Toyota Corolla Cross: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	REAR DRIVE SHAFT DUST COVER	41336K		-	-
2	REAR DRIVE SHAFT OUTBOARD JOINT BOOT	-		-	-
3	REAR NO. 2 DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP	42346F		-	-
4	REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP	42346D		-	-
5	REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY	-		-	-
6	REAR DRIVE SHAFT INBOARD JOINT BOOT	-		-	-
7	REAR NO. 2 DRIVE SHAFT INBOARD JOINT BOOT CLAMP	42347F		-	-
8	REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP	42347D		-	-
9	INSPECT REAR DRIVE SHAFT ASSEMBLY	42340B		-	-

CAUTION / NOTICE / HINT

NOTICE:

• When using a vise, place aluminum plates between the part and vise.
• When using a vise, do not overtighten it.

HINT:

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

PROCEDURE

1. INSTALL REAR DRIVE SHAFT DUST COVER

(1) Using SST, a steel plate and a press, install a new rear drive shaft dust cover to the rear drive shaft inboard joint assembly.

SST: 09527-10011

NOTICE:

• Make sure to install the rear drive shaft dust cover in the correct direction.
• Do not damage the rear drive shaft dust cover.
• The rear drive shaft dust cover should be installed completely.

2. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT

*1	Rear Drive Outboard Joint Shaft Assembly	*2	Rear No. 2 Drive Shaft Outboard Joint Boot Clamp
*3	Rear Drive Shaft Outboard Joint Boot	*4	Rear Drive Shaft Outboard Joint Boot Clamp
	Outboard Joint Side		Inboard Joint Side
	Grease	-	-

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

(2) Install new parts to the rear drive outboard joint shaft assembly in the following order:

1. Rear No. 2 drive shaft outboard joint boot clamp

2. Rear drive shaft outboard joint boot

3. Rear drive shaft outboard joint boot clamp

(3) Pack the joint portion of the rear drive outboard joint shaft assembly and rear drive shaft outboard joint boot with grease.

Standard Grease Capacity:

37 to 47 g (1.31 to 1.66 oz.)

(4) Install the rear drive shaft outboard joint boot to the rear 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.

3. INSTALL REAR NO. 2 DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

(1) Install the rear No. 2 drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.

NOTICE:

Be sure to install the clamp in the correct position.

(2) Using a screwdriver, install the rear No. 2 drive shaft outboard joint boot clamp.

NOTICE:

Do not damage the rear drive shaft outboard joint boot.

4. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT CLAMP

*a	Hold	-	-
	Turn	-	-

(1) Install the rear drive shaft outboard joint boot clamp to the rear drive shaft outboard joint boot.

(2) Place SST onto the rear drive shaft outboard joint boot clamp, press it against the boot and slightly tighten SST.

SST: 09521-24010

NOTICE:

• Be sure to install the clamp in the correct position.
• Do not damage the rear drive shaft outboard joint boot.

(3) Tighten SST so that the rear drive shaft outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(4) Using SST, measure the clearance of the rear drive shaft outboard joint boot clamp.

SST: 09240-00021

Clearance:

1.2 mm (0.0472 in.) or less

(5) If the clearance is not as specified, retighten SST.

5. INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSEMBLY

*1	Rear Drive Shaft Inboard Joint Boot Clamp	*2	Rear Drive Shaft Inboard Joint Boot
*3	Rear No. 2 Drive Shaft Inboard Joint Boot Clamp	-	-
*a	Matchmark	-	-
	Outboard Joint Side		Inboard Joint Side
	Grease	-	-

(1) Wrap the spline of the rear drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

(2) Install new parts to the rear drive outboard joint shaft assembly in the following order:

1. Rear drive shaft inboard joint boot clamp

2. Rear drive shaft inboard joint boot

3. Rear No. 2 drive shaft inboard joint boot clamp

(3) Remove the protective tape.

(4) Align the matchmarks and install the tripod joint to the rear drive outboard joint shaft assembly.

NOTICE:

Face the serrated side of the tripod joint outward and install it to the outboard joint end.

(5) Using a brass bar and a hammer, install the tripod joint to the rear 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.

(6) Using a snap ring expander, install a new rear drive shaft snap ring to the rear drive outboard joint shaft assembly.

(7) Pack the rear drive shaft inboard joint assembly and rear drive shaft inboard joint boot with grease.

Standard Grease Capacity:

88 to 98 g (3.10 to 3.46 oz.)

(8) Align the matchmarks and install the rear drive shaft inboard joint assembly to the rear drive outboard joint shaft assembly.

6. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT

(1) Install the rear drive shaft inboard joint boot to the rear drive shaft inboard joint assembly.

NOTICE:

• Keep the grooves free of grease.
• Keep the inside of the rear drive shaft inboard joint boot free of foreign matter.

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

Dimension (A):

(3) While keeping dimension (A) within the specified length, equalize the pressure within the inboard joint with atmospheric pressure by slightly lifting the rear drive shaft inboard joint boot from the rear drive shaft inboard joint assembly.

7. INSTALL REAR NO. 2 DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(1) Install the rear No. 2 drive shaft inboard joint boot clamp to the rear drive shaft inboard joint boot.

NOTICE:

Be sure to install the clamp in the correct position.

(2) Using needle-nose pliers, engage the claw to install the rear No. 2 drive shaft inboard joint boot clamp as shown in the illustration.

NOTICE:

• Do not damage the rear drive shaft inboard joint boot.
• Do not damage the claws.

8. INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT CLAMP

(a) Use the same procedure described for the rear No. 2 drive shaft inboard joint boot clamp.

9. INSPECT REAR DRIVE SHAFT ASSEMBLY

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