FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (for 2AR-FE)


    1. B006QG9C02
      *a Steel Plate

      Using SST, a steel plate and a press, install a new drive shaft bearing case sub-assembly to the front drive inboard joint assembly.

      SST
      09710-30012   ( 09710-04081 )

      Note


      • Make sure to fully install the bearing.

      • Do not put force on the drive shaft bearing case sub-assembly.

    2. B006NGG

      Using a snap ring expander, install a new snap ring.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER LH (for 2AR-FE)


    1. B006QJTC06
      *a Steel Plate

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

      Note


      • Make sure to fully install the front drive shaft dust cover LH.

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

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 2AR-FE)


    1. B006PL1C06
      *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)
      91.0 to 92.0 mm (3.59 to 3.62 in.)

      Note

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

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. B006PCOC04
      *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. B006MFUC01
      *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
      B006QOD Outboard Joint Side
      B006LKF 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.

  5. 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. B006N30N01

      Place SST onto 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. B006NUCN11

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

      SST
      09240-00021
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  6. 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. B006OT2N01

      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. B006PKGN06

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

      SST
      09240-00021
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  7. INSTALL FRONT DRIVE SHAFT DAMPER (for LH Side)


    1. B006PU7C02
      *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)
      168 to 172 mm (6.62 to 6.77 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.

  8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for LH Side)

    Tech Tips

    Use the same procedure for each front drive shaft damper clamp.


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

      Note

      Do not overtighten the vise.

    2. B006OVME02

      Place SST onto the front drive shaft damper clamp, press it against the damper and slightly tighten SST.

      SST
      09521-24010

    3. Tighten SST so that the front drive shaft damper clamp is pinched.

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. B006N4SN02

      Using SST, measure the clearance of the front drive shaft damper clamp.

      SST
      09240-00021
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B006KR4C02
      *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
      B006QOD Outboard Joint Side
      B006LKF 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. B006PT4C02
      *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. 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.

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

    6. B006KRL

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

    7. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

      Standard Grease Capacity (for 2AR-FE)
      140 to 150 g (4.94 to 5.29 oz)
      Standard Grease Capacity (for 2GR-FKS)
      for LH Side 136 to 146 g (4.80 to 5.15 oz)
      for RH Side 155 to 165 g (5.47 to 5.82 oz)
    8. B006N50C01
      *a Matchmark

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

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B006ORMC01
      *A for LH Side
      *B for RH Side

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

      Dimension (A) (for 2AR-FE)
      for LH Side 595.2 mm (1.95 ft.)
      for RH Side 911.15 mm (2.99 ft.)
      Dimension (A) (for 2GR-FKS)
      for LH Side 584.35 mm (1.92 ft.)
      for RH Side 925.15 mm (3.03 ft.)

  11. 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. B006Q4DN01

      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. B006QZKN02

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

      SST
      09240-00021
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (for 2AR-FE)


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

    2. B006R1W

      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.

  13. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (for 2GR-FKS)


    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. B006N5WN03

      Place SST onto 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. B006KKPN08

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

      SST
      09240-00021
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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