FRONT DRIVE SHAFT ASSEMBLY(for 2GR-FE) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)


    1. A01W38TE15
      Text in Illustration
      *1 Steel Plate

      Using SST, a steel plate and a press, install a new front drive shaft bearing.

      SST
      09527-10011

      Note

      The bearing should be completely installed.

    2. A01W1Q5

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01W21CE13
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

      Dimension (A)
      110.0 to 111.0 mm (4.33 to 4.37 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover RH.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01W0LXE25
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover LH.

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover LH.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01W0ZRE03
      Text in Illustration
      *1 Protective Tape

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

    2. A01W20JE02
      Text in Illustration
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      B001O8N Outboard Joint Side
      B001OAO Inboard Joint Side

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


      1. Front No. 2 axle outboard joint boot clamp

      2. Front axle outboard joint boot

      3. Front axle outboard joint boot clamp

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

      Standard grease capacity
      164 to 184 g (5.78 to 6.48 oz.)

    4. Install the front axle outboard joint boot onto the front drive 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.

  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP


    1. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.

    3. A01W0WBE02

      Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

    4. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. A01W1WBE01

      Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


    1. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.

    2. A01VZ76E04

      Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. A01W4DEE04

      Using SST, measure the clearance of the front axle outboard joint boot clamp.

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

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


    1. A01W2LGE02

      Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

    2. Set the dimension as specified below.

      Dimension (A)
      228.0 to 232.0 mm (8.98 to 9.13 in.)

    3. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    4. Install a new front drive shaft damper clamp onto the front drive shaft damper.

      Note

      Be sure to install the clamp in the correct position.

    5. A01W23DE07

      Place SST onto the front drive shaft damper clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

    6. Tighten SST so that the front drive shaft damper clamp is pinched.

      Note

      Do not overtighten SST.

    7. Remove SST.

    8. A01W4VU

      Using SST, measure the clearance of the front drive shaft damper clamp.

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

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


    1. A01W3RKE02
      Text in Illustration
      *A LH Side
      *B RH Side

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

    2. Set the dimension as specified below.

      Dimension (A)
      226.9 to 230.9 mm (8.94 to 9.09 in.)
    3. A01W5K4

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

      Note

      Be sure to install the clamp in the correct position.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01W1DOE05
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      B001O8N Outboard Joint Side
      B001OAO Inboard Joint Side

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


      1. Front axle inboard joint boot clamp

      2. Front axle inboard joint boot

      3. Front No. 2 axle inboard joint boot clamp

    2. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A01W295E45
      Text in Illustration
      *a Matchmark

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

    5. Align the matchmarks placed before removal.

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

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

    7. A01W1WA

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

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

      Standard grease capacity
      155 to 175 g (5.47 to 6.17 oz.)
    9. A01W4WZE37
      Text in Illustration
      *a Matchmark

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

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT


    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.

    2. A01W0WCE04
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Dimension (A)
      Dimension (A)
      LH Side 587.5 mm (1.93 ft.)
      RH Side 906.4 mm (2.97 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.

    3. A01VZJWE04

      Place SST onto the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. A01VZL0E01

      Using SST, measure the clearance of the front axle inboard joint boot clamp.

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

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


    1. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.

    2. A01VZWYE04

      Place SST onto the front No. 2 axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

    3. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. A01W3WTE17

      Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

  13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new front drive shaft hole snap ring LH.

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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