Front Extension Housing: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL BALL BEARING 
   1. Using SST and a press, press in the ball bearing to the front extension housing.

      SST 09316-60011 (09316-00011, 09316-00031) 

      Fig 1: Pressing In Ball Bearing To Front Extension Housing Using SST & Press

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS
      
      

      Mark	Thickness mm (in.)
      A	1.70 (0.0669)
      B	1.80 (0.0709)

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL OIL SEAL 
   1. Apply MP grease to the lip of a new oil seal.
   2. Using SST and a hammer, tap in the oil seal to the front extension housing.

      SST 09316-60011 (09316-00011, 09316-00061) 

      Fig 3: Tapping In Oil Seal To Front Extension Housing Using SST & Hammer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL DUST DEFLECTOR 
   1. Using a plastic-faced hammer, install a new dust deflector to the front extension housing.
      Fig 4: Installing New Dust Deflector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST and a press, press in a new dust deflector to the front output shaft.

      SST 09316-20011, 09316-60011 (09316-00011) 

      Fig 5: Pressing In New Dust Deflector To Front Output Shaft Using SST & Press

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH HUB 
   1. Using SST and a press, press in the output shaft and drive clutch hub.

      SST 09316-20011, 09316-60011 (09316-00011, 09316-00041, 09316-00071) 

      Fig 6: Pressing In Output Shaft & Drive Clutch Hub Using SST & Press

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      A	1.80 (0.0709)	D	2.10 (0.0827)
      B	1.90 (0.0748)	E	2.20 (0.0866)
      C	2.00 (0.0787)	-	-

   3. Using a snap ring expander, install a new snap ring.
      Fig 7: Installing New Snap Ring Using Snap Ring Expander

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002