Special Service Tool
| Tool Name / Number | Illustration | Description |
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Band installer 0K495 - 2W001 |
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Used for installing hook type boot band (low profile) |
Removal
• Driveshaft joints require special grease, so do not add any other type of grease.
• When replacing the boot band, it must be a new one.
1.Remove the front driveshaft.(Refer to Front Driveshaft Assembly (4WD) - "Front Driveshaft")
2.Remove the reduction gear side large diameter (A) and small diameter (B) boot bands.
| Ear type | Hook type |
Hook type [Low profile] |
| Flat-head screwdriver | Flat-head screwdriver | SST (0K495 - 2W001) |
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3.Remove the reduction gear side joint housing (A).
4.Remove the snap ring (A) using a snap ring pliers.
5.Remove the spider assembly (B) from the driveshaft using a puller (A).
6.Remove reduction gear side boot (A).
7.Clean the inside of the spider assembly and joint housing.
Special Service Tool
| Tool Name / Number | Illustration | Description |
|
Band installer 0K495 - C5000 |
|
Used for installing of ear type boot band (Sharing handle with 0K495 - 2W000) |
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Band installer 0K495 - 2W001 |
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Used for installing hook type boot band (low profile) |
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Band installer 09495 - 39100 |
|
Used for installing hook type boot band |
Installation
• When assembling, be careful not to let dust and foreign substances enter.
• Driveshaft joints require special grease, so do not add any other type of grease.
• When replacing the boot band, it must be a new one.
1.Install the reduction gear side boot (A) and boot band (B) on the driveshaft.
2.Install the spider assembly (A) on the shaft (B), then press it using a rubber mallet.
• When installing the spider assembly (A), install it in the correct direction.
• Installing in the wrong direction can cause secondary quality problems.
3.Install the snap ring (A) using the snap ring pliers.
• When replacing the joint assembly, use the new one provided in the joint kit.
• Do not reuse the snap ring.
• After installing the snap ring, make sure that there are only 2 - 3 splines in position (A).
4.Install the reduction gear side joint boot (A) in the correct position.
• When installing boot (A), make sure the boot fits into the groove (B).
• When installing the spider assembly, fit the assembly to the boot shape.
5.Apply specified grease inside the joint housing (A) and boot (B).
• Use the grease provided with the joint/boot kit.
• Apply about 70% grease to the housing (A) and about 30% grease to the boot (B).
• Driveshaft joints require special grease, so do not add any other type of grease.
6.Install the reduction gear side joint housing (A).
• When installing the housing, turn the boot to fit each other.
• If the shape of housing and boot does not fit, there is a possibility of leakage due to the gap. Be very careful.
7.Adjust the air inside the boot to normal as shown below.
| Normal | Lack of air | Too much air |
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8.Install the reduction gear side joint large diameter (A) and small diameter (B) boot band.
| Ear type | Hook type |
Hook type [Low profile] |
| SST (0K495 - C5000) | SST (09495 - 39100) | SST (0K495 - 2W001) |
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• Install in the following order : large diameter boot band (A) → small diameter boot band (B).
• Installing in the wrong order can cause leaks.
• When installing the boot band, align the fastened direction with the wheel side joint boot band.
• Clean if there is any grease around the boot band after installing.
• When installing the ear type boot band, check the clearance (A) as shown below.
Clearance (A) : 2.0 mm (0.0787 in.) or less.
• When using the low profile hook type boot band, fit the SST tip (B) into the boot band hole (A) as shown below.
9.Install the front driveshaft.(Refer to Front Driveshaft Assembly (4WD) - "Front Driveshaft")
Inspection
1.Check spline (A) for damage / wear / crack.
2.Check the boot for water or foreign objects.
3.Check joint assembly for damage / wear / crack and rust.
4.Replace any defective parts.
