FRONT DRIVE SHAFT ASSEMBLY(for TMC Made) REASSEMBLY

Info Added 2017-10-06

PROCEDURE


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


    1. for AWD:


      1. A001WPFE16

        Using SST, install a new front drive shaft bearing.

        SST
        09527-10011
        09527-30010

        Note

        The front drive shaft bearing should be completely installed.

      2. A001UBZ

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A001XEWC04
      *a Steel Plate

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

      Note


      • The dust cover should be completely installed.

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

      • Install the front drive shaft dust cover LH in the correct direction.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. for 2WD:


      1. Perform the same procedure as for the LH side.

    2. for AWD:


      1. A001SKBC03

        Using SST and a press, install a new front drive shaft dust cover RH until the distance (A) from the tip of the center drive shaft to the front drive shaft dust cover RH meets the specification.

        SST
        09527-10011
        Distance (A)
        102.1 to 103.1 mm (4.02 to 4.05 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.

        • Install the front drive shaft dust cover RH in the correct direction.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A001T9HC01
      *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. A001Y3KC01
      *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
      B00495X Outboard joint side
      B0049DE Inboard joint side

      Install new parts onto 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 into the front drive outboard joint shaft assembly groove.

      Note


      • Do not allow grease to adhere to the boot clamp track of the front axle outboard joint boot.

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

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

    CAUTION:


    • A001VDN

      When installing the front No. 2 axle outboard joint boot clamp, do not perform the work without wearing protective gloves.

    • If work is performed without using protective gloves, injuries may occur.


    1. A001TLC

      Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and provisionally bend the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and lever for any deformation before bending the lever.

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

    2. A001URKC01
      *a Weight
      *b Contact

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

      Note

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

    3. A001XCQ

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

      Note

      Do not damage the front axle outboard joint boot.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:


    • A001VDN

      When installing the front axle outboard joint boot clamp, do not perform the work without wearing protective gloves.

    • If work is performed without using protective gloves, injuries may occur.


    1. A001WAW

      Install the front axle outboard joint boot clamp to the front axle outboard joint boot and provisionally bend the lever.

      Note


      • Set the lever into the guide groove correctly.

      • Check the band and lever for any deformation before bending the lever.

    2. A001WHVC01
      *a Place the tip near the center of the lever

      Using water pump pliers, pinch the front axle outboard joint boot clamp to provisionally fix it.

    3. A001VUM

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

      Note

      Do not damage the front axle outboard joint boot.

  7. INSTALL FRONT DRIVE SHAFT DAMPER LH


    1. A001XP9C09
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front Drive Shaft Damper LH
      *3 Front Drive Shaft Damper Clamp

      Install parts to the front drive outboard joint shaft assembly in the following order as shown in the illustration.


      1. New front drive shaft damper clamp

      2. Front drive shaft damper LH

      3. New front drive shaft damper clamp

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

      Dimension (A)
      211.7 to 215.7 mm (8.34 to 8.49 in.)

    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 LH.

      Note

      Be sure to install the clamp in the correct position.

    5. A001YGV

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

  8. INSTALL FRONT DRIVE SHAFT DAMPER RH (for 2WD)


    1. A001STPC07
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front Drive Shaft Damper RH
      *3 Front Drive Shaft Damper Clamp

      Install parts to the front drive outboard joint shaft assembly in the following order as shown in the illustration.


      1. New front drive shaft damper clamp

      2. Front drive shaft damper RH

      3. New front drive shaft damper clamp

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

      Dimension (A)
      488 to 492 mm (1.60 to 1.61 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 RH.

      Note

      Be sure to install the clamp in the correct position.

    5. A001YGV

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

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A001XJTC01
      *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
      B00495X Outboard joint side
      B0049DE 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 front drive outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A001SYLC01
      *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 front drive outboard joint shaft assembly 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.

    6. A001WBV

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

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

      Standard grease capacity
      168 to 178 g (5.93 to 6.28 oz.)
    8. A001TVAC04
      *a Groove

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

      Note


      • Align the phase of the protrusions and depressions, and assemble the front axle inboard joint grommet to the front drive inboard joint assembly.

      • Make sure the protrusion on the inner corner of the front axle inboard joint grommet is securely inserted into the groove in the outer surface of the joint.

    9. A001VUKC18
      *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.

      Note


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

      • Keep the grooves free of grease.

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:


    • When installing the front axle inboard joint boot clamp, do not perform the procedure without wearing protective gloves.

    • Performing the procedure without wearing protective gloves could result in injury.

    A001VDN

    1. A001WAW

      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. A001W8YC01
      *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.

    3. A001UB2

      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 damage the front axle inboard joint boot.

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

    CAUTION:


    • When installing the front No. 2 axle inboard joint boot clamp, do not perform the procedure without wearing protective gloves.

    • Performing the procedure without wearing protective gloves could result in injury.

    A001VDN

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

    2. A001XJIN05

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

      Dimension (A)
      LH Side 615.9 mm (2.02 ft.)
      RH Side (for 2WD) 870.9 mm (2.86 ft.)
      RH Side (for AWD) 876.5 mm (2.88 ft.)
    3. A001SPNC02
      *a Support Point
      *b Indented Portion

      While holding dimension (A) to the specified length, pull the indented portion of the inboard joint grommet outward with your finger, etc. to release air from inside the inboard joint and equalize the air pressure with the atmospheric pressure.

    4. Set the folding support point of the clamp so that it is aligned with any of the A portions indicated by arrows in the illustration.

    5. A001T0GC04
      *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.

    6. A001UUY

      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 damage the front axle inboard joint boot.

  13. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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