Reassembly

DRIVE SHAFT: REAR DRIVE SHAFT (for TMMC Made 4WD): REASSEMBLY

REASSEMBLY

1. INSTALL REAR DRIVE SHAFT DUST COVER

(a) Using SST(s) and a steel plate, install a new drive shaft dust cover.
SST: 09527-21011
- The dust cover should be completely installed.
- Be careful not to damage the dust cover.

2. INSTALL REAR DRIVE SHAFT SNAP RING
(a) Install a new rear drive shaft snap ring.
NOTE: Be careful not to damage the boot.

3. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT
(a) Hold the drive shaft lightly in a vise between aluminium plates.
NOTE: Do not overtighten the vise.

(b) Install a new outboard joint boot and 2 outboard joint boot clamps.
HINT: Before installing the boot, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged.

(c) Coat the outboard joint and boot with grease in the boot kit.
Grease capacity:
90 to 110 g (3.2 to 3.9 oz.)
(d) Make sure that the 2 boots are on the shaft groove.
4. INSTALL NO. 2 REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP
(a) Install the 2 outboard joint boot clamps to the boot.

(b) Place SST(s) onto the No. 2 rear drive shaft outboard joint boot clamp.
SST: 09521-24010
(c) Tighten the SST(s) so that the No. 2 rear drive shaft outboard joint boot clamp is pinched.
NOTE: Do not overtighten the SST(s).

(d) Using SST(s), measure the clearance of the No. 2 rear drive shaft outboard joint boot clamp.
SST: 09240-00020
Clearance:
1.2 to 4.0 mm (0.047 to 0.158 in.)
NOTE: When the measured value is greater than the specified value, retighten the clamp.

5. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

(a) Place SST(s) onto the rear drive shaft outboard joint boot clamp.
SST: 09521-24010
(b) Tighten the SST(s) so that the rear drive shaft outboard joint boot clamp is pinched.
NOTE: Do not overtighten the SST(s).

(c) Using SST(s), measure the clearance of the rear drive shaft outboard joint boot clamp.
SST: 09240-00020
Clearance:
1.2 to 4.0 mm (0.047 to 0.158 in.)
NOTE: When the measured value is greater than the specified value, retighten the clamp.

6. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY
(a) Install a new inboard joint boot to the drive shaft with the 2 clamps.

(b) Align the matchmarks. Using a brass bar and a hammer, install the inner race.

(d) Align the matchmarks, and install the cage to the inner race.
(e) Install the 6 balls with grease to the inner race.
(f) Coat the outboard joint shaft and boot with grease.
Grease capacity:
130 to 150 g (4.6 to 5.3 oz.)

(g) Align the matchmarks, and install the inboard joint assembly to the outboard joint shaft assembly.
7. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT
(a) Install the inboard joint boot to the outboard joint shaft.
8. INSTALL NO. 2 REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(a) Using a screwdriver, install the No. 2 rear drive shaft inboard joint boot clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

9. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(a) Using a screwdriver, install the rear drive shaft inboard joint boot clamp as shown in the illustration.
NOTE: Be careful not to damage the boot.

10. INSPECT REAR DRIVE SHAFT ASSEMBLY Rear Drive Shaft (for TMMC Made 4WD)