Page 953 of 1954
12. Thread the free end of the band through the nose
section of the commercially available boot band
tool KD-3191 or equivalent, and into the slot on the
winding mandrel.
13. Place a wrench on the winding mandrel of the boot
band tool, and tighten the band until the marked
spot on the band meets the edge of the clip.
BOOT BAND TOOL
(KD-3191
or equivalent)
Mark on band.
15. Unwind the boot band tool, and cut off the excess
free end of the band to leave a 5 - 10 mm (0.2 - 0.4
in) tail protruding from the clip.
16. Bend the band end by tapping it down with a ham-
mer.
NOTE:
• Make sure the band does not move.
• Remove any grease remaining on the surround-
ing surfaces.
5- 10 mm
(0.2
-
0.4
in)
Fold over.
17. Install the new set ring.
SET RING
Replace.
14. Lift up the boot band tool to bend the free end of
the band 90 degrees to the clip. Center-punch the
clip, then fold over the remaining tail onto the clip.
HAMMER
PUNCH
WINDING
MANDRELProCarManuals.com
Page 954 of 1954
2. Instal l th e boo t ban d an d outboar d boot , the n
remov e th e viny l tape . Tak e car e no t t o damag e th e
boot .
3. Instal l th e sto p rin g int o th e driveshaf t groove .
STOP RIN GReplace .
GROOV E
DRIVESHAF T
Driveshafts
Reassembl y (cont'd )
Outboar d Join t Side :
1 . Wra p th e spline s wit h viny l tap e to preven t damag e
t o th e boot .
TPE TYPE :
OUTBOAR D BOO T
VINYL TAP E
BOOT BAN DReplace .
RUBBER TYPE :
OUTBOAR D BOO T(RUBBER )
VINYL TAP E
4. Inser t th e driveshaf t int o th e outboar d join t unti l th e
sto p rin g is clos e o n th e joint .
5 . T o completel y sea t th e outboar d joint , pic k u p th e
driveshaf t an d joint , an d dro p the m fro m abou t 1 0
c m (4 in. ) ont o a har d surface . D o no t us e a hamme r
a s excessiv e forc e ma y damag e th e driveshaft .
DRIVESHAF TOUTBOARD JOIN T
STOP RIN G
ProCarManuals.com
Page 955 of 1954
6. Check the alignment of the paint mark with the out-
board joint end.
PAINT MARK
DRIVESHAFT
OUTBOARD
JOINT END
7. Pack the outboard joint with the joint grease included
in the new joint boot set.
Grease quantity:
'96 - 98 models: 130 - 140 g (4.6 - 4.9 oz)
'98 Canada and '99 - 01 models:
140
-
150
g(4.9
-
5.3
oz)
DRIVESHAFT
OUTBOARD JOINT
EAR CLAMP BAND
Replace.
8. Fit the boot ends onto the driveshaft and outboard
joint.
OUTBOARD BOOT (TPE)
OUTBOARD BOOT
DRIVESHAFT
OUTBOARD BOOT
OUTBOARD JOINT
9. Install the boot bands.
• For '96-98 models, go to step 13
• For '98 Canada and '99 - 01 models, go to
step 10.
10. Set the ear clamp band by threading the tab into the
holes of the band.
HOLE
TAB
(cont'd)ProCarManuals.com
Page 956 of 1954
3.0 m m (0.1 2 in) MA X
6.0 m m (0.2 4 in) MA X
Reassembl y (cont'd )
11. Clos e th e ea r portio n o f th e ban d wit h a commerciall y
availabl e boo t ban d pincer s Kent-Moor e J-3591 0 o r
equivalent .
Driveshaft s
13. Fi t th e boo t end s ont o th e driveshaf t an d th e
outboar d joint .
14. Fi t th e doubl e loo p boo t band s ont o th e boo t ends .
15 . Pul l u p th e slac k in th e ban d b y hand .
16 . Mar k a positio n o n th e ban d 1 0 - 1 4 m m (0. 4 - 0. 6
in.) fro m th e clip .
12. Chec k th e clearanc e betwee n th e close d ea r portio n
o f th e band . I f th e clearanc e i s no t withi n th e stan -
dard , clos e th e ea r portio n o f th e ban d further .
BOOT BAN D PINCER S
Kent-Moor e J-3591 0
o r equivalen t
EA R PORTIO N
ProCarManuals.com
Page 957 of 1954
17. Thread the free end of the band through the nose
section of the commercially available boot band
tool KD-3191 or equivalent, and into the slot on the
winding mandrel.
BOOT BAND TOOL
(Commercially available)
KD-3191 or equivalent
Mark spot.
WINDING
MANDREL
18. Place a wrench on the winding mandrel of the boot
band tool, and tighten the band until the marked
spot on the band meets the edge of the clip.
19. Lift up the boot band tool to bend the free end of
the band 90° to the clip. Center punch the clip, then
fold over the remaining tail onto the clip.
21. Bend the band by tapping it down with a hammer.
NOTE: Make sure the band and the clip do not
interfere with anything, and the band does not
move. Remove any grease remaining in the sur-
rounding surfaces.
20. Unwind the boot band tool, and cut off the excess
free end of the band to leave a 5 - 10 mm (0.2 - 0.4
in) tail protruding from the clip.
BAND END
5-10
mm
(0.2
-
0.4
in)ProCarManuals.com
Page 958 of 1954

3. Instal l a ne w se t rin g ont o th e driveshaf t o r interme -
diat e shaf t groove .
CAUTION : Alway s us e a ne w se t rin g wheneve r
th e driveshaf t i s bein g installed .
SET RIN G GROOV E
Driveshaft s
Installation
1. Instal l th e outboar d join t int o th e knuckle .
KNUCKL E
4. Inser t th e inboar d en d o f th e driveshaf t int o th e dif -
ferentia l o r intermediat e shaf t unti l th e se t rin g
lock s in th e groove .
NOTE : Clea n th e area s wher e th e driveshaf t con -
tacts th e differentia l thoroughl y wit h solven t o r car -
bureto r cleaner , an d dr y wit h compresse d air .
INTERMEDIAT E SHAF T
GROOV E
INBOAR D JOIN T
SET RIN GReplace .
INBOAR D JOIN T
SET RIN GReplace .GROOV E
DIFFERENTIA L
5. Instal l th e knuckl e ont o th e lowe r arm , the n tighte n
th e castl e nut , an d instal l a ne w cotte r pin .
NOTE : Wip e of f th e greas e befor e tightenin g th e
nu t a t th e bal l joint .
CAUTION :
• B e carefu l no t t o damag e th e bal l join t boot .
• Torqu e th e castl e nu t t o th e lowe r torqu e speci -
fication , the n tighte n it onl y fa r enoug h t o alig n
the slo t wit h th e pi n hole . D o no t alig n th e nu t
by loosenin g it . Instal l a ne w cotte r pin .
CASTL E NU T14 x 2. 0 m m69 - 7 8 N- m(7. 0 - 8. 0 kgf-m ,51 - 5 8 Ibf-ft )
COTTE R PI NReplace .On reassembly ,bend th e cotte r pi n
a s shown .
2. Appl y 0. 5 - 1. 0 g (0.0 2 - 0.0 4 oz ) o f greas e t o th e
whol e spline d surfac e o f th e intermediat e shaft .
NOTE : Afte r applyin g grease , remove the greas e
from th e spline d groove s a t interval s o f 2 - 3 spline s
and fro m th e se t rin g groov e s o ai r ca n blee d fro m
the inboar d joint .
SET RIN GReplace .
OUTBOAR D JOIN T
ProCarManuals.com
Page 959 of 1954

6. Instal l th e dampe r for k ove r th e driveshaf t an d ont o
the lowe r arm . Instal l th e dampe r i n th e dampe r
for k s o th e alignin g ta b i s aligne d wit h th e slo t i n
th e dampe r fork .
ALIGNIN G TAB
DAMPE R FOR K
FLANG E BOL T10 x 1.2 5 mm43 N- m (4. 4 kgf-m , 3 2 Ibf-ft )
SELF-LOCKIN G NU T12 x 1.2 5 mm69 N- m (7. 0 kgf-m , 5 1 Ibf-ft )Replace .
7. Loosel y instal l th e flang e bolt s an d th e ne w self -
lockin g nut .
NOTE : Th e bolt s an d nu t shoul d b e tightene d wit h
th e vehicle' s weigh t o n th e damper .
8 . Appl y engin e oi l t o th e seatin g surfac e o f th e ne w
spindl e nut . WHEE L NU T 1 2 x 1. 5 m m
108 N- m (11. 0 kgf-m , 8 0 Ibf-ft )
SPINDL E NU T 2 4 x 1. 5 m m245 N- m (25. 0 kgf-m , 18 1 Ibf-ft ) Replace .NOTE: Afte r tightening , us e a drif t t o
stak e th e spindl e nu t shoulde r agains t th e driveshaft .
9. Instal l a ne w spindl e nut , the n tighte n th e nut .
10 . Instal l th e fron t whee l wit h th e whee l nuts .
NOTE : Befor e installin g th e wheel , clea n th e matin g
surface s o f th e brak e dis c an d th e wheel .
11 . Tighten the flang e bolt s an d th e ne w self-lockin g
nu t wit h th e vehicle' s weigh t o n th e damper .
12 . Refil l th e differentia l with recommende d oi l (se e
sectio n 15 ).
13 . Chec k th e fron t whee l alignment , an d adjus t i t i f
necessar y (se e sectio n 18 ).
FRON T WHEE L
ProCarManuals.com
Page 960 of 1954
Intermediate Shaf t
Remova l
1. Drai n th e differentia l oi l (se e sectio n 15 ).
2 . Remov e th e lef t driveshaf t (se e pag e 16-3 ).
3 . Remov e th e thre e flang e bolts .
FLANG E BOL T8 x 1.2 5 mm
4. Remov e th e intermediat e shaf t fro m th e differential .
INTERMEDIAT E SHAFT
ProCarManuals.com