Reassembly

DRIVE SHAFT: FRONT DRIVE SHAFT:

REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT BEARING






(a) Using SST and a press, install a new front drive shaft bearing.
SST: 09726-40010
SST: 09527-10011
NOTE: Bearing should be completely installed.

2. INSTALL FRONT DRIVE SHAFT RH HOLE SNAP RING






(a) Using a snap ring expander, install a new front drive shaft RH hole snap ring.
3. INSTALL FRONT DRIVE SHAFT DUST COVER






(a) Using SST and a press, install a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover meets the specification, as shown in the illustration.
SST: 09726-40010
SST: 09527-10011
Distance (A):
26.8 to 27.4 mm (1.0551 to 1.0787 in.)
4. INSTALL FRONT DRIVE SHAFT DUST COVER LH






(a) Using SST and a press, install a new drive shaft dust cover LH.
SST: 09527-10011
- Dust cover should be completely installed.
- Be careful not to damage the dust cover.

5. INSTALL FRONT DRIVE SHAFT DUST COVER RH






(a) Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.
SST: 09527-10011
Distance (A):
109.5 mm (4.311 in.)
6. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new hole snap ring to the inboard joint shaft assembly.
7. INSTALL OUTBOARD JOINT BOOT
HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.





(a) Install new parts to the outboard joint shaft assembly in the following order.
(1) Outboard joint boot No.2 clamp (A)
(2) Outboard joint boot (B)
(3) Outboard joint boot clamp (C)
(b) Pack the outboard joint shaft and boot with grease.
Grease capacity:
205 to 225 g (7.2 to 7.9 oz.)
8. INSTALL OUTBOARD JOINT BOOT NO.2 CLAMP
(a) Hold the outboard joint shaft assembly between aluminium plates in a vise.
NOTE: Do not overtighten the vise.

(b) Install the outboard joint boot No.2 clamp onto the boot.
(c) Place SST onto the outboard joint boot No.2 clamp.
SST: 09521-24010






(d) Tighten the SST so that the outboard joint boot No.2 clamp is pinched.
SST: 09521-24010
NOTE: Do not overtighten the SST.





(e) Using SST, measure the clearance of the outboard joint boot No.2 clamp.
SST: 09240-00020
Clearance:
0.8 mm (0.031 in.) or less
NOTE: When the measured value is greater than the specified value, retighten the clamp.

9. INSTALL OUTBOARD JOINT BOOT CLAMP
(a) Install the outboard joint boot clamp perform the same procedures as for the outboard joint boot No.2 clamp.
10. INSTALL FRONT DRIVE SHAFT DAMPER
(a) Install the drive shaft damper to the drive shaft.
(b) Make sure that the damper is on the shaft groove.






(c) Set the distance, as specified below.
Distance (A):
225.5 to 229.5 mm (8.8779 to 9.0354 in.)
11. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP
(a) Hold the outboard joint shaft assembly between aluminium plates in a vise.
NOTE: Do not overtighten the vise.

(b) Install the drive shaft damper clamp to the damper.
NOTE: Be sure to install the clamp in the correct position.

(c) Place SST onto the drive shaft damper clamp.
SST: 09521-24010






(d) Tighten the SST so that the clamp is pinched.
SST: 09521-24010
NOTE: Do not overtighten the SST.





(e) Using SST, measure the clearance of the drive shaft damper clamp.
SST: 09240-00020
Clearance:
0.8 mm (0.031 in.) or less
NOTE: Using SST, measure the clearance of the drive shaft damper clamp.

12. INSTALL INBOARD JOINT SHAFT ASSEMBLY






(a) Install new parts to the inboard joint shaft assembly in the following order.
(1) Inboard joint boot clamp (A)
(2) Inboard joint boot (B)
(3) Inboard joint boot No.2 clamp (C)
(b) Hold the outboard joint shaft assembly between aluminium plates in a vise.
NOTE: Do not overtighten the vise.

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






(d) Align the matchmarks.






(e) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft.
- Do not tap the roller.
- Be sure to install the tripod in the correct direction.





(f) Using a snap ring expander, install a new front inner shaft snap ring.
(g) Pack the inboard joint shaft and boot with grease.
Grease capacity:
155 to 175 g (5.5 to 6.2 oz.)






(h) Align the matchmarks, install the inboard joint assembly to the outboard joint shaft assembly.
13. INSTALL INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assembly.
14. INSTALL INBOARD JOINT BOOT NO.2 CLAMP
(a) Hold the outboard joint shaft assembly between aluminium plates in a vise.
NOTE: Do not overtighten the vise.

(b) Install the inboard joint boot No.2 clamp onto the boot.
(c) Place SST onto the inboard joint boot No.2 clamp.
SST: 09521-24010






(d) Tighten the SST so that the inboard joint boot No.2 clamp is pinched.
SST: 09521-24010
NOTE: Do not overtighten the SST.





(e) Using SST, measure the clearance of the inboard joint boot No.2 clamp.
SST: 09240-00020
Clearance:
0.8 mm (0.031 in.) or less
NOTE: When the measured value is greater than the specified value, retighten the clamp.

15. INSTALL INBOARD JOINT BOOT CLAMP
(a) Install the outboard joint boot clamp perform the same procedures as for the inboard joint boot No.2 clamp.
16. INSPECT FRONT DRIVE SHAFT ASSEMBLY






(a) Check that there is no excessive play in the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust direction.
(c) Check that there is no excessive play in the radial directions of the inboard joint.
(d) Check the boots for damage.