FRONT DRIVE SHAFT ASSEMBLY(for 1PP) REASSEMBLY

PROCEDURE

  1. 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. C304805C01

      *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.

    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.

  2. 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. F100510N01

      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.

      Note:

      Make sure that the front No. 2 axle outboard joint boot clamp is securely installed to the front axle outboard joint boot.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

    Tip:

    Perform the same procedure as for the front No. 2 axle outboard joint boot clamp.

  4. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

    1. C304806C01

      *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. C157561C03

      *a

      Matchmark

      Align the matchmarks and install the tripod joint to 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.

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

    7. C166353

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

    8. C304799

      Install the inboard joint spring to the front drive outboard joint shaft assembly.

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

    10. C304803C01

      *a

      Matchmark

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

  5. INSTALL FRONT AXLE INBOARD JOINT BOOT

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

    2. C304794N01

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

      Dimension (A)

      for LH Side

      549.8 mm (1.80 ft.)

      for RH Side

      642.0 mm (2.11 ft.)

  6. 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. C304792N01

      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.

      Note:

      Make sure that the front axle inboard joint boot clamp is securely installed to the front axle inboard joint boot.

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

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

    2. C304802

      Using pliers, install the front No. 2 axle inboard joint boot clamp.

      Note:

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

  8. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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