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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Drive Shaft / Propeller Shaft - Service Information >> REAR DRIVE SHAFT ASSEMBLY (for A25A-FXS) >> Reassembly [12/2019 - ] >> Procedure

Reassembly [12/2019 - ]: Procedure

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

      Standard Grease Capacity

      68 to 78 g (2.40 to 2.75 oz)

    4. Install the rear drive shaft outboard joint boot to the rear drive shaft 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.
  2. INSTALL REAR NO. 2 DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the rear No. 2 drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.
    3. Place SST onto the rear No. 2 drive shaft 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 rear No. 2 drive shaft outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

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

      Clearance

      0 to 2.1 mm (0 to 0.0827 in.)

      If the clearance is not as specified, retighten SST.

  3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the rear drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.
    3. Place SST onto the rear drive shaft outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY917433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09521-24010 
    4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the rear drive shaft outboard joint boot clamp.
      GTY439728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00021 

      Clearance

      0 to 1.3 mm (0 to 0.0512 in.)

      If the clearance is not as specified, retighten SST.

  4. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY 
    1. Install new parts to the rear drive shaft outboard joint shaft assembly in the following order:
      GTY440271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Drive Shaft Inboard Joint Boot Clamp
      *2 Rear Drive Shaft Inboard Joint Boot
      *3 Rear No. 2 Drive Shaft Inboard Joint Boot Clamp
      *a Protective Tape
      Outboard Joint Side
      Inboard Joint Side
      1. Rear drive shaft inboard joint boot clamp
      2. Rear drive shaft inboard joint boot
      3. Rear No. 2 drive shaft 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 rear drive shaft outboard joint shaft assembly.
      NOTE:

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

      GTY424060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    5. Using a brass bar and a hammer, install the tripod joint to the rear drive shaft 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 rear drive shaft outboard joint shaft assembly.
      GTY445530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pack the rear drive shaft inboard joint assembly and rear drive shaft inboard joint boot with grease.

      Standard Grease Capacity

      134 to 144 g (4.73 to 5.08 oz)

    8. Align the matchmarks and install the rear drive shaft inboard joint assembly to the rear drive shaft outboard joint shaft assembly.
      GTY659732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
  5. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT 
    1. Install the rear drive shaft inboard joint boot to the rear drive shaft inboard joint assembly.
    2. Check whether the drive shaft dimension (A) is within specification.

      Dimension (A)

      for LH Side 738.6 mm (2.42 ft.)
      for RH Side 813.6 mm (2.67 ft.)
      GTY649354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR NO. 2 DRIVE SHAFT INBOARD JOINT BOOT CLAMP 

    HINT: 

    Perform the same procedure as for the rear No. 2 drive shaft outboard joint boot clamp.

  7. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP 
    1. Secure the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the rear drive shaft inboard joint boot clamp to the rear drive shaft inboard joint boot.
    3. Place SST onto the rear drive shaft inboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY924739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09521-24010 
    4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the rear drive shaft inboard joint boot clamp.
      GTY452770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00021 

      Clearance

      0 to 1.3 mm (0 to 0.0512 in.)

      If the clearance is not as specified, retighten SST.

  8. INSPECT REAR DRIVE SHAFT ASSEMBLY 

    Refer to INSPECTION [12/2019 - ] 

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