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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Drive Shaft / Propeller Shaft - Service Information >> FRONT DRIVE SHAFT ASSEMBLY (for 2GR-FKS) >> Reassembly [12/2019 - 10/2022] >> Procedure

Reassembly [12/2019 - 10/2022]: Procedure

  1. INSTALL FRONT DRIVE SHAFT BEARING (for AWD RH Side) 
    1. Using SST, a steel plate and a press, install a new front drive shaft bearing.
      GTY433479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      • SST: 09527-10011 
      NOTE:

      The bearing should be completely installed.

    2. Using a snap ring expander, install a new drive shaft hole snap ring.
      GTY441319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the drive shaft hole snap ring securely.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for AWD RH Side) 
    1. Using a steel plate and a press, install a new front drive shaft dust cover RH until the dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

      Dimension (A)

      341.7 to 342.3 mm (13.45 to 13.48 in.)

      GTY614483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      NOTE:

      Be careful not to damage the front drive shaft dust cover RH.

  3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.
      GTY447139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Install new parts to the front drive outboard joint shaft assembly in the following order:
      GTY425440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      Outboard Joint Side
      Inboard Joint Side
      1. Front No. 2 axle outboard joint boot clamp
      2. Front axle outboard joint boot
      3. Front axle outboard joint boot clamp
    4. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

      Standard Grease Capacity

      115 to 135 g (4.06 to 4.76 oz)

    5. Install the front axle outboard joint boot to the front drive outboard joint shaft assembly groove.
      NOTE:
      • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.
      • Keep the inside of the outboard joint boot free of foreign matter.
  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front axle outboard joint boot clamp to the front axle outboard joint boot.
    3. Place SST to the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY695519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09521-24010 
    4. Tighten SST so that the front axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front axle outboard joint boot clamp.
      GTY437912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00021 

      Clearance

      1.2 to 4.0 mm (0.0472 to 0.1575 in.)

      If the clearance is not as specified, retighten SST.

  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.
    3. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY720984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09521-24010 
    4. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.
      GTY711420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00021 

      Clearance

      1.2 to 4.0 mm (0.0472 to 0.1575 in.)

      If the clearance is not as specified, retighten SST.

  6. INSTALL FRONT DRIVE SHAFT DAMPER 
    1. Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.
      GTY767783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Drive Shaft Damper Clamp
      *2 Front Drive Shaft Damper
    2. Set the dimension (A) as specified below.

      Dimension (A)

      for LH Side 240.7 to 244.7 mm (9.48 to 9.63 in.)
      for RH Side 242.7 to 246.7 mm (9.56 to 9.71 in.)
  7. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Using needle-nose pliers, install the 2 front drive shaft damper clamps as shown in the illustration.
      GTY429228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to install the clamps in the correct position.
      • Do not damage the front drive shaft damper.
  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY 
    1. Install new parts to the front drive outboard joint shaft assembly in the following order:
      GTY440271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      Outboard Joint Side
      Inboard Joint Side
      1. Front axle inboard joint boot clamp
      2. Front axle inboard joint boot
      3. Front No. 2 axle inboard joint boot clamp
    2. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    3. Remove the protective tape.
    4. Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.
      NOTE:

      Face the serrated side of the tripod joint outward and install it to the outboard joint end.

      GTY426614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    5. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.
      NOTE:
      • Do not tap the rollers.
      • Keep the tripod joint free of foreign matter.
      • Be sure to install the tripod joint in the correct direction.
    6. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.
      GTY918656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pack the front drive inboard joint assembly and front axle inboard joint boot with grease.

      Standard Grease Capacity

      220 to 240 g (7.76 to 8.47 oz)

    8. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.
      GTY741738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
  9. INSTALL FRONT AXLE INBOARD JOINT BOOT 
    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.
    2. Check whether the dimension (A) of each drive shaft is within the specification.
      NOTE:

      Keep the drive shaft assembly level during inspection.

      GTY751187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for LH Side
      *B for RH Side

      Dimension (A)

      for LH Side 621.1 mm (2.04 ft.)
      for RH Side for 2WD 946.5 mm (3.10 ft.)
      for AWD 949 mm (3.11 ft.)
  10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front axle inboard joint boot clamp to the front axle inboard joint boot.
    3. Place SST onto the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.
      • SST: 09521-24010 
      GTY729505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front axle inboard joint boot clamp.
      • SST: 09240-00021 

      Clearance

      1.2 to 4.0 mm (0.0472 to 0.1575 in.)

      If the clearance is not as specified, retighten SST.

      GTY452770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front No. 2 axle inboard joint boot clamp to the front axle inboard joint boot.
    3. Place SST onto the front No. 2 axle inboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY690095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09521-24010 
    4. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.
      GTY438716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00021 

      Clearance

      1.2 to 4.0 mm (0.0472 to 0.1575 in.)

      If the clearance is not as specified, retighten SST.

  12. INSPECT FRONT DRIVE SHAFT ASSEMBLY 

    See step  1

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