FRONT DRIVE SHAFT ASSEMBLY(for 1WW) REASSEMBLY

PROCEDURE

  1. INSTALL FRONT DRIVE SHAFT DUST COVER LH

    1. F041033C04

      *a

      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.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH

    1. C296443C01

      *a

      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)

      115.5 to 116.5 mm (4.55 to 4.58 in.)

      Note:

      • The dust cover should be completely installed.

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

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

    1. C166359C04

      *a

      Protective Tape

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

    2. C274276C01

      *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
      V100135

      Outboard Joint Side
      V100136

      Inboard Joint Side

      Install new parts to 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

      105 to 125 g (3.71 to 4.40 oz)

    4. Install the front axle outboard joint boot into 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.

  4. 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 to the front axle outboard joint boot.

    3. C128947N02

      Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten 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. C128948N02

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

      09240-00020

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

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

  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

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

    2. C128949N02

      Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten 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. C128950N02

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

      09240-00020

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

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

  6. INSTALL FRONT DRIVE SHAFT DAMPER LH (w/ Drive Shaft Damper)

    1. C296445N01

      Install the front drive shaft damper LH to the front drive outboard joint shaft assembly.

    2. Set the dimension as specified below.

      Dimension (A)

      161 to 165 mm (6.34 to 6.49 in.)

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

      Note:

      Do not overtighten the vise.

    4. Install a new front drive shaft damper clamp onto the front drive shaft damper LH.

      Note:

      Be sure to install the clamp in the correct position.

    5. C197579N02

      Place SST onto the front drive shaft damper clamp, press it against the front drive shaft damper LH and slightly tighten SST.

      09521-24010

    6. Tighten SST so that the front drive shaft damper clamp is pinched.

      Note:

      Do not overtighten SST.

    7. Remove SST.

    8. C296444N01

      Using SST, measure the clearance of the front drive shaft damper clamp.

      09240-00020

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

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

  7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

    1. C274277C02

      *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
      V100135

      Outboard Joint Side
      V100136

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

      Note:

      Do not overtighten the vise.

    3. Remove the protective tape.

    4. C067417C02

      *a

      Matchmark

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

    5. Align the matchmarks placed before removal.

    6. 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.

    7. F045046

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

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

      Standard Grease Capacity

      172 to 188 g (6.07 to 6.63 oz)

    9. F045461C01

      *a

      Matchmark

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

  8. INSTALL FRONT AXLE INBOARD JOINT BOOT

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

    2. C296442C01

      *A

      LH Side

      *B

      RH Side

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

      Dimension (A)

      Dimension (A)

      LH Side

      556.8 mm (1.83 ft.)

      RH Side

      912.3 mm (2.99 ft.)

  9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

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

      Note:

      Do not overtighten the vise.

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

    3. C195759N01

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

      09521-24010

    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.

      Note:

      Do not overtighten SST.

    5. Remove SST.

    6. C195760N01

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

      09240-00020

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

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

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

    1. C239401

      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.

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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