FRONT DRIVE SHAFT ASSEMBLY (for 2AR) REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)


    1. A01HXUEE07
      Text in Illustration
      *1 Steel Plate

      Using SST, a steel plate and a press, install a new front drive shaft bearing.

      SST
      09527-10011

      Note

      The bearing should be completely installed.

    2. A01I070

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)


    1. A01HYRBE04
      Text in Illustration
      *1 Steel Plate

      Using SST, a steel plate and a press, install a new front drive shaft dust cover.

      SST
      09726-40010
      Dimension (A)
      26.6 to 27.6 mm (1.05 to 1.08 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01I02LE07
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

      Dimension (A)
      110.0 to 111.0 mm (4.33 to 4.37 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover RH.

  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01HYRWE14
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover LH.

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover LH.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01I003E03
      Text in Illustration
      *1 Protective Tape

      Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

    2. A01I1KAE01
      Text in Illustration
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      A01I0B8 Outboard Joint Side
      A01HZQC Inboard Joint Side

      Install new parts onto 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. Front axle outboard joint boot clamp

    3. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

      Standard grease capacity
      100 to 120 g (3.53 to 4.23 oz.)

    4. Install the front axle outboard joint boot onto the front drive outboard joint shaft assembly groove.

      Note


      • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.

      • Keep the inside of the outboard joint boot free of foreign matter.

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


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

      Note

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.

    3. A01I1TYE01

      Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. A01HYMFE01

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

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

      If the clearance is outside the specified range, retighten SST.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


    1. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.

    2. A01HXRPE01

      Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. A01I0F3E01

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

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

      If the clearance is outside the specified range, retighten SST.

  8. INSTALL FRONT DRIVE SHAFT DAMPER


    1. A01I24UE01

      Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

    2. Set the dimension as specified below.

      Dimension (A)
      for LH Side 223.8 to 227.8 mm (8.81 to 8.96 in.)
      for RH Side 223.4 to 227.4 mm (8.80 to 8.95 in.)
    3. A01HYZB

      Using needle-nose pliers, install the 2 front drive shaft damper clamps as shown in the illustration.

      Note

      Be sure to install the clamps in the correct position.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01HYP4E15
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      A01I0B8 Outboard Joint Side
      A01HZQC Inboard Joint Side

      Install new parts onto 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. Front No. 2 axle inboard joint boot clamp

    2. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A01I12XE03
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.

    5. Align the matchmarks placed before removal.

    6. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

    7. A01I1ZN

      Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

    8. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

      Standard grease capacity (LH Side)
      150 to 170 g (5.29 to 5.99 oz.)
      Standard grease capacity (RH Side)
      155 to 175 g (5.47 to 6.17 oz.)
    9. A01HYDDE21
      Text in Illustration
      *a Matchmark

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

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A01HZ9TE01
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Dimension (A)
      Dimension (A)
      LH Side 587.4 mm (1.93 ft.)
      RH Side 906.6 mm (2.97 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.

    2. A01I01Z

      Using needle nose pliers, install the front axle inboard joint boot clamp.

      Note

      Be careful not to damage the front axle inboard joint boot.

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


    1. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.

    2. A01I1BS

      Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.

      Note

      Be careful not to damage the front axle inboard joint boot.

  13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new front drive shaft hole snap ring LH.

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A01I1N4

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

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

    3. Check that there is no excessive play in the radial direction of the inboard joint.

    4. Check the boots for damage.

    5. A01HZ9TE01
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      Dimension (A)
      LH Side 587.4 mm (1.93 ft.)
      RH Side 906.6 mm (2.97 ft.)