REAR DRIVE SHAFT (for 4WD): Reassembly

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. Rear drive shaft outboard joint boot No.2 clamp (A)
   2. Rear drive shaft outboard joint boot (B)
   3. Rear drive shaft outboard joint boot clamp (C)
2. Pack the outboard joint shaft and boot with grease.

   Grease capacity: 71 to 81 g (2.5 to 2.9 oz.) 

   Fig 1: Installing Outboard Joint Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the outboard joint boot clamp as shown in the illustration.
   NOTE: Be careful not to damage the boot.
   Fig 2: Installing Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the outboard joint boot No.2 clamp as shown in the illustration.
   NOTE: Be careful not to damage the boot.
   Fig 3: Identifying Outboard Joint Boot No. 2 Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install new parts to the outboard joint shaft assembly in the following order.
   1. Rear drive shaft inboard joint boot clamp (A)
   2. Rear drive shaft inboard joint boot (B)
   3. Rear drive shaft inboard joint boot No.2 clamp (C)
      Fig 4: Installing Rear Drive Shaft Inboard Joint Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cage to the rear drive outboard joint shaft assembly.
   NOTE: Face the smaller inside diameter side to the outboard joint shaft assembly and insert.
3. Hold the rear drive outboard joint shaft assembly between aluminum plates in a vise.
   NOTE: Do not overtighten the vise.
4. Align the matchmarks.
5. Using a brass bar and hammer, tap in the inner race to the rear drive outboard joint shaft.
   Fig 5: Taping In Inner Race To Rear Drive Outboard Joint Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a snap ring expander, install a new rear drive shaft snap ring.
   Fig 6: Installing New Rear Drive Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Align the matchmarks and install the cage to the inner race.
8. Apply grease to the 6 balls.
9. Install the 6 balls.
   NOTE: Be careful not to drop the balls.
10. Pack the inboard joint assembly and boot with grease.

    Grease capacity: 132 to 142 g (4.7 to 5.0 oz.) 

    Fig 7: Aligning Matchmarks

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. 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 8: Aligning Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the inboard joint boot clamp as shown in the illustration.
   NOTE: Be careful not to damage the boot.
   Fig 9: Installing Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the inboard joint boot No.2 clamp as shown in the illustration.
   NOTE: Be careful not to damage the boot.
   Fig 10: Installing Inboard Joint Boot No. 2 Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 11: Inspecting Rear Drive Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002