Rear Drive Shaft Assembly: Reassembly: Reassembly

1. Wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged.
2. Install new parts to the rear drive shaft outboard joint shaft assembly in the following order.
   Fig 1: Identifying Rear Shaft Outboard Boot And Tape Wrapped Spline

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Vinyl Tape

   1. Rear No. 2 drive shaft outboard joint boot clamp
   2. Rear drive shaft outboard joint boot clamp
   3. Rear drive shaft outboard joint boot
3. Pack the rear drive outboard joint shaft assembly and rear drive shaft outboard joint boot with grease from the boot kit.

   Grease capacity

   50 to 70 g (1.8 to 2.5 oz.)

1. Hold the rear drive shaft assembly lightly in a vise between aluminum plates.
   NOTE:

   Do not overtighten the vise.

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 
   Fig 2: Installing Rear Drive Shaft Outboard Joint Boot Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the SST so that the rear drive shaft outboard joint boot clamp is pinched.
   NOTE:

   Do not overtighten the SST.

5. Using SST, inspect the clearance of the rear drive shaft outboard joint boot clamp.
   Fig 3: Measuring Clearance Of Rear Drive Shaft Outboard Joint Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09240-00020 

   Clearance

   1.2 to 4.0 mm (0.047 to 0.157 in.)

   NOTE:

   If the measured value exceeds the specified value, retighten the clamp.

1. Using a screwdriver, install a new rear No. 2 drive shaft outboard joint boot clamp as shown in the illustration.
   Fig 4: Installing No. 2 Rear Drive Shaft Outboard Joint Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Do not damage the outboard joint boot.

1. Wrap the spline of the rear drive shaft outboard joint shaft assembly with vinyl tape to prevent the boot from being damaged.
   Fig 5: Identifying Inboard Joint Boot And Tape Wrapped Spline

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Vinyl Tape

2. Install new parts to the rear drive shaft outboard joint shaft assembly in the following order.
   1. Rear drive shaft inboard joint boot
   2. Rear drive shaft inboard joint boot clamp
   3. Rear No. 2 drive shaft inboard joint boot clamp
3. Install the ball cage to the rear drive shaft outboard joint shaft assembly.
   Fig 6: Identifying Smaller Inner Diameter Of Ball Cage Facing Outboard Joint

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	Outboard Joint Side

   NOTE:

   Install the ball cage with its smaller inner diameter side facing the outboard joint.

4. Align the matchmarks placed before removal and install the inner race to the rear drive outboard joint shaft assembly using a brass bar and a hammer.
   Fig 7: Installing Inner Race At Rear Drive Outboard Joint Shaft Assembly Using A Brass Bar & Hammer To Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   Matchmark

   NOTE:

   Be careful not to damage the inner race.

5. Using a snap ring expander, install a new shaft snap ring.
   Fig 8: Remove/Install Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the matchmarks placed before removal and install the ball cage to the inner race.
   Fig 9: Identifying Rear Drive Shaft Outboard Joint Shaft Assembly, Inner Race & Ball Cage Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   Matchmark

7. Install the 8 balls with grease to the inner race.
   NOTE:

   Be careful not to drop the balls.

   HINT: 

   Apply grease onto the balls to keep them from falling.

8. Pack the rear drive shaft inboard joint assembly and rear drive shaft inboard boot with grease.

   Grease capacity

   90 to 110 g (3.2 to 3.8 oz.)

9. Align the matchmarks and install the rear drive shaft inboard joint assembly to the rear drive shaft outboard joint shaft assembly.
   Fig 10: Identifying Inboard & Outboard Drive Shaft Joint Assembly Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   Matchmark

10. Using a screwdriver, install the new drive shaft snap ring to the rear drive shaft inboard joint assembly.
    Fig 11: Remove/Install Drive Shaft Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear drive shaft inboard joint boot to the rear drive shaft inboard joint assembly.
2. Check whether the drive shaft dimensions are within the following specifications.

   HINT: 

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

   Fig 12: Inspecting Rear Drive Shaft Assembly Dimensions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Dimension (A)

   698.3 to 704.3 mm (27.5 to 27.7 in.)

1. Using needle-nose pliers, engage the 2 claws to install a new rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration.
   Fig 13: Remove/Install No. 2 Drive Shaft Inboard Joint Boot Clamp & Claws Using Needle-Nose Pliers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT: 

Perform the same procedure as for the rear No. 2 drive shaft inboard joint boot clamp.