FRONT DRIVE SHAFT ASSEMBLY (for 2AR-FE) REASSEMBLY

INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)
1. 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. Using a snap ring expander, install a new drive shaft hole snap ring.
INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)
1. 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.
INSTALL FRONT DRIVE SHAFT DUST COVER RH
1. 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)
  
  110.0 to 111.0 mm (4.33 to 4.37 in.)
  Note
  - The dust cover should be completely installed.
  - Be careful not to damage the front drive shaft dust cover RH.
INSTALL FRONT DRIVE SHAFT DUST COVER LH
1. 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.

Text in Illustration
*1	Steel Plate

Text in Illustration
*1	Steel Plate

Dimension (A)
26.6 to 27.6 mm (1.05 to 1.08 in.)

Text in Illustration
*1	Steel Plate

Dimension (A)
110.0 to 111.0 mm (4.33 to 4.37 in.)

Text in Illustration
*1	Steel Plate

INSTALL FRONT AXLE OUTBOARD JOINT BOOT

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.

Text in Illustration
*1	Protective Tape

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
	Outboard Joint Side
	Inboard Joint Side

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

Front No. 2 axle outboard joint boot clamp
Front axle outboard joint boot
Front axle outboard joint boot clamp

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

Standard grease capacity (for TMC Made)

171 to 181 g (6.0 to 6.3 oz.)

Standard grease capacity (except TMC Made)

100 to 120 g (3.5 to 4.2 oz.)
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.

INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for TMC Made)
CAUTION:

Wear protective gloves. Sharp areas on the parts may injure your hands.
1. Install the front No. 2 axle outboard joint boot clamp onto the front axle 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. 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 surface. Roll the outboard joint and fold the lever until a click sound can be heard.
  Note
  
  Do not damage the speed sensor rotor.
  
  Make sure that the outboard joint is in direct contact with the work surface.
3. 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 use too much force when tapping with the plastic hammer.
  
  Do not damage the front axle outboard joint boot.
INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (except TMC Made)
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. 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. 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.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for TMC Made)
CAUTION:

Wear protective gloves. Sharp areas on the parts may injure your hands.
1. Install the front axle outboard joint boot clamp onto the front axle 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. 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. 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 front axle outboard joint boot.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (except TMC Made)
1. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.
2. 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. 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.

Standard grease capacity (for TMC Made)
171 to 181 g (6.0 to 6.3 oz.)

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

Text in Illustration
*a	Weight
*b	Contact

Clearance
1.2 to 4.0 mm (0.0472 to 0.157 in.)

Text in Illustration
*a	Place the tip near the center of the lever.

Clearance
1.2 to 4.0 mm (0.0472 to 0.157 in.)

INSTALL FRONT DRIVE SHAFT DAMPER (w/ 1 Clamp)

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

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.

Set the dimension as specified below.

Dimension (A)

223.4 to 227.4 mm (8.80 to 8.95 in.)
Install the front drive shaft damper clamp onto the front drive shaft damper.

Note

Be sure to install the clamp in the correct position.
Hold the drive shaft in a vise between aluminum plates.

Note

Do not overtighten the vise.

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

Text in Illustration
*A	for One Touch Type
*B	for Claw Engagement Type

for TMC Made One Touch Type:

Using a screwdriver, install the front drive shaft damper clamp.

for TMC Made Claw Engagement Type:
1. Using needle nose pliers, install the front drive shaft damper clamp.
except TMC Made:
1. Text in Illustration
  
  *a Claws
  
  Using needle nose pliers, install the front drive shaft damper clamp.

Text in Illustration
*a	Claws

INSTALL FRONT DRIVE SHAFT DAMPER (w/ 2 Clamps)

Text in Illustration
*A	for TMC Made
*B	except TMC Made
*1	Front Drive Shaft Damper
*2	Front Drive Shaft Damper Clamp

Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

Set the dimension as specified below.

Dimension (A)
for TMC Made	LH	277.9 to 281.9 mm (10.9 to 11.1 in.)
for TMC Made	RH	261.4 to 265.4 mm (10.3 to 10.4 in.)
except TMC Made	LH	223.4 to 227.4 mm (8.80 to 8.95 in.)
except TMC Made	RH	223.8 to 227.8 mm (8.81 to 8.97 in.)

Install the 2 front drive shaft damper clamps onto the front drive shaft damper.

Note

Be sure to install the clamp in the correct position.
Hold the drive shaft in a vise between aluminum plates.

Note

Do not overtighten the vise.
Text in Illustration

*a Claws

for TMC Made:
1. Using needle nose pliers, install the 2 front drive shaft damper clamps.
except TMC Made:
1. Using needle nose pliers, install the 2 front drive shaft damper clamps.

Text in Illustration
*a	Claws

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (for TMC Made)

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
	Outboard Joint Side
	Inboard Joint Side

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

Front axle inboard joint boot clamp
Front axle inboard joint boot
Front No. 2 axle inboard joint boot clamp

Hold the drive shaft in a vise between aluminum plates.

Note

Do not overtighten the vise.
Remove the protective tape.
Text in Illustration

*a Matchmark

Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.
Align the matchmarks placed before removal.
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.
Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.
Pack the front drive inboard joint assembly and front axle inboard boot with grease.

Standard grease capacity

175 to 185 g (6.2 to 6.5 oz.)
Text in Illustration

*a Matchmark

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

Text in Illustration
*a	Matchmark

Standard grease capacity
175 to 185 g (6.2 to 6.5 oz.)

Text in Illustration
*a	Matchmark

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (except TMC Made)

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
	Outboard Joint Side
	Inboard Joint Side

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

Front axle inboard joint boot clamp
Front axle inboard joint boot
Front No. 2 axle inboard joint boot clamp

Hold the drive shaft in a vise between aluminum plates.

Note

Do not overtighten the vise.
Remove the protective tape.
Text in Illustration

*a Matchmark

Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.
Align the matchmarks placed before removal.
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.
Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.
Pack the front drive inboard joint assembly and front axle inboard boot with grease.

Standard grease capacity (LH Side)

150 to 170 g (5.3 to 5.9 oz.)

Standard grease capacity (RH Side)

155 to 175 g (5.5 to 6.1 oz.)
Text in Illustration

*a Matchmark

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

Text in Illustration
*a	Matchmark

Standard grease capacity (LH Side)
150 to 170 g (5.3 to 5.9 oz.)

Standard grease capacity (RH Side)
155 to 175 g (5.5 to 6.1 oz.)

Text in Illustration
*a	Matchmark

INSTALL FRONT AXLE INBOARD JOINT BOOT

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

Text in Illustration
*A	LH Side
*B	RH Side

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

Dimension (A)

	for TMC Made	except TMC Made
LH Side	585.2 mm (1.92 ft.)	587.4 mm (1.93 ft.)
RH Side	910.0 mm (2.99 ft.)	906.6 mm (2.97 ft.)

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (for TMC Made)
1. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.
2. for One Touch Type:
  1. Using a screwdriver, install the front axle inboard joint boot clamp.
3. Text in Illustration
  
  *a Claw
  
  for Claw Engagement Type:
  1. Using needle nose pliers, install the front axle inboard joint boot clamp.
    
    Note
    
    Be careful not to damage the front axle inboard joint boot.
INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (except TMC Made)
1. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.
2. Using needle nose pliers, install the front axle inboard joint boot clamp.
  
  Note
  
  Be careful not to damage the front axle inboard joint boot.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (for TMC Made)
1. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.
2. for One Touch Type:
  1. Using a screwdriver, install front No. 2 axle inboard joint boot clamp.
3. Text in Illustration
  
  *a Claw
  
  for Claw Engagement Type:
  1. Using needle nose pliers, install front No. 2 axle inboard joint boot clamp.
    
    Note
    
    Be careful not to damage the front axle inboard joint boot.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (except TMC Made)
1. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.
2. 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.
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.

Text in Illustration
*a	Claw

Text in Illustration
*a	Claw

INSPECT FRONT DRIVE SHAFT ASSEMBLY

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

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)

	for TMC Made	except TMC Made
LH Side	585.2 mm (1.92 ft.)	587.4 mm (1.93 ft.)
RH Side	910.0 mm (2.99 ft.)	906.6 mm (2.97 ft.)