Reassembly

FRONT DRIVE SHAFT

REASSEMBLY
1. INSTALL FRONT DRIVE SHAFT BEARING
a. Install a new bearing bracket hole snap ring to the front driver shaft assembly RH.





b. Using SST and a steel plate, install a new front drive shaft bearing.
SST 09710-30021 (09710-03141)

NOTICE: Bearing should be completely installed.





c. Using a snap ring expander, install a new drive shaft hole snap ring.





2. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, install a new drive shaft dust cover.
SST 09726-40010, 09527-10011

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.





3. INSTALL FRONT DRIVE SHAFT DUST COVER RH
a. Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.
SST 09527-10011
Distance (A):
3MZ-FE: 109.0 to 110.0 mm (4.291 to 4.330 inch)
2AZ-FE: 90.0 to 91.0 mm (3.543 to 3.583 inch)

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.





4. INSTALL FRONT DRIVE SHAFT DUST COVER LH
a. Using SST and a press, install a new drive shaft dust cover LH.
SST 09527-10011

NOTICE:
^ Dust cover should be completely installed.
^ Be careful not to damage the dust cover.

5. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
a. Install a new hole snap ring.





6. 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. Hold the drive shaft lightly in a soft vise.
b. Temporarily install a new outboard joint boot with 2 clamps to the drive shaft.





c. Pack the outboard joint shaft and boot with grease.

7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP





a. Secure the 2 outboard joint boot clamps onto the boot.
b. Place SST onto the outboard joint boot LH No.2 clamp.
SST 09521-24010
c. Tighten the SST so that the outboard joint boot LH No.2 clamp is pinched.

NOTICE: Do not overtighten the SST.





d. Using SST, measure the clearance of the outboard joint boot LH No.2 clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

NOTICE: When the measured value is greater than the specified value, retighten the clamp.

8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP
a. The procedure for the outboard joint boot LH clamp is the same as above.
SST 09521-24010, 09240-00020
Clearance: 0.8 mm (0.031 inch) or less

9. INSTALL FRONT DRIVE SHAFT DAMPER LH

HINT: This procedure is unnecessary for a manual transaxle vehicle because it does not have a drive shaft damper.

a. Install the drive shaft damper LH to the drive shaft.
b. Make sure that the damper is on the shaft groove.





c. Set the distance, as shown below.
Distance:
3MZ-FE: 204.5 to 208.5 mm (8.051 to 8.209 inch)
2AZ-FE: 204.4 to 208.4 mm (8.047 to 8.205 inch)





d. Hold the front drive shaft lightly in a soft vise.
e. Install the drive shaft damper clamp to the damper.

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

f. Place SST onto the drive shaft damper clamp. SST 09521-24010
g. Tighten the SST so that the clamp is pinched.

NOTICE: Do not overtighten the SST.





h. Using SST, measure the clearance of the drive shaft damper clamp.
SST 09240-00020
Clearance: 0.5 to 1.2 mm (0.020 to 0.047 inch)

NOTICE: When the measured value is greater than the specified value, retighten the clamp.

10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH
a. Temporarily install a new inboard joint boot with 2 clamps to the drive shaft.
b. Place the beveled side of the tripod joint axial spline toward the outboard joint shaft.





c. Align the matchmarks.
d. Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.

NOTICE:
^ Do not tap the roller.
^ Be sure to install the tripod joint assembly in the correct direction.





e. Using a snap ring expander, install a new shaft snap ring.
f. Pack the outboard joint shaft and boot with grease.

Grease Capacity:

g. Aligning the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.

11. INSTALL INBOARD JOINT BOOT
a. Install the inboard joint boot to the inboard joint assembly.

12. INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP





a. 2AZ-FE Engine: Claw Engagement
1 Using pliers, install the inboard joint boot LH No.2 clamp, as shown in the illustration.





b. 3MZ-FE Engine: Omega Clamp Type
Install new inboard joint boot clamps.
1 Hold the drive shaft lightly in a soft vise.
2 Install 2 new inboard joint boot clamps to the boot.
3 Place SST onto the inboard joint boot LH No.2 clamp.
SST 09521-24010
4 Tighten the SST so that the inboard joint boot LH No.2 clamp is pinched.

NOTICE: Do not overtighten the SST.





5 Using SST, measure the clearance of the inboard joint boot LH No.2 clamp.
SST 09240-00020
Clearance: 1.9 mm (0.075 inch) or less

NOTICE: When the measured value is greater than the specified value, retighten the clamp.

13. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP





a. Install new inboard joint boot clamps.
1 Hold the drive shaft lightly in a soft vise.
2 Install 2 new inboard joint boot clamps to the boot.
3 Place SST onto the inboard joint boot LH clamp.
SST 09521-24010
4 Tighten the SST so that the inboard joint boot LH clamp is pinched.

NOTICE: Do not overtighten the SST.





5 Using SST, measure the clearance of the inboard joint boot LH clamp.
SST 09240-00020
Clearance: 1.9 mm (0.075 inch) or less

NOTICE: When the measured value is greater than the specified value, retighten the clamp.