Disassembly and Assembly

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY
1. 1Z-FE engine (M/T) and 2Z-GE engine: DISASSEMBLE DRIVE SHAFT





a. Check the drive shaft.
(1) Check to see that there is no remarkable play in the outboard joint.
(2) Check to see that the inboard joint slides smoothly in the thrust direction.
(3) Check to see that there is no remarkable play in the radial direction of the inboard joint.
(4) Check the boots for damage.
b. Remove the inboard and outboard joint boot clamps.
(1) Using a screwdriver, disclamp the 2 inboard joint boot clamps.
(2) Using a side cutter, cut the 2 outboard joint boot clamps and remove them.
c. M/T:
Remove the dynamic damper clamp.
Using a screwdriver, disclamp the dynamic damper clamp.
d. Remove the inboard joint shaft.
(1) Slide the inboard joint boot toward the outboard joint.





(2) Place matchmarks on the outboard joint shaft and inboard joint shaft.

NOTICE: Do not punch the marks.





(3) Using a screwdriver, remove the snap ring.
(4) Remove the inboard joint shaft from the outboard joint shaft.
e. Disassemble the outboard joint shaft.





(1) Place matchmarks on the outboard joint shaft, inner race and cage.

NOTICE: Do not punch the marks.

(2) Remove the 6 balls.
(3) Slide the cage toward outboard joint.





(4) Using a snap ring expander, remove the snap ring.





(5) Using a brass bar and hammer, remove the inner race.

NOTICE: Be careful not to damage the inner race.

(6) Remove the cage.
f. Remove the dynamic damper (M/T), damper clamp (M/T), inboard and outboard joint boots and inboard joint clamps.

NOTICE: Do not disassemble the outboard joint.

2. 1Z-FE engine (A/T): DISASSEMBLE DRIVE SHAFT





a. Check the drive shaft.
(1) Check to see that there is no remarkable play in the outboard joint.
(2) Check to see that the inboard joint slides smoothly in the thrust direction.
(3) Check to see that there is no remarkable play in the radial direction of the inboard joint.
(4) Check the boots for damage.
b. Remove the inboard and outboard joint boot clamps.
(1) Using a screwdriver, disclamp the 2 inboard joint boot clamps.
(2) Using a side cutter, cut the 2 outboard joint boot clamps and remove them.





c. Remove the inboard joint shaft.
(1) Slide the inboard joint boot toward the outboard joint.
(2) Place matchmarks on the inboard joint shaft, tripod and outboard joint shaft.

NOTICE: Do not punch the marks.

(3) Remove the inboard joint shaft from the outboard joint shaft.





d. Remove the tripod.
(1) Using a snap ring expander, remove the snap ring.
(2) Place matchmarks on the outboard joint shaft and tripod.

NOTICE: Do not punch the marks.

(3) Using a brass bar and hammer, remove the tripod from the outboard joint shaft.

NOTICE: Do not tap the roller.

e. Remove the inboard and outboard joint boots and inboard joint clamps.

NOTICE: Do not disassemble the out board joint.

3. DISASSEMBLE INBOARD JOINT SHAFT





a. LH: Remove the dust cover.
Using SST and a press, remove the dust cover.
SST 09950-00020
b. LH shaft of 1Z-FE engine (M/T) and 2Z-GE engine: Using a snap ring expander, remove the outer snap ring.





c. RH: Remove the transaxle side dust cover.
Using a press, remove the transaxle side dust cover.
d. RH: Remove the center bearing.





(1) Using a screwdriver, remove the outside snap ring.
(2) Using a press, remove the center bearing case.
(3) Using a pin punch and hammer, remove the straight pin from the center bearing case.





(4) Using SST and a press, remove the dust cover.
SST 09950-00020
(5) Using a snap ring expander, remove the inside snap ring.





(6) Using a press, remove the center bearing.

REASSEMBLY
1. REASSEMBLE INBOARD JOINT SHAFT





a. LH: Install dust cover.
Using a press, install a new dust cover.
b. LH shaft of 1Z-FE engine (M/T) and 2ZZ-GE engine; Using a snap ring expander, install a new outer snap ring.
c. RH: Install center bearing.





(1) Using a pin punch and hammer, install the straight pin into the center bearing case.





(2) Using SST and a press, install a new center bearing into the bearing case.
SST 09950-60010 (09951-00650), 09950-70010 (09951-07150)
(3) Using a screwdriver, install a new outside snap ring.





(4) Using SST and a press, install the center bearing with the bearing case assembly to the inboard joint shaft.
SST 09710-30021 (09710-03141)
(5) Using a snap ring expander, install a new inside snap ring.





(6) Using SST, an extension bar and press, install a new dust cover.
SST 09506-35010

HINT: The clearance between the dust cover and bearing should be kept in the ranges as shown in the illustration.





d. RH: Install the transaxle side dust cover.
Using a steel plate and press, install a new transaxle side dust cover until the distance from the tip of the inboard joint shaft to the dust cover reaches the specified value, as shown in the illustration.
2. 1Z-FE engine (A/T): REASSEMBLE DRIVE SHAFT





a. Temporarily install new outboard and inboard joint boots and new clamps.

HINT: Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged.

(1) Place 2 new clamps on a new outboard joint boot and install them to the outboard joint shaft.
(2) Place 2 new clamps on a new inboard joint boot and install them to the outboard joint shaft.
b. Install the tripod.
(1) Place the beveled side of the tripod axial spline toward the outboard joint.
(2) Align the matchmarks placed before removal.
(3) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft.

NOTICE: Do not tap the roller.

(4) Using a snap ring expander, install a new snap ring.
c. Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow ocher) 110 - 120 g (3.9 - 4.2 oz.)





d. Install the inboard joint shaft to outboard joint shaft.
(1) Pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow ocher) 180 - 190 g (6.3 - 6.7 oz.)
(2) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft.
(3) Temporarily install the boot to the inboard joint.
e. Assemble the boot clamps to both boots.





(1) Make sure that the boots are on the shaft grooves.
(2) Make sure that the boots are not stretched or contracted when the drive shaft is at standard length.





Drive shaft standard length

(3) Bend the band and lock the inboard joint boot clamps with a screwdriver.
(4) Secure the 2 outboard joint boot clamps onto the boot.





(5) Place SST onto the outboard joint large boot clamp.
SST 09521-24010
(6) Tighten the SST so that the large clamp is pinched.

NOTICE: Do not overtighten the SST.





(7) Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm (0.031 inch) or less
(8) Employ the same manner to the outboard joint small boot clamp.
3. 1Z-FE engine (M/T) and 2ZZ-GE engine: REASSEMBLE DRIVE SHAFT





a. Temporarily install dynamic damper (M/T), new outboard and inboard joint boots and new clamps.

HINT: Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged.

(1) Place 2 new clamps on a new outboard joint boot and install them to the outboard joint shaft.
(2) M/T: Place new clamp on the dynamic damper and install them to the outboard joint shaft.
(3) Place 2 new clamps on a new inboard joint boot and install them to the outboard joint shaft.
b. Assemble the outboard joint shaft.





(1) Install the cage to the outboard joint shaft.

NOTICE: The side with smaller diameter must face outboard joint.

(2) Align the matchmarks on the inner race and outboard joint shaft.





(3) Using a brass bar and hammer, tap in the inner race to the outboard joint shaft.

NOTICE: Be careful not to damage the inner race.





(4) Using a snap ring expander, install a new snap ring.





(5) Align the matchmarks on the cage and inner race.
(6) Install the cage to the inner race.
(7) Install the 6 balls.

HINT: Apply grease onto the balls to keep them from falling.

c. Install the boot to outboard joint. Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Black) 115 - 135 g (4.1 - 4.8 oz.)
d. Install the inboard joint shaft to outboard joint shaft.
(1) Before assembling the boot, pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Gray) 100 - 120 g (3.5 - 4.2 oz.)





(2) Align the matchmarks on the inboard joint shaft and outboard joint shaft.
(3) Install the inboard joint shaft to the outboard joint shaft.





(4) Install a new snap ring.
(5) Temporarily install the boot to the inboard joint shaft.
e. Assemble the boot clamps to both boots.





(1) Make sure that the boots are on the shaft grooves.
(2) Make sure that the boots are not stretched or contracted when the drive shaft is at standard length.





Drive shaft standard length

(3) Bend the band and lock the inboard joint boot clamps with a screwdriver.
(4) Secure the 2 outboard joint boot clamps onto the boot.





(5) Place SST onto the outboard joint large boot clamp.
SST 09521-24010
(6) Tighten the SST so that the large clamp is pinched.

NOTICE: Do not overtighten the SST.





(7) Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 1.2 - 4.0 mm (0.047 - 0.157 inch)
(8) Employ the same manner to the outboard joint small boot clamp.





f. M/T: Assemble the dynamic damper clamp.
(1) Set the dynamic damper distance, as described.
Distance: 155.0 ± 2.0 mm (6.102 ± 0.079 inch)
(2) Bend the band and lock the dynamic damper clamp with a screwdriver.
4. CHECK DRIVE SHAFT