FRONT DRIVE SHAFT ASSEMBLY(for 2WD) REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. PRECAUTION

   

   *A	for Type A
   *B	for Type B

   As the installation procedure of the front drive shaft assembly differs depending on the shape of the front axle inboard joint boot, confirm it before installing.

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

   1. w/o Drive Shaft Bearing Case:

      1. 

         Using SST and a press, install a new front drive shaft bearing to the front drive inboard joint assembly RH.

         09527-10011

         09710-30012

         09710-04081

         Note:

         • Make sure the front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.

         • Do not apply weight to the dust cover and outer race of the front drive shaft bearing.

      2. 

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

         Note:

         The Snap ring should be installed completely.

3. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY (for RH Side)

   1. w/ Drive Shaft Bearing Case:

      1. 

         Using SST and a press, install a new drive shaft bearing case sub-assembly to the front drive inboard joint assembly RH.

         09527-10011

         09710-30012

         09710-04081

         Note:

         • Make sure the front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.

         • Do not apply weight to the dust cover and outer race of the front drive shaft bearing.

      2. 

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

         Note:

         The Snap ring should be installed completely.

4. INSTALL FRONT DRIVE SHAFT DUST COVER LH

   1. 

      Using SST and a press, press in the front drive inboard joint assembly LH until the new front drive shaft dust cover LH contacts the edge of the front drive inboard joint assembly LH.

      09527-10011

      Note:

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

      • Do not damage the front drive shaft dust cover LH.

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

5. INSTALL FRONT DRIVE SHAFT DUST COVER RH

   1. 

      Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint assembly RH until the distance from the tip of the front drive inboard joint assembly RH to the front drive shaft dust cover RH onto reaches the specification as shown in the illustration.

      09527-10011

      Standard Distance (A)

      Item	Length
      for 2WW (Manual Transaxle)	110.0 to 111.0 mm (4.331 to 4.370 in.)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle)	91.0 to 92.0 mm (3.583 to 3.622 in.)
      for 3ZR-FE (Manual Transaxle)
      for 3ZR-FE (CVT)

      Note:

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

      • Do not damage the front drive shaft dust cover RH.

      • Front drive shaft dust cover RH should be installed completely.

6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

   Tip:

   Use the same procedure for the RH and LH sides.

   1. 

      *a	Protective Tape

      Before installing the front axle outboard joint boot, wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the front axle outboard joint boot from being damaged.

   2. 

      *1	Front No. 2 Axle Outboard Joint Boot Clamp
      *2	Front Axle Outboard Joint Boot
      *3	Front Axle Outboard Joint Boot Clamp
      	Outboard Joint Side
      	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. Install the front axle outboard joint boot so that it is between the front No. 2 axle outboard joint boot clamp and front drive outboard joint shaft assembly.

   4. Temporarily install the front axle outboard joint boot clamp to the front axle outboard joint boot.

   5. Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.

      Standard Grease Capacity

      Item	Grease Capacity
      for 2WW (Manual Transaxle)	205 to 215 g (7.3 to 7.5 oz)
      for 2AR-FE (Automatic Transaxle)
      for 2AR-FE (Manual Transaxle)
      for 3ZR-FE (Manual Transaxle)
      for 3ZR-FE (CVT)	171 to 181 g (6.1 to 6.3 oz)

   6. Install the front axle outboard joint boot to the groove of the front drive outboard joint shaft assembly.

      Note:

      • Do not apply grease to the part of the front axle outboard joint boot that contacts the groove.

      • Do not allow foreign matter to enter the front axle outboard joint boot.

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

   

   CAUTION:

   Wear protective gloves to avoid injuries to your hands.

   1. Install the front No. 2 axle outboard joint boot clamp LH 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 front No. 2 axle outboard joint boot clamp LH as close to the inside of the vehicle as possible.

      • Check the band and lever for any deformation before folding back the lever.

   2. 

      Lean your weight on your hand and roll the front drive outboard joint shaft assembly LH forward while pressing the front drive outboard joint shaft assembly LH against a surface until a click sound is heard.

      Note:

      • Do not damage the deflector.

      • Make sure that the front drive outboard joint shaft assembly LH is in direct contact with the surface.

   3. 

      Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

      Note:

      Do not damage the front axle outboard joint boot.

8. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP RH

   Tip:

   Use the same procedure described for the LH side.

9. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

   

   CAUTION:

   Wear protective gloves to avoid injuries to your hands.

   1. Install the front axle outboard joint boot clamp LH to 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 lever for any deformation before folding back the lever.

   2. 

      Using water pump pliers, pinch the front axle outboard joint boot clamp LH to temporarily fix it in place.

   3. 

      Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

      Note:

      Do not damage the front axle outboard joint boot.

10. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

    Tip:

    Use the same procedure described for the LH side.

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

    1. w/ 1 Clamp:

       1. 

          *A	for 3ZR-FE
          *B	except 3ZR-FE
          *1	Front Drive Shaft Damper Clamp LH
          *2	Front Drive Shaft Damper LH

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

          Tip:

          Make sure the front drive shaft damper clamp LH is on the outboard joint side.

       2. Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.

          Standard Distance (A)

          Item	Length
          for 3ZR-FE	199.0 to 203.0 mm (7.835 to 7.992 in.)
          except 3ZR-FE	212.5 to 216.5 mm (8.367 to 8.523 in.)

    2. w/ 2 Clamps:

       1. 

          *A	for 3ZR-FE
          *B	except 3ZR-FE
          *1	Front Drive Shaft Damper Clamp LH
          *2	Front Drive Shaft Damper LH

          Install 2 new front drive shaft damper clamp LH and the front drive shaft damper LH onto the front drive outboard joint shaft assembly LH.

       2. Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.

          Standard Distance (A)

          Item	Length
          for 3ZR-FE	199.0 to 203.0 mm (7.835 to 7.992 in.)
          except 3ZR-FE	212.5 to 216.5 mm (8.367 to 8.523 in.)

12. INSTALL FRONT DRIVE SHAFT DAMPER RH (w/ Drive Shaft Damper)

    1. w/ 1 Clamp:

       1. 

          *1	Front Drive Shaft Damper Clamp RH
          *2	Front Drive Shaft Damper RH

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

          Tip:

          Make sure the front drive shaft damper clamp RH is on the outboard joint side.

       2. Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.

          Standard Distance (A)

          199.0 to 203.0 mm (7.835 to 7.992 in.)

    2. w/ 2 Clamps:

       1. 

          *1	Front Drive Shaft Damper Clamp RH
          *2	Front Drive Shaft Damper RH

          Install 2 new front drive shaft damper clamp RH and the front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

       2. Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.

          Standard Distance (A)

          199.0 to 203.0 mm (7.835 to 7.992 in.)

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

    1. 

       *A	for One Touch Type
       *B	for Claw Engagement Type
       *a	Claw Engagement

       w/ 1 Clamp:

       Install the front drive shaft damper clamp LH.

       Note:

       Be sure to install the front drive shaft damper clamp LH in the correct position.

       1. for One Touch Type:

          Using a screwdriver, install the front drive shaft damper clamp LH as shown in the illustration.

       2. for Claw Engagement Type:

          Using needle-nose pliers, install the front drive shaft damper clamp LH as shown in the illustration.

          Note:

          Do not deform the claw engagement of the front drive shaft damper clamp LH.

    2. 

       *A	for One Touch Type
       *B	for Claw Engagement Type
       *a	Claw Engagement

       w/ 2 Clamps:

       Install the 2 front drive shaft damper clamp LH.

       Note:

       Be sure to install the front drive shaft damper clamp LH in the correct position.

       1. for One Touch Type:

          Using a screwdriver, install the 2 front drive shaft damper clamp LH as shown in the illustration.

       2. for Claw Engagement Type:

          Using needle-nose pliers, hold the 2 front drive shaft damper clamp LH at the claw engagement.

          Note:

          Do not deform the claw engagement of the front drive shaft damper clamp LH.

14. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (w/ Drive Shaft Damper)

    Tip:

    Use the same procedure described for the LH side.

15. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

    1. 

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

       Install new parts to the front drive outboard joint shaft assembly LH in the following order.

       1. Front axle inboard joint boot clamp LH

       2. Front axle inboard joint boot

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

    2. Remove the protective tape from the front drive outboard joint shaft assembly LH.

    3. 

       *a

       Matchmark

       Align the matchmarks and place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly LH.

       Note:

       Face the cut edge of the spline toward the inboard joint side and insert the spline onto the outboard joint shaft assembly LH.

    4. 

       Using a brass bar and hammer, tap the tripod joint onto the front drive outboard joint shaft assembly LH.

       Note:

       • Do not tap the rollers.

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

    5. 

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

       Note:

       The Snap ring should be installed completely.

    6. Pack the front drive inboard joint assembly LH and front axle inboard joint boot with grease from the boot kit.

       Standard Grease Capacity (for Type A)

       175 to 185 g (6.2 to 6.5 oz)

       Standard Grease Capacity (for Type B)

       205 to 215 g (7.3 to 7.5 oz)

    7. 

       *a

       Matchmark

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

16. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

17. INSTALL FRONT AXLE INBOARD JOINT BOOT

    Tip:

    Use the same procedure for the RH and LH sides.

    1. for Type A:

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

          Note:

          • Do not apply grease to the part of the front axle inboard joint boot that contacts the groove.

          • Do not allow foreign matter to enter the front axle inboard joint boot.

       2. 

          *A	for LH Side
          *B	for RH Side

          Check that the front axle inboard joint boot and front axle outboard joint boot are not stretched or contracted when the front drive shaft assembly is at the standard length.

          Length (A)

          Item		Length
          for 2WW (Manual Transaxle)	LH Side	565.6 mm (1.86 ft.)
          	RH Side	914.2 mm (3.00 ft.)
          for 2AR-FE (Automatic Transaxle)	LH Side	577.6 mm (1.89 ft.)
          	RH Side	914.4 mm (3.00 ft.)
          for 2AR-FE (Manual Transaxle)	LH Side	583.6 mm (1.91 ft.)
          	RH Side	906.4 mm (2.97 ft.)
          for 3ZR-FE (Manual Transaxle)	LH Side	594.6 mm (1.95 ft.)
          	RH Side	893.4 mm (2.93 ft.)
          for 3ZR-FE (CVT)	LH Side	591.2 mm (1.94 ft.)
          	RH Side	890.0 mm (2.92 ft.)

          Note:

          Keep the drive shaft assembly level during inspection.

          If the front axle inboard joint boot and front axle outboard joint boot are stretched or contracted, correct them.

    2. for Type B (When a jig is supplied with the front axle inboard joint boot kit):

       1. 

          *A	for LH Side
          *B	for RH Side
          	Jig

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

          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 LH to check that the front axle inboard joint boot is installed to the correct position.

    3. for Type B (When a jig is not supplied with the front axle inboard joint boot kit):

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

       2. 

          *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.

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

    1. 

       *A	for One Touch Type
       *B	for Claw Engagement Type
       *a	Claw

       for Type A (for One Touch Type):

       1. Using a screwdriver, install the front No. 2 axle inboard joint boot clamp LH as shown in the illustration.

          Note:

          • Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.

          • Do not damage the front axle inboard joint boot.

    2. for Type A (for Claw Engagement Type):

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

          Note:

          Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.

       2. Using needle-nose pliers, hold the front No. 2 axle inboard joint boot clamp LH at the claw engagement.

          Note:

          • Do not damage the front axle inboard joint boot.

          • Do not deform the claw engagement of the front No. 2 axle inboard joint boot clamp LH.

    3. for Type B:

       CAUTION:

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

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

       Note:

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

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

          

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

          Tip:

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

       2. 

          *a	Welded Area

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

          Note:

          • Make sure the front No. 2 axle inboard joint boot clamp LH 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 LH and the lever are not deformed or damaged.

          Tip:

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

       3. 

          Using water pump pliers, temporarily secure the front No. 2 axle inboard joint boot clamp LH by pinching the front No. 2 axle inboard joint boot clamp LH 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 LH, set one tip of the water pump pliers on the welded area of the lever.

          Tip:

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

       4. 

          *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 that the front axle inboard joint boot is installed to the correct position.

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

    Tip:

    Use the same procedure described for the LH side.

20. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

    1. for Type A:

       Tip:

       Use the same procedure described for the front No. 2 axle inboard joint boot clamp LH.

    2. for Type B:

       Note:

       A new front axle inboard joint boot clamp LH is coated with lubricant. Do not remove the lubricant.

       1. 

          *A	for LH Side
          *B	for RH Side

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

          Length (A)

          Item		Length
          for 2WW (Manual Transaxle)	LH Side	565.6 mm (1.86 ft.)
          	RH Side	914.2 mm (3.00 ft.)
          for 2AR-FE (Automatic Transaxle)	LH Side	577.6 mm (1.89 ft.)
          	RH Side	914.4 mm (3.00 ft.)
          for 2AR-FE (Manual Transaxle)	LH Side	583.6 mm (1.91 ft.)
          	RH Side	906.4 mm (2.97 ft.)
          for 3ZR-FE (Manual Transaxle)	LH Side	594.6 mm (1.95 ft.)
          	RH Side	893.4 mm (2.93 ft.)
          for 3ZR-FE (CVT)	LH Side	591.2 mm (1.94 ft.)
          	RH Side	890.0 mm (2.92 ft.)

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

       3. 

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

          Note:

          Do not damage the front axle inboard joint boot.

21. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

    Tip:

    Use the same procedure described for the LH side.

22. INSPECT FRONT DRIVE SHAFT

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