Front Drive Shaft Assembly (For 2Zr-Fe) Reassembly

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:

1. Install the front drive shaft dust cover in the correct direction.
   
2. Do not deform the front drive shaft dust cover.
   

Wrap the splines of the front axle outboard joint shaft with vinyl tape to prevent the boot from being damaged.

Install new parts onto the front axle outboard joint shaft in the following order.

1. No. 2 front axle outboard joint boot clamp
   

2. Outboard joint boot
   

3. Front axle outboard joint boot clamp
   

Pack the joint portion of the front axle outboard joint shaft and outboard joint boot with grease.

Grease capacity:

90 to 110 g (3.2 to 3.8 oz.)

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

NOTICE:

Keep the groove free of grease.

Hold the front axle outboard joint shaft in a vise using aluminum plates.

NOTICE:

Do not overtighten the vise.

Place SST onto the No. 2 front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

SST

09521-24010

Tighten SST so that the clearance comes within the specified range.

NOTICE:

Do not overtighten SST.

Remove SST.

Using SST, measure the clearance of the No. 2 front axle outboard joint boot clamp as shown in the illustration.

SST

09240-00020

Standard Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

NOTICE:

If the clearance is outside the specified range, retighten SST.

Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

SST

09521-24010

Tighten SST so that the clearance comes within the specified range.

NOTICE:

Do not overtighten SST.

Remove SST.

Using SST, measure the clearance of the front axle outboard joint boot clamp as shown in the illustration.

SST

09240-00020

Standard Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

NOTICE:

If the clearance is outside the specified range, retighten SST.

Hold the front axle outboard joint shaft in a vise using aluminum plates.

NOTICE:

Do not overtighten the vise.

Temporarily install a new front drive shaft damper clamp RH on the front drive shaft damper RH.

Install the front drive shaft damper RH onto the front axle outboard joint shaft as shown in the illustration.

NOTICE:

Be sure to install the front drive shaft damper RH in the correct direction.

for One Touch Type:

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

   NOTICE:

   Be sure to install the clamp in the correct position.

for Claw Engagement Type:

1. Using needle nose pliers, install the front drive shaft damper clamp RH as shown in the illustration.
   

   NOTICE:

   Be sure to install the clamp in the correct position.

Wrap the splines of the front axle outboard joint shaft with vinyl tape to prevent the boot from being damaged.

HINT:

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

Install new parts onto the front axle outboard joint shaft in the following order.

1. Front axle inboard joint boot clamp
   

2. Inboard joint boot
   

3. No. 2 front axle inboard joint boot clamp
   

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

NOTICE:

Do not overtighten the vise.

Remove the vinyl tape.

Align the matchmarks and install the tripod joint onto the front axle outboard joint shaft.

NOTICE:

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

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

NOTICE:

1. Do not tap the rollers.
   
2. Be sure to install the tripod joint in the correct direction.
   
3. Keep the tripod joint free of foreign matter.
   

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

Pack the inboard joint with grease.

Align the matchmarks and install the inboard joint onto the front axle outboard joint shaft.

Install the inboard joint boot to the front drive inboard joint assembly.

NOTICE:

Keep the grooves free of grease.

Check whether the drive shaft dimensions are within the following specifications.

for One Touch Type:

1. Using a screwdriver, install a new front axle inboard joint boot clamp as shown in the illustration.
   

   NOTICE:

   Be careful not to damage the boot.

for Claw Engagement Type:

1. Using needle nose pliers, install a new front axle inboard joint boot clamp as shown in the illustration.
   

   Text in Illustration

   *a

   Claw

   NOTICE:

   Be careful not to damage the boot.

for One Touch Type:

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

   NOTICE:

   Be careful not to damage the boot.

for Claw Engagement Type:

1. Using needle nose pliers, install a new No. 2 front axle inboard joint boot clamp as shown in the illustration.
   

   Text in Illustration

   *a

   Claw

   NOTICE:

   Be careful not to damage the boot.

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

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

Check that the inboard joint has no excessive play in the radial direction.

Check the boots for damage.

NOTICE:

Keep the drive shaft assembly level during inspection.