Front Drive Shaft Assembly Reassembly

Using a brass bar and hammer, tap on a new dust seal.

NOTICE:

Do not damage the dust seal.

Using SST and a press, install a new dust cover.

SST

09527-10011

Before installing the boot, wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.

Install new parts to the outboard joint shaft in the following order.

1. Large outboard joint boot clamp
   

2. Outboard joint boot
   

3. Small outboard joint boot clamp
   

Pack the outboard joint shaft and boot with grease from the boot kit.

Standard grease capacity:

60 to 80 g (2.2 to 2.8 oz.)

Install a new large boot clamp to the joint boot.

Place SST onto the boot clamp.

SST

09521-24010

Tighten SST so that the boot clamp is pinched.

NOTICE:

Do not overtighten SST.

Using SST, adjust the clearance of the boot clamp.

SST

09240-00020

Standard clearance:

0.8 mm (0.0314 in.) or less

NOTICE:

If the measured value exceeds the specified value, retighten the boot clamp.

Use the same procedure described above to install a new outboard joint small boot clamp.

Before installing the boot, wrap the splines of the drive shaft with protective tape to prevent the boot from being damaged.

Install new parts to the outboard joint shaft in the following order.

1. Small inboard joint boot clamp
   

2. Inboard joint boot
   

3. Large inboard joint boot clamp
   

Place the beveled side of the tripod axial spline toward the outboard joint shaft.

Align the matchmarks placed before removal.

Using a brass bar and hammer, tap the tripod onto the outboard joint.

NOTICE:

1. Do not tap the rollers.
   
2. Be sure to install the tripod in the correct direction.
   

Pack the inboard joint and boot with grease from the boot kit.

Standard grease capacity:

121 to 141 g (4.3 to 4.9 oz.)

Using a snap ring expander, install a new snap ring.

Align the matchmarks and install the inboard joint to the outboard joint shaft.

Install a new inboard joint boot to the inboard joint.

Check that the 2 joint boots are not stretched or contracted when the front drive shaft is at the standard length.

Length (A):

Item	Length
for LH Side	540.9 mm (1.77 ft.)
for RH Side

NOTICE:

Keep the front drive shaft level during inspection.

Using pliers, install a new large boot clamp as shown in the illustration.

NOTICE:

Be careful not to damage the joint boot.

Install a new small boot clamp to the boot.

Place SST onto the clamp.

SST

09521-24010

Tighten SST so that the boot clamp is pinched as shown in the illustration.

NOTICE:

Do not overtighten SST.

Using SST, adjust the clearance of the small boot clamp.

SST

09240-00020

Standard clearance:

0.8 mm (0.0314 in.) or less

Check that there is no excessive play in the radial direction of the outboard joint.

Check that the inboard joint slides smoothly in the thrust direction.

Check that there is no excessive play in the radial direction of the inboard joint.

Check the 2 joint boots for damage.

Check that the 2 joint boots are not stretched or contracted when the front drive shaft is at the standard length.

Length (A):

Item	Length
for LH Side	540.9 mm (1.77 ft.)
for RH Side

NOTICE:

Keep the front drive shaft level during inspection.