Reassembly

DRIVE SHAFT / PROPELLER SHAFT: REAR DRIVE SHAFT ASSEMBLY (for TMC Made): REASSEMBLY

1. INSTALL REAR DRIVE SHAFT DUST COVER

(a) Using SST and a steel plate, install a new rear drive shaft dust cover.





Text in Illustration





SST : 09527-10011

NOTICE:
* The rear drive shaft dust cover should be completely installed.
* Be careful not to damage the rear drive shaft dust cover.

2. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT

(a) Wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.





Text in Illustration





(b) Install new parts to the outboard joint shaft in the following order:

(1) Rear drive shaft outboard joint boot clamp

(2) Outboard joint boot

(3) No. 2 rear drive shaft outboard joint boot clamp

(c) Pack the outboard joint shaft assembly and outboard joint boot with grease from the boot kit.

Grease capacity:

84 to 94 g (3.0 to 3.3 oz.)

3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

(a) Hold the rear drive shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Secure the rear drive shaft outboard joint boot clamp onto the boot.

(c) Place SST onto the rear drive shaft outboard joint boot clamp.





SST : 09521-24010

(d) Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.

NOTICE:
Do not overtighten SST.

(e) Using SST, inspect the clearance of the rear drive shaft outboard joint boot clamp.





SST : 09240-00020

Clearance:

1.3 mm (0.0511 in.) or less

NOTICE:
If the measured value exceeds the specified value, retighten the clamp.

4. INSTALL NO. 2 REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

(a) Hold the drive shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Secure the outboard joint boot clamp onto the boot.

(c) Place SST onto the No. 2 rear drive shaft outboard joint boot clamp.





SST : 09521-24010

(d) Tighten SST so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.

NOTICE:
Do not overtighten SST.

(e) Using SST, inspect the clearance of the No. 2 rear drive shaft outboard joint boot clamp.





SST : 09240-00020

Clearance:

1.3 mm (0.0511 in.) or less

NOTICE:
If the measured value exceeds the specified value, retighten the clamp.

5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY

(a) Wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.





Text in Illustration





(b) Install new parts to the outboard joint shaft in the following order:

(1) No. 2 rear drive shaft inboard joint boot clamp

(2) Inboard joint boot

(3) Rear drive shaft inboard joint boot clamp

(c) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft assembly.





Text in Illustration





(d) Align the matchmarks placed before removal.

(e) Using a brass bar and a hammer, tap the tripod joint onto the outboard joint shaft assembly.





NOTICE:
* Do not tap the rollers.
* Be sure to install the tripod joint in the correct direction.

(f) Using a snap ring expander, install a new shaft snap ring.





(g) Pack the outboard joint shaft and boot with grease.

Grease capacity:

115 to 125 g (4.1 to 4.4 oz.)

(h) Align the matchmarks, and install the inboard joint assembly to the outboard joint shaft assembly.





Text in Illustration





6. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT

(a) Install the rear drive shaft inboard joint boot to the outboard joint shaft.

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





Dimension (A):

750.6 mm (2.46 ft.)

7. INSPECT REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(a) Hold the rear drive shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Secure the rear drive shaft inboard joint boot clamp onto the boot.

(c) Place SST onto the rear drive shaft inboard joint boot clamp.





SST : 09521-24010

(d) Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.

NOTICE:
Do not overtighten SST.

(e) Using SST, inspect the clearance of the rear drive shaft inboard joint boot clamp.





SST : 09240-00020

Clearance:

1.1 mm (0.0433 in.) or less

NOTICE:
If the measured value exceeds the specified value, retighten the clamp.

8. INSTALL NO. 2 REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

SST : 09521-24010

SST : 09240-00020

(a) Using needle-nose pliers, install a new No. 2 rear drive shaft inboard joint boot clamp as shown in the illustration.





NOTICE:
Be careful not to damage the boot.

9. INSTALL REAR DRIVE SHAFT SNAP RING

(a) Install a new rear drive shaft snap ring.

10. INSPECT REAR DRIVE SHAFT ASSEMBLY Rear Drive Shaft Assembly (For TMC Made)