Removal (To 08/2009): Removal

HINT: 

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

1. PRECAUTION (w/ Air Suspension) 
   NOTE:

   Be sure to read Precaution thoroughly before servicing. Refer to PRECAUTION .

2. REMOVE FRONT WHEEL 
3. REMOVE FRONT AXLE SHAFT NUT  . Refer to REMOVAL - Step 6
4. SEPARATE FRONT SPEED SENSOR 
   1. Remove the bolt and resin clamp, and separate the front speed sensor.
      Fig 1: Separating Front Speed Sensor

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Hole
      *2	Resin Clamp

      NOTE:

      • Be sure to completely separate the front speed sensor from the front shock absorber with coil spring.
      • Be careful not to damage the front speed sensor.
      • Clean the speed sensor installation hole and the surfaces every time the speed sensor is removed.
5. SEPARATE FRONT DRIVE SHAFT ASSEMBLY 
   1. Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.
      Fig 2: Separating Front Drive Shaft Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1

      Matchmark

   2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.
      Fig 3: Separating Front Drive Shaft Assembly From Front Axle Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Loosen the staked part of the front axle hub nut completely, otherwise the threads of the drive shaft may be damaged.

6. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY 
   1. Remove the 2 bolts and separate the front disc brake caliper assembly.
      Fig 4: Locating Front Disc Brake Caliper Assembly Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose.

7. REMOVE FRONT DISC  . Refer to REMOVAL - Step 15
8. SEPARATE TIE ROD ASSEMBLY  . Refer to REMOVAL - Step 6
9. SEPARATE FRONT LOWER SUSPENSION ARM 
   1. Remove the bolt and 2 nuts, and separate the front lower suspension arm from the lower ball joint.
      Fig 5: Locating Front Lower Suspension Arm Bolt And Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT AXLE ASSEMBLY 
    1. Remove the 2 bolts, 2 nuts and front axle assembly.
       Fig 6: Identifying Front Axle Assembly With Bolts And Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       When removing the nuts, keep the bolts from rotating.

11. REMOVE FRONT LOWER BALL JOINT ASSEMBLY 
    1. Secure the front axle assembly in a vise using aluminum plates.
       Fig 7: Identifying Front Axle Assembly In Vise

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       When using a vise, do not overtighten it.

    2. When removing the nut (Type A):
       1. Remove the clip and nut.
          Fig 8: Identifying Clip And Nut

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When removing the nut (Type B):
       1. Remove the cotter pin and nut.
          Fig 9: Identifying Cotter Pin And Nut

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install SST to the front lower ball joint as shown in the illustration.
       Fig 10: Identifying Clearance Between SST And Front Axle Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • SST: 09960-20010 
         • 09961-02050
         • 09961-02050
       NOTE:

       Check that the clearance measurement between SST and the front axle assembly is 1 mm (0.0394 in.).

    5. Using SST, remove the front lower ball joint from the front axle assembly as shown in the illustration.
       Fig 11: Removing Front Lower Ball Joint From Front Axle Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Apply grease	*2	Apply grease
       *3	Place the wrench here	*4	Turn

       • SST: 09960-20010 
         • 09961-02010
       WARNING:

       Apply grease to the threads and end of the SST bolt.

       NOTE:

       • Install SST so that A and B are parallel.
       • Be sure to place a wrench on the part indicated in the illustration.
       • Do not damage the front lower ball joint dust cover.