FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When using a vise, place aluminum plates between the part and vise.

  • When using a vise, do not overtighten it.

Tech Tips


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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. INSTALL FRONT AXLE HUB DUST SEAL


    1. B003N7N

      Using a brass bar and hammer, tap on the front drive outboard joint assembly until a new front axle hub dust seal contacts the edge of the front drive outboard joint assembly.

      Note


      • Do not damage the front axle hub dust seal.

      • The front axle hub dust seal should be installed completely.

      • Make sure to install the front axle hub dust seal in the correct direction.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. B003PU1N01

      Using SST and a press, press in a new front drive shaft dust cover until the inboard joint contacts the edge of the inboard joint.

      SST
      09527-10011
      09316-20011

      Note


      • Do not damage the front drive shaft dust cover.

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

      • Make sure to install the front drive shaft dust cover in the correct direction.

  3. INSTALL OUTBOARD JOINT BOOT

    B003RPFC05
    *a Protective Tape

    1. Before installing the outboard joint boot, wrap the splines of the front drive outboard joint assembly with protective tape to prevent the outboard joint boot from being damaged.

    2. B003NJEC01
      *1 Front No. 2 Axle Outboard Joint Boot Clamp
      *2 Outboard Joint Boot
      *3 Front Axle Outboard Joint Boot Clamp
      *4 Front Drive Outboard Joint Assembly
      B003R2S Outboard Joint Side
      B003LF2 Inboard Joint Side

      Install new parts to the front drive outboard joint assembly in the following order.


      1. Front No. 2 axle outboard joint boot clamp

      2. Outboard joint boot

      3. Front axle outboard joint boot clamp

    3. Install the outboard joint boot so that it is between the front No. 2 axle outboard joint boot clamp and front drive outboard joint assembly.

    4. Temporarily install the front axle outboard joint boot clamp to the outboard joint boot.

    5. Pack the front drive outboard joint assembly and outboard joint boot with grease from the boot kit.

      Standard grease capacity
      268.0 to 288.0 g (9.46 to 10.15 oz)

    6. Install the outboard joint boot to the groove of the front drive outboard joint assembly.

      Note


      • Do not apply grease to the part of the outboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the outboard joint boot.

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


    1. Install SST to the front No. 2 axle outboard joint boot clamp LH, and then while pressing the outboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front No. 2 axle outboard joint boot clamp LH to the guide groove.

      • Do not damage the outboard joint boot.

    2. B003J83C02
      *a Turn
      *b Hold

      Tighten SST so that the front No. 2 axle outboard joint boot clamp LH is pinched.

      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note


      • When tightening SST, make sure the clearance of the front No. 2 axle outboard joint boot clamp LH is within the standard clearance.

      • Do not damage the outboard joint boot.

    3. Remove SST from the front No. 2 axle outboard joint boot clamp LH.

    4. B003NPBN07

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

      SST
      09240-00020
      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front No. 2 axle outboard joint boot clamp LH.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH


    1. Install SST to the front axle outboard joint boot clamp LH, and then while pressing the outboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front axle outboard joint boot clamp LH to the guide groove.

      • Do not damage the outboard joint boot.

    2. B003ROAC01
      *a Turn
      *b Hold

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

      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note


      • When tightening SST, make sure the clearance of the front axle outboard joint boot clamp LH is within the standard clearance.

      • Do not damage the outboard joint boot.

    3. Remove SST from the front axle outboard joint boot clamp LH.

    4. B003Q0HN01

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

      SST
      09240-00020
      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front axle outboard joint boot clamp LH.

  6. INSTALL INBOARD JOINT


    1. B003NOEC01
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      B003R2S Outboard Joint Side
      B003LF2 Inboard Joint Side

      Install new parts to the front drive outboard joint assembly in the following order.


      1. Front axle inboard joint boot clamp

      2. Inboard joint boot

      3. Front No. 2 axle inboard joint boot clamp

    2. Remove the protective tape from the front drive outboard joint assembly.

    3. B003OUWC01
      *a Matchmark

      Align the matchmarks and place the beveled side of the tripod joint axial spline toward the front drive outboard joint assembly.

    4. B003QL8

      Using a brass bar and hammer, tap the tripod onto the outboard joint.

      Note


      • Do not tap the rollers.

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

    5. B003Q6V

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

      Note

      The snap ring should be installed completely.

    6. Pack the inboard joint and inboard joint boot with grease from the boot kit.

      Standard grease capacity
      165.0 to 185.0 g (5.82 to 6.52 oz)
    7. B003JI2C05
      *a Matchmark

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

  7. INSTALL INBOARD JOINT BOOT


    1. Install the inboard joint boot to the inboard joint.

      Note


      • Do not apply grease to the part of the inboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the inboard joint boot.

    2. B003OBBN05

      Check that the inboard joint boot and outboard joint boot are not stretched or contracted when the front drive shaft assembly is at the standard length.

      Length (A)
      555.9 mm (1.82 ft.)

      Note

      Keep the front drive shaft assembly level during inspection.

      If the inboard joint boot and outboard joint boot are stretched or contracted, correct them.

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


    1. Install SST to the front axle inboard joint boot clamp LH, and then while pressing the inboard joint boot, slightly tighten the SST bolt.

      SST
      09521-24010

      Note


      • Correctly set the front axle inboard joint boot clamp LH to the guide groove.

      • Do not damage the inboard joint boot.

    2. B003NBLC03
      *a Turn
      *b Hold

      Tighten SST so that the front axle inboard joint boot clamp LH is pinched.

      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note


      • When tightening SST, make sure the clearance of the front axle inboard joint boot clamp LH is within the standard clearance.

      • Do not damage the inboard joint boot.

    3. Remove SST from the front axle inboard joint boot clamp LH.

    4. B003OLRN04

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

      SST
      09240-00020
      Standard clearance
      0.8 mm (0.0314 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the front axle inboard joint boot clamp LH.

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


    1. B003OEQC01
      *a Claw Engagement

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

      Note

      Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.

    2. Using needle-nose pliers, hold the front No. 2 axle inboard joint boot clamp LH at the claw engagement.

      Note


      • Do not damage the inboard joint boot.

      • Do not deform the claw engagement of the front No. 2 axle inboard joint boot clamp LH.

  10. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

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