Toyota Celica 1986-1993 Repair Guide

Front Halfshafts

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REMOVAL & INSTALLATION




CAUTION
On vehicles equipped with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work. Do NOT attempt to disassemble the bumper shocks, since they may be under high pressure.


WARNING
The hub bearing could be damaged if subjected to the full weight of the vehicle, such as if the vehicle is moved without the driveshafts. If it is absolutely necessary to place the full vehicle weight on the hub bearing, first support the bearing with SST No. 09608-16041, or equivalent.

1986-89 Models Except 4WD

Vehicles with the 2S-E or 3S-FE engines use the ST161 series axles. Vehicles with the 3S-GE engine use the ST162 series axles.

  1. Disconnect the negative battery terminal. Raise the front of the vehicle and support it safely.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the cotter pin and locknut cap.
  6.  
  7. Have an assistant depress the brake pedal and loosen the bearing locknut. Remove the engine under cover.
  8.  
  9. Remove the transaxle case protector, if equipped.
  10.  
  11. On the ST161 series, loosen the 6 nuts holding the front driveshaft to the center driveshaft or differential side gear shaft.
  12.  
  13. Disconnect the tie rod end by removing the cotter pin and nut.
  14.  
  15. Disconnect the tie rod with a press tool or, being careful not to damage the dust boot, separate with a fork tool.
  16.  
  17. Remove the bolts and nuts and disconnect the steering knuckle from the lower arm.
  18.  
  19. On the ST161 series, use SST No. 09950-20016 or equivalent to push the front driveshaft from the axle hub.
  20.  
  21. On the ST162 series left shaft, mark a spot somewhere on the driveshaft. Measure and note the distance between the transaxle case and the spot on the driveshaft. Using SST 09520-32060 or equivalent, pull out the left driveshaft.
  22.  
  23. On the ST162 series right shaft, use SST No. 09950-20016 or equivalent to push the front driveshaft from the knuckle. Remove the snapring and pull out the driveshaft with the center shaft.
  24.  
  25. To remove the center shaft on ST161 series, drain the transaxle lubricant. Remove the snapring and pull out the center shaft.
  26.  

To install:

  1. On ST161 series, install the center shaft, applying grease to the oil seal lip. Install the snapring.
  2.  
  3. On ST162 series, install the right shaft, applying grease to the oil seal lip. Install the snapring.
  4.  
  5. To install the front shaft on ST161 series, install the outboard joint to the axle hub. Finger tighten the nuts holding the driveshaft to the center shaft or differential side gear shaft.
  6.  
  7. To install the left shaft on ST162 series, install a new snapring to the inboard joint shaft. Apply grease to the lip of the transaxle oil seal. Install the left shaft to the transaxle and drive in with SST 09520-32060, or equivalent. Push in the left shaft and measure the distance between the case and mark made previously. Check that the shaft will not come out by hand.
  8.  
  9. Install the protector, if equipped.
  10.  
  11. Install the outboard side of the driveshaft to the axle hub.
  12.  


WARNING
Be careful not to damage the boots.

  1. Connect the steering knuckle to the ball joint.
  2.  
  3. Install the two bolts and torque them to 94 ft. lbs. (127 Nm).
  4.  
  5. Connect the tie rod end, torque the nut to 36 ft. lbs. (49 Nm), then install a new cotter pin.
  6.  
  7. Have an assistant depress the brake pedal and torque the bearing locknut to 137 ft. lbs. (186 Nm).
  8.  
  9. Install the locknut cap and a new cotter pin. Always tighten the nut if the holes do not line up. Never loosen the nut.
  10.  
  11. Depress the brake pedal and torque the six driveshaft nuts to 27 ft. lbs. (36 Nm).
  12.  
  13. Install the case protector, if equipped.
  14.  
  15. Fill the transaxle to the proper level with lubricant and install the cover. Connect the battery, install the wheels, check the front end alignment, then test drive the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 1 Front axle shaft components1986-89 models except 1989 4WD

1988-89 4WD Vehicle
  1. Disconnect the battery. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the cotter pin, cap and locknut from the hub.
  6.  
  7. Remove the engine undercovers.
  8.  
  9. Disconnect the tie rod end from the steering knuckle.
  10.  
  11. Disconnect the lower control arm at the steering knuckle.
  12.  
  13. Matchmark the axle to the side gear shaft. Depress the brake pedal and remove nuts and bolts of the inner joint.
  14.  
  15. Support the inner joint, then use a plastic hammer and carefully tap the outer end of the halfshaft until it frees itself from the axle hub.
  16.  
  17. Pull out the outer joint from the knuckle and remove the shaft.
  18.  

To install:

  1. Pack grease between the side gear shaft and the inner joint.
  2.  
  3. Put the outer end of each shaft into the axle hub, being careful not to damage the boots. Line up the matchmarks made previously and finger tighten the nuts and bolts.
  4.  
  5. Connect the lower control arm to the steering arm and tighten the bolt to 94 ft. lbs. (127 Nm).
  6.  
  7. Connect the tie rod to the steering knuckle and tighten the nut to 36 ft. lbs. (49 Nm). Use a new cotter pin to secure it. Always tighten the nut if the holes do not line up. Never loosen the nut.
  8.  
  9. Install the axle bearing locknut and tighten it to 137 ft. lbs. (186 Nm) while stepping on the brake pedal. Install the locknut cap and then a new cotter pin.
  10.  
  11. Tighten the nuts and bolts of the inner joint to 48 ft. lbs. (65 Nm).
  12.  
  13. Check the transaxle lubricant, install the undercovers and wheels. Lower the vehicle and check the front end alignment. Connect the battery and test drive.
  14.  



Click image to see an enlarged view

Fig. Fig. 2 Front axle shaft components1988-89 4WD

1990-93 Models Except 4WD
  1. Disconnect the negative battery terminal. Raise the front of the vehicle and support it safely.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the cotter pin and locknut cap.
  6.  
  7. Have an assistant depress the brake pedal and loosen the bearing locknut. Remove the engine under cover. Drain the transaxle lubricant.
  8.  
  9. Remove the brake caliper and rotor (See ).
  10.  
  11. Disconnect the tie rod end by removing the cotter pin and nut.
  12.  
  13. Disconnect the tie rod with a press tool or, being careful not to damage the dust boot, separate with a fork tool.
  14.  
  15. Remove the bolts and nuts and disconnect the steering knuckle from the lower arm.
  16.  
  17. Use SST No. 09950-20017 or equivalent to push the front driveshaft from the axle hub. Be careful not to damage the abs sensor serrations on the driveshaft, if equipped with abs.
  18.  
  19. Carefully pry out the left inner joint from the transaxle.
  20.  
  21. On models with the 5S-FE engine, remove the bolts of the center bearing bracket and pull out the right shaft together with the center bearing case and center drive shaft. On models with the 4A-FE engine, tap out the inner joint from the transaxle.
  22.  
  23. Lower the shaft.
  24.  

To install:

  1. Install the left shaft into the case, tapping the inner joint to snap the axle into place. Make sure the opening of the snapring is facing downward when installing the shaft. Insert the outer joint through the hub.
  2.  
  3. Install the right shaft on models with the 5S-FE engine. Install the center driveshaft with the right shaft through the bearing bracket. Install so the straight pin on the center bearing case aligns with the hole on the bearing bracket. Torque the bracket bolts to 47 ft. lbs. (64 Nm). Insert the outer joint into the hub.
  4.  
  5. Install the right shaft on models with the 4A-FE engine into the case, tapping the inner joint to snap the axle into place. Make sure the opening of the snapring is facing downward when installing the shaft. Insert the outer joint through the hub.
  6.  
  7. On the left shaft on models with both engines and on the right shaft on models with the 4A-FE engine, check that there is 0.08-0.12 in. (2-3mm) of axial play. Check also that the halfshaft will not come out by trying to pull it by hand.
  8.  
  9. Connect the steering knuckle to the lower control arm and tighten the bolts to 94 ft. lbs. (127 Nm).
  10.  
  11. Connect the tie rod end to the steering knuckle and tighten the nut to 36 ft. lbs. (49 Nm). Install a new cotter pin. Always tighten the nut if the holes do not line up. Never loosen the nut.
  12.  
  13. Install the rotor and caliper, torquing the bolts to 79 ft. lbs. (107 Nm).
  14.  
  15. Tighten the hub locknut to 166 ft. lbs. (226 Nm) while depressing the brake pedal. Install the cap and use a new cotter pin.
  16.  
  17. Fill the transaxle with lubricant.
  18.  
  19. Install the engine under cover and wheels. Check the front end alignment. Reconnect the battery and road test.
  20.  



Click image to see an enlarged view

Fig. Fig. 3 Front axle shaft components1990-93 models with 4A-FE engine



Click image to see an enlarged view

Fig. Fig. 4 Front axle shaft components1990-93 models with 5S-FE engine



Click image to see an enlarged view

Fig. Fig. 5 Front axle shaft abs sensor serrations1990-93 models shown

1990-93 Models With 4WD
  1. Disconnect the negative battery terminal. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the cotter pin, cap and locknut from the hub while depressing the brake pedal.
  6.  
  7. Remove the dust shield, if equipped.
  8.  
  9. Loosen the 6 nuts attaching the inner end of the halfshaft while depressing the brake pedal.
  10.  
  11. Remove the 2 bolts attaching the lower arm to the steering knuckle.
  12.  
  13. Remove the tie rod nut and disconnect the tie rod.
  14.  
  15. Using SST 09950-20017, or equivalent, press the outer end of the halfshaft from the steering knuckle and then remove the halfshaft. Pry out the inner shaft section from the case.
  16.  

To install:

  1. Place the inner joint snapring facing downward. Tap in the driveshaft until it makes contact with the pinion shaft. It will make a sound when it is driven home.
  2.  
  3. Install the protector, torquing the bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the outboard joint into the hub.
  6.  
  7. Position the inner end and install the 6 nuts and bolts, torquing to 48 ft. lbs. (65 Nm).
  8.  
  9. Reconnect the lower arm to the steering knuckle and tighten the fasteners to 94 ft. lbs. (127 Nm).
  10.  
  11. Install the tie rod. Tighten the nut to 36 ft. lbs. (49 Nm). Always tighten the nut if the holes do not line up. Never loosen the nut.
  12.  
  13. Tighten the wheel bearing locknut to 166 ft. lbs. (226 Nm) while depressing the brake pedal. Install the locknut cap and use a new cotter pin.
  14.  
  15. Install the wheels.
  16.  
  17. Fill the transaxle to the proper level. Reconnect the battery, check the front end alignment and test drive.
  18.  



Click image to see an enlarged view

Fig. Fig. 6 Front axle shaft components1990-93 models with 4WD

CV-JOINT OVERHAUL



1986-89 Models Except 4WD
  1. Place removed driveshaft into a suitable holding fixture. Check the driveshaft for no play in the inboard and outboard joints, that the inboard joint slides smoothly in the thrust direction and that there is no significant play in the radial direction of the inboard joint.
  2.  
  3. Remove inboard joint boot clamps.
  4.  
  5. Disassemble inboard joint tulip on the ST161 series by following the service procedure as outlined below:
    1. Place matchmarks on the inboard joint tulip and tripod.
    2.  
    3. Remove the inboard joint tulip from the driveshaft.
    4.  
    5. Disassemble tripod joint. Using snapring pliers, remove the snapring.
    6.  
    7. Place matchmarks on the shaft and tripod.
    8.  
    9. Using a brass punch or equivalent remove the tripod joint from the driveshaft.
    10.  

  6.  
  7. Disassemble inboard joint tulip on the ST162 series by following the service procedure as outlined below:
    1. Place matchmarks on the inboard joint outer race and driveshaft.
    2.  
    3. Remove the snapring from inboard joint outer race.
    4.  
    5. Remove inboard joint outer race from the driveshaft.
    6.  
    7. Disassemble inboard joint. Place matchmarks on the driveshaft, cage and inner race.
    8.  
    9. Remove the 6 balls. Remove the ball cage from the inner race.
    10.  
    11. Using snapring pliers, remove the snapring.
    12.  
    13. Using a brass punch or equivalent remove the inner race from the driveshaft. Remove the snapring.
    14.  

  8.  
  9. Remove inboard joint boot.
  10.  
  11. Remove the outboard joint boot clamps and boot. Do NOT disassemble the outboard joint.
  12.  
  13. Remove the dust covers. Remove the snapring and remove the bearing. Remove the last snapring.
  14.  

To reassemble:

  1. Install the snapring to the center driveshaft, press on the bearing and install the retaining snapring.
  2.  
  3. Install the dust covers.
  4.  
  5. Install the boot and new boot clamps to the outboard joint. Apply tape to the splines to avoid damaging the boot.
  6.  
  7. Install the inboard boot onto the shaft.
  8.  
  9. Assemble the tripod joint, if equipped, by placing the beveled side of the axial spline toward the outboard joint. Align the matchmarks. Install the snapring after tapping on the joint.
  10.  
  11. If equipped with the ball cage type, install a new snapring onto the shaft, then install the cage with the large end to the inboard joint side.
  12.  
  13. Install the ball race and snapring. Match the cage to the race so they mesh, then install the 6 balls. Coat them with grease so they will not fall out.
  14.  
  15. Pack the outer cv-joints with 0.25 lb. (125g) of suitable grease. Pack the inboard joint tulip on the ST161 series with 0.48 lb. (220g) of special grease and the inboard race on ST162 series with 0.25 lb. (125g) of suitable grease.
  16.  
  17. On the ST162 series, install the inboard joint to the inboard outer race and boot, then install the large inner snapring.
  18.  



Click image to see an enlarged view

Fig. Fig. 7 Installing dust covers on transaxle side1986-89 models except 4WD



Click image to see an enlarged view

Fig. Fig. 8 Installing dust covers on driveshaft side1986-89 models except 4WD



Click image to see an enlarged view

Fig. Fig. 9 Installing ST161 series tripod joint with beveled side toward outboard joint1986-89 models except 4WD



Click image to see an enlarged view

Fig. Fig. 1 0Measuring standard driveshaft length on ST161 series1986-89 models except 4WD

  1. Use new boot retaining clamps and snaprings to secure the boots to the joints. When assembling the boots and clamps, make sure the boot is not stretched or contracted when the driveshaft is at standard length:

    ST161 series: 17.531 inches (445.3mm)
     
    1986 ST162 series, left side: 18.291 inches (464.6mm)
     
    1986 ST162 series, right side: 18.370 inches (466.6mm)
     
    1987-89 ST162 series, left side: 18.083 inches (459.3mm)
     
    1987-89 ST162 series, right side: 18.181 inches (461.8mm)
     

  2.  



Click image to see an enlarged view

Fig. Fig. 1 1Measuring standard driveshaft length on ST162 series1986-89 models except 4WD

1988-89 Models With 4WD
  1. Mount the front driveshaft in a vise and check that there is no play in the inboard and outboard joint.
  2.  
  3. Make sure that the inboard joint slides smoothly in the thrust direction.
  4.  
  5. Make sure that there is no excessive play in the radial direction of the inboard joint.
  6.  
  7. Inspect the boots for damage.
  8.  
  9. Remove the inboard joint boot clamps.
  10.  
  11. With chalk or paint, matchmark the inboard joint and the driveshaft. Do NOT use a punch.
  12.  
  13. Remove the snapring securing the joint to the driveshaft.
  14.  
  15. Using SST No. 09726-10010 or equivalent, a socket wrench and a press, remove the inboard joint from the driveshaft.
  16.  
  17. Remove the bolts, nuts, and washers from the inboard joint.
  18.  
  19. Remove the inboard joint from the joint cover.
  20.  


WARNING
When lifting the cover, keep the inner and outer race together or the joint may come apart.

  1. Should the joint come apart, assemble it in the following manner:
    1. Align the matchmarks.
    2.  
    3. Insert a spark plug wrench into the inner race.
    4.  
    5. Lift the outer race and cage and insert the six ball bearings.
    6.  
    7. Jiggle the outer race and cage to seat the balls in their respective grooves.
    8.  
    9. Lower the outer race and cage so that they fit tightly with the inner race.
    10.  

  2.  
  3. Remove the inboard and outboard joint boots.
  4.  
  5. Check the inside and outside of the boots for damage.
  6.  

To reassemble:


WARNING
Before installing the boot, wrap the spline end of the shaft with masking tape to prevent damage to the boot.

  1. Temporarily install the inboard and outboard joint boots with the new clamps.
  2.  
  3. Apply a bead of seal packing No. 08826-00801 or equivalent to the inboard joint cover. A thin bead will do, avoid applying too much.
  4.  
  5. Align the bolt holes of the cover with the holes of the inboard joint and then insert the bolts.
  6.  
  7. Tap the rim of the inboard joint into place with a plastic or rubber mallet in a crisscross pattern. Repeat the pattern several times until the cover is properly seated.
  8.  
  9. Hold the inboard joint together with the bolts, nuts and washers. Make the bolts finger tight as not to scratch the flange surface.
  10.  
  11. Align the matchmarks made in the driveshaft and joint.
  12.  
  13. Tap the inboard joint onto the driveshaft with a brass bar and a hammer.
  14.  


WARNING
Make sure to tap the inner race of the joint and not the cage.

  1. Install a new snapring.
  2.  
  3. Pack the outboard joint with about 0.25 lbs. (120g) of the grease supplied in the boot kit.
  4.  
  5. Pack the inboard tulip joint with about 0.20 lbs. (90g) of the grease supplied in the boot kit.
  6.  
  7. Install the inboard boot the inboard joint.
  8.  
  9. Make sure that the boot is properly installed on the driveshaft.
  10.  
  11. Make sure that the boot is not stretched or contracted when the driveshaft is at standard length.

    Standard driveshaft length: 15.77 in. (400.6mm).
     

  12.  
  13. To lock the boot bands, bend the band back and close the locking tabs.
  14.  
  15. Mount the driveshaft in vise and check that there is no play in the inboard or outboard joints. Check that the inboard joint slides smoothly in the thrust direction.
  16.  



Click image to see an enlarged view

Fig. Fig. 1 2Installing inboard joint cover, tightening bolts in order1988-89 models with 4WD



Click image to see an enlarged view

Fig. Fig. 1 3Measuring standard driveshaft length1988-89 models with 4WD

1990-93 Models Except 4WD
  1. Place removed driveshaft into a suitable holding fixture. Check the driveshaft for no play in the inboard and outboard joints, that the inboard joint slides smoothly in the thrust direction and that there is no significant play in the radial direction of the inboard joint.
  2.  
  3. Remove the snapring from the inboard joint shaft, except on the right driveshaft on models with the 5S-FE engine.
  4.  
  5. Remove the inboard joint boot clamps.
  6.  
  7. Remove the inboard joint tulip or center driveshaft. Place matchmarks on parts for reassembly. Do NOT punch the marks.
  8.  
  9. Remove the tripod joint, removing the end snapring, sliding the tripod forward, then moving the inner snapring. Tap the tripod from the shaft, without touching the roller.
  10.  
  11. Remove the inboard joint boot.
  12.  
  13. Remove the damper from the right driveshaft on models with the 4A-FE engine.
  14.  
  15. Remove the outboard joint boot, but do NOT disassemble the joint.
  16.  
  17. Remove the dust cover, except on the right driveshaft on models with the 5S-FE engine. Press out the dust cover from the center driveshaft on models with the 5S-FE engine.
  18.  
  19. Disassemble the center driveshaft on models with the 5S-FE engine. Remove the snapring, press out the bearing case and dust cover. Remove the snapring, press out the bearing, remove the snapring, then tap out the straight pin.
  20.  

To reassemble:

  1. Assemble the center driveshaft, installing the straight pin into the bearing case. Press in the bearing and install the snapring.
  2.  
  3. Press the bearing case assembly onto the center driveshaft and install the snapring.
  4.  
  5. Install dust covers, making sure they are pressed to the proper location.
  6.  
  7. Temporarily install the outboard joint boot and new boot clamps. The boot and clamp of the outboard joint are smaller than those of the inboard joint. Place tape on the splines to avoid damaging the boots.
  8.  
  9. Install the damper and new damper clamp in line with the groove of the right driveshaft on models with 4A-FE engine.
  10.  
  11. After the inboard boot is placed on the shaft, place the beveled side of the tripod joint axial spline toward the outboard joint. Align all matchmarks made previously. Tap it on without tapping on the roller part, then install the snapring.
  12.  
  13. Pack the outer cv-joints with 0.25 lb. (125g) of special black grease. Pack the inboard joint tulip on models with 4A-FE engine with 0.40 lb. (185g) of special yellow ocher grease. Pack on models with 5S-FE engine with 0.52 lb. (240g) of special yellow ocher grease.
  14.  
  15. Install new boot retaining clamps and snaprings. When assembling the boots and clamps, make sure the boot is not stretched or contracted when the driveshaft is at standard length:

    1990-91 with 4A-FE, left side: 21.248 inches (539.7mm)
     
    1990-91 with 4A-FE, right side: 33.693 inches (855.8mm)
     
    1990-91 with 5S-FE, left side: 21.996 inches (558.7mm)
     
    1990-91 with 5S-FE, right side: 33.276 inches (845.2mm)
     
    1992-93 with 4A-FE and at, left side: 21.248 inches (539.7mm)
     
    1992-93 with 4A-FE and at, right side: 33.693 inches (855.8mm)
     
    1992-93 with 4A-FE and mt, left side: 21.301 inches (541.0mm)
     
    1992-93 with 4A-FE and mt, right side: 33.968 inches (862.8mm)
     
    1992-93 with 5S-FE, left side: 21.996 inches (558.7mm)
     
    1992-93 with 5S-FE, right side: 33.276 inches (845.2mm)
     

  16.  



Click image to see an enlarged view

Fig. Fig. 1 4Installing straight pin into bearing case on right driveshaftModels with 5S-FE



Click image to see an enlarged view

Fig. Fig. 1 5Installing dust cover on center driveshaftModels with 5S-FE



Click image to see an enlarged view

Fig. Fig. 1 6Installing dust cover on right driveshaftModels with 5S-FE



Click image to see an enlarged view

Fig. Fig. 1 7Installing damper on right driveshaftModels with 4A-FE



Click image to see an enlarged view

Fig. Fig. 1 8Measuring standard driveshaft length1990-93 models except 4WD

1990-93 Models With 4WD
  1. Mount the front driveshaft in a vise and check that there is no play in the inboard and outboard joint.
  2.  
  3. Make sure that the inboard joint slides smoothly in the thrust direction.
  4.  
  5. Make sure that there is no excessive play in the radial direction of the inboard joint.
  6.  
  7. Disconnect the side gear shaft, removing the 6 bolts and washers. Inspect the boots for damage.
  8.  
  9. Remove the inboard joint boot clamps.
  10.  
  11. With chalk or paint, matchmark the inboard joint and the driveshaft. Do NOT use a punch.
  12.  
  13. Remove the snapring securing the joint to the driveshaft.
  14.  
  15. Using SST No. 09726-10010 or equivalent, a socket wrench and a press, remove the inboard joint from the driveshaft.
  16.  
  17. Remove the bolts, nuts, and washers from the inboard joint.
  18.  
  19. Remove the inboard joint from the joint cover.
  20.  


WARNING
When lifting the cover, keep the inner and outer race together or the joint may come apart.

  1. Should the joint come apart, assemble it in the following manner:
    1. Align the matchmarks.
    2.  
    3. Insert a spark plug socket into the inner race.
    4.  
    5. Lift the outer race and cage and insert the six ball bearings.
    6.  
    7. Jiggle the outer race and cage to seat the balls in their respective grooves.
    8.  
    9. Lower the outer race and cage so that they fit tightly with the inner race.
    10.  

  2.  
  3. Remove the inboard boot, damper and outboard joint boot.
  4.  
  5. Remove the dust cover from the side gear shaft. Replace the side gear shaft O-ring, then press a new dust cover to the side gear shaft.
  6.  

To reassemble:


WARNING
Before installing the boot, wrap the spline end of the shaft with masking tape to prevent damage to the boot.

  1. Temporarily install the inboard joint boot, damper on the right shaft and outboard joint boot with the new clamps. Pack the outboard joint with 0.25 lb. (120g) of grease first.
  2.  
  3. Apply a bead of seal packing No. 08826-00801 or equivalent to the inboard joint cover. A thin bead will do, so avoid applying too much.
  4.  
  5. Align the bolt holes of the cover with the holes of the inboard joint and then insert the bolts.
  6.  
  7. Tap the rim of the inboard joint into place with a plastic or rubber mallet in a crisscross pattern. Repeat the pattern several times until the cover is properly seated.
  8.  
  9. Hold the inboard joint together with the bolts, nuts and washers. Make the bolts finger tight as not to scratch the flange surface.
  10.  
  11. Align the matchmarks made in the driveshaft and joint.
  12.  
  13. Tap the inboard joint onto the driveshaft with a brass bar and a hammer.
  14.  


WARNING
Make sure to tap the inner race of the joint and not the cage.

  1. Install a new snapring.
  2.  
  3. Pack the inboard tulip and boot with about 0.20 lbs. (90g) of the grease supplied in the boot kit.
  4.  
  5. Install the inboard boot to the inboard joint.
  6.  
  7. Make sure that the boot is properly installed on the driveshaft.
  8.  
  9. Make sure that the boot is not stretched or contracted when the driveshaft is at standard length.

    Standard driveshaft length: 15.96 in. (405.4mm).
     

  10.  
  11. To lock the boot bands and damper band, bend the band back and close the locking tabs.
  12.  
  13. Install the side gear shaft, packing with 0.09 lb. (43g) of special grease. Tighten the 6 fasteners to 48 ft. lbs. (65 Nm).
  14.  



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Fig. Fig. 1 9Installing balls into outer race and cage1990-93 models with 4WD



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Fig. Fig. 2 0Installing dust cover to side gear shaft1990-93 models with 4WD



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Fig. Fig. 2 1Installing damper to right driveshaft1990-93 models with 4WD

  1. Mount the driveshaft in vise and check that there is no play in the inboard or outboard joints. Check that the inboard joint slides smoothly in the thrust direction.
  2.  



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Fig. Fig. 2 2Installing inboard joint cover, tightening bolts in order1990-93 models with 4WD



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Fig. Fig. 2 3Measuring standard driveshaft length1990-93 models with 4WD

 
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