FRONT DRIVE SHAFT ASSEMBLY (for 2WD): Reassembly

1. Install the bearing snap ring.
2. Using SST and a press, press in the drive shaft bearing case to the inboard joint RH.

   SST 09527-10011, 09710-04081 

   NOTE: The bearing should be installed completely.
   Fig 1: Pressing In Drive Shaft Bearing Case To Inboard Joint RH

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3. Using a snap ring expander, install a new snap ring.
   Fig 2: Installing New Snap Ring

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

   SST 09726-40010, 09527-10011 

   Standard dust cover depth:: 

   1 mm (0.04 in.) 

   NOTE: Be careful not to damage the dust cover.
   Fig 3: Pressing In New Drive Shaft Dust Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover reaches the specification, as shown.
   Fig 4: Installing Front Drive Shaft Dust Cover RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09527-10011 

   Standard distance 

   STANDARD DISTANCE
   
   

   Item	Distance
   2AZ-FE	91.0 to 92.0 mm (3.583 to 3.622 in.)
   2GR-FE	110 to 111 mm (4.330 to 4.370 in.)

   NOTE: Be careful not to damage the dust cover.

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

   SST 09527-10011 

   Fig 5: Installing Front Drive Shaft Dust Cover LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • The dust cover should be installed so that the drive shaft contacts the dust cover at the location indicated by the arrows in the illustration.
   • Be careful not to damage the dust cover.

1. Install a new hole snap ring.

HINT:

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

Fig 6: Wrapping Spline Of Drive Shaft With Vinyl Tape

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1. Install new parts to the outboard joint shaft in the following order.
   1. Outboard joint boot No. 2 clamp
   2. Outboard joint boot
   3. Outboard joint boot clamp
2. Pack the outboard joint shaft and boot with grease from the boot kit.

   Standard grease capacity 

   STANDARD GREASE CAPACITY
   
   

   Item	Grease capacity
   2AZ-FE	190 to 200 g (6.7 to 7.1 oz.)
   2GR-FE	205 to 215 g (7.2 to 7.6 oz.)

1. Install a new boot clamp to the outboard joint boot and temporarily bend the lever.
   NOTE:

   • When temporarily bending the lever, make sure not to deform the band and lever.
   • Set the clamp correctly in the guide groove and align it with the interior of the vehicle as much as possible.
     Fig 7: Installing Front Axle Outboard Joint Boot No. 2 Clamp

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. With the joint on the working surface, use your body weight to press down on the joint with one hand. Then, roll the joint forward, as shown in Fig 8, and press the lever in until a "click" sound is heard.
   NOTE:

   • Do not damage the deflector.
   • Make sure the joint is in full contact with the joint surface at all times.
     Fig 8: Rolling Joint Forward

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer, fix the buckle into place by tapping it. At the same time, use the plastic-faced hammer to adjust the lift of the lever so that the gaps between the buckle flange and lever end flange become even.
   NOTE: Do not damage the boot.
   Fig 9: Using A Plastic-Faced Hammer, Fix Buckle Into Place By Tapping

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new boot clamp to the outboard joint boot and temporarily bend the lever.
   NOTE: When temporarily bending the lever, make sure not to deform the band and lever.
   Fig 10: Installing Front Axle Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using water pump pliers, temporarily lock the boot clamp by clamping it down until a "click" sound is heard.
   Fig 11: Locking Boot Clamp By Clamping

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3. Using a plastic-faced hammer, fix the buckle into place by tapping it. At the same time, use the plastic-faced hammer to adjust the lift of the lever so that the gaps between the buckle flange and lever end flange become even.
   NOTE: Do not strike the drive shaft forcefully with the plastic-faced hammer.
   Fig 12: Measuring Gaps Between Buckle Flange And Lever End Flange

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new drive shaft damper clamp and the drive shaft damper to the drive shaft.

   HINT:

   Install the damper clamp to outboard joint side.

2. Set the distance, as described below.

   Standard distance: 

   161 to 165 mm (6.339 to 6.496 in.) 

   Fig 13: Installing Front Drive Shaft Damper LH (For LH)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the front drive shaft lightly in a soft vise.
2. Install the drive shaft damper clamp to the damper.
   NOTE: Be sure to install the clamp in the correct position.
3. One touch type:

   Using a screwdriver, install the drive shaft damper clamp, as shown in the illustration.

4. Claw engagement type:

   Using needle-nose pliers, install the drive shaft damper clamp, as shown in the illustration.

Fig 14: Installing Drive Shaft Damper Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
2. Install new parts to the outboard joint shaft in the following order.
   1. Inboard joint boot clamp
   2. Inboard joint boot No. 2 clamp
   3. Inboard joint boot
3. Place the beveled side of the tripod axial spline toward the outboard joint.
4. Align the matchmarks placed before removal.
   Fig 15: Aligning Matchmarks, And Installing Inboard Joint To Outboard Joint Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and hammer, tap the tripod joint onto the drive shaft.
   NOTE:

   • Do not tap the rollers.
   • Be sure to install the tripod joint in the correct direction.
6. Pack the inboard joint shaft and boot with grease from the boot kit.

   Standard grease capacity: 

   175 to 185 g (6.2 to 6.5 oz.) 

7. Using a snap ring expander, install a new shaft snap ring.
   Fig 16: Installing Inboard Joint Boot Clamp

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

HINT:

Use the same procedures described for the LH side.

1. Install the inboard joint boot to the inboard joint.

1. One touch type:

   Using a screwdriver, install the inboard joint boot clamp, as shown in Fig 17.

   NOTE: Be careful not to damage the boot.
2. Claw engagement type:

   Using needle-nose pliers, install the inboard joint boot clamp, as shown in the illustration.

   NOTE: Be careful not to damage the boot.
   Fig 17: Installing Inboard Joint Boot Clamp

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1. One touch type:

   Using a screwdriver, install the No. 2 inboard joint boot clamp, as shown in Fig 18.

   NOTE: Be careful not to damage the boot.
2. Claw engagement type:

   Using needle-nose pliers, install the No. 2 inboard joint boot clamp, as shown in the illustration.

   NOTE: Be careful not to damage the boot.
   Fig 18: Installing No. 2 Inboard Joint Boot Clamp

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1. Check that there is no severe play in the radial direction of the outboard joint.
2. Check that the inboard joint slides smoothly in the thrust direction.
3. Check that there is no severe play in the radial direction of the inboard joint.
   Fig 19: Inspecting Front Drive Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the boots for damage.
   NOTE: Keep the drive shaft assembly level during inspection.

   HINT:

   For dimension (A), refer to the following values.

   Fig 20: Inspecting Front Drive Shaft Measuring A

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   Standard reference value 

   STANDARD REFERENCE VALUE
   
   

   Item	Drive shaft LH (Dimension)	Drive shaft RH (Dimension)
   2AZ-FE	585.2 mm (23.039 in.)	902.0 mm (35.512 in.)
   2GR-FE	570.9 mm (22.476 in.)	914.4 mm (36.000 in.)