FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT DUST COVER (for LH Side)


    1. A01JAQLE08

      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 front drive shaft dust cover in the correct direction.

      • Do not deform the front drive shaft dust cover.

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


    1. A01JAPGE01

      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 front drive shaft dust cover in the correct direction.

      • Do not deform the front drive shaft dust cover.

  3. INSTALL OUTBOARD JOINT BOOT (for LH Side)


    1. A01JCRCE12
      Text in Illustration
      *1 Protective Tape

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

    2. A01JAWTE02

      Install new parts onto the front axle outboard joint shaft assembly in the following order:


      1. Front No. 2 axle outboard joint boot clamp (A)

      2. Outboard joint boot (B)

      3. Front axle outboard joint boot clamp (C)

    3. Pack the joint portion of the front axle outboard joint shaft assembly and outboard joint boot with grease.

      Standard grease capacity
      135 to 145 g (4.8 to 5.1 oz.)

    4. Install the outboard joint boot onto the front axle 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.

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

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


    1. A01JBIK

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

      Note


      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    2. A01J8X1E12

      Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.

      Note


      • Do not damage the deflector.

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

    3. A01JB1U

      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 outboard joint boot.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

    CAUTION:

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


    1. A01J8XY

      Install the front axle outboard joint boot clamp onto the 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. A01JD5PE06

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

    3. A01J9PX

      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 outboard joint boot.

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


    1. A01JAQKE04

      Install the front drive shaft damper onto the front axle outboard joint shaft assembly as shown in the illustration.

      Tech Tips

      Make sure that the front drive shaft damper is on the shaft groove.

      Dimension (A)
      163 to 165 mm (6.42 to 6.49 in.)

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


    1. A01J8Q6E01

      Install the front drive shaft damper onto the front axle outboard joint shaft assembly as shown in the illustration.

      Tech Tips

      Make sure that the front drive shaft damper is on the shaft groove.

      Dimension (A)
      460 to 462 mm (1.50 to 1.51 ft.)

  8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for LH Side)


    1. Secure the front axle outboard joint shaft assembly in a vise using aluminum plates.

      Note

      Do not overtighten the vise.

    2. for one touch type:


      1. A01JB1FE02

        Using a screwdriver, install a new front drive shaft damper clamp, as shown in the illustration.

        Note

        Do not damage the outboard joint boot.

    3. for claw engagement type:


      1. Using needle-nose pliers, install a new front drive shaft damper clamp, as shown in the illustration.

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


    1. A01JBYM

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

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01J9B2E01

      Install new parts onto the front axle outboard joint shaft assembly in the following order:


      1. Front axle inboard joint boot clamp (A)

      2. Inboard joint boot (B)

      3. Front No. 2 axle inboard joint boot clamp (C)

    2. Secure the front axle outboard joint shaft assembly in a vise using aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A01JD8GE16
      Text in Illustration
      *1 Matchmark

      Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft assembly as shown in the illustration.

      Note

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

    5. Using a brass bar and a hammer, install the tripod joint to the front axle outboard joint shaft assembly.

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

    6. A01JBAY

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

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

      Standard grease capacity
      168 to 178 g (5.9 to 6.2 oz.)
    8. A01JA7VE02
      Text in Illustration
      *1 Groove

      Install a new front axle inboard joint grommet onto the inboard joint groove.

      Note

      Securely fit the protrusion on the inboard joint grommet into the inboard joint groove.

    9. A01J9OXE04
      Text in Illustration
      *1 Matchmark

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

  11. INSTALL INBOARD JOINT BOOT


    1. Install the inboard joint boot into the grooves of the inboard joint grommet and inboard joint boot.

      Note

      Keep the grooves free of grease.

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

    CAUTION:

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


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

    2. A01J9U2E01

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

      Dimension (A)
      LH Side RH Side
      556.2 mm (1.82 ft.) 905.2 mm (2.96 ft.)
    3. A01J972E07

      While keeping dimension (A) within the specified length, put the inside of the inboard joint under atmospheric pressure by pulling the recessed parts on the inboard joint grommet out.

    4. Set the lever fulcrum point at any point A indicated in the illustration and temporarily bend the lever.

      Note


      • Perform this work with the inside of the inboard joint kept at atmospheric pressure.

      • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.

      • Check the band and the lever for any deformation before folding back the lever.

    5. A01J8H1E04

      Lean your weight on your hand and roll the inboard joint forward while pressing the inboard joint against the work plane. Roll the inboard joint and fold the lever until a click sound can be heard.

      Note

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

    6. A01JB41

      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 inboard joint boot.

  13. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:

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


    1. A01J8XY

      Install the front axle inboard joint boot clamp onto the inboard 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. A01JD5PE09

      Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

    3. A01J9PX

      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 inboard joint boot.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A01J8GH

      Check that there is no excessive play in 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 directions of the inboard joint.

    4. A01J9U2E01

      Check the boots for damage.

      Note

      Keep the drive shaft assembly level during inspection.

      Tech Tips

      For dimensions (A), refer to the following values.

      Dimension (A)
      LH Side RH Side
      556.2 mm (1.82 ft.) 905.2 mm (2.96 ft.)