REAR DRIVE SHAFT (for 4WD): Reassembly

1. Using SST and a steel plate, install a new rear drive shaft dust cover.

   SST 09527-21011 

   NOTE:

   • The rear drive shaft dust cover should be completely installed.
   • Be careful not to damage the rear drive shaft dust cover.
   Fig 1: Using SST & Steel Plate To Install New Rear Drive Shaft Dust Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

Fig 2: Identifying Vinyl Tape On Drive Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Grease capacity: 95 to 105 g (3.4 to 3.7 oz.) 

1. Hold the rear drive shaft in a vise with aluminum plates in between.
2. Secure the rear drive shaft outboard joint boot clamp onto the boot.
3. Place SST onto the rear drive shaft outboard joint boot clamp.

   SST 09521-24010 

   Fig 3: Placing SST Onto Rear Drive Shaft Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
5. Using SST, inspect the clearance of the rear drive shaft outboard joint boot clamp.

   SST 09240-00020 

   Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

   NOTE: If the measured value exceeds the specified value, retighten the clamp.
   Fig 4: Measuring Clearance Of Rear Drive Shaft Outboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the front drive shaft in a vise between aluminum plates.
2. Secure the outboard joint boot clamp onto the boot.
3. Place SST onto the No. 2 rear drive shaft outboard joint boot clamp.

   SST 09521-24010 

   Fig 5: Placing SST Onto Rear Drive Shaft Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten SST so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
5. Using SST, inspect the clearance of the No. 2 rear drive shaft outboard joint boot clamp.

   SST 09240-00020 

   Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

   NOTE: If the measured value exceeds the specified value, retighten the clamp.
   Fig 6: Measuring Clearance Of No. 2 Rear Drive Shaft Outboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Wrap the splines of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.
2. Install new parts to the outboard joint shaft in the following order:
   1. No. 2 rear drive shaft inboard joint boot clamp
   2. Inboard joint boot
   3. Rear drive shaft inboard joint boot clamp
3. Place the beveled side of the tripod joint axial spline toward the outboard joint shaft assembly.
4. Align the matchmarks placed before removal.
   Fig 7: Identifying Matchmarks & Rear Drive Shaft Inboard Joint Assembly

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

   • Do not tap the rollers.
   • Be sure to install the tripod joint in the correct direction.

   Fig 8: Taping In Tripod Joint Onto Outboard Joint Shaft Assembly Using Brass Bar & Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a snap ring expander, install a new shaft snap ring.
   Fig 9: Using Snap Ring Expander To Install New Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Pack the outboard joint shaft and boot with grease.

   Grease capacity: 125.5 to 135.5 g (4.4 to 4.7 oz.) 

8. Align the matchmarks, and install the inboard joint assembly to the outboard joint shaft assembly.
   Fig 10: Identifying Matchmarks On Inboard Joint Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the inboard joint boot to the outboard joint shaft.
2. Check whether the drive shaft dimensions are within the following specifications.

   HINT:

   The following shows the dimension (A) of the drive shaft.

   Dimension (A): 754.7 to 764.6 mm (29.71 to 30.10 in.) 

   Fig 11: Identifying Drive Shaft Dimension

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the rear drive shaft in a vise with aluminum plates in between.
2. Secure the rear drive shaft inboard joint boot clamp onto the boot.
3. Place SST onto the rear drive shaft inboard joint boot clamp.

   SST 09521-24010 

   Fig 12: Placing SST Onto Rear Drive Shaft Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
5. Using SST, inspect the clearance of the rear drive shaft inboard joint boot clamp.

   SST 09240-00020 

   Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

   NOTE: If the measured value exceeds the specified value, retighten the clamp.
   Fig 13: Measuring Clearance Of Rear Drive Shaft Inboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the rear drive shaft in a vise with aluminum plates in between.
2. Secure the No. 2 rear drive shaft inboard joint boot clamp onto the boot.
3. Place SST onto the No. 2 rear drive shaft inboard joint boot clamp.

   SST 09521-24010 

   Fig 14: Placing SST Onto No. 2 Rear Drive Shaft Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
5. Using SST, inspect the clearance of the inboard joint boot clamp.

   SST 09240-00020 

   Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

   NOTE: If the measured value exceeds the specified value, retighten the clamp.
   Fig 15: Measuring Clearance Of Inboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new rear drive shaft snap ring.