FRONT DRIVE SHAFT ASSEMBLY (for 1ZR-FAE, 2ZR-FAE) REASSEMBLY

INSTALL FRONT DRIVE SHAFT DUST COVER LH
1. Using SST and a press, press on a new drive shaft dust cover.
  
  SST
  
  09527-10011
  Note
  
  The dust cover should be installed completely.
  
  Be careful not to damage the dust cover.
INSTALL FRONT DRIVE SHAFT DUST COVER RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH
Text in Illustration

*1 Vinyl Tape

Tech Tips

Before installing the boot, wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.
1. Hold the front drive shaft in a vise between aluminum plates.
2. Install new parts to the outboard joint shaft in the following order.
  1. No. 2 axle outboard joint boot clamp
  2. Outboard joint boot
  3. Outboard joint boot clamp
3. Pack the outboard joint shaft and boot with grease from the boot kit.
  
  Standard grease capacity
  
  120 to 130 g (4.24 to 4.58oz.)
INSTALL FRONT AXLE OUTBOARD JOINT BOOT RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH
1. Hold the front drive shaft in a vise between aluminum plates.
2. Secure the No. 2 axle outboard joint boot clamp to the boot.
3. Place SST onto the No. 2 axle outboard joint boot clamp.
  
  SST
  
  09521-24010
4. Tighten SST so that the No. 2 axle outboard joint boot clamp is pinched.
  
  Note
  
  Do not overtighten SST.
5. Using SST, adjust the clearance of the clamp.
  
  SST
  
  09240-00020
  
  Standard clearance
  
  0.5 to 1.5 mm (0.0197 to 0.0591 in.)
  
  Note
  
  If the measured value exceeds the specified value, retighten the clamp.
INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH
1. Hold the front drive shaft in a vise between aluminum plates.
2. Secure the outboard joint boot clamp to the boot.
3. Place SST onto the outboard joint boot clamp.
  
  SST
  
  09521-24010
4. Tighten SST so that the outboard joint boot clamp is pinched.
  
  Note
  
  Do not overtighten SST.
5. Using SST, adjust the clearance of the clamp.
  
  SST
  
  09240-00020
  
  Standard clearance
  
  0.5 to 1.5 mm (0.0197 to 0.0591 in.)
  
  Note
  
  If the measured value exceeds the specified value, retighten the clamp.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT DRIVE SHAFT DAMPER LH
1. Install the drive shaft damper to the drive shaft.
  
  Note
  
  Make sure that the damper is on the shaft groove.
2. Adjust the position of the damper so that the dimension is as described below.
  
  Standard dimension (A)
  
  161 to 165 mm (6.34 to 6.50 in.)
INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH
1. Hold the front drive shaft in a vise between aluminum plates.
2. Install a new drive shaft damper clamp to the damper.
  
  Note
  
  Be sure to install the clamp on the inboard joint side in the correct position.
3. Place SST onto the damper clamp.
  
  SST
  
  09521-24010
4. Tighten SST so that the damper clamp is pinched.
  
  Note
  
  Do not overtighten SST.
5. Using SST, adjust the clearance of the damper clamp.
  
  SST
  
  09240-00020
  
  Standard clearance
  
  0.5 to 1.5 mm (0.0197 to 0.0591 in.)
  
  Note
  
  If the measured value exceeds the specified value, retighten the clamp.
INSTALL FRONT DRIVE SHAFT DAMPER RH
1. Install the drive shaft damper to the drive shaft.
2. Adjust the position of the damper so that the dimension is as described below.
  
  Standard dimension (B)
  
  442 to 446 mm (17.4 to 17.6 in.)
INSTALL DRIVE SHAFT DAMPER SETTING CLAMP RH
1. Hold the front drive shaft in a vise between aluminum plates.
2. Install a new drive shaft damper clamp to the damper.
  
  Note
  
  Be sure to install the clamp on the inboard joint side in the correct position.
3. Place SST onto the damper clamp.
  
  SST
  
  09521-24010
4. Tighten SST so that the damper clamp is pinched.
  
  Note
  
  Do not overtighten SST.
5. Using SST, adjust the clearance of the damper clamp.
  
  SST
  
  09240-00020
  
  Standard clearance
  
  0.5 to 1.5 mm (0.0197 to 0.0591 in.)
  
  Note
  
  If the measured value exceeds the specified value, retighten the clamp.
INSTALL FRONT DRIVE INBOARD JOINT LH
1. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
2. Install new parts to the outboard joint shaft in the following order.
  1. Inboard joint boot clamp
  2. Inboard joint boot
  3. No. 2 axle inboard joint boot clamp
3. Place the beveled side of the tripod axial spline toward the outboard joint.
4. Align the matchmarks placed before removal.
  
  Text in Illustration
  
  *1 Matchmark
5. Using a brass bar and hammer, tap the tripod onto the drive shaft.
  Note
  - Do not tap the rollers.
  - Be sure to install the tripod in the correct direction.
6. Pack the inboard joint shaft and boot with grease from the boot kit.
  
  Standard grease capacity
  
  155 to 171 g (5.47 to 6.03 oz.)
7. Using a snap ring expander, install a new shaft snap ring.
8. Text in Illustration
  
  *1 Matchmark
  
  Align the matchmarks and install the inboard joint to the outboard joint shaft.
INSTALL FRONT DRIVE INBOARD JOINT RH

Tech Tips

Use the same procedures described for the LH side.

INSTALL INBOARD JOINT BOOT

Install the inboard joint boot to the inboard joint.

A00OIAVE10

Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

Dimension (A)

for LH Side	for RH Side
603.28 mm (23.8 in.)	886.28 mm (34.9 in.)

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH
1. Hold the front drive shaft in a vise between aluminum plates.
2. Secure the inboard joint boot clamp to the boot.
3. Place SST onto the inboard joint boot clamp.
  
  SST
  
  09521-24010
4. Tighten SST so that the clamp is pinched.
  
  Note
  
  Do not overtighten SST.
5. Using SST, adjust the clearance of the clamp.
  
  SST
  
  09240-00020
  
  Standard clearance
  
  0.5 to 1.5 mm (0.0197 to 0.0591 in.)
  
  Note
  
  If the measured value exceeds the specified value, retighten the clamp.
INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP LH
1. Using needle-nose pliers, install the axle inboard joint boot clamp as shown in the illustration.
  
  Note
  
  Be careful not to damage the boot.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH

Tech Tips

Use the same procedures described for the LH side.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH
1. Install a new hole snap ring.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

Tech Tips

Use the same procedures described for the LH side.

INSPECT DRIVE SHAFT

Check that there is no severe play in the radial direction of the outboard joint.
Check that the inboard joint slides smoothly in the thrust direction.
Check that there is no severe play in the radial direction of the inboard joint.
Check the 2 boots for damage.

A005U27E10

Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

Dimension (A)

for LH Side	for RH Side
603.28 mm (23.8 in.)	886.28 mm (34.9 in.)

If the boots are stretched or contracted, correct them.