REAR DRIVE SHAFT ASSEMBLY(for AWD) REASSEMBLY

PROCEDURE


  1. INSTALL REAR DRIVE SHAFT DUST COVER


    1. B003ZBSC01
      *a Steel Plate

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

      SST
      09527-10011

      Note


      • The rear drive shaft dust cover should be completely installed.

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

  2. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT


    1. B00401MC04
      *a Protective Tape

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

    2. B003ZU5C01
      *1 Rear Drive Shaft Outboard Joint Assembly
      *2 Rear No. 2 Drive Shaft Outboard Joint Boot Clamp
      *3 Rear Drive Shaft Outboard Joint Boot
      *4 Rear Drive Shaft Outboard Joint Boot Clamp
      B003ZIE Outboard joint side
      B003Z8F Inboard joint side

      Install new parts to the rear drive shaft outboard joint shaft assembly in the following order:


      1. Rear No. 2 drive shaft outboard joint boot clamp

      2. Rear drive shaft outboard joint boot

      3. Rear drive shaft outboard joint boot clamp

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

      Standard Grease Capacity
      50 to 60 g (1.77 to 2.11 oz)

    4. Install the rear drive shaft outboard joint boot to the rear drive shaft 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 REAR NO. 2 DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP


    1. A0026WR

      Using a screwdriver, install the rear No. 2 drive shaft outboard joint boot clamp as shown in the illustration.

      Note

      Be careful not to damage the rear drive shaft outboard joint boot.

  4. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

    2. Install the rear drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.

    3. B003ZMZN01

      Place SST to the rear drive shaft outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

    4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B003ZJDN02

      Using SST, measure the clearance of the rear drive shaft outboard joint boot clamp.

      SST
      09240-00020
      Clearance
      1.2 mm (0.0472 in.) or less

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

  5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY


    1. B004036C02
      *1 Rear Drive Shaft Inboard Joint Boot Clamp
      *2 Rear Drive Shaft Inboard Joint Boot
      *3 Rear No. 2 Drive Shaft Inboard Joint Boot Clamp
      *a Protective Tape
      B003ZIE Outboard joint side
      B003Z8F Inboard joint side

      Install new parts to the rear drive shaft outboard joint shaft assembly in the following order:


      1. Rear drive shaft inboard joint boot clamp

      2. Rear drive shaft inboard joint boot

      3. Rear No. 2 drive shaft 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. B003Z72C03
      *a Matchmark

      Align the matchmarks and install the tripod joint to the rear drive shaft outboard joint shaft assembly.

      Note

      Face the serrated side of the tripod joint outward and install it to the outboard joint end.

    5. Align the matchmarks placed before removal.

    6. Using a brass bar and a hammer, install the tripod joint to the rear drive shaft outboard joint shaft assembly.

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

      • Be sure to install the tripod joint in the correct direction.

    7. A002ARO

      Using a snap ring expander, install a new shaft snap ring to the rear drive shaft outboard joint shaft assembly.

    8. Pack the rear drive shaft inboard joint assembly and rear drive shaft inboard joint boot with grease.

      Standard Grease Capacity
      93 to 103 g (3.29 to 3.63 oz)
    9. B003ZS7C01
      *a Matchmark

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

  6. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT


    1. Install the rear drive shaft inboard joint boot to the rear drive shaft inboard joint assembly.

    2. B003YWKN07

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

      Dimension (A)
      for LH Side 758.25 mm (2.49 ft.)
      for RH Side 738.25 mm (2.42 ft.)

  7. INSTALL REAR NO. 2 DRIVE SHAFT INBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

    2. B003ZPXC01
      *A for Type A
      *B for Type B
      *a Claw

      Using needle nose pliers, install the rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration (for Type A).

      Note

      Be careful not to damage the rear drive shaft inboard joint boot.

    3. Using needle-nose pliers, engage the 2 claws to install the rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration (for Type B).

      Note

      Be careful not to damage the rear drive shaft inboard joint boot.

  8. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

    Tech Tips

    Perform the same procedure as for the rear No. 2 drive shaft inboard joint boot clamp.

  9. INSPECT REAR DRIVE SHAFT ASSEMBLY

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