Front Drive Shaft Assembly - Reassembly

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - DRIVE SHAFT / PROPELLER SHAFT

FRONT DRIVE SHAFT ASSEMBLY - REASSEMBLY

  • HINT:
Use the same procedure for the RH and LH sides.
The procedure listed below is for the LH side.
  • NOTICE:
When using a vise, place aluminum plates between the part and vise.
When using a vise, do not overtighten it.
Do not allow brake fluid, front differential oil, gasoline, or battery fluid to contact the front axle inboard joint boot and front axle outboard joint boot, as the front axle inboard joint boot and front axle outboard joint boot may be damaged.
1. INSTALL FRONT DRIVE SHAFT DUST COVER LH
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using SST, a steel plate and press, press in a new front drive shaft dust cover LH.

  • SST
  • 09316-20011
  • Standard Distance (A):
  • 108.4 to 109.0 mm (4.27 to 4.29 in.)
  • NOTICE:
  • Do not damage the front drive shaft dust cover LH.
2. INSTALL DUST SEAL
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using SST and a press, press in a new dust seal until it reaches the end of the outboard joint shaft.

  • SST
  • 09950-00020
  • NOTICE:
  • Do not damage the dust seal.
  • HINT:
  • Place SST on a level surface.
3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

Before installing the front axle outboard joint boot, wrap protective tape around the spline of the outboard joint shaft to prevent damaging the front axle outboard joint boot.

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

Front No. 1 axle outboard joint boot setting clamp

Front axle outboard joint boot

Front No. 2 axle outboard joint boot setting clamp

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Slide the front axle outboard joint boot onto the outboard joint shaft.

Text in Illustration
*aProtective Tape

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

  • Standard grease capacity:
  • 310 to 320 g (11.0 to 11.2 oz.)

Install the front axle outboard joint boot to the outboard joint shaft groove.

  • NOTICE:
Do not allow grease to adhere to the front No. 1 axle outboard joint boot setting clamp and front No. 2 axle outboard joint boot setting clamp track of the front axle outboard joint boot.
Keep the inside of the front axle outboard joint boot free of foreign matter.
4. INSTALL FRONT NO.1 AXLE OUTBOARD JOINT BOOT SETTING CLAMP

Secure the front No. 1 axle outboard joint boot setting clamp to the front axle outboard joint boot.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Place SST onto the front No. 1 axle outboard joint boot setting clamp.

  • SST
  • 09521-24010

Tighten SST so that the front No. 1 axle outboard joint boot setting clamp is pinched.

Text in Illustration
*aTurn
*bHold
  • NOTICE:
  • Do not overtighten SST.

Remove SST.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using SST, adjust the clearance of the front No. 1 axle outboard joint boot setting clamp.

  • SST
  • 09240-00020
  • Standard clearance:
  • 1.5 mm (0.0590 in.) or less

If the clearance is more than the standard, retighten the front No. 1 axle outboard joint boot setting clamp.


5. INSTALL FRONT NO.2 AXLE OUTBOARD JOINT BOOT SETTING CLAMP

Use the same procedure described for the front No. 1 axle outboard joint boot setting clamp.

6. INSTALL FRONT AXLE INBOARD JOINT SET LH
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Slide a new front axle inboard joint boot onto the outboard joint shaft.

Text in Illustration
*aProtective Tape
  • HINT:
  • Before installing the front axle inboard joint boot, wrap protective tape around the spline of the outboard joint shaft to prevent damaging the front axle inboard joint boot.
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Text in Illustration
*1Front No. 1 Axle Inboard Joint Boot Setting Clamp
*2Front Axle Inboard Joint Boot
*3Front No. 2 Axle Inboard Joint Boot Setting Clamp
*aProtective Tape
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200Outboard Joint Side
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200Inboard Joint Side

Front No. 1 axle inboard joint boot setting clamp

Front axle inboard joint boot

Front No. 2 axle inboard joint boot setting clamp

Remove the protective tape from the outboard joint shaft.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the cage to the outboard joint shaft.

Text in Illustration
*aOutboard Joint Side
  • NOTICE:
  • Insert the cage with its smaller inner diameter side facing the outboard joint.
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Align the matchmarks and install the inner race to the outboard joint shaft.

Text in Illustration
*aMatchmark
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Align the matchmarks placed before removal, and install the cage to the inner race.

Text in Illustration
*aMatchmark
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the 6 balls.

  • HINT:
  • Apply grease onto the balls to keep them from falling out.

Pack the front axle inboard joint set LH and front axle inboard joint boot with grease from a boot kit.

  • Standard grease capacity:
  • 314 to 324 g (11.1 to 11.4 oz.)
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Align the matchmarks placed before removal, and install the front axle inboard joint set LH to the outboard joint shaft.

Text in Illustration
*aMatchmark
7. INSTALL FRONT AXLE INBOARD JOINT BOOT

Install the front axle inboard joint boot to the front drive inboard joint set LH.

  • HINT:
  • Make sure that the front axle inboard joint boot is on the outboard joint shaft groove.
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

  • Length (A):
  • 582.67 mm (1.91 ft.)

If the front axle inboard joint boot and front axle outboard joint boot are stretched or contracted, correct them.


8. INSTALL FRONT AXLE INBOARD JOINT BOOT SETTING NO.2 CLAMP
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using a screwdriver, install the front No. 2 axle inboard joint boot setting clamp as shown in the illustration.

  • NOTICE:
Be sure to install the front No. 2 axle inboard joint boot setting clamp in the correct position.
Do not damage the front axle inboard joint boot.
9. INSTALL FRONT NO.1 AXLE INBOARD JOINT BOOT SETTING CLAMP

Secure the front No. 1 axle inboard joint boot setting clamp to the front axle inboard joint boot.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Place SST onto the front No. 1 axle inboard joint boot setting clamp.

  • SST
  • 09521-24010

Tighten SST so that the front No. 1 axle inboard joint boot setting clamp is pinched.

Text in Illustration
*aTurn
*bHold
  • NOTICE:
  • Do not overtighten SST.

Remove SST.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using SST, adjust the clearance of the front No. 1 axle inboard joint boot setting clamp.

  • SST
  • 09240-00020
  • Standard clearance:
  • 1.5 mm (0.0590 in.) or less

If the clearance is more than the standard, retighten the front No. 1 axle inboard joint boot setting clamp.


10. INSTALL FRONT AXLE INBOARD JOINT SET SETTING SHAFT SNAP RING
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install a new front axle inboard joint set setting shaft snap ring to the front axle inboard joint set LH.

  • CAUTION:
  • Do not damage the spline of the front axle inboard joint set LH.
11. INSPECT FRONT DRIVE SHAFT ASSEMBLY
  • NOTICE:
  • Move the drive shaft while keeping it level.
Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Check if there is excessive play in the outboard joint.

Check if the inboard joint shaft slides smoothly in the thrust direction.

Check if there is excessive play in the radial direction of the inboard joint shaft.

Check the boots for damage.

Front Drive Shaft Assembly - Reassembly. DRIVE SHAFT / PROPELLER SHAFT. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

  • Standard drive shaft length:
  • 583 mm (1.91 ft.)

If the boots are stretched or contracted, correct them.