FRONT DRIVE SHAFT ASSEMBLY(for 1AR-FE) REASSEMBLY

PROCEDURE


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


    1. B003Z0PC05
      *a 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. B003ZTX

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

      Note

      Install the drive shaft hole snap ring securely.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. B003ZF4C05
      *a Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until the 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 (4.34 to 4.37 in.)

      Note


      • The front drive shaft dust cover RH 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. B003Z0OC06
      *a Steel Plate

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

      Note


      • The front drive shaft dust cover LH should be completely installed.

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

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. B00401MC04
      *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. B003ZU5C01
      *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
      B003ZIE Outboard joint side
      B003Z8F Inboard joint side

      Install new parts to 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
      174 g (6.14 oz)

    4. Install the front axle outboard joint boot to 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


    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 to the front axle outboard joint boot.

    3. B003ZWAN01

      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. B00403NN06

      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 0.0590 in.)

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

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

    2. B00403ON01

      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. B003ZW8N01

      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 0.0590 in.)

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

  7. INSTALL FRONT DRIVE SHAFT DAMPER


    1. w/ 1 Clamp:


      1. B003Z5DN02

        Install the front drive shaft damper to the front drive outboard joint shaft assembly.

      2. Set the dimension (A) as specified below.

        Dimension (A)
        for LH Side 237.0 to 241.0 mm (9.34 to 9.48 in.)
        for RH Side 231.0 to 235.0 mm (9.10 to 9.25 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 to the front drive shaft damper.

        Note

        Be sure to install the clamp in the correct position.

      5. B003ZNXE02

        Place SST to the front drive shaft damper clamp, press it against the damper 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. B003Z9LN01

        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.

    2. w/ 2 Clamps:


      1. B003ZU2C05
        *1 Front Drive Shaft Damper Clamp
        *2 Front Drive Shaft Damper

        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 (A) as specified below.

        Dimension (A)
        for LH Side 237.0 to 241.0 mm (9.33 to 9.48 in.)
        for RH Side 228.9 to 232.9 mm (9.02 to 9.16 in.)

      3. Install the 2 front drive shaft damper clamps to the front drive shaft damper.

        Note

        Make sure to install the clamps in the correct position.

      4. B003ZA8

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

  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B004036C02
      *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
      B003ZIE Outboard joint side
      B003Z8F Inboard joint side

      Install new parts to 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. B003ZLHC02
      *a Matchmark

      Align the matchmarks and install the tripod joint to the front drive 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 front drive 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. B003ZGQ

      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
      145 g (5.11 oz)
    9. B00404HC01
      *a Matchmark

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

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B00406FC02
      *A for LH Side
      *B for RH Side

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

      Dimension (A)
      for LH Side 602.36 mm (1.98 ft.)
      for RH Side 918.96 mm (3.01 ft.)

  10. 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 to the front axle inboard joint boot.

    3. B003Z66N01

      Place SST to 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. B004053N02

      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.

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


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

    2. A002C0H

      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.

  12. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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