FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

INSTALL BEARING BRACKET HOLE SNAP RING (for RH Side)
1. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.
INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)
1. Using SST, install a new front drive shaft bearing.
  
  SST
  
  09527-10011
  
  09527-30010
  
  Note
  
  The bearing should be completely installed.
2. Using a snap ring expander, install a new drive shaft hole snap ring.
INSTALL FRONT DRIVE SHAFT DUST COVER (for 2WD RH Side)
1. Using SST and a press, install a new front drive shaft dust cover.
  
  SST
  
  09527-10011
  
  09726-40010
  
  Distance
  
  26.6 to 27.6 mm (1.05 to 1.09 in.)
  Note
  
  The dust cover should be completely installed.
  
  Be careful not to damage the dust cover.
INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 2WD RH Side)
1. Using SST and a press, install a new front drive shaft dust cover RH until the distance (A) from the tip of the center drive shaft to the front drive shaft dust cover RH meets the specification.
  
  SST
  
  09527-10011
  
  Distance (A)
  
  109 to 110 mm (4.29 to 4.33 in.)
  Note
  
  The dust cover should be completely installed.
  
  Be careful not to damage the dust cover.
INSTALL FRONT DRIVE SHAFT DUST COVER LH (for LH Side)
1. Using SST and a press, install a new front drive shaft dust cover LH.
  
  SST
  
  09527-10011
  Note
  
  The dust cover should be completely installed.
  
  Be careful not to damage the dust cover.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT
1. Text in Illustration
  
  *1 Vinyl tape
  
  Wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.
2. Install new parts to the front drive outboard joint shaft assembly 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
3. Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.
  
  Grease capacity
  
  164 to 184 g (5.8 to 6.4 oz.)
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP
1. Hold the drive shaft lightly 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. 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. 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.
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. 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. 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.

Distance
26.6 to 27.6 mm (1.05 to 1.09 in.)

Distance (A)
109 to 110 mm (4.29 to 4.33 in.)

Text in Illustration
*1	Vinyl tape

Grease capacity
164 to 184 g (5.8 to 6.4 oz.)

Clearance
0.5 to 1.5 mm (0.0197 to 0.0591 in.)

Clearance
0.5 to 1.5 mm (0.0197 to 0.0591 in.)

INSTALL FRONT DRIVE SHAFT DAMPER

Install the front drive shaft damper to the drive shaft.

Note

Make sure that the damper is on the shaft groove.

Set the distance as specified below.

Distance
LH	237 to 241 mm (9.33 to 9.49 in.)
RH	231 to 235 mm (9.09 to 9.25 in.)

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.
Place SST onto the front drive shaft damper clamp.

SST

09521-24010
Tighten SST so that the clamp is pinched.

Note

Do not overtighten SST.
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.)

Note

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

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
1. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
2. Text in Illustration
  
  *1 Vinyl tape
  
  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. Text in Illustration
  
  *1 Matchmark
  
  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 a 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 in the correct direction.
6. 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
  
  135 to 155 g (4.8 to 5.4 oz.)
8. Text in Illustration
  
  *1 Matchmark
  
  Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

Clearance
0.5 to 1.5 mm (0.0197 to 0.0591 in.)

Text in Illustration
*1	Vinyl tape

Text in Illustration
*1	Matchmark

Grease capacity
135 to 155 g (4.8 to 5.4 oz.)

Text in Illustration
*1	Matchmark

INSTALL FRONT AXLE INBOARD JOINT BOOT

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

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

Tech Tips

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

Dimension (A)
for 2WD	LH	600.36 to 604.36 mm (1.97 to 1.98 ft.)
for 2WD	RH	916.96 to 920.96 mm (3.01 to 3.02 ft.)
for AWD	LH	600.36 to 604.36 mm (1.97 to 1.98 ft.)
for AWD	RH	892.21 to 896.21 mm (2.93 to 2.94 ft.)

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP
1. Hold the drive shaft lightly in a vise between aluminum plates.
  
  Note
  
  Do not overtighten the vise.
2. Secure the front axle inboard joint boot clamp onto the front axle inboard joint boot.
3. Place SST onto the front axle 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. 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.
INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP
1. Using needle-nose pliers, engage the 2 claws to install the No. 2 front axle inboard joint boot clamp as shown in the illustration.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
1. Install a new front drive shaft hole snap ring.

Clearance
0.5 to 1.5 mm (0.0197 to 0.0591 in.)

INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

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

Tech Tips

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

Dimension (A)
for 2WD	LH	600.36 to 604.36 mm (1.97 to 1.98 ft.)
for 2WD	RH	916.96 to 920.96 mm (3.01 to 3.02 ft.)
for AWD	LH	600.36 to 604.36 mm (1.97 to 1.98 ft.)
for AWD	RH	892.21 to 896.21 mm (2.93 to 2.94 ft.)

Check that there is no excessive play in the outboard joint.
Check that the inboard joint slides smoothly in the thrust direction.
Check that there is no excessive play in the radial direction of the inboard joint.
Check the boots for damage.