Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 3

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) Using a 5 mm hexagon wrench, remove the bolt and

separate the front speed sensor.

(b) Disengage the 3 clamps.
(c) Remove the bolt and separate the skid control

sensor wire from the steering knuckle.

5.

REMOVE FRONT AXLE HUB GREASE CAP
(a) Using a screwdriver and a hammer, remove the

front axle hub grease cap.
NOTICE:
Do not damage the axle hub.

6.

REMOVE FRONT AXLE HUB NUT
(a) Remove the cotter pin and adjusting lock cap.
(b) Remove the front axle hub nut.

7.

SEPARATE TIE ROD END SUB-ASSEMBLY
(a) Remove the cotter pin and nut.

C133044

F042729

F042732

DS–4

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD)

DS

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

steering knuckle.
SST

09628-62011

8.

SEPARATE FRONT LOWER BALL JOINT
ATTACHMENT
(a) Remove the 2 bolts and separate the front lower ball

joint attachment from the steering knuckle.

9.

REMOVE FRONT DRIVE SHAFT
(a) Using SST, remove the front drive shaft.

SST

09520-01010, 09520-24010 (09520-32040)

NOTICE:
Do not damage the oil seal.

DISASSEMBLY

1.

INSPECT FRONT DRIVE SHAFT
(a) Check that there is no remarkable play in the

outboard joint.

(b) Check that the inboard joint slides smoothly in the

thrust direction.

(c) Check that 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 NO.
2 CLAMP
(a) Using a screwdriver, release the staked part of the

boot clamp and separate the boot clamp.

SST

F051679E01

G020159

SST

F042739E01

W001721

F040958

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD)

DS–5

DS

3.

REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) Using a screwdriver, release the staked part of the

boot clamp and separate the boot clamp.

4.

SEPARATE INBOARD JOINT BOOT
(a) Separate the inboard joint boot from the inboard

joint.

5.

REMOVE FRONT DRIVE INBOARD JOINT
ASSEMBLY
(a) Remove the old grease from the inboard joint.

(b) Place matchmarks on the inboard joint, tripod and

outboard joint shaft.
NOTICE:
Do not punch the marks.

(c) Remove the inboard joint from the outboard joint

shaft.

(d) Fix the outboard joint shaft in a vise between

aluminum plates.
NOTICE:
Do not overtighten the vise.

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

(f)

Place matchmarks on the outboard joint shaft and
tripod.
NOTICE:
Do not punch the marks.

(g) Using a brass bar and hammer, remove the tripod

from the outboard joint shaft.
NOTICE:
Do not tap the roller.

(h) Remove the inboard joint boot No. 2 clamp, the

inboard joint boot and the inboard joint boot clamp.

6.

REMOVE FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP
(a) Using a screwdriver, release the staked part of the

boot clamp and remove the boot clamp.

F040959

Matchmark

FA01615E02

G022501

Matchmarks

N000194E02

C063445

DS–6

DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD)

DS

7.

REMOVE FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Using pliers, remove the boot clamp, as shown in

the illustration.

8.

REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard

joint shaft.

(b) Remove the old grease from the outboard joint.

9.

REMOVE FRONT DRIVE SHAFT HOLE SNAP RING
(a) Using a screwdriver, remove the snap ring.

10. REMOVE FRONT DRIVE SHAFT DUST COVER

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

SST

09950-00020

REASSEMBLY

1.

INSTALL FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, install a new dust cover into

the inboard joint until it is flush with the end.
SST

09527-10011

NOTICE:
•

Install the dust cover in the correct
orientation.

•

Do not deform the dust cover.

2.

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
(a) Install a new snap ring.

3.

INSTALL OUTBOARD JOINT BOOT
(a) Wrap the spline of the outboard joint shaft with

protective tape.

(b) Install new parts onto the outboard joint shaft in the

following order.

C081566

C057543

SST

F040647E01

SST

F041033E01

1.

Front axle outboard joint boot No. 2 clamp

2.

Front axle outboard joint boot

3.

Front axle outboard joint boot clamp