE BOOT TO OUTBOARD JOINTBefore assembling the boot, pack with only the same amount
of grease that was wiped off.
Grease capacity:
100 ± 105 g (0.22 ± 0.23 lb, 3.5 ± 3.7 oz.)
HINT: Use the grease supplied in the boot kit.
NOTICE:
wKeep grease off the joint connection groove of the boot.
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±71
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wPack with grease all over the ball contact surface inside
the joint.
6. ASSEMBLE BOOT TO INBOARD JOINT
Before assembling the boot, pack with grease.
Grease capacity:
100±105 g (0.22±0.23 lb, 3.5±3.7 oz.)
HINT: Use the grease supplied in the boot kit.
NOTICE:
wKeep grease off the joint connection groove of the boot.
w Pack with grease all over the ball contact surface inside
the joint.
7. INSTALL NEW BOOT CLAMPS TO BOTH BOOTS
(a) Position the clamp onto the boot. HINT: Pinch the inboard side of the boot clamp, as shown in
the illustration.
(b) Place SST onto the clamp. SST 09521±24010
(c) Tighten SST so that the clamp is pinched.
NOTICE: Do not overtighten the SST.
(d) Using SST, adjust the clearance of the clamp. SST 09240±00020
Clearance:
0.8 mm (0.031 in.) or less
SA±72±
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(e) The drive shaft is designed to move + 20 mm from the normalposition.
Drive shaft standard length:
RH 598.5 mm (23.563 in.)
LH 553.5 mm (21.791 in.)
8. INSTALL NEW END COVER
(a) Pack grease into the end cover.
Grease capacity:50±55 g (0.11±0.12 lb, 1.8±1.9 oz.)
(b) Remove grease from the surface of the inboard joint facingthe cover.
(c) Glue on a new gasket, with the side with adhesive on it facing
toward the outer race side of the inboard joint.
(d) Align the bolt holes of the cover with those of the inboard joint.
(e) Install the 6 hexagon bolts and washer from the end cover side.
(f) Install the 6 nuts to the boot side.
(g) Using a 10 mm hexagon wrench, tighten the bolts. Do this in
the order shown, and repeat several times.
(h) Check that the claw of the end cover touches the inboard joint.
9. CHECK DRIVE SHAFT Check that operation of the joint is smooth within the sliding
region in the axial direction.
HINT: If a large angle is used for the cross±groove type joint,
the joint will feel like it is catching, but this does not indicate
an abnormality.
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±73
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SUSPENSION BALL JOINT INSPECTION ± PG012-02 October 11, 2002
Page 4 of 5
B. Move the lower arm by hand (All
models with strut type suspension
and some models with wish±bone
type suspension):
a. Lift up the vehicle.
b. Inspect the free play while moving the lower arm up and
down at a force of 67 lbf
(294 N, 30 kgf).
2. Inspect Upper Ball Joint Play Move the upper arm by hand (Models
where the LOWER control arm are
linked by a torsion bar, and all models
using a coil spring.
A. Remove the front tire.
B. Inspect the free play while moving the upper arm up and down at a
force of 67 lbf (294 N, 30 kgf).
3. Inspect the Suspension Arm Ball Joint Free Play
A. Lift up the vehicle.
B. Inspect the free play while moving the control arm by hand.
(Reference)
Free Play Inspection Method
(Gauge Installation) Position the dial gauge between the
arm (upper or lower) and the knuckle,
and measure free play.
(This illustration shows how to
measure free play for vehicles with
double wishbone type suspension
with coil spring).
Inspect Ball Joint Dust Cover
Check for cracks and grease leaks on the
dust cover (boots).Free Play
Inspection
(Continued)
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