Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — 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
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