Page 705 of 6000

4C–39 DRIVE SHAFT SYSTEM
401RW053
401RW052
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: If equipped with torque on demand (TOD), when
removing, installing or carring for front propeller shaft, be
sure to wind a piece of cloth round the part of the boot with
which fittings may interfere so that the boot can be
protected. The boot may be damaged if bending force is
applied to the constant velocity joint of the shaft.
401RW051
Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque:63Nꞏm (6.4kgꞏm/46lbft)
2. Install the exhaust and transfer protectors.
3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .
401RS019
Page 706 of 6000
4C–40
DRIVE SHAFT SYSTEM
Disassembly (Except TOD 44)
401RW057
Legend
(1) Sleeve Yoke(2) Seal
(3) Tube Assembly
1. Apply alignment marks (1) on the sleeve yoke and
tube assembly then remove sleeve yoke.
401RW056
2. Remove seal.
3. Remove tube assembly.
Page 707 of 6000
4C–41 DRIVE SHAFT SYSTEM
Universal Joint Disassembly
401RW055
Legend
(1) Flange Yoke
(2) Spider(3) Snap Ring
(4) Needle Roller Bearing
(5) Grease Fitting
1. Apply alignment marks (1) on the yokes of the
universal joint, then remove snap ring.
401RS028
2. Tap out the needle roller bearing by gently striking the
shoulder of the yoke, using a mallet or a copper
hammer.
401RS006
Page 708 of 6000

4C–42
DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Constant velocity joint
Outside Diameter of Spider Pin
Standard: 17.00 mm (0.669 in)
Limit: 16.90 mm (0.665 in)
401RS007
Propeller Shaft Run–out
Support the ends of the propeller shaft on V-blocks (2)
and check for run–out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If
the amount of run–out is beyond the standard value for
assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly.
Standard: 0.3 mm (0.012 in)
Limit: 0.5 mm (0.02 in)
401RS027
Play in Splines in Normal Direction of
Rotation
Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)
401RS009
Page 709 of 6000
4C–43 DRIVE SHAFT SYSTEM
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)
401RS010
Constant Velocity Joint
NOTE: LJ and BJ constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.
Play in Constant Velocity Joint
Fix the shaft in a vise throrgh pieces of wood, and try to
move the joint vertically, right and left, and back and forth
to make sure of smooth motions and no remarkable play.
401RW050
401RW049
Boot of Constant Velocity Joint
Check the boot (2) for crack, damage and grease leak,
and the boot band (1) for loosening and damage. Check
the both sides of the joint and make sure that there is no
leak of grease from the cover press-in parts(3).
401RW048
Page 710 of 6000
4C–44
DRIVE SHAFT SYSTEM
401RW047
Front Axle Flange Run-out
1. Set a dial gage at right angle near the outer
circumference of the flange face and check the
run-out of the flange face.
Limit: 0.15 mm (0.006 in)
401RW046
2. Set a dial gage at right angle near the inner
circumference and check the run-out of the flange.
Limit: 0.15 mm (0.006 in)
401RW045
3. If vibration is felt during the 4H AUTO drive, disconnct
the propeller shaft at the front axle. Reinstall the
propeller shaft at 60
, 120, 180, 240, and 300
and conduct test drive in each position and check if
there is vibration.
401RW044
Page 711 of 6000

4C–45 DRIVE SHAFT SYSTEM
Universal Joint Reassembly
1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Apply a molybdenum–disulfide grease or a
multi–purpose type grease NLGI No. 2 to inside of the
bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)
401RS011
3. Using either a mallet (or copper hammer) or a press,
install the needle roller bearing into the yoke so that
the snap ring can be installed in its groove.
CAUTION: The needle roller bearing cannot be
installed smoothly if it is set at an incorrect angle
with the flange and excessive hammering will
damage the needle roller bearing.
401RS012
4. Align setting marks (1) and join the yokes.
401RS028
5. Install snap ring.
NOTE: Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a
snap ring of suitable thickness so that the end play of the
spider pin is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
1.5 mm (0.059 in); Blue
1.53 mm (0.060 in); White
1.59 mm (0.063 in); Yellow
1.62 mm (0.064 in); Green
1.68 mm (0.066 in); Not colored
NOTE: Be sure to use snap rings of the same thickness
on both sides.
Page 712 of 6000
4C–46
DRIVE SHAFT SYSTEM
Reassembly (Except TOD 44)
401RW057
Legend
(1) Sleeve Yoke(2) Seal
(3) Tube Assembly
1. Discard used seal and install new one.
2. Align the alignment marks and install tube assembly
to sleeve yoke.