FRONT DRIVE SHAFT ASSEMBLY (for 1AZ-FE) REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)


    1. A01EXT2E07
      Text in Illustration
      *1 Steel Plate

      Using SST, a steel plate and a press, install a new front drive shaft bearing.

      SST
      09527-10011

      Note

      The bearing should be completely installed.

    2. A01EX1Q

      Using a snap ring expander, install a new drive shaft hole snap ring.

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


    1. A01ETV2E04
      Text in Illustration
      *1 Steel Plate

      Using SST, a steel plate and a press, install a new front drive shaft dust cover.

      SST
      09726-40010
      Dimension (A)
      26.6 to 27.6 mm (1.05 to 1.08 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. A01EYARE07
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

      Dimension (A)
      91.0 to 92.0 mm (3.58 to 3.62 in.)

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover RH.

  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01EWGXE14
      Text in Illustration
      *1 Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover LH.

      Note


      • The dust cover should be completely installed.

      • Be careful not to damage the front drive shaft dust cover LH.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


    1. A01EY2TE03
      Text in Illustration
      *1 Protective Tape

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

    2. A01EVB9E01
      Text in Illustration
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      A01EUL1 Outboard Joint Side
      A01ETOA Inboard Joint Side

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

      Standard grease capacity
      100 to 120 g (3.5 to 4.2 oz.)

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

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


    1. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.

    3. A01EX3NE01

      Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      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. Remove SST.

    6. A01EUFKE01

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

      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

      If the clearance is outside the specified range, retighten SST.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP


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

    2. A01ET1WE01

      Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    4. Remove SST.

    5. A01EVP0E01

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

      SST
      09240-00020
      Clearance
      1.2 to 4.0 mm (0.0472 to 0.157 in.)

      If the clearance is outside the specified range, retighten SST.

  8. INSTALL FRONT DRIVE SHAFT DAMPER


    1. Install a new front drive shaft damper clamp onto the front drive outboard joint shaft assembly.

    2. A01ETVLE01
      Text in Illustration
      *1 Front Drive Shaft Damper
      *2 Front Drive Shaft Damper Clamp

      Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

    3. Set the dimension as specified below.

      Dimension (A)
      223.4 to 227.4 mm (8.80 to 8.95 in.)

    4. Install the front drive shaft damper clamp onto the front drive shaft damper.

      Note

      Be sure to install the clamp in the correct position.

    5. A01EW6E

      Using needle nose pliers, install the front drive shaft damper clamp.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. A01EVR0E15
      Text in Illustration
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      A01EUL1 Outboard Joint Side
      A01ETOA Inboard Joint Side

      Install new parts onto the front drive 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. Hold the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. A01EU1TE03
      Text in Illustration
      *a Matchmark

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

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

      Note


      • Do not tap the rollers.

      • Keep the tripod joint free of foreign matter.

    6. A01EVIE

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

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

      Standard grease capacity
      LH Side RH Side
      150 to 170 g (5.3 to 5.9 oz.) 155 to 175 g (5.5 to 6.1 oz.)
    8. A01EWKUE21
      Text in Illustration
      *a Matchmark

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

  10. INSTALL FRONT AXLE INBOARD JOINT BOOT


    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.

    2. A01EU3ME01
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Dimension (A)
      Dimension (A)
      LH Side 600.4 mm (1.97 ft.)
      RH Side 898.6 mm (2.95 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


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

    2. A01EUIE

      Using needle nose pliers, install the front axle inboard joint boot clamp.

      Note

      Be careful not to damage the front axle inboard joint boot.

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


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

    2. A01EWRH

      Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.

      Note

      Be careful not to damage the front axle inboard joint boot.

  13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


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

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY


    1. A01EYP7

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

    4. Check the boots for damage.

    5. A01EU3ME01
      Text in Illustration
      *A LH Side
      *B RH Side

      Check whether the drive shaft dimensions (A) are within the following specifications.

      Note

      Keep the drive shaft assembly level during inspection.

      Dimension (A)
      Dimension (A)
      LH Side 600.4 mm (1.97 ft.)
      RH Side 898.6 mm (2.95 ft.)