FRONT DRIVE SHAFT (for 1AR-FE): Reassembly

1. Install the bearing bracket hole snap ring.
2. Using SST and a press, press in the side gear shaft holder bearing to the front drive inboard joint assembly RH.

   SST 09527-10011, 09527-30010 

Fig 1: Pressing Side Gear Shaft Holder Bearing To Front Drive Inboard Joint Assembly RH

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1. Using a snap ring expander, install a new front drive shaft hole snap ring RH.

Fig 2: Installing Front Drive Shaft Hole Snap Ring RH

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1. Using SST and a press, install a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover meets the specification, as shown in the illustration.

   SST 09726-40010, 09527-10011 

   Distance (A): 

   26.6 to 27.6 mm (1.0472 to 1.0866 in.) 

   NOTE: Be careful not to damage the dust cover.
   Fig 3: Identifying Distance Between Tip Of Center Drive Shaft And Drive Shaft Dust Cover

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

   SST 09527-10011 

Fig 4: Installing Front Drive Shaft Dust Cover LH

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1. Install a new front drive inboard joint hole snap ring LH.

1. Using SST and a press, press in a new front drive shaft dust cover RH until the distance (A) from the tip of the center drive shaft to the drive shaft dust cover reaches the specification, as shown in the illustration.

   SST 09527-10011 

   Distance (A): 

   110.0 to 111.0 mm (4.3307 to 4.3700 in.) 

Fig 5: Identifying Distance Between Tip Of Center Drive Shaft And Drive Shaft Dust Cover

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1. Before installing the boots, wrap the spline of the drive shaft with protective tape to prevent the boot from being damaged.
   Fig 6: Wrapping Spline Of Drive Shaft With Protective Tape

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2. Install new parts to the outboard joint shaft assembly in the following order:
   1. No. 2 front axle outboard joint boot clamp LH (A)
   2. Outboard joint boot (B)
   3. Front axle outboard joint boot clamp LH (C)
3. Pack the outboard joint shaft and boot with grease from the boot kit.

Fig 7: Packing Outboard Joint Shaft And Boot With Grease

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Grease capacity: 

205 to 215 g (7.2 to 7.5 oz.) 

HINT:

Perform the same procedure as for the LH side.

1. Install a new No. 2 front axle outboard joint boot clamp LH onto the outboard joint boot and temporarily fold back the lever.
   NOTE:

   • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.
   • Check the band and the lever for any deformation before folding back the lever.
   Fig 8: Installing Boot Clamp Onto Outboard Joint Boot

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2. Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.
   NOTE:

   • Make sure that the outboard joint is in direct contact with the work plane.
   • Do not damage deflector.
   Fig 9: [Rolling Outboard Joint]

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3. Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

HINT:

Perform the same procedure as for the LH side.

Fig 10: Identifying Clearance Between Lever And Groove

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1. Install a new front axle outboard joint boot clamp LH onto the outboard joint boot and temporarily fold back the lever.
   NOTE:

   • Set the lever into the guide groove correctly.
   • Check the band and the lever for any deformation before folding back the lever.
   Fig 11: Installing Front Axle Outboard Joint Boot Clamp LH Onto Outboard Joint Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using water pump pliers, pinch the front axle outboard joint boot clamp LH to temporarily secure it.
   Fig 12: Pinching Front Axle Outboard Joint Boot Clamp LH

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3. Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

HINT:

Perform the same procedure as for the LH side.

Fig 13: Tapping Buckle Using Plastic Hammer

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1. Install a new front drive shaft damper clamp LH and the front drive shaft damper LH to the front drive outboard joint shaft assembly LH.
2. Set the distance as specified below.

   Distance (A): 

   233.9 to 237.9 mm (9.21 to 9.36 in.) 

HINT:

Perform the same procedure as for the LH side.

1. Hold the front drive outboard joint shaft assembly LH in a vise using aluminum plates.
   Fig 14: Identifying Drive Shaft Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not overtighten the vise.
2. Install the front drive shaft damper clamp LH to the front drive shaft damper.
   NOTE: Be sure to install the clamp in the correct position.
3. for one touch type:
   1. Using a screwdriver, install the drive shaft damper clamp LH as shown in the illustration.
   NOTE: Do not damage the outboard joint boot.
4. for claw engagement type:
   1. Using needle-nose pliers, install a new front drive shaft damper clamp LH as shown in the illustration.

HINT:

Perform the same procedure as for the LH side.

1. Before installing the boot, wrap the spline of the front drive outboard joint assembly LH with protective tape to prevent the boot from being damaged.
   Fig 15: Installing Front Drive Shaft Damper Clamp LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install new parts to the front drive outboard joint assembly LH in the following order for one touch type:
   1. Front axle inboard joint boot clamp LH (A)
   2. Inboard joint boot (B)
   3. No. 2 front axle inboard joint boot clamp LH (C)
   Fig 16: Identifying Front Axle Inboard Joint Boot Clamp LH, Inboard Joint Boot And No. 2 Front Axle Inboard Joint Boot Clamp LH

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3. Install new parts to the front drive outboard joint assembly LH in the following order for claw engagement type:
   1. Inboard joint boot
4. Place the beveled side of the tripod axial spline toward the outboard joint.
   Fig 17: Identifying Front Drive Outboard Joint Assembly LH

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5. Align the matchmarks placed before removal.
6. Using a brass bar and a hammer, tap the tripod joint onto the front axle outboard joint shaft assembly LH.
   NOTE:

   • Do not tap the roller portion.
   • Be sure to install the tripod joint in the correct direction.
   • Keep the tripod joint free of foreign matter.
   Fig 18: Aligning Matchmarks On Front Drive Joint Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a snap ring expander, install a new shaft snap ring.
8. 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.) 

   Fig 19: Installing Shaft Snap Ring

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9. Align the matchmarks, and install the front drive inboard joint assembly LH to the front drive outboard joint shaft assembly LH.

HINT:

Perform the same procedure as for the LH side.

Fig 20: Identifying Matchmarks On Front Drive Inboard Joint Assembly LH And Front Drive Outboard Joint Shaft Assembly LH

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1. Install the inboard joint boot into the grooves of the front drive inboard joint assembly.
   NOTE: Keep the grooves free of grease.
2. Check whether the dimensions (A) of the drive shaft are within the following specifications.

Fig 21: Identifying Dimensions Of Front Drive Shaft Assembly

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Dimension (A) 

1. for one touch type:
   1. Install a new front axle inboard joint boot clamp LH onto the inboard joint boot and temporarily fold back the lever.
   NOTE:

   • Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.
   • Check the band and the lever for any deformation before folding back the lever.
   Fig 22: Installing Front Axle Outboard Joint Boot Clamp LH Onto Outboard Joint Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using water pump pliers, pinch the front axle outboard joint boot clamp LH to the temporarily secure it.
   Fig 23: Pinching Front Axle Outboard Joint Boot Clamp LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.
   NOTE: Do not damage the inboard joint boot.
   Fig 24: Tapping Buckle Using Plastic Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. for claw engagement type:
   1. Using needle-nose pliers, install a new front axle inboard joint boot clamp LH as shown in the illustration.
   NOTE: Be careful not to damage the boot.

HINT:

Perform the same procedure as for the LH side.

Fig 25: Installing Front Axle Inboard Joint Boot Clamp LH

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1. for one touch type:
   1. Install a new No. 2 front axle inboard joint boot clamp LH onto the inboard joint boot.
   2. Using a screwdriver, install a new No. 2 front axle inboard joint boot clamp LH as shown in the illustration.
   NOTE: Do not damage the inboard joint boot.
   Fig 26: Installing No. 2 Front Axle Inboard Joint Boot Clamp LH (One Touch Type)

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2. for claw engagement type:
   1. Using needle-nose pliers, install a new No. 2 front axle inboard joint boot clamp LH as shown in the illustration.
   NOTE: Be careful not to damage the boot.

HINT:

Perform the same procedure as for the LH side.

Fig 27: Installing No. 2 Front Axle Inboard Joint Boot Clamp LH (Claw Engagement Type)

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HINT:

(See INSPECTION ).