Reassembly

DRIVE SHAFT: FRONT DRIVE SHAFT: REASSEMBLY

REASSEMBLY
HINT:
- Use the same procedures for the RH and LH side.
- The procedures listed below are for the LH side.

1. INSTALL FRONT DRIVE SHAFT BEARING
(a) Using SST and a press, press in a new drive shaft bearing.
SST: 09950-60020
09951-00710
SST: 09950-70010
09951-07100

2. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY SNAP RING
(a) Using a screwdriver, install a new bearing case snap ring.
3. INSTALL DRIVE SHAFT BEARING CASE SUB-ASSEMBLY

(a) Using SST and a press, press in the drive shaft bearing case to the inboard joint RH.
SST: 09527-10011
SST: 09710-04081
NOTE: Bearing should be installed completely.

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

4. INSTALL FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, press in a new drive shaft dust cover.
SST: 09726-40010
SST: 09527-10011
Standard distance (A):
0 to 1.0 mm (0 to 0.039 in.)
NOTE: Be careful not to damage the dust cover.

(b) Install the straight pin.

5. INSTALL FRONT DRIVE SHAFT DUST COVER RH
(a) Using SST and a press, press in a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover reaches the specification, as shown in the illustration.
SST: 09527-10011
Standard distance (A):
91.0 to 92.0 mm (3.582 to 3.622 in.)
NOTICE:
- The dust cover should be installed completely.
- Be careful not to damage the dust cover.

6. INSTALL FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, press in a new drive shaft dust cover.
SST: 09527-10011
NOTICE:
- The dust cover should be installed completely.
- Be careful not to damage the dust cover.

7. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
(a) Install a new hole snap ring.

8. INSTALL OUTBOARD JOINT BOOT
HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.

(a) Install new parts to the outboard joint shaft assembly in the following order.
(1) No. 2 outboard joint boot clamp
(2) Outboard joint boot
(3) Outboard joint boot clamp
(b) Pack the outboard joint shaft and boot with grease from the boot kit.
Standard grease capacity:
190 to 200 g (6.7 to 7.1 oz.)
9. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

(a) Secure the No. 2 outboard joint boot clamp onto the boot.
(b) Place SST onto the No. 2 outboard joint boot clamp.
SST: 09521-24010
(c) Tighten SST so that the No. 2 outboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.

(d) Using SST, measure the clearance of the outboard joint boot clamp.
SST: 09240-00020
Standard clearance:
0.8 mm (0.031 in.) or less
NOTE: When the measured value is greater than the specified value, retighten the clamp.

10. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Secure the outboard joint boot clamp onto the boot.
(b) Place SST onto the outboard joint boot clamp.
SST: 09521-24010
(c) Tighten SST so that the outboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.

HINT: Install the damper clamp to outboard joint side.

(a) Install a new drive shaft damper clamp and the drive shaft damper to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Distance:
202.4 to 206.4 mm (7.969 to 8.126 in.)

(d) Hold the front drive shaft lightly in a soft vise.
(e) Install the drive shaft damper clamp to the damper.
NOTE: Be sure to install the clamp in the correct position.

(f) One touch type:
Using a screwdriver, install the drive shaft damper clamp, as shown in the illustration.
(g) Claw engagement type:
Using needle-nose pliers, install the drive shaft damper clamp, as shown in the illustration.
12. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
(a) Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
(b) Install new parts to the outboard joint shaft in the following order.
(1) Inboard joint boot clamp
(2) No. 2 inboard joint boot clamp
(3) Inboard joint boot

(c) Place the beveled side of the tripod axial spline toward the outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap the tripod joint onto the drive shaft.
NOTICE:
- Do not tap the rollers.
- Be sure to install the tripod joint in the correct direction.

(f) Pack the inboard joint shaft and boot with grease from the boot kit.
Standard grease capacity:
175 to 185 g (6.2 to 6.5 oz.)

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

(h) Aligning the matchmarks, and install the inboard joint to the outboard joint shaft.
13. INSTALL FRONT DRIVE SHAFT INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint and outboard joint shaft.

14. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP
(a) One touch type:
Using a screwdriver, install the No. 2 inboard joint boot clamp, as shown in the illustration.
NOTE: Be careful not to damage the boot.

(b) Claw engagement type:
Using needle-nose pliers, install the No. 2 inboard joint boot clamp, as shown in the illustration.
NOTE: Be careful not to damage the boot.

15. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP
(a) One touch type:
Using a screwdriver, install the inboard joint boot clamp, as shown in the illustration.
NOTE: Be careful not to damage the boot.

(b) Claw engagement type:
Using needle-nose pliers, install the inboard joint boot clamp, as shown in the illustration.
NOTE: Be careful not to damage the boot.

16. INSPECT FRONT DRIVE SHAFT

(a) Check that there is no severe play in the radial direction of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust direction.
(c) Check that there is no severe play in the radial direction of the inboard joint.

(d) Check the boots for damage.
NOTE: Keep the drive shaft assembly level during inspection.
HINT: For dimension (A), refer to the following values.

Reference value:
873.0 to 883.0 mm (34.370 to 34.764 in.) for RH side
556.2 to 566.2 mm (21.898 to 22.291 in.) for LH side