FRONT DRIVE SHAFT ASSEMBLY(for 1AD-FTV) REASSEMBLY

PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (for RH Side)


    1. A01LYHVC02
      *a Steel Plate

      Using SST and a steel plate, install the drive shaft bearing case sub-assembly to the front drive inboard joint assembly.

      SST
      09710-30012   ( 09710-04081 )

      Note

      The bearing should be installed completely.

    2. A01LXPD

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

  2. INSTALL DRIVE SHAFT BEARING CASE SNAP RING (for RH Side)


    1. A01LVF3

      Using a screwdriver, install a new drive shaft bearing case snap ring.

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


    1. A01LZUJC02
      *a Steel Plate

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

      Standard dust cover depth (A)
      1.0 mm (0.0394 in.)
      SST
      09726-40010

      Note

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

  4. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01M24RC02
      *a 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)
      115.5 to 116.5 mm (4.55 to 4.58 in.)

      Note


      • The dust cover should be completely installed.

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

  5. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01M1A9C04
      *a 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.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01LVB7C04
      *a Protective Tape

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

    2. A01LYBTC01
      *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
      A01M03W Outboard Joint Side
      A01LZQW 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
      105 to 125 g (3.71 to 4.40 oz)

    4. Install the front axle outboard joint boot into 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.

  7. 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. A01LZPBN02

      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. A01LXIQN02

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

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

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

  8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

    2. A01LX09N02

      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. A01M1PMN02

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

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

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

  9. INSTALL FRONT DRIVE SHAFT DAMPER LH


    1. A01M3JAN03

      Install the front drive shaft damper LH onto the front drive outboard joint shaft assembly.

    2. Set the dimension as specified below.

      Dimension (A)
      161 to 165 mm (6.34 to 6.49 in.)

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

      Note

      Do not overtighten the vise.

    4. Install a new front drive shaft damper clamp onto the front drive shaft damper LH.

      Note

      Be sure to install the clamp in the correct position.

    5. A01M1UMN02

      Place SST onto the front drive shaft damper clamp, press it against the front drive shaft damper LH and slightly tighten SST.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    7. Remove SST.

    8. A01LY6QN01

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

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

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

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01M345C02
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      A01M03W Outboard Joint Side
      A01LZQW 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. A01M18GC02
      *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. A01M1FA

      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
      140 to 160 g (4.94 to 5.64 oz)
    9. A01M0C5C01
      *a Matchmark

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

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A01LUV3C01
      *A LH Side
      *B RH Side

      Check whether each drive shaft dimension (A) is within specification.

      Dimension (A)
      Dimension (A)
      LH Side 538.2 mm (1.77 ft.)
      RH Side 917.5 mm (3.01 ft.)

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. A01M3CBN01

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. A01LZJQN01

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

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

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

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


    1. A01LVPR

      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.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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