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

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


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

      Note

      Do not overtighten the vise.

    2. B0071NBC04
      *a Protective Tape

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

    3. B006YFHC01
      *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
      B006Z38 Outboard Joint Side
      B006ZY0 Inboard Joint Side

      Install new parts to 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

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

      Standard Grease Capacity
      81 to 91 g (2.86 to 3.20 oz)

    5. Install the front axle outboard joint boot to 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.

  2. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. B006YWPC01
      *a Turn
      *b Hold

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B0071KUN01

      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 0.0590 in.)

      If the clearance is not as specified, retighten SST.

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


    1. Secure 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 to the front axle outboard joint boot.

    3. B0071NKC04
      *a Turn
      *b Hold

      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. B006ZZMN13

      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 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  4. INSTALL FRONT DRIVE SHAFT DAMPER


    1. B0070ABC06
      *1 Front Drive Shaft Damper Clamp
      *2 Front Drive Shaft Damper

      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 (A) as specified below.

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

  5. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for LH Side)


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

      Note

      Do not overtighten the vise.

    2. Install the 2 front drive shaft damper clamps to the front drive shaft damper.

      Note

      Make sure to install the clamps in the correct position.

    3. B0070KXN07

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B006WZFN01

      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 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  6. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for RH Side)


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

      Note

      Do not overtighten the vise.

    2. Install the 2 front drive shaft damper clamps to the front drive shaft damper.

      Note

      Be sure to install the clamps in the correct position.

    3. B006WZW

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

      Note


      • Be sure to install the clamps in the correct position.

      • Do not damage the front drive shaft damper.

  7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B006YFOC02
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      B006Z38 Outboard Joint Side
      B006ZY0 Inboard Joint Side

      Install new parts to 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. Secure the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. B006ZFEC02
      *a Matchmark

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

      Note

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

    5. 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.

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

    6. B006ZN0

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

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

      Standard Grease Capacity
      190 to 200 g (6.71 to 7.05 oz)
    8. B006Z8VC02
      *a Lip

      Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

      Note


      • Securely fit the protrusion on the front axle inboard joint grommet into the front drive inboard joint assembly.

      • Make sure that the lip of the front axle inboard joint grommet is not damaged.

    9. B006Y0NC03
      *a Matchmark

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

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B006Y5BC05
      *A for LH Side
      *B for RH Side

      Check whether the dimension (A) of each drive shaft is within specification.

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      for LH Side 598.75 mm (1.96 ft.)
      for RH Side 924.55 mm (3.03 ft.)

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. B0070WGC02
      *a Turn
      *b Hold

      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. B006YGDN02

      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 0.0590 in.)

      If the clearance is not as specified, retighten SST.

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


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

      Note

      Do not overtighten the vise.

    2. Install the front No. 2 axle inboard joint boot clamp to the front axle inboard joint boot.

    3. B006XK0C02
      *a Turn
      *b Hold

      Place SST onto the front No. 2 axle inboard 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 inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B006X1MN05

      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 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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