#### OVERHAUL

##### 200SX (Halfshaft Assembly)

NOTE: When overhauling the halfshaft assembly on the 240SX use this procedure as a service guide. Review the complete procedure before starting.

1. Clamp the halfshaft in a vise using soft jaws.
2. Using pliers, pry the plug from the wheel side of the halfshaft.
3. Remove the plug seal, spring, spring cap and the boot bands.

   NOTE: Never reuse boot bands once they have been removed.

4. Scribe a matchmark on the spider assembly and the halfshaft.
5. Remove the spider assembly with a press. Do not attempt to touch the contact surface of the halfshaft end at the spring cap or housing subassembly. Always support the halfshaft with your hand while you are removing the spider assembly.
6. Draw out the slide joint boot and the boot bands.
7. Loosen the vise and turn the halfshaft around so that the differential end is up.
8. Using a hacksaw, cut off the hold joint boot assembly and then remove the housing subassembly.

   NOTE: When cutting the hold joint boot assembly, make sure that the halfshaft is pushed into the housing subassembly in order to prevent the spider assembly from being scratched. Never reuse the boot assembly after it has been removed.

9. Remove and discard the boot band and then remove the spider assembly as detailed in Steps 4–5.
10. Cut off the remaining part of the hold joint boot assembly and remove it from the housing subassembly. Be careful not to scratch the housing ring or assembly.
11. Remove and discard the housing cover and the O-ring.
12. Remove the housing ring.
13. Remove all remaining parts of the hold joint boot assembly and the boot band from the halfshaft.
14. Attach a housing ring, an O-ring, a housing subassembly and a housing cover to a new hold joint boot assembly. Place the assembled unit flange in a vise. Don't forget to grease the O-ring.
15. Place a board on a housing cover to prevent it from being scratched. Use a mallet and bend the edge over along the entire circumference.
16. Withdraw the housing subassembly, install a new boot band and then hold the joint boot assembly on the halfshaft.
17. Install the spider assembly securely, making sure that the matchmarks are aligned. Make sure that when press fitting the assembly, the serration chamfer faces the shaft.
18. Stake the serration sides evenly at three places, avoiding areas that have been previously staked. Always stake two or three teeth in an area where the staked gap is more than 0.1mm.
19. Pack with grease.
20. Install the greased O-ring to the housing assembly and then place the hold joint boot assembly so that its flange is in the vise. Be sure that no other part of the assembly is in the vise.
21. Insert the housing subassembly into place and then bend the edge as detailed in Step 2 for the housing cover.
22. Apply sealant. Set the boot and install the boot bands.
23. Turn the halfshaft in the vise so that the wheel side is up.
24. Install the new boot bands, slide joint boot and slide joint housing on the halfshaft. Be careful not to scratch the boot with the end of the shaft.
25. Install the spider assembly as previously detailed.
26. Install the large diameter boot band and then pack with grease.
27. Install the spring cap, spring and plug seal. Install the plug and secure with dummy bolts. Lock the plug by bending it and then remove the dummy bolts.
28. Install the small diameter boot band and replace the halfshaft.
29. The specific amount of grease for the wheel side boot is 6.52–6.8 oz. of suitable grease. The specific amount of grease for the differential side boot is 5.47–5.82 oz. of suitable grease. Refer to the illustrations.

    Fig. 1: Use pliers to remove the plug

    Fig. 2: Matchmark the spider assembly to the shaft

    Fig. 3: Cutting the joint boot

    Fig. 4: Exploded view of the halfshaft assembly — 200SX

    Fig. 5: Bending the housing cover

    Fig. 6: Installing the boot bands

    Fig. 7: You must stake the serrated sides of the spider assembly upon installation

    Fig. 8: Exploded view of the halfshaft assembly — 240SX

    Fig. 9: Install CV-boot on wheel side

    Fig. 10: Apply sealant in this area for CV-boot installation on differential carrier side

    Fig. 11: Install CV-boot on differential carrier side