Reassembly

DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY: REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT DUST COVER (for LH Side)

(a) Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

SST : 09527-10011

NOTICE:
* Install the front drive shaft dust cover in the correct direction.
* Do not deform the front drive shaft dust cover.

2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side)

(a) Using SST and a press, install a new front drive shaft dust cover into the front drive inboard joint assembly until it is flush with the end.

SST : 09527-10011

NOTICE:
* Install the front drive shaft dust cover in the correct direction.
* Do not deform the front drive shaft dust cover.

3. INSTALL OUTBOARD JOINT BOOT (for LH Side)

(a) Wrap the splines of the front axle outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

Text in Illustration

(b) Install new parts onto the front axle outboard joint shaft assembly in the following order:

Text in Illustration

(1) Front No. 2 axle outboard joint boot clamp (A)

(2) Outboard joint boot (B)

(3) Front axle outboard joint boot clamp (C)

(c) Pack the joint portion of the front axle outboard joint shaft assembly and outboard joint boot with grease.

Standard grease capacity:

135 to 145 g (4.8 to 5.1 oz.)

(d) Install the outboard joint boot onto the front axle outboard joint shaft assembly groove.

NOTICE:
* 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.

4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the front No. 2 axle outboard joint boot clamp onto the outboard joint boot and temporarily fold back the lever.

NOTICE:
* Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.
* Check the band and the lever for any deformation before folding back the lever.

(b) Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work plane. Roll the outboard joint and fold the lever until a click sound can be heard.

Text in Illustration

NOTICE:
* Do not damage the deflector.
* Make sure that the outboard joint is in direct contact with the work plane.

(c) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:
Do not damage the outboard joint boot.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the front axle outboard joint boot clamp onto the outboard joint boot and temporarily fold back the lever.

NOTICE:
* Set the lever into the guide groove correctly.
* Check the band and the lever for any deformation before folding back the lever.

(b) Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.

Text in Illustration

(c) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:
Do not damage the outboard joint boot.

6. INSTALL FRONT DRIVE SHAFT DAMPER (for LH Side)

(a) Install the front drive shaft damper onto the front axle outboard joint shaft assembly as shown in the illustration.

HINT
Make sure that the front drive shaft damper is on the shaft groove.

Dimension (A):

161 to 165 mm (6.34 to 6.49 in.)

7. INSTALL FRONT DRIVE SHAFT DAMPER (for RH Side)

(a) Install the front drive shaft damper onto the front axle outboard joint shaft assembly as shown in the illustration.

HINT
Make sure that the front drive shaft damper is on the shaft groove.

Dimension (A):

458 to 462 mm (1.50 to 1.51 ft.)

8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for LH Side)

(a) Secure the front axle outboard joint shaft assembly in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) for one touch type:

(1) Using a screwdriver, install a new front drive shaft damper clamp, as shown in the illustration.

Text in Illustration

NOTICE:
Do not damage the outboard joint boot.

(c) for claw engagement type:

(1) Using needle-nose pliers, install a new front drive shaft damper clamp, as shown in the illustration.

9. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (for RH Side)

(a) Using needle-nose pliers, install 2 new front drive shaft damper clamps, as shown in the illustration.

10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Install new parts onto the front axle outboard joint shaft assembly in the following order:

Text in Illustration

(1) Front axle inboard joint boot clamp (A)

(2) Inboard joint boot (B)

(3) Front No. 2 axle inboard joint boot clamp (C)

(b) Secure the front axle outboard joint shaft assembly in a vise using aluminum plates.

NOTICE:
Do not overtighten the vise.

(c) Remove the protective tape.

(d) Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft assembly as shown in the illustration.

Text in Illustration

NOTICE:
Face the serrated side of the tripod joint outward and install it onto the outboard joint end.

(e) Using a brass bar and a hammer, install the tripod joint to the front axle outboard joint shaft assembly.

NOTICE:
* Do not tap the rollers.
* Keep the tripod joint free of foreign matter.

(f) Using a snap ring expander, install a new shaft snap ring to the front axle outboard joint shaft assembly.

(g) Pack the front drive inboard joint assembly and inboard joint boot with grease.

Standard grease capacity:

168 to 178 g (5.9 to 6.2 oz.)

(h) Install a new front axle inboard joint grommet onto the inboard joint groove.

Text in Illustration

NOTICE:
Securely fit the protrusion on the inboard joint grommet into the inboard joint groove.

(i) Align the matchmarks and install the front drive inboard joint assembly onto the front axle outboard joint shaft assembly.

Text in Illustration

11. INSTALL INBOARD JOINT BOOT

(a) Install the inboard joint boot into the grooves of the inboard joint grommet and inboard joint boot.

NOTICE:
Keep the grooves free of grease.

12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the boot clamp onto the inboard joint boot.

(b) Adjust dimension (A) until it is within the specified length.

Dimension (A)

(c) While keeping dimension (A) within the specified length, put the inside of the inboard joint under atmospheric pressure by pulling the recessed parts on the inboard joint grommet out.

Text in Illustration

(d) Set the lever fulcrum point at any point A indicated in the illustration and temporarily bend the lever.

NOTICE:
* Perform this work with the inside of the inboard joint kept at atmospheric pressure.
* Set the lever into the guide groove correctly and install the clamp as far into the inside of the vehicle as possible.
* Check the band and the lever for any deformation before folding back the lever.

(e) Lean your weight on your hand and roll the inboard joint forward while pressing the inboard joint against the work plane. Roll the inboard joint and fold the lever until a click sound can be heard.

Text in Illustration

NOTICE:
Make sure that the outboard joint is in direct contact with the work plane.

(f) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:
Do not damage the inboard joint boot.

13. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

CAUTION:
Wear protective gloves. Sharp areas on the parts may injure your hands.

(a) Install the front axle inboard joint boot clamp onto the inboard joint boot and temporarily fold back the lever.

Text in Illustration

(c) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:
Do not damage the inboard joint boot.

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY Component Tests and General Diagnostics