Front Drive Shaft Assembly Reassembly

Using a screwdriver and hammer, tap in a new dust seal.

NOTICE:

Do not damage the dust seal.

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

SST

09527-10011

Install a new snap ring.

Temporarily install a new outboard joint boot (with 2 boot clamps) to the drive shaft.

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

Standard grease capacity:

60 to 80 g (2.2 to 2.8 oz.)

Mount the drive shaft in a soft vise.

Secure a new outboard joint large boot clamp onto the boot.

1. Place SST onto the clamp.
   

   SST

   09521-24010
   

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

   NOTICE:

   Do not overtighten SST.





3. Using SST, adjust the clearance of the clamp.
   

   SST

   09240-00020
   

   Standard clearance:

   0.8 mm (0.0314 in.) or less
   

For the outboard joint small boot clamp, use the same procedures described above.

Install a new inboard joint boot to the outboard joint shaft.

Align the matchmarks of the tripod and outboard joint.

HINT:

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

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

NOTICE:

Do not tap the rollers.

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

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

Standard grease capacity:

121 to 141 g (4.3 to 4.9 oz.)

Align the matchmarks of the inboard joint and outboard joint.

Install the inboard joint to the outboard joint.

Using pliers, squeeze together the hooks of a new large clamp and install the large clamp.

Secure a new small boot clamp onto the boot.

1. Place SST onto the small boot clamp.
   

   SST

   09521-24010
   

2. Tighten SST so that the small 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:

1.0 to 4.0 mm (0.039 to 0.158 in.)

*1: Check that there is no excessive play in the outboard joint.

*2: Check that the inboard joint slides smoothly in the thrust direction.

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

*4: Check the boots for damage.