DRIVE SHAFT / PROPELLER SHAFT  FRONT DRIVE SHAFT ASSEMBLY  REASSEMBLY  

0.521,0.271 0.677,0.271 0.677,0.271 0.854,0.479 false 0.469,1.708 0.708,1.708 false 0.156,0.219 0.615,0.417 0.458,0.198 10 false SST 0.135,1.615 0.594,1.813 0.458,0.198 10 false SST

*a	Steel Plate

Using SST and a press, press in the front drive inboard joint assembly RH until the new front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH.

SST

09527-10011  
09710-30012  (09710-04081)

NOTICE:

·

Make sure the front drive shaft bearing contacts the edge of the front drive inboard joint assembly RH, but do not press it in more than necessary.

·

Do not apply weight to the dust cover and outer race of the front drive shaft bearing.

Using a snap ring expander, install a new snap ring.

NOTICE:

The snap ring should be installed completely.

0.323,1.417 0.49,1.417 0.49,1.417 0.573,1.75 false 0.031,1.333 0.49,1.531 0.458,0.198 10 false SST 2.969,0.99 3.219,1.24 0.25,0.25 10 false (A)

Using SST and a press, install a new front drive shaft dust cover RH to the front drive inboard joint assembly as shown in the illustration.

SST

09527-10011  

Dimension (A):

87.7 to 88.3 mm (3.46 to 3.47 in.)

NOTICE:

·

Make sure to install the front drive shaft dust cover RH in the correct direction.

·

Do not damage the front drive shaft dust cover RH.

·

The front drive shaft dust cover RH should be installed completely.

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.

1.031,1.781 1.031,1.406 false 2.979,1.813 2.979,1.229 false 1.656,1.802 1.656,1.479 false 2.417,1.802 2.417,1.375 false 0.979,1.813 1.292,1.969 0.313,0.156 10 false *1 1.615,1.844 1.927,2 0.313,0.156 10 false *2 2.354,1.833 2.667,1.99 0.313,0.156 10 false *3 2.917,1.833 3.229,1.99 0.313,0.156 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
	Outboard joint side
	Inboard joint side

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

2.219,1.26 2.74,1.26 true 2.792,1.177 3.25,1.375 0.458,0.198 10 false SST 2.448,1.719 2.76,1.917 0.313,0.198 10 false *a 1.542,0.125 1.854,0.323 0.313,0.198 10 false *b

*a	Turn
*b	Hold

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

SST

09521-24010  

1.781,1.5 2.531,1.5 false 2.573,1.417 3.031,1.615 0.458,0.198 10 false SST

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

SST

09240-00021  

Clearance:

1.2 to 4.0 mm (0.0472 to 0.1575 in.)

If the clearance is not as specified, retighten SST.

0.708,0.646 1.469,1.021 false 2.656,0.594 2.969,0.792 0.313,0.198 10 false *a 1.219,0.292 1.531,0.49 0.313,0.198 10 false *b 0.427,0.552 0.885,0.75 0.458,0.198 10 false SST

*a	Turn
*b	Hold

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

SST

09521-24010  

2.031,1.031 2.698,1.844 false 2.646,1.865 3.094,2.104 0.448,0.24 10 SST

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

SST

09240-00021  

Clearance:

1.2 to 4.0 mm (0.0472 to 0.1575 in.)

If the clearance is not as specified, retighten SST.

Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and partially bend down the lever.

NOTICE:

·

Make sure the front No. 2 axle outboard joint boot clamp is positioned correctly within the groove of the front axle outboard joint boot as far toward the inside of the vehicle as possible.

·

Before bending the lever, confirm that the front No. 2 axle outboard joint boot clamp and the lever are not deformed or damaged.

1.521,0.333 1.854,0.625 0.333,0.292 10 false *a 2.219,2.063 2.552,2.333 0.333,0.271 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 deflector.

·

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

1.698,3.75 1.031,4.448 1.031,4.448 1.917,3.802 true 0.865,4.396 1.146,4.583 0.281,0.188 10 false *a

*a

Buckle

Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

NOTICE:

·

Do not use excessive force when tapping with the plastic hammer.

·

Do not damage the front axle outboard joint boot.

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

NOTICE:

·

Make sure that the front axle outboard joint boot clamp is correctly positioned within the groove.

·

Confirm that the front axle outboard joint boot clamp and lever are not deformed or damaged.

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, temporarily secure the front axle outboard joint boot clamp by pinching the front axle outboard joint boot clamp until a click sound is heard.

NOTICE:

Do not damage the front axle outboard joint boot.

1.375,3.552 1.073,4.313 1.073,4.313 1.646,3.563 true 0.906,4.281 1.219,4.479 0.313,0.198 10 false *a

*a

Buckle

Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

NOTICE:

·

Do not use excessive force when tapping with the plastic hammer.

·

Do not damage the front axle outboard joint boot.

for Type A:

i.

0.719,1.688 0.719,1.375 false 0.208,1.677 0.208,1.323 false 1.406,1.677 1.406,1.323 false 1.344,1.698 1.656,1.854 0.313,0.156 10 false *1 0.667,1.708 0.979,1.865 0.313,0.156 10 false *2 1.802,0.313 1.958,0.51 0.156,0.198 10 false A 0.146,1.708 0.458,1.865 0.313,0.156 10 false *1

*1	Front Drive Shaft Damper Clamp
*2	Front Drive Shaft Damper

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.

for Type B:

i.

1.417,1.688 1.417,1.313 false 0.729,1.688 0.729,1.375 false 0.208,1.688 0.208,1.313 false 1.521,0.323 1.677,0.521 0.156,0.198 10 false A 1.365,1.698 1.677,1.896 0.313,0.198 10 false *1 0.667,1.698 0.979,1.896 0.313,0.198 10 false *2 0.125,1.698 0.438,1.896 0.313,0.198 10 false *1

*1	Front Drive Shaft Damper Clamp
*2	Front Drive Shaft Damper

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.

for Type A:

i.

0.51,1.844 0.698,1.938 0.698,1.938 1,1.76 false 0.635,1.938 0.948,2.094 0.313,0.156 10 false *a

*a

Claw

Using needle-nose pliers, engage each claw to 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 .

·

Do not damage the claws.

for Type B:

i.

1.594,1.073 1.229,0.51 1.229,0.51 1.125,0.51 true 0.771,0.427 1.083,0.583 0.313,0.156 10 false SST 2.688,1.844 3,2.042 0.313,0.198 10 true *a 1.813,0.146 2.125,0.344 0.313,0.198 10 true *b

*a	Turn
*b	Hold

Place SST onto the front drive shaft damper clamp, press it against the damper and slightly tighten SST.

SST

09521-24010  

iii.

0.635,1.24 1.063,1.24 true 0.333,1.167 0.792,1.365 0.458,0.198 10 false SST

Using SST, measure the clearance of the front drive shaft damper clamp.

SST

09240-00021  

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

If the clearance is not as specified, retighten SST.

for Type C:

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.

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
	Outboard Joint Side
	Inboard Joint Side

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

1.438,1.719 2.531,1.958 2.531,1.958 2.021,1.365 true 2.604,1.875 2.927,2.104 0.323,0.229 10 false *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.

0,0 0,0 false

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

for Type A:

i.

2.177,1.667 2.531,1.667 2.531,1.667 2.531,1.365 false 2.021,1.573 2.333,1.771 0.313,0.198 10 false *a

*a

Groove

Install a new front axle inboard joint grommet to the inboard joint groove.

NOTICE:

Securely fit the protrusion on the front axle inboard joint grommet into the inboard joint groove.

1.948,0.667 0.938,0.25 0.938,0.25 1.396,1.281 false 0.74,0.167 0.927,0.344 0.188,0.177 10 false *a

*a

Matchmark

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

for Gasoline Model 2WD, HV Model:

i.

0.271,0.333 0.646,0.573 0.375,0.24 10 false *A 0.146,1.635 0.521,1.875 0.375,0.24 10 false *B 1.448,1.188 1.677,1.5 0.229,0.313 10 false A 1.531,2.531 1.76,2.844 0.229,0.313 10 false A

*A	for LH Side
*B	for RH Side

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

NOTICE:

·

Keep the grooves free of grease.

·

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

·

Keep the drive shaft assembly level during inspection.

Dimension (A)(for Type A):

for LH Side	605.2 mm (1.99 ft.)
for RH Side	905.0 mm (2.97 ft.)

Dimension (A)(for Type B):

for LH Side	607.6 mm (1.99 ft.)
for RH Side	906.4 mm (2.97 ft.)

for Gasoline Model AWD:

i.

0.177,0.333 0.552,0.573 0.375,0.24 10 false *A 0.177,1.635 0.552,1.875 0.375,0.24 10 false *B 1.448,1.177 1.677,1.49 0.229,0.313 10 false A 1.479,2.552 1.708,2.865 0.229,0.313 10 false A

*A	for LH Side
*B	for RH Side

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

NOTICE:

·

Keep the grooves free of grease.

·

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

·

Keep the drive shaft assembly level during inspection.

Dimension (A):

for LH Side	605.2 mm (1.99 ft.)
for RH Side	913.5 mm (3.00 ft.)

1.74,1.396 2.104,1.708 2.104,1.708 2.729,1.708 true 2.781,1.625 3.24,1.823 0.458,0.198 10 false SST 2.729,0.094 3.042,0.292 0.313,0.198 10 false *a 1.448,0.521 1.76,0.719 0.313,0.198 10 false *b

*a	Turn
*b	Hold

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

SST

09521-24010  

1.531,1.5 2.365,1.5 false 2.406,1.417 2.854,1.667 0.448,0.25 10 false SST

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

SST

09240-00021  

Clearance:

1.2 to 4.0 mm (0.0472 to 0.1575 in.)

If the clearance is not as specified, retighten SST.

0.677,1.625 1.521,1.625 1.521,1.625 2.146,1.125 true 0.385,1.542 0.844,1.74 0.458,0.198 10 false SST 2.281,1.76 2.594,1.958 0.313,0.198 10 false *a 1.938,0.073 2.25,0.271 0.313,0.198 10 false *b

*a	Turn
*b	Hold

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

SST

09521-24010  

0.708,1.333 1.125,1.333 1.125,1.333 1.656,0.885 true 0.406,1.25 0.865,1.448 0.458,0.198 10 false SST

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

SST

09240-00021  

Clearance:

1.2 to 4.0 mm (0.0472 to 0.1575 in.)

If the clearance is not as specified, retighten SST.

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

HINT:

1.688,0.531 1.958,0.302 false 0.677,0.833 1.083,0.833 false 0.406,2.656 0.938,2.656 false 2,0.188 2.365,0.406 0.365,0.219 10 false *a 0.5,0.729 0.813,0.927 0.313,0.198 10 false *1 0.229,2.552 0.542,2.75 0.313,0.198 10 false *2 1.698,1.094 2.01,1.281 0.313,0.188 10 false A 2.729,3.021 3.042,3.208 0.313,0.188 10 false A 0.635,3.021 0.948,3.208 0.313,0.188 10 false A

*1	Front No. 2 Axle Inboard Joint Boot Clamp
*2	Front Axle Inboard Joint Boot
*a	Bending Point

To make installation easier, align the bending point of the lever of the front No. 2 axle inboard joint boot clamp with any of the positions indicated by the arrows (A) shown in the illustration.

1.042,0.781 1.667,0.781 true 0.865,0.677 1.177,0.875 0.313,0.198 10 false *a

*a	Welded Area

Temporarily bend the lever of the front No. 2 axle inboard joint boot clamp.

NOTICE:

·

Make sure the front No. 2 axle inboard joint boot clamp is positioned correctly within the groove of the front axle inboard joint boot as far toward the inside of the vehicle as possible.

·

Before bending the lever, confirm that the front No. 2 axle inboard joint boot clamp and the lever are not deformed or damaged.

HINT:

When temporarily bending the lever, push the lever at the welded area.

Using water pump pliers, temporarily secure the front No. 2 axle inboard joint boot clamp by pinching the front No. 2 axle inboard joint boot clamp until a click sound is heard.

NOTICE:

·

Do not damage the front axle inboard joint boot.

·

To avoid deformation of the front No. 2 axle inboard joint boot clamp, set one tip of the water pump pliers on the welded area of the lever.

HINT:

·

As the front No. 2 axle inboard joint boot clamp is tightened, the tip of the water pump pliers will slide along the front No. 2 axle inboard joint boot clamp until it contacts the protrusion.

·

Set the water pump pliers to an appropriate size before tightening the front No. 2 axle inboard joint boot clamp.

2.594,0.635 2.073,0.271 2.073,0.271 2.792,0.625 true 1.885,0.177 2.177,0.417 0.292,0.24 10 false *a

*a

Buckle

Using a plastic hammer, bend the buckle to secure the lever.

NOTICE:

·

Do not use excessive force when tapping with the plastic hammer.

·

Do not damage the front axle inboard joint boot.

·

Check the front axle inboard joint boot is installed to the correct position.

Using a screwdriver, install the front axle inboard joint boot clamp.

NOTICE:

Do not damage the front axle inboard joint boot.