PROPELLER SHAFT ASSEMBLY(for TSAM Made) REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When using a vise, place aluminum plates between the part and vise.

  • When using a vise, do not overtighten it.

Tech Tips

The following chart describes vehicle types A and B, which are referred to throughout the procedure.

for 2WD and Pre-Runner:
Vehicle Type A Vehicle Type B
Engine Type Transmission Type Engine Type Transmission Type
1GR-FE AC60E 1GD-FTV AC60E
2GD-FTV R151 RC61
2KD-FTV R151 2GD-FTV RC60
1TR-FE R151 2KD-FTV RC61
2TR-FE R151 - -
for 4WD:
Vehicle Type A Vehicle Type B
Engine Type Transmission Type Engine Type Transmission Type
1GR-FE AC60F 1KD-FTV RC61F
1KD-FTV A750F 1GD-FTV AC60F
5L-E R151F RC61F
2TR-FE AC60F 2GD-FTV RC60F
R151F 2KD-FTV RC61F

PROCEDURE


  1. INSTALL CENTER NO. 1 SUPPORT BEARING ASSEMBLY


    1. B0024WZC02
      *a Front Side
      *b Seal
      *c Engraved Arrow

      Install the center No. 1 support bearing assembly to the intermediate shaft.

      Note


      • Carefully insert the part so that the seal does not invert.

      • Make sure to install the part so that the engraved arrow faces the front of the vehicle.

    2. Install the 2 washers to the intermediate shaft.

    3. B0025A8C08
      *a Matchmark

      Align the matchmarks on the center yoke and intermediate shaft, and then install the center yoke to the intermediate shaft.

    4. Install the washer to the intermediate shaft.

    5. B0026UU

      Clamp the center yoke in a vise between aluminum plates and press the bearing into position by installing a new lock nut.

      Torque:
      127.5 N*m  { 1300 kgf*cm, 94 ft.*lbf }
    6. B0028ER

      Using a chisel and hammer, stake the lock nut.

      Note


      • Fully stake the lock nut along the entire groove.

      • Do not damage the threads of the intermediate shaft.

  2. INSTALL UNIVERSAL JOINT SPIDER ASSEMBLY

    Tech Tips

    Use the same procedure for all universal joint spider assemblies.


    1. B0028ND

      Apply grease to a new spider and new spider bearings.

      Grease
      Lithium base chassis grease NLGI No. 2

      Note

      Do not apply too much grease.

    2. Install the universal joint spider assembly to the flange yoke.

    3. B00259XN01

      Using SST, install the spider bearing to the universal joint spider assembly.

      SST
      09332-25010

    4. Using SST, adjust both spider bearings so that the snap ring grooves are as wide as possible and equal in width.

      SST
      09332-25010
    5. B0028KM

      Install 2 new snap rings to the installed spider bearings. The snap rings must have equal thickness and allow 0 to 0.05 mm (0 to 0.00196 in.) of axial play.

      Note

      While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

      Standard Snap Ring Thickness
      for Vehicle Type A
      Part No. Color Thickness
      90080-52038 Blue 1.638 mm (0.0645 in.)
      90080-52039 Yellow 1.588 mm (0.0625 in.)
      90080-52040 White 1.537 mm (0.0605 in.)
      90080-52041 Black 1.486 mm (0.0585 in.)
      90080-52042 Copper 1.511 mm (0.0595 in.)
      90080-52156* - -
      *: For cup with grease nipple.
      for Vehicle Type B
      Part No. Mark Thickness
      90521-A0003* Black 1.486 mm (0.0587 in.)
      90521-A0005* Yellow 1.588 mm (0.0626 in.)
      90521-A0006* Copper 1.512 mm (0.0594 in.)
      90521-A0008 Black 1.517 mm (0.0598 in.)
      90521-A0010 Blue 1.638 mm (0.0646 in.)
      90521-A0011 Black 1.542 mm (0.0606 in.)
      90521-A0013 Black 1.618 mm (0.0638 in.)
      90521-A0014 Black 1.486 mm (0.0587 in.)
      90521-A0015 Copper 1.512 mm (0.0594 in.)
      90521-A0016 White 1.556 mm (0.0614 in.)
      *: For cup with grease nipple.

      Note


      • While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196in.), select 2 snap rings that have as close to the same thickness as possible.

      • Use a new snap ring.

      • Use a snap ring with as close to the same thickness as possible on both ends.

    6. B00276CC01
      *a Hammering Point

      Using a hammer, tap the flange yoke until there is no clearance between the spider bearing outer race and snap ring.

      Tech Tips

      Install the spider bearing on the sleeve side using the procedure described above.

    7. Align the matchmarks on the flange yoke and propeller shaft.

    8. for 2WD and Pre-Runner:


      1. B0028KIC01
        *a Matchmark

        Align the matchmarks on the center yoke and propeller shaft.

      2. B0024Z3C01
        *a Matchmark

        Align the matchmarks on the sleeve yoke and intermediate shaft.

    9. for 4WD:


      1. B002559C01
        *a Matchmark

        Align the matchmarks on the center yoke and sleeve yoke.

      2. B002592C01
        *a Matchmark

        Align the matchmarks on the flange yoke and intermediate shaft.

    10. B0024KAC01
      *a Turn
      *b Hold

      Using SST, install the 2 spider bearings to the universal joint spider assembly.

      SST
      09332-25010

      Tech Tips

      Before installing SST, sufficiently raise the part labeled A. If the part labeled A is too low, it may be difficult to install SST.

    11. Using SST, adjust both spider bearings so that the front propeller shaft joint spider bearing snap ring grooves are as wide as possible and equal in width.

      SST
      09332-25010
    12. B0028KM

      Install 2 new snap rings to the installed spider bearings. The snap rings must have equal thickness and allow 0 to 0.05 mm (0 to 0.00196 in.) of axial play.

      Note

      While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196 in.), select 2 snap rings that have as close to the same thickness as possible.

      Tech Tips

      Do not reuse the snap rings.

      Note


      • While the installed snap rings should have equal thickness, if the axial play is greater than 0.05 mm (0.00196in.), select 2 snap rings that have as close to the same thickness as possible.

      • Use a new snap ring.

      • Use a snap ring with as close to the same thickness as possible on both ends.

      Standard Snap Ring Thickness
      for Vehicle Type A
      Part No. Color Thickness
      90080-52038 Blue 1.638 mm (0.0645 in.)
      90080-52039 Yellow 1.588 mm (0.0625 in.)
      90080-52040 White 1.537 mm (0.0605 in.)
      90080-52041 Black 1.486 mm (0.0585 in.)
      90080-52042 Copper 1.511 mm (0.0595 in.)
      90080-52156* - -
      *: For cup with grease nipple.
      for Vehicle Type B
      Part No. Mark Thickness
      90521-A0003* Black 1.486 mm (0.0587 in.)
      90521-A0005* Yellow 1.588 mm (0.0626 in.)
      90521-A0006* Copper 1.512 mm (0.0594 in.)
      90521-A0008 Black 1.517 mm (0.0598 in.)
      90521-A0010 Blue 1.638 mm (0.0646 in.)
      90521-A0011 Black 1.542 mm (0.0606 in.)
      90521-A0013 Black 1.618 mm (0.0638 in.)
      90521-A0014 Black 1.486 mm (0.0587 in.)
      90521-A0015 Copper 1.512 mm (0.0594 in.)
      90521-A0016 White 1.556 mm (0.0614 in.)
      *: For cup with grease nipple.
    13. B0027D8C01
      *a Hammering Point

      Using a hammer, tap the propeller shaft until there is no clearance between the spider bearing outer race and snap ring.

      Tech Tips

      Install the spider bearing on the sleeve side using the procedure described above.

  3. INSTALL REAR SLIDING SHAFT BOOT (for 4WD)


    1. B0024FKC02
      *1 Propeller Shaft Boot Clamp
      *2 Rear Sliding Shaft Boot
      *a Matchmark of Propeller Shaft and Sleeve Yoke
      *b Matchmark of Pinching Portion of Propeller Shaft Boot Clamp
      *c Pinching Portion

      Temporarily install a new rear sliding shaft boot to the propeller shaft with 2 new clamps.

    2. Coat the splines of the propeller shaft with grease.

      Standard Grease Capacity
      7.0 to 10.0 g (0.25 to 0.35 oz)

    3. Align the matchmarks on the propeller shaft and sleeve yoke.

    4. Install the sleeve yoke to the propeller shaft and connect the rear sliding shaft boot.

    5. Align the matchmarks on the propeller shaft, sleeve yoke and the pinching portions of the 2 rear propeller shaft boot clamps.

      Tech Tips

      Make sure to align the matchmarks of the propeller shaft boot clamp.

      If the pinching portions are installed at different locations than where they were located before disassembly, the rotational balance of the propeller shaft cannot be ensured, which may result in vibrations and noise.

    6. B00275LC01
      *a Turn
      *b Hold

      Secure one of the rear propeller shaft boot clamps to the rear sliding shaft boot.

      Tech Tips


      • Use the same procedure for each rear propeller shaft boot clamp.

      • Make sure that the matchmarks of the pinching portion of the rear propeller shaft boot clamp are aligned.


      1. Install SST to the rear propeller shaft boot clamp, and then while pressing the rear sliding shaft boot, slightly tighten the SST bolt.

        SST
        09521-24010

        Note


        • Correctly set the rear propeller shaft boot clamp to the guide groove.

        • Do not damage the rear sliding shaft boot.

      2. Tighten SST so that the boot clamp is pinched as shown in the illustration.

        Standard clearance
        3.1 mm (0.122 in.) or less

        Note


        • When tightening SST, make sure the clearance of the rear propeller shaft boot clamp is within the standard clearance.

        • Do not damage the rear sliding shaft boot.

      3. Remove SST from the rear propeller shaft boot clamp.

      4. B0027F7N01

        Using SST, measure the clearance of the rear propeller shaft boot clamp.

        SST
        09240-00020
        Standard clearance
        3.1 mm (0.122 in.) or less

        Note

        If the measured value exceeds the specified value, retighten the rear propeller shaft boot clamp.

  4. INSPECT PROPELLER SHAFT GREASE FITTING DIRECTION

    Tech Tips


    • When replacing a spider bearing, be sure that the grease fitting hole is facing the direction shown in the illustration.

    • Fill the grease fittings with grease.

      Grease
      Lithium base chassis grease NLGI No. 2
    B00245GC02
    *A for 2WD and Pre-Runner (Vehicle Type B) *B for 4WD
    *1 No. 1 Grease Fitting *2 No. 2 Grease Fitting
    *3 No. 3 Grease Fitting - -
    *a Rear Side - -

  5. INSPECT SPIDER BEARING

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