REAR DRIVE SHAFT ASSEMBLY (for AWD) REASSEMBLY


  1. INSTALL REAR DRIVE SHAFT DUST COVER


    1. A01EIQSE01
      Text in Illustration
      *1 Steel plate

      Using SST and a steel plate, install a new rear drive shaft dust cover to the rear drive shaft inboard joint assembly.

      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 REAR DRIVE SHAFT OUTBOARD JOINT BOOT


    1. A01EKLZE03
      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 outboard joint shaft in the following order:


      1. Rear drive shaft outboard joint boot clamp

      2. Rear drive shaft outboard joint boot

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

    3. Pack the rear drive outboard joint shaft assembly and rear drive shaft outboard joint boot with grease from the boot kit.

      Grease capacity
      50 to 70 g (1.8 to 2.5 oz.)

  3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. A01EKOOE02

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A01EMGHE01

      Using SST, inspect the clearance of the rear drive shaft outboard joint boot clamp.

      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 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. A01EJT6

      Using a screwdriver, install a new No. 2 rear drive shaft outboard joint clamp as shown in the illustration.

      Note

      Do not damage the outboard joint boot.

  5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY


    1. A01EJ02E01
      Text in Illustration
      *1 Vinyl tape

      Wrap the spline 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. Rear drive shaft inboard joint boot

      3. Rear drive shaft inboard joint boot clamp

    3. A01EMDKE01

      Install the ball cage to the outboard joint shaft.

      Note

      Install the ball cage with its smaller inner diameter side facing the outboard joint.

    4. A01EJ5SE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks placed before removal and install the inner race to the rear drive outboard joint shaft assembly using a brass bar and a hammer.

      Note

      Be careful not to damage the inner race.

    5. A01EISU

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

    6. A01EIUVE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks placed before removal and install the cage to the inner race.

    7. Install the 8 balls with grease to the inner race.

      Note

      Be careful not to drop the balls.

      Tech Tips

      Apply grease onto the balls to keep them from falling.

    8. Pack the inboard joint shaft and boot with grease.

      Grease capacity
      85 to 105 g (3.0 to 3.7 oz.)
    9. A01EKATE01
      Text in Illustration
      *1 Matchmark

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

    10. A01EJKT

      Using a screwdriver, install the drive shaft snap ring to the rear drive shaft inboard joint assembly.

  6. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT


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

    2. A01ELK8E04

      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)
      LH 762.1 to 772.1 mm (2.50 to 2.53 ft.)
      RH 742.1 to 752.1 mm (2.43 to 2.47 ft.)

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


    1. A01EJV7

      Using needle-nose pliers, engage the 2 claws to install a new No. 2 rear drive shaft inboard joint clamp as shown in the illustration.

  8. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

    Tech Tips

    Perform the same procedure as for the No. 2 rear drive shaft inboard joint boot clamp.

  9. INSTALL REAR DRIVE SHAFT SNAP RING


    1. Install a new rear drive shaft snap ring.

  10. INSPECT REAR DRIVE SHAFT ASSEMBLY


    1. A01ELK8E04

      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)
      LH 762.1 to 772.1 mm (2.50 to 2.53 ft.)
      RH 742.1 to 752.1 mm (2.43 to 2.47 ft.)
    2. A01ELCKE03

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

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

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

    5. Check the boots for damage.