FRONT DRIVE SHAFT ASSEMBLY(for 3ZR-FE, 3ZR-FAE) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A0057CHE01

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

      SST
      09527-10011

      Note


      • The dust cover should be installed completely.

      • Be careful not to damage the dust cover.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A0056QTE15

      Using SST and a press, press on a new drive shaft dust cover until the dimension from the tip of the center drive shaft to the drive shaft dust cover reaches the specification as shown in the illustration.

      SST
      09527-10011
      Standard dimension (A)
      91.0 to 92.0 mm (3.59 to 3.62 in.)

      Note


      • The dust cover should be installed completely.

      • Be careful not to damage the dust cover.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH

    A00574BE15

    Tech Tips

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

    Text in Illustration
    *a Protective Tape

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


      1. No. 2 axle outboard joint boot clamp

      2. Outboard joint boot

      3. Outboard joint boot clamp

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

      Standard grease capacity
      120 to 130 g (4.24 to 4.58 oz.)

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT RH

    Tech Tips

    Use the same procedures described for the LH side.

  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH


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

      Note

      Do not overtighten the vise.

    2. Secure the No. 2 axle outboard joint boot clamp to the boot.

    3. A0058D9E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A0056CVE04

      Using SST, adjust the clearance of the clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedures described for the LH side.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH


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

      Note

      Do not overtighten the vise.

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

    3. A00590DE01
      Text in Illustration
      *a Turn
      *b Hold

      Place SST onto the outboard joint boot clamp.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A0059LTE03

      Using SST, adjust the clearance of the clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedures described for the LH side.

  9. INSTALL FRONT DRIVE SHAFT DAMPER LH


    1. Install the drive shaft damper to the drive shaft.

      Note

      Make sure that the damper is on the shaft groove.

    2. A0056OOE02

      Adjust the position of the damper so that the dimension is as described below.

      Standard dimension (A)
      161 to 165 mm (6.34 to 6.49 in.)

  10. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH


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

      Note

      Do not overtighten the vise.

    2. Install a new drive shaft damper clamp to the damper.

      Note

      Be sure to install the clamp on the inboard joint side in the correct position.

    3. A00541JE01
      Text in Illustration
      *a Turn
      *b Hold

      Place SST onto the damper clamp.

      SST
      09521-24010

    4. Tighten SST so that the damper clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0057IZE01

      Using SST, adjust the clearance of the damper clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  11. INSTALL FRONT DRIVE SHAFT DAMPER RH


    1. Install the drive shaft damper to the drive shaft.

    2. A0055EBE02

      Adjust the position of the damper so that the dimension is as described below.

      Standard dimension (B)
      161 to 165 mm (6.34 to 6.49 in.)

  12. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP


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

      Note

      Do not overtighten the vise.

    2. Install a new drive shaft damper clamp to the damper.

      Note

      Be sure to install the clamp on the inboard joint side in the correct position.

    3. A00541JE01
      Text in Illustration
      *a Turn
      *b Hold

      Place SST onto the damper clamp.

      SST
      09521-24010

    4. Tighten SST so that the damper clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0056NIE01

      Using SST, adjust the clearance of the damper clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  13. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH


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

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


      1. Inboard joint boot clamp

      2. Inboard joint boot

      3. No. 2 axle inboard joint boot clamp

    3. Remove the protective tape.

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

    5. A0058UIE07
      Text in Illustration
      *a Matchmark

      Align the matchmarks placed before removal.

    6. Using a brass bar and hammer, tap the tripod onto the drive shaft.

      Note


      • Do not tap the rollers.

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

    7. Pack the inboard joint shaft and boot with grease from the boot kit.

      Standard Grease Capacity
      Item capacity
      for RH side 155 to 171 g (5.47 to 6.03 oz.)
      for LH side 162 to 178 g (5.72 to 6.27 oz.)
    8. A00583G

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

    9. A0053V8E16
      Text in Illustration
      *a Matchmark

      Align the matchmarks install the inboard joint to the outboard joint shaft.

  14. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  15. INSTALL FRONT AXLE INBOARD JOINT BOOT LH


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

    2. A005362E06
      Text in Illustration
      *a for LH Side
      *b for RH Side

      Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

      Dimension (A)
      Item Dimension
      for LH side 591.1 mm (23.3 in.)
      for RH side 888.1 mm (35.0 in.)

  16. INSTALL FRONT AXLE INBOARD JOINT BOOT RH

    Tech Tips

    Use the same procedures described for the LH side.

  17. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


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

      Note

      Do not overtighten the vise.

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

    3. A0053X2E02
      Text in Illustration
      *a Turn
      *b Hold

      Place SST onto the inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0059LTE02

      Using SST, adjust the clearance of the clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  18. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedures described for the LH side.

  19. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP LH


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

      Note

      Do not overtighten the vise.

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

    3. A0052FGE01
      Text in Illustration
      *a Turn
      *b Hold

      Place SST onto the inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the clamp is pinched.

      Note

      Do not overtighten SST.

    5. A0057U3

      Using SST, adjust the clearance of the clamp.

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

      If the measured value exceeds the specified value, retighten the clamp.

  20. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH


    1. A005535

      Using needle-nose pliers, install the axle inboard joint boot clamp as shown in the illustration.

      Note

      Be careful not to damage the boot.

  21. INSPECT DRIVE SHAFT

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