RM38T0EC _52 Drivetrain _112266 DRIVE SHAFT / PROPELLER SHAFT _0604511 FRONT DRIVE SHAFT ASSEMBLY(for HEV Model) A

DRIVE SHAFT / PROPELLER SHAFT  FRONT DRIVE SHAFT ASSEMBLY(for HEV Model)  REASSEMBLY  


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
C506978N02
1.167,0.083 1.917,1.417 0.75,1.333 1.167,1.417 1.917,2.667 0.75,1.25 2.833,2.417 3.667,3.667 0.833,1.25 2.833,0.917 3.667,2.417 0.833,1.5 2.552,0.823 2.813,0.49 2.813,0.49 2.979,0.49 false 4.542,2.333 4.542,2.667 false 3.229,1.729 3.229,2.063 false 3.24,2.99 3.24,3.323 false 1.531,0.646 1.531,0.979 false 1.542,1.896 1.542,2.229 false 3.406,0.375 3.958,0.729 0.552,0.354 18 false 1 3.26,0.417 3.448,0.635 0.188,0.219 10 false 3.229,2.094 3.427,2.313 0.198,0.219 10 false 1.552,1.01 1.74,1.229 0.188,0.219 10 false 1.698,0.979 2.25,1.333 0.552,0.354 18 false 3 3.365,2.073 3.917,2.427 0.552,0.354 18 false 2 0.083,0.083 0.333,0.333 0.25,0.25 12 false *A 4.479,2.677 4.792,2.875 0.313,0.198 10 false *1 3.229,3.333 3.427,3.552 0.198,0.219 10 false 3.375,3.302 3.927,3.656 0.552,0.354 18 false 2 1.563,2.25 1.75,2.469 0.188,0.219 10 false 1.708,2.229 2.26,2.583 0.552,0.354 18 false 3 1.208,0.125 1.458,0.375 0.25,0.25 12 false *B 2.875,0.958 3.125,1.208 0.25,0.25 12 false *B 2.875,2.458 3.125,2.708 0.25,0.25 12 false *C 1.208,1.458 1.458,1.708 0.25,0.25 12 false *C

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FRONT AXLE OUTBOARD JOINT BOOT - (Click here) - -
2 FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 43447F (Click here) - -
3 FRONT AXLE OUTBOARD JOINT BOOT CLAMP 43447E (Click here) - -

*A for LH Side *B for Type A
*C for Type B - -
*1 FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY - -
Non-reusable part - -

C464887N02
4.302,2.115 4.302,1.844 false 5.594,2.865 5.594,2.604 false 6.208,3.125 6.208,2.885 false 3.625,1.802 3.625,1.469 false 3.208,1.5 3.208,1.167 false 2.635,1.25 2.635,0.948 false 0.906,2.271 0.906,1.938 false 1.417,2.656 1.417,2.323 false 2.042,2.938 2.042,2.583 false 3.854,4.021 3.854,3.625 false 6.521,0.292 6.781,0.292 false 4.885,2.552 4.885,2.219 false 2.677,1.24 3.229,1.594 0.552,0.354 18 false 6 6.365,3.146 6.917,3.5 0.552,0.354 18 false 8 5.708,2.896 6.26,3.25 0.552,0.354 18 false 7 4.271,2.219 4.646,2.458 0.375,0.24 10 false 5.552,2.948 5.927,3.188 0.375,0.24 10 false 6.208,3.198 6.583,3.438 0.375,0.24 10 false 0.896,2.354 1.271,2.594 0.375,0.24 10 false 3.146,1.552 3.542,1.792 0.396,0.24 10 false 3.792,4.052 4.188,4.292 0.396,0.24 10 false *3 2.198,2.979 2.75,3.333 0.552,0.354 18 false 5 1.479,2.667 2.031,3.021 0.552,0.354 18 false 4 2.042,3.031 2.417,3.271 0.375,0.24 10 false 1.052,2.302 1.604,2.656 0.552,0.354 18 false 5 4.375,2.167 4.927,2.521 0.552,0.354 18 false 9 3.552,1.823 3.948,2.063 0.396,0.24 10 false *1 4.792,2.573 5.188,2.813 0.396,0.24 10 false ● *2 6.229,0.156 6.781,0.51 0.552,0.354 18 false 10

Procedure Part Name Code
Z101186

Z101188

Z101187

4 FRONT DRIVE SHAFT DAMPER 43474E (Click here) - -
5 FRONT DRIVE SHAFT DAMPER CLAMP 43474G (Click here) - -
6 FRONT DRIVE INBOARD JOINT ASSEMBLY 43040 (Click here) - -
7 FRONT AXLE INBOARD JOINT BOOT - (Click here) - -
8 FRONT AXLE INBOARD JOINT BOOT CLAMP 43448F (Click here) - -
9 FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 43448G (Click here) - -
10 INSPECT FRONT DRIVE SHAFT ASSEMBLY 43420 (Click here) - -

*1 TRIPOD JOINT *2 FRONT AXLE INBOARD JOINT GROMMET
*3 FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY - -
Non-reusable part - -

CAUTION / NOTICE / HINT

NOTICE:
·

Secure the drive shaft in a vise between aluminum plates.

·

Do not overtighten the vise.



HINT:
·

Use the same procedure for the RH side and LH side.

·

The following procedure is for the LH side.



PROCEDURE

Hide 1.INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)

a.
C445316C03
0.719,0.333 1.219,0.635 0.5,0.302 18 false i 4.094,0.302 4.646,0.656 0.552,0.354 18 false ii 0.708,2.167 1.26,2.521 0.552,0.354 18 false iii 4.063,2.146 4.344,2.5 0.281,0.354 18 false iv
V100135

Outboard Joint Side
V100136

Inboard Joint Side
V100137

Parts insertion direction
V100138

Grease


i.

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


ii.

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

1. Front No. 2 axle outboard joint boot clamp

2. Front axle outboard joint boot

3. Front axle outboard joint boot clamp


iii.

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

Standard Grease Capacity:

86 to 96 g (3.03 to 3.39 oz.)



iv.

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 2.INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

Z101186

CAUTION:
·
C331975

When installing the front No. 2 axle outboard joint boot clamp, do not perform the work without wearing protective gloves.

·

If work is performed without using protective gloves, injuries may occur.




a.

for Type A:

C464889C01
6.198,1.458 5.854,1.458 false 5.135,1.219 4.792,1.219 false 6.281,2.135 5.938,2.135 false 0.417,0.094 0.698,0.448 0.281,0.354 18 false i 6.25,1.375 6.563,1.573 0.313,0.198 10 false *a 4.615,1.146 4.927,1.344 0.313,0.198 10 false *b 5.75,2.063 6.063,2.26 0.313,0.198 10 false *c
*a Fulcrum Point *b Lever Push Position
*c Band Support Position - -
V113147

Turn - -


i.

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

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.

·

The lever folds easily at the fulcrum point when pushed at the position shown in the illustration.

·

When folding back the lever, do not push at the end of the lever.

C415873C01
6.771,1.49 6.125,1.49 true 5.948,1.417 6.26,1.573 0.313,0.156 10 false *a
*a Temporary Claw - -


·

If the lever bends in the middle, it may not engage with the temporary claws or may not be held in the correct position.





b.

for Type A:

C464890C01
3.604,1.063 3.135,1.417 3.135,1.417 3.708,1.052 true 2.083,1.49 1.594,1.49 true 1.438,2.281 1.438,1.906 true 5.625,2.26 5.625,1.958 5.625,1.958 5.448,1.958 true 1.417,1.417 1.729,1.573 0.313,0.156 10 false *a 1.385,2.302 1.698,2.458 0.313,0.156 10 false *b 0.406,0.094 0.688,0.448 0.281,0.354 18 false i 2.958,1.385 3.271,1.542 0.313,0.156 10 false *a 5.271,1.885 5.583,2.042 0.313,0.156 10 false *a
*a Temporary Claw *b Fulcrum Point
V100135

Press down
V100136

Contact Point
V113147

Turn
V113148

Install in this Direction


i.

As shown in the illustration, while pressing the outboard joint area against the work surface, firmly press the lever into place by rolling the outboard joint area forward from the folded fulcrum point to the temporary claw area until a click sound is heard.

NOTICE:
·

Do not damage the deflector.

·

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





c.

for Type A:

C464891C01
5.458,1.146 4.865,1.563 4.865,1.563 5.25,1.063 true 0.417,0.083 0.698,0.438 0.281,0.354 18 false i 4.708,1.563 5.021,1.76 0.313,0.198 10 false *a
*a Buckle - -


i.

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 excessive force when tapping with the plastic hammer.

·

Do not damage the front axle outboard joint boot.





d.

for Type B:

C464075N01
1.219,0.625 2.021,0.781 true 6.01,0.896 6.583,1.469 true 0.385,0.042 1.5,0.417 1.115,0.375 18 false i, ii, iii, iv 3.958,0.052 4.51,0.406 0.552,0.354 18 false v, vi 0.917,0.521 1.375,0.719 0.458,0.198 10 false SST 6.5,1.5 6.958,1.698 0.458,0.198 10 false SST

i.

Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.


ii.

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

SST
09521-24010  


iii.

Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.



iv.

Remove SST.


v.

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

SST
09240-00021  

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0591 in.)



vi.

If the clearance is not as specified, retighten SST.



Hide 43447E 3.INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

Z101186

CAUTION:
·
C465062

When installing the front axle outboard joint boot clamp, do not perform the work without wearing protective gloves.

·

If work is performed without using protective gloves, injuries may occur.




a.

for Type A:

C464892C01
5.271,5.219 4.729,5.542 4.729,5.542 5,5.073 true 0.49,3.979 0.802,4.323 0.313,0.344 18 false iii 3.969,3.979 4.302,4.292 0.333,0.313 18 false iii 3.948,1.833 4.281,2.146 0.333,0.313 18 false ii 0.479,1.823 0.813,2.135 0.333,0.313 18 false ii 1.906,0.156 2.24,0.469 0.333,0.313 18 false i 4.594,5.563 4.906,5.76 0.313,0.198 10 false *a
*a Buckle - -
V113147

Turn
V113148

Install in this Direction
V113146

Place the tip near the center of the lever - -


i.

Install the front axle outboard joint boot clamp to the front axle outboard joint boot and provisionally bend the lever.

NOTICE:
·

Set the lever into the guide groove correctly.

·

Check the band and lever for any deformation before bending the lever.




ii.

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


iii.

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

NOTICE:

Do not damage the front axle outboard joint boot.




b.

for Type B:

C464076N01
0.979,0.75 1.781,0.906 true 5.708,1.042 6.281,1.219 true 0.385,0.042 1.5,0.417 1.115,0.375 18 false i, ii, iii, iv 3.958,0.052 4.51,0.406 0.552,0.354 18 false v, vi 0.688,0.656 1.146,0.854 0.458,0.198 10 false SST 6.344,1.135 6.802,1.333 0.458,0.198 10 false SST

i.

Install the front axle outboard joint boot clamp to the front axle outboard joint boot.


ii.

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

SST
09521-24010  


iii.

Tighten SST so that the front axle outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.



iv.

Remove SST.


v.

Using SST, measure the clearance of the front axle outboard joint boot clamp.

SST
09240-00021  

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0591 in.)



vi.

If the clearance is not as specified, retighten SST.



Hide 43474E 4.INSTALL FRONT DRIVE SHAFT DAMPER

a.
C431939C03
2.354,1.365 2.354,1.031 false 3.323,1.365 3.323,1.031 false 2.833,1.396 2.833,1.063 false 3.427,0.177 3.677,0.375 0.25,0.198 10 false (A) 0.448,0.031 0.854,0.396 0.406,0.365 18 false i, ii 2.771,1.406 3.083,1.563 0.313,0.156 10 false *1 2.281,1.385 2.594,1.542 0.313,0.156 10 false *2 3.26,1.365 3.573,1.521 0.313,0.156 10 false *2
*1 Front Drive Shaft Damper *2 Front Drive Shaft Damper Clamp


i.

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.


ii.

Set the dimension (A) as specified below.

Dimension (A):
for LH Side 211.7 to 215.7 mm (8.33 to 8.49 in.)
for RH Side 488 to 492 cm (1.60 to 1.61 ft.)




Hide 43474G 5.INSTALL FRONT DRIVE SHAFT DAMPER CLAMP

a.

for Type A:

C464893C02
2.469,1.5 2.677,1.563 2.677,1.563 2.896,1.458 false 0.417,0.094 1.073,0.427 0.656,0.333 18 false i 2.615,1.552 2.813,1.75 0.198,0.198 10 false *a
*a Claw - -


i.

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

NOTICE:
·

Be sure to install the clamps in the correct position.

·

Do not damage the front drive shaft damper.





b.

for Type B:

C469404N01
0.396,0.021 0.677,0.375 0.281,0.354 18 false i

i.

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

NOTICE:
·

Be sure to install the clamps in the correct position.

·

Do not damage the front drive shaft damper.





Hide 43040 6.INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

a.
C502326C01
4.938,1.552 5.823,1.594 5.823,1.594 5.323,1.333 true 4.698,4.135 5.219,4.135 5.219,4.135 5.219,4.438 true 4.781,4.917 4.781,4.146 true 2.229,5.302 2.229,5.083 true 0.469,0.135 1.021,0.458 0.552,0.323 18 false i, ii 4.073,0.104 4.625,0.427 0.552,0.323 18 false iii, iv 0.458,1.927 1.01,2.25 0.552,0.323 18 false v 4.083,1.927 4.635,2.25 0.552,0.323 18 false vi 0.438,3.854 0.99,4.177 0.552,0.323 18 false vii 5.896,1.542 6.448,1.865 0.552,0.323 10 false *a 2.177,5.323 2.729,5.646 0.552,0.323 10 false *b 4.531,4.063 5.083,4.385 0.552,0.323 10 false *a 4.063,3.865 4.615,4.188 0.552,0.323 18 false viii
*a Matchmark *b Groove
V100135

Outboard Joint Side
V100136

Inboard Joint Side
V100137

Parts insertion direction
V100138

Grease


i.

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

1. Front axle inboard joint boot clamp

2. Front axle inboard joint boot

3. Front No. 2 axle inboard joint boot clamp


ii.

Remove the protective tape.


iii.

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.



iv.

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.




v.

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


vi.

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

Standard Grease Capacity:

168 to 178 g (5.93 to 6.28 oz.)



vii.

Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

NOTICE:
·

Align the phase of the protrusions and depressions, and assemble the front axle inboard joint grommet to the front drive inboard joint assembly.

·

Make sure the protrusion on the inner corner of the front axle inboard joint grommet is securely inserted into the groove in the outer surface of the joint.




viii.

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.
C464895N01
0.406,0.083 0.698,0.396 0.292,0.313 18 false i

i.

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

NOTICE:
·

Keep the grooves free of grease.

·

Keep the inside of the front axle inboard joint boot free of foreign matter.





Hide 43448F 8.INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

Z101186

CAUTION:
·
C465062

When installing the front axle inboard joint boot clamp, do not perform the procedure without wearing protective gloves.

·

Performing the procedure without wearing protective gloves could result in injury.




a.
C464892C01
5.271,5.219 4.729,5.542 4.729,5.542 5,5.073 true 0.49,3.979 0.802,4.323 0.313,0.344 18 false iii 3.969,3.979 4.302,4.292 0.333,0.313 18 false iii 3.948,1.833 4.281,2.146 0.333,0.313 18 false ii 0.479,1.823 0.813,2.135 0.333,0.313 18 false ii 1.906,0.156 2.24,0.469 0.333,0.313 18 false i 4.594,5.563 4.906,5.76 0.313,0.198 10 false *a
*a Buckle - -
V113147

Turn
V113148

Install in this Direction
V113146

Place the tip near the center of the lever - -


i.

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

NOTICE:
·

Set the lever into the guide groove correctly.

·

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




ii.

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


iii.

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 inboard joint boot.




Hide 43448G 9.INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

Z101186

CAUTION:
·
C331975

When installing the front No. 2 axle inboard joint boot clamp , do not perform the work without wearing protective gloves.

·

Performing the procedure without wearing protective gloves could result in injury.




a.
C464896C01
1.125,3.521 1.552,3.521 true 2.531,3.521 2.948,3.521 true 2.167,4.25 2.594,4.25 true 1.479,4.802 1.677,4.802 1.677,4.802 1.927,5.031 true 5.781,3.438 6.01,3.25 6.01,3.25 6.219,3.25 true 1.625,0.229 1.906,0.583 0.281,0.354 18 false i 0.406,2.74 0.688,3.094 0.281,0.354 18 false ii 4.167,2.74 4.448,3.094 0.281,0.354 18 false iii 3.469,1.51 3.729,1.771 0.26,0.26 10 false A 0.948,3.448 1.177,3.677 0.229,0.229 10 false *a 3,3.448 3.229,3.677 0.229,0.229 10 false *a 2.635,4.167 2.865,4.396 0.229,0.229 10 false *a 1.302,4.729 1.531,4.958 0.229,0.229 10 false *a 6.26,3.177 6.49,3.406 0.229,0.229 10 false *b 5.594,3.802 5.823,4.031 0.229,0.229 10 false B 6.354,5.094 6.583,5.323 0.229,0.229 10 false B 4.802,5.094 5.031,5.323 0.229,0.229 10 false B
*a Indented Portion *b Support Point


i.

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

Dimension (A):
for LH Side 587.2 to 595.2 mm (1.93 to 1.95 ft.)
for RH Side 891.2 to 899.2 mm (2.92 to 2.95 ft.)



ii.

While holding dimension (A) to the specified length, pull the indented portion of the inboard joint grommet outward with your finger, etc. to release air from inside the inboard joint and equalize the air pressure with the atmospheric pressure.


iii.

Set the folding support point of the clamp so that it is aligned with any of the A portions indicated by arrows in the illustration.



b.
C464897C01
5.844,1.49 6.229,1.49 false 4.823,1.292 5.208,1.292 false 5.813,2.063 6.198,2.063 false 0.417,0.083 0.698,0.438 0.281,0.354 18 false i 6.271,1.417 6.583,1.615 0.313,0.198 10 false *a 4.656,1.219 4.969,1.417 0.313,0.198 10 false *b 5.625,1.99 5.938,2.188 0.313,0.198 10 false *c
*a Fulcrum Point *b Lever Push Position
*c Band Support Position - -


i.

Temporarily fold back the lever at the fulcrum point.

NOTICE:
·

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

·

The lever folds easily at the fulcrum point when pushed at the position shown in the illustration.

·

When folding back the lever, do not push at the end of the lever.

C415873C01
6.771,1.49 6.125,1.49 true 5.948,1.417 6.26,1.573 0.313,0.156 10 false *a
*a Temporary Claw - -


·

If the lever bends in the middle, it may not engage with the temporary claws or may not be held in the correct position.





c.
C464890C01
3.604,1.063 3.135,1.417 3.135,1.417 3.708,1.052 true 2.083,1.49 1.594,1.49 true 1.438,2.281 1.438,1.906 true 5.625,2.26 5.625,1.958 5.625,1.958 5.448,1.958 true 1.417,1.417 1.729,1.573 0.313,0.156 10 false *a 1.385,2.302 1.698,2.458 0.313,0.156 10 false *b 0.406,0.094 0.688,0.448 0.281,0.354 18 false i 2.958,1.385 3.271,1.542 0.313,0.156 10 false *a 5.271,1.885 5.583,2.042 0.313,0.156 10 false *a
*a Temporary Claw *b Fulcrum Point
V100135

Press down
V100136

Contact Point
V113147

Turn
V113148

Install in this Direction


i.

As shown in the illustration, while pressing the outboard joint area against the work surface, firmly press the lever into place by rolling the outboard joint area forward from the folded fulcrum point to the temporary claw area until a click sound is heard.

NOTICE:
·

Do not damage the deflector.

·

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





d.
C464899C01
5.448,1.021 4.938,1.406 4.938,1.406 5.25,0.948 true 0.417,0.083 0.698,0.438 0.281,0.354 18 false i 4.792,1.427 5.104,1.625 0.313,0.198 10 false *a
*a Buckle - -


i.

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 excessive force when tapping with the plastic hammer.

·

Do not damage the front axle outboard joint boot.