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Axle Shafts: Reassembly

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using press, install new front axle bearing.
  2. Using snap ring expander, install new axle shaft hole snap ring.
  3. Using press, install new axle shaft dust cover. See Fig 1.
    NOTE: The clearance between axle shaft dust cover and axle shaft bearing should at specified distance of 1.68-1.72 in. (41.6-42.6 mm).
    Fig 1: Installing Front Axle Shaft Dust Cover
    G00309976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Using press, stall new dust cover on right axle shaft inboard joint. The distance from the tip of the center axle shaft to the right axle shaft dust cover reaches the specific distance of 4.38-4.42 in. (110-111 mm). See Fig 2
    Fig 2: Installing Right Axle Shaft Dust Cover
    G00299409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Using press, install new left axle inboard joint dust cover. See Fig 3.
    Fig 3: Installing Left Axle Shaft Dust Cover
    G00299410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install new axle shaft hole snap ring.
  7. Temporarily install new outboard joint boot with 2 clamps on axle shaft. Before installing boot, wrap spline of axle shaft with vinyl tape to prevent boots from being damaged.
  8. Pack outboard joint shaft and boot with specified grease from boot kit. For grease specifications, see BOOT GREASE SPECIFICATIONS .
  9. Mount axle shaft in soft vise and secure 2 outboard joint clamps onto boot.
  10. Using appropriate clamp tightening tool on outboard joint boot clamps, tighten the tool so that the large clamp is pinched. DO NOT overtighten tool. See Fig 4.
    Fig 4: Installing Outboard Joint Boot Clamp
    G00299413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Adjust the clearance of the clamps. Clearance should be approximately .032 in. (.8 mm). See Fig 5.
    Fig 5: Adjusting Clamp Clearances
    G00299414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Install left axle shaft damper and clamp. For ES300 models, damper distance should be set to approximately 7.971-8.129 in. (202.4-206.4 mm). For ES330 models, damper distance should be set to approximately 8.791-8.949 in. (223.4-227.4 mm). Ensure that the left axle shaft damper is on shaft groove and secure damper clamp. See Fig 6.
    Fig 6: Installing Front Axle Shaft Damper
    G00299428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. Place beveled side of tripod axial spline toward outboard joint shaft and align marks placed before removal.
  14. Using brass drift and hammer, tap in tripod to outboard shaft. DO NOT tap the roller.
  15. Using snap ring expander, install new tripod retaining snap ring on axle shaft.
  16. Pack inboard joint shaft and inboard joint boot with grease from boot kit. For grease specifications, see BOOT GREASE SPECIFICATIONS .
  17. Install axle inboard joint boot to outboard joint shaft. Install inboard joint boot clamps.
  18. Inspect axle shaft. Ensure that the 2 boots are on the shaft groove and the boots are not stretched or contracted while axle shafts are at standard length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig 7.
    Fig 7: Measuring Axle Shaft Standard Length
    G96B01298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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