LS400 1990-1997

CV-Joints

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CV-Joint Boots



Replacement


Click image to see an enlarged view

Fig. Removing the inboard joint cover from the joint



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Fig. Inboard joint cover installation sequence

If the Outboard joint CV-boot is being replaced, the Inboard CV-joint and boot must be removed first.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear tire and wheel assembly.
  4.  
  5. Remove the halfshaft.
  6.  
  7. Secure the halfshaft in a suitable holding fixture.
  8.  
  9. Wrap a shop towel around the speed sensor rotor to prevent damage.
  10.  
  11. Pry out the end cover.
  12.  
  13. Install nuts, bolts and washers finger-tight to keep the inboard joint together.
  14.  
  15. Remove the boot clamps from the inboard and outboard joint boots.
  16.  
  17. Matchmark the inboard joint and the halfshaft.
    NOTE
    Do not use punchmarks as the matchmarks.

  18.  
  19. Remove the snapring, using the proper pliers.
  20.  
  21. Press out the inboard joint from the halfshaft with the proper tools. Secure the inboard joint in a suitable holding fixture.
  22.  
  23. Tap out the inboard joint cover.
    NOTE
    Ensure the cage and inner race are not positioned too much to one side of the outer race.

  24.  
  25. Wrap the shaft splines with tape.
  26.  
  27. Remove both the inboard and outboard joint boots.
  28.  

To install:

  1. If the joint has been disassembled:
    1. Align the inboard joint matchmarks made prior to disassembly.
    2.  
    3. Install the inner race to the cage so that the indented beveled part of the inner race is on the opposite side to the beveled top of the cage.
    4.  
    5. Install the outer race so that the indented side of the outer race is facing the same side as the beveled surface of the cage.
    6.  
    7. Match the narrow projections of the inner race with the wide projections of the outer race.
    8.  
    9. Tilt the cage and the inner race to the side and insert the balls one by one.
      NOTE
      When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out.

    10.  

  2.  
  3. Temporarily install the four CV-boot clamps. Install the boots and pack them with grease.
    1. Outboard and inboard CV-joint grease capacity: 100-105g (3.5-3.7 oz). Use all the grease supplied in the boot kit and thoroughly pack the ball contact surface inside the joint.
    2.  

  4.  
  5. Apply seal packing 08826-00801, Three Bond 1121®, or equivalent to the inboard joint cover as shown in the illustration.
    NOTE
    Avoid applying an excessive amount to the surface.

  6.  
  7. Remove the grease from the surface of the inboard joint facing the cover.
  8.  
  9. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
  10.  
  11. Using a plastic tipped hammer, tap the inboard joint cover onto the joint. Strike the cover in the order shown and repeat several times.
  12.  
  13. Align the matchmarks for the joint and the halfshaft.
  14.  
  15. Using a brass bar and a hammer, tap the inboard joint onto the halfshaft.
    NOTE
    Ensure the brass bar is contacting the inner race and not the cage.

  16.  
  17. Install a new snapring.
  18.  
  19. Remove the hexagon bolts, nuts and washers.
  20.  
  21. Position the boots and tighten the clamps.
  22.  
  23. Ensure the boots are not stretched with the halfshaft at normal length of:

    Left halfshaft - 21.791 inches (553.5mm)
     
    Right halfshaft - 23.602 inches (598.5mm)
     
    1993-94 LS400 Left halfshaft - 22.855 inches (580.5mm)
     
    1993-94 LS400 Right halfshaft - 24.666 inches (626.5mm)
     
    1995 LS400 Left halfshaft - 22.579 inches (573.5mm)
     
    1995 LS400 Right halfshaft - 24.390 inches (619.5mm)
     

  24.  
  25. Pack grease into the end cover.
    1. End cover grease capacity: 50-55g (1.8-1.9 oz).
    2.  

  26.  
  27. Wipe off any excess grease and install a new gasket on the end cover.
  28.  
  29. Align the bolt holes of the end cover with those of the inboard joint.
  30.  
  31. Install the 6 hexagon bolts and washers from the end cover side and 6 nuts to the boot side. Tighten the bolts in the following sequence several times.
  32.  
  33. Ensure the claw of the end cover touches the inboard joint.
  34.  
  35. Ensure the operation of the joint is smooth within the sliding region in the axial direction.
    NOTE
    If a large angle is used for the cross-groove type joint, the joint will feel like it is catching, but this does not indicate an abnormality.



    Click image to see an enlarged view

    Fig. Checking the CV-joint operation

  36.  
  37. Install the halfshaft.
  38.  
  39. Install the wheel.
  40.  
  41. Lower the vehicle.
  42.  

 
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