FRONT DRIVE SHAFT REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT DUST COVER

    A013779E01

    1. Using SST and a press, install a new dust cover, as shown in the illustration.

      SST
      09527-10011

      Note


      • Install the dust cover securely.

      • Do not damage the dust cover.

  2. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


    1. A01368X

      Install a new snap ring onto the inboard joint assembly.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. Wrap the spline of the outboard joint assembly with vinyl tape to prevent it from being damaged.

    2. Install new parts onto the outboard joint assembly in the following order.


      1. Outboard joint boot No. 2 clamp

      2. Outboard joint boot

      3. Outboard joint boot clamp

    3. Pack the outboard joint assembly with grease.

      Standard
      Engine Grease Capacity
      1KR-FE 72 to 82 g (2.54 to 2.89 oz.)
      2WZ-TV 78 to 88 g (2.75 to 3.10 oz.)

    4. Install the outboard joint boot onto the outboard joint assembly.

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


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

    2. A0136RJE01

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. A0136TUE01

      Using SST, adjust the clearance of the outboard joint boot No. 2 clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.031 in.) or less

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

    2. Place SST onto the outboard joint boot clamp.

      SST
      09521-24010
    3. A01388SE01

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

      Note

      Do not overtighten SST.

    4. A0136Y6E01

      Using SST, adjust the clearance of the outboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.031 in.) or less

  6. INSTALL FRONT DRIVE SHAFT DAMPER (for 2WZ-TV RH Side)


    1. A0138LD

      Install the drive shaft damper onto the outboard joint assembly.

      Note

      Install the damper in the correct direction.

    2. A013890E01

      Set the distance, as described below.

      Standard Distance (A)
      508 to 512 mm (20.00 to 20.15 in.)

  7. INSTALL DRIVE SHAT DAMPER SETTING CLAMP (for 2WZ-TV RH Side)


    1. Secure the drive shaft damper setting clamp onto the drive shaft damper.

    2. Place SST onto the drive shaft damper clamp.

      SST
      09521-24010
    3. A0138U4E01

      Tighten the SST so that the drive shaft setting clamp is pinched.

      Note

      Do not overtighten the SST.

    4. A0137CXE01

      Using SST, adjust the clearance of the drive shaft setting clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.031 in.) or less

  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. Wrap the spline of the outboard joint assembly with vinyl tape to prevent it from being damaged.

    2. Install new parts onto the outboard joint assembly in the following order.


      1. Inboard joint boot clamp

      2. Inboard joint boot

      3. Inboard joint boot No. 2 clamp

    3. A0136TJE02

      Align the matchmarks and install the tripod joint assembly onto the outboard joint assembly.

    4. Using a brass bar and hammer, install the tripod joint assembly.

      Note

      Do not tap the roller.

    5. A01390Y

      Using a snap ring expander, install a new front drive inner shaft snap ring.

    6. Pack the inboard joint assembly with grease.

      Grease capacity
      98 to 112 g (3.46 to 3.95 oz.)
    7. A0138D1E01

      Align the matchmarks and install the inboard joint assembly onto the outboard joint assembly.

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT


    1. Install the inboard joint boot onto the inboard joint assembly.

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

    2. Place SST onto the inboard joint boot clamp.

      SST
      09521-24010
    3. A0137K6E01

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

      Note

      Do not overtighten SST.

    4. A0137X3E01

      Using SST, adjust the clearance of the inboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.031 in.) or less

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


    1. Secure the inboard joint boot clamp No. 2 onto the boot.

    2. A0135U1E01

      Adjust dimension (A) until the drive shaft is within the specified length.

      Dimension (A)
      Engine LH (mm) RH (mm)
      1KR-FE 580.3 770.3
      2WZ-TV 523.8 828.3
    3. A0138NQ

      Using needle-nose pliers, align the concave part with the protrusion of the inboard joint boot clamp No. 2 in order to fix it.

      Note


      • Do not scratch the inboard joint boot.

      • Do not deform the claw of the hook.

  12. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A0135U1E01

      Check whether the front drive shaft assembly is within the following dimensions.

      Dimension (A)
      Engine LH (mm) RH (mm)
      1KR-FE 580.3 770.3
      2WZ-TV 523.8 828.3
    2. A0136I6

      Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction.

    3. Check for cracks, damage and grease leakage on the joint boot.

      Note

      Keep the front drive shaft assembly level while moving it.