FRONT DRIVE SHAFT ASSEMBLY(for 1ZR-FAE) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. A012J4LC04
      *a Steel Plate

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

      Note


      • The dust cover should be completely installed.

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

  2. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)


    1. A012N3HC04
      *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. A012FHJC01
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp LH
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp LH
      A012M0O Outboard Joint Side
      A012L0C 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 LH

      2. Front axle outboard joint boot

      3. Front axle outboard joint boot clamp LH

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

      Standard Grease Capacity
      149.5 to 159.5 g (5.28 to 5.62 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.

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


    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 LH onto the front axle outboard joint boot.

    3. A012I1LN02

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. A012KWNN02

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

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

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

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH


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

    2. A012K26N02

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. A012HLTN02

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

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

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

  5. INSTALL FRONT DRIVE SHAFT DAMPER LH (w/ Drive Shaft Damper)


    1. A012L35N01

      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. A012HJON01

      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. A012M05N01

      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 0.0590 in.)

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

  6. INSTALL FRONT DRIVE SHAFT DAMPER RH (w/ Drive Shaft Damper)


    1. A012N2VN03

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

    2. Set the dimension as specified below.

      Dimension (A)
      434 to 438 mm (1.424 to 1.436 ft.)

    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 RH.

      Note

      Be sure to install the clamp in the correct position.

    5. A012HJON02

      Place SST onto the front drive shaft damper clamp, press it against the front drive shaft damper RH 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. A012M05N01

      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 0.0590 in.)

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

  7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A012J9KC02
      *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
      A012M0O Outboard Joint Side
      A012L0C 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. A012G9TC01
      *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. A012MXJ

      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 162 to 178 g (5.72 to 6.27 oz)
      RH Side 155 to 171 g (5.47 to 6.03 oz)
    9. A012KXBC03
      *a Matchmark

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

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A012FZPN21

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

      Dimension (A)
      Dimension (A)
      LH Side 589.5 mm (1.93 ft.)
      RH Side 875.25 mm (2.87 ft.)

  9. 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. A012GJUN01

      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. A012G1MN01

      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 0.0590 in.)

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

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


    1. for LH Side:


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

      2. A012J4ZN01

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

        SST
        09521-24010

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

        Note

        Do not overtighten SST.

      4. Remove SST.

      5. A012F3YN04

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

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

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

    2. for RH Side:


      1. A012GVWC01
        *a Claw

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

        Note

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

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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