FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER (for LH Side)


    1. A003LACC11
      *a Steel Plate

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

      Note


      • The dust cover should be completely installed.

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

      • Install the front drive shaft dust cover in the correct orientation.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)


    1. A003KDQC04
      *a Steel Plate

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

      Note


      • The dust cover should be completely installed.

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

      • Install the front drive shaft dust cover in the correct orientation.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)


    1. A003K1VC04
      *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. A003KPSC01
      *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
      B006IR6 Outboard Joint Side
      B006IKP 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
      135 to 145 g (4.77 to 5.11 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.

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. A003NJE

      Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever to the guide groove correctly and install the clamp as far to the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    2. A003N5FC05
      *a Weight
      *b Contact

      Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work surface. Roll the outboard joint and fold the lever until a click sound can be heard.

      Note


      • Do not damage the deflector.

      • Make sure that the outboard joint is in direct contact with the work surface.

    3. A003KMDC11
      *a Buckle

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. A003MJ3

      Install the front axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever to the guide groove correctly.

      • Check the band and the lever for any deformation before folding back the lever.

    2. A003L74C01
      *a Place the tip near the center of the lever

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it until a click sound can be heard.

      Note

      Do not damage the front axle outboard joint boot.

    3. A003MS0C13
      *a Buckle

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  6. INSTALL FRONT DRIVE SHAFT DAMPER


    1. A003M27C06
      *1 Front Drive Shaft Damper
      *2 Front Drive Shaft Damper Clamp

      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 211.7 to 215.7 mm (8.34 to 8.49 in.)
      for RH Side 488.0 to 492.0 mm (1.601 to 1.613 ft.)

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

      Note

      Do not overtighten the vise.

    4. 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.

    5. A003LVYC05
      *a Claw

      Using needle-nose pliers, engage each claw to install the 2 front drive shaft damper clamps as shown in the illustration.

      Note


      • Be sure to install the clamp in the correct position.

      • Do not damage the front drive shaft damper.

      • Do not damage the claws.

  7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A003K4AC02
      *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
      B006IR6 Outboard Joint Side
      B006IKP 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. A003OGDC01
      *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.

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

    6. A003MUK

      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
      168 to 178 g (5.93 to 6.27 oz)
    8. A003KYLC06
      *a Groove

      Install a new front axle inboard joint grommet to the inboard joint groove.

      Note

      Securely fit the protrusion on the front axle inboard joint grommet into the inboard joint groove.

    9. A003KAQC13
      *a Matchmark

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

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

      Note


      • Keep the grooves free of grease.

      • Keep the inside of the front axle inboard joint boot free of foreign matter.

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. A003MJ3

      Install the front axle inboard joint boot clamp to the front axle inboard joint boot and temporarily fold back the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and the lever for any deformation before folding back the lever.

    2. A003L74C01
      *a Place the tip near the center of the lever

      Using water pump pliers, pinch the front axle inboard joint boot clamp to temporarily secure it until a click sound can be heard.

      Note

      Do not damage the front axle inboard joint boot.

    3. A003MS0C12
      *a Buckle

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle inboard joint boot.

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

    CAUTION:

    Wear protective gloves. Sharp areas on the parts may injure your hands.


    1. A003P1ON47
      A003LNTC01
      *1 Front Axle Inboard Joint Grommet
      *a Recessed Parts

      While keeping dimension (A) within the specified length, equalize the pressure within the inboard joint with atmospheric pressure by slightly lifting one of the recessed areas of the front axle inboard joint grommet from the front drive inboard joint assembly.

      Dimension (A)
      for LH Side for RH Side
      581.2 mm (1.91 ft.) 880.2 mm (2.89 ft.)
    2. A003M8UC01
      *1 Front No. 2 Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Grommet
      *a Fulcrum Point

      Set the lever fulcrum point at any point (B) indicated in the illustration and temporarily bend the lever.

      Note


      • Perform this work with the inside of the inboard joint kept at atmospheric pressure.

      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    3. A003MB3C04
      *a Weight
      *b Contact

      Lean your weight on your hand and roll the inboard joint forward while pressing the inboard joint against the work surface. Roll the inboard joint and fold the lever until a click sound can be heard.

      Note


      • Make sure that the inboard joint is in direct contact with the work surface.

      • Do not damage the front drive shaft dust cover.

    4. A003MF5C07
      *a Buckle

      Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle inboard joint boot.

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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