FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. A01V1Q3E01
      Text in Illustration
      *1 Press

      Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

      SST
      09527-10011

      Note


      • Install the dust cover in the correct orientation.

      • Do not deform the dust cover.

  2. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


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

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    A01V23XE10
    Text in Illustration
    *1 Protective Tape

    1. Wrap the spline of the outboard joint shaft assembly with protective tape.

    2. Install new parts onto the 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 outboard joint shaft assembly and the front axle outboard joint boot with grease.

      Standard Grease Capacity
      151 to 161 g (5.4 to 5.6 oz.)

    4. Install the front axle outboard joint boot into the grooves of the outboard joint shaft assembly.

      Note

      Keep the groove free of grease.

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


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install a new front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.

    3. A01UZCGE01

      Place SST onto the front No. 2 axle outboard joint boot clamp.

      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. A01V14LE04

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

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the boot clamp.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install a new front axle outboard joint boot clamp to the front axle outboard joint boot.

    3. A01V0AAE01

      Place SST onto the front axle outboard joint boot clamp.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. A01UXRAE01

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

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the boot clamp.

  6. INSTALL FRONT DRIVE SHAFT DAMPER (for RH Side)

    A01UZ26E07

    1. Install the front drive shaft damper RH onto dimension (A) shown in the illustration.

      Dimension (A)
      425.6 to 429.6 mm (1.396 to 1.409 ft.)

      Note

      Install the damper in the correct orientation.

  7. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (for RH Side)


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install a new front drive shaft damper clamp RH to the front drive shaft damper.

      Note

      Be sure to install the drive shaft damper clamp on the inboard joint side in the correct position.

    3. A01UZK7E01

      Place SST onto the front drive shaft damper clamp RH.

      SST
      09521-24010

    4. Tighten SST so that the front drive shaft damper clamp RH is pinched.

      Note

      Do not overtighten SST.

    5. A01UYYME01

      Using SST, adjust the clearance of the front drive shaft damper clamp RH.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the drive shaft damper clamp.

  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. Install new parts onto the 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. Fix the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A01V14IE15
      Text in Illustration
      *a Matchmark

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

      Note

      Face the serrated side of the tripod joint outward and install it onto the outboard joint end.

    5. Using a brass bar and hammer, install the tripod joint assembly.

      Note


      • Do not hit the rollers.

      • Keep the tripod joint free of foreign matter.

    6. A01V1RP

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

    7. Pack the front drive inboard joint assembly with grease.

      Standard Grease Capacity
      125 to 135 g (4.4 to 4.7 oz.)
    8. A01V11KE11
      Text in Illustration
      *a Matchmark

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

    9. Install the front axle inboard joint boot into the grooves of the front drive inboard joint assembly and the outboard joint shaft assembly.

      Note

      Keep the grooves free of grease.

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Hold the outboard joint shaft assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install a new front axle inboard joint boot clamp to the front axle inboard joint boot.

    3. A01V1QPE01

      Place SST onto the front axle inboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A01UY3LE01

      Using SST, adjust the clearance of the front axle inboard joint boot clamp.

      SST
      09240-00020
      Standard Clearance
      0.8 mm (0.0315 in.) or less

      Note

      If the measured value exceeds the specified value, retighten the boot clamp.

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


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

    2. A01UYYLE01

      Adjust dimension (A) until the drive shaft is within the specified length.

      Dimension (A)
      LH RH

      561.9 mm

      (1.84 ft.)

      845.9 mm

      (2.77 ft.)
    3. A01V1XU

      Using needle-nose pliers, engage the 2 claws and install the front No. 2 axle inboard joint boot clamp as shown in the illustration.

      Note


      • Do not damage the boot.

      • Do not deform the claw of the hook.

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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