Front Drive Shaft Assembly (For 2Wd) Reassembly

Using SST and a press, press the drive shaft bearing case onto the inboard joint RH.

SST

09527-10011
09710-04081

NOTICE:

Make sure the bearing is be completely installed.

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

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

SST

09726-40010
09527-10011

Standard dust cover depth:

1 mm (0.0394 in.)

NOTICE:

Be careful not to damage the dust cover.

Using SST and a press, press a new drive shaft dust cover onto the inboard joint until the distance from the tip of the inboard joint to the drive shaft dust cover onto reaches the specification, as shown in the illustration.

SST

09527-10011

Standard distance:

91.0 to 92.0 mm (3.583 to 3.622 in.)

NOTICE:

Be careful not to damage the dust cover.

Using SST and a press, press in a new drive shaft dust cover onto the inboard joint.

SST

09527-10011

NOTICE:

1. The dust cover should be installed completely.
   
2. Be careful not to damage the dust cover.
   

Install a new hole snap ring.

Temporarily install a new outboard joint boot No. 2 clamp to the outboard joint shaft.

Install a new outboard joint boot so that it is between the outboard joint boot No. 2 clamp and outboard joint shaft.

Temporarily install a new outboard joint boot clamp to the outboard joint boot.

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

Standard grease capacity:

Item	Specified Condition
for U241E	190 to 200 g (6.7 to 7.1 oz.)
for E352 for EB61	205 to 215 g (7.2 to 7.6 oz.)

Install a new boot clamp to the outboard joint boot and temporarily bend the lever.

NOTICE:

1. When temporarily bending the lever, make sure not to deform the band and lever.
   
2. Set the clamp correctly in the guide groove and align it with the interior of the vehicle as much as possible.
   

With the joint on the working surface, use your body weight to press down on the joint with one hand. Then, roll the joint forward, as shown in the illustration, and press the lever in until a "click" sound is heard.

NOTICE:

1. Do not damage the deflector.
   
2. Make sure the joint is in full contact with the warking surface at all times.
   

Using a plastic-faced hammer, fix the buckle into place by tapping it. At the same time, use the plastic-faced hammer to adjust the lift of the lever so that the gaps between the buckle flange and lever end flange become even.

NOTICE:

Do not damage the boot.

Install a new boot clamp to the outboard joint boot and temporarily bend the lever.

NOTICE:

When temporarily bending the lever, make sure not to deform the band and lever.

Using water pump pliers, temporarily lock the boot clamp by bending the lever down until a "click" sound is heard.

Using a plastic-faced hammer, bend the tabs of the buckle to fix the lever in place. At the same time, use the plastic-faced hammer to adjust the position of the lever so that the end of the lever is aligned with the edge of the buckle.

NOTICE:

Do not strike the shaft forcefully with the plasticfaced hammer.

Secure the shaft in a vise between aluminum plates.

Temporarily install a new drive shaft damper clamp to the shaft, and then install the drive shaft damper so that it is between the damper clamp and the shaft.

HINT:

Make sure the damper clamp is on the outboard joint side.

Adjust the position of the drive shaft damper so that the distance shown in the illustration is within the specified range.

Standard distance:

161 to 165 mm (6.339 to 6.496 in.)

Secure the shaft in a vise between aluminum plates.

Tighten the drive shaft damper clamp.

NOTICE:

Make sure the clamp is installed in the correct position.

1. for One Touch Type Clamp:
   Using a screwdriver, tighten the drive shaft damper clamp, as shown in the illustration.
   

2. for Claw Engagement Type Clamp:
   Using needle-nose pliers, tighten the drive shaft damper clamp, as shown in the illustration.
   

Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged

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

1. Inboard joint boot clamp
   

2. No. 2 inboard joint boot clamp
   

3. Inboard joint clamp
   

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

Align the matchmarks placed before removal.

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

NOTICE:

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

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

Standard grease capacity:

175 to 185 g (6.2 to 6.5 oz.)

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

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

Install the boot to the inboard joint.

for One Touch Type Clamp:
Using a screwdriver, tighten the clamp, as shown in the illustration.

NOTICE:

Be careful not to damage the boot.

for Claw Engagement Type Clamp:
Using needle-nose pliers, tighten the clamp, as shown in the illustration.

NOTICE:

Be careful not to damage the boot.

for One Touch Type Clamp:
Using a screwdriver, tighten the clamp, as shown in the illustration.

NOTICE:

Be careful not to damage the boot.

for Claw Engagement Type Clamp:
Using needle-nose pliers, tighten the clamp, as shown in the illustration.

NOTICE:

Be careful not to damage the boot.

Secure the shaft in a vise between aluminum plates.

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

Check the boots for damage.

Measure length (A) of the drive shaft.

NOTICE:

Keep the drive shaft assembly level during inspection.

Standard (Reference):

Item	Drive shaft LH (Dimension)	Drive shaft RH (Dimension)
for U241E	585.2 mm (1.92 ft.)	902.0 mm (2.96 ft.)
for E352	583.6 mm (1.91 ft.)	906.4 mm (2.97 ft.)
for EB61	594.6 mm (1.95 ft.)	893.4 mm (2.93 ft.)