Honda Insight 2000-2006

Overhaul

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Outboard Joint





Click image to see an enlarged view

Fig. Exploded view of the driveshaft/CV-joint assembly-Insight

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
     
    Outboard joint boot clamps and push the boot back
     
    Outboard joint by using a slide hammer to pull it off the driveshaft
     
    Snap ring
     
    Outboard joint boot
     

  4.  

To install:

Click image to see an enlarged view

Fig. Drive shaft assembled length dimensions-Insight


NOTE
Use new circlips and boot clamps for assembly.

  1. Install the outboard joint boot and clamps to the axle shaft.
  2.  
  3. Install a new snap ring on the driveshaft groove.
  4.  
  5. Insert the driveshaft into the joint until the snap ring closes.
  6.  
  7. Seat the joint by dropping it straight down onto a hard surface from about 4 inches. DO NOT use a hammer to seat the joint.
  8.  
  9. Fill the outboard joint with grease.
  10.  
  11. Adjust the length of the driveshaft to the dimensions shown. Adjust the boots to half-way between full extension and full compression.
  12.  
  13. On the right driveshaft, position the dynamic damper to the length shown.
  14.  
  15. Fit the boot ends onto the driveshaft.
  16.  
  17. Crimp the clamps onto the boots.
  18.  
  19. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Right driveshaft dynamic damper dimensions-Insight

  20.  

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
     
    Outboard joint boot clamps and push the boot back
     
    Outboard joint by using a slide hammer to pull it off the driveshaft
     
    Snap ring
     
    Outboard joint boot
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the driveshaft/CV-joint assembly-Insight



Click image to see an enlarged view

Fig. Drive shaft assembled length dimensions-Insight


NOTE
Use new circlips and boot clamps for assembly.

  1. Install the outboard joint boot and clamps to the axle shaft.
  2.  
  3. Install a new snap ring on the driveshaft groove.
  4.  
  5. Insert the driveshaft into the joint until the snap ring closes.
  6.  
  7. Seat the joint by dropping it straight down onto a hard surface from about 4 inches. DO NOT use a hammer to seat the joint.
  8.  
  9. Fill the outboard joint with grease.
  10.  
  11. Adjust the length of the driveshaft to the dimensions shown. Adjust the boots to half-way between full extension and full compression.
  12.  
  13. On the right driveshaft, position the dynamic damper to the length shown.
  14.  
  15. Fit the boot ends onto the driveshaft.
  16.  
  17. Crimp the clamps onto the boots.
  18.  
  19. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Right driveshaft dynamic damper dimensions-Insight

  20.  

Inner Joint



  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The inboard joint and rollers must be installed in their original positions. Matchmark the inboard joint in relation to each roller and mark each roller and its position on the spider.



    Axle halfshaft from the vehicle.
     
    Circlip from the joint
     
    Inboard joint boot clamps and push the boot back
     



    Inboard joint housing from the axle
     
    Rollers from the spider
     
    Snapring and the spider from the axle shaft
     
    Inboard joint boot
     

  4.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Install or connect the following:

    Inboard joint boot and clamps to the axle shaft
     
    Spider with a new snapring
     
    Rollers to the spider
     

  2.  
  3. Fill the joint housing with grease and install it.
  4.  
  5. Fill the inboard joint boot with grease and install the boot clamps.
  6.  
  7. Install the axle halfshaft to the vehicle.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The inboard joint and rollers must be installed in their original positions. Matchmark the inboard joint in relation to each roller and mark each roller and its position on the spider.



    Axle halfshaft from the vehicle.
     
    Circlip from the joint
     
    Inboard joint boot clamps and push the boot back
     



    Inboard joint housing from the axle
     
    Rollers from the spider
     
    Snapring and the spider from the axle shaft
     
    Inboard joint boot

    Click image to see an enlarged view

    Fig. Exploded view of the driveshaft/CV-joint assembly-Insight

     

  4.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Install or connect the following:

    Inboard joint boot and clamps to the axle shaft
     
    Spider with a new snapring
     
    Rollers to the spider
     

  2.  
  3. Fill the joint housing with grease and install it.
  4.  
  5. Fill the inboard joint boot with grease and install the boot clamps.
  6.  
  7. Install the axle halfshaft to the vehicle.
  8.  

 
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