FRONT DRIVE SHAFT ASSEMBLY(for 1ZR-FE, 2ZR-FE) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. A01T9BIC04
      *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. A01T8MGC04
      *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. A01TCIWC01
      *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
      A01TCE3 Outboard Joint Side
      A01TBGJ 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. A01TBR3N02

      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. A01TCS9N02

      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. A01T8NLN02

      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. A01T8DDN02

      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. A01T90NN02

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

    2. Set the dimension as specified below.

      Dimension (A)
      160 to 166 mm (6.30 to 6.53 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. A01TAOLN01

      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. A01TALKN01

      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


    1. A01TDR1N05

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

    2. Set the dimension as specified below.

      Dimension (A)
      433 to 439 mm (1.421 to 1.439 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. A01TAOLN02

      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. A01TALKN01

      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. A01TBGZC02
      *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
      A01TCE3 Outboard Joint Side
      A01TBGJ 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. A01TCJCC01
      *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. A01TAFV

      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
      for LH Side 162 to 178 g (5.72 to 6.27 oz)
      for RH Side 155 to 171 g (5.47 to 6.03 oz)
    9. A01TD6IC03
      *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. A01TD54N23

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

      Dimension (A)
      for LH Side 589.5 mm (1.93 ft.)
      for 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. A01T8VON01

      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. A01T9GKN01

      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 Omega Type:


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

      2. A01TCTKN01

        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. A01TAU5N04

        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 Claw Engagement Type:


      1. A01TAPQC01
        *a Claw

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

        Note

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

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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