Reassembly

DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2ZR-FE): REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT DUST COVER





(a) Using SST and a press, install a new dust cover into the front drive inboard joint assembly until it is flush with the end.
SST: 09527-10011

NOTICE:
- Install the dust cover in the correct direction.
- Do not deform the dust cover.

2. INSTALL OUTBOARD JOINT BOOT





(a) Wrap the splines of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
(b) Install new parts onto the 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:
85 to 105 g (3.0 to 3.7 oz.)
(d) Install the outboard joint boot onto the outboard joint shaft groove.
NOTE: Keep the groove free of grease.

3. INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP
(a) Hold the outboard joint shaft in a vise using aluminum plates.
NOTE: 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) Tighten SST so that the clearance comes within the specified range.
NOTE: Do not overtighten SST.

(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 (0.0473 to 0.157 in.)
NOTE: If the clearance is outside the specified range, retighten SST.

4. 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) Tighten SST so that the clearance comes within the specified range.
NOTE: Do not overtighten SST.

(c) Remove SST.





(d) 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 (0.0473 to 0.157 in.)
NOTE: If the clearance is outside the specified range, retighten SST.

5. INSTALL FRONT DRIVE SHAFT DAMPER RH





(a) Install the drive shaft damper onto the front axle outboard shaft assembly as shown in the illustration.
Distance:
412.5 to 416.5 mm (1.3535 to 1.3665 ft.)
6. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (for RH Side)





(a) Using pliers, install a new drive shaft damper clamp, as shown in the illustration.
7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
(a) Install new parts onto the 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
(b) Secure the front axle outboard joint shaft in a vise using aluminum plates.
NOTE: Do not overtighten the vise.

(c) Remove the protective tape.





(d) Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft.
NOTE: 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 to the front axle outboard joint shaft.
NOTICE:
- Do not hit the roller portion.
- Keep the tripod joint free of foreign matter.





(f) Using a snap ring expander, install a new snap ring to the front axle outboard joint shaft.
(g) Pack the inboard joint with grease.

Grease Capacity









(h) Align the matchmarks and install the inboard joint onto the front axle outboard joint shaft.
8. INSTALL INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assembly.
9. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP





(a) Using pliers, install a new No. 2 front axle inboard joint boot clamp as shown in the illustration.
10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP





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





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






11. INSPECT FRONT DRIVE SHAFT Component Tests and General Diagnostics