FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When using a vise, place aluminum plates between the part and vise.

  • When using a vise, do not overtighten it.

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A004N2QE01

      Using SST and a press, press in the front drive inboard joint LH until the new front drive shaft dust cover LH contacts the edge of the front drive inboard joint LH.

      SST
      09527-10011

      Note


      • Do not damage the front drive shaft dust cover LH.

      • The front drive shaft dust cover LH should be installed completely.

      • Make sure to install the front drive shaft dust cover LH in the correct direction.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A004QJSE03

      Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint RH until the distance from the tip of the front drive inboard joint RH to the front drive shaft dust cover RH reaches the specification as shown in the illustration.

      SST
      09527-10011
      Standard distance (A)
      115.5 to 116.5 mm (4.55 to 4.58 in.)

      Note


      • Do not damage the front drive shaft dust cover RH.

      • The front drive shaft dust cover RH should be installed completely.

      • Make sure to install the front drive shaft dust cover RH in the correct direction.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    Tech Tips

    Use the same procedure for the RH and LH sides.


    1. A004S1ZE04
      Text in Illustration
      *a Protective Tape

      Before installing the front axle outboard joint boot, wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the front axle outboard joint boot from being damaged.

    2. Install new parts to the front drive outboard joint shaft assembly in the following order.


      1. Front No. 2 axle outboard joint boot clamp

      2. Front axle outboard joint boot

      3. A004SLLE02
        Text in Illustration
        *1 Front No. 2 Axle Outboard Joint Boot Clamp
        *2 Front Axle Outboard Joint Boot
        *3 Front Axle Outboard Joint Boot Clamp
        *4 Front Drive Outboard Joint Shaft Assembly
        A004NPW Outboard Joint Side
        A004NAK Inboard Joint Side

        Front axle outboard joint boot clamp

    3. Install the front axle outboard joint boot so that it is between the front No. 2 axle outboard joint boot clamp and front drive outboard joint shaft assembly.

    4. Temporarily install the front axle outboard joint boot clamp to the front axle outboard joint boot.

    5. Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.

      Standard grease capacity
      105.0 to 125.0 g (3.71 to 4.40 oz.)

    6. Install the front axle outboard joint boot to the groove of the front drive outboard joint shaft assembly.

      Note


      • Do not apply grease to the part of the front axle outboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the front axle outboard joint boot.

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


    1. Install SST to the front No. 2 axle outboard joint boot clamp LH, and then while pressing the front axle outboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front No. 2 axle outboard joint boot clamp LH to the guide groove.

      • Do not damage the front axle outboard joint boot.

    2. A004TX9E01
      Text in Illustration
      *a Turn
      *b Hold

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

      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • When tightening SST, make sure the clearance of the front No. 2 axle outboard joint boot clamp LH is within the standard clearance.

      • Do not damage the front axle outboard joint boot.

    3. Remove SST from the front No. 2 axle outboard joint boot clamp LH.

    4. A004PXDE04

      Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp LH.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • If the measured value exceeds the specified value, retighten the front No. 2 axle outboard joint boot clamp LH.

      • If the result is lower than the specified range, install a new front No. 2 axle outboard joint boot clamp LH.

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

    Tech Tips

    Use the same procedure described for the LH side.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH


    1. Install SST to the front axle outboard joint boot clamp LH, and then while pressing the front axle outboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front axle outboard joint boot clamp LH to the guide groove.

      • Do not damage the front axle outboard joint boot.

    2. A004NBYE01
      Text in Illustration
      *a Turn
      *b Hold

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

      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • When tightening SST, make sure the clearance of the front axle outboard joint boot clamp LH is within the standard clearance.

      • Do not damage the front axle outboard joint boot.

    3. Remove SST from the front axle outboard joint boot clamp LH.

    4. A004OYBE02

      Using SST, measure the clearance of the front axle outboard joint boot clamp LH.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • If the measured value exceeds the specified value, retighten the front axle outboard joint boot clamp LH.

      • If the result is lower than the specified range, install a new front axle outboard joint boot clamp LH.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

  8. INSTALL FRONT DRIVE SHAFT DAMPER LH


    1. Install the front drive shaft damper LH to the front drive outboard joint shaft assembly LH.

      Note


      • Make sure that the front drive shaft damper LH is on the front drive outboard joint shaft assembly LH groove.

      • Make sure to install the front drive shaft damper LH in the correct direction.

    2. A004SSEE01

      Adjust the position of the front drive shaft damper LH so that the distance shown in the illustration is within the specified range.

      Standard distance (A)
      161.0 to 165.0 mm (6.34 to 6.49 in.)

  9. INSTALL FRONT DRIVE SHAFT DAMPER RH

    Tech Tips

    Use the same procedure described for the LH side.

  10. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH


    1. Install SST to the front drive shaft damper clamp LH, and then while pressing the front drive shaft damper LH, slightly tighten the SST bolt.

      SST
      09521-24010

      Note

      Correctly set the front drive shaft damper clamp LH to the guide groove.

    2. A004MXQE01
      Text in Illustration
      *a Turn
      *b Hold

      Tighten SST so that the front drive shaft damper clamp LH is pinched.

      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note

      When tightening SST, make sure the clearance of the front drive shaft damper clamp LH is within the standard clearance.

    3. Remove SST from the front drive shaft damper clamp LH.

    4. A004N0IE01

      Using SST, measure the clearance of the front drive shaft damper clamp LH.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • If the measured value exceeds the specified value, retighten the front drive shaft damper clamp LH.

      • If the result is lower than the specified range, install a new front drive shaft damper clamp LH.

  11. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP

    Tech Tips

    Use the same procedure described for the front drive shaft damper clamp LH.

  12. INSTALL FRONT DRIVE INBOARD JOINT LH


    1. Install new parts to the front drive outboard joint shaft assembly LH in the following order.


      1. Front axle inboard joint boot clamp LH

      2. Front axle inboard joint boot

      3. A004U48E02
        Text in Illustration
        *1 Front Axle Inboard Joint Boot Clamp LH
        *2 Front Axle Inboard Joint Boot
        *3 Front No. 2 Axle Inboard Joint Boot Clamp LH
        *4 Front Drive Outboard Joint Shaft Assembly LH
        A004NPW Outboard Joint Side
        A004NAK Inboard Joint Side

        Front No. 2 axle inboard joint boot clamp LH

    2. Remove the protective tape from the front drive outboard joint shaft assembly LH.

    3. A004MN9E02
      Text in Illustration
      *a Matchmark
      A004NPW Inboard Joint Side

      Align the matchmarks and place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly LH.

      Note

      Face the cut edge of the spline toward the inboard joint side and insert the spline onto the front drive outboard joint shaft assembly LH.

    4. A004PEP

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

      Note


      • Do not tap the rollers.

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

    5. A004SIF

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

      Note

      The shaft snap ring should be installed completely.

    6. Pack the front drive inboard joint LH and front axle inboard joint boot with grease from the boot kit.

      Standard grease capacity
      172.0 to 188.0 g (6.07 to 6.63 oz.)
    7. A004MVEE15
      Text in Illustration
      *a Matchmark

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

  13. INSTALL FRONT DRIVE INBOARD JOINT RH

    Tech Tips

    Use the same procedure described for the LH side.

  14. INSTALL FRONT AXLE INBOARD JOINT BOOT

    Tech Tips

    Use the same procedure for the RH and LH sides.


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

      Note


      • Do not apply grease to the part of the front axle inboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the front axle inboard joint boot.

    2. A004N14E02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Check that the front axle inboard joint boot and front axle outboard joint boot are not stretched or contracted when the front drive shaft assembly is at the standard length.

      Length (A)
      Item Specified Condition
      for LH side 561.8 mm (1.84 ft.)
      for RH side 912.3 mm (2.99 ft.)

      Note

      Keep the front drive shaft assembly level during inspection.

      If the boots are stretched or contracted, correct them.

  15. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


    1. Install SST to the front axle inboard joint boot clamp LH, and then while pressing the front axle inboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front axle inboard joint boot clamp LH to the guide groove.

      • Do not damage the front axle inboard joint boot.

    2. A004QY0E01
      Text in Illustration
      *a Turn
      *b Hold

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

      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • When tightening SST, make sure the clearance of the front axle inboard joint boot clamp LH is within the standard clearance.

      • Do not damage the front axle inboard joint boot.

    3. Remove SST from the front axle inboard joint boot clamp LH.

    4. A004TIOE02

      Using SST, measure the clearance of the front axle inboard joint boot clamp LH.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      Note


      • If the measured value exceeds the specified value, retighten the front axle inboard joint boot clamp LH.

      • If the result is lower than the specified range, install a new front axle inboard joint boot clamp LH.

  16. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

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


    1. A004R67E01
      Text in Illustration
      *a Claw Engagement

      Install the front No. 2 axle inboard joint boot clamp LH to the front axle inboard joint boot.

      Note

      Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.

    2. Using needle-nose pliers, hold the front No. 2 axle inboard joint boot clamp LH at the claw engagement.

      Note


      • Do not damage the front axle inboard joint boot.

      • Do not deform the claw engagement of the front No. 2 axle inboard joint boot clamp LH.

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

    Tech Tips

    Use the same procedure described for the LH side.

  19. INSPECT FRONT DRIVE SHAFT ASSEMBLY

    Click here