FRONT DRIVE SHAFT REASSEMBLY


  1. INSTALL SIDE GEAR SHAFT HOLDER BEARING (for 2WD RH Side)


    1. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.

    2. A017D9ME02

      Using SST, install a new front drive shaft bearing.

      SST
      09527-30010
      09527-10011

      Note

      The bearing should be completely installed.

    3. A017CVFE02

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

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


    1. A017F2VE06

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

      SST
      09726-40010
      09527-10011
      Distance
      26.6 to 27.6 mm (1.047 to 1.0866 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the dust cover.

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


    1. A017EPFE02

      Using SST and a press, install a new drive shaft dust cover RH until distance (A) from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification.

      SST
      09527-10011
      Distance (A)
      109.0 to 110.0 mm (4.2913 to 4.3307 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the dust cover.

  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A017CJ8E03

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

      SST
      09527-10011

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the dust cover.

  5. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 4WD RH Side)

    Tech Tips

    Perform the same procedure as for the LH side.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    Tech Tips

    Before installing the boots, wrap the splines of the drive shaft with vinyl tape to prevent the boot from being damaged.

    A017B99E04

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


      1. No. 2 front axle outboard joint boot clamp

      2. Front axle outboard joint boot

      3. Front axle outboard joint boot clamp

    2. Pack the front drive outboard joint shaft and front axle outboard joint boot with grease.

      Grease capacity
      2WD 164 to 184 g (5.8 to 6.5 oz.)
      4WD 100 to 120 g (3.5 to 4.2 oz.)

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. A017CAYE08

      Place SST onto the front axle outboard joint boot clamp.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A017FM8E01

      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.)

      Note

      If the measured value is greater than the specified value, retighten the clamp.

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


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

    2. A017DYME12

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. A017FPWE08

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

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

      Note

      If the measured value is greater than the specified value, retighten the clamp.

  9. INSTALL FRONT DRIVE SHAFT DAMPER


    1. A017DDLE03

      Install the drive shaft damper to the drive shaft.

    2. Make sure that the damper is on the shaft groove.

    3. Set the distance as specified below.

      Distance
      2WD LH 228.0 to 232.0 mm (8.976 to 9.134 in.)
      RH 231.0 to 235.0 mm (9.094 to 9.252 in.)
      4WD LH 228.8 to 229.0 mm (9.008 to 9.016 in.)
      RH 228.2 to 232.2 mm (8.984 to 9.142 in.)

    4. Install the drive shaft damper clamp onto the drive shaft damper.

      Note

      Be sure to install the clamp in the correct position.

    5. A017BVWE03

      Place SST onto the drive shaft damper clamp.

      SST
      09521-24010

    6. Tighten SST so that the clamp is pinched.

      Note

      Do not overtighten SST.

    7. A017D0D

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

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

      Note

      If the measured value is greater than the specified value, retighten the clamp.

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


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

    2. A017DKTE13

      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. No. 2 front axle inboard joint boot clamp

    3. Place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly.

    4. Align the matchmarks placed before removal.

    5. Using a brass bar and hammer, tap in the tripod joint to the front drive outboard joint shaft assembly.

      Note


      • Do not tap the roller.

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

    6. A017BTX

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

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

      Grease capacity
      2WD 155 to 175 g (5.5 to 6.2 oz.)
      4WD 106 to 126 g (3.7 to 4.4 oz.)
    8. A017CU4E18

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

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A017E75E04

      Check whether the drive shaft dimensions are within the following specifications.

      Tech Tips

      The following table shows dimension (A) of the drive shaft.

      Dimension (A) :
      2WD LH 601.1 to 605.1 mm (23.67 to 23.82 in.)
      RH 920.4 to 924.4 mm (36.24 to 36.39 in.)
      4WD LH 576.4 to 580.4 mm (22.69 to 22.85 in.)
      RH 959.9 to 963.9 mm (37.79 to 37.95 in.)

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

    2. Secure the inboard joint boot clamp onto the boot.

    3. A017FC4E08

      Place SST onto the inboard joint boot clamp.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A017BS0E01

      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.)

      Note

      If the measured value is greater than the specified value, retighten the clamp.

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


    1. Hold the inboard joint shaft assembly in a vise with aluminium plates in between.

      Note

      Do not overtighten the vise.

    2. Secure the No. 2 front axle inboard joint boot clamp onto the boot.

    3. A017DRVE11

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A017E0UE09

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

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

      Note

      If the measured value is greater than the specified value, retighten the clamp.

  14. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


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

  15. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A017ERIE02

      Check that there is no excessive play in the outboard joint.

    2. Check that the inboard joint slides smoothly in the thrust direction.

    3. Check that there is no excessive play in the radial direction of the inboard joint.

    4. Check the boots for damage.