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Removal & Installation: AVALON: Reassembly

WARNING: This page is about a different car, the 2004 Toyota Avalon, 2003 Toyota Avalon, and 2002 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install NEW No. 2 dust deflector using Transmission Rear Bearing Replacer (SST 09309-36010) and Transfer Bearing Replacer (SST 09316-20011) tools, or equivalent.
  2. To reassembly right axle shaft, use the following steps:
    1. Install new snap right to inboard joint shaft.
    2. Using steel plate and press, install new bearing.
    3. Using snap ring expander, install new snap ring.
    4. Using Differential Drive Pinion Rear Bearing Replacer (SST 09506-35010) tool, or equivalent, an extension bar and press, install new bearing side dust cover. Clearance between dust cover and bearing should be kept within approximately 0.039 in. (1.0 mm). See Fig 1.
    5. Using steel plate and press, install new transaxle side dust cover until distance from the tip of the inboard joint shaft to the dust cover fall within 4.31-4.35 in. (109.5-110.5 mm) of each other. See Fig 1.
  3. To reassembly left drive shaft, first install new dust cover using a press.
  4. Temporarily install outboard and inboard joint boots and new boot clamps. Before installing boots, wrap the spline of outboard joint shaft with vinyl tape and prevent boots from being damaged. Also, replace 3 clamps to small boots ends and large boot end (outboard joint side).
  5. Place beveled side of tripod axial spline toward outboard joint. Align marks placed before removal.
  6. Using brass bar and hammer, tap in tripod to outboard joint shaft. DO NOT tap the roller. Install new snap ring.
  7. Pack outboard joint and boot with specified grease. See BOOT GREASE SPECIFICATIONS . Install boot to outboard joint.
  8. Pack inward joint and boot with specified grease. See BOOT GREASE SPECIFICATIONS . Align marks previously made and install inboard joint shaft to outboard joint shaft.
  9. Temporarily install boot to inboard joint shaft.
  10. Check axle shaft length. Ensure that the 2 boots are on the shaft groove and that boots are not stretched or contracted when axle shaft is at standard length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig 2.
  11. Install boot clamp to inboard joint shaft boot. Using pliers, pinch the claws to compress the clamp and engage the other claws.
  12. Secure 3 previously placed clamps onto boots. Using Drive Shaft Boot Clamping Tool (SST 09521-24010), or equivalent, pinch the clamp secure. DO NOT overtighten the tool.
  13. Using Wire Gauge Set (SST 09240-00020), or equivalent, adjust the clearances of the clamps to the following clearances as shown in the illustration. Clearance "A" = .075 in. (1.9 mm) or less, clearance "B" = .059-.098 in. (1.5-2.5 mm) and clearance "C" = .118-157 in. (3-4 mm). See Fig 3.
  14. Inspect axle shaft. See Inspection .
Fig 1: Installing Axle Shaft Dust Cover
G96E01313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Measuring Axle Shaft Standard Length
G96B01298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Adjusting Boot Clamp Clearance
G99D08253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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