FRONT DRIVE SHAFT ASSEMBLY (for 2AR) REASSEMBLY

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

    1. Using SST, a steel plate and a press, install a new front drive shaft bearing.

      A011QUTE07
      Text in Illustration
      *1 Steel Plate
      SST
      09527-10011

      Note

      The bearing should be completely installed.

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

      A011QXA

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

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

      A011UFCE04
      Text in Illustration
      *1 Steel Plate
      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. 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.

      A011T5JE07
      Text in Illustration
      *1 Steel Plate
      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. Using a steel plate and a press, install a new front drive shaft dust cover LH.

      A011UH1E14
      Text in Illustration
      *1 Steel Plate

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

      A011ULKE03
      Text in Illustration
      *1 Protective Tape

    2. Install new parts onto the front drive outboard joint shaft assembly in the following order:

      A011TZLE01
      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
      A011T1X Outboard Joint Side
      A011V7Q Inboard Joint Side

      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
      100 to 120 g (3.53 to 4.23 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

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

      Note

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.

    3. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      A011S98E01
      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

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

      A011UZKE01
      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

      If the clearance is outside the specified range, retighten SST.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

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

    2. Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      A011S3CE01
      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. Remove SST.

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

      A011VA5E01
      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

      If the clearance is outside the specified range, retighten SST.

  8. INSTALL FRONT DRIVE SHAFT DAMPER

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

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

      A011U8FE01
      Text in Illustration
      *1 Front Drive Shaft Damper
      *2 Front Drive Shaft Damper Clamp

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

      A011S1O

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

    1. Install new parts onto the front drive outboard joint shaft assembly in the following order:

      A011QSQE15
      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
      A011T1X Outboard Joint Side
      A011V7Q Inboard Joint Side

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

      A011UTHE03
      Text in Illustration
      *a Matchmark

    5. Align the matchmarks placed before removal.

    6. 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.

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

      A011RCS

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

      Standard grease capacity (LH Side)
      150 to 170 g (5.29 to 5.99 oz.)
      Standard grease capacity (RH Side)
      155 to 175 g (5.47 to 6.17 oz.)

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

      A011RUZE21
      Text in Illustration
      *a Matchmark

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT

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

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

      A011QTTE01
      Text in Illustration
      *A LH Side
      *B RH Side
      Dimension (A)
      Dimension (A)
      LH Side 587.4 mm (1.93 ft.)
      RH Side 906.6 mm (2.97 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. Using needle nose pliers, install the front axle inboard joint boot clamp.

      A011T02

      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. Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.

      A011US8

      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

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

      A011U1V

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

      A011QTTE01
      Text in Illustration
      *A LH Side
      *B RH Side

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      Dimension (A)
      LH Side 587.4 mm (1.93 ft.)
      RH Side 906.6 mm (2.97 ft.)