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Front Drive Shaft Assembly: Reassembly: Reassembly

  1. INSTALL SIDE GEAR SHAFT HOLDER BEARING (for RH Side) 
    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.
      Fig 1: Front Drive Shaft Bearing Using SST
      GTY180295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      • SST: 09527-30010 
      NOTE:

      The bearing should be completely installed.

    3. Using a snap ring expander, install a new drive shaft hole snap ring.
      Fig 2: Installing Drive Shaft Hole Snap Ring
      GTY140411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side) 
    1. Using SST and a press, install a new drive shaft dust cover.
      Fig 3: Identifying Front Drive Shaft Dust Cover (For RH Side)
      GTY208982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      • SST: 09726-40010 

      Distance

      26.6 to 27.6 mm (1.047 to 1.0866 in.)

      NOTE:
      • The dust cover should be completely installed.
      • Be careful not to damage the dust cover.
  3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for RH Side) 
    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.
      Fig 4: Identifying Front Drive Shaft Dust Cover (For RH Side)
      GTY201561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 

      Distance (A)

      110.0 to 111.0 mm (4.3307 to 4.3700 in.)

      NOTE:
      • The dust cover should be completely installed.
      • Be careful not to damage the dust cover.
  4. INSTALL FRONT DRIVE SHAFT DUST COVER LH (for LH Side) 
    1. Using SST and a press, install a new drive shaft dust cover LH.
      Fig 5: Installing Drive Shaft Dust Cover LH
      GTY154527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      NOTE:
      • The dust cover should be completely installed.
      • Be careful not to damage the dust cover.
  5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT 

    HINT: 

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

    Fig 6: Installing Outboard Joint Boot To Drive Shaft
    GTY156520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
    2. Pack the front drive outboard joint shaft and front axle outboard joint boot with grease.

      Grease capacity

      170 to 190 g (6.0 to 6.7 oz.)

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    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.
      Fig 7: Tightening Outboard Joint Boot Clamp
      GTY133305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the front axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Using SST, measure the clearance of the front axle outboard joint boot clamp.
      Fig 8: Measuring Clearance Of Outboard Joint Boot Clamp
      GTY103462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.8 mm (0.0315 in.) or less

      NOTE:

      If the measured value is greater than the specified value, retighten the clamp.

  7. INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    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.
      Fig 9: Installing No. 2 Front Axle Outboard Joint Boot Clamp
      GTY178183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    3. Tighten SST so that the No. 2 front axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    4. Using SST, measure the clearance of the No. 2 front axle outboard joint boot clamp.
      Fig 10: Measuring Clearance Of No. 2 Outboard Joint Boot Clamp
      GTY156466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.8 mm (0.0315 in.) or less

      NOTE:

      If the measured value is greater than the specified value, retighten the clamp.

  8. INSTALL FRONT DRIVE SHAFT DAMPER 
    1. Install the drive shaft damper to the drive shaft.
      Fig 11: Identifying Front Drive Shaft Damper Distance
      GTY208923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the damper is on the shaft groove.
    3. Set the distance as specified below.

      Distance (A)

      231.0 to 235.0 mm (9.094 to 9.252 in.)

    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.
      Fig 12: Placing SST Onto Drive Shaft Damper Clamp
      GTY200884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    6. Tighten SST so that the clamp is pinched.
      NOTE:

      Do not overtighten SST.

    7. Using SST, measure the clearance of the drive shaft damper clamp.
      Fig 13: Measuring Clearance Of Drive Shaft Damper Clamp
      GTY138670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.8 mm (0.0315 in.) or less

      NOTE:

      If the measured value is greater than the specified value, retighten the clamp.

  9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY 
    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:
      Fig 14: Identifying Matchmarks On Front Drive Inboard Joint Assembly
      GTY200594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
      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.
      Fig 15: Identifying Snap Ring
      GTY154769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

      Grease capacity

      155 to 175 g (5.5 to 6.2 oz.)

    8. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.
      Fig 16: Identifying Matchmarks On Front Drive Inboard Joint Assembly And Front Drive Outboard Joint Shaft Assembly
      GTY208912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT AXLE INBOARD JOINT BOOT 
    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.
    2. Check whether the drive shaft dimensions are within the following specifications.
      Fig 17: Identifying Drive Shaft Dimensions
      GTY176695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      DIMENSION (A) :

      LH 591.8 to 596.4 mm (23.30 to 23.48 in.)
      RH 933.06 to 937.66 mm (36.74 to 36.91 in.)
  11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft lightly in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Secure the inboard joint boot clamp onto the boot.
    3. Place SST onto the inboard joint boot clamp.
      Fig 18: Securing Inboard Joint Boot Clamp Onto Boot
      GTY176528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Using SST, measure the clearance of the front axle inboard joint boot clamp.
      Fig 19: Measuring Clearance Of Clamp
      GTY149478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.8 mm (0.0315 in.) or less

      NOTE:

      If the measured value is greater than the specified value, retighten the clamp.

  12. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP 
    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.
      Fig 20: Placing SST Onto No. 2 Front Axle Inboard Joint Boot Clamp
      GTY175015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the No. 2 front axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Using SST, measure the clearance of the No. 2 front axle inboard joint boot clamp.
      Fig 21: Measuring Clearance Of No. 2 Front Axle Inboard Joint Boot Clamp
      GTY200721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.8 mm (0.0315 in.) or less

      NOTE:

      If the measured value is greater than the specified value, retighten the clamp.

  13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING 
    1. Install a new front drive shaft hole snap ring.
  14. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH  See step  1
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