Front Drive Shaft Installation

INSTALLATION OF DRIVE SHAFT





1. INSTALL SIDE GEAR SHAFT
(a) Insure that a new snap ring is positioned securely in the groove of the side gear shaft

(b) Using a brass bar and hammer, tap in the drive shaft until it makes contact with the pinion shaft.

HINT:
- Before installing the drive shaft, set the snap ring opening side facing downward.

- Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.





2. CHECK INSTALLATION OF SIDE GEAR SHAFT
(a) Check that the side gear shaft will not come Out by trying to pull it completely out by hand.

(b) Push the side gear shaft to the differential and measure the distance between the. side gear shaft and the transaxle case. Check that the distance between the two is the same as the measurement taken before removing the side gear shaft.





3. PACK IN GREASE TO SIDE GEAR SHAFT
Pack in grease to the side gear shaft.

Grease capacity: 43-53 g (0.09-0.12 lb)

HINT: Use the grease supplied in the boot kit. Supply of grease only is also available.

Part No 90999-94029





4. INSTALL DRIVE SHAFT

(LH drive shaft)
(a) Place the new gasket on the inboard joint.

(b) Align the matchmarks on the side gear shaft and inboard joint.

NOTICE: When moving the drive shaft, do not compress the inboard boot

(c) Insert and finger tighten the six hexagon bolts and the three washers.





(RH drive shaft)
(a) Pack in grease to the center drive shaft.

Grease capacity: 43-53 g (0.09-0.12 lb)

HINT: Use the grease supplied in the boot kit.

Supply of grease only is also available.

Part No.90999-94029

(b) Place the new gasket on the inboard joint.





(c) Install the center drive shaft to the RH drive shaft.

NOTICE: When moving the drive shaft, do not compress the inboard boot.

(d) Install the three washers and six hexagon bolts, and using SST, temporarily tighten them.

SST 09923-00020





(e) Install the drive shaft with the center drive shaft to the transaxle through the bearing bracket

(f) Using pliers, install the snap ring.





5. INSTALL DRIVE SHAFT TO AXLE HUB

Install the outboard joint side of the drive shaft to the axle hub.

NOTICE: Be careful not to damage the boot, oil seal and deflector.





6. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Install and torque the nut.

Torque: 500 kg-cm (36 ft-lb, 49 Nm)

(b) Install a new cotter pin.

HINT: If the cotter pin hole does not line up, correct by tightening the nut by the smallest amount possible.





7. CONNECT STEERING KNUCKLE TO LOWER ARM

Torque: 1,150 kg-cm (83 ft-lb. 113 Nm)





8. TIGHTEN SIX HEXAGON BOLTS

Using SST, tighten the six hexagon bolts while depressing the brake pedal.

SST 09043-88010

Torque:
TOYOTA Type: 680 kg-cm (48 ft-lb, 65 Nm)
GKN Type: 642 kg-cm (46 ft-lb. 63 Nm)





9. INSTALL BEARING LOCK NUT. LOCK NUT CAP AND NEW COTTER PIN
(a) Torque the bearing lock nut while depressing the brake pedal.

Torque: 1,900 kg-cm (137 ft-lb. 186 Nm)

(b) Install the lock nut cap and, using pliers. install a new cotter pin.

10. FILL TRANSAXLE WITH GEAR OIL

11. INSTALL ENGINE UNDER COVERS

12. CHECK FRONT WHEEL ALIGNMENT Alignment