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

PROCEDURE

  1. INSTALL FRONT DRIVE SHAFT DUST COVER

    1. F041033C04

      *a

      Steel Plate

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

      Note:

      • The dust cover should be completely installed.

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

  2. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)

    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. C274280C01

      *1

      Front Drive Outboard Joint Shaft Assembly

      *2

      Front No. 2 Axle Outboard Joint Boot Clamp LH

      *3

      Front Axle Outboard Joint Boot

      *4

      Front Axle Outboard Joint Boot Clamp LH
      V100135

      Outboard Joint Side
      V100136

      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 LH

      2. Front axle outboard joint boot

      3. Front axle outboard joint boot clamp LH

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

      Standard Grease Capacity

      149.5 to 159.5 g (5.28 to 5.62 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.

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

    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 LH onto the front axle outboard joint boot.

    3. C128947N02

      Place SST onto the front No. 2 axle outboard joint boot clamp LH, 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 LH 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 LH.

      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.

  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

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

    2. C128949N02

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

      09521-24010

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

      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 DRIVE SHAFT DAMPER LH (w/ Drive Shaft Damper)

    1. C274282N02

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

    2. Set the dimension as specified below.

      Dimension (A)

      160 to 166 mm (6.30 to 6.53 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. C197579N01

      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. C275178N01

      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.

  6. INSTALL FRONT DRIVE SHAFT DAMPER RH

    1. C171727N05

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

    2. Set the dimension as specified below.

      Dimension (A)

      433 to 439 mm (1.421 to 1.439 ft.)

    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 RH.

      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 RH 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. C275178N01

      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 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. C067417C01

      *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

      for LH Side

      162 to 178 g (5.72 to 6.27 oz)

      for RH Side

      155 to 171 g (5.47 to 6.03 oz)
    9. C127646C03

      *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. C157783N23

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

      Dimension (A)

      for LH Side

      589.5 mm (1.93 ft.)

      for RH Side

      875.25 mm (2.87 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 onto 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. for Omega Type:

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

      2. C274281N01

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

        09521-24010

      3. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.

        Note:

        Do not overtighten SST.

      4. Remove SST.

      5. C086270N04

        Using SST, measure the clearance of the front No. 2 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.

    2. for Claw Engagement Type:

      1. C215097C01

        *a

        Claw

        Using needle nose pliers, engage the 2 claws to install the front No. 2 axle inboard joint boot clamp as shown in the illustration.

        Note:

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

  11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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