- a) Install the pin into the bearing holder.
- b) Using the special tool and a press, install the new bearing into the bearing holder.
- c) Using a screwdriver, install a new retaining ring.
- d) Using the special tool and a press, install the bearing retainer assembly onto the center drive shaft.
- d) Using the special tool, install a new retaining ring.
- e) Using the special tool and a press, install the new boot.
Note: There must be a gap between the boot and the bearing as shown in the figure.
2. (3S-GE, 3S-FE and 4S-FE) Install the new boot as shown in the figure.
3. Temporarily install the hinge boots with new clamps on the shaft.
Note: Before installing the boot, wrap electrical tape around the drive shaft splines to prevent damage to the boot.
(For right drive shaft of models with 2C, 4A-FE engines) Temporarily install the damper and a new damper clamp. Standard distance:
- 4A-FE: 431.6±5.0 mm
- 2C: 351.5±5.0 mm
4. (3S-GE) Install the inner joint.
- a) Using the special tool, install a new snap ring.
- b) Align the timing marks and install the inner race onto the center drive shaft using a brass rod and hammer.
Caution: Be careful not to damage the inner race.
- c) Using the special tool, install a new retaining ring.
- d) Align the alignment marks and install the separator on the inner race.
Caution: Install the separator with the smaller diameter towards the outer hinge.
- d) Place six balls.
Note: Apply grease to the balls.
(3S-FE, 2C, 4A-FE and 4S-FE) Install the triple joint.
- a) (3S-FE and 4S-FE) Using the special tool, install a new snap ring.
- b) Turn the triple joint with the chamfer made on the splines towards the outer joint.
- 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.
5. Install the cover on the outer hinge, having first applied grease to the hinge and cover.
Note: When assembling, use grease intended only for hinges. Grease quantity:
- 3S-GE: 100-120 g
- 3S-FE, 2C and 4A-FE: 120-130 g
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. Grease quantity:
- 3S-GE: 100-120 g
- 3S-FE, 2C, 4A-FE and 4S-FE: 180-190 g
- b) Align the timing marks and install the inner joint sleeve onto the drive shaft.
- c) (3S-GE) Install a new snap ring.
- d) Install the cover on the inner hinge collar.
7. Install the cover clamps. (For right drive shaft of models with 2C, 4A-FE engines) Secure the damper clamp.
- a) Check that the boot is in the groove of the shaft.
- b) Check that the boot has not been stretched or compressed when the drive shaft is at standard length.
Standard drive shaft length:
- Left side for models with engine:
- 3S-GE: 554.2±5.0 mm
- 3S-FE: 558.2±5.0 mm
- 2C: 548.5±5.0 mm
- 4A-FE: 541.3±5.0 mm
- Right side for models with engine:
- 3S-GE: 841.8±5.0 mm
- 3S-FE: 844.6±5.0 mm
- 2C: 859.9±5.0 mm
- 4A-FE: 855.8±5.0mm
- c) Secure the clamps.