ES300 1992-1997

CV-Joints

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CV-Joint Boots



Inspection

Specific to:

Lexus ES250 1990-1991

Lexus ES300 1992-1999

  1. Raise and safely support the vehicle. Remove the front tire and wheel assembly.
  2.  
  3. Disconnect the center halfshaft from the right side halfshaft, using the proper tool. Remove the inboard joint clamp.
  4.  
  5. Place matchmarks on the inboard joint and the halfshaft. Remove the snap ring with the proper tool.
  6.  
  7. Remove the inboard joint from the halfshaft, using the proper tool to press out the joint.
  8.  
  9. Remove the inboard joint from the inboard joint cove. When lifting the inboard joint, hold on to the inner race and outer race.
  10.  
  11. Remove the inboard joint boot and the outboard joint boot.
  12.  
  13. Reverse the removal procedure for installation. Pack the boot with a suitable grease prior to installation.
  14.  

Replacement

Specific to:

Lexus ES300 1993-1997



Click image to see an enlarged view

Fig. Inboard joint cover installation sequence - ES300



Click image to see an enlarged view

Fig. Axle shaft measuring points - ES300

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front tire and wheel assembly.
  4.  
  5. Remove the front halfshaft.
  6.  
  7. Remove the six bolts and three washers and disconnect the center axle shaft from the right axle shaft. Remove the joint end cover gasket from the axle shaft.
    NOTE
    Do not compress the inboard boot.

  8.  
  9. Install nuts, bolts and washers finger-tight to keep the inboard joint together.
  10.  
  11. Remove the inboard and outboard CV-boot clamps.
  12.  
  13. Matchmark the inboard joint and axle shaft.
  14.  
  15. Remove the snapring.
  16.  
  17. Remove the inboard joint from the axle shaft, using the proper tool to press out the joint.
  18.  
  19. Remove the inboard joint from the inboard axle shaft.
  20.  
  21. Remove the nuts, bolts and the washers.
  22.  
  23. Using a prybar and hammer, pry around the whole perimeter of the inboard joint cover.
  24.  
  25. Secure the inner and outer races and remove the inboard joint from the cover.
  26.  
  27. Remove the inner and outer boots.
  28.  

To install:

  1. Wrap vinyl tape around the spline of the shaft to prevent damage to the boot.
  2.  
  3. Pack the outer CV-boot with the grease provided in the kit.
  4.  
  5. Install the outboard CV-boot.
  6.  
  7. Install the inboard CV-boot.
  8.  
  9. Apply seal packing 08826-00801 or Three Bond 1121® or equivalent, to the inboard joint cover.
    NOTE
    Avoid applying an excess amount to the surface.

  10.  
  11. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
  12.  
  13. Using a plastic faced hammer, tap the rim of the inboard joint cover into place. Repeat several times until seated.
  14.  
  15. Install the bolts, nuts and the washers finger-tight to keep the joint assembled.
  16.  
  17. Align the matchmarks placed before removal.
  18.  
  19. Using a brass bar and hammer, tap the inboard joint onto the axle shaft.
    WARNING
    Ensure the brass bar contacts the inner race, not the cage.

  20.  
  21. Remove the nuts, bolts and the washers.
  22.  
  23. Install a new snapring.
  24.  
  25. Pack grease into the inboard boot and joint.

    Click image to see an enlarged view

    Fig. Clamp installation - ES300

  26.  
  27. Install new clamps onto the CV-boots. Ensure the boots are on the shaft groove and are not stretched or contracted when the driveshaft is at the standard length of:

    Right side - 17.949 inches (455.0mm)
     
    Left side - 17.953 inches (455.9mm)
     

  28.  
  29. Pack grease into the center axle shaft or side gear shaft.
  30.  
  31. Ensure there is not play in the inboard and outboard joint.
  32.  
  33. Ensure the inboard joint slides smoothly in the thrust direction.
  34.  
  35. Install the axle shaft.
  36.  
  37. Install the wheel.
  38.  
  39. Lower the vehicle.
  40.  

Overhaul



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front tire and wheel assembly.
  4.  
  5. Remove the front halfshaft.
  6.  
  7. Remove the six bolts and three washers and disconnect the center axle shaft from the right axle shaft. Remove the joint end cover gasket from the axle shaft.
    NOTE
    Do not compress the inboard boot.

  8.  
  9. Install nuts, bolts and washers finger-tight to keep the inboard joint together.
  10.  
  11. Remove the inboard and outboard CV-boot clamps.
  12.  
  13. Matchmark the inboard joint and axle shaft.
  14.  
  15. Remove the snapring.
  16.  
  17. Remove the inboard joint from the axle shaft, using the proper tool to press out the joint.
  18.  
  19. Remove the inboard joint from the inboard axle shaft.
  20.  
  21. Remove the nuts, bolts and the washers.
  22.  
  23. Using a prybar and hammer, pry around the whole perimeter of the inboard joint cover.
  24.  
  25. Secure the inner and outer races and remove the inboard joint from the cover.
  26.  
  27. Remove the inner and outer boots.

    Click image to see an enlarged view

    Fig. Axle shaft measuring points

  28.  

To install:

Click image to see an enlarged view

Fig. Inboard joint cover installation sequence

  1. Wrap vinyl tape around the spline of the shaft to prevent damage to the boot.
  2.  
  3. Pack the outer CV-boot with the grease provided in the kit.
  4.  
  5. Install the outboard CV-boot.
  6.  
  7. Install the inboard CV-boot.
  8.  
  9. Apply seal packing 08826-00801 or Three Bond 1121® or equivalent, to the inboard joint cover.
    NOTE
    Avoid applying an excess amount to the surface.

  10.  
  11. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
  12.  
  13. Using a plastic faced hammer, tap the rim of the inboard joint cover into place. Repeat several times until seated.
  14.  
  15. Install the bolts, nuts and the washers finger-tight to keep the joint assembled.
  16.  
  17. Align the matchmarks placed before removal.
  18.  
  19. Using a brass bar and hammer, tap the inboard joint onto the axle shaft.
    WARNING
    Ensure the brass bar contacts the inner race, not the cage.

  20.  
  21. Remove the nuts, bolts and the washers.
  22.  
  23. Install a new snapring.
  24.  
  25. Pack grease into the inboard boot and joint.

    Click image to see an enlarged view

    Fig. Clamp installation

  26.  
  27. Install new clamps onto the CV-boots. Ensure the boots are on the shaft groove and are not stretched or contracted when the driveshaft is at the standard length of:

    Right side: 17.949 inches (455.0mm)
     
    Left side: 17.953 inches (455.9mm)
     

  28.  
  29. Pack grease into the center axle shaft or side gear shaft.
  30.  
  31. Ensure there is not play in the inboard and outboard joint.
  32.  
  33. Ensure the inboard joint slides smoothly in the thrust direction.
  34.  
  35. Install the axle shaft.
  36.  
  37. Install the wheel.
  38.  
  39. Lower the vehicle.
  40.  

 
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