Front Drive Shaft (1ZZ-FE): Overhaul

HINT:

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

1. DRAIN MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE) 

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

2. DRAIN AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE) 

   Torque: 18 N.m (178 kgf.cm, 13 ft.lbf) 

3. REMOVE FRONT WHEEL 
4. REMOVE ENGINE UNDER COVER LH 
5. REMOVE FRONT AXLE HUB LH NUT 
   1. Using SST and a hammer, unstake the staked part of the hub LH nut.

      SST 09930-00010

      Fig 1: Removing Front Axle Hub LH Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. While applying the brakes, remove the hub LH nut.
   NOTE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.
6. SEPARATE FRONT STABILIZER LINK ASSY LH 
   1. Remove the nut, separate the front stabilizer link assy LH from the shock absorber assy front LH.

   HINT:

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

   Fig 2: Separating Front Stabilizer Link Assy LH From Shock Absorber Assy Front LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. SEPARATE SPEED SENSOR FRONT LH (W7 ABS) 
   1. Remove the bolt, separate the speed sensor front LH and flexible hose from the shock absorber assy front LH.
      Fig 3: Separating Speed Sensor Front LH And Flexible Hose

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the bolt, separate the speed sensor front LH from the steering knuckle.
      Fig 4: Separating Speed Sensor Front LH From Steering Knuckle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 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

      Fig 5: Separating Tie Rod End Sub-Assy LH From Steering Knuckle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 
   1. Remove a bolt and 2 nuts, separate the front suspension arm sub-assy lower No.1 LH from the lower ball joint.
   Fig 6: Separating Front Suspension Arm Sub-Assy Lower No.1 LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. SEPARATE FRONT AXLE ASSY LH 
    1. Using a plastic hammer, separate the front drive shaft assy LH from the front axle assy LH.
       Fig 7: Separating Front Drive Shaft Assy LH From Front Axle Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Be careful not to damage the boot.
    • w/ ABS: Be careful not to damage the speed sensor rotor.
11. REMOVE FRONT DRIVE SHAFT ASSY LH 
    1. Using SST, remove the front drive shaft assy LH. SST 09520-01010, 09520-24010 (09520-32040)
       Fig 8: Removing Front Drive Shaft Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to damage the dust cover, boot and oil seal.

    HINT:

    In case of not being able to remove the drive shaft at the position of the illustration (A), hook the claw of SST to the position of the illustration (B), remove it.

12. REMOVE FRONT DRIVE SHAFT ASSY RH 

    HINT:

    Remove the RH side by the same procedures as the LH side.

    NOTE: Be careful not to damage the dust cover and oil seal.
13. FIX FRONT AXLE ASSY LH 
    NOTE: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed.
    Fig 9: Removing Front Drive Shaft Assy RH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Therefore, make sure to support the hub bearing with SST when the vehicle weight is applied. 

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

14. INSPECT FRONT DRIVE SHAFT ASSY LH 
    1. Check that there is no remarkable play in the outboard joint.
    2. Check that the inboard joint slides smoothly in the thrust direction.
    3. Check that there is no remarkable play in the radial direction of the inboard joint.
    4. Check the boots for damage.
       Fig 10: Inspecting Front Drive Shaft Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Keep the drive shaft assy level during inspection.
15. REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP 
    1. Using a needle nose pliers, remove the inboard joint boot LH No.2 clamp as shown in the illustration.
       Fig 11: Removing Inboard Joint Boot LH No.2 Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP 
    1. Using a side cutter, cut the inboard joint boot LH clamp, then remove it.
17. SEPARATE INBOARD JOINT BOOT 
    1. Separate the inboard joint boot from the inboard joint sub-assy LH.
18. REMOVE FRONT AXLE INBOARD JOINT SUB-ASSY LH 
    1. Remove the old grease from the inboard joint sub-assy LH.
    2. Put matchmarks on the inboard joint sub-assy LH and outboard joint shaft assy.
       Fig 12: Putting Matchmarks On Inboard Joint Sub-Assy LH And Outboard Joint Shaft Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not punch the marks.
    3. Remove the inboard joint sub-assy LH from the outboard joint shaft assy.
    4. Using a snap ring expander, remove the inner LH shaft snap ring.
       Fig 13: Removing Inner LH Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Put matchmarks on the outboard joint shaft assy and tripod joint assy.
       NOTE: Do not punch the marks.
    6. Using a brass bar and a hammer, remove the tripod joint assy from the outboard joint shaft assy.
       Fig 14: Removing Tripod Joint Assy From Outboard Joint Shaft Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not tap the roller.
    7. Using a snap ring expander, remove the inner LH shaft snap ring.
    8. Remove the inboard joint boot.
       Fig 15: Removing Inboard Joint Boot

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE DRIVE SHAFT DAMPER (RH DRIVE SHAFT) 
    1. Using a side cutter, cut the drive shaft damper setting clamp, then remove it.
    2. Remove the drive shaft damper.
20. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING 
    1. Using a screwdriver, remove the LH hole snap ring.
       Fig 16: Removing LH Hole Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, remove the dust cover LH. SST 09950-00020
       Fig 17: Removing Dust Cover LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, install a new dust cover LH, as shown in the illustration.

       SST 09527-10011

       Fig 18: Installing Dust Cover LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Dust cover should be installed completely.
    • Be careful not to damage the dust cover.
23. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING 
    1. Install a new LH hole snap ring.
24. INSTALL DRIVE SHAFT DAMPER (RH DRIVE SHAFT) 
    1. Set the distance, as described below.

       Distance (A): 438 to 442 mm (17.24 to 17.40 in.) 

    2. Through the damper setting clamp to the shaft.
       Fig 19: Installing Drive Shaft Damper (RH Drive Shaft)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount drive shaft in a soft vise.
    4. Secure the damper setting clamp onto the damper.
    5. Place SST onto the damper setting clamp. SST 09521-24010
    6. Tighten the SST so that the clamp is pinched.
       Fig 20: Placing SST Onto Damper Setting Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not overtighten the SST.
    7. Using SST, adjust the clearance of the damper setting clamp.

       SST 09240-00020 (09242-00150)

       Clearance: 1.5 mm (0.059 in.) or less 

       Fig 21: Adjusting Clearance Of Damper Setting Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL FRONT AXLE INBOARD JOINT SUB-ASSY LH 

    HINT:

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

    1. Install new parts to the outboard joint shaft assy in the following order.
       1. Inboard joint boot LH clamp
       2. Inboard joint boot LH No.2 clamp
       3. Inboard joint boot
    2. Using a snap ring expander, install a new inner LH shaft snap ring.
       Fig 22: Installing Inner LH Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks, install tripod joint assy to the outboard joint assy.
    4. Using a brass bar and a hammer, install the tripod joint assy.
       Fig 23: Installing Tripod Joint Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not tap the roller.
    5. Using a snap ring expander, install a new inner LH shaft snap ring.
    6. Pack the inboard joint sub-assy LH with grease.

       Grease Capacity: 135 to 155 g (4.8 to 5.5 oz.) 

       Fig 24: Installing Inner LH Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the matchmarks, install the inboard joint sub-assy LH to the outboard joint shaft assy.
       Fig 25: Aligning Matchmarks

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL INBOARD JOINT BOOT 
    1. Install the inboard joint boot to the inboard joint assy.
27. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP 
    1. Mount drive shaft in a soft vise.
    2. Secure the clamp onto the boot.
    3. Place SST onto the clamp. SST 09521-24010
    4. Tighten the SST so that the clamp is pinched.
       Fig 26: Placing SST Onto Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not overtighten the SST.
    5. Using SST, adjust the clearance of the clamp. SST 09240-00020 (09242-00150)

       Clearance: 1.5 mm (0.059 in.) or less. 

       Fig 27: Adjusting Clearance Of Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP 
    1. Using a needle nose pliers, install the inboard joint boot LH No.2 clamp as shown in the illustration.
       Fig 28: Installing Inboard Joint Boot LH No.2 Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSPECT FRONT DRIVE SHAFT ASSY LH 
    NOTE: Keep the drive shaft assy level during inspection.
    1. Check that there is no remarkable play in the outboard joint.
    2. Check that the inboard joint slides smoothly in the thrust direction.
       Fig 29: Inspecting Front Drive Shaft Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that there is no remarkable play in the radial direction of the inboard joint.
    4. Check the boots for damage.

    HINT:

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

    Fig 30: Checking Front Drive Shaft Dimension

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    FRONT DRIVE SHAFT DIMENSION
    
    

    RH	843.3 to 853.3 mm (33.201 to 33.594 in.)
    LH	564.3 to 574.3 mm (22.216 to 22.610 in.)

30. INSTALL FRONT DRIVE SHAFT ASSY LH 
    1. ATT:

       Coat the spline of the inboard joint shaft assy with ATF.

    2. M/T:

       Coat the spline of the inboard joint shaft assy with gear oil.

    3. Align the shaft splines, install the drive shaft assy with a brass bar and a hammer.
       Fig 31: Aligning Shaft Splines

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Set the hole snap ring with opening side facing downwards.
    • Be careful not to damage the oil seal.

    HINT:

    Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving it in.

31. INSTALL FRONT DRIVE SHAFT ASSY RH 

    HINT:

    Install the RH side by the same procedure as the LH side.

    NOTE: Do not damage the oil seal.
32. INSTALL FRONT AXLE ASSY LH 
    1. Install the drive shaft assy LH to the front axle assy LH.
    NOTE:

    • Be careful not to damage the outboard joint boot.
    • w/ ABS:

      Be careful not to damage the speed sensor rotor.

33. 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 a bolt and 2 nuts.

       Torque: 89 N.m (908 kgf.cm, 66 ft.lbf) 

       Fig 32: Installing Lower Ball Joint To Front Suspension Arm Sub-Assy Lower No.1 LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. 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 further to 60°.
35. INSTALL SPEED SENSOR FRONT LH (W/ ABS) 
    1. Install the speed sensor front LH and flexible hose to shock absorber assy front LH with the bolt.

       Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

       Fig 33: Installing Speed Sensor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the speed sensor front LH to the steering knuckle with the bolt.

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

       Fig 34: Installing Speed Sensor Front LH To Steering Knuckle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Be careful not to damage the speed sensor.
    • Keep the speed sensor clean.
    • Do not twist the sensor wire when installing the sensor.
36. INSTALL FRONT STABILIZER LINK ASSY LH 
    1. Install the front stabilizer link assy LH with the nut.

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

       Fig 35: Installing Front Stabilizer Link Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

37. INSTALL FRONT AXLE HUB LH NUT 
    1. Install a new hub LH nut.

       Torque: 216 N.m (2,200 kgf.cm, 159 ft.lbf) 

    2. Using a chisel and a hammer, stake the hub LH nut.
       Fig 36: Staking Hub LH Nut

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

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

39. ADD MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE) 
40. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE) (See  MANUAL TRANSAXLE OIL (MTM)  ) 
41. ADD AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE) 
42. INSPECT AND ADJUST AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE) (See  AUTOMATIC TRANSAXLE FLUID (A245E)  ) 
43. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  FRONT WHEEL ALIGNMENT  ) 
44. CHECK ABS SPEED SENSOR SIGNAL (W/ABS)(See  TEST MODE PROCEDURE (1ZZ-FE)  or  TEST MODE PROCEDURE (2ZZ-GE)  )