Front Axle Shafts: Reassembly

WARNING: This page is about a different car, the 2001 Toyota Sequoia, 2001 Toyota RAV4, 2001 Toyota MR2, and 2001 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.

Wrap splines on axle shaft ends with plastic tape to prevent damage during reassembly. On FWD models, using a press, install new bearing. Install bearing case sub assembly and a new snap ring into bearing case. Using a press, install bearing case to inboard joint. Install a new snap ring.
Using a press, install new dust cover. Ensure dust cover is positioned on shaft so distance from end of center drive shaft to dust cover is 3.58-3.62" (91-92 mm).
On 4WD models, using a press, install new dust cover. Install a new snap ring on axle shaft. Temporarily install new outboard joint boot with 2 clamps to axle shaft. Apply grease supplied with overhaul kit to outboard joint and boot. Install boot and boot clamps onto outboard joint.
Mount axle shaft in a soft jawed vise. Tighten 2 outboard joint clamps. Install drive shaft damper. Ensure damper is positioned on shaft groove and distance is set to 8.13-8.28" (202.4-206.4 mm). See Fig 1.
On LH axle shaft, position beveled side of tripod axial spline toward outboard joint. Align reference marks. Using brass punch and hammer, tap tripod onto axle shaft.
Apply grease supplied with overhaul kit to inboard joint shaft and boot. Install inboard boot onto outboard joint shaft. Secure inboard boot clamps.

Fig 1: Measuring Front Axle Shaft Length (Highlander)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

On FWD models, install NEW dust deflector onto axle shaft. Using a pin punch and hammer, install straight pin into bearing case. Using a press, install NEW bearing into bearing case. Install snap ring.
Using a press, install bearing assembly on axle shaft. Install NEW snap ring. Press NEW dust cover against bearing, leaving .039" (1.0 mm) between bearing and dust cover.
Using a press, install NEW dust cover onto axle shaft. Right-side (transaxle side) dust cover must be positioned 3.39-3.43" (86.0-87.0 mm) from end of axle shaft. Wrap splines on axle shaft with tape to prevent damaging boots during installation. Install NEW boots and NEW boot clamps onto axle shaft.
Apply grease supplied with overhaul kit to outboard joint and boot. Install dynamic damper and NEW clamps Install boot and boot clamps onto outboard joint.
Install inboard tripod joint onto axle shaft, with reference mark aligned. Using a hammer and brass drift, drive on inner race until fully seated on axle shaft. DO NOT allow brass drift to contact cage on inboard tripod joint during installation.
Install NEW snap ring on end of axle shaft. Apply grease supplied with overhaul kit into inboard joint housing and boot.
Install boot on inboard joint cover. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig 1. Position dynamic damper on outboard end of left axle shaft. Tighten dynamic damper clamps and install and tighten boot clamps.

Fig 1: Measuring Front Axle Shaft Length (RAV4)

Using a screwdriver and hammer, install a new dust cover. Using a screwdriver and hammer, install a new dust seal. Before reassembly, wrap splined axle shaft ends with plastic tape to prevent damage.
Temporarily install outboard and inboard joint boots and clamps. Apply grease supplied with kit to outboard joint and boot. Apply grease supplied with kit to inboard joint and boot. Temporarily install inboard boot to inboard joint shaft.
Ensure both boots are positioned on axle shaft groove. Ensure boots are not stretched or contracted when axle shaft is at standard length. Drive shaft standard length is 20.53-20.69" (521.5-525.5 mm). See Fig 1.
Position large inboard joint boot clamp and secure clamp. Position remaining boot clamps and secure.

Fig 1: Measuring Front Axle Shaft Length (Sequoia)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002