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Home >> Toyota >> 2012 >> Yaris Hatchback L4-1.5L (1NZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Overhaul >> Reassembly (from 07/2011)

Reassembly (from 07/2011)





DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for Hatchback): REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT DUST COVER

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





Text in Illustration





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 LH

(a) Install a new snap ring.

3. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

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

4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

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





Text in Illustration





(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:

116 to 126 g (4.1 to 4.4 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.

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

CAUTION:
Wear protective gloves to avoid injuries to your hands.

(a) Install a new boot clamp onto the outboard joint boot and provisionally fold back the lever.





NOTICE:
* Set the lever into the guide groove correctly and install the clamp as far into the inner side 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.





Text in Illustration





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 fix it while adjusting the clearance between the lever and the groove to make the clearances between the buckle edge and the lever end even.





NOTICE:
Do not damage the outboard joint boot.

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

6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

CAUTION:
Wear protective gloves to avoid injuries to your hands.

(a) Install a new boot clamp onto the outboard joint boot and provisionally 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 water pump pliers, pinch the boot clamp to provisionally fix it.





Text in Illustration





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





NOTICE:
Do not damage the outboard joint boot.

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

7. INSTALL FRONT DRIVE SHAFT DAMPER RH

(a) Install the drive shaft damper onto dimension (A) shown in the illustration.





Dimension (A):

425.6 to 429.6 mm (16.76 to 16.91 in.)

NOTICE:
Install the damper in the correct orientation.

8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH





(a) One touch type:

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

(b) Claw engagement type:

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

Text in Illustration





9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Install a 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:

125 to 135 g (4.4 to 4.8 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.

10. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) Install the inboard joint boot into the grooves of the inboard joint 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.

11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

CAUTION:
Wear protective gloves to avoid injuries to your hands.

(a) One touch type:

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

(2) Using water pump pliers, pinch the boot clamp to provisionally fix it.





Text in Illustration





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





NOTICE:
Do not damage the inboard joint boot.

(b) Claw engagement type:

(1) Using needle-nose pliers, install a new 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.

12. 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):





(c) One touch type:

(1) Install a new boot clamp onto the inboard joint boot and provisionally fold back the lever.





CAUTION:
Wear protective gloves to avoid injuries to your hands.

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

(2) 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.





Text in Illustration





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

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





NOTICE:
Do not damage the boot.

(d) Claw engagement type:

(1) 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.

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