FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER (for LH Side)


    1. B005YA1E31

      Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

      SST
      09527-10011

      Note


      • Install the front drive shaft dust cover in the correct direction.

      • Do not deform the front drive shaft dust cover.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)


    1. B005XIWE01

      Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

      SST
      09527-10011

      Note


      • Install the front drive shaft dust cover in the correct direction.

      • Do not deform the front drive shaft dust cover.

  3. INSTALL OUTBOARD JOINT BOOT (for LH Side)


    1. B005YCEE14
      Text in Illustration
      *a Protective Tape

      Wrap the splines of the front axle outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

    2. B005XCYE02
      Text in Illustration
      *1 Front Axle Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      B005XEC Outboard Joint Side
      B005Y3Y Inboard Joint Side

      Install new parts onto the front axle outboard joint shaft assembly in the following order:


      1. Front No. 2 axle outboard joint boot clamp

      2. Outboard joint boot

      3. Front axle outboard joint boot clamp

    3. Pack the joint portion of the front axle outboard joint shaft assembly and outboard joint boot with grease.

      Standard grease capacity
      135 to 145 g (4.76 to 5.11 oz.)

    4. Install the outboard joint boot onto the front axle outboard joint shaft assembly groove.

      Note


      • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.

      • Keep the inside of the outboard joint boot free of foreign matter.

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. B005YSA

      Install the front No. 2 axle outboard joint boot clamp onto the outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    2. B005YYLE04
      Text in Illustration
      *1 Deflector
      B005XEC Weight
      B005Y3Y Contact
      B005Z0S Roll

      Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work surface. Roll the outboard joint and fold the lever until a click sound can be heard.

      Note


      • Do not damage the deflector.

      • Make sure that the outboard joint is in direct contact with the work surface.

    3. B005ZHC

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note

      Do not damage the outboard joint boot.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. B005ZIR

      Install the front axle outboard joint boot clamp onto the outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and the lever for any deformation before folding back the lever.

    2. B005Y9ME08
      Text in Illustration
      *a Place the tip near the center of the lever.

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

    3. B005XNZ

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note

      Do not damage the outboard joint boot.

  6. INSTALL FRONT DRIVE SHAFT DAMPER (w/ 1 Clamp)


    1. B005XCRE07

      Install the front drive shaft damper onto the front axle outboard joint shaft assembly as shown in the illustration.

      Dimension (A)
      161 to 165 mm (6.34 to 6.49 in.)

  7. INSTALL FRONT DRIVE SHAFT DAMPER (w/ 2 Clamps)


    1. B005Z5FE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front axle outboard joint shaft assembly as shown in the illustration.

      Dimension (A)
      for LH Side 211.7 to 215.7 mm (8.33 to 8.49 in.)
      for RH Side 488 to 492 mm (1.602 to 1.614 ft.)

  8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (w/ 1 Clamp)


    1. Secure the front axle outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. for One Touch Type:


      1. B005YF3E01
        Text in Illustration
        *A for One Touch Type
        *B for Claw Engagement Type

        Using a screwdriver, install a new front drive shaft damper clamp, as shown in the illustration.

    3. for Claw Engagement Type:


      1. Using needle-nose pliers, install a new front drive shaft damper clamp, as shown in the illustration.

  9. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (w/ 2 Clamps)


    1. Secure the front axle outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. B005YFTC01
      *A for Type A
      *B for Type B
      *a Claw

      for Type A:


      1. Using needle-nose pliers, engage each claw to install the 2 front drive shaft damper clamps as shown in the illustration.

    3. for Type B:


      1. Using needle-nose pliers, install the 2 front drive shaft damper clamps as shown in the illustration.

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B005Y6FE09
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      B005XEC Outboard Joint Side
      B005Y3Y Inboard Joint Side

      Install new parts onto the front axle outboard joint shaft assembly in the following order:


      1. Front axle inboard joint boot clamp

      2. Inboard joint boot

      3. Front No. 2 axle inboard joint boot clamp

    2. Secure the front axle outboard joint shaft assembly in a vise using aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. B005ZBIE53
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft assembly as shown in the illustration.

      Note

      Face the serrated side of the tripod joint outward and install it onto the outboard joint end.

    5. Using a brass bar and a hammer, install the tripod joint to the front axle outboard joint shaft assembly.

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

    6. B005ZUZ

      Using a snap ring expander, install a new shaft snap ring to the front axle outboard joint shaft assembly.

    7. Pack the front drive inboard joint assembly and inboard joint boot with grease.

      Standard grease capacity
      168 to 178 g (5.92 to 6.27 oz.)
    8. B005Y1QE03
      Text in Illustration
      *a Groove

      Install a new front axle inboard joint grommet onto the inboard joint groove.

      Note

      Securely fit the protrusion on the inboard joint grommet into the inboard joint groove.

    9. B005ZTZE05
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive inboard joint assembly onto the front axle outboard joint shaft assembly.

  11. INSTALL INBOARD JOINT BOOT


    1. Install the inboard joint boot into the grooves of the inboard joint grommet and front axle outboard joint shaft assembly.

      Note

      Keep the grooves free of grease.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. B005ZIR

      Install the front axle inboard joint boot clamp onto the inboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and the lever for any deformation before folding back the lever.

    2. B005Y9ME08
      Text in Illustration
      *a Place the tip near the center of the lever.

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

    3. B005XNZ

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note

      Do not damage the inboard joint boot.

  13. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. Install the boot clamp onto the inboard joint boot.

    2. B005XR8E16

      Adjust dimension (A) until it is within the specified length.

      Dimension (A)
      LH Side RH Side
      556.2 mm (1.82 ft.) 905.2 mm (2.97 ft.)

    3. While keeping dimension (A) within the specified length, put the inside of the inboard joint under atmospheric pressure by pulling the recessed parts on the inboard joint grommet out.

      B005Y2DE01
      Text in Illustration
      *1 Boot Clamp
      *2 Inboard Joint Grommet
      *a Fulcrum Point
      *b Recessed Parts

    4. Set the lever fulcrum point at any point A indicated in the illustration and temporarily bend the lever.

      Note


      • Perform this work with the inside of the inboard joint kept at atmospheric pressure.

      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    5. B005XTK

      Lean your weight on your hand and roll the inboard joint forward while pressing the inboard joint against the work surface. Roll the inboard joint and fold the lever until a click sound can be heard.

      Text in Illustration
      B005XEC Weight
      B005Y3Y Contact
      B005Z0S Roll

      Note

      Make sure that the inboard joint is in direct contact with the work surface.

    6. B005Y9A

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note

      Do not damage the inboard joint boot.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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