Lexus ES manuals

Lexus ES: Reassembly

Lexus ES (XZ10) Service Manual / Drivetrain / Drive Shaft / Propeller Shaft / Front Drive Shaft Assembly (for A25a-fxs) / Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL FRONT AXLE OUTBOARD JOINT BOOT

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

NOTICE:

Do not overtighten the vise.

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

*a

Protective Tape

(c) Install new parts to 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

(d) Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

Standard Grease Capacity (for TMC Made):

205 to 215 g (7.24 to 7.58 oz)

Standard Grease Capacity (for TMMK Made):

110 g (3.88 oz)

(e) Install the front axle outboard joint boot to 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.

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

(a) for TMC Made:

CAUTION:

  • Wear protective gloves when installing the front No. 2 axle outboard joint boot clamp.
  • If protective gloves are not worn, injuries may occur.

(1) Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever at the fulcrum point.

*a

Fulcrum Point

*b

Lever Push Position

*c

Band Support Position

NOTICE:

  • Set the lever to the guide groove correctly and install the clamp as far to the inside of the vehicle as possible.
  • Check the band and the lever for any deformation before folding back the lever.
  • The lever folds easily at the fulcrum point when pushed at the position shown in the illustration.
  • When folding back the lever, do not push at the end of the lever.

    *a

    Temporary Claw

    -

    -
  • If the lever bends in the middle, it may not engage with the temporary claws or may not be held in the correct position.

(2) As shown in the illustration, while pressing the outboard joint area against the work surface, firmly press the lever into place by rolling the outboard joint area forward from the folded fulcrum point to the temporary claw area until a click sound is heard.

*a

Press down

*b

Contact Point

*c

Roll forward

*d

Temporary Claw

*e

Fulcrum Point

-

-

NOTICE:

  • Do not damage the deflector.
  • Make sure that the outboard joint is in direct contact with the work surface.

(3) Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

NOTICE:

  • Do not use excessive force when tapping with the plastic hammer.
  • Do not damage the front axle outboard joint boot.

*a

Buckle

(b) for TMMK Made:

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

NOTICE:

Do not overtighten the vise.

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

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

SST: 09521-24010

*a

Turn

*b

Hold

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

NOTICE:

Do not overtighten SST.

(5) Remove SST.

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

SST: 09240-00021

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

If the clearance is not as specified, retighten SST.

3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) for TMC Made:

CAUTION:

  • Wear protective gloves when installing the front axle outboard joint boot clamp.
  • If protective gloves are not worn, injuries may occur.

(1) Install the front axle outboard joint boot clamp to the front axle outboard joint boot and partially bend down the lever.

NOTICE:

  • Make sure that the front axle outboard joint boot clamp is correctly positioned within the groove.
  • Confirm that the front axle outboard joint boot clamp and lever are not deformed or damaged.

(2) Using water pump pliers, temporarily secure the front axle outboard joint boot clamp by pinching the front axle outboard joint boot clamp until a click sound is heard.

NOTICE:

Do not damage the front axle outboard joint boot.

*a

Place the tip near the center of the lever

(3) Using a plastic hammer, bend the buckle to secure the lever and confirm that the tip of the lever is aligned with the buckle as shown in the illustration.

NOTICE:

  • Do not use excessive force when tapping with the plastic hammer.
  • Do not damage the front axle outboard joint boot.

*a

Buckle

(b) for TMMK Made:

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

NOTICE:

Do not overtighten the vise.

(2) Install the front axle outboard joint boot clamp to the front axle outboard joint boot.

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

SST: 09521-24010

*a

Turn

*b

Hold

(4) Tighten SST so that the front axle outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(5) Remove SST.

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

SST: 09240-00021

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

If the clearance is not as specified, retighten SST.

4. INSTALL FRONT DRIVE SHAFT DAMPER

(a) Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

*1

Front Drive Shaft Damper

*2

Front Drive Shaft Damper Clamp

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

Dimension (A) (for TMC Made):

for LH Side

277.9 to 281.9 mm (10.95 to 11.09 in.)

for RH Side

261.4 to 265.4 mm (10.30 to 10.44 in.)

Dimension (B) (for TMMK Made):

for LH Side

223.4 to 227.4 mm (8.80 to 8.95 in.)

for RH Side

223.4 to 227.4 mm (8.80 to 8.95 in.)

5. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP

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

NOTICE:

Do not overtighten the vise.

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

NOTICE:

  • Be sure to install the clamps in the correct position.
  • Do not damage the front drive shaft damper.
  • Do not damage the claws.

*a

Claw

6. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Install new parts to 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.

(c) Remove the protective tape.

(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.

*a

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 rollers.
  • 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 (for TMC Made):

205 to 215 g (7.24 to 7.58 oz)

Standard Grease Capacity (for TMMK Made):

195 g (6.88 oz)

(h) for TMMK Made:

(1) Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

NOTICE:

  • Securely fit the protrusion on the front axle inboard joint grommet into the front drive inboard joint assembly.
  • Make sure that the lip of the front axle inboard joint grommet is not damaged.

*a

Lip

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

*a

Matchmark

7. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) When a jig is supplied with the front drive shaft inboard joint boot kit:

(1) Using a jig, install the front axle inboard joint boot to the front drive inboard joint assembly.

*A

for LH Side

*B

for RH Side

Jig

NOTICE:

  • Keep the grooves free of grease.
  • Keep the inside of the front axle inboard joint boot free of foreign matter.
  • If the front axle inboard joint boot is not installed at the position indicated by the jig, damage to the front axle inboard joint boot may result.
  • Place the jig at several points around the circumference of the front drive inboard joint assembly to check that the front axle inboard joint boot is installed to the correct position.

(b) When a jig is not supplied with the front drive shaft inboard joint boot kit:

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

(2) Adjust the position of the front axle inboard joint boot so that the dimension (A) is as specified.

Dimension (A):

for LH Side

51.8 to 52.2 mm (2.04 to 2.05 in.)

for RH Side

66.8 to 67.2 mm (2.63 to 2.64 in.)

NOTICE:

  • Keep the grooves free of grease.
  • Keep the inside of the front axle inboard joint boot free of foreign matter.
  • If the front axle inboard joint boot is installed while the dimension (A) is not as specified, damage to the front axle inboard joint boot may result.

*A

for LH Side

*B

for RH Side

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

(a) for TMC Made:

CAUTION:

  • Wear protective gloves when installing the front No. 2 axle inboard joint boot clamp.
  • If protective gloves are not worn, injuries may occur.

NOTICE:

New front No. 2 axle inboard joint boot clamp is coated with lubricant. Do not remove the lubricant.

(1) Install the front No. 2 axle inboard joint boot clamp to the front axle inboard joint boot.

*1

Front No. 2 Axle Inboard Joint Boot Clamp

*2

Front Axle Inboard Joint Boot

*a

Bending Point

HINT:

To make installation easier, align the bending point of the lever of the front No. 2 axle inboard joint boot clamp with any of the positions indicated by the arrows (A) shown in the illustration.

(2) Temporarily bend the lever of the front No. 2 axle inboard joint boot clamp.

NOTICE:

  • Make sure the front No. 2 axle inboard joint boot clamp is positioned correctly within the groove of the front axle inboard joint boot as far toward the inside of the vehicle as possible.
  • Before bending the lever, confirm that the front No. 2 axle inboard joint boot clamp and the lever are not deformed or damaged.

HINT:

When temporarily bending the lever, push the lever at the welded area.

*a

Welded Area

(3) Using water pump pliers, temporarily secure the front No. 2 axle inboard joint boot clamp by pinching the front No. 2 axle inboard joint boot clamp until a click sound is heard.

NOTICE:

  • Do not damage the front axle inboard joint boot.
  • To avoid deformation of the front No. 2 axle inboard joint boot clamp, set one tip of the water pump pliers on the welded area of the lever.

HINT:

  • As the front No. 2 axle inboard joint boot clamp is tightened, the tip of the water pump pliers will slide along the front No. 2 axle inboard joint boot clamp until it contacts the protrusion.
  • Set the water pump pliers to an appropriate size before tightening the front No. 2 axle inboard joint boot clamp.

(4) Using a plastic hammer, bend the buckle to secure the lever.

NOTICE:

  • Do not use excessive force when tapping with the plastic hammer.
  • Do not damage the front axle inboard joint boot.
  • Check the front axle inboard joint boot is installed to the correct position.

*a

Buckle

(b) for TMMK Made:

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

NOTICE:

Do not overtighten the vise.

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

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

SST: 09521-24010

*a

Turn

*b

Hold

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

NOTICE:

Do not overtighten SST.

(5) Remove SST.

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

SST: 09240-00021

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

If the clearance is not as specified, retighten SST.

9. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) for TMC Made:

NOTICE:

New front axle inboard joint boot clamp is coated with lubricant. Do not remove the lubricant.

(1) Check whether the dimension (A) of each drive shaft is within specification.

Dimension (A):

for LH Side

607.6 mm (1.99 ft.)

for RH Side

906.4 mm (2.97 ft.)

*A

for LH Side

*B

for RH Side

(2) Install the front axle inboard joint boot clamp to the front axle inboard joint boot.

(3) Using a screwdriver, install the front axle inboard joint boot clamp.

NOTICE:

Do not damage the front axle inboard joint boot.

(b) for TMMK Made:

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

NOTICE:

Do not overtighten the vise.

(2) Install the front axle inboard joint boot clamp to the front axle inboard joint boot.

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

SST: 09521-24010

*a

Turn

*b

Hold

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

NOTICE:

Do not overtighten SST.

(5) Remove SST.

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

SST: 09240-00021

Clearance:

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

If the clearance is not as specified, retighten SST.

10. INSPECT FRONT DRIVE SHAFT ASSEMBLY

Click here

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