18 2005 2006 toyota hilux factory service manual propeller and drive shaft truc cac dang va truyen luc

Tài liệu hướng dẫn sửa chữa Hệ thống truyền lực và trục cac đăng trên xe 18 2005 2006 toyota hilux factory service manual propeller and drive shaft truc cac dang va truyen luc. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán sửa chữa nhanh chóng, chính xác, hiệu quả

PR–4 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD)

Maximum bearing axial play:

(a) Place matchmarks on the propeller shaft and yoke

(b) Using a brass bar and a hammer, slightly tap in the spider bearing outer races

(c) Using needle-nose pliers, remove the 4 snap rings from the grooves

(d) Using SST, push the spider bearing out of the propeller shaft

1 INSPECT PROPELLER SHAFT ASSEMBLY

(a) Using a dial indicator, check the propeller shaft runout

(b) Fit the spider into the flange yoke

(c) Measure dimension A between the snap ring grooves

(d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the universal joint

NOTICE:

When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together.

PR–6 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD)

• Use new snap rings.

• If possible, use snap rings of the same thickness for both edges.

(f) Insert the spider into the yoke, and then using SST, press the spider bearing into the snap ring groove.(g) Press in the spider bearing on the opposite side in the same way

SST 09332-25010 NOTICE:

When pressing in the spider bearing, be careful not to damage its lip.

(h) Using needle-nose pliers, install new snap rings into the grooves of the yoke

2 INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING

(a) Check the spider bearings for wear and damage.(b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

0 to 0.05 mm (0 to 0.002 in.)

INSTALLATION

1 INSTALL PROPELLER SHAFT ASSEMBLY

(a) Remove SST from the extension housing

(b) Install the propeller shaft assembly into the extension housing

G038874

Color Thickness mm (in.) Green 1.384 (0.0545) Red 1.435 (0.0565) Black 1.486 (0.0585) Copper 1.511 (0.0595) Silver 1.537 (0.0605) Yellow 1.588 (0.0625) Blue 1.638 (0.0645)

F052205

G038875

SST

D033911E01

(c) Align the matchmarks on the propeller shaft flange and differential flange

(d) Install the propeller shaft assembly with the 4 bolts,

4 nuts and 4 washers

Torque: 88 N*m (899 kgf*cm, 65 ft.*lbf)

2 INSPECT TRANSMISSION OIL LEAKAGE

Matchmarks

C060588E01

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–3

DS

REMOVAL

1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2 REMOVE FRONT WHEEL

3 DRAIN DIFFERENTIAL OIL

4 SEPARATE FRONT SPEED SENSOR

(a) Remove the bolt and separate the front speed sensor

(b) Disengage the 2 clamps

(c) Remove the bolt and separate the speed sensor wire harness from the steering knuckle

5 SEPARATE TIE ROD END SUB-ASSEMBLY

(a) Remove the cotter pin and nut

(b) Using SST, separate the tie rod end from the steering knuckle

SST 09628-62011

6 REMOVE FRONT AXLE HUB NUT

(a) Using a screwdriver and a hammer, remove the front axle hub grease cap

F052163E03

SST

F051679E01

F042729

(b) Remove the cotter pin and adjusting cap

(c) Remove the front axle hub nut

7 SEPARATE FRONT SUSPENSION LOWER ARM

(a) Remove the 2 bolts and separate the front lower ball joint attachment front from the steering knuckle

8 REMOVE FRONT DRIVE SHAFT

(a) Using SST, remove the front drive shaft

SST 09520-01010, 09520-24010 (09520-32040) NOTICE:

Be careful not to damage the oil seal.

DISASSEMBLY

1 INSPECT FRONT DRIVE SHAFT

(a) Check whether there is no remarkable play in the outboard joint

(b) Check whether the inboard joint slides smoothly in the thrust direction

(c) Check whether there is no remarkable play in the radial direction of the inboard joint

(d) Check the boots for damage

NOTICE:

Move the drive shaft while keeping it level.

2 REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Using pliers, disengage the hooks together and remove the large clamp

(b) Using a side cutter, cut the small boot clamp

3 SEPARATE INBOARD JOINT BOOT

(a) Slide the inboard joint boot toward the outboard joint

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–5

Do not punch the marks.

(b) Remove the inboard joint from the outboard joint shaft

(c) Using a snap ring expander, remove the snap ring

(d) Place matchmarks on the outboard joint shaft and tripod

NOTICE:

Do not punch the marks.

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

NOTICE:

Do not tap the roller.

(f) Remove the inboard joint boot from the outboard joint shaft

5 REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Using a side cutter, cut the boot clamps

6 REMOVE OUTBOARD JOINT BOOT

(a) Remove the outboard joint boot from the outboard joint shaft

7 REMOVE FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING

(a) Using a screwdriver, remove the snap ring

8 REMOVE FRONT DRIVE SHAFT DUST COVER

(a) Using SST and a press, remove the dust cover

SST 09950-00020

9 REMOVE FRONT AXLE HUB OIL SEAL

(a) Using a screwdriver and a hammer, remove the oil seal

REASSEMBLY

1 INSTALL FRONT AXLE HUB OIL SEAL

(a) Using a screwdriver and a hammer, install a new oil seal

NOTICE:

Do not damage the oil seal.

2 INSTALL FRONT DRIVE SHAFT DUST COVER

(a) Using SST and a press, install a new dust cover

SST 09527-10011

3 INSTALL FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING

(a) Install a new snap ring

4 INSTALL OUTBOARD JOINT BOOT

HINT:

• Before installing the boots, wrap the spline of the outboard joint with vinyl tape to prevent the boots from being damaged

• Before installing the boot, place 2 new boot clamps on the small boot end and large boot ends

(a) Provisionally install a new outboard joint boot with 2 new clamps onto the outboard joint shaft

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–7

(c) Provisionally install the boot onto the outboard joint

5 INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Install the boot clamps onto the boot

(b) Place SST onto the large boot clamp

SST 09521-24010

(c) Tighten the SST so that the large boot clamp is pinched

NOTICE:

Do not overtighten the SST.

(d) Using SST, adjust the clearance of the large boot clamp

SST 09240-00020 Clearance:

1.0 to 5.0 mm (0.039 to 0.197 in.)

(e) Use the same procedure for the small boot clamp

6 INSTALL INBOARD JOINT BOOT

7 INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Place the beveled side of the tripod toward the inboard joint

(b) Align the matchmarks and install the tripod into the inboard joint

(c) Using a brass bar and hammer, tap the tripod into the outboard joint shaft

NOTICE:

Do not tap the roller.

(d) Using a snap ring expander, install a new snap ring

(e) Pack the inboard joint and boot with grease from the boot kit

Grease capacity:

182 to 202 g (6.4 to 7.1 oz.)

(f) Align the matchmarks placed before removal and install the inboard joint onto the outboard joint shaft

(g) Provisionally install the boot onto the inboard joint

8 INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Place the large boot clamp

C067417E02

G022501

(b) Using pliers, compress the large clamp and attach the claws

(c) Secure the boot clamp onto the boot

(d) Place SST onto the small boot clamp

SST 09521-24010

(e) Tighten the SST so that the small boot clamp is pinched

NOTICE:

Do not overtighten the SST.

(f) Using SST, adjust the clearance of the small boot clamp

SST 09240-00020 Clearance:

1.0 to 4.0 mm (0.039 to 0.157 in.)

9 INSPECT FRONT DRIVE SHAFT

(a) Check whether there is no remarkable play in the outboard joint

(b) Check whether the inboard joint slides smoothly in the thrust direction

(c) Check whether there is no remarkable play in the radial direction of the inboard joint

(d) Check the boots for damage

NOTICE:

Move the drive shaft while keeping it level.

(e) Make sure that the boots are not stretched or contracted when the drive shaft is at standard length

Drive shaft standard length:

484.4 to 488.4 mm (19.071 to 19.226 in.) NOTICE:

Move the drive shaft keeping it level.

PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double

(a) Check the spider bearings for wear and damage

(b) Check each spider bearings axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

NOTICE:

Do not tap the shaft tube.

HINT:

Remove the spider bearing from the opposite side

of the spider using the same procedure

(g) Separate the propeller with center bearing shaft assembly from the propeller shaft assembly

(h) Reinstall the 2 removed spider bearings onto the spider and clamp the spider bearings in a vise.(i) Using SST, push the bearing out of the yoke

(k) Remove the spider

3 REMOVE PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING

(a) Place matchmarks on the flange yoke and sleeve yoke

(b) Using a brass bar and hammer, slightly tap in the spider bearing

(c) Using 2 needle-nose pliers, remove the 4 snap rings from the grooves

(d) Clamp the propeller shaft in a vise between the aluminum plates

(e) Using SST, push the spider bearing out of the propeller shaft

PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double

PR

(f) Clamp the removed spider bearing outer race in a vise and tap the propeller shaft to remove the spider bearing

NOTICE:

Do not tap the shaft tube.

HINT:

Remove the spider bearing from the opposite side

of the spider using the same procedure

(g) Separate the flange yoke and spider from the propeller shaft

(h) Reinstall the 2 removed spider bearings onto the spider and clamp the spider bearings in a vise

(i) Using SST, push the bearing out of the yoke

(k) Remove the spider

4 REMOVE CENTER SUPPORT BEARING ASSEMBLY

NO 2

(a) Fix the yoke at the center bearing section in a vice

(b) Using a chisel and a hammer, loosen the staked part of the lock nut

(c) Place matchmarks on the yoke and shaft

(d) Using a brass bar and hammer, remove the center yoke, spacer and center support bearing from the intermediate shaft

2 INSPECT PROPELLER SHAFT

(a) Using a dial indicator, check the propeller shaft runout

If there are any defects, replace it

2 INSTALL CENTER SUPPORT BEARING ASSEMBLY

(d) Install the spacer

(e) Fix the yoke at the center bearing section in a vice.(f) Clamp the yoke in a vise, and press the bearing into position by tightening a new nut

Torque: 182 N*m (1,850 kgf*cm, 134 ft.*lbf)

(g) Loosen the nut

(h) Torque the nut again

PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double

(b) Fit the spider into the flange yoke

(c) Measure dimension A between the snap ring grooves

(d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the universal joint

NOTICE:

When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together.

(e) Select snap rings to make dimensions A and B the same

Snap Ring Type

NOTICE:

• Use new snap rings.

• If possible, use snap rings of the same thickness for both edges.

(f) Insert the spider into the yoke, and then using SST, press the spider bearing into the snap ring groove

F052205

Maximum bearing axial play:

0 to 0.05 mm (0 to 0.002 in.)

INSTALLATION

1 INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

(a) Remove SST from the extension housing

(b) Install the propeller shaft into the extension housing

(c) Align the matchmarks on the propeller shaft flange and differential flange

(d) Install the propeller shaft with the 4 bolts, 4 nuts and

Shaft Axial Direction 90q

D033899E01

PR–14 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double Cab 2WD)

Maximum bearing axial play:

0 to 0.05 mm (0 to 0.002 in.)

INSTALLATION

1 INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

(a) Remove SST from the extension housing

(b) Install the propeller shaft into the extension housing

(c) Align the matchmarks on the propeller shaft flange and differential flange

(d) Install the propeller shaft with the 4 bolts, 4 nuts and

Shaft Axial Direction 90q

D033899E01

(g) Torque the 2 bolts.

Torque: 36 N*m (369 kgf*cm, 27 ft.*lbf)

2 INSPECT TRANSMISSION OIL LEAKAGE

Center Bearing Center Line

Bearing Housing Center Line -1.0 to 1.0 mm (-0.039 to 0.039 in.)

F052184E02

PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) PR–17

PR

DISASSEMBLY

1 INSPECT FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING

(a) Check the spider bearings for wear and damage

(b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

F044192E01

1 INSPECT FRONT PROPELLER SHAFT ASSEMBLY

(a) Using a dial indicator, check the propeller shaft runout

(b) Fit the spider into the flange yoke

(c) Measure dimension A between the snap ring grooves

(d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the universal joint

NOTICE:

When measuring dimension B, fix the spider and needle roller bearings in a vise and hold them firmly together.

PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) PR–19

• Use new snap rings.

• If possible, use snap rings of the same thickness for both edges.

(f) Insert the spider into the yoke, and then using SST, press in the spider bearing into the snap ring groove

(a) Check the spider bearings for wear and damage

(b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

0 to 0.05 mm (0 to 0.002 in.)

G038874

Color Thickness mm (in.) Green 1.384 (0.0545) Red 1.435 (0.0565) Black 1.486 (0.0585) Copper 1.511 (0.0595) Silver 1.537 (0.0605) Yellow 1.588 (0.0625) Blue 1.638 (0.0645)

SST

F052205E01

G038875

2 INSTALL FRONT PROPELLER SHAFT ASSEMBLY

(a) Align the matchmarks on the yoke and differential flange

(b) Install the propeller shaft with the 4 bolts, 4 nuts and

PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) PR–21

DISASSEMBLY

1 INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING

(a) Check the spider bearings for wear and damage

(b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

PR–24 PROPELLER SHAFT – REAR PROPELLER SHAFT ASSEMBLY (for Regular Cab 4WD)

1 INSPECT PROPELLER SHAFT ASSEMBLY

(a) Using a dial indicator, check the propeller shaft runout

(b) Fit the spider into the flange yoke

(c) Measure dimension A between the snap ring grooves

(d) Insert the thrust washer and spider bearing into the spider journal portion, and then measure dimension

B of the universal joint

NOTICE:

When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together.

• Use new snap rings.

• If possible, use snap rings of the same thickness for both edges.

(f) Insert the spider into the yoke, and then using SST, press the spider bearing into the snap ring groove

(g) Press in the spider bearing on the opposite side in the same way

SST 09332-25010 NOTICE:

When pressing in the spider bearing, be careful not to damage its lip.

(h) Using needle-nose pliers, install new snap rings into the grooves of the yoke

2 INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING

(a) Check the spider bearings for wear and damage

(b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly

Maximum bearing axial play:

0 to 0.05 mm (0 to 0.002 in.)

G038874

Color Thickness mm (in.) Green 1.384 (0.0545) Red 1.435 (0.0565) Black 1.486 (0.0585) Copper 1.511 (0.0595) Silver 1.537 (0.0605) Yellow 1.588 (0.0625) Blue 1.638 (0.0645)

F052205

G038875