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

INSTALL BEARING BRACKET HOLE SNAP RING (for RH Side)
1. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.
INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)
1. Using SST, install a new front drive shaft bearing.
  
  Fig 1: Installing Front Drive Shaft Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09527-10011
  - SST: 09527-30010
  NOTE:
  The bearing should be completely installed.
2. Using a snap ring expander, install a new drive shaft hole snap ring.
  
  Fig 2: Installing Drive Shaft Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE SHAFT DUST COVER (for 2WD RH Side)
1. Using SST and a press, install a new front drive shaft dust cover.
  
  Fig 3: Installing Front Drive Shaft Dust Cover, SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09527-10011
  - SST: 09726-40010
  Distance (A)
  
  26.6 to 27.6 mm (1.05 to 1.09 in.)
  NOTE:
  - The front drive shaft dust cover should be completely installed.
  - Be careful not to damage the front drive shaft dust cover.
INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 2WD RH Side)
1. Using SST and a press, install a new front drive shaft dust cover RH until the distance (A) from the tip of the center drive shaft to the front drive shaft dust cover RH meets the specification.
  
  Fig 4: Identifying Front Drive Shaft Dust Cover (For RH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09527-10011
  Distance (A)
  
  110 to 111 mm (4.33 to 4.37 in.)
  NOTE:
  - The front drive shaft dust cover RH should be completely installed.
  - Be careful not to damage the front drive shaft dust cover RH.
INSTALL FRONT DRIVE SHAFT DUST COVER LH (for LH Side)
1. Using SST and a press, install a new front drive shaft dust cover LH.
  
  Fig 5: Installing Drive Shaft Dust Cover LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09527-10011
  NOTE:
  - The front drive shaft dust cover LH should be completely installed.
  - Be careful not to damage the front drive shaft dust cover LH.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT
1. Wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.
  
  Fig 6: Identifying Outboard Joint Boot & Tape Wrapped Around Drive Shaft Spline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Vinyl tape
2. Install new parts to the front drive outboard joint shaft assembly in the following order.
  1. Front No. 2 axle outboard joint boot clamp
  2. Front axle outboard joint boot
  3. Front axle outboard joint boot clamp
3. Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.
  Grease capacity
  
  170 to 190 g (6.0 to 6.7 oz.)
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: Installing Front Axle Outboard Joint Boot Clamp
  Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP
1. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.
2. Place SST onto the front No. 2 axle outboard joint boot clamp.
  
  Fig 9: Installing No. 2 Front Axle Outboard Joint Boot Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09521-24010
3. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.
  NOTE:
  Do not overtighten SST.
4. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.
  
  Fig 10: Measuring Clearance Of No. 2 Outboard Joint Boot Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL FRONT DRIVE SHAFT DAMPER (for LH Side)
1. Install the front drive shaft damper onto dimension (A) shown in the illustration.
  
  Fig 11: Identifying Drive Shaft Damper Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Install the damper in the correct orientation.
  
  Dimension (A)
  
  283 to 287 mm (11.1 to 11.3 in.)
2. Install a new front drive shaft damper clamp onto the front drive shaft damper.
  NOTE:
  Be sure to install the clamp in the correct position.
3. Place SST onto the front drive shaft damper clamp.
  
  Fig 12: Installing Front Drive Shaft Damper Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09521-24010
4. Tighten SST so that the clamp is pinched.
  NOTE:
  Do not overtighten SST.
5. Using SST, measure the clearance of the front drive shaft damper clamp.
  
  Fig 13: Measuring Clearance Of Front Drive Shaft Damper Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
1. Wrap the spline 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 Inboard Joint Boot & Tape Wrapped Spline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Vinyl tape
  1. Front axle inboard joint boot clamp
  2. Front axle inboard joint boot
  3. Front No. 2 axle inboard joint boot clamp
3. Place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly.
  
  Fig 15: Identifying Tripod Joint Axial Spline & Front Drive Outboard Joint Shaft Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Matchmark
4. Align the matchmarks placed before removal.
5. Using a brass bar and a 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 in the correct direction.
6. Using a snap ring expander, install a new shaft snap ring.
  
  Fig 16: Identifying Snap Ring
  Courtesy 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 17: Identifying Front Drive Inboard & Outboard Joint Shaft Assembly Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Matchmark

INSTALL FRONT AXLE INBOARD JOINT BOOT

Install the front axle inboard joint boot to the front drive inboard joint assembly.

Check whether the drive shaft dimensions are within the following specifications.

Fig 18: Inspecting Drive Shaft Assembly Dimensions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	LH Side:
*b	RH Side:

HINT:

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

Dimension (A)

Drive Type	LH Side	RH Side
for 2WD	650.5 mm (2.13 ft.)	971.7 mm (3.187 ft.)
for AWD	650.5 mm (2.13 ft.)	973.1 mm (3.191 ft.)

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 front axle inboard joint boot clamp onto the front axle inboard joint boot.
3. Place SST onto the front axle inboard joint boot clamp.
  
  Fig 19: Installing Front Axle Inboard Joint Boot Clamp
  Courtesy 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 20: Measuring Clearance Of Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP
1. Hold the front drive inboard joint shaft assembly in a vise between aluminum plates.
  NOTE:
  Do not overtighten the vise.
2. Secure the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.
3. Place SST onto the front No. 2 axle inboard joint boot clamp.
  
  Fig 21: Installing No. 2 Front Axle Inboard Joint Boot Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09521-24010
4. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.
  NOTE:
  Do not overtighten SST.
5. Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.
  
  Fig 22: Measuring Clearance Of No. 2 Front Axle Inboard Joint Boot Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
1. Install a new front drive shaft hole snap ring.
INSPECT FRONT DRIVE SHAFT ASSEMBLY LH See step 1