Front Drive Shaft Disassembly and Reassembly: Reassembly

Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.

Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried.

Replace boot(s) (3) with new one(s).

Fig 1: Identifying Wheel Side Joint Assembly And Tripod Joint Housing

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1. Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2. Clean boots with cloth.
3. Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare parts.

   Grease color 

   : Tan 

   Amount 

   : 90 - 110 g (3.2 - 3.8 oz) 

4. Install wheel side boot to drive shaft.
5. Fill up boot inside with specified grease.
6. Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.
   Fig 2: Identifying Wheel Side Boot Small Band

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7. Fasten boot band (1) securely using special tool as shown in figure.

   Distance "a" 

   : 2.6 ± 1.4 mm (0.102 ± 0.055 in.) 

   Special Tool 

   (A): 09943-57011 

   Fig 3: Fastening Boot Band

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8. Place new wheel side boot big band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.
   CAUTION: Squeezing or otherwise distorting the boot will reduce its durability. Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with bands.
   Fig 4: Placing New Wheel Side Boot Big Band Onto Boot Putting Band Outer End

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9. Fasten wheel side boot big band (1) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4).

   Special Tool 

   (A): 09943-57021 

   Fig 5: Fastening Wheel Side Boot Big Band By Drawing Hooks With Special Tool

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10. Install damper (1) to specified position on drive shaft, if equipped.

    Drive shaft damper installing position (right side) 

    "a": 208.6 - 214.6 mm (8.213 - 8.448 in,) (2WD-M/T model) 

    "a": 359.0 - 365.0 mm (14.134 - 14.370 in,) (CVT model and 4WD-M/T model) 

    Drive shaft damper installing position (left side) 

    "a": 249.0 - 255.0 mm (9.804 - 10.039 in,) (M/T model) 

    Fig 6: Identifying Drive Shaft Damper Installing Position

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11. Set new differential side small band and new differential side boot (1) on shaft temporarily, and then apply grease to tripod joint (2). Use specified grease in tube included in spare parts.
12. Install tripod joint (3) on shaft using snap ring pliers (5) with hammer, directing its chamfered spline toward wheel side, and then fasten it with new snap ring (4).

    Special Tool 

    (A): 09925-98220 

    Fig 7: Installing Tripod Joint On Shaft Using Snap Ring Pliers With Hammer

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13. Apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint.

    Grease color 

    "A": Tan 

    Amount 

    "A": 85 - 105 g (3.2 - 3.8 oz) 

    Fig 8: Identifying Tripod Joint Housing Grease Application Areas

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14. Fit boot (1) to grooves of shaft and housing (2) adjust length to specification below.

    Drive shaft boot fixing position (distance between housing end and small boot band) 

    Left side drive shaft "a": 184.0 - 194.0 mm (7.245 - 7.637 in,) 

    Right side drive shaft "b": 227.6 - 237.6 mm (8.961 - 9.354 in,) (M/T model) 

    Right side drive shaft "b": 226.1 - 236.1 mm (8.902 - 9.295 in,) (CVT model) 

    Fig 9: Checking Distance Between Housing End And Small Boot Band

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15. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
16. Fasten boot bands (1) as shown in figure.
    CAUTION:

    • If a boot band is installed with its outer end pointing in the forward rotating direction, the band's end may be caught by something and be raised to loosen the band. This could lead to leakage of grease and eventually to a broken drive shaft. Be sure to install each boot band with its outer end pointing against the forward rotating direction.
    • Squeezing or otherwise distorting the boot will reduce its durability. Do not try to force air out of the boot by squeezing or otherwise distorting it when fastening it with its band.
    Fig 10: Locating Boot Bands

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