Reassembly

DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY: REASSEMBLY

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

(a) Using SST and a press, install a new front drive shaft bearing to the drive shaft bearing case.





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SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

(b) Secure the drive shaft bearing case in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(c) Using a screwdriver, install a new bearing case snap ring to the drive shaft bearing case as shown in the illustration.





2. INSTALL FRONT DRIVE SHAFT STRAIGHT PIN (for RH Side)

(a) Install a new front drive shaft straight pin to the drive shaft bearing case.

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

(a) Using SST and a press, install the drive shaft bearing case sub-assembly to the front drive inboard joint assembly RH as shown in the illustration.





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SST : 09527-10011

SST : 09710-04081

NOTICE:
The bearing should be installed completely.

(b) Using a snap ring expander, install a new snap ring as shown in the illustration.





4. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)

(a) Using SST and a press, install a new front drive shaft dust cover as shown in the illustration.





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SST : 09527-10011

SST : 09726-40010

Standard dust cover depth (A):

1 mm (0.0394 in.)

NOTICE:
* Install the front drive shaft dust cover in the correct direction.
* Do not press the front drive shaft dust cover excessively.

5. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for RH Side)

(a) Using SST and a press, install a new front drive shaft dust cover RH as shown in the illustration.





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SST : 09527-10011

Distance (A):

110.0 to 111.0 mm (4.33 to 4.37 in.)

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

6. INSTALL FRONT DRIVE SHAFT DUST COVER LH (for LH Side)

(a) Using SST and a press, install a new front drive shaft dust cover LH into the front drive inboard joint assembly LH until it is flush with the end.

SST : 09527-10011





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NOTICE:
* Install the front drive shaft dust cover LH in the correct direction.
* Do not deform the front drive shaft dust cover LH.

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

(a) Wrap the splines of the front axle outboard joint shaft assembly LH with protective tape to prevent the boot from being damaged.





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(b) Install new parts onto the front axle outboard joint shaft assembly LH in the following order:





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(1) Install the front No. 2 axle outboard joint boot clamp LH (A).

(2) Install the front axle outboard joint boot (B).

(3) Install the front axle outboard joint boot clamp LH (C).

(c) Pack the joint portion of the front axle outboard joint shaft assembly LH and outboard joint boot with grease.

Standard grease capacity:

190 to 200 g (6.7 to 7.0 oz.)

(d) Install the outboard joint boot onto the front axle outboard joint shaft assembly LH groove.

NOTICE:
* 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.

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

HINT
Use the same procedure as for the LH side.

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

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the front No. 2 axle outboard joint boot clamp LH onto the outboard joint boot and temporarily fold back the lever.





NOTICE:
* Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.
* Check the band and the lever for any deformation before folding back the lever.

(b) Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.





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NOTICE:
* Do not damage the deflector.
* Make sure that the outboard joint is in direct contact with the work plane.

(c) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.





NOTICE:
Do not damage the outboard joint boot.

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

HINT
Use the same procedure as for the LH side.

11. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the front axle outboard joint boot clamp LH onto the outboard joint boot and temporarily fold back the lever.





NOTICE:
* Set the lever into the guide groove correctly.
* Check the band and the lever for any deformation before folding back the lever.

(b) Using channel lock pliers, pinch the front axle outboard joint boot clamp LH to temporarily secure it.





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(c) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.





NOTICE:
Do not damage the outboard joint boot.

12. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH

HINT
Use the same procedure as for the LH side.

13. INSTALL FRONT DRIVE SHAFT DAMPER LH

NOTICE:
A new drive shaft damper clamp must be installed before the front drive shaft damper LH is installed (for one touch type).

(a) Install the front drive shaft damper LH onto the front axle outboard joint shaft assembly LH as shown in the illustration.

HINT
Install the damper clamp LH to the outboard joint side.





(b) Set the distance as specified below.

Distance (A):

158.0 to 162.0 mm (6.221 to 6.378 in.)

14. INSTALL FRONT DRIVE SHAFT DAMPER RH

NOTICE:
A new drive shaft damper clamp is installed before the front drive shaft damper RH is installed (for one touch type).

(a) Install the front drive shaft damper RH onto the front axle outboard joint shaft assembly RH as shown in the illustration.

HINT
Install the damper clamp RH to the outboard joint side.





(b) Set the distance as specified below.

Distance (A):

161.0 to 165.0 mm (6.339 to 6.496 in.)

15. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH

(a) Secure the front axle outboard joint shaft assembly LH in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Install the front drive shaft damper clamp LH to the damper.

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

(c) For one touch type:

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





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NOTICE:
Do not damage the outboard joint boot.

(d) For claw engagement type:

(1) Using needle-nose pliers, install a new front drive shaft damper clamp LH as shown in the illustration.

16. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH

HINT
Perform the same procedure as for the front drive shaft damper clamp LH.

17. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

(a) Before installing the boot, wrap the splines of the front drive outboard joint assembly LH with protective tape to prevent the boot from being damaged.

(b) Install new parts to the front drive outboard joint assembly LH in the following order (for one touch type):





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(1) Install the front axle inboard joint boot clamp LH (A).

(2) Install the inboard joint boot (B).

(3) install the front No. 2 axle inboard joint boot clamp LH (C).

(c) Install a new inboard joint boot to the front drive outboard joint assembly LH (for claw engagement type):





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(d) Secure the front axle outboard joint shaft assembly LH in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(e) Remove the protective tape.

(f) Place the beveled side of the tripod joint axial spline toward the front drive outboard joint assembly LH.





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(g) Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft assembly LH as shown in the illustration.

NOTICE:
Face the serrated side of the tripod outward and install it onto the outboard joint end.

(h) Using a brass bar and a hammer, install the tripod joint to the front axle outboard joint shaft assembly LH.

NOTICE:
* Do not tap the rollers.
* Be sure to install the tripod joint in the correct direction.
* Keep the tripod joint free of foreign matter.

(i) Using a snap ring expander, install a new shaft snap ring to the front axle outboard joint shaft assembly LH.





(j) Pack the front drive inboard joint assembly LH and inboard joint boot with grease.

Standard grease capacity:

175 to 185 g (6.2 to 6.5 oz.)

(k) Align the matchmarks and install the front drive inboard joint assembly LH onto the front axle outboard joint shaft assembly LH.





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18. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH

HINT
Use the same procedure as for the LH side.

19. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) Install the inboard joint boot into the grooves of the front drive inboard joint assembly and front axle outboard joint shaft assembly.





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NOTICE:
* Keep the inside of the inboard joint boot free of foreign matter.
* Keep the grooves free of grease.

HINT
The following table shows dimension (A) of the front drive shaft assembly.

Dimension (A)





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

(a) For one touch type:

(1) Install the front No. 2 axle inboard joint boot clamp LH onto the inboard joint boot.

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





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NOTICE:
Do not damage the inboard joint boot.

(b) For claw engagement type:

(1) Set the front No. 2 axle inboard joint boot clamp LH to the inboard joint boot.

(2) Using needle-nose pliers, engage the 2 claws to install the front No. 2 axle inboard joint boot clamp LH as shown in the illustration.

NOTICE:
* Do not damage the inboard joint boot.
* Do not deform the claw.

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

HINT
Use the same procedure as for the LH side.

22. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

(a) For one touch type:

(1) Install the front axle inboard joint boot clamp LH onto the inboard joint boot.

(2) Using a screwdriver, install the front axle inboard joint boot clamp LH as shown in the illustration.





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NOTICE:
Be careful not to damage the boot.

(b) For claw engagement type:

(1) Set the front axle inboard joint boot clamp LH to the inboard joint boot.

(2) Using needle-nose pliers, engage the 2 claws to install the front axle inboard joint boot clamp LH as shown in the illustration.

NOTICE:
* Do not damage the inboard joint boot.
* Do not deform the claw.

23. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH

HINT
Use the same procedure as for the LH side.

24. INSPECT FRONT DRIVE SHAFT ASSEMBLY Component Tests and General Diagnostics