FRONT DRIVE SHAFT ASSEMBLY(for 1ZR-FAE, 2ZR-FAE) REASSEMBLY

CAUTION / NOTICE / HINT

Note:

  • When using a vise, place aluminum plates between the part and vise.

  • When using a vise, do not overtighten it.

PROCEDURE

  1. INSTALL FRONT DRIVE SHAFT DUST COVER LH

    1. C157559E01

      Using SST and a press, press on a new drive shaft dust cover.

      09527-10011

      Note:

      • The dust cover should be installed completely.

      • Be careful not to damage the dust cover.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH

    Tip:

    Use the same procedures described for the LH side.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    C127681E19
    Tip:

    Before installing the boot, wrap the spline of the drive shaft with protective tape to prevent the boot from being damaged.

    Table 1. Text in Illustration

    *a

    Protective Tape

    1. Install new parts to the outboard joint shaft in the following order.

      1. No. 2 outboard joint boot clamp LH

      2. Outboard joint boot

      3. Outboard joint boot clamp LH

    2. Pack the outboard joint shaft and boot with grease from the boot kit.

      Standard Grease Capacity

      Engine Type

      Transaxle Type

      Grease Capacity

      1ZR-FAE

      Manual transaxle

      120 to 130 g (4.24 to 4.58 oz.)

      2ZR-FAE

      Continuously variable transaxle

      Manual transaxle

      149.5 to 159.5 g (5.28 to 5.62 oz.)

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH

    1. Secure the No. 2 outboard joint boot clamp to the boot.

    2. U122599E02

      Place SST onto the No. 2 outboard joint boot clamp.

      09521-24010

      Table 2. Text in Illustration

      *a

      Turn

      *b

      Hold

    3. Tighten SST so that the No. 2 outboard joint boot clamp is pinched.

      Note:

      Do not overtighten SST.

    4. C116426E08

      Using SST, adjust the clearance of the clamp.

      09240-00020

      Standard clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note:

      If the measured value exceeds the specified value, retighten the clamp.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

    1. Secure the outboard joint boot clamp to the boot.

    2. U123419E02

      Place SST onto the outboard joint boot clamp.

      09521-24010

      Table 3. Text in Illustration

      *a

      Turn

      *b

      Hold

    3. Tighten SST so that the outboard joint boot clamp is pinched.

      Note:

      Do not overtighten SST.

    4. C116429E05

      Using SST, adjust the clearance of the clamp.

      09240-00020

      Standard clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note:

      If the measured value exceeds the specified value, retighten the clamp.

  6. INSTALL FRONT DRIVE SHAFT DAMPER RH

    1. Install the drive shaft damper to the drive shaft.

    2. C207917E03

      Adjust the position of the damper so that the dimension is as described below.

      Standard Distance (B)

      Engine Type

      Transaxle Type

      Specified Condition

      1ZR-FAE

      Manual transaxle

      434 to 438 mm (1.424 to 1.430 ft.)

      2ZR-FAE

      Continuously variable transaxle

      Manual transaxle

      433 to 439 mm (1.421 to 1.439 ft.)

  7. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP RH

    1. Install a new drive shaft damper clamp to the damper.

      Note:

      Be sure to install the clamp on the inboard joint side in the correct position.

    2. U122972E02

      Place SST onto the damper clamp.

      09521-24010

      Table 4. Text in Illustration

      *a

      Turn

      *b

      Hold

    3. Tighten SST so that the damper clamp is pinched.

      Note:

      Do not overtighten SST.

    4. C201463E02

      Using SST, adjust the clearance of the damper clamp.

      09240-00020

      Standard clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note:

      If the clearance is more than the standard, retighten the clamp.

  8. INSTALL FRONT DRIVE INBOARD JOINT LH

    1. Wrap the spline of the outboard joint shaft with protective tape to prevent the boot from being damaged.

    2. Install new parts to the outboard joint shaft in the following order.

      1. Inboard joint boot clamp

      2. Inboard joint boot

      3. No. 2 inboard joint boot clamp

    3. C127694E17

      Place the beveled side of the tripod axial spline toward the outboard joint.

    4. Align the matchmarks placed before removal.

      Table 5. Text in Illustration

      *a

      Matchmark

    5. Using a brass bar and hammer, tap the tripod onto the drive shaft.

      Note:

      • Do not tap the rollers.

      • Be sure to install the tripod in the correct direction.

    6. Pack the inboard joint shaft and boot with grease from the boot kit.

      Standard Grease Capacity

      Engine Type

      Transaxle Type

      Grease Capacity

      1ZR-FAE

      Manual transaxle

      155 to 171 g (5.47 to 6.03 oz.)

      2ZR-FAE

      Continuously variable transaxle

      Manual transaxle

      for LH Side:

      172 to 188 g (6.07 to 6.63 oz.)

      for RH Side:

      170 to 186 g (6.00 to 6.56 oz.)
    7. C207911

      Using a snap ring expander, install a new shaft snap ring.

    8. C127646E23

      Align the matchmarks and install the inboard joint to the outboard joint shaft.

      Table 6. Text in Illustration

      *a

      Matchmark

  9. INSTALL FRONT DRIVE INBOARD JOINT RH

    Tip:

    Use the same procedures described for the LH side.

  10. INSTALL INBOARD JOINT BOOT

    1. Install the inboard joint boot to the inboard joint.

    2. C127699E18

      Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

      Length (A) (for LH Side)

      Engine Type

      Transaxle Type

      Specified Condition

      1ZR-FAE

      Manual transaxle

      589.25 mm (1.93 ft.)

      2ZR-FAE

      Continuously variable transaxle

      Manual transaxle

      590.4 mm (1.94 ft.)

      Length (A) (for RH Side)

      Engine Type

      Transaxle Type

      Specified Condition

      1ZR-FAE

      Manual transaxle

      875.25 mm (2.87 ft.)

      2ZR-FAE

      Continuously variable transaxle

      Manual transaxle

      869.3 mm (2.85 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

    1. Secure the inboard joint boot clamp to the boot.

    2. U123418E02

      Place SST onto the inboard joint boot clamp.

      09521-24010

      Table 7. Text in Illustration

      *a

      Turn

      *b

      Hold

    3. Tighten SST so that the clamp is pinched.

      Note:

      Do not overtighten SST.

    4. C206956

      Using SST, adjust the clearance of the clamp.

      09240-00020

      Standard clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note:

      If the clearance is more than the standard, retighten the clamp.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tip:

    Use the same procedures described for the LH side.

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

    1. Secure the inboard joint boot clamp to the boot.

    2. C116423

      Using needle-nose pliers, install the axle inboard joint boot clamp as shown in the illustration.

      Note:

      Be careful not to damage the boot.

  14. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH

    Tip:

    Use the same procedures described for the LH side.

  15. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    1. Install a new hole snap ring.

  16. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tip:

    Use the same procedures described for the LH side.

  17. INSPECT DRIVE SHAFT

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