Page 1049 of 2189
Driveshafts
Reassembly lcont'd)
Installthe outboard boot and the boot bands.. lf the boot is the rubber type. go to step 13.. lf the boot is the TPE type, go to step 9.
Fit the boot ends onto the driveshaft and outboard
ioint.
10, Set the ear clamp band by threading the tab into theholes of the band.
EAR CLAMP BANDReolace.
8.
16-16
11. Close the ear portion of the band with a commer-cially available boot band Dincerc.
BOOT BAND PINCERSKENT-MOORE J,35910or eouivalent
Chsck the clearanca between the closed ear oonionof the band. lf the clesrance is not within the stan-
dard, close the ear portion of ths band further.
6.0 mm (0.24 in) MAX
3.0 mm 10.t2 inl MAX
EAR FOFNON
Page 1050 of 2189
I
13. Fit the boot ends onto the driveshaft and the
outboard joint
Fit the double loop boot bands onto the boot ends'
Pull up the slack in the band by hand'
Mark a position on the band 10 - 14 mm {0 4 - 0 6
in,) from the cliP.
14.
16.
CLIP
lrz
17. Thread the free end of the band through the nose
section of a commercially avaiiable boot band tool
KD-3191 or equivalent and into the slot on the wind-
ing mandrel.
BOOT BAND TOOL
lCommerciallY available)
KD-3191 or equivalent
MANDREL
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'
Lift uo 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
Mark spot.
18.
1q
(cont'd)
16-17
Page 1051 of 2189
Driveshafts
Reassembly (cont'dl
20. Unwind the boot band tool, and cut off the excessfree end of the band to leave a 5 - 10 mm (0.2 - 0.4in.) tail protruding from the clip.
21. Bend the band by tapping it down with a hammer.
NOTE: Maks sure the band and the clip does notinterfere with anything, and the band does notmov6. Remove any grease remaining in the sur-
rounding surtaces.
AANO END
16-18
INBOARD JOiIT
SET RII{G GR(X)VE
Installation
1, Install the new set ring onto the driveshaft groove.
Always use a new set ring whenever the driveshaftis being installed.
2. Install the outboard joint into the knuckte.
OUTBOARD JOINT
KNUCKI.E
Page 1052 of 2189

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl
Page 1053 of 2189
Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
r 4).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
OOWEL BOLTS'10 x 1.25 mm
Remove the intermediate shaft from the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
'1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring.
2. Remove the intermediate shaft outer seal from theDeaflng suppon.
3. Remove the external circlip,
Page 1054 of 2189

Disassembly
Press the intermediate shaft out of the shaft bearing
using the special tools and a press as shown.
Remove the internal circliP
Press
I
SUPPORT BASEATTACHMENT07JAF - SH20400INTERNAL CIBCLIP
BEARING SUPPORT RING
Check for damage or distortion
6. Press the intermediate shaft bearing out ot the bear-
ing support using the special tools and a press as
shown.
HANOLE DRIVER
0?749 - 00' 10000
Press
I
DRIVER ATTACHMENT,12x47 mm07746 - 0010300FLOATING RUBBEB
DAMPERCheck for deterioration
and oamage.SUPPORT BASE
ATTACHMENT07JAF _ SH20it00
BEARING SUPPORT
Check for damage
I sErR'NG
A4 Reolace
VUOUTER SEALReplace.(cont'd)
ReassemblY
NOTE:
. clean the disassembted parts with solvent, and dry them thoroughly with compressed air' Do not wash the rubber
parts with solvent.
. Becareful not to da mage the metal ringson the intermediate shaftduring reassembly'
BEARING SUPPORT RINGDOWEL BOLTS10 x 1.25 mm39 N.m 14.0 kgf.m,29 lbIftl
EXTERNAL CIRCLIP
Pack the interiorof the outer seal.2.0-35s10.07-012oz)
INTERNAL CIRCLIP
INTERMEDTATE SHAFT BEARING
Replace,
INTERMEDIATE SHAFT RING
lJ
16-21
Page 1055 of 2189
lntermediate Shaft
Reassembly (cont'd)
1. Press the intermediate shaft bearing into the bear-ing support using the special tools and a press asshown.
Prass
I
DRIVER ATTACHMENT,52x55mm07746 - 001 0(X)
Seat the internal circlip in the groove of the bearingsuppon.
Press the intermediate shaft into the shaft bearingusing the special tools and a press.
Praa.r
I
@---
LJ
INTERMEDIATE SHAFT
DRIVER ATTACHMENT,35 mm LD.
16-22
Seat the external circlip in the groove of the inter-mediate shaft.
Install the outer seal into the bearing support usingthe special tools as shown.
NOTE: Install the seal ftush with the bearing sup-port.
Pre$
t HANDr.r DRTVER- 0011r(x)0
Pack the Interiorof the ouler seal.2.0- 3.5 g {0.07 -0.12 ozl
OUTEN SEAL
Install the new set ringgroove.
ORIVER ATTACHMENT,52x55mm077i16 - 0010/O0
in the intermediate shaft
Page 1056 of 2189
lnstallation
1. lnsert the intermediate shaft assembly into the dif-
ferential.
CAUTION: Hold the intermodiate shaft horizontal
to prevent damag€ to the difterential oil seal'
NOTE: Clean the areas where the intermediate shaft
contacts the transmission (differential) thoroughly
with solvent or carburetor cleaner, and dry with com-
Dressed air,
2. Install the three dowel bolts, then tighten them'
DOWEL BOLTS10 x 1.25 mm39 N.m {i1.0 kgf'm, 29 lbf'ftl
lz
16-23