FRONT DRIVE SHAFT ASSEMBLY(for 2GR-FKS) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT BEARING (for AWD)


    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 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
      164 to 174 g (5.79 to 6.13 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.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

      Note

      Do not overtighten the vise.

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

    3. B00403OC01
      *a Turn
      *b Hold

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. 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.

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP


    1. Secure 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. B003ZI6C04
      *a Turn
      *b Hold

      Place SST to 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. B003ZCON13

      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.

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


    1. B003ZU2C04
      *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 234.9 to 238.9 mm (9.25 to 9.40 in.)
      for RH Side 229.9 to 233.9 mm (9.06 to 9.20 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.

  6. 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. Secure 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 joint boot with grease.

      Standard Grease Capacity
      195 to 205 g (6.88 to 7.23 oz)
    9. B003Z1YC02
      *a Lip

      Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

      Note


      • Securely fit the protrusion on the front axle inboard joint grommet into the front drive inboard joint assembly.

      • Make sure that the lip of the front axle inboard joint grommet is not damaged.

    10. B003YXUC03
      *a Matchmark

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

  7. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B00408VN28

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

      Dimension (A) (for 2WD)
      for LH Side 604.75 mm (1.98 ft.)
      for RH Side 925.55 mm (3.04 ft.)
      Dimension (A) (for AWD)
      for LH Side 604.75 mm (1.98 ft.)
      for RH Side 926.55 mm (3.04 ft.)

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Secure 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. B003Z66C02
      *a Turn
      *b Hold

      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.

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


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

      Note

      Do not overtighten the vise.

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

    3. B003ZLAC02
      *a Turn
      *b Hold

      Place SST to the front No. 2 axle inboard 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 inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B00401KN05

      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.

  10. INSPECT FRONT DRIVE SHAFT ASSEMBLY

    Click here