Front Drive Shaft: Reassembly

RH for 2WD: REASSEMBLE INBOARD JOINT SHAFT
1. Assemble the bearing case.
  1. Using a pin punch and a hammer, install the straight pin into the bearing case.
    
    Fig 1: Installing Straight Pin Into Bearing Case Using Pin Punch And Hammer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using SST and a press, install a new bearing into the bearing case.
    SST 09950-60020 (09951-00720), 09950-70010 (09951-07150)
  3. Using a screwdriver, install a new snap ring (large).
    
    Fig 2: Installing Bearing Into Bearing Case Using SST And Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bearing case.
  1. Using SST and a press, install the bearing with the bearing case assembly to the inboard shaft.
    SST 09710-04081
  2. Using a snap ring expander, install a new snap ring (small).
    
    Fig 3: Installing Bearing With Bearing Case Assembly To Inboard Shaft Using SST And Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the dust covers.
  1. Using SST and a press, install a new No. 2 dust cover.
    SST 09710-04081
    
    Fig 4: Installing Number Dust Cover Using SST And Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using a press, install a new No. 1 dust cover, as shown.
    
    Fig 5: Installing Number Dust Cover Using Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Except RH for 2WD: INSTALL NEW DUST COVER
Using a press, install a new dust cover.

REASSEMBLE DRIVE SHAFT

Temporarily install a new outboard joint boot (dynamic damper), a new inboard joint boot and new boot clamps.

Fig 6: Installing Dust Cover Using Special Tool
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Before installing the boots, wrap vinyl tape around the spline of the drive shaft to prevent damaging the boots.

Fig 7: Wrapping Vinyl Tape Around Spline Of Drive Shaft To Prevent Damaging Boot
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. install a new outboard joint boot to the outboard joint shaft, and place new boot clamps on the outboard joint boot.
2. w/dynamic damper: Install the dynamic damper to the outboard joint shaft, and place a new boot clamp on it.
  HINT:
  
  The dynamic damper direction is shown.
3. Place new boot clamps on a new inboard boot, and install them to the outboard joint shaft.
  
  Fig 8: Placing Boot Clamps On Inboard Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the tripod.
1. Place the beveled side of the tripod axial spline toward the outboard joint.
2. Align the matchmarks placed before removal procedure.
3. Using a brass bar and a hammer, tap the tripod to the drive shaft.
  
  Fig 9: Identifying Matchmarks Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not tap the roller.
4. Using a snap ring expander, install a new snap ring.
Cover the outboard joint boot.
Pack the outboard joint and boot with grease in the boot kit, and cover the outboard joint with the boot.

Grease capacity: (Color = yellow) 190-200 g (6.8 - 7.1 oz.)
Cover the inboard joint boot.
1. Pack the inboard joint shaft and boot with grease in the boot kit.
  Grease capacity: (Color = ocher yellow) 185-195 g (6.6 - 7.0 oz.)
2. Align the matchmarks placed before removal procedure, and install the inboard joint shaft to the outboard joint shaft.
3. Cover the inboard joint shaft with the boot.
  
  Fig 10: Installing Inboard Joint Shaft To Outboard Joint Shaft With Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Tighten the boot clamps.

Make sure that the 2 boots are on the shaft groove.

Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.

Fig 11: Identifying Drive Shaft Standard Length

Drive shaft standard length:

DRIVE SHAFT STANDARD LENGTH SPECIFICATIONS

2WD RH	858.5 +/- 5.0 mm (33.80 +/- 0.197 in.)
2WD LH	585.4 +/- 5.0 mm (23.00 +/- 0.197 in.)
4WD RH	920.5 +/- 5.0 mm (36.24 +/- 0.197 in.)
4WD LH	520.5 +/- 5.0 mm (20.47 +/- 0.197 in.)

w/dynamic damper: Slide the dynamic damper by the distance, as shown.
Distance: 155.9 - 159.9 mm (6.14 - 6.30 in.)
Bend the band and tighten the boot clamps (and dynamic damper clamp) with a screwdriver.

Fig 12: Identifying Dynamic Damper Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002