Reassembly [12/2012 - 08/2014]: Procedure

INSTALL FRONT DRIVE SHAFT BEARING

Using SST and a press, install a new front driveshaft bearing to the front drive inboard joint assembly RH.

SST: 09527-10011
SST: 09710-30012
1. 09710-04081

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Make sure the bearing is completely installed.

Using a snap ring expander, install a new snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DRIVE SHAFT DUST COVER LH

Using SST and a press, install a new front drive shaft dust cover LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09527-10011

NOTE:

The front drive shaft dust cover LH should be installed completely.
Be careful not to damage the front drive shaft dust cover LH.

INSTALL FRONT DRIVE SHAFT DUST COVER RH

for TMMC Made:

Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint assembly RH as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09527-10011

Standard Distance (A)

87.7 to 88.3 mm (3.453 to 3.476 in.)

NOTE:

Be careful not to damage the front drive shaft dust cover RH.

except TMMC Made:

Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint assembly RH as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09527-10011

Standard Distance (A)

103.5 to 104.5 mm (4.075 to 4.114 in.)

NOTE:

Be careful not to damage the front drive shaft dust cover RH.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT

Before installing the front axle outboard joint boot, wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the front axle outboard joint boot from being damaged.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protective Tape

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
Install the front axle outboard joint boot so that it is between the front No. 2 axle outboard joint boot clamp and front drive outboard joint shaft assembly.
Temporarily install the front axle outboard joint boot clamp to the front axle outboard joint boot.
Pack the front drive outboard joint shaft assembly and front axle outboard joint boot with grease from the boot kit.
Standard Grease Capacity

for TMMC Made

100 to 120 g (3.6 to 4.2 oz)

except TMMC Made

205 to 215 g (7.3 to 7.5 oz)

INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH

WARNING:

Wear protective gloves to avoid injuries to your hands.

for TMMC Made:

Install the front No. 2 axle outboard joint boot clamp LH onto the outboard joint boot.

Place SST onto the front No. 2 axle outboard joint boot clamp LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

SST: 09521-24010

Tighten SST so that the front No. 2 axle outboard joint boot clamp LH is pinched.
NOTE:
Do not overtighten SST.

Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09240-00020
1. 09242-00120
2. 09242-00300

Standard Clearance

1.2 to 4.0 mm (0.0473 to 0.1574 in.)

NOTE:

If the measured value exceeds the specified value, retighten the front No. 2 axle outboard joint boot clamp LH.

except TMMC Made:

Install the front No. 2 axle outboard joint boot clamp LH onto the front axle outboard joint boot and temporarily fold back the lever.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Set the lever into the guide groove correctly and install the front No. 2 axle outboard joint boot clamp LH as close to the inside of the vehicle as possible.
Check the band and lever for any deformation before folding back the lever.

Lean your weight on your hand and roll the front drive outboard joint shaft assembly LH forward while pressing the front drive outboard joint shaft assembly LH against a surface until a click sound is heard.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not damage the deflector.
Make sure that the front drive outboard joint shaft assembly LH is in direct contact with the surface.

Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not damage the front axle outboard joint boot.

INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP RH
HINT:

Use the same procedure described for the LH side.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

WARNING:

Wear protective gloves to avoid injuries to your hands.

for TMMC Made:

Install the front axle outboard joint boot clamp LH onto the outboard joint boot.

Place SST onto the front axle outboard joint boot clamp LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

SST: 09521-24010

Tighten SST so that the front axle outboard joint boot clamp LH is pinched.
NOTE:
Do not overtighten SST.

Using SST, measure the clearance of the front axle outboard joint boot clamp LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09240-00020
1. 09242-00120
2. 09242-00300

Standard Clearance

1.2 to 4.0 mm (0.0473 to 0.1574 in.)

NOTE:

If the measured value exceeds the specified value, retighten the front axle outboard joint boot clamp LH.

except TMMC Made:

Install the front axle outboard joint boot clamp LH to the front axle outboard joint boot and temporarily fold back the lever.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Set the lever into the guide groove correctly.
Check the band and lever for any deformation before folding back the lever.

Using water pump pliers, pinch the front axle outboard joint boot clamp LH to temporarily fix it in place.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a plastic-faced hammer, tap the buckle to fix the lever in place while making sure that the end of the lever is even with the edge of the buckle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not damage the front axle outboard joint boot.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH
HINT:

Use the same procedure described for the LH side.

INSTALL FRONT DRIVE SHAFT DAMPER LH

for TMMC Made:

Install a new front drive shaft damper clamp LH and front drive shaft damper LH onto the front drive outboard joint shaft assembly LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Front Drive Shaft Damper Clamp LH
*2	Front Drive Shaft Damper LH

HINT:

Make sure the front drive shaft damper clamp LH is on the inboard joint side.

Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.
Standard Distance (A)

153.0 to 157.0 mm (6.024 to 6.181 in.)

except TMMC Made:

Install a new front drive shaft damper clamp LH and front drive shaft damper LH onto the front drive outboard joint shaft assembly LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Front Drive Shaft Damper Clamp LH
*2	Front Drive Shaft Damper LH

HINT:

Make sure the front drive shaft damper clamp LH is on the outboard joint side.

Adjust the position of the drive shaft damper LH so that the distance shown in the illustration is within the specified range.
Standard Distance (A)

158.0 to 162.0 mm (6.221 to 6.377 in.)

INSTALL FRONT DRIVE SHAFT DAMPER RH

for TMMC Made:

Install a new front drive shaft damper clamp RH and front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

*1	Front Drive Shaft Damper Clamp RH
*2	Front Drive Shaft Damper RH

HINT:

Make sure the front drive shaft damper clamp RH is on the inboard joint side.

Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.
Standard Distance (A)

161.0 to 165.0 mm (6.339 to 6.496 in.)

except TMMC Made:

Install a new front drive shaft damper clamp RH and front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

*1	Front Drive Shaft Damper Clamp RH
*2	Front Drive Shaft Damper RH

HINT:

Make sure the front drive shaft damper clamp RH is on the outboard joint side.

Adjust the position of the drive shaft damper RH so that the distance shown in the illustration is within the specified range.
Standard Distance (A)

161.0 to 165.0 mm (6.339 to 6.496 in.)

INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH

Install the front drive shaft damper clamp LH.

*A	for One Touch Type
*B	for Claw Engagement Type

NOTE:

Be sure to install the front drive shaft damper clamp LH in the correct position.

for One Touch Type:
Using a screwdriver, install the front drive shaft damper clamp LH as shown in the illustration.
for Claw Engagement Type:
Using needle-nose pliers, install the front drive shaft damper clamp LH as shown in the illustration.

INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH
HINT:

Use the same procedure described for the LH side.

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

Install new parts to the front drive outboard joint shaft assembly LH in the following order.
1. Front axle inboard joint boot clamp LH
2. Front axle inboard joint boot
3. Front No. 2 axle inboard joint boot clamp LH
Remove the protective tape from the front drive outboard joint shaft assembly LH.

Matchmark

Align the matchmarks and place the beveled side of the tripod joint axial spline toward the front drive outboard joint shaft assembly LH.

Using a brass bar and hammer, tap the tripod joint onto the front drive outboard joint shaft assembly LH.
NOTE:
- Do not tap the rollers.
- Be sure to install the tripod in the correct direction.

Using a snap ring expander, install a new snap ring.

Pack the front drive inboard joint assembly LH and front axle inboard joint boot with grease from the boot kit.
Standard grease capacity

for TMMC Made

150 to 170 g (5.3 to 5.9 oz)

except TMMC Made

175 to 185 g (6.2 to 6.5 oz)

Align the matchmarks and install the front drive inboard joint assembly LH to the front drive outboard joint shaft assembly LH.

Matchmark

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY RH
HINT:

Use the same procedure described for the LH side.

INSTALL FRONT AXLE INBOARD JOINT BOOT

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

Check that the 2 joint boots are not stretched or contracted when the front drive shaft is at the standard length.

*A	for LH Side
*B	for RH Side

Length (A)

Item		Length
for TMMC Made	LH Side	571.9 mm (1.88 ft.)
for TMMC Made	RH Side	918.0 mm (3.01 ft.)
except TMMC Made	LH Side	577.6 mm (1.89 ft.)
except TMMC Made	RH Side	922.4 mm (3.03 ft.)

NOTE:

Keep the drive shaft assembly level during inspection.

If the boots are stretched or contracted, correct them.

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

*A	for One Touch Type
*B	for Claw Engagement Type

for One Touch Type:
Using a screwdriver, install the front axle inboard joint boot clamp LH as shown in the illustration.

NOTE:
Be careful not to damage the boot.
for Claw Engagement Type:
Using needle-nose pliers, install the front axle inboard joint boot clamp LH as shown in the illustration.

NOTE:
Be careful not to damage the boot.

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP RH
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP LH
HINT:

Use the same procedure described for the front axle inboard joint boot clamp LH.
INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP RH
HINT:

Use the same procedure described for the LH side.
INSPECT FRONT DRIVE SHAFT
Refer to INSPECTION [12/2012 - ]