REAR DRIVE SHAFT (for 4WD): Reassembly

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

   SST 09527-21011 

Fig 1: Installing 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.

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.

Fig 2: Wrapping Splines Of Drive Shaft With Vinyl Tape

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 

4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 3: Tightening Rear Drive Shaft Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.) 

Fig 4: Measuring Clearance Of Rear Drive Shaft Outboard Joint Boot Clamp

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 

4. Tighten SST so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 5: Tightening No. 2 Rear Drive Shaft Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.) 

Fig 6: Measuring Clearance Of No. 2 Rear Drive Shaft Outboard Joint Boot 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 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 On Outboard Joint Shaft 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: Tapping Tripod Joint Onto Outboard Joint Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a snap ring expander, install a new shaft snap ring.
7. Pack the outboard joint shaft and boot with grease.

   Grease capacity: 

   125.5 to 135.5 g (4.4 to 4.7 oz.) 

   Fig 9: Installing Shaft Snap Ring

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

1. Install the inboard joint boot to the outboard joint shaft.
   Fig 10: Identifying Matchmarks On Inboard Joint Assembly And 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): 

   754.7 to 764.6 mm (29.71 to 30.10 in.) 

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.
   Fig 11: Identifying Drive Shaft Dimensions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST onto the rear drive shaft inboard joint boot clamp.

   SST 09521-24010 

4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 12: Tightening Rear Drive Shaft Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.) 

Fig 13: Measuring Clearance Of Rear Drive Shaft Inboard Joint Boot Clamp

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 

4. Tighten SST so that the rear drive shaft inboard joint boot clamp is pinched.
   NOTE: Do not overtighten SST.
   Fig 14: Tightening Rear Drive Shaft Inboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.) 

Fig 15: Measuring Clearance Of Inboard Joint Boot Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new rear drive shaft snap ring.