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Reassembly








DRIVE SHAFT: FRONT DRIVE SHAFT: REASSEMBLY

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

1. INSTALL FRONT DRIVE SHAFT DUST COVER LH





(a) Using SST and a press, install a new front drive shaft dust cover and press it in until it contacts the end of the inboard joint.
SST: 09527-10011
NOTICE:
- Install the front drive shaft dust cover LH in the correct direction.
- Do not deform the front drive shaft dust cover LH.

2. INSTALL FRONT DRIVE SHAFT DUST COVER RH
HINT: Install the front drive shaft dust cover RH following the same procedures as the LH side.

SST: 09527-10011
3. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH
(a) Install a new front drive shaft hole snap ring.
4. INSTALL OUTBOARD JOINT BOOT
(a) Wrap protective tape around the spline of the outboard joint.
(b) Install the following new parts on the outboard joint LH in order.
(1) No. 2 outboard joint boot clamp LH
(2) Outboard joint boot
(3) Outboard joint boot clamp LH
(c) Apply grease to the joint of the outboard joint LH and outboard joint boot.
Standard capacity:
112 to 122 g (4.0 to 4.3 oz.)
(d) Install the outboard joint boot into the outboard joint groove.
NOTE: Do not apply grease in the groove.

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





(a) Hold the front drive shaft in a vise between 2 aluminum plates.
NOTE: Do not overtighten the vise.

(b) Set SST to the No. 2 outboard joint boot clamp and slightly tighten the SST bolt while pushing the outboard joint on.
SST: 09521-24010
(c) Hold SST and tighten the SST bolt so that the clearance is within the specified value.
Standard clearance:
0.8 mm (0.031 in.) or less
NOTE: Do not damage the outboard joint.

(d) Remove SST.





(e) Using SST, measure the clearance of the No. 2 outboard joint boot clamp LH.
SST: 09240-00020
Standard clearance:
0.8 mm (0.031 in.) or less
NOTE: If the clearance exceeds the maximum, retighten it.

6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH





(a) Set SST to the outboard joint boot clamp LH and slightly tighten the SST bolt while pushing the outboard joint on.
(b) Hold SST and tighten the SST bolt so that the clearance is within the specified value.
SST: 09521-24010
Standard clearance:
0.8 mm (0.031 in.) or less
NOTE: Do not damage the outboard joint.

(c) Remove SST.





(d) Using SST, measure the clearance of the outboard joint boot clamp LH.
SST: 09240-00020
Standard clearance:
0.8 mm (0.031 in.) or less
NOTE: If the clearance exceeds the maximum, retighten it.

7. INSTALL FRONT DRIVE SHAFT DAMPER RH
HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.





(a) Install the drive shaft damper to the outboard joint LH.
Standard distance:
427 +-2.0 mm (16.81 +-0.079 in.)
NOTE: Install in the correct direction.

8. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP





(a) When using a one touch clamp:
Install the drive shaft damper clamp to the drive shaft damper and stake the drive shaft damper clamp using a flat-head screwdriver.
(b) When using a hook type:
Using needle-nose pliers, align the concave part and protrusion of the drive shaft damper clamp in order to lock it.
9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH
(a) Install the following new parts on the outboard joint LH in order.
(1) Inboard joint boot clamp
(2) Inboard joint boot
(3) No. 2 inboard joint boot clamp
(b) Hold the drive shaft in a vise between 2 aluminum plates.
NOTE: Do not overtighten the vise.

(c) Remove the protective tape.





(d) Align the matchmarks and install the tripod joint onto the outboard joint.
NOTE: Face the serration side of the tripod joint outward and install it to the outboard joint end.

(e) Using a brass bar and hammer, drive the tripod joint in.
NOTICE:
- Do not hit the roller portion.
- Do not attach any foreign matter on the tripod joint.





(f) Using a snap ring expander, install a new front drive inner shaft snap ring.
(g) Fill grease in the joint of the inboard joint and outboard joint boot.
Standard capacity:
125 to 135 g (4.4 to 4.8 oz.)





(h) Align the matchmarks and install the inboard joint onto the outboard joint.
10. INSTALL FRONT AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot into the inboard joint LH and outboard joint LH grooves.
NOTE: Do not apply grease in the groove.

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





(a) When using a one touch clamp:
Install the No. 2 inboard joint boot clamp LH to the inboard joint boot and stake the No. 2 inboard joint boot clamp LH using a flat-head screwdriver.
NOTE: Do not scratch the inboard joint boot.





(b) When using a hook type:
Using needle-nose pliers, align the concave part with the protrusion of the No. 2 inboard joint boot clamp LH in order to lock it.
NOTICE:
- Do not scratch the inboard joint boot.
- Do not deform the claw of the hook.

12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH





(a) When using a one touch clamp:
Install the inboard joint boot clamp to the inboard joint boot and stake the inboard joint boot clamp using a flat-head screwdriver.
NOTE: Do not scratch the inboard joint boot.





(b) When using a hook type:
Using needle-nose pliers, align the concave part with the protrusion of the No. 2 inboard joint boot clamp in order to lock it.
NOTICE:
- Do not scratch the inboard joint boot.
- Do not deform the claw of the hook.

13. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH





(a) Check if the front drive shaft is within the following dimension.
Standard dimension (A):






(b) Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction.
(c) Check for cracks, damage or grease leaks on the joint boot.
NOTE: Carry the front drive shaft LH levelly.
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