FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE

  1. INSTALL FRONT DRIVE SHAFT DUST COVER

    C258185N01

    1. Using SST and a press, install a new dust cover.

      09527-10011

  2. INSTALL SHAFT SNAP RING

    C174231

    1. Install a new shaft snap ring.

  3. INSTALL OUTBOARD JOINT BOOT

    C177228C01

    *1

    Vinyl Tape
    Tip:

    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damage to the boot.

    1. Temporarily install a new outboard joint boot with 2 new clamps to the outboard joint.

    2. Pack the outboard joint and boot with grease from the boot kit.

      Standard grease capacity

      266 to 276 g (9.4 to 9.7 oz.)

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

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

      Note:

      Do not overtighten the vise.

    2. C258181C01

      *a

      Hold

      *b

      Turn

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

      09521-24010

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

      Note:

      Do not overtighten SST.

    4. C258186N01

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

      09240-00020

      Standard clearance

      2.1 mm (0.0827 in.) or less

      Note:

      If the measured value is more than the specified value, retighten the clamp.

  5. INSTALL FRONT NO. 1 AXLE OUTBOARD JOINT BOOT CLAMP

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

      Note:

      Do not overtighten the vise.

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

    3. C258187C01

      *a

      Hold

      *b

      Turn

      Place SST onto the outboard joint boot clamp.

      09521-24010

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

      Note:

      Do not overtighten SST.

    5. C258188N01

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

      09240-00020

      Standard clearance

      1.3 mm (0.0512 in.) or less

      Note:

      If the measured value is more than the specified value, retighten the clamp.

  6. INSTALL INBOARD JOINT BOOT

    1. Temporarily install a new inboard joint boot to the outboard joint.

  7. INSTALL FRONT AXLE INBOARD JOINT ASSEMBLY

    1. Install new parts to the outboard joint 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 outboard joint shaft in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    3. C258189C02

      *1

      Matchmark

      *a

      Beveled Side

      Align the matchmarks and install the tripod joint to the outboard joint.

      Note:

      Position tripod so that the beveled side of the tripod faces toward the inboard joint.

    4. Align the matchmarks and install the tripod to the inboard joint.

    5. Using a brass bar and hammer, tap the tripod onto the outboard joint.

      Note:

      • Do not hit the roller portion.

      • Keep the tripod joint free of foreign matter.

    6. C258233

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

    7. Pack the inboard joint assembly and boot with grease from the boot kit.

      Standard grease capacity

      239 to 249 g (8.4 to 8.8 oz.)

    8. C258190C01

      *1

      Matchmark

      Align the matchmarks and install the inboard joint onto the outboard joint.

  8. INSTALL FRONT NO. 1 AXLE INBOARD JOINT BOOT CLAMP

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

      Note:

      Do not overtighten the vise.

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

    3. C258191C01

      *a

      Hold

      *b

      Turn

      Place SST onto the inboard joint boot clamp.

      09521-24010

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

      Note:

      Do not overtighten SST.

    5. C258192N01

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

      09240-00020

      Standard clearance

      1.3 mm (0.0512 in.) or less

      Note:

      If the measured value is more than the specified value, retighten the clamp.

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

    1. Hold the inboard joint shaft assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C258193C01

      *a

      Hold

      *b

      Turn

      Place SST onto the No. 2 front axle inboard joint boot clamp.

      09521-24010

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

      Note:

      Do not overtighten SST.

    4. C258194N01

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

      09240-00020

      Standard clearance

      2.1 mm (0.0827 in.) or less

      Note:

      If the measured value is more than the specified value, retighten the clamp.