FRONT DRIVE SHAFT (for 2GR-FE): Reassembly

1. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.
2. Using SST, install a new front drive shaft bearing.

   SST 09527-10011, 09527-30010 

   NOTE: The bearing should be completely installed.
   Fig 1: Installing Front Drive Shaft Bearing

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3. Using a snap ring expander, install a new drive shaft hole snap ring.

Fig 2: Installing Drive Shaft Hole Snap Ring

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

   SST 09527-10011, 09726-40010 

   Distance: 

   26.6 to 27.6 mm (1.047 to 1.0866 in.) 

Fig 3: Installing Drive Shaft Dust Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new drive shaft dust cover RH until distance (A) from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification.

   SST 09527-10011 

   Distance (A): 

   110.0 to 111.0 mm (4.3307 to 4.3700 in.) 

Fig 4: Installing Front Drive Shaft Dust Cover RH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09527-10011 

   NOTE:

   • The dust cover should be completely installed.
   • Be careful not to damage the dust cover.
   Fig 5: Installing Drive Shaft Dust Cover LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform the same procedure as for the LH side.

HINT:

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

1. Install new parts to the outboard joint shaft in the following order:
   1. No. 2 front axle outboard joint boot clamp
   2. Front axle outboard joint boot
   3. Front axle outboard joint boot clamp
   Fig 6: Installing Outboard Joint Boot To Drive Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pack the front drive outboard joint shaft and front axle outboard joint boot with grease.

   Grease capacity 

   GREASE CAPACITY CHART
   
   

   2WD	170 to 190 g (6.0 to 6.7 oz.)
   4WD	100 to 120 g (3.5 to 4.2 oz.)

1. Hold the drive shaft lightly in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
2. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.
3. Place SST onto the front axle outboard joint boot clamp.

   SST 09521-24010 

4. Tighten SST so that the front axle outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 7: Tightening Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the front axle 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 is greater than the specified value, retighten the clamp.
   Fig 8: Measuring Clearance Of Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 2 front axle outboard joint boot clamp onto the front axle outboard joint boot.
2. Place SST onto the No. 2 front axle outboard joint boot clamp.

   SST 09521-24010 

3. Tighten SST so that the No. 2 front axle outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 9: Tightening No. 2 Front Axle Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, measure the clearance of the No. 2 front axle outboard joint boot clamp.

   SST 09240-00020 

   Clearance: 

   0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

Fig 10: Measuring Clearance Of No. 2 Outboard Joint Boot Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the drive shaft damper to the drive shaft.
2. Make sure that the damper is on the shaft groove.
3. Set the distance as specified below.

   Distance 

   DISTANCE REFERENCE
   
   

   2WD	LH	228.0 to 232.0 mm (8.976 to 9.134 in.)
   	RH	231.0 to 235.0 mm (9.094 to 9.252 in.)
   4WD	LH	226.9 to 230.9 mm (8.933 to 9.090 in.)
   	RH	228.2 to 232.2 mm (8.984 to 9.142 in.)

   Fig 11: Identifying Front Drive Shaft Damper LH Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the drive shaft damper clamp onto the drive shaft damper.
   NOTE: Be sure to install the clamp in the correct position.
5. Place SST onto the drive shaft damper clamp.

   SST 09521-24010 

6. Tighten SST so that the clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 12: Tightening Front Drive Shaft Damper Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, measure the clearance of the drive shaft damper clamp.

   SST 09240-00020 

   Clearance: 

   0.5 to 1.5 mm (0.0197 to 0.0591 in.) 

   NOTE: If the measured value is greater than the specified value, retighten the clamp.
   Fig 13: Measuring Clearance Of Drive Shaft Damper Clamp

   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 front drive outboard joint shaft assembly in the following order:
   1. Front axle inboard joint boot clamp
   2. Front axle inboard joint boot
   3. No. 2 front axle inboard joint boot clamp
3. Place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly.
4. Align the matchmarks placed before removal.
5. Using a brass bar and hammer, tap in the tripod joint to the front drive outboard joint shaft assembly.
   Fig 14: Identifying Matchmarks On Front Drive Inboard Joint Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Do not tap the roller.
   • Be sure to install the tripod joint assembly in the correct direction.
6. Using a snap ring expander, install a new shaft snap ring.
7. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

   Grease capacity 

   GREASE CAPACITY REFERENCE
   
   

   2WD	155 to 175g (5.5 to 6.2 oz.)
   4WD	106 to 126g (3.7 to 4.4 oz.)

   Fig 15: Installing Shaft Snap Ring

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

1. Install the front axle inboard joint boot to the front drive inboard joint assembly.
   Fig 16: Identifying Matchmarks On Front Drive Inboard Joint Assembly And Front Drive Outboard Joint Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check whether the drive shaft dimensions are within the following specifications.

   HINT:

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

   Dimension (A): 

   DIMENSION REFERENCE
   
   

   2WD	LH	600.8 to 605.4 mm (23.66 to 23.83 in.)
   	RH	920.06 to 924.66 mm (36.23 to 36.40 in.)
   4WD	LH	576.14 to 580.74 mm (22.69 to 22.86 in.)
   	RH	950.64 to 955.24 mm (37.43 to 37.60 in.)

1. Hold the drive shaft lightly in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
   Fig 17: Identifying Drive Shaft Dimensions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Secure the inboard joint boot clamp onto the boot.
3. Place SST onto the inboard joint boot clamp.

   SST 09521-24010 

4. Tighten SST so that the front axle inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 18: Tightening Front Axle Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the front axle 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 is greater than the specified value, retighten the clamp.
   Fig 19: Measuring Clearance Of Front Axle Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the inboard joint shaft assembly in a vise between aluminium plates.
   NOTE: Do not overtighten the vise.
2. Secure the No. 2 front axle inboard joint boot clamp onto the boot.
3. Place SST onto the No. 2 front axle inboard joint boot clamp.

   SST 09521-24010 

4. Tighten SST so that the No. 2 front axle inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 20: Placing SST Onto No. 2 Front Axle Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, measure the clearance of the No. 2 front axle 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 is greater than the specified value, retighten the clamp.

1. Install a new front drive shaft hole snap ring.

Fig 21: Measuring Clearance Of No. 2 Front Axle Inboard Joint Boot Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002