FRONT DRIVE SHAFT ASSEMBLY(for 1WW) 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. A002Q0ZE08

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

      SST
      09527-10011

      Note


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

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A002OVTE04

      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

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

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    A002NXHE04
    Text in Illustration
    *a Protective Tape

    Tech Tips

    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.


    1. 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. Front axle outboard joint boot clamp

    2. 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.)

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


    1. Secure the front No. 2 axle outboard joint boot clamp LH to the front axle outboard joint boot.

    2. A002M3TE02

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

      SST
      09521-24010

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

      Text in Illustration
      *a Turn
      *b Hold

      Note

      Do not overtighten SST.

    4. A002M3SE07

      Using SST, adjust 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.)

      If the clearance is more than the standard, retighten the 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. Secure the front axle outboard joint boot clamp LH to the front axle outboard joint boot.

    2. A002LRZE02

      Place SST onto the front axle outboard joint boot clamp LH.

      SST
      09521-24010

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

      Text in Illustration
      *a Turn
      *b Hold

      Note

      Do not overtighten SST.

    4. A002OBEE02

      Using SST, adjust 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.)

      If the clearance is more than the standard, retighten the 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.

    2. A002MAEE02

      Adjust the position of the front drive shaft damper LH so that the distance is as described below.

      Standard Distance (A)
      164.0 to 168.0 mm (6.46 to 6.61 in.)

  9. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH


    1. Install a new front drive shaft damper clamp LH to the front drive shaft damper LH.

      Note

      Be sure to install the front drive shaft damper clamp LH on the inboard joint side in the correct position.

    2. A002M7YE01

      Place SST onto the front drive shaft damper clamp LH.

      SST
      09521-24010

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

      Text in Illustration
      *a Turn
      *b Hold

      Note

      Do not overtighten SST.

    4. A002QH4E02

      Using SST, adjust 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.)

      If the clearance is more than the standard, retighten the front drive shaft damper clamp LH.

  10. 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. Front No. 2 axle inboard joint boot clamp LH

    2. Remove the protective tape.

    3. Place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly LH.

    4. A002O3JE16
      Text in Illustration
      *a Matchmark

      Align the matchmarks placed before removal.

    5. 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.

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

      Standard Grease Capacity
      Item Capacity
      for LH side 172.0 to 188.0 g (6.07 to 6.63 oz.)
      for RH side 170.0 to 190.0 g (6.00 to 6.70 oz.)
    7. A002NT8

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

    8. A002M9ME21
      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.

  11. INSTALL FRONT DRIVE INBOARD JOINT RH

    Tech Tips

    Use the same procedure described for the LH side.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A002NBNE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

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

      Length (A)
      Item Specified Condition
      for LH side 558.8 mm (1.83 ft.)
      for RH side 906.3 mm (2.97 ft.)

      Note

      Keep the front drive shaft assembly level during inspection.

      If the boots are stretched or contracted, correct them.

  13. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


    1. Secure the front axle inboard joint boot clamp LH to the front axle inboard joint boot.

    2. A002MFBE02

      Place SST onto the front axle inboard joint boot clamp LH.

      SST
      09521-24010

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

      Text in Illustration
      *a Turn
      *b Hold

      Note

      Do not overtighten SST.

    4. A002MESE04

      Using SST, adjust 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.)

      If the clearance is more than the standard, retighten the front axle inboard joint boot clamp LH.

  14. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedure described for the LH side.

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


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

    2. A002PI9

      Using needle-nose pliers, install the front No. 2 axle inboard joint boot clamp LH as shown in the illustration.

      Note

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

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

    Tech Tips

    Use the same procedure described for the LH side.

  17. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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