2. (Right shaft)
Assemble the intermediate shaft.
(4S-FE, 3S-FE (2WD)):
a) Using a special tool and a press, install the new bearing into the holder.
b) Using a screwdriver, install a new retaining ring.
c) Using a special tool and a press, install the bearing holder on the shaft.
d) Using the special tool, install a new retaining ring.
d) Using a special tool, install a new bearing dust cover.
Note: There must be a gap between the boot and the bearing as shown in the figure.
e) Using a press, install the new boot as shown in the figure.
(ZS-T):
a) Using a special tool and a press, install a new bearing.
b) Using the special tool, install a new retaining ring.
c) Using a special tool, install a new bearing dust cover.
Note: There must be a gap between the boot and the bearing as shown in the figure.
d) Using a press, install the new boot as shown in the figure.
3. (Left shaft)
Using the special tool and press, install the new boot as shown in the figure.
4. Temporarily install the hinge covers and the damper with the clamp on the shaft in the order shown in the figure.
Note: For 4WD models with 3S-FE engine, the damper and clamp are installed on the right drive shaft.
Note: Before installing the boot, wrap electrical tape around the drive shaft splines to prevent damage to the boot.
5. Install the triple joint.
a) (ZS-T)
Using a special tool, install a new retaining ring.
b) Turn the triple joint with the chamfer made on the splines towards the outer joint.
(The material is reprinted from an online resource: www.ToyotaMAN.ru)
c) Align the alignment marks made before disassembly.
d) Using a brass 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 retaining ring.
6. Install the inner joint cage onto the drive shaft.
a) Apply grease to the inner joint race and boot.
Note: When assembling, use only grease intended for hinges.
Amount of grease:
- 4S-FE, 3S-FE — 180-190 g
- ZS-T — 232-242 g
b) Align the alignment marks and install the inner joint sleeve onto the drive shaft.
c) Install the cover on the inner hinge collar.
7. Install the cover on the outer hinge, having first applied grease to the hinge and cover.
Note: When assembling, use grease intended for hinges only.
- Amount of grease - 120-130 g
8. Install the hinge boot clamps.
a) (Right shaft of 4WD models, 3S-FE) Make sure the damper is installed as shown in the figure.
b) Install the clamp and secure it.
c) Make sure that the covers are installed in the shaft grooves.
d) Install new clamps and secure them.