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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Drive Shaft (Service Information) (Hybrid) >> Front Drive Shaft Assembly >> Disassembly [02/2014 - 11/2016] >> Procedure

Disassembly [02/2014 - 11/2016]: Procedure

  1. SEPARATE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Using pliers, separate the front No. 2 axle inboard joint boot clamp as shown in the illustration.
      GTY113958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. SEPARATE FRONT AXLE INBOARD JOINT BOOT CLAMP 

    HINT: 

    Perform the same procedure as for the front No. 2 axle inboard joint boot clamp.

  3. SEPARATE FRONT AXLE INBOARD JOINT BOOT 
    1. Separate the front axle inboard joint boot from the front drive inboard joint assembly.
  4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY 
    1. Remove the old grease from the front drive inboard joint assembly.
    2. Put matchmarks on the front drive inboard joint assembly and front drive outboard joint shaft assembly.
      NOTE:

      Do not use a punch for the marks.

      GTY427122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    3. Remove the front drive inboard joint assembly from the front drive outboard joint shaft assembly.
    4. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    5. Using a snap ring expander, remove the shaft snap ring from the front drive outboard joint shaft assembly.
      GTY426949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Put matchmarks on the front drive outboard joint shaft assembly and tripod joint.
      NOTE:

      Do not use a punch for the marks.

      GTY443175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    7. Using a brass bar and a hammer, tap out the tripod joint from the front drive outboard joint shaft assembly.
      NOTE:
      • Do not tap the rollers.
      • Do not drop the tripod joint.
  5. REMOVE FRONT AXLE INBOARD JOINT BOOT 
    1. Remove the front No. 2 axle inboard joint boot clamp, front axle inboard joint boot and front axle inboard joint boot clamp.
  6. REMOVE FRONT DRIVE SHAFT DAMPER 
    1. w/ 1 Clamp:
      1. Using pliers, separate the front drive shaft damper clamp.
        GTY205523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the front drive shaft damper and front drive shaft damper clamp from the front drive outboard joint shaft assembly.
    2. w/ 2 Clamps:
      1. Using needle-nose pliers, separate the 2 front drive shaft damper clamps.
        GTY429228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the front drive shaft damper and 2 front drive shaft damper clamps from the front drive outboard joint shaft assembly.
  7. SEPARATE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Using pliers, separate the front No. 2 axle outboard joint boot clamp.
      GTY114501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. SEPARATE FRONT AXLE OUTBOARD JOINT BOOT CLAMP 

    HINT: 

    Perform the same procedure as for the front No. 2 axle outboard joint boot clamp.

  9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT 
    1. Remove the front axle outboard joint boot clamp, front axle outboard joint boot and front No. 2 axle outboard joint boot clamp from the front drive outboard joint shaft assembly.
    2. Remove the old grease from the outboard joint.
  10. REMOVE FRONT DRIVE SHAFT DUST COVER LH 
    1. Using SST and a press, remove the front drive shaft dust cover LH.
      GTY440620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      NOTE:
      • Do not drop the front drive inboard joint assembly.
      • Do not overtighten SST.
  11. REMOVE FRONT DRIVE SHAFT DUST COVER RH 
    1. Using a press, remove the front drive shaft dust cover RH.
      GTY137534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the front drive inboard joint assembly.

  12. REMOVE FRONT DRIVE SHAFT DUST COVER (for RH Side) 
    1. w/ Cover:
      1. Using SST and a press, remove the front drive shaft dust cover.
        GTY430446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09950-00020 
        NOTE:
        • Do not drop the front drive inboard joint assembly.
        • Do not overtighten SST.

        HINT: 

        If the front drive shaft dust cover is removed, it is not necessary to reinstall it.

  13. REMOVE FRONT DRIVE SHAFT BEARING (for RH Side) 
    1. Using a snap ring expander, remove the drive shaft hole snap ring.
      GTY441319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the front drive shaft bearing.
      GTY446412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      NOTE:

      Do not drop the front drive inboard joint assembly.

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