FRONT DRIVE SHAFT ASSEMBLY INSTALLATION

  1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    1. Coat the spline of the front drive inboard joint assembly with ATF.

    2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease.

    3. Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

      A011WFM

      Note

      • Face the end gap of the front drive shaft hole snap ring LH downward.

      • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

      • Do not damage the front axle inboard joint boot.

      • Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

      Tech Tips

      Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

    4. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

      A011VJA
      Text in Illustration
      A011VR0 Mineral Oil Base Grease

      Tech Tips

      Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

    5. Align the matchmarks and install the front drive shaft assembly LH to the front axle hub sub-assembly.

      A011X5KE01
      Text in Illustration
      *a Matchmark

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    1. Coat the spline of the front drive inboard joint assembly with ATF.

    2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease.

    3. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.

    4. Install the front drive shaft assembly RH.

      Note

      • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

      • Do not damage the front axle inboard joint boot.

      • When inserting the front drive shaft assembly RH, keep it level.

    5. Install the bearing bracket hole snap ring and a new bolt.

      A011XNL
      Torque:
      32 N*m  { 330 kgf*cm, 24 ft.*lbf }

    6. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

      A011Y7R
      Text in Illustration
      A011VR0 Mineral Oil Base Grease

      Tech Tips

      Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

    7. Align the matchmarks and install the front drive shaft assembly RH to the front axle hub sub-assembly.

      A011XLME01
      Text in Illustration
      *a Matchmark

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  3. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

    1. Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

      Torque:
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }

  4. CONNECT TIE ROD ASSEMBLY

    1. Connect the tie rod assembly 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

      Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

  5. INSTALL FRONT SPEED SENSOR

    1. Install the front speed sensor and front flexible hose to the front shock absorber with the bolt and clamp.

      Torque:
      19 N*m  { 192 kgf*cm, 14 ft.*lbf }

      Note

      Do not twist the front speed sensor when installing it.

      Tech Tips

      Install the speed sensor harness bracket first and then the front flexible hose.

    2. Install the front speed sensor to the steering knuckle with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Do not twist the front speed sensor when installing it.

  6. INSTALL FRONT STABILIZER LINK ASSEMBLY

    1. Install the front stabilizer link assembly to the front shock absorber assembly with the nut.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

      If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

  7. INSTALL FRONT AXLE SHAFT NUT

    1. Clean the threaded parts on the front drive shaft assembly and a new axle shaft nut using a non-residue solvent.

      Note

      • Be sure to perform this work even when using a new drive shaft.

      • Keep the threaded parts free of oil and foreign matter.

    2. Using a socket wrench (30 mm), install the front axle shaft nut.

      A011YO7
      Torque:
      294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

    3. Using a chisel and a hammer, stake the front axle shaft nut.

  8. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  9. ADD HYBRID TRANSAXLE FLUID

    1. Add transaxle fluid until the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening.

      A011YVKE01
      Text in Illustration
      *1 Filler Nozzle
      *2 Filler Plug

      Note

      • Stop the vehicle on a level surface.

      • Use Toyota Genuine ATF WS.

      • Be sure to fully insert the filler nozzle into the filler plug opening.

      • Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening.

      • Be sure to directly check that the transaxle fluid level is within the specified range.

      • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

      Reference
      3.7 liters (3.9 US qts, 3.2 Imp. qts)

    2. After adding fluid, leave it for 30 seconds so that the fluid surface can become still again, and then check that the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

      Note

      After adding fluid, make sure to check the fluid level.

  10. INSPECT HYBRID TRANSAXLE FLUID

    1. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

      A011WK2E01
      Text in Illustration
      *1 Filler Plug

    2. Check that the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

      Note

      • Stop the vehicle on a level surface.

      • Be sure to directly check that the transaxle fluid level is within the specified range.

      • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

      • If the fluid was replaced or fluid was added, make sure to recheck the fluid level after driving the vehicle.

    3. Check for leaks if the quantity of transaxle fluid is low.

    4. Using a 10 mm hexagon socket wrench, install the filler plug with a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  11. INSTALL FRONT FENDER APRON SEAL LH

  12. INSTALL FRONT FENDER APRON SEAL RH

  13. INSTALL ENGINE UNDER COVER LH

  14. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

  15. INSTALL ENGINE UNDER COVER RH

  16. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  17. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  18. CHECK FOR SPEED SENSOR SIGNAL

    Click here