FRONT DRIVE SHAFT ASSEMBLY (for 2AR-FE) REASSEMBLY


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


    1. A01G6FHE07
      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. A01G4SH

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

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


    1. A01G7BHE04
      Text in Illustration
      *1 Steel Plate

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

      SST
      09726-40010
      Dimension (A)
      26.6 to 27.6 mm (1.05 to 1.08 in.)

      Note


      • The dust cover should be completely installed.

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

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01G4I6E07
      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.

  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01G7Z4E14
      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.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01G833E03
      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. A01G4TCE01
      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
      A01G8AH Outboard Joint Side
      A01G47H 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
      171 to 181 g (6.03 to 6.38 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.

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

    CAUTION:

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


    1. A01G78V

      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. A01G9K9E02
      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. A01G98G

      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.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:

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


    1. A01G5G9

      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. A01G78PE08
      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. A01G9UO

      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.

  8. 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. A01G5P4E01
      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. A01G8IRE09
      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

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


    1. A01G5SME01
      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)
      for LH Side 277.9 to 281.9 mm (10.9 to 11.1 in.)
      for RH Side 261.4 to 265.4 mm (10.3 to 10.4 in.)
    3. A01G5KHE01
      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.

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01G9HXE15
      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
      A01G8AH Outboard Joint Side
      A01G47H 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. A01G8DGE26
      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. A01G4XH

      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. A01G4CHE21
      Text in Illustration
      *a Matchmark

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

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. A01G4QGE01
      Text in Illustration
      *A LH Side
      *B RH Side

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

      Dimension (A)
      Dimension
      LH Side 585.2 mm (1.92 ft.)
      RH Side 910.0 mm (2.99 ft.)

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

    2. A01G75E

      for One Touch Type:


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

    3. A01G690E01
      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.

  13. 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. A01G5UA

      for One Touch Type:


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

    3. A01G7EVE01
      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.

  14. 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.

  15. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A01G7K1

      Check that there is no excessive play in the radial direction of the outboard joint.

    2. Check that the inboard joint slides smoothly in the thrust direction.

    3. Check that there is no excessive play in the radial direction of the inboard joint.

    4. Check the boots for damage.

    5. A01G4QGE01
      Text in Illustration
      *A LH Side
      *B RH Side

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

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      Dimension
      LH Side 585.2 mm (1.92 ft.)
      RH Side 910.0 mm (2.99 ft.)