FRONT DRIVE SHAFT ASSEMBLY (for 1ZR-FAE, 2ZR-FAE) REASSEMBLY


  1. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. A01IQ3FE01

      Using SST and a press, press on a new drive shaft dust cover.

      SST
      09527-10011

      Note


      • The dust cover should be installed completely.

      • Be careful not to damage the dust cover.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH

    Tech Tips

    Use the same procedures described for the LH side.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    A01IRXME11
    Text in Illustration
    *1 Vinyl Tape

    Tech Tips

    Before installing the boot, wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.


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

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


      1. No. 2 outboard joint boot clamp LH

      2. Outboard joint boot

      3. Outboard joint boot clamp LH

    3. Pack the outboard joint shaft and boot with grease from the boot kit.

      Standard grease capacity
      120 to 130 g (4.24 to 4.58oz.)

  4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH


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

    2. Secure the No. 2 outboard joint boot clamp to the boot.

    3. A01IP83E05

      Place SST onto the No. 2 outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the No. 2 outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A01ISPGE05

      Using SST, adjust the clearance of the clamp.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note

      If the measured value exceeds the specified value, retighten the clamp.

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH


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

    2. Secure the outboard joint boot clamp to the boot.

    3. A01IQEAE05

      Place SST onto the outboard joint boot clamp.

      SST
      09521-24010

    4. Tighten SST so that the outboard joint boot clamp is pinched.

      Note

      Do not overtighten SST.

    5. A01IMZUE04

      Using SST, adjust the clearance of the clamp.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note

      If the measured value exceeds the specified value, retighten the clamp.

  6. INSTALL FRONT DRIVE SHAFT DAMPER RH


    1. Install the drive shaft damper to the drive shaft.

    2. A01IP7YE01

      Adjust the position of the damper so that the dimension is as described below.

      Standard dimension (B)
      434 to 438 mm (14.2 to 14.4 ft.)

  7. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP RH


    1. Install a new drive shaft damper clamp to the damper.

      Note

      Be sure to install the clamp on the inboard joint side in the correct position.

    2. A01ISY6E01

      Place SST onto the damper clamp.

      SST
      09521-24010

    3. Tighten SST so that the damper clamp is pinched.

      Note

      Do not overtighten SST.

    4. A01IRAIE01

      Using SST, adjust the clearance of the damper clamp.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note

      If the clearance is more than the standard, retighten the clamp.

  8. INSTALL FRONT DRIVE INBOARD JOINT LH


    1. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.

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


      1. Inboard joint boot clamp

      2. Inboard joint boot

      3. No. 2 axle inboard joint boot clamp

    3. A01ITI0E06

      Place the beveled side of the tripod axial spline toward the outboard joint.

    4. Align the matchmarks placed before removal.

      Text in Illustration
      *1 Matchmark

    5. Using a brass bar and hammer, tap the tripod onto the drive shaft.

      Note


      • Do not tap the rollers.

      • Be sure to install the tripod in the correct direction.

    6. Pack the inboard joint shaft and boot with grease from the boot kit.

      Standard Grease Capacity
      Engine Type Transaxle Type Capacity
      for 1ZR-FAE Manual transaxle 155 to 171 g (5.47 to 6.03 oz.)
      for 2ZR-FAE Continuously variable transaxle
      Manual transaxle for RH Side: 170 to 186 g (6.00 to 6.56 oz.)
      for LH Side: 172 to 188 g (6.07 to 6.63 oz.)
    7. A01IPLA

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

    8. A01ITV5E08
      Text in Illustration
      *1 Matchmark

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

  9. INSTALL FRONT DRIVE INBOARD JOINT RH

    Tech Tips

    Use the same procedures described for the LH side.

  10. INSTALL INBOARD JOINT BOOT


    1. Install the inboard joint boot to the inboard joint.

    2. A01IOTEE10

      Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

      Standard Dimension (A) (for LH Side)
      Engine Type Transaxle Type Specified Condition
      for 1ZR-FAE Manual transaxle 589.28 mm (1.93 ft.)
      for 2ZR-FAE Continuously variable transaxle
      Manual transaxle 590.4 mm (1.94 ft.)
      Standard Dimension (A) (for RH Side)
      Engine Type Transaxle Type Specified Condition
      for 1ZR-FAE Manual transaxle 875.28 mm (2.87 ft.)
      for 2ZR-FAE Continuously variable transaxle
      Manual transaxle 869.25 mm (2.85 ft.)

  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH


    1. Secure the inboard joint boot clamp to the boot.

    2. A01IUOKE01

      Place SST onto the inboard joint boot clamp.

      SST
      09521-24010

    3. Tighten SST so that the clamp is pinched.

      Note

      Do not overtighten SST.

    4. A01IRFI

      Using SST, adjust the clearance of the clamp.

      SST
      09240-00020
      Standard clearance
      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      Note

      If the clearance is more than the standard, retighten the clamp.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedures described for the LH side.

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


    1. Secure the inboard joint boot clamp to the boot.

    2. A01IONJ

      Using needle-nose pliers, install the axle inboard joint boot clamp as shown in the illustration.

      Note

      Be careful not to damage the boot.

  14. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH

    Tech Tips

    Use the same procedures described for the LH side.

  15. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new hole snap ring.

  16. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Use the same procedures described for the LH side.

  17. INSPECT DRIVE SHAFT


    1. A01IR7P

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

    4. Check the 2 boots for damage.

    5. A01IOTEE10

      Check that the 2 boots are not stretched or contracted when the drive shaft is at the standard length.

      Standard Dimension (A) (for LH Side)
      Engine Type Transaxle Type Specified Condition
      for 1ZR-FAE Manual transaxle 589.28 mm (1.93 ft.)
      for 2ZR-FAE Continuously variable transaxle
      Manual transaxle 590.4 mm (1.94 ft.)

      If the boots are stretched or contracted, correct them.

      Standard Dimension (A) (for RH Side)
      Engine Type Transaxle Type Specified Condition
      for 1ZR-FAE Manual transaxle 875.28 mm (2.87 ft.)
      for 2ZR-FAE Continuously variable transaxle
      Manual transaxle 869.25 mm (2.85 ft.)

      If the boots are stretched or contracted, correct them.