FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY


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


    1. A003XVCE08

      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. A003XMUE01

      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. A003VR9E14
      Text in Illustration
      *a Protective Tape

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

    2. A003ZI7E09
      Text in Illustration
      *a Outboard Joint Side

      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. A003W39

      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. A003XBDE13
      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 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. A003Z8D

      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. A003YWL

      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. A003ZQ5E08
      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. A003Y7H

      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. A003ZIGE07

      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)
      161 to 165 mm (6.34 to 6.49 in.)

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


    1. A003ZGWE02

      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)
      458 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. A003YH8E05
        Text in Illustration
        *A for One Touch Type
        *B for Claw Engagement Type

        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. A003Y60

      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. A003ZFWE10
      Text in Illustration
      *a Outboard Joint Side

      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. A003Y1CE26
      Text in Illustration
      *a 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. A003VZW

      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. A003ZVTE03
      Text in Illustration
      *a 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. A003W5BE05
      Text in Illustration
      *a 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. A003VEDE02

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

      Dimension (A)
      LH Side RH Side

      552.2 to 560.2 mm

      (1.81 to 1.84 ft.)

      901.2 to 909.2 mm

      (2.96 to 2.98 ft.)
    3. A003V7GE08
      Text in Illustration
      *1 Boot Clamp
      *2 Inboard Joint Grommet
      *a Fulcrum Point
      *b Recessed Parts

      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. A003Y1QE05
      Text in Illustration
      *a Weight
      *b Contact

      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 inboard joint is in direct contact with the work plane.

    6. A003V5P

      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. A003YWL

      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. A003ZQ5E08
      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. A003Y7H

      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. A003VPJ

      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. A003VEDE02

      Check the boots for damage.

      Note

      Keep the drive shaft assembly level during inspection.

      Tech Tips

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

      Dimension (A)
      LH Side RH Side

      552.2 to 560.2 mm

      (1.81 to 1.84 ft.)

      901.2 to 909.2 mm

      (2.96 to 2.98 ft.)