Front Drive Shaft: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FRONT AXLE HUB DUST SEAL
1. Using SST and a press, press in a new dust seal to the outboard joint shaft.
  SST 09950-00020
  
  NOTE: Be careful not to damage the dust seal.
  
  Fig 1: Pressing Dust Seal To Outboard Joint Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE SHAFT DUST COVER
1. Using SST, a steel plate and press, press in a new dust cover.
  SST 09316-20011
  
  NOTE: Be careful not to damage the dust cover.
  
  Fig 2: Pressing Dust Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTBOARD JOINT BOOT
1. Place 2 new boot clamps on the boot.
  HINT:
  
  Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.
2. Temporarily install a new boot to the outboard joint shaft.
3. Position the inside clamp onto the boot.
  
  Fig 3: Installing Boot To Outboard Joint Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, pinch the inside clamp.
  SST 09521-24010
  
  NOTE: Do not overtighten SST.
5. Pack the outboard joint and boot with grease in the boot kit.
  Standard grease capacity: 368 to 378 g (13.0 to 13.3 oz.)
6. Position the outside clamp onto the boot.
  
  Fig 4: Pinching Inside Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, pinch the outside clamp.
  SST 09521-24010
  
  NOTE: Do not overtighten SST.
  
  Fig 5: Pinching Outside Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using SST, adjust the clearance of the clamps.
  SST 09240-00020
  
  Standard clearance: 0.8 mm (0.031 in.)
TEMPORARILY INSTALL INBOARD JOINT BOOT
1. Temporarily install 2 new boot clamps and a boot to the outboard joint shaft.
  
  Fig 6: Adjusting Clearance Of Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE FRONT AXLE INBOARD JOINT SET
1. Install the cage to the outboard joint shaft.
  NOTE: Insert the cage with its smaller inner diameter side facing the outboard joint.
  
  Fig 7: Identifying Cage Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the matchmarks placed before removal.
3. Install the inner race.
4. Using a snap ring expander, install a new snap ring.
5. Align the matchmarks placed before removal, and install the cage to the inner race.
6. Install the 6 balls.
  HINT:
  
  Apply grease onto the balls to keep them from falling.
7. Pack the inboard joint tulip and boot with grease in the boot kit.
  Standard grease capacity: 293 to 303 g (10.3 to 10.7 oz.)
8. Align matchmarks placed before removal, and install the inboard joint tulip to the outboard joint shaft.
9. Install a new snap ring.
10. Temporarily install the boot to the inboard joint tulip.
11. Make sure that the boot is on the shaft groove.
12. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
  Standard drive shaft length A: 573.9 +/- 5.0 mm (22.594 +/- 0.197 in.)
13. Using a screwdriver, bend the clamps and lock them.
  
  Fig 8: Identifying Drive Shaft Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FRONT DRIVE SHAFT ASSEMBLY (See FRONT DRIVE SHAFT )