2002 HONDA CIVIC boot

Special Tools Required. Boot band tool, KD-3191 or equivalent, commercially
available. Boot band pincers, Kent-Moore J-359'10 or equivalent,
commerclally available. Boot band pincers,commercially available
NOTE: Refer to the Exploded View as needed during
this procedure.
lnboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent
damage to the inboard boot.
Install the inboard boot onto the driveshaft, then
remove the vinyl tape, Be careful not to damage
inboard boot.
Ine
4.
5
3. Installthe spider (A) onto the driveshaft by aligning
the marks (B) on the spider and the end of the
driveshaft.
Fit the circlip (C) into the driveshaft groove. Always
rotate the circlip in its groove to make sure it is fully
seated.
Fit the rollers (A) onto the spider {B) with their high
shoulders facing outward, and note these items:
' Reinstallthe rollers in their original positions on
the spider by aligning the marks (C).
. Hold the driveshaft pointed up to prevent the
rollers from falling off.
(cont'd)
@\
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16-11

Driveline/Axle
6.
Driveshafts Reassembly (cont'd)
Pack the inboard joint with the joint grease
included in the new driveshaft set.
Grease quantity
Inboard ioint: 130 140 g (4.6-4.9 oz)
Use the grease included in theinboard boot set.
Fit the inboard joint onto the driveshaft, and note
these items:
. Reinstall the inboard joint onto the driveshaft by
aligning the marks (A) on the inboard joint and
the rollers.. Hold the driveshaft so the inboard joint is
pointing up to prevent it trom falling off.
7.
16-12
11.
8.Make sure the ends of the boot are sealed in the
grooves in the driveshaft and joint, then installthe
boot bands.
. For the double loop type, go to step 12.(Replacement boot bands only). For the low profile type, go to step 9.
Installthe new low profile band {A) onto the boot
{B). then hook the tab (C) of the band,
Close the hook portion of the band (A) with a
commercially available boot band pincers (B), then
hook the tabs of the band.
Install the boot band on the other end of the boot,
and reoeat steos 9 and 10.
9.
\10.
I

Fit the boot ends onto the driveshaft and the
inboard joint, then install the new double loop band
{A) onto the boot.
Pull up the slack in the band by hand
Mark a position (A) on the band 10- 14 mm (0.4-
0.6 in.) from the clip {B).
15. Thread the free end ofthe band through the nose
section of the commercially available boot band
tool KD-3191 or equivalent (A), and into the slot on
the winding mandrel (B).
Place a wrench on the winding mandrel of the boot
band tool, and tighten the band until the marked
spot (C) on the band meets the edge of the clip
Lift uD the boot band tool tobendthefree end of
the band 90 degrees to the clip. Center-punch the
clio, then fold over the remaining tail onto the clip.
16.
17.
(cont'd)
16-13

Driveline/Axle
Driveshafts Reassembly (cont'dl
18. Unwind the boot band tool, and cut off the excessfree end of the bandto leave a 5- 10 mm (0.2-0.4
in.) tail protruding from the clip
19. Bend the band end (A) by tapping it down with anammer.
NOTE;. Make sure the band and clip do not interfere withanything and the band does not move.. Remove any grease remaining on the
surrounding surfaces
20. Repeat steps 12 through 19 for the band on theother end of the boot.
16-14
{
2'1. Installthe new set ring.

Outboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent
damage to the outboard boot.
Installthe new ear clamp bands (B) and outboard
boot, then remove the vinyl tape. Be careful not to
damage the outboard boot.
Install the new stop ring into the driveshaft groove
(A).3.
t
4. Insert the driveshaft (A) into the outboard joint (B)
until the stop ring (C) is close to the joint.
To completely seat the outboard joint, pick up the
driveshaft and joint, and drop them from about 10
cm (4 in.) onto a hard surface. Do not use a
hammer as excessive force may damage the
driveshaft. Be careful not to damage the threaded
section (A) of the outboard joint.
5.
10 cm(4 in.)
- ..,..,1 ;,t ,:-,;
{cont'd)
16-15

Driveline/Axle
Driveshafts Reassembly (cont'd)
Check the alignment of the paint mark (A) with theoutboard joint end (B).
7. Pack the outboard joint (A)with the joint grease
included in the new ioint boot set.
Grease quantity
Outboard ioint: 105 115 g (3.7 4.1 ozl
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16-16
8. Adjust the length of the driveshafts to the figurebelow, then adjust the boots to halfway betweenfull compression and full extension. Make sure theends of the boots seat in the grooves of thedriveshaft and joint.
Left driveshaft:497 502 mm (19.6 19.8in.)
Rightdriveshaft: 475 480 mm {18.7
t
-tTfi'.D.ilTD
18.9 in.l
Fit the boot (A) ends onto the driveshaft (B) andoutboard joinl (C).
9.
{

10. Close the ear portion (A) of the band with a
commercially available boot band pincers Kent-
Moore J-35910 or equivalent (B).
Check the clearance between the closed ear portlon
of the bands. lf the clearance is not within the
standard, close the ear podion of the bands farther.
11.
12.Repeat steps 10 and 11 for the band on the other
end of the boot.
6.0 mm 10.24 in.) MAX
3.0 mm {0.12 in.} MAX
Driveshafts Installataon
1. Install a new set ring onto the set ring groove of the
driveshaft {left driveshaft ).
Apply 0.5 1.0 g {0.02 0.04 oz) of specified grease
tothewhole splined surface (A) ofthe right
driveshaft. After applying grease, remove the
grease from the splined grooves at intervals of 2-
3 splines and from the set ring groove (B) so that
air can bleed from the intermediate shaft.
(cont'd)
16-17

Driveline/Axle
Driveshafts Installation (cont'd)
Clean the areas where the driveshaft contacts thedifferential thoroughly with solvent, and dry withcompressed air. Insenthe inboard end {A) ofthedriveshaft into the differential (B) or intermediateshaft {C) until the set ring (D) locks in the groove (E).
4. Install the outboard joint (A) into the front hub (B).
16-18
5. Wipe offthe grease from the ball ioint and lowerarm tapered surfaces. Installthe knuckle (A) ontothe lower arm {B). Be careful not to damage the balljoint boot. Wipe off the grease before tighteningthe nut at the ball joint. Torque the new castle nut(C) to the lower torque specification, then tighten itonly far enough to align the slot with the ball joint
pin hole. Do not align the nut by loosening it.
NOTE: Make sure the ball joint boot is not damageor cracks.
"-'t-
12 x 1.25 mm59 69 N.m(6.0 -7.0 kgf m,43 51 tbt.ftl
Installthe new lock pin {D) into the balljoint pin
hole from the inside to the outside of the vehicle.
Connect the front stabilizer link {A) to the lower arm.Hold the stabilizer link balljoint pin (B) with a hexwrench {C), and tighten the newflange nut {D).
7.
'10 x 1.25 mm39 N.m{4.0 kgf.m,29 lbf.ft)
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