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Front Drive Shaft: Reassembly

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

  1. INSTALL FRONT DRIVE SHAFT BEARING 
    1. Using SST and a press, press in a new drive shaft bearing.

      SST 09950-60020 (09951-00710), 09950-70010 (09951-07100) 

      Fig 1: Pressing In New Drive Shaft Bearing
      G04222852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL DRIVE SHAFT BEARING CASE SUBASSEMBLY SNAP RING 
    1. Using a screwdriver, install a new bearing case snap ring.
    Fig 2: Installing New Bearing Case Snap Ring
    G04222853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL DRIVE SHAFT BEARING CASE SUBASSEMBLY 
    1. Using SST and a press, press in the drive shaft bearing case to the inboard joint RH.

      SST 09527-10011, 09710-04081 

      NOTE: Bearing should be installed completely.
      Fig 3: Pressing Drive Shaft Bearing Case To Inboard Joint Rh
      G04222854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install a new drive shaft hole snap ring.
    Fig 4: Installing New Drive Shaft Hole Snap Ring
    G04222855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DRIVE SHAFT DUST COVER 
    1. Using SST and a press, press in a new drive shaft dust cover.

      SST 09726-40010, 09527-10011 

      Standard distance (A): 

      0 to 1.0 mm (0 to 0.039 in.) 

      NOTE: Be careful not to damage the dust cover.
    2. Install the straight pin.
    Fig 5: Installing Front Drive Shaft Dust Cover
    G04222856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DRIVE SHAFT DUST COVER RH 
    1. Using SST and a press, press in a new drive shaft dust cover until the distance from the tip of the center drive shaft to the drive shaft dust cover reaches the specification, as shown in the illustration.

      SST 09527-10011 

      Standard distance (A): 

      91.0 to 92.0 mm (3.582 to 3.622 in.) 

      NOTE:
      • The dust cover should be installed completely.
      • Be careful not to damage the dust cover.
      Fig 6: Installing Front Drive Shaft Dust Cover Rh
      G04222857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, press in a new drive shaft dust cover.

      SST 09527-10011 

      NOTE:
      • The dust cover should be installed completely.
      • Be careful not to damage the dust cover.
  7. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING 
    1. Install a new hole snap ring.
    Fig 7: Installing New Hole Snap Ring
    G04222858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OUTBOARD JOINT BOOT 
    Fig 8: Installing Outboard Joint Boot
    G04222859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

    1. Install new parts to the outboard joint shaft assembly in the following order.
      1. No. 2 outboard joint boot clamp
      2. Outboard joint boot
      3. Outboard joint boot clamp
    2. Pack the outboard joint shaft and boot with grease from the boot kit.

    Standard grease capacity: 

    190 to 200 g (6.7 to 7.1 oz.) 

  9. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Secure the No. 2 outboard joint boot clamp onto the boot.
    2. Place SST onto the No. 2 outboard joint boot clamp.

      SST 09521-24010 

    3. Tighten SST so that the No. 2 outboard joint boot clamp is pinched.
      NOTE: Do not overtighten SST.
      Fig 9: Installing Front No 2 Axle Outboard Joint Boot Clamp
      G04222860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, measure the clearance of the outboard joint boot clamp.

      SST 09240-00020 

      Standard clearance: 

      0.8 mm (0.031 in.) or less 

      NOTE: When the measured value is greater than the specified value, retighten the clamp.
      Fig 10: Measuring Clearance Of Outboard Joint Boot Clamp
      G04222861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Secure the outboard joint boot clamp onto the boot.
    2. Place SST onto the outboard joint boot clamp.

      SST 09521-24010 

    3. Tighten SST so that the outboard joint boot clamp is pinched.
      NOTE: Do not overtighten SST.
      Fig 11: Installing Front Axle Outboard Joint Boot Clamp
      G04222862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, measure the clearance of the outboard joint boot clamp.

      SST 09240-00020 

      Standard clearance: 

      0.8 mm (0.031 in.) or less 

      NOTE: When the measured value is greater than the specified value, retighten the clamp.
      Fig 12: Measuring Clearance Of Outboard Joint Boot Clamp
      G04222863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DRIVE SHAFT DAMPER 

    HINT:

    Install the damper clamp to outboard joint side.

    1. Install a new drive shaft damper clamp and the drive shaft damper to the drive shaft.
    2. Make sure that the damper is on the shaft groove.
    3. Set the distance, as described below.

      Distance: 

      202.4 to 206.4 mm (7.969 to 8.126 in.) 

      Fig 13: Installing Front Drive Shaft Damper
      G04222864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the front drive shaft lightly in a soft vise.
    5. Install the drive shaft damper clamp to the damper.
      NOTE: Be sure to install the clamp in the correct position.
    6. One touch type:

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

    7. Claw engagement type:

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

  12. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY 
    1. Wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
    2. 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 boot
      Fig 14: Holding Front Drive Shaft Lightly Soft Vise
      G04222865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the beveled side of the tripod axial spline toward the outboard joint.
    4. Align the matchmarks placed before removal.
    5. Using a brass bar and hammer, tap the tripod joint onto the drive shaft.
      NOTE:
      • Do not tap the rollers.
      • Be sure to install the tripod joint in the correct direction.
    6. 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.) 

      Fig 15: Aligning Matchmarks
      G04222866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a snap ring expander, install a new shaft snap ring.
      Fig 16: Installing New Shaft Snap Ring
      G04222867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Aligning the matchmarks, and install the inboard joint to the outboard joint shaft.
  13. INSTALL FRONT DRIVE SHAFT INBOARD JOINT BOOT 
    1. Install the inboard joint boot to the inboard joint and outboard joint shaft.
    Fig 17: Installing Inboard Joint Boot To Inboard Joint And Outboard Joint Shaft
    G04222868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 
    1. One touch type:

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

      NOTE: Be careful not to damage the boot.
    2. Claw engagement type:

      Using needle-nose pliers, install the No. 2 inboard joint boot clamp, as shown in the illustration.

      NOTE: Be careful not to damage the boot.
      Fig 18: Installing No 2 Inboard Joint Boot Clamp
      G04222869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. One touch type:

      Using a screwdriver, install the inboard joint boot clamp, as shown in the illustration.

      NOTE: Be careful not to damage the boot.
    2. Claw engagement type:

      Using needle-nose pliers, install the inboard joint boot clamp, as shown in the illustration.

      NOTE: Be careful not to damage the boot.
      Fig 19: Installing Inboard Joint Boot Clamp
      G04222870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT FRONT DRIVE SHAFT 
    1. Check that there is no severe play in the radial direction of the outboard joint.
    2. Check that the inboard joint slides smoothly in the thrust direction.
    3. Check that there is no severe play in the radial direction of the inboard joint.
      Fig 20: Inspecting Front Drive Shaft
      G04222871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check the boots for damage.
      NOTE: Keep the drive shaft assembly level during inspection.

      HINT:

      For dimension (A), refer to the following values.

      Reference value: 

      873.0 to 883.0 mm (34.370 to 34.764 in.) for RH side 

      556.2 to 566.2 mm (21.898 to 22.291 in.) for LH side 

      Fig 21: Checking Boots For Damage
      G04222872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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