FRONT DRIVE SHAFT ASSEMBLY (for 2AR-FE) REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)


    1. B000GY6E07
      Text in Illustration
      *1 Steel Plate

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

      SST
      09527-10011

      Note

      The bearing should be completely installed.

    2. B000MO5

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. B000IJ0E09
      Text in Illustration
      *1 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)
      110.0 to 111.0 mm (4.33 to 4.37 in.)

      Note


      • The dust cover should be completely installed.

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

  3. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. B000L1QE14
      Text in Illustration
      *1 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.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. B000KKZE03
      Text in Illustration
      *1 Protective Tape

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

    2. B000N69E01
      Text in Illustration
      *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
      B000K70 Outboard Joint Side
      B000IB9 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 (for TMC Made)
      171 to 181 g (6.0 to 6.3 oz.)
      Standard Grease Capacity (except TMC Made)
      100 to 120 g (3.5 to 4.2 oz.)

    4. Install the front axle outboard joint boot onto 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.

  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for TMC Made)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. B000KGE

      Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    2. B000K8VE02
      Text in Illustration
      *a Weight
      *b Contact

      Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work surface. Roll the outboard joint and fold the lever until a click sound can be heard.

      Note


      • Do not damage the speed sensor rotor.

      • Make sure that the outboard joint is in direct contact with the work surface.

    3. B000KQP

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note


      • Do not use too much force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (except TMC Made)


    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. B000N2KE01

      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. B000M88E01

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

      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

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

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for TMC Made)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. B000N7U

      Install the front axle outboard joint boot clamp onto the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and the lever for any deformation before folding back the lever.

    2. B000KWAE08
      Text in Illustration
      *a Place the tip near the center of the lever.

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

    3. B000MM8

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note

      Do not damage the front axle outboard joint boot.

  8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (except TMC Made)


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

    2. B000KLFE01

      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. B000JUNE01

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

      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

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

  9. INSTALL FRONT DRIVE SHAFT DAMPER


    1. B000N4UE02
      Text in Illustration
      *A for TMC Made
      *B except TMC Made
      *1 Front Drive Shaft Damper
      *2 Front Drive Shaft Damper Clamp

      Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

    2. Set the dimension as specified below.

      Dimension (A)
      for TMC Made LH 277.9 to 281.9 mm (10.9 to 11.1 in.)
      RH 261.4 to 265.4 mm (10.3 to 10.4 in.)
      except TMC Made LH 223.8 to 227.8 mm (8.81 to 8.97 in.)
      RH 223.4 to 227.4 mm (8.80 to 8.95 in.)
    3. B000J2GE03
      Text in Illustration
      *a Claws

      for TMC Made:


      1. Using needle nose pliers, install the 2 front drive shaft damper clamps.

        Note

        Be sure to install the clamp in the correct position.

    4. B000LQT

      except TMC Made:


      1. Using needle nose pliers, install the 2 front drive shaft damper clamps.

        Note

        Be sure to install the clamp in the correct position.

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (for TMC Made)


    1. B000KEFE15
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      B000K70 Outboard Joint Side
      B000IB9 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. B000H3FE26
      Text in Illustration
      *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. B000KXF

      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
      175 to 185 g (6.2 to 6.5 oz.)
    9. B000NN9E21
      Text in Illustration
      *a Matchmark

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

  11. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (except TMC Made)


    1. B000KEFE15
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      B000K70 Outboard Joint Side
      B000IB9 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. B000JS6E03
      Text in Illustration
      *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. B000K0IE04
      Text in Illustration
      *A for Type A
      *B for Type B

      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)
      150 to 170 g (5.3 to 5.9 oz.)
      Standard Grease Capacity (RH Side)
      155 to 175 g (5.5 to 6.1 oz.)
    9. B000NN9E21
      Text in Illustration
      *a Matchmark

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

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B000HAAE02
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Dimension (A)
      for TMC Made except TMC Made
      LH Side 585.2 mm (1.92 ft.) 587.4 mm (1.93 ft.)
      RH Side 910.0 mm (2.99 ft.) 906.6 mm (2.97 ft.)

  13. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (for TMC Made)


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

    2. B000MKN

      for One Touch Type:


      1. Using a screwdriver, install the front axle inboard joint boot clamp.

    3. B000JK2E01
      Text in Illustration
      *a Claw

      for Claw Engagement Type:


      1. Using needle nose pliers, install the front axle inboard joint boot clamp.

        Note

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

  14. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (except TMC Made)


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

    2. B000I0O

      Using needle nose pliers, install the front axle inboard joint boot clamp.

      Note

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

  15. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (for TMC Made)


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

    2. B000N80

      for One Touch Type:


      1. Using a screwdriver, install front No. 2 axle inboard joint boot clamp.

    3. B000HDKE01
      Text in Illustration
      *a Claw

      for Claw Engagement Type:


      1. Using needle nose pliers, install front No. 2 axle inboard joint boot clamp.

        Note

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

  16. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (except TMC Made)


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

    2. B000MO9

      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.

  17. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new front drive shaft hole snap ring LH.

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  18. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. B000JPY

      Check that there is no excessive play in the radial direction of the outboard joint.

    2. Check that the inboard joint slides smoothly in the thrust direction.

    3. Check that there is no excessive play in the radial direction of the inboard joint.

    4. Check the boots for damage.

    5. B000HAAE02
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      for TMC Made except TMC Made
      LH Side 585.2 mm (1.92 ft.) 587.4 mm (1.93 ft.)
      RH Side 910.0 mm (2.99 ft.) 906.6 mm (2.97 ft.)