FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. B001EAVE15

      Using SST and a press, install a new dust cover.

      SST
      09527-10011

  2. INSTALL SHAFT SNAP RING


    1. B001F1Q

      Install a new snap ring.

  3. INSTALL OUTBOARD JOINT BOOT

    Tech Tips

    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damage to the boot.

    B001D3IE02
    Text in Illustration
    *1 Vinyl Tape

    1. Temporarily install a new outboard joint boot with 2 new clamps to the outboard joint shaft.

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

      Standard grease capacity
      266 to 276 g (9.4 to 9.7 oz.)

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


    1. B001CUZE01

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

      Note

      Do not overtighten the vise.

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

      SST
      09521-24010
      Text in Illustration
      *a Hold
      *b Turn

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

      Note

      Do not overtighten SST.

    4. B001EBPE04

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

      SST
      09240-00020
      Standard clearance
      2.1 mm (0.0827 in.) or less

      Note

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

  5. INSTALL FRONT NO. 1 AXLE OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. B001FTEE01
      Text in Illustration
      *a Hold
      *b Turn

      Place SST onto the 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. B001HL0E01

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

      SST
      09240-00020
      Standard clearance
      1.3 mm (0.0512 in.) or less

      Note

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

  6. INSTALL INBOARD JOINT BOOT


    1. Temporarily install a new inboard joint boot to the outboard joint shaft.

  7. INSTALL FRONT AXLE INBOARD JOINT ASSEMBLY


    1. Install new parts to the outboard joint shaft 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. Secure the outboard joint shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. B001FESE49
      Text in Illustration
      *a Beveled
      *b Matchmark

      Align the matchmarks and install the tripod joint to the outboard joint shaft.

      Note

      Position tripod so that the beveled side of the tripod faces toward the inboard joint.

    4. Align the matchmarks and install the tripod to the inboard joint.

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

      Note


      • Do not hit the roller portion.

      • Keep the tripod joint free of foreign matter.

    6. B001E5R

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

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

      Standard grease capacity
      239 to 249 g (8.4 to 8.7 oz.)
    8. B001EXUE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the inboard joint onto the outboard joint shaft.

  8. INSTALL FRONT NO. 1 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 inboard joint boot clamp to the boot.

    3. B001FVAE05
      Text in Illustration
      *a Hold
      *b Turn

      Place SST onto the 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. B001ESDE12

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

      SST
      09240-00020
      Standard clearance
      1.3 mm (0.0512 in.) or less

      Note

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

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


    1. Hold the inboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Temporarily install the front No. 2 axle inboard joint boot clamp in the groove of the front axle inboard joint boot.

      Tech Tips

      When temporarily installing the front No. 2 axle inboard joint boot clamp in the groove of the front axle inboard joint boot, check that the protrusion (staking portion) of the front No. 2 axle inboard joint boot clamp is within one of the 3 ranges shown in the illustration.

      B001F2HN01
    3. B001F6ME04
      Text in Illustration
      *a Front No. 2 Axle Inboard Joint Boot Clamp
      *b Front Axle Inboard Joint Boot
      *a Viewpoint
      *b Protrusion (Staking Portion)
      *c Installation Range

      Place SST onto the No. 2 front axle inboard joint boot clamp.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. B001EJ1E19
      Text in Illustration
      *a Hold
      *b Turn

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

      SST
      09240-00020
      Standard clearance
      2.1 mm (0.0827 in.) or less

      Note

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