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Reassembly [10/2014 - ]: Procedure

  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side) 
    1. Using SST, a steel plate and a press, install a new front drive shaft bearing.
      GTY591081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Steel Plate
      • SST: 09527-10011 
      NOTE:

      The bearing should be completely installed.

    2. Using a snap ring expander, install a new drive shaft hole snap ring.
      GTY441319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH 
    1. Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.
      GTY539529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Steel Plate

      Dimension (A)

      110.0 to 111.0 mm (4.33 to 4.37 in.)

      NOTE:
      • The dust cover should be completely installed.
      • Be careful not to damage the front drive shaft dust cover RH.
  3. INSTALL FRONT DRIVE SHAFT DUST COVER LH 
    1. Using a steel plate and a press, install a new front drive shaft dust cover LH.
      GTY591905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Steel Plate
      NOTE:
      • The dust cover should be completely installed.
      • Be careful not to damage the front drive shaft dust cover LH.
  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT 
    1. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.
      GTY323495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
    2. Install new parts onto the front drive outboard joint shaft assembly in the following order:
      GTY600346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      Outboard Joint Side
      Inboard Joint Side
      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 joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

      Standard Grease Capacity

      164 to 184 g (5.78 to 6.48 oz.)

    4. Install the front axle outboard joint boot into the front drive outboard joint shaft assembly groove.
      NOTE:
      • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.
      • Keep the inside of the outboard joint boot free of foreign matter.
  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.
    3. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY317532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.
      GTY315006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.
    2. Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY546860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    3. Tighten SST so that the front axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    4. Remove SST.
    5. Using SST, measure the clearance of the front axle outboard joint boot clamp.
      GTY601086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

  7. INSTALL FRONT DRIVE SHAFT DAMPER 
    1. Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.
      GTY424805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for LH Side
      *B for RH Side

      Dimension (A)

      222.3 to 226.3 mm (8.76 to 8.90 in.)

    2. Using needle-nose pliers, install the 2 front drive shaft damper clamps as shown in the illustration.
      GTY429228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to install the clamps in the correct position.

  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY 
    1. Install new parts onto the front drive outboard joint shaft assembly in the following order:
      GTY574126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *4 Protective Tape
      Outboard Joint Side
      Inboard Joint Side
      1. Front axle inboard joint boot clamp
      2. Front axle inboard joint boot
      3. Front No. 2 axle inboard joint boot clamp
    2. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    3. Remove the protective tape.
    4. Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.
      GTY598837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Matchmark
    5. Align the matchmarks placed before removal.
    6. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.
      NOTE:
      • Do not tap the rollers.
      • Keep the tripod joint free of foreign matter.
    7. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.
      GTY426949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

      Standard Grease Capacity

      135 to 155 g (4.76 to 5.46 oz.)

    9. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.
      GTY558755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Matchmark
  9. INSTALL FRONT AXLE INBOARD JOINT BOOT 
    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.
    2. Check whether each drive shaft dimension (A) is within specification.
      GTY572789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A LH Side
      *B RH Side

      Dimension (A)

        Dimension (A)
      LH Side 581.5 mm (1.90 ft.)
      RH Side 914.9 mm (3.00 ft.)
  10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install 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, press it against the boot and slightly tighten SST.
      GTY593155Courtesy 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. Remove SST.
    6. Using SST, measure the clearance of the front axle inboard joint boot clamp.
      GTY179054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0591 in.)

      If the clearance is outside the specified range, retighten SST.

  11. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 
    1. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.
    2. Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.
      GTY431506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the front axle inboard joint boot.

  12. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH 
    1. Install a new front drive shaft hole snap ring LH.
      NOTE:

      Face the end gap of the front drive shaft hole snap ring downward.

  13. INSPECT FRONT DRIVE SHAFT ASSEMBLY 

    See step  1

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