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Rear Axle Shafts (Except Sequoia): Reassembly

WARNING: This page is about a different car, the 2001 Toyota Sequoia, 2001 Toyota RAV4, 2001 Toyota MR2, and 2001 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using a press, install NEW end cover and No. 1 dust deflector on axle shaft. Wrap splines on axle shaft with tape to prevent damaging boots during installation.
  2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle shaft.
  3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint. Ensure match marks are aligned.
  4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig 1. Install and tighten boot clamps.
Fig 1: Measuring Rear Axle Shaft Length (Highlander & RAV4)
G96B19209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


  1. Using a press, install NEW dust deflector on left side axle shaft. Wrap splines on axle shaft with tape to prevent damaging boots during installation. Using a punch and hammer, install straight pin onto center bearing case on right side axle shaft. Press center bearing into bearing case. Install center bearing and bearing case assembly to inboard joint shaft. Right-side (transaxle side) dust cover must be positioned 3.39-3.43" (86.0-87.0 mm) from end of axle shaft.
  2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle shaft.
  3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint. Ensure match marks are aligned.
  4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig 1. Install and tighten boot clamps.
Fig 1: Measuring Rear Axle Shaft Length (MR2)
G00015976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


  1. Using a press, install NEW dust deflector on axle shaft. Wrap splines on axle shaft with tape to prevent damaging boots during installation.
  2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle shaft.
  3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint. Ensure match marks are aligned.
  4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Figure. Install and tighten boot clamps.
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