FRONT DRIVE SHAFT ASSEMBLY(for 2AR-FE, 6AR-FSE) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


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


    1. B0070VAC10
      *a 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. B006WXR

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

  2. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. B006Y51C01
      *a Steel Plate

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

      Note


      • Make sure to fully install the front drive shaft dust cover LH in the correct direction.

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

      • The front drive shaft dust cover LH should be completely installed.

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH


    1. B006X0LC10
      *a Steel Plate

      Using a steel plate and a press, install a new front drive shaft dust cover RH until the 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.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT


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

      Note

      Do not overtighten the vise.

    2. B0071NBC27
      *a Protective Tape

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

    3. B0070BDC01
      *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
      B00888T Outboard Joint Side
      B0086HX 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

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

      Standard Grease Capacity
      171 to 181 g (6.04 to 6.38 oz)

    5. 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.

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

    CAUTION:


    • Wear protective gloves when installing the front No. 2 axle outboard joint boot clamp.

    • If protective gloves are not worn, injuries may occur.


    1. B0070D1

      Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and partially bend down the lever.

      Note


      • Make sure the front No. 2 axle outboard joint boot clamp is positioned correctly within the groove of the front axle outboard joint boot as far toward the inside of the vehicle as possible.

      • Before bending the lever, confirm that the front No. 2 axle outboard joint boot clamp and the lever are not deformed or damaged.

    2. B006YLKC05
      *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 deflector.

      • Make sure that the outboard joint is in direct contact with the work surface.

    3. B006XGDC08
      *a Buckle

      Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    CAUTION:


    • Wear protective gloves when installing the front axle outboard joint boot clamp.

    • If protective gloves are not worn, injuries may occur.


    1. B006YO8

      Install the front axle outboard joint boot clamp to the front axle outboard joint boot and partially bend down the lever.

      Note


      • Make sure that the front axle outboard joint boot clamp is correctly positioned within the groove.

      • Confirm that the front axle outboard joint boot clamp and lever are not deformed or damaged.

    2. B006Z1PC01
      *a Place the tip near the center of the lever

      Using water pump pliers, temporarily secure the front axle outboard joint boot clamp by pinching the front axle outboard joint boot clamp until a click sound is heard.

      Note

      Do not damage the front axle outboard joint boot.

    3. B006XWSC11
      *a Buckle

      Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle outboard joint boot.

  7. INSTALL FRONT DRIVE SHAFT DAMPER


    1. B00715KC01
      *1 Front Drive Shaft Damper Clamp
      *2 Front Drive Shaft Damper

      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.

    2. Set the dimension (A) as specified below.

      Dimension (A)
      for LH Side 256.9 to 260.9 mm (10.12 to 10.27 in.)
      for RH Side 261.4 to 265.4 mm (10.30 to 10.44 in.)

  8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP


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

      Note

      Do not overtighten the vise.

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

      Note

      Be sure to install the clamps in the correct position.

    3. B0071CKC05
      *a Claw

      Using needle-nose pliers, engage each claw to install the 2 front drive shaft damper clamps as shown in the illustration.

      Note


      • Be sure to install the clamps in the correct position.

      • Do not damage the front drive shaft damper.

      • Do not damage the claws.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B006YFOC02
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      B00888T Outboard Joint Side
      B0086HX Inboard Joint Side

      Install new parts to 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. Secure the drive shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. B00716JC01
      *a Matchmark

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

      Note

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

    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.

      • Make sure to install the tripod joint in the correct direction.

    6. B006ZN0

      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
      205 to 215 g (7.24 to 7.58 oz)
    8. B006ZNKC02
      *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. When a jig is supplied with the front drive shaft inboard joint boot kit:


      1. B007063C02
        *A for LH Side
        *B for RH Side
        B0088BT Jig

        Using a jig, install the front axle inboard joint boot to the front drive inboard joint assembly.

        Note


        • Keep the grooves free of grease.

        • Keep the inside of the front axle inboard joint boot free of foreign matter.

        • If the front axle inboard joint boot is not installed at the position indicated by the jig, damage to the front axle inboard joint boot may result.

        • Place the jig at several points around the circumference of the front drive inboard joint assembly to check that the front drive inboard joint boot is installed to the correct position.

    2. When a jig is not supplied with the front drive shaft inboard joint boot kit:


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

      2. B006XO1C02
        *A for LH Side
        *B for RH Side

        Adjust the position of the front axle inboard joint boot so that the dimension (A) is as specified.

        Dimension (A)
        for LH Side 51.8 to 52.2 mm (2.04 to 2.05 in.)
        for RH Side 66.8 to 67.2 mm (2.63 to 2.64 in.)

        Note


        • Keep the grooves free of grease.

        • Keep the inside of the front axle inboard joint boot free of foreign matter.

        • If the front axle inboard joint boot is installed while the dimension (A) is not as specified, damage to the front axle inboard joint boot may result.

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

    CAUTION:


    • Wear protective gloves when installing the front No. 2 axle inboard joint boot clamp.

    • If protective gloves are not worn, injuries may occur.

    Note

    New front No. 2 axle inboard joint boot clamp is coated with lubricant. Do not remove the lubricant.


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

      Tech Tips

      B0070LDC01
      *1 Front No. 2 Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *a Bending Point

      To make installation easier, align the bending point of the lever of the front No. 2 axle inboard joint boot clamp with any of the positions indicated by the arrows (A) shown in the illustration.

    2. B006YVPC01
      *a Welded Area

      Temporarily bend the lever of the front No. 2 axle inboard joint boot clamp.

      Note


      • Make sure the front No. 2 axle inboard joint boot clamp is positioned correctly within the groove of the front axle inboard joint boot as far toward the inside of the vehicle as possible.

      • Before bending the lever, confirm that the front No. 2 axle inboard joint boot clamp and the lever are not deformed or damaged.

      Tech Tips

      When temporarily bending the lever, push the lever at the welded area.

    3. B006WT3

      Using water pump pliers, temporarily secure the front No. 2 axle inboard joint boot clamp by pinching the front No. 2 axle inboard joint boot clamp until a click sound is heard.

      Note


      • Do not damage the front axle inboard joint boot.

      • To avoid deformation of the front No. 2 axle inboard joint boot clamp, set one tip of the water pump pliers on the welded area of the lever.

      Tech Tips


      • As the front No. 2 axle inboard joint boot clamp is tightened, the tip of the water pump pliers will slide along the front No. 2 axle inboard joint boot clamp until it contacts the protrusion.

      • Set the water pump pliers to an appropriate size before tightening the front No. 2 axle inboard joint boot clamp.

    4. B0070UPC02
      *a Buckle

      Using a plastic hammer, bend the buckle to secure the lever.

      Note


      • Do not use excessive force when tapping with the plastic hammer.

      • Do not damage the front axle inboard joint boot.

      • Check the front axle inboard joint boot is installed to the correct position.

  12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

    Note

    New front axle inboard joint boot clamp is coated with lubricant. Do not remove the lubricant.


    1. B0070R4C06
      *A for LH Side
      *B for RH Side

      Check whether the dimension (A) of each drive shaft is within specification.

      Dimension (A)
      for LH Side 591.2 mm (1.94 ft.)
      for RH Side 910.0 mm (2.98 ft.)

    2. Install the front axle inboard joint boot clamp to the front axle inboard joint boot.

    3. B0070ZL

      Using a screwdriver, install the front axle inboard joint boot clamp.

      Note

      Do not damage the front axle inboard joint boot.

  13. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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