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Home >> Toyota >> 2017 >> Highlander XLE, AWD >> Repair and Diagnosis >> Drivelines & Axles >> Driveshaft & Universal Joints >> Drive Shaft / Propeller Shaft (Service Information) (Except Hybrid) >> REAR DRIVE SHAFT ASSEMBLY (for AWD) >> Reassembly [12/2013 - ] >> Procedure

Reassembly [12/2013 - ]: Procedure

  1. INSTALL REAR DRIVE SHAFT DUST COVER 
    1. Using SST, a steel plate and a press, install a new rear drive shaft dust cover.
      • SST: 09527-10011 
      GTY443562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      NOTE:
      • The rear drive shaft dust cover should be completely installed.
      • Be careful not to damage the rear drive shaft dust cover.
  2. 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 60 g (1.77 to 2.11 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.
  3. 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.

      GTY382836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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 mm (0.0472 in.) or less

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

  5. 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. Align the matchmarks and install the tripod joint to the rear drive shaft outboard joint shaft assembly.
      NOTE:

      Face the serrated side of the tripod joint outward and install it to the outboard joint end.

      GTY424060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    5. Align the matchmarks placed before removal.
    6. Using a brass bar and a hammer, install the tripod joint to the rear drive shaft outboard joint shaft assembly.
      NOTE:
      • Do not tap the rollers.
      • Keep the tripod joint free of foreign matter.
      • Be sure to install the tripod joint in the correct direction.
    7. Using a snap ring expander, install a new shaft snap ring to the rear drive shaft outboard joint shaft assembly.
      GTY445530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Pack the rear drive shaft inboard joint assembly and rear drive shaft inboard joint boot with grease.

      Standard Grease Capacity

      93 to 103 g (3.29 to 3.63 oz)

    9. Align the matchmarks and install the rear drive shaft inboard joint assembly to the rear drive shaft outboard joint shaft assembly.
      GTY440947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
  6. 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.
      GTY439187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (A)

      for LH Side 758.25 mm (2.49 ft.)
      for RH Side 738.25 mm (2.42 ft.)
  7. 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 (for Type A).
      GTY450912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A
      *B for Type B
      *a Claw
      NOTE:

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

    3. Using needle-nose pliers, engage the 2 claws to install the rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration (for Type B).
      NOTE:

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

  8. 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.

  9. INSPECT REAR DRIVE SHAFT ASSEMBLY 

    Refer to INSPECTION [12/2013 - ] 

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