DRIVE SHAFT / PROPELLER SHAFT  FRONT DRIVE SHAFT ASSEMBLY(for 2NZ-FE)  REASSEMBLY  


PROCEDURE

Hide 41336E 1.INSTALL FRONT DRIVE SHAFT DUST COVER

a.
C157559
1.292,0.719 1.292,0.292 1.292,0.292 1.427,0.292 false 1.469,0.229 1.938,0.542 0.469,0.313 10 false *a
*a Steel Plate


Using a steel plate and a press, install a new front drive shaft dust cover.

NOTICE:
·

Install the front drive shaft dust cover in the correct direction.

·

The front drive shaft dust cover should be completely installed.

·

Be careful not to damage the front drive shaft dust cover.




Hide 2.INSTALL FRONT AXLE OUTBOARD JOINT BOOT

a.
C166359
1.917,0.885 2.427,0.375 2.427,0.375 2.792,0.375 false 2.823,0.281 3.177,0.49 0.354,0.208 10 *a
*a Protective Tape


Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.


b.
C274276
1.26,1.875 1.26,1.458 false 1.729,1.875 1.729,1.49 false 2.323,1.885 2.323,1.479 false 3.052,1.865 3.052,1.24 false 1.177,1.896 1.375,2.094 0.198,0.198 10 false *1 1.646,1.896 1.854,2.083 0.208,0.188 10 false *2 2.24,1.896 2.469,2.083 0.229,0.188 10 false *3 2.969,1.885 3.177,2.073 0.208,0.188 10 false *4
*1 Front Drive Outboard Joint Shaft Assembly
*2 Front No. 2 Axle Outboard Joint Boot Clamp
*3 Front Axle Outboard Joint Boot
*4 Front Axle Outboard Joint Boot Clamp
V100135

Outboard Joint Side
V100136

Inboard Joint Side


Install new parts to the front drive outboard joint shaft assembly in the following order:

i.

Front No. 2 axle outboard joint boot clamp


ii.

Front axle outboard joint boot


iii.

Front axle outboard joint boot clamp



c.

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

Standard Grease Capacity:

130 to 140 g (4.59 to 4.94 oz)



d.

Install the front axle outboard joint boot to the front drive outboard joint shaft assembly groove.

NOTICE:
·

Do not allow grease to adhere to the boot clamp track of the outboard joint boot.

·

Keep the inside of the outboard joint boot free of foreign matter.




Hide 43447F 3.INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

CAUTION:

Wear protective gloves. Sharp areas on the parts may injure your hands.


a.
C219374

Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever.

NOTICE:
·

Set the lever to the guide groove correctly and install the clamp as far to the inside of the vehicle as possible.

·

Check the band and the lever for any deformation before folding back the lever.




b.
C219375
1.771,0.583 2.042,0.875 0.271,0.292 10 false *a 2.177,2.073 2.49,2.323 0.313,0.25 10 false *b
*a Weight
*b Contact


Lean your weight on your hand and roll the outboard joint forward while pressing the outboard joint against the work surface. Roll the outboard joint and fold the lever until a click sound can be heard.

NOTICE:
·

Do not damage the speed sensor rotor.

·

Make sure that the outboard joint is in direct contact with the work surface.




c.
C219376

Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:
·

Do not use too much force when tapping with the plastic hammer.

·

Do not damage the front axle outboard joint boot.




Hide 43447E 4.INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

CAUTION:

Wear protective gloves. Sharp areas on the parts may injure your hands.


a.
C107948

Install the front axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever.

NOTICE:
·

Set the lever to the guide groove correctly.

·

Check the band and the lever for any deformation before folding back the lever.




b.
C158356
2.469,0.938 2.771,1.219 0.302,0.281 10 false *a
*a Place the tip near the center of the lever.


Using water pump pliers, pinch the front axle outboard joint boot clamp to temporarily secure it.


c.
C264475

Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

NOTICE:

Do not damage the front axle outboard joint boot.



Hide 43474E 5.INSTALL FRONT DRIVE SHAFT DAMPER (for RH Side)

a.
C305752
1.604,0.375 1.76,0.573 0.156,0.198 10 false A

Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

Dimension (A):

474 to 478 mm (1.55 to 1.57 ft.)



b.

Hold the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.



c.

Install the 2 front drive shaft damper clamps to the front drive shaft damper.

NOTICE:

Be sure to install the clamp in the correct position.



d.
C205160

Using needle-nose pliers, engage the 2 claws to install the 2 front drive shaft damper clamps as shown in the illustration.


Hide 6.INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

a.
C274277
0.688,1.875 0.688,1.333 false 1.698,1.854 1.698,1.615 false 2.49,1.875 2.49,1.667 false 2.927,1.885 2.927,1.25 false 0.625,1.896 0.938,2.052 0.313,0.156 10 *1 1.635,1.896 1.948,2.052 0.313,0.156 10 *2 2.417,1.906 2.729,2.063 0.313,0.156 10 *3 2.875,1.896 3.188,2.052 0.313,0.156 10 *a
*1 Front Axle Inboard Joint Boot Clamp
*2 Front Axle Inboard Joint Boot
*3 Front No. 2 Axle Inboard Joint Boot Clamp
*a Protective Tape
V100135

Outboard joint side
V100136

Inboard joint side


Install new parts to the front drive outboard joint shaft assembly in the following order:

i.

Front axle inboard joint boot clamp


ii.

Front axle inboard joint boot


iii.

Front No. 2 axle inboard joint boot clamp



b.

Hold the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.



c.

Remove the protective tape.


d.
C157561
1.542,1.615 2.354,1.781 2.354,1.781 2.073,1.281 false 2.396,1.719 2.594,1.885 0.198,0.167 10 *a
*a Matchmark


Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

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



e.

Align the matchmarks placed before removal.


f.

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

NOTICE:
·

Do not tap the rollers.

·

Keep the tripod joint free of foreign matter.

·

Be sure to install the tripod joint in the correct direction.




g.
F040223

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


h.

Pack the front drive inboard joint assembly and front axle inboard boot with grease.

Standard Grease Capacity:

180 to 190 g (6.35 to 6.70 oz)



i.
C160821
1.427,1.198 1.427,0.646 true 1.802,0.76 1.802,0.448 1.802,0.448 1.521,0.448 true 1.427,0.688 1.427,0.448 false 1.115,0.448 1.521,0.448 false 0.969,0.375 1.156,0.542 0.188,0.167 10 *a
*a Matchmark


Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.


Hide 7.INSTALL FRONT AXLE INBOARD JOINT BOOT

a.

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


b.
C157783
1.531,1.698 1.76,1.875 0.229,0.177 10 false A

Check whether the drive shaft dimension (A) is within specification.

Dimension (A):
LH Side 576.9 mm (1.89 ft.)
RH Side 854.7 mm (2.80 ft.)



Hide 43448G 8.INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

a.
C067083

for One Touch Type:

i.

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



b.
C157518
0.5,0.75 1.021,1.302 1.021,1.302 1.406,0.698 false 0.958,1.313 1.271,1.51 0.313,0.198 10 false *a
*a Claw


for Claw Engagement Type:

i.

Using needle-nose pliers, engage the 2 claws to install the front No. 2 axle inboard joint boot clamp as shown in the illustration.

NOTICE:

Be careful not to damage the front axle inboard joint boot.




Hide 43448F 9.INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

HINT:

Perform the same procedure as for the front No. 2 axle inboard joint boot clamp.