Toyota CH-R Service Manual: Reassembly

Toyota CH-R Service Manual / Drive Shaft / Propeller Shaft / Front Drive Shaft Assembly / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL FRONT DRIVE SHAFT DUST COVER LH

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

NOTICE:

The dust cover should be completely installed.
Be careful not to damage the front drive shaft dust cover.
Install the front drive shaft dust cover LH in the correct direction.

*a	Steel Plate

2. INSTALL FRONT DRIVE SHAFT DUST COVER RH

(a) Using SST and a press, install a new front drive shaft dust cover RH until the distance (A) from the tip of the center drive shaft to the front drive shaft dust cover RH meets the specification.

SST: 09527-10011

Distance (A):

91.0 to 92.0 mm (3.59 to 3.62 in.)

NOTICE:

The front drive shaft dust cover RH should be completely installed.
Be careful not to damage the front drive shaft dust cover RH.
Install the front drive shaft dust cover RH in the correct direction.

3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

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

*a	Protective Tape

(b) Install new parts onto the front drive outboard joint shaft assembly in the following order:

*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

(1) Front No. 2 axle outboard joint boot clamp

(2) Front axle outboard joint boot

(3) 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:

80 to 100 g (2.83 to 3.52 oz.)

(d) Install the front axle outboard joint boot into 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.

4. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot.

SST: 09521-24010

*a	Hold
*b	Turn

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

NOTICE:

Do not overtighten SST.

(e) Remove SST.

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

SST: 09240-00020

Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

If the clearance is outside the specified range, retighten SST.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Install the front axle outboard joint boot clamp onto the front axle outboard joint boot.

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

SST: 09521-24010

*a	Hold
*b	Turn

NOTICE:

Do not overtighten SST.

(d) Remove SST.

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

SST: 09240-00020

Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

If the clearance is outside the specified range, retighten SST.

6. INSTALL FRONT DRIVE SHAFT DAMPER LH

(a) Install parts to the front drive outboard joint shaft assembly in the following order as shown in the illustration.

(1) New front drive shaft damper clamp

(2) Front drive shaft damper LH

(3) New front drive shaft damper clamp

*1	Front Drive Outboard Joint Shaft Assembly
*2	Front Drive Shaft Damper RH
*3	Front Drive Shaft Damper Clamp

(b) Set the dimension (A) as specified below.

Dimension (A):

229 to 233 mm (9.02 to 9.17 in.)

NOTICE:

Do not overtighten the vise.

(d) Install the 2 front drive shaft damper clamps to the front drive shaft damper LH.

NOTICE:

Be sure to install the clamp in the correct position.

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

7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Install new parts onto 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
*a	Protective Tape
	Outboard joint side
	Inboard joint side

(1) Front axle inboard joint boot clamp

(2) Front axle inboard joint boot

(3) Front No. 2 axle inboard joint boot clamp

(b) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(d) 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.

Matchmark

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

NOTICE:

Do not tap the areas where the rollers contact the tripod joint.
Keep the tripod joint free of foreign matter.
Make sure to install the tripod joint in the correct direction.

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

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

Standard grease capacity:

195 to 215 g (6.88 to 7.58 oz.)

(h) Install the 3 rollers to the tripod joint.

NOTICE:

Make sure to install the rollers in the correct direction as shown in the illustration.
Do not drop the rollers.

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

Matchmark

8. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) Install the front axle inboard joint boot to the front drive inboard joint assembly.

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

Dimension (A):

LH Side	590.5 mm (1.94 ft.)
RH Side	887.1 mm (2.91 ft.)

*a	LH Side
*b	RH Side

9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front axle inboard joint boot clamp onto the front axle inboard joint boot.

SST: 09521-24010

(d) Tighten SST so that the front axle inboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(e) Remove SST.

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

SST: 09240-00020

Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

If the clearance is outside the specified range, retighten SST.

10. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

(a) Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot.

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

SST: 09521-24010

NOTICE:

Do not overtighten SST.

(d) Remove SST.

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

SST: 09240-00020

Clearance:

1.2 to 4.0 mm (0.0473 to 0.157 in.)

If the clearance is outside the specified range, retighten SST.

11. INSPECT FRONT DRIVE SHAFT ASSEMBLY

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