Reassembly

DRIVE SHAFT / PROPELLER SHAFT: REAR DRIVE SHAFT ASSEMBLY (for 4WD): REASSEMBLY

REASSEMBLY
HINT:
- Use the same procedure for the RH side and LH side.
- The procedure listed below is for the LH side.

1. INSTALL REAR DRIVE SHAFT DUST COVER





(a) Using SST and a steel plate, install a new rear drive shaft dust cover.
SST: 09527-21011

NOTICE:
- The rear drive shaft dust cover should be completely installed.
- Be careful not to damage the rear drive shaft dust cover.

2. INSTALL OUTBOARD JOINT BOOT
HINT: Before installing the boot, wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.





(a) Temporarily install new parts to the outboard joint shaft in the following order.
(1) Rear drive shaft outboard joint boot clamp
(2) Outboard joint boot
(3) No. 2 rear drive shaft outboard joint boot clamp
(b) Pack the outboard joint shaft assembly and outboard joint boot with grease that comes with the boot kit.
Grease capacity:
82 to 92 g (2.9 to 3.2 oz.)
3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP
(a) Hold the rear drive shaft in a vise using aluminum plates.
(b) Secure the rear drive shaft outboard joint boot clamp onto the boot.





(c) Place SST onto the rear drive shaft outboard joint boot clamp.
SST: 09521-24010
(d) Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.





(e) Using SST, measure the clearance of the rear drive shaft outboard joint boot clamp.
SST: 09240-00020
Standard clearance:
0.5 to 1.5 mm (0.0197 to 0.0590 in.)
NOTE: If the measured value exceeds the specified value, retighten the clamp.

4. INSTALL NO. 2 REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP
(a) Hold the front drive shaft in a vise using aluminum plates.
(b) Secure the outboard joint boot clamp onto the boot.





(c) Place SST onto the No. 2 rear drive shaft outboard joint boot clamp.
SST: 09521-24010
(d) Tighten SST so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.





(e) Using SST, measure the clearance of the No. 2 rear drive shaft outboard joint boot clamp.
SST: 09240-00020
Standard clearance:
0.5 to 1.5 mm (0.0197 to 0.0590 in.)
NOTE: If the measured value exceeds the specified value, retighten the clamp.

5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY
(a) Wrap the splines of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
(b) Temporarily install new parts to the outboard joint shaft in the following order.
(1) No. 2 rear drive shaft inboard joint boot clamp
(2) Inboard joint boot
(3) Rear drive shaft inboard joint boot clamp





(c) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft assembly.
(d) Align the matchmarks placed before removal.





(e) Using a brass bar and a hammer, tap in the tripod joint onto the outboard joint shaft assembly.

NOTICE:
- Do not tap the rollers.
- Be sure to install the tripod joint in the correct direction.





(f) Using a snap ring expander, install a new shaft snap ring.
(g) Pack the outboard joint shaft and boot with grease.
Grease capacity:
98 to 111 g (3.5 to 3.9 oz.)





(h) Align the matchmarks and install the inboard joint assembly to the outboard joint shaft assembly.
6. INSTALL INBOARD JOINT BOOT
(a) Install the inboard joint boot to the outboard joint shaft.





(b) Check whether dimension (A) of the drive shaft is within the following specification.
Dimension (A):
703.4 mm (2.31 ft.)
7. INSPECT REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP
(a) Hold the rear drive shaft in a vise using aluminum plates.
(b) Secure the rear drive shaft inboard joint boot clamp onto the boot.





(c) Place SST onto the rear drive shaft inboard joint boot clamp.
SST: 09521-24010
(d) Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.





(e) Using SST, measure the clearance of the rear drive shaft inboard joint boot clamp.
SST: 09240-00020
Standard clearance:
0.5 to 1.5 mm (0.0197 to 0.0590 in.)
NOTE: If the measured value exceeds the specified value, retighten the clamp.

8. INSTALL NO. 2 REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP
(a) Hold the rear drive shaft in a vise using aluminum plates.
(b) Secure the No. 2 rear drive shaft inboard joint boot clamp onto the boot.





(c) Place SST onto the No. 2 rear drive shaft inboard joint boot clamp.
SST: 09521-24010
(d) Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
NOTE: Do not overtighten SST.





(e) Using SST, measure the clearance of the inboard joint boot clamp.
SST: 09240-00020
Standard clearance:
0.5 to 1.5 mm (0.0197 to 0.0590 in.)
NOTE: If the measured value exceeds the specified value, retighten the clamp.

9. INSPECT REAR DRIVE SHAFT ASSEMBLY Rear Drive Shaft Assembly