Reassembly

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

1. INSTALL FRONT DRIVE SHAFT DUST COVER

(a) Using SST and a press, press a new dust cover into the inboard joint until it is flush with the end.

SST : 09527-10011

NOTICE:
* Install the dust cover in the correct orientation.
* Do not deform the dust cover.

HINT
Use the same procedure for the RH side as for the LH side.

2. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING

(a) Install a new snap ring.

HINT
Use the same procedure for the RH side as for the LH side.

3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

(a) Wrap the spline of the outboard joint shaft with protective tape.

(b) Install new parts onto the outboard joint shaft in the following order.

Installation Order

(c) Pack the joint portion of the outboard joint shaft and the outboard joint boot with grease.

Standard Quantity:

85 to 105g (3.0 to 3.7 oz.)

(d) Install the outboard joint boot onto the outboard joint shaft groove.

NOTICE:
Keep the groove free of grease.

HINT
Use the same procedure for the RH side as for the LH side.

4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

(a) Fix the outboard joint shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Place SST onto the boot clamp, press it against the boot and slightly tighten SST.

SST : 09521-24010

(c) Fix SST and tighten it so that the clearance comes to within the specified range.

Standard Clearance:

1.2 to 4.0 mm (0.0472 to 0.157 in.)

(d) Remove SST.

(e) Using SST, measure the clearance of the boot clamp as shown in the illustration.

SST : 09240-00020

Standard Clearance:

1.2 to 4.0 mm (0.0472 to 0.157 in.)

NOTICE:
If the clearance is outside the specified range, retighten it.

HINT
Use the same procedure for the RH side as for the LH side.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Place SST onto the boot clamp, press it against the boot and slightly tighten SST.

SST : 09521-24010

(b) Fix SST and tighten it so that the clearance comes to within the specified range.

Standard Clearance:

1.2 to 4.0 mm (0.0472 to 0.157 in.)

(c) Remove SST.

(d) Using SST, measure the clearance of the boot clamp as shown in the illustration.

Dimension (A):

305.6 to 309.6 mm (12.03 to 12.19 in.)

NOTICE:
Install the damper in the correct orientation.

7. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for RH Side)

(a) Install a new damper clamp onto the front drive shaft damper and fix the damper clamp with a screwdriver.

8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Install new parts onto the outboard joint shaft in the following order.

Installation Order

(b) Fix the outboard joint shaft in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(c) Remove the protective tape.

(d) Align the matchmarks and install the tripod joint onto the outboard joint shaft.

Text in Illustration

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

(e) Using a brass bar and hammer, install the tripod joint.

NOTICE:
* Do not hit the rollers.
* Keep the tripod joint free of foreign matter.

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

(g) Pack the inboard joint with grease.

Standard Quantity:

95 to 115g (3.4 to 4.1 oz.)

(h) Align the matchmarks and install the inboard joint onto the outboard joint shaft.

Text in Illustration

HINT
Use the same procedure for the RH side as for the LH side.

9. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) Install the inboard joint boot into the grooves of the inboard joint grommet and outboard joint shaft.

NOTICE:
Keep the grooves free of grease.

HINT
Use the same procedure for the RH side as for the LH side.

10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Using needle-nose pliers, engage the 2 claws and install the boot clamp as shown in the illustration.

NOTICE:
* Do not damage the boot.
* Do not deform the claw of the hook.

HINT
Use the same procedure for the RH side as for the LH side.

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

(a) Install a new boot clamp onto the inboard joint boot.

(b) Adjust dimension (A) until the drive shaft is within the specified length.

Dimension (A):

NOTICE:
* Do not damage the boot.
* Do not deform the claw of the hook.

HINT
Use the same procedure for the RH side as for the LH side.

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