REAR DRIVE SHAFT (for 4WD) REASSEMBLY


  1. INSTALL REAR DRIVE SHAFT DUST COVER


    1. A017G0DE01

      Using SST and a steel plate, install a new rear drive shaft dust cover.

      SST
      09527-21011

      Note


      • The rear drive shaft dust cover should be completely installed.

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

  2. INSTALL OUTBOARD JOINT BOOT

    Tech Tips

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

    A017EC1E01

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


      1. Rear drive shaft outboard joint boot clamp

      2. Outboard joint boot

      3. No. 2 rear drive shaft outboard joint boot clamp

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

      Grease capacity
      95 to 105 g (3.4 to 3.7 oz.)

  3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP


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

    2. Secure the rear drive shaft outboard joint boot clamp onto the boot.

    3. A017DRHE01

      Place SST onto the rear drive shaft outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A017EF8E01

      Using SST, inspect the clearance of the rear drive shaft 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 exceeds the specified value, retighten the clamp.

  4. INSTALL NO. 2 REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP


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

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

    3. A017EQOE01

      Place SST onto the No. 2 rear drive shaft outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A017BR6E01

      Using SST, inspect the clearance of the No. 2 rear drive shaft 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 exceeds the specified value, retighten the clamp.

  5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY


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

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


      1. No. 2 rear drive shaft inboard joint boot clamp

      2. Inboard joint boot

      3. Rear drive shaft inboard joint boot clamp

    3. A017CDKE01

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

    4. Align the matchmarks placed before removal.

    5. A017BOC

      Using a brass bar and hammer, tap in the tripod joint onto the outboard joint shaft assembly.

      Note


      • Do not tap the rollers.

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

    6. A017DW6

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

    7. Pack the outboard joint shaft and boot with grease.

      Grease capacity
      125.5 to 135.5 g (4.4 to 4.7 oz.)
    8. A017BV1E01

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

  6. INSTALL INBOARD JOINT BOOT


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

    2. A017D6IE03

      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)
      754.7 to 764.6 mm (29.71 to 30.10 in.)

  7. INSPECT REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP


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

    2. Secure the rear drive shaft inboard joint boot clamp onto the boot.

    3. A017CVZE01

      Place SST onto the rear drive shaft inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A017FQFE01

      Using SST, inspect the clearance of the rear drive shaft 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 exceeds the specified value, retighten the clamp.

  8. INSTALL NO. 2 REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP


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

    2. Secure the No. 2 rear drive shaft inboard joint boot clamp onto the boot.

    3. A017BBHE01

      Place SST onto the No. 2 rear drive shaft inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A017CA1E01

      Using SST, inspect the clearance of the 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 exceeds the specified value, retighten the clamp.

  9. INSTALL REAR DRIVE SHAFT SNAP RING


    1. Install a new rear drive shaft snap ring.

  10. INSPECT REAR DRIVE SHAFT ASSEMBLY


    1. A017ERIE03

      Check that there is no remarkable play in the radial direction of the outboard joint.

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

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

    4. Check the boots for damage.