Contents: Disassembly ↓ Checking the front wheel drive…↓ Disassembling the front wheel drive ↓ Removal the left front wheel drive…↓ Installation ↓
Caution! Do not disassemble the outer hinge
Disassembly
Drain the automatic transmission fluid (automatic transmission).
Drain the oil from the manual transmission in the block with the main gear (manual transmission).
Remove the front wheel.
Fig. 3.99. Disconnecting the deformed part of the flange of the front wheel hub nut
Using special tool 09930-00010 and a hammer, bend back the deformed part of the flange of the front wheel hub nut (Fig. 3.99).
Caution! Bend back the deformed part of the flange completely, otherwise the thread on the drive may be damaged.
Loosen the front wheel hub nut while pressing the brake pedal.
Fig. 3.100. Disconnecting the front anti-roll bar from the front suspension shock absorber
Loosen the nut, disconnect the front anti-roll bar from the front suspension shock absorber (fig. 3.100).
Note: If the ball joint pin rotates with the nut, use a socket wrench (6mm) to secure the pin.
Remove the speed sensor wire clamp.
Fig. 3.101. Disconnecting the speed sensor wire clamp
Loosen the bolt, disconnect the sensor wire and the front flexible hose No.1 from the front suspension shock absorber strut (fig. 3.101).
Fig. 3.102. Disconnecting the speed sensor from the steering knuckle
Loosen the bolt, disconnect the speed sensor from the steering knuckle (fig. 3.102).
Remove the cotter pin and nut.
Fig. 3.103. Disconnecting the steering rod from the steering knuckle
Using special tool 09628-00011, disconnect the steering rod from the steering knuckle (fig. 3.103).
Fig. 3.104. Disconnecting suspension arm No.1 from the lower ball joint
Remove the bolt and 2 nuts and separate the #1 suspension arm from the lower ball joint (fig. 3.104).
Using a nylon hammer, disconnect the front wheel drive assembly from the wheel hub.
Caution: Be careful not to damage the boot or the speed sensor rotor.
Remove the front wheel drive assembly.
Fig. 3.105. Removing the front wheel drive assembly
Using special tool 09520-01010, 09520-24010, remove the front wheel drive assembly (fig. 3.105).
Caution: Be careful not to damage the seal.
Loosen the bolt and remove the right front wheel drive assembly.
Secure the front wheel hub.
Caution! The hub bearing may be damaged by the weight of the vehicle when moving the vehicle with the drive shaft removed.
Fig. 3.106. Fixing the hub relative to the steering knuckle using a special device
Therefore, if it is necessary to move the car on wheels, first fix the hub relative to the steering knuckle using a special device 09608-16042 (fig. 3.106).
Checking the front wheel drive assembly
Check the front wheel drive assembly.
Make sure there is no significant play in the outer joint.
Make sure that the inner joint moves smoothly in the axial direction.
Make sure there is no significant radial play in the inner joint
Fig. 3.107. Front wheel drive assembly test diagram
Make sure the protective covers are not damaged (fig. 3.107).
Caution: Move the drive shaft while keeping it horizontal.
Disassembling the front wheel drive
Fig. 3.108. Removing the inner hinge boot clamp
Using a screwdriver, remove the inner hinge boot clamps (fig. 3.108).
Remove the inner hinge cover.
Fig. 3.109. Applying mounting marks to the tripod, shaft and hinge housing
Apply mounting marks to the tripod, shaft and hinge housing (fig. 3.109).
Caution! Do not make marks with a center punch or chisel.
Remove the inner joint housing from the shaft.
Using a snap ring expander, remove the shaft snap ring.
Place mounting marks on the tripod and shaft.
Caution! Do not make marks with a center punch or chisel.
Fig. 3.110. Removing the tripod assembly from the shaft
Using a brass rod and hammer, remove the tripod assembly from the shaft (fig. 3.110).
Caution! Do not hit the rollers.
Removal the left front wheel drive damper (manual transmission)
Using a screwdriver, remove the damper clamp.
Remove the front wheel drive damper.
Using a screwdriver, remove the damper clamp.
Remove the front wheel drive damper (except for 1mz-fe engine).
Using a screwdriver, remove the outer hinge boot clamps.
Remove the outer hinge protective cover
Fig. 3.111. Removing the front wheel drive retaining ring
Remove the front wheel drive retaining ring. Using a screwdriver, remove the retaining ring (fig. 3.111).
Fig. 3.112. Removing the left front wheel drive dust cover
Using special tool 09950-00020 and a press, remove the left front wheel drive dust ring (fig. 3.112).
Fig. 3.113. Removing the right front wheel drive dust cover
Using a press, remove the right front wheel drive dust cover ring (fig. 3.113).
Fig. 3.114. Removing the front wheel drive dust ring
Using special tool 09950-00020 and a press, remove the front wheel drive dust ring.
Fig. 3.115. Removing the right retaining ring
Using snap ring pliers, remove the right snap ring (fig. 3.115).
Fig. 3.116. Removing the front wheel drive bearing
Using special tool 09527-10011 and a press, remove the front wheel drive bearing (fig. 3.116).
Installation
Install the front wheel drive bearing
Fig. 3.117. Installing a new front wheel drive bearing
Using special tool 09527-30010, 09527-10011 and a press, install the new front wheel drive bearing (fig. 3.117).
Fig. 3.118. Installing a new right retaining ring
Using a snap ring expander, install a new right snap ring (fig. 3.118).
Install the front wheel drive dust cover.
Fig. 3.119. Installation diagram of the new front wheel drive dust cover
Using special tool 09527-10011, 09726-40010 and a press, install a new front wheel drive dust boot. The distance from the end of the drive shaft to the dust boot, as shown in Figure 3.119, must comply with the standard.
Distance A: 0±1.0 mm.
Install the right front wheel drive dust cover
Fig. 3.120. Installation diagram of the new right front wheel drive ring
Using special tool 09527-10011 and a press, install a new right front wheel drive dust ring. The distance from the end of the drive shaft to the dust ring, as shown in Figure 3.120, must comply with the standard.
Size A: 91–92 mm.
Install the left front wheel drive dust cover.
Fig. 3.121. Installation diagram of the new right front wheel drive ring
Using special tool 09527-10011 and a press, install a new left front wheel drive dust ring (fig. 3.121).
Install a new left front wheel drive snap ring.
Fig. 3.122. Installing the outer hinge protective cover
Install the outer hinge protective cover (fig. 3.122).
Note: Before installing the boots, wrap the splined portion of the drive shaft with tape to avoid damaging the boots.
Amount of grease:
- CD-FTV: 105–125 g.
- 3ZZ-FE, 1ZZ-FE: 152–162 g.
Temporarily install a new outer joint boot with 2 clamps onto the drive shaft.
Fill the inner joint housing and boot with grease.
Fig. 3.123. Installing the outer hinge protective boot clamp
Install the outer hinge boot clamp (fig. 3.123).
Place the drive shaft in a soft vice.
Attach the 2 outer hinge boot clamps to the boot.
Install special tool 09521-24010 onto the larger outer joint boot clamp.
Attention! The position of the right clamp of the outer joint protective boot and the left clamp of the outer joint protective boot in the boot grooves during tightening must be as shown in Figure 3.123.
Gap: 0.8mm or more.
Tighten the special tool screw until the large clamp is compressed.
Caution: Do not overtighten the special tool screw.
Fig. 3.124. Adjusting the clearance of the large clamp
Using special tool 09240-00020, adjust the clearance of the large clamp (fig. 3.124).
Gap: 0.8mm or less.
Install the small outer hinge boot clamp in the same manner.
Install the front wheel drive damper (manual transmission).
Fig. 3.125. Front wheel drive damper installation distance
Make sure the front wheel drive damper is in the groove of the shaft (fig. 3.125).
It is necessary to maintain the distance given below.
Install the front wheel drive inner joint
Position the tripod with the lead-in chamfer facing the outer joint shaft.
Fig. 3.126. Alignment of the mounting marks applied before disassembly before installing the inner hinge
Align the mounting marks made before disassembly (fig. 3.126).
Using a brass rod and a hammer, install the tripod onto the outer pivot shaft.
Caution! Do not hit the rollers.
Using a snap ring expander, install a new snap ring onto the shaft.
Fill the inner joint housing and boot with grease.
Install the inner joint boot onto the shaft.
Install the inner hinge boot clamp
Fig. 3.127. Fixing the clamps of the inner hinge boot with a screwdriver
Bend the tape and secure the inner hinge boot clamps with a screwdriver (fig. 3.127).
Check the front wheel drive.
Make sure there is no significant play in the outer joint.
(Make sure that the inner joint moves smoothly in the axial direction.
Make sure there is no significant radial play in the inner joint.
Make sure that the protective covers are not damaged.
Caution: Move the drive shaft while keeping it horizontal.
Make sure the boots are in the grooves of the shaft.
Make sure the boots are not stretched or compressed when the drive shaft is in a free position.