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Reassembly [02/2014 - ]: Procedure

  1. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT 
    1. Wrap the splines of the rear drive shaft outboard joint shaft assembly with protective tape to prevent the boot from being damaged.
      GTY447139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    2. Install new parts to the rear drive shaft outboard joint shaft assembly in the following order:
      GTY425440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Drive Shaft Outboard Joint Assembly
      *2 Rear No. 2 Drive Shaft Outboard Joint Boot Clamp
      *3 Rear Drive Shaft Outboard Joint Boot
      *4 Rear Drive Shaft Outboard Joint Boot Clamp
      Outboard joint side
      Inboard joint side
      1. Rear No. 2 drive shaft outboard joint boot clamp
      2. Rear drive shaft outboard joint boot
      3. Rear drive shaft outboard joint boot clamp
    3. Pack the joint portion of the rear drive shaft outboard joint shaft assembly and rear drive shaft outboard joint boot with grease.

      Standard Grease Capacity

      50 to 70 g (1.77 to 2.46 oz)

    4. Install the rear drive shaft outboard joint boot to the rear drive shaft 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.
  2. INSTALL REAR NO. 2 DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP 
    1. Using a screwdriver, install the rear No. 2 drive shaft outboard joint boot clamp as shown in the illustration.
      NOTE:

      Be careful not to damage the rear drive shaft outboard joint boot.

      GTY275186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the rear drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.
    3. Place SST to the rear drive shaft outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY435109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the rear drive shaft outboard joint boot clamp.
      GTY439728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      1.2 to 4.0 mm (0.0473 to 0.1574 in.)

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

  4. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY 
    1. Install new parts to the rear drive shaft outboard joint shaft assembly in the following order:
      GTY440271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Drive Shaft Inboard Joint Boot Clamp
      *2 Rear Drive Shaft Inboard Joint Boot
      *3 Rear No. 2 Drive Shaft Inboard Joint Boot Clamp
      *a Protective Tape
      Outboard joint side
      Inboard joint side
      1. Rear drive shaft inboard joint boot clamp
      2. Rear drive shaft inboard joint boot
      3. Rear No. 2 drive shaft 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. Install the ball cage to the rear drive shaft outboard joint shaft assembly.
      NOTE:

      Face the smaller inside diameter side to the rear drive shaft outboard joint shaft assembly and insert.

    5. Align the matchmarks placed before removal.
      GTY430663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    6. Using a brass bar and a hammer, install the inner race to the rear drive shaft outboard joint shaft assembly.
      NOTE:

      Be careful not to damage the inner race.

    7. Using a snap ring expander, install a new shaft snap ring to the rear drive shaft outboard joint shaft assembly.
      GTY434570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Align the matchmarks and install the ball cage to the inner race.
      GTY439550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    9. Install the 8 balls with grease to the inner race.
      NOTE:

      Be careful not to drop the balls.

      HINT: 

      Apply grease to the balls to keep them from falling.

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

      Standard Grease Capacity

      90 to 110 g (3.18 to 3.88 oz)

    11. Align the matchmarks and install the rear drive shaft inboard joint assembly to the rear drive shaft outboard joint shaft assembly.
      GTY434489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    12. Using a screwdriver, install a new drive shaft snap ring to the rear drive shaft inboard joint assembly.
      GTY425496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT 
    1. Install the rear drive shaft inboard joint boot to the rear drive shaft inboard joint assembly.
    2. Check whether the drive shaft dimension (A) is within specification.
      GTY438439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (A)

      620.2 mm (2.03 ft.)

  6. INSTALL REAR NO. 2 DRIVE SHAFT INBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Using needle nose pliers, install the rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration.
      GTY426834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the rear drive shaft inboard joint boot.

  7. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP 

    HINT: 

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

  8. INSPECT REAR DRIVE SHAFT ASSEMBLY 

    Refer to INSPECTION [02/2014 - ] 

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