Front Drive Shaft: Overhaul

HINT:

• COMPONENTS: see COMPONENTS 
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.

1. REMOVE ENGINE UNDER COVER LH 
2. DRAIN AUTOMATIC TRANSAXLE FLUID 
   1. Remove the drain plug and gasket, and then drain the ATF.
   2. Install a new gasket and drain plug.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

3. REMOVE FRONT WHEEL 
4. REMOVE FRONT AXLE HUB LH NUT 
   1. Using SST and hammer, release the staked part of the front axle hub LH nut.

      SST 09930-00010

      NOTE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.
   2. While applying the brakes, remove the front axle hub LH nut.
      Fig 1: Removing Front Axle Hub LH Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. SEPARATE FRONT STABILIZER LINK ASSY LH 
   1. Remove the nut and separate the front stabilizer link assy LH.

      HINT:

      If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

      Fig 2: Removing Nut & Separate Front Stabilizer Link Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. SEPARATE SPEED SENSOR FRONT LH 
   1. Remove the bolt and clip, and separate the speed sensor wire and flexible hose from the shock absorber.
      Fig 3: Separating Speed Sensor Wire And Flexible Hose From Shock Absorber

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the bolt and separate the speed sensor front LH from the steering knuckle.
      NOTE:

      • Prevent foreign matter from adhering to the speed sensor.
      • Be careful not to damage the speed sensor.
      Fig 4: Removing Bolt & Separating Speed Sensor Front LH From Steering Knuckle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. SEPARATE TIE ROD END SUB-ASSY LH 
   1. Remove the cotter pin and nut.
   2. Using SST, separate the tie rod end sub-assy LH from the steering knuckle.

      SST 09628-62011

      NOTE: Do not damage the ball joint dust cover.
      Fig 5: Separating Tie Rod End Sub-Assy LH From Steering Knuckle Using SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 
   1. Remove the bolt and 2 nuts, and separate the front suspension arm sub-assy lower No.1 LH from the lower ball joint.
      Fig 6: Removing Bolt & Nuts, & Separate Front Suspension Arm Sub-Assy Lower No.1 LH From Lower Ball Joint

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. SEPARATE FRONT AXLE ASSY LH 
   1. Put matchmarks on the front drive shaft assy LH and the axle hub.
   2. Using a plastic hammer, separate the front drive shaft assy LH from the front axle hub sub-assy LH.
      NOTE: Be careful not to damage the drive shaft boot and speed sensor rotor.
      Fig 7: Separating Front Drive Shaft Assy LH From Front Axle Hub Sub-Assy LH Using Plastic Hammer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT DRIVE SHAFT ASSY LH 
    1. Using SST, remove the front drive shaft assy LH.

       SST 09520-01010, 09520-24010 (09520-32040)

       NOTE:

       • Be careful not to damage the drive shaft dust cover, boot and oil seal.
       • Be careful not to drop the drive shaft assy.
       Fig 8: Removing Front Drive Shaft Assy LH Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DRIVE SHAFT ASSY RH 
    1. Using a screwdriver, remove the bearing bracket hole snap ring.
    2. Remove the bolt and front drive shaft assy RH from the drive shaft bearing bracket.
       NOTE: Do not damage the boot and oil seal.
       Fig 9: Removing Front Drive Shaft Assy Rh

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. FIX FRONT AXLE HUB SUB-ASSY LH 

    SST 09608-16042 (09608-02021, 09608-02041)

    NOTE: The hub bearing could be damaged if it is subjected to the vehicle's full weight, such as moving the vehicle with the drive shaft removed.
    If it is necessary to place the vehicle's weight on the hub bearing, first support it with SST.
    Fig 10: Fixing Front Axle Hub Sub-Assy LH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSPECT FRONT DRIVE SHAFT ASSY LH 
    1. Check that there is no excessive play in the outboard joint.
    2. Check that the inboard joint slides smoothly in the thrust direction.
    3. Check that there is no excessive play in the radial directions of the inboard joint.
    4. Check the boots for damage.
       Fig 11: Inspecting Front Drive Shaft Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DRIVE INNER SHAFT OUTER LH SHAFT SNAP RING 
    1. Using a screwdriver, remove the front drive inner shaft outer LH shaft snap ring.
       Fig 12: Removing Front Drive Inner Shaft Outer LH Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Using pliers, remove the inboard joint boot LH No.2 clamp and inboard joint boot LH clamp, as shown in the illustration.
       Fig 13: Removing Front Axle Inboard Joint Boot Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. SEPARATE FR AXLE INBOARD JOINT BOOT 
    1. Separate the inboard joint boot from the inboard joint assy.
17. REMOVE FRONT DRIVE INBOARD JOINT ASSY LH 
    1. Put matchmarks on the inboard joint assy and outboard joint shaft.
       NOTE: Do not use a punch for the marks.
    2. Remove the inboard joint assy from the outboard joint shaft.
       Fig 14: Putting Matchmarks On Inboard Joint Assy & Outboard Joint Shaft

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, remove the shaft snap ring.
       Fig 15: Removing Shaft Snap Ring Using Snap Ring Expander

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Put matchmarks on the outboard joint shaft and tripod joint.
       NOTE: Do not use a punch for the marks.
    5. Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft.
       NOTE: Do not tap the roller.
       Fig 16: Removing Tripod Joint From Outboard Joint Shaft Using Brass Bar And Hammer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DRIVE SHAFT DAMPER LH 
    1. Using pliers, remove the drive shaft damper clamp, as shown in the illustration.
    2. Remove the drive shaft damper.
       Fig 17: Removing Drive Shaft Damper Clamp Using Pliers Using Pliers

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Using pliers, remove the outboard joint boot LH No.2 clamp and outboard joint boot LH clamp, as shown in the illustration.
       Fig 18: Removing Outboard Joint Boot LH No.2 Clamp & Outboard Joint Boot LH Clamp Using Pliers

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE OUTBOARD JOINT BOOT 
    1. Remove the outboard joint boot from the outboard joint shaft.
    2. Remove the grease from the outboard joint.
21. REMOVE FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, remove the drive shaft dust cover LH.

       SST 09950-00020

       NOTE: Be careful not to drop the inboard joint assy.
       Fig 19: Removing Drive Shaft Dust Cover LH Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE FRONT DRIVE SHAFT DUST COVER RH 
    1. Using a press, remove the drive shaft dust cover RH.
       Fig 20: Removing Drive Shaft Dust Cover RH Using A Press

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE FRONT DRIVE SHAFT DUST COVER 
    1. Using SST and a press, remove the drive shaft dust cover.

       SST 09950-00020

       Fig 21: Removing Drive Shaft Dust Cover Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE FRONT DRIVE SHAFT BEARING 
    1. Using a snap ring expander, remove the drive shaft hole snap ring.
       Fig 22: Removing Drive Shaft Hole Snap Ring Using Snap Ring Expander

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the bearing.

       SST 09527-10011

    3. Remove the bearing bracket hole snap ring.
       NOTE: Be careful not to drop the inboard joint assy.
       Fig 23: Removing Bearing Bracket Hole Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL FRONT DRIVE SHAFT BEARING 
    1. Install a new bearing bracket hole snap ring to the front driver shaft assy RH.
    2. Using SST and a steel plate, install a new front drive shaft bearing.

       SST 09527-30010, 09527-10011

       NOTE: Bearing should be completely installed.
       Fig 24: Installing A New Front Drive Shaft Bearing Using SST & A Steel Plate

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install a new drive shaft hole snap ring.
       Fig 25: Installing Drive Shaft Hole Snap Ring Using Snap Ring Expander

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT DRIVE SHAFT DUST COVER 
    1. Using SST and a press, install a new drive shaft dust cover.

       SST 09726-40010, 09527-10011

       NOTE:

       • Dust cover should be completely installed.
       • Be careful not to damage the dust cover.
       Fig 26: Installing New Drive Shaft Dust Cover Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL FRONT DRIVE SHAFT DUST COVER RH 
    1. Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.

       SST 09527-10011

       Distance (A): 110.0 to 111.0 mm (4.3307 to 4.3701 in.) 

       NOTE:

       • Dust cover should be completely installed.
       • Be careful not to damage the dust cover.
       Fig 27: Installing Front Drive Shaft Dust Cover RH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, install a new drive shaft dust cover LH.

       SST 09527-10011

       NOTE:

       • Dust cover should be completely installed.
       • Be careful not to damage the dust cover.
       Fig 28: Installing Front Drive Shaft Dust Cover LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL OUTBOARD JOINT BOOT 

    HINT:

    Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.

    1. Hold the drive shaft lightly in a soft vise.
    2. Temporarily install a new outboard joint boot to the drive shaft with 2 clamps.
    3. Pack the outboard joint shaft and boot with grease.

       Grease capacity: 120 to 140 g (4.2 to 4.9 oz.) 

       Fig 29: Installing Outboard Joint Boot

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft lightly in a soft vise.
    2. Install the 2 outboard joint boot clamps onto the boot.
    3. Place SST onto the outboard joint large boot clamp.

       SST 09521-24010

    4. Tighten the SST so that the outboard joint large boot clamp is pinched.
       NOTE: Do not overtighten the SST.
       Fig 30: Holding Drive Shaft Lightly In Soft Vise

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, measure the clearance of the outboard joint large boot clamp.

       SST 09240-00020

       Clearance: 1.2 to 4.0 mm (0.0472 to 0.1575 in.) 

       NOTE: When the measured value is greater than the specified value, retighten the clamp.
    6. Install the outboard joint small boot clamp using the same procedures.
       Fig 31: Measuring Clearance Of Outboard Joint Large Boot Clamp Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL FRONT DRIVE SHAFT DAMPER LH 
    1. Install the drive shaft damper LH to the drive shaft.
    2. Make sure that the damper is on the shaft groove.
    3. Set the distance, as specified below.

       Distance : 204.5 to 208.5 mm (8.051 to 8.209 in.) 

       Fig 32: Making Sure That Damper Is On Shaft Groove

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using pliers, install a new drive shaft damper clamp, as shown in the illustration.
       Fig 33: Install A New Drive Shaft Damper Clamp Using Pliers

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH 
    1. Temporarily install a new inboard joint boot with 2 clamps to the drive shaft.
    2. Place the beveled side of the tripod joint axial spline toward the outboard joint shaft.
    3. Align the matchmarks.
    4. Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.
       NOTE:

       • Do not tap the roller.
       • Be sure to install the tripod joint assy in the correct direction.
       Fig 34: Placing Beveled Side Of Tripod Joint Axial Spline Toward Outboard Joint Shaft

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a snap ring expander, install a new shaft snap ring.
    6. Pack the outboard joint shaft and boot with grease.

       Grease capacity: 190 to 210 g (6.7 to 7.4 oz.) 

       Fig 35: Installing Shaft Snap Ring Using Snap Ring Expander

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the matchmarks and install the inboard joint assy to the outboard joint shaft assy.
       Fig 36: Aligning Matchmarks & Install Inboard Joint Assy To Outboard Joint Shaft Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. INSTALL FR AXLE INBOARD JOINT BOOT 
    1. Install the inboard joint boot to the inboard joint assy.
34. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Using pliers, install the new inboard joint boot LH No.2 clamp and inboard joint boot LH clamp, as shown in the illustration.
       Fig 37: Installing New Inboard Joint Boot LH No.2 Clamp & Inboard Joint Boot LH Clamp Using Pliers

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. INSPECT FRONT DRIVE SHAFT 
    1. Check that there is no excessive play in the outboard joint.
    2. Check that the inboard joint slides smoothly in the thrust direction.
    3. Check that there is no excessive play in the radial directions of the inboard joint.
    4. Check the boots for damage.
       Fig 38: Checking Inboard Joint Slides Smoothly In Thrust Direction

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       For dimension (A), refer to the following table.

       FRONT DRIVE SHAFT DIMENSION (A) SPECIFICATION
       
       

       LH	588.0 to 592.0 mm (23.150 to 23.307 in.)
       RH	906.2 to 910.2 mm (35.677 to 35.835 in.)

       Fig 39: Measuring Dimension "A"

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. INSTALL FRONT DRIVE INNER SHAFT OUTER LH SHAFT SNAP RING 
    1. Install a new hole snap ring.
37. INSTALL FRONT DRIVE SHAFT ASSY LH 
    1. Coat the spline of the inboard joint shaft assy with ATF.
    2. Align the shaft splines and install the drive shaft assy LH with a brass bar and hammer.
       NOTE:

       • Set the shaft snap ring with the opening side facing down.
       • Be careful not to damage the drive shaft dust cover, boot and oil seal.
       • Move the drive shaft assy while keeping it level.
       Fig 40: Installing Front Drive Shaft Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. INSTALL FRONT DRIVE SHAFT ASSY RH 
    1. Coat the spline of the inboard joint shaft assy with ATF.
    2. Install the front drive shaft assy RH.
    3. Using a screwdriver, install a new bearing bracket hole +snap ring.
       NOTE:

       • Do not damage the boot and oil seal.
       • Move the drive shaft assy while keeping it level.
    4. Install a new bolt.

       Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) 

       Fig 41: Installing Front Drive Shaft Assy RH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. INSTALL FRONT AXLE ASSY LH 
    1. Align the matchmarks and install the front drive shaft assy LH to the front axle hub sub-assy LH.
       NOTE: Be careful not to damage the drive shaft boot and speed sensor rotor.
       Fig 42: Aligning Matchmarks & Install Front Drive Shaft Assy LH To Front Axle Hub Sub-Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
40. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 
    1. Install the lower ball joint to the front suspension arm sub-assy lower No.1 LH with the bolt and 2 nuts.

       Torque: 75 N.m (765 kgf.cm, 55 ft.lbf) 

       Fig 43: Installing Front Suspension Arm Sub-Assy Lower No.1 LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. INSTALL TIE ROD END SUB-ASSY LH 
    1. Install the tie rod end sub-assy LH to the steering knuckle with the nut.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    2. Install a new cotter pin.
       NOTE: If the holes for the cotter pin are not aligned,tighten the nut up to 60° further.
42. INSTALL SPEED SENSOR FRONT LH 
    1. Install the speed sensor front LH to the steering knuckle with the bolt.

       Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

       NOTE:

       • Prevent foreign matter from adhering to the speed sensor.
       • Be careful not to damage the speed sensor.
       Fig 44: Installing Speed Sensor Front LH To Steering Knuckle With Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the sensor clip on the knuckle.

       Torque: 19 N.m (192 kgf.cm, 14 ft.lbf) 

       NOTE:

       • Be careful not to damage the speed sensor.
       • Prevent foreign matter from adhering to the speed sensor.
       • Do not twist the sensor wire when installing the speed sensor.
       Fig 45: Installing Flexible Hose & Speed Sensor To Shock Absorber With Bolt & Set Sensor Clip On Knuckle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL FRONT STABILIZER LINK ASSY LH 
    1. Install the stabilizer link assy LH with the nut.

       Torque: 74 N.m (755 kgf.cm, 55 ft.lbf) 

       HINT:

       If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

       Fig 46: Installing Stabilizer Link Assy LH With Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
44. INSTALL FRONT AXLE HUB LH NUT 
    1. Using a socket wrench (30 mm), install a new axle hub LH nut.

       Torque: 294 N.m (3,000 kgf.cm, 217 ft.lbf) 

    2. Using a chisel and hammer, stake the front axle hub LH nut.
       Fig 47: Staking Front Axle Hub LH Nut Using Chisel And Hammer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
45. INSTALL FRONT WHEEL 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

46. ADD AUTOMATIC TRANSAXLE FLUID (SEE  AUTOMATIC TRANSMISSION FLUID (ATM)  ) 
47. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE  AUTOMATIC TRANSMISSION FLUID (ATM)  ) 
48. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE  ADJUSTMENT  ) 
49. INSTALL ENGINE UNDER COVER LH 
50. CHECK ABS SPEED SENSOR SIGNAL 
    1. ABS WITH EBD & TRAC & VSC SYSTEM (see TEST MODE PROCEDURE )
    2. ABS WITH EBD SYSTEM (see TEST MODE PROCEDURE )