FRONT DRIVE SHAFT ASSEMBLY(for 1ND-TV) REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DRIVE SHAFT DUST COVER


    1. A005K7DE01

      Using SST and a press, install a new dust cover into the inboard joint 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.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  2. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new snap ring.

  3. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Use the same procedure for the RH side as for the LH side.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


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

    2. Install new parts onto the outboard joint shaft in the following order.

      Installation Order
      Order Part Name
      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 and the outboard joint boot with grease.

      Standard Quantity
      135 to 145 g (4.8 to 5.1 oz.)

    4. Install the outboard joint boot onto the outboard joint shaft groove.

      Note

      Keep the groove free of grease.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

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

    CAUTION:

    Wear protective gloves to avoid injuries to your hands.


    1. A005KET

      Install a new boot clamp onto the outboard joint boot and provisionally fold back the lever.

      Note


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

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

    2. A005JH7E01
      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. A005KK6

      Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

      Note

      Do not damage the boot.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:

    Wear protective gloves to avoid injuries to your hands.


    1. A005I3N

      Install a new boot clamp onto the outboard joint boot and provisionally 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. A005K87E11
      Text in Illustration
      *a Place the tip near the center of the lever

      Using water pump pliers, pinch the boot clamp to provisionally fix it.

    3. A005IRB

      Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

      Note

      Do not damage the boot.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

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


    1. A005LKGE01

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

      Note

      Install the damper in the correct orientation.

      Dimension (A)
      Standard Length
      416.5 to 420.5 mm (16.40 to 16.56 in.)

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

    A005L7BE03
    Text in Illustration
    *a One Touch Type
    *b Claw Engagement Type

    1. One touch type:


      1. Install the new damper clamp onto the front drive shaft damper and fix the damper clamp with a screwdriver.

    2. Claw engagement type:


      1. Using needle-nose pliers, engage the 2 claws and install the new damper clamp as shown in the illustration.

  9. INSTALL FRONT AXLE INBOARD JOINT GROMMET

    A005MIEE03
    Text in Illustration
    *a Groove

    1. Install a new inboard joint grommet onto the inboard joint groove.

      Note

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

  10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. Install the new front axle inboard joint grommet.

    2. Install new parts onto the outboard joint shaft in the following order.

      Installation Order
      Order Part Name
      1. Front axle inboard joint boot clamp
      2. Front axle inboard joint boot
      3. Front No. 2 axle inboard joint boot clamp

    3. Fix the outboard joint shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    4. Remove the protective tape.

    5. A005LNAE12
      Text in Illustration
      *a Matchmark

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

      Note

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

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

      Note


      • Do not hit the rollers.

      • Keep the tripod joint free of foreign matter.

    7. A005HZW

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

    8. Pack the inboard joint with grease.

      Note

      Keep the seal section of the boot free of grease.

      Standard Quantity
      168 to 178 g (5.9 to 6.3 oz.)
    9. A005JSGE07
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the inboard joint onto the outboard joint shaft.

      Note

      Keep the seal section of the boot and the grommet groove free of grease.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

      Note

      Keep the grooves free of grease.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    CAUTION:

    Wear protective gloves to avoid injuries to your hands.


    1. A005I3N

      Install a new boot clamp onto the inboard joint boot and provisionally 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. A005K87E11
      Text in Illustration
      *a Place the tip near the center of the lever

      Using water pump pliers, pinch the boot clamp to provisionally fix it.

    3. A005IRB

      Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

      Note

      Do not damage the boot.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

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


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

    2. A005J7VE01

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

      Dimension (A)
      LH RH
      585.9 mm (23.07 in.) 820.9 mm (32.32 in.)

    3. 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.

      A005IFPE01
      Text in Illustration
      *1 Boot Clamp
      *2 Inboard Joint Grommet
      *a Fulcrum Point
      *b Recessed Part

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

      CAUTION:

      Wear protective gloves to avoid injuries to your hands.

      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 inner side of the vehicle as possible.

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

    5. A005K50E01
      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


      • Do not damage the deflector.

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

    6. A005M0E

      Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.

      Note

      Do not damage the boot.

      Tech Tips

      Use the same procedure for the RH side as for the LH side.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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