Front Drive Shaft: Reassembly

1. Using SST and a press, install a new front drive shaft bearing.

   SST 09726-40010, 09527-10011 

   NOTE: Bearing should be completely installed.
   Fig 1: Installing Front Drive Shaft Bearing

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1. Using a snap ring expander, install a new front drive shaft RH hole snap ring.
   Fig 2: Installing Drive Shaft Bearing Snap Ring

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1. Using SST and a press, install a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover meets the specification, as shown in the illustration.

   SST 09726-40010, 09527-10011 

   Distance (A): 26.8 to 27.4 mm (1.0551 to 1.0787 in.) 

   Fig 3: Identifying Distance Between Tip Of Center Drive Shaft And Drive Shaft Dust Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new drive shaft dust cover LH.

   SST 09527-10011 

   NOTE:

   • Dust cover should be completely installed.
   • Be careful not to damage the dust cover.
     Fig 4: Locating Front Drive Shaft Dust Cover

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.

   SST 09527-10011 

   Distance (A): 109.5 mm (4.311 in.) 

   Fig 5: Identifying Distance Between Tip Of Center Drive Shaft And Drive Shaft Dust Cover RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new hole snap ring to the inboard joint shaft assembly.

HINT:

Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.

1. Install new parts to the outboard joint shaft assembly in the following order.
   1. Outboard joint boot No.2 clamp (A)
   2. Outboard joint boot (B)
   3. Outboard joint boot clamp (C)
2. Pack the outboard joint shaft and boot with grease.

   Grease capacity: 205 to 225 g (7.2 to 7.9 oz.) 

   Fig 6: Installing Outboard Joint Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the outboard joint shaft assembly between aluminum plates in a vise.
   NOTE: Do not overtighten the vise.
2. Install the outboard joint boot No.2 clamp onto the boot.
3. Place SST onto the outboard joint boot No.2 clamp.

   SST 09521-24010 

4. Tighten the SST so that the outboard joint boot No.2 clamp is pinched.

   SST 09521-24010 

   NOTE: Do not overtighten the SST.
   Fig 7: Tightening SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the outboard joint boot No.2 clamp.

   SST 09240-00020 

   Clearance: 0.8 mm (0.031 in.) or less 

   NOTE: When the measured value is greater than the specified value, retighten the clamp.
   Fig 8: Measuring Clearance Of Front Axle Outboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the outboard joint boot clamp perform the same procedures as for the outboard joint boot No.2 clamp.

1. Install the drive shaft damper to the drive shaft.
2. Make sure that the damper is on the shaft groove.
3. Set the distance, as specified below.

   Distance (A): 225.5 to 229.5 mm (8.8779 to 9.0354 in.) 

   Fig 9: Identifying Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the outboard joint shaft assembly between aluminum plates in a vise.
   NOTE: Do not overtighten the vise.
2. Install the drive shaft damper clamp to the damper.
   NOTE: Be sure to install the clamp in the correct position.
3. Place SST onto the drive shaft damper clamp.

   SST 09521-24010 

4. Tighten the SST so that the clamp is pinched.

   SST 09521-24010 

   NOTE: Do not overtighten the SST.
   Fig 10: Tightening SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the drive shaft damper clamp.

   SST 09240-00020 

   Clearance: 0.8 mm (0.031 in.) or less 

   NOTE: Using SST, measure the clearance of the drive shaft damper clamp.
   Fig 11: Measuring Clearance Of Drive Shaft Damper Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install new parts to the inboard joint shaft assembly in the following order.
   1. Inboard joint boot clamp (A
   2. Inboard joint boot (B)
   3. Inboard joint boot No.2 clamp (C)
2. Hold the outboard joint shaft assembly between aluminum plates in a vise.
   NOTE: Do not overtighten the vise.
3. Place the beveled side of the tripod axial spline toward the outboard joint shaft.
   Fig 12: Installing Inboard Joint Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 13: Aligning Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the matchmarks.
5. Using a brass bar and hammer, tap in the tripod to the outboard joint shaft.
   NOTE:

   • Do not tap the roller.
   • Be sure to install the tripod in the correct direction.
     Fig 14: Installing Tripod Joint Assembly

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a snap ring expander, install a new front inner shaft snap ring.
7. Pack the inboard joint shaft and boot with grease.

   Grease capacity: 155 to 175 g (5.5 to 6.2 oz.) 

   Fig 15: Installing Front Inner Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Align the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.

1. Install the inboard joint boot to the inboard joint assembly.
   Fig 16: Aligning Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the outboard joint shaft assembly between aluminum plates in a vise.
   NOTE: Do not overtighten the vise.
2. Install the inboard joint boot No.2 clamp onto the boot.
3. Place SST onto the inboard joint boot No.2 clamp.

   SST 09521-24010 

4. Tighten the SST so that the inboard joint boot No.2 clamp is pinched.

   SST 09521-24010 

   NOTE: Do not overtighten the SST.
   Fig 17: Tightening SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the inboard joint boot No.2 clamp.

   SST 09240-00020 

   Clearance: 0.8 mm (0.031 in.) or less 

   NOTE: When the measured value is greater than the specified value, retighten the clamp.
   Fig 18: Measuring Clearance Of Inboard Joint Boot No. 2 Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the outboard joint boot clamp perform the same procedures as for the inboard joint boot No.2 clamp.

1. Check that there is no excessive play in the outboard joint.
2. Check that the inboard joint slides smoothly in the thrust direction.
3. Check that there is no excessive play in the radial directions of the inboard joint.
4. Check the boots for damage.
   Fig 19: Inspecting Front Drive Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002