Reassembly

DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2ZR-FE): REASSEMBLY; 2013 MY Corolla [07/2012 -]

1. INSTALL FRONT DRIVE SHAFT DUST COVER

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





SST : 09527-10011

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

2. INSTALL OUTBOARD JOINT BOOT

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





Text in Illustration





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

(1) No. 2 front axle outboard joint boot clamp

(2) Outboard joint boot

(3) Front axle outboard joint boot clamp

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

Grease capacity:

90 to 110 g (3.2 to 3.8 oz.)

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

NOTICE:
Keep the groove free of grease.

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

(a) Hold the front axle outboard joint shaft in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Place SST onto the No. 2 front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.





SST : 09521-24010

(c) Tighten SST so that the clearance comes within the specified range.

NOTICE:
Do not overtighten SST.

(d) Remove SST.

(e) Using SST, measure the clearance of the No. 2 front axle outboard joint boot clamp as shown in the illustration.





SST : 09240-00020

Standard Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

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

4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

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





SST : 09521-24010

(b) Tighten SST so that the clearance comes within the specified range.

NOTICE:
Do not overtighten SST.

(c) Remove SST.

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





SST : 09240-00020

Standard Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

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

5. INSTALL FRONT DRIVE SHAFT DAMPER RH

(a) Hold the front axle outboard joint shaft in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Temporarily install a new front drive shaft damper clamp RH on the front drive shaft damper RH.

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

NOTICE:
Be sure to install the front drive shaft damper RH in the correct direction.





Text in Illustration





Dimension





6. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH

(a) for One Touch Type:





Text in Illustration





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

NOTICE:
Be sure to install the clamp in the correct position.

(b) for Claw Engagement Type:

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

NOTICE:
Be sure to install the clamp in the correct position.

7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

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

HINT
Before installing the boot, wrap the splines of the drive shaft with vinyl tape to prevent the boot from being damaged.

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

(1) Front axle inboard joint boot clamp

(2) Inboard joint boot

(3) No. 2 front axle inboard joint boot clamp

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

NOTICE:
Do not overtighten the vise.

(d) Remove the vinyl tape.

(e) Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft.





Text in Illustration





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

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

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.

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





(h) Pack the inboard joint with grease.

Grease Capacity





(i) Align the matchmarks and install the inboard joint onto the front axle outboard joint shaft.





Text in Illustration





8. INSTALL INBOARD JOINT BOOT

(a) Install the inboard joint boot to the front drive inboard joint assembly.

NOTICE:
Keep the grooves free of grease.

(b) Check whether the drive shaft dimensions are within the following specifications.





Dimension





9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) for One Touch Type:

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





NOTICE:
Be careful not to damage the boot.

(b) for Claw Engagement Type:

(1) Using needle nose pliers, install a new front axle inboard joint boot clamp as shown in the illustration.





Text in Illustration





NOTICE:
Be careful not to damage the boot.

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

(a) for One Touch Type:

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





NOTICE:
Be careful not to damage the boot.

(b) for Claw Engagement Type:

(1) Using needle nose pliers, install a new No. 2 front axle inboard joint boot clamp as shown in the illustration.





Text in Illustration





NOTICE:
Be careful not to damage the boot.

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