Section 13 (Propeller W/Center Bearing Shaft Assembly (AWD)): Overhaul

WARNING: This page is about a different variant/trim than selected.

HINT:

COMPONENTS: See COMPONENTS

REMOVE EXHAUST PIPE ASSY
REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
1. Depress the brake pedal and hold it.
2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.
  HINT:
  
  Put a piece of shop rag or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.
  
  Fig 1: Loosening Cross Groove Joint Set Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place matchmarks on both the flanges.
4. Remove the 4 nuts, bolts and washers.
  
  Fig 2: Removing Nuts, Bolts & Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 4 bolts, 2 adjusting shims and propeller shaft w/ center bearing shaft assy.
  
  Fig 3: Adjusting Shims and Propeller Shaft W/Center Bearing Shaft Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert SST in the transfer to prevent oil leakage. SST 09325-20010
Fig 4: Inserting SST In Transfer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PROPELLER SHAFT ASSY 3.
1. Place matchmarks on both the flanges.
2. Remove the 4 nuts, bolts and washers.
Fig 5: Placing Matchmarks and Removing Nuts, Bolts & Washers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTERMEDIATE SHAFT
1. Place matchmarks on the joint and flange.
  NOTE: Do not make matchmarks with a punch.
2. Using a hexagon wrench (6 mm), remove the 6 bolts and 2 washers and separate the intermediate shaft from the rear propeller shaft.
Fig 6: Removing Intermediate Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SPIDER BEARING
1. Check the spider bearing axial play by turning the flange while holding the shaft tightly
HINT:

If necessary, replace the shaft

Fig 7: Inspecting Spider Bearing Axial Play
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT
1. Using a dial indicator, inspect the runout of the shaft
  Maximum runout: 0.8 mm (0.031 in.)
  
  HINT:
  
  If the shaft runout exceeds the maximum, replace the shaft
  
  Fig 8: Inspecting Runout of Shaft Using a Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, inspect the front side of the intermediate shaft flange runout
  Maximum runout: 0.1 mm (0.004 in.)
  
  HINT:
  
  If the shaft runout exceeds the maximum, replace the shaft
  
  Fig 9: Inspecting Front Side of Intermediate Shaft Flange Runout By using a Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a dial indicator, inspect the rear side of the intermediate shaft flange runout in the horizontal direction
  Maximum runout: 0.1 mm (0.004 in.)
  
  HINT:
  
  If the intermediate shaft flange runout exceeds the maximum, replace the intermediate shaft
  
  Fig 10: Inspecting Rear Side of Intermediate Shaft Flange Run Out in Horizontal Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a dial indicator, inspect the rear side of the intermediate shaft flange runout in the vertical direction
  Maximum runout: 0.1 mm (0.004 in.)
HINT:

If the intermediate shaft flange runout exceeds the maximum, replace the intermediate shaft

Fig 11: Inspecting Rear Side of Intermediate Shaft Flange Runout in Vertical Direction
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PROPELLER SHAFT ASSY
1. Using a dial indicator, inspect the runout of the propeller shaft
  Maximum runout: 0.8 mm (0.031 in.)
HINT:

If the shaft runout exceeds the maximum, replace the propeller shaft

Fig 12: Inspecting Runout Of Propeller Shaft Using A Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER SUPPORT BEARING ASSY NO.2
1. Using a chisel and a hammer, loosen the staked part of the nut
2. Using SST to hold the front flange, remove the nut and plate washer
  SST 09330-00021
  
  Fig 13: Loosening Staked Part A Nut & Removing Nut & Plate Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place matchmarks on the rear flange and shaft
  
  Fig 14: Placing Matchmarks On Rear Flange and Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the rear flange
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
5. Remove the center support bearing assy No.2 and plate washer
Fig 15: Removing Rear Flange, Center Support Bearing Assy No.2 and Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER SUPPORT BEARING ASSY NO.1
1. Using a chisel and a hammer, loosen the staked part of the nut
2. Using SST to hold the front flange, remove the nut and plate washer
  SST 09330-00021
  
  Fig 16: Loosening and Remaining Nut & Plate Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place matchmarks on the front flange and shaft
  
  Fig 17: Placing Matchmarks On Front Flange & Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the front flange
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
5. Remove the center support bearing assy No.1 and plate washer
Fig 18: Removing Front Flange, Center Support Bearing Assy No.1 and Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CENTER SUPPORT BEARING ASSY NO.2
1. Turn the bearing by hand with applying force in the rotation direction. Check the bearing turns smoothly
2. Check that the seals are not cracked or damaged
HINT:

If the bearing is damaged, worn, or does not turn freely, replace it

Fig 19: Inspecting Center Support Bearing Assy No.2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CENTER SUPPORT BEARING ASSY NO.1
1. Inspect the center support bearing assy No.1 by the same procedures with center support bearing assy No.2
INSPECT PROPELLER SHAFT
1. Using a dial indicator, inspect the runout of the rear propeller shaft
  Maximum runout: 0.8 mm (0.031 in.)
HINT:

If the shaft runout exceeds the maximum, replace the rear propeller shaft

Fig 20: Inspecting Propeller Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER SUPPORT BEARING ASSY NO.1
1. Set the center support bearing assy No.1 on the intermediate shaft, as shown in the illustration
2. Install the plate washer to the intermediate shaft
  
  Fig 21: Installing Plate Washer To Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the matchmarks on the front flange and shaft and place the flange on the shaft
  
  Fig 22: Aligning Matchmarks On Front Flange and Shaft and Placing Flange On Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST to hold the front flange, press the center support bearing assy No.1 into position by tightening down a new nut and plate washer
  SST 09330-00021
  
  Torque: 182 N.m (1,850 kgf.cm, 134 ft.lbf)
5. Loosen the nut
6. Torque the nut again
  Torque: 69 N.m (700 kgf.cm, 51 ft.lbf)
7. Using a chisel and a hammer, stake the nut
Fig 23: Loosening, Torquing and Staking Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER SUPPORT BEARING ASSY NO.2
1. Set the center support bearing assy No.2 on the shaft as shown in the illustration
2. Install the plate washer to the shaft
  
  Fig 24: Installing Plate Washer To Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the matchmarks on the rear flange and shaft and place the flange on the shaft
  
  Fig 25: Aligning Matchmarks On Rear Flange & Shaft and Placing Flange On Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST to hold the front flange, press the center support bearing assy No.2 into position by tightening down a new nut and plate washer
  SST 09330-00021
  
  Torque: 182 N.m Loosen the nut
5. Loosen the nut.
6. Torque the nut again
  Torque: 69 N.m (700 kgf.cm, 51 ft.lbf)
7. Using a chisel and a hammer, stake the nut
Fig 26: Loosening, Torquing And Staking Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTERMEDIATE SHAFT
1. Align the matchmarks on the intermediate shaft and rear propeller shaft, then install the 2 washers and 6 bolts
2. Using a hexagon wrench (6 mm), tighten the 6 bolts temporarily
Fig 27: Installing Intermediate Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PROPELLER SHAFT ASSY
1. Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts
  Torque: 74 N.m (750 kgf.cm, 54 ft.lbf)
2. Check that the each joint of the propeller shaft is facing to the direction, as shown in the illustration
Fig 28: Aligning Matchmarks And Connecting Shaft With Bolt, Washer And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 29: Checking Each Joint Of Propeller Shaft Facing To Direction
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY
1. Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts
  
  Fig 30: Aligning Matchmarks And Connecting Shaft With Bolts, Washer And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove SST from the transaxle
3. Insert the yoke into the transaxle
  
  Fig 31: Removing SST And Inserting Yoke Into Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 adjusting shims and propeller shaft w/ center bearing, and temporarily tighten the 4 bolts
  
  Fig 32: Installing Adjusting Shim And Propeller Shaft W/Center Bearing And Tightening Bolt Temporarily
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tighten the 4 nuts.
  Torque: 74 N.m (750 kgf.cm, 54 ft.lbf)
Fig 33: Tightening Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY

Remove the shop rag to the joint
Using a hexagon wrench (6 mm), tighten the 6 bolts
Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)

Fig 34: Removing Shop Rag To Joints Tightening Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft, as shown in the illustration

Fig 35: Adjusting Dimension B/W Rear Side Of Cover And Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Under the same condition as (a), adjust the front and rear dimensions between edge surface of the center support bearing and the edge surface of the cushion to 12.5 +/- 1.0 mm (0.492 +/- 0.039 in.) respectively as shown, then torque the bolts
Torque: 37 N.m (375 kgf.cm, 27 ft.lbf)
Check that the center line of the bracket is at the right angle in the shaft axial direction

Fig 36: Adjusting Front And Rear Dimensions, Torquing Bolts And Checking Center Line Of Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If any vibration or noise occurs, perform joint angle check as follows and replace the adjusting shim with proper one

Turn the propeller shaft several times by hand to stabilize the center support bearings
Using a jack, raise and lower the differential to stabilize the differential mounting cushion
Remove the transfer dynamic damper
Using SST, measure the installation angle of the transfer (A) and front propeller shaft (B)
SST 09370-50010

No.1 joint angle: A - B = -1.6° to -3.6 °
Using SST, measure the installation angle of the rear propeller shaft (C) and rear differential (D)

SST 09370-50010

No.2 joint angle: C - D = 2.1° to 4.1°

Fig 37: Performing Joint Angle Check

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

If the measured angle is not within the specification, adjust it with the center support bearing adjusting shim

Center support bearing adjusting shim thickness:

CENTER SUPPORT BEARING ADJUSTING SHIM THICKNESS

Thickness mm (in.)	Thickness mm (in.)
3.2 (0.126)	11.0 (0.433)
4.5 (0.177)	13.5 (0.531)
6.5 (0.256)	15.5 (0.610)
9.0 (0.354)	17.5 (0.689)

Install the transfer dynamic damper
Torque: 26 N.m (260 kgf.cm, 19 ft.lbf)

INSTALL EXHAUST PIPE ASSY
CHECK FOR EXHAUST GAS LEAKS
INSPECT AND ADJUST TRANSFER OIL