2. (Right shaft)
Assemble the intermediate shaft.
(4S-FE, 3S-FE (2WD)):
A) Using the special tool and a press, install the new bearing into the holder.
b) Using a screwdriver, install a new circlip.
V) Using the special tool and a press, install the bearing holder onto the shaft.
G) Using the special tool, install a new circlip.
d) Using the special tool, install a new bearing boot.
Note: The clearance shown in the figure must remain between the dust boot and the bearing.
e) Using a press, install a new boot as shown in the figure.
(ZS-T):
A) Using the special tool and a press, install the new bearing.
b) Using the special tool, install a new circlip.
V) With the help of a special tool. install a new bearing boot.
Note: There must be a gap between the boot and the bearing, as shown in the figure.
G) Using a press, install a new boot as shown in the illustration.
3. (Left shaft)
Using the special tool and a press, install the new dust boot as shown.
4. Temporarily install the hinge covers and damper with clamp on the shaft, in the order shown in the figure.
Attention: for 4WD models with 3S-FE engine, the damper and clamp are installed on the right drive shaft.
Note: Before installing boot, wrap electrical tape around drive shaft splines to prevent damage to boot.
5. Install the triple pivot.
A) (ZS-T)
With the help of a special tool. install a new retaining ring.
b) Rotate the triple joint with the splined chamfer towards the outer joint.
V) Align the alignment marks made before disassembly.
G) Using a copper rod and a hammer, press the triple joint onto the drive shaft.
Attention: do not drop the hinge.
d) Using the special tool, install a new circlip.
6. Install the inner joint race on the drive shaft.
A) Apply grease to the inner joint race and boot.
Note: Use only grease designed for hinges when assembling.
Amount of lubricant:
- 4S-FE, 3S-FE - 180-190 g
- ZS-T - 232-242 g
b) Align the alignment marks, and install the inner joint race on the drive shaft.
V) Install the cover on the inner hinge race.
7. Install the cover on the outer hinge, having previously laid grease in the hinge and the boot.
Note: When assembling, use a lubricant designed for hinges only.
- The amount of lubricant - 120-130 g
8. Establish collars of covers of hinges.
A) (Right shaft of 4WD, 3S-FE models) Make sure the damper is installed as shown in the picture.
b) Install the clamp and secure it.
V) Make sure that the boots are installed in the grooves of the shaft.
G) Install new clamps and fix them.