FRONT DRIVE SHAFT ASSEMBLY REASSEMBLY

PROCEDURE


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


    1. B005MHZC05
      *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. A01VY44

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

      Note

      Install the drive shaft hole snap ring securely.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER LH


    1. B005MX3C06
      *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.

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

  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 2WD RH Side)


    1. B005O6QC09
      *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)
      115.5 to 116.5 mm (4.55 to 4.58 in.)

      Note

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

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


    1. B005O41C04
      *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. B005MX2C01
      *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
      B007WXX Outboard joint side
      B00803L 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
      81 to 91 g (2.86 to 3.20 oz)

    4. Install the front axle outboard joint boot to 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 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)


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

      Note

      Do not overtighten the vise.

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

    3. B005PRFN01

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B005P6FN11

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

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)


    1. Secure 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. B005Q07N01

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

      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. B005PS6N06

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

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for 2WD RH Side)

    Tech Tips

    Perform the same procedure as for the LH side.

  8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for 2WD RH Side)

    Tech Tips

    Perform the same procedure as for the LH side.

  9. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for 2WD RH Side)

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. B005MJDC04
      *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 235.0 to 239.0 mm (9.26 to 9.40 in.)
      for RH Side 240.0 to 244.0 mm (9.45 to 9.60 in.)

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

      Note

      Make sure to install the clamps in the correct position.

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


    1. A01VVUL

      Using needle nose pliers, install the 2 front drive shaft damper clamps.

  12. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY


    1. B005LVLC02
      *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
      B007WXX Outboard joint side
      B00803L 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. B005Q4KC02
      *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. A01VUJK

      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
      190 to 210 g (6.71 to 7.40 oz)
    8. B005MAFC02
      *a Lip

      Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

      Note


      • Securely fit the protrusion on the front axle inboard joint grommet into the front drive inboard joint assembly.

      • Make sure that the lip of the front axle inboard joint grommet is not damaged.

    9. B005LZ7C02
      *a Matchmark

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

  13. INSTALL FRONT AXLE INBOARD JOINT BOOT


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

    2. B005MZNN28

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

      Dimension (A)
      for LH Side 600.85 mm (1.97 ft.)
      for RH Side 2WD 925.55 mm (3.04 ft.)
      AWD 926.55 mm (3.04 ft.)

  14. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP


    1. Secure 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. B005NE4N01

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

      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. B005OGZN02

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

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

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


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

      Note

      Do not overtighten the vise.

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

    3. B005Q53N03

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

      SST
      09521-24010

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

      Note

      Do not overtighten SST.

    5. Remove SST.

    6. B005PSLN08

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

      SST
      09240-00020
      Clearance
      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is not as specified, retighten SST.

  16. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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