FRONT DRIVE SHAFT ASSEMBLY (for 2ZR-FE): Reassembly: Reassembly

INSTALL FRONT DRIVE SHAFT DUST COVER
1. Using SST and a press, install a new dust cover into the front drive inboard joint assembly until it is flush with the end.
  
  Fig 1: Installing Front Drive Shaft Dust Cover Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09527-10011
  NOTE:
  - Install the dust cover in the correct direction.
  - Do not deform the dust cover.
INSTALL OUTBOARD JOINT BOOT
1. Wrap the splines of the outboard joint shaft with protective tape to prevent the boot from being damaged.
  
  Fig 2: View Of Protective Tape Around Splines Of Outboard Joint Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install new parts onto the outboard joint shaft in the following order.
  1. No. 2 front axle outboard joint boot clamp
  2. Outboard joint boot
  3. Front axle outboard joint boot clamp
3. Pack the joint portion of the front axle outboard joint shaft and outboard joint boot with grease.
  Grease capacity
  
  85 to 105 g (3.0 to 3.7 oz.)
4. Install the outboard joint boot onto the outboard joint shaft groove.
  NOTE:
  Keep the groove free of grease.
INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP
1. Hold the outboard joint shaft in a vise using aluminum plates.
  NOTE:
  Do not overtighten the vise.
2. Place SST onto the boot clamp, press it against the boot and slightly tighten SST.
  
  Fig 3: Tightening No. 2 Front Axle Outboard Joint Boot Clamp Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09521-24010
3. Tighten SST so that the clearance comes within the specified range.
  NOTE:
  Do not overtighten SST.
4. Remove SST.
5. Using SST, measure the clearance of the boot clamp as shown in the illustration.
  
  Fig 4: Measuring Clearance Of Boot Clamp Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09240-00020
  Standard clearance
  
  1.2 to 4.0 mm (0.0473 to 0.157 in.)
  
  NOTE:
  If the clearance is outside the specified range, retighten SST.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP
1. Place SST onto the boot clamp, press it against the boot and slightly tighten SST.
  
  Fig 5: Tightening Front Axle Outboard Joint Boot Clamp Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09521-24010
2. Tighten SST so that the clearance comes within the specified range.
  NOTE:
  Do not overtighten SST.
3. Remove SST.
4. Using SST, measure the clearance of the boot clamp as shown in the illustration.
  
  Fig 6: Measuring Clearance Of Boot Clamp Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09240-00020
  Standard clearance
  
  1.2 to 4.0 mm (0.0473 to 0.157 in.)
  
  NOTE:
  If the clearance is outside the specified range, retighten SST.
INSTALL FRONT DRIVE SHAFT DAMPER RH
1. Install the drive shaft damper onto the front axle outboard shaft assembly as shown in the illustration.
  
  Fig 7: Identifying Front Drive Shaft Damper Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Dimension (A)
  
  429.5 to 433.5 mm (1.41 to 1.42 ft.)
INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH
1. Using pliers, install a new drive shaft damper clamp as shown in the illustration.
  
  Fig 8: Remove/Install Front Drive Shaft Damper Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
1. Temporarily install new parts onto the outboard joint shaft in the following order.
  1. Front axle inboard joint boot clamp
  2. Inboard joint boot
  3. No. 2 front axle inboard joint boot clamp
2. Secure the front axle outboard joint shaft in a vise using aluminum plates.
  NOTE:
  Do not overtighten the vise.
3. Remove the protective tape.
4. Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft assembly.
  
  Fig 9: Aligning Tripod Joint Matchmarks Onto Front Axle Outboard Joint Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Face the serrated side of the tripod joint outward and install it onto the outboard joint end.
5. Using a brass bar and a hammer, install the tripod joint to the front axle outboard joint shaft assembly.
  NOTE:
  - Do not hit the roller portion.
  - Keep the tripod joint free of foreign matter.
6. Using a snap ring expander, install a new snap ring to the front axle outboard joint shaft assembly.
  
  Fig 10: Remove/Install Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Pack the inboard joint with grease.
  Grease capacity
  
  110 to 130 g (3.9 to 4.6 oz.)
8. Align the matchmarks and install the inboard joint onto the front axle outboard joint shaft assembly.
  
  Fig 11: Identifying Matchmarks On Inboard Joint And Outboard Joint Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INBOARD JOINT BOOT
1. Install the inboard joint boot to the inboard joint assembly.
INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP
1. Using pliers, install a new No. 2 front axle inboard joint boot clamp as shown in the illustration.
  
  Fig 12: Remove/Install No. 2 Front Axle Inboard Joint Boot Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

Using pliers, install a new front axle inboard joint boot clamp as shown in the illustration.

Fig 13: Remove/Install Front Axle Inboard Joint Boot Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check whether dimension (A) of the drive shaft is within the following specification.

Fig 14: Identifying Front Drive Shaft Dimension

Dimension (A)

LH side	RH side
580.3 mm (1.90 ft.)	856.3 mm (2.81 ft.)

INSPECT FRONT DRIVE SHAFT See step 1