Toyota Tundra Service Manual: Reassembly

Toyota Tundra Service Manual / Engine, Hybrid System / Drive Shaft / Front Drive Shaft Assembly(for 4wd) / Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

Do not allow brake fluid, front differential oil, gasoline, or battery fluid to contact the drive shaft boots, as they may damage the boots.

PROCEDURE

1. INSTALL DUST SEAL

(a) Using SST and a press, press in a new dust seal to the outboard joint shaft.

SST: 09950-00020

NOTICE:

Be careful not to damage the dust seal.

2. INSTALL FRONT DRIVE SHAFT DUST COVER LH

(a) Using SST, a steel plate and press, press in a new dust cover.

SST: 09316-20011

NOTICE:

Be careful not to damage the dust cover.

3. INSTALL OUTBOARD JOINT BOOT

(a) Place 2 new boot clamps on the boot.

HINT:

Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

(b) Temporarily install a new boot to the outboard joint shaft.

(c) Position the inside clamp onto the boot.

(d) Using SST, pinch the inside clamp.

SST: 09521-24010

NOTICE:

Do not overtighten SST.

(e) Pack the outboard joint and boot with grease in the boot kit.

Standard grease capacity:

292 to 312 g (10.3 to 11.0 oz.)

(f) Position the outside clamp onto the boot.

(g) Using SST, pinch the outside clamp.

SST: 09521-24010

NOTICE:

Do not overtighten SST.

(h) Using SST, adjust the clearance of the clamps.

SST: 09240-00020

Standard clearance:

Clamp

Specified Condition

Inside

2.8 to 3.8 mm (0.110 to 0.150 in.)

Outside

3.5 to 4.5 mm (0.138 to 0.177 in.)

4. TEMPORARILY INSTALL INBOARD JOINT BOOT

(a) Temporarily install 2 new boot clamps and a boot to the outboard joint shaft.

5. INSTALL INBOARD JOINT SHAFT

(a) Install the cage to the outboard joint shaft.

NOTICE:

Insert the cage with its smaller inner diameter side facing the outboard joint.

(b) Align the matchmarks placed before removal.

(c) Install the inner race.

(d) Using a snap ring expander, install a new snap ring.

(e) Align the matchmarks placed before removal, and install the cage to the inner race.

(f) Install the 6 balls.

HINT:

Apply grease onto the balls to keep them from falling out.

(g) Pack the inboard joint shaft and boot with grease in the boot kit.

Standard grease capacity:

380 to 400 g (13.3 to 14.1 oz.)

(h) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft.

(i) Install a new snap ring.

(j) Temporarily install the boot to the inboard joint shaft.

HINT:

Make sure that the boot is on the shaft groove.

(k) Check that the 2 boots are not stretched or contracted when the drive shaft is at standard length.

Standard drive shaft length (A):

625.8 mm (2.05 ft.)

If the boots are stretched or contracted, correct them.

(l) Install the inboard joint boot clamps in the same manner as the outboard side.

HINT:

Adjust the clearance of the inboard joint boot clamps.

Standard clearance:

Clamp

Specified Condition

Inside

2.8 to 3.8 mm (0.110 to 0.150 in.)

Outside

3.0 to 4.0 mm (0.118 to 0.158 in.)

6. INSPECT FRONT DRIVE SHAFT ASSEMBLY

    Installation

    Removal

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