Propeller Shaft Assembly: Replacement

WARNING: This page is about a different car, the 2003 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

SEPARATE INTERMEDIATE SHAFT AND PROPELLER SHAFT
1. Place matchmarks on the intermediate shaft and propeller shaft.
  
  Fig 1: Matchmarking On Intermediate Shaft & Propeller Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Separate the intermediate shaft and propeller shaft.
3. Remove the dust boot from the propeller shaft.
  HINT:
  
  If the dust boot is reused, remove it after wrapping vinyl tape around the spline, so it will not be damaged.
REMOVE CENTER SUPPORT BEARING
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the center support bearing and dust deflector.
  SST 09950-00020
  
  Fig 2: Removing Center Support Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT AND PROPELLER SHAFT RUNOUT
Using a dial indicator, check the runout of the shafts.

Maximum Runout: 0.8 mm (0.031 in.)

If the runout exceeds the maximum, replace the propeller shaft assembly.

Fig 3: Inspecting Intermediate Shaft & Propeller Shaft Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SPIDER BEARING
1. Check if the spider bearing rotates smoothly.
2. Check if there is any play in the spider bearing.
  If necessary, replace the propeller shaft.
  
  Fig 4: Inspecting Spider Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER SUPPORT BEARING
NOTE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation.
1. Using SST and a press, install the center support bearing.
  SST 09330-50010
  
  Fig 5: Installing Center Support Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, insert a new dust deflector until it almost touches the rubber of the center support bearing.
  SST 09608-00071, 09608-06041
  
  Fig 6: Inserting Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the dust deflector.
  SST 09330-50010
4. Using a snap ring expander, install a new snap ring.
  
  Fig 7: Installing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE INTERMEDIATE SHAFT AND PROPELLER SHAFT
1. Install the dust boot.
  NOTE: Assemble after wrapping vinyl tape around the spline so it will not damage the boot.
2. Apply grease to the spline.
  Grease:
  
  Molybdenum Disulphide Lithium Base, NLGI No. 2
  
  Fig 8: Wrapping Vinyl Tape Around Splines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the matchmarks and assemble the intermediate shaft and propeller shaft.
  
  Fig 9: Aligning Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Cover the adjusting nut with the dust boot.
  NOTE: The directions of the intermediate shaft companion flange and the propeller shaft companion flange should differ by 180°.
  
  Fig 10: Installing Intermediate Shaft Companion Flange 180° To Propeller Shaft Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tighten the adjusting nut fully by hand.