Reassembly [08/2014 - ]: Procedure

INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)

Using SST and a press, press in the front drive inboard joint assembly RH until the new front drive shaft bearing contacts the edge of 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 front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.
Do not apply weight to the dust cover and outer race of the front driveshaft bearing.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

The Snap ring should be installed completely.

INSTALL FRONT DRIVE SHAFT DUST COVER LH

Using SST and a press, press in the front drive inboard joint assembly LH until the new front drive shaft dust cover LH contacts the edge of the front drive inboard joint assembly LH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09527-10011

NOTE:

Make sure to install the front drive shaft dust cover LH in the correct direction.
Do not damage the front drive shaft dust cover LH.
The front drive shaft dust cover LH should be installed completely.

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:

Make sure to install the front drive shaft dust cover RH in the correct direction.
Do not damage the front drive shaft dust cover RH.
Front drive shaft dust cover RH should be installed completely.

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:

Make sure to install the front drive shaft dust cover RH in the correct direction.
Do not damage the front drive shaft dust cover RH.
Front drive shaft dust cover RH should be installed completely.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT

HINT:

Use the same procedure for the RH and LH sides.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Front No. 2 Axle Outboard Joint Boot Clamp
*2	Front Axle Outboard Joint Boot
*3	Front Axle Outboard Joint Boot Clamp
	Outboard joint side
	Inboard joint side

Install new parts to the front drive outboard joint shaft assembly in the following order.

Front No. 2 axle outboard joint boot clamp
Front axle outboard joint boot
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 the front axle outboard joint boot to the groove of the front drive outboard joint shaft assembly.
NOTE:
- Do not apply grease to the part of the front axle outboard joint boot that contacts the groove.
- Do not allow foreign matter to enter the front axle outboard joint boot.

INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP LH

for TMMC Made:

Install SST to the front No. 2 axle outboard joint boot clamp LH, and then while pressing the front axle outboard joint boot, slightly tighten the SST bolt.
- SST: 09521-24010
NOTE:
- Correctly set the front No. 2 axle outboard joint boot clamp LH to the guide groove.
- Do not damage the front axle outboard joint boot.

Tighten SST so that the front No. 2 axle outboard joint boot clamp LH is pinched.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

Standard clearance

1.2 to 4.0 mm (0.0473 to 0.1574 in.)

NOTE:

When tightening SST, make sure the clearance of the front No. 2 axle outboard joint boot clamp LH is within the standard clearance.
Do not damage the front axle outboard joint boot.

Remove SST from the front No. 2 axle outboard joint boot clamp LH.

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

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.
If the result is lower than the specified range, install a new front No. 2 axle outboard joint boot clamp LH.

except TMMC Made:

WARNING:

Wear protective gloves to avoid injuries to your hands.

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

for TMMC Made:
HINT:

Use the same procedure described for the front No. 2 axle outboard joint boot clamp LH.

except TMMC Made:

WARNING:

Wear protective gloves to avoid injuries to your hands.

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 (w/ 1 Clamp)

for TMMC Made:

Install a new front drive shaft damper clamp LH and the 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 front 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 the 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 front drive shaft damper LH so that the distance shown in the illustration is within the specified range.
Standard distance (A)

212.5 to 216.5 mm (8.367 to 8.523 in.)

INSTALL FRONT DRIVE SHAFT DAMPER LH (w/ 2 Clamps)

for TMMC Made:

Install 2 new front drive shaft damper clamp LH and the 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

Adjust the position of the front 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 2 new front drive shaft damper clamp LH and the 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

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

212.5 to 216.5 mm (8.367 to 8.523 in.)

INSTALL FRONT DRIVE SHAFT DAMPER RH (w/ 1 Clamp)

for TMMC Made:

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*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 front drive shaft damper RH so that the distance shown in the illustration is within the specified range.
Standard distance (A)

158.9 to 162.9 mm (6.256 to 6.413 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

199.0 to 203.0 mm (7.835 to 7.992 in.)

INSTALL FRONT DRIVE SHAFT DAMPER RH (w/ 2 Clamps)

for TMMC Made:

Install 2 new front drive shaft damper clamp RH and the front drive shaft damper RH onto the front drive outboard joint shaft assembly RH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

158.9 to 162.9 mm (6.256 to 6.413 in.)

except TMMC Made:

Install 2 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

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

199.0 to 203.0 mm (7.835 to 7.992 in.)

INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH (w/ 1 Clamp)

Install the front drive shaft damper clamp LH.

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

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, hold the front drive shaft damper clamp LH at the claw engagement.

NOTE:
Do not deform the claw engagement of the front drive shaft damper clamp LH.

INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH (w/ 2 Clamps)

Install the 2 front drive shaft damper clamp LH.

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

NOTE:

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

HINT:

Use the same procedure for each front drive shaft damper clamp LH.

for One Touch Type:
Using a screwdriver, install the 2 front drive shaft damper clamp LH as shown in the illustration.
for Claw Engagement Type:
Using needle-nose pliers, hold the 2 front drive shaft damper clamp LH at the claw engagement.

NOTE:
Do not deform the claw engagement of the front drive shaft damper clamp LH.

INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (w/ 1 Clamp)
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH (w/ 2 Clamps)
HINT:

Use the same procedure described for the LH side.

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH

*1	Front Axle Inboard Joint Boot Clamp LH
*2	Front Axle Inboard Joint Boot
*3	Front No. 2 Axle Inboard Joint Boot Clamp LH
*a	Protective Tape
	Outboard joint side
	Inboard joint side

Install new parts to the front drive outboard joint shaft assembly LH in the following order.

Front axle inboard joint boot clamp LH
Front axle inboard joint boot
Front No. 2 axle inboard joint boot clamp LH

Remove the protective tape from the front drive outboard joint shaft assembly LH.

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

*a	Matchmark
	Inboard joint side

NOTE:

Face the cut edge of the spline toward the inboard joint side and insert the spline onto the 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 as shown in the illustration.

*A	for TMMC Made
*B	except TMMC Made

NOTE:

The Snap ring should be installed completely.

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

HINT:

Use the same procedure for the RH and LH sides.

Install the front axle inboard joint boot to the front drive inboard joint assembly.
NOTE:
- Do not apply grease to the part of the front axle inboard joint boot that contacts the groove.
- Do not allow foreign matter to enter the front axle inboard joint boot.

Check that the front axle inboard joint boot and front axle outboard joint boot 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 front axle inboard joint boot and front axle outboard joint boot are stretched or contracted, correct them.

INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH

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

for One Touch Type:
Using a screwdriver, install the front axle inboard joint boot clamp LH as shown in the illustration.
NOTE:
- Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.
- Do not to damage the front axle inboard joint boot.
for Claw Engagement Type:
1. Install the front No. 2 axle inboard joint boot clamp LH to the drive shaft inboard joint boot.
  NOTE:
  Correctly set the front No. 2 axle inboard joint boot clamp LH to the guide groove.
2. Using needle-nose pliers, hold the front No. 2 axle inboard joint boot clamp LH at the claw engagement.
  NOTE:
  - Do not to damage the front axle inboard joint boot.
  - Do not deform the claw engagement of the front No. 2 axle inboard joint boot clamp LH.

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 - ]