FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

Info Added 2017-08-02

PROCEDURE


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


    1. A0008BUE17
      Text in Illustration
      *1 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. A00091C

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A00047AE14
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until 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)
      110.0 to 111.0 mm (4.33 to 4.37 in.)

      Note


      • The dust cover should be completely installed.

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

  3. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A000684E28
      Text in Illustration
      *1 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.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A000511E03
      Text in Illustration
      *1 Protective Tape

      Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

    2. A0007IEE03
      Text in Illustration
      *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
      A0005GR Outboard Joint Side
      A0009JS 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
      205 to 215 g (7.23 to 7.58 oz.)

    4. Install the front axle outboard joint boot onto 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 NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:

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


    1. A0005YW

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

      Note


      • Set the lever into 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. A0008Z4E05
      Text in Illustration
      *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 speed sensor rotor.

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

    3. A0005XS

      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 too much force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:

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


    1. A000787

      Install the front axle outboard joint boot clamp onto the front axle outboard 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. A00074XE08
      Text in Illustration
      *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.

    3. A00085I
      A0006AJ

      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 outboard joint boot.

  7. INSTALL FRONT DRIVE SHAFT DAMPER (w/ 1 Clamp)


    1. Install a new front drive shaft damper clamp onto the front drive outboard joint shaft assembly.

    2. A0003TQE03
      Text in Illustration
      *1 Front Drive Shaft Damper
      *2 Front Drive Shaft Damper Clamp

      Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

    3. Set the dimension as specified below.

      Dimension (A)
      223.4 to 227.4 mm (8.80 to 8.95 in.)

    4. Install the front drive shaft damper clamp onto the front drive shaft damper.

      Note

      Be sure to install the clamp in the correct position.

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

      Note

      Do not overtighten the vise.

    6. A0009A4E01
      Text in Illustration
      *A for One Touch Type
      *B for Claw Engagement Type

      for One Touch Type:


      1. Using a screwdriver, install the front drive shaft damper clamp.

    7. for Claw Engagement Type:


      1. Using needle nose pliers, install the front drive shaft damper clamp.

        Text in Illustration
        *a Claw

  8. INSTALL FRONT DRIVE SHAFT DAMPER (w/ 2 Clamps)


    1. A0009QSE02
      Text in Illustration
      *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 as specified below.

      Dimension (A)
      261.4 to 265.4 mm (10.3 to 10.4 in.)
    3. A0009B9E02
      Text in Illustration
      *a Claw

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

      Note

      Be sure to install the clamp in the correct position.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A0006SVE06
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      A0005GR Outboard Joint Side
      A0009JS Inboard Joint Side

      Install new parts onto 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. A000933E48
      Text in Illustration
      *a Matchmark

      Align the matchmarks and set the tripod joint onto the front drive outboard joint shaft assembly.

    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. A000992

      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
      175 to 185 g (6.17 to 6.52 oz.)
    8. A0004UVE41
      Text in Illustration
      *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. A0009I5E03
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Dimension (A)
      Dimension (A)
      LH Side 576.9 mm (1.89 ft.)
      RH Side 914.4 mm (3.00 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.

    2. A00041T

      for One Touch Type:


      1. Using a screwdriver, install the front axle inboard joint boot clamp.

    3. A0007T3E04
      Text in Illustration
      *a Claw

      for Claw Engagement Type:


      1. Using needle nose pliers, install the front axle inboard joint boot clamp.

        Note

        Be careful not to damage the front axle inboard joint boot.

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


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

    2. A0005EE

      for One Touch Type:


      1. Using a screwdriver, install the front No. 2 axle inboard joint boot clamp.

    3. A0003SSE05
      Text in Illustration
      *a Claw

      for Claw Engagement Type:


      1. 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 DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new front drive shaft hole snap ring LH.

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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