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Section 15 (Propeller W/Center Bearing Shaft Assembly (4WD)): Overhaul

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY 
    1. Depress the brake pedal and hold it.
    2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.
      Fig 1: Loosening Cross Groove Joint Set Bolts Using A Hexagon Wrench
      G02865570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Put a piece of cloth inside the cross groove joint cover so that the boot does not touch the inside of the cross groove joint cover.
    3. Place matchmarks on the propeller shaft sub-assy and differential carrier assy.
      4. Fig 2: Placing Matchmarks On Propeller Shaft Sub-Assy & Differential Carrier Assy
      G02865571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and washers, separate the propeller shaft sub-assy.
    5. Remove the 2 bolts and 2 bearing washer No.2, separate the propeller w/ center bearing shaft assy.
      6. Fig 3: Separating Propeller W/Center Bearing Shaft Assy
      G02865572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Pull out the propeller w/ center bearing shaft assy from the transfer.
      NOTE:
      • When removing the propeller shaft, do not apply a large force to the universal joint.
      • During and after the removal of the propeller shaft, keep the universal joint angle straight (within 15 degrees).
      • Be careful not to damage the oil seal.
    7. Insert SST into the transfer to prevent oil leakage.

      SST 09325-20010

      NOTE: Be careful not to damage the oil seal.
      Fig 4: Inserting SST Into Transfer
      G02865573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE INTERMEDIATE SHAFT 
    1. Place matchmarks on the propeller shaft sub-assy and universal joint flange.
      NOTE: Do not place the matchmarks with a punch.
    2. Using a hexagon wrench (6 mm), remove the 6 bolts and 2 washers to separate intermediate shaft sub-assy and propeller shaft sub-assy.
      Fig 5: Removing Bolts & Washers To Separate Intermediate Shaft Sub-Assy & Propeller Shaft Sub-Assy Using A Hexagon Wrench
      G02865574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT INTERMEDIATE SHAFT 
    1. Using a dial indicator, inspect the intermediate shaft sub-assy.
      Fig 6: Inspecting Intermediate Shaft Sub-Assy Using A Dial Indicator
      G02865575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum runout: 0.4 mm (0.016 in.) 

      NOTE: The dial indicator must be set at a right angle to the center of the propeller shaft.

      If the shaft runout is greater than the maximum, replace the propeller w/ center bearing shaft assy.

    2. Using a dial indicator, inspect the rear side of universal joint flange runout in the vertical direction.
      Fig 7: Inspecting Rear Side Of Universal Joint Flange Runout In Vertical Direction Using A Dial Indicator
      G02865576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum runout: 0.1 mm (0.004 in.) 

    3. Using a dial indicator, inspect the rear side of universal joint flange runout in the horizontal direction.
      Fig 8: Inspecting Rear Side Of Universal Joint Flange Runout In Horizontal Direction Using A Dial Indicator
      G02865577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum runout: 0.1 mm (0.004 in.) 

  4. INSPECT PROPELLER SHAFT 
    1. Using a dial indicator, inspect the propeller shaft sub-assy.
      Fig 9: Inspecting Propeller Shaft Sub-Assy Using A Dial Indicator
      G02865578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum runout: 0.4 mm (0.016 in.) 

      NOTE: The dial indicator must be set at a right angle to the center of the propeller shaft.

      If the shaft runout is greater than the maximum, replace the propeller w/ center bearing shaft assy.

  5. REMOVE CENTER SUPPORT BEARING ASSY NO.1 
    1. Using a hammer and a chisel, loosen the staked part of the nut.
    2. Using a soft vise to hold the universal joint flange, remove the nut and washer.
      NOTE: Do not overtighten the vise.
    3. Place matchmarks on the universal joint flange and intermediate shaft sub-assy.
      Fig 10: Placing Matchmarks On Universal Joint Flange & Intermediate Shaft Sub-Assy
      G02865579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the universal joint flange.
      Fig 11: Removing Universal Joint Flange Using SST
      G02865580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

      NOTE: Be careful not to damage the universal joint flange.
    5. Remove the center support bearing assy No.1 and washer.
  6. INSPECT CENTER SUPPORT BEARING ASSY NO.1 
    1. Turn the center support bearing assy No.1 by hand with applying force in the rotation direction. Check the bearing turns smoothly.
    2. Check that the seals and bracket are not cracked or damaged.

      If the center support bearing assy No.1 is damaged, worn, or does not turn freely, replace it.

      Fig 12: Inspecting Center Support Bearing
      G02865581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CENTER SUPPORT BEARING ASSY NO.1 
    1. Set the center support bearing No.1 on the intermediate shaft sub-assy as shown in the illustration.
      NOTE: Be sure to install the bearing in the correct orientation.
    2. Install the new washer to the intermediate shaft sub-assy.
      Fig 13: Installing Center Support Bearing On Intermediate Shaft Sub-Assy
      G02865582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks on the universal joint flange and intermediate shaft sub-assy, place the flange on the shaft.
      Fig 14: Aligning Matchmarks On Universal Joint Flange & Intermediate Shaft Sub-Assy
      G02865583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a soft vise to hold the universal joint flange, press the bearing into position by tightening down a new nut and washer.
      Fig 15: Using Soft Vise For Holding Universal Joint Flange
      G02865584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 181.4 N.m (1,850 kgf.cm, 134 ft.lbf) 

    5. Loosen the nut.
    6. Torque the nut again.

      Torque: 68.6 N.m (700 kgf.cm, 51 ft.lbf) 

    7. Using a chisel and a hammer, stake the nut.
  8. INSTALL INTERMEDIATE SHAFT 
    1. Align the matchmarks on the intermediate shaft sub-assy and propeller shaft sub-assy.
    2. Using a hexagon wrench (6 mm), tighten the 6 bolts with 2 washers temporarily.
      Fig 16: Tightening Bolts & Washers Using A Hexagon Wrench
      G02865585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY 
    1. Remove SST from the transfer.
      2. Fig 17: Removing SST From Transfer
      G02865586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the propeller w/ center bearing shaft assy.
      NOTE:
      • Be careful not to damage the oil seal.
      • Be careful not to damage the universal joint boot when installing the propeller shaft.
    3. Align matchmarks on the propeller shaft sub-assy and differential carrier assy, install the 4 bolts and washers temporarily.
      Fig 18: Aligning Matchmarks On Propeller Shaft Sub-Assy & Differential Carrier Assy
      G02865587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the center support bearing assy No.1 with 2 bolts and 2 center support bearing washer No.2.
      Fig 19: Connecting Center Support Bearing Assy
      G02865588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Use the removed washers when installation.
    5. Tighten the 4 bolts.

      Torque: 73.5 N.m (749 kgf.cm, 54 ft.lbf) 

      Fig 20: Tightening Propeller Shaft Sub-Assy Bolts
      G02865589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY 
    1. Remove the cloth from the universal joint.
    2. Depress the brake pedal and hold it.
    3. Using a hexagon wrench (6 mm), tighten the 6 bolts.

      Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

      Fig 21: Tightening Propeller W/Center Bearing Shaft Assy Bolts Using A Hexagon Wrench
      G02865590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. With the vehicle in the unladen condition, adjust the dimension between the rear side of cover and the shaft, as shown in the illustration.
      Fig 22: Adjusting Dimension Between Rear Side Of Cover & Shaft
      G02865591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. With the same condition, adjust the dimension between the rear side of center bearing housing and the rear side of cushion, as shown in the illustration.
      6. Fig 23: Adjusting Dimension Between Rear Side Of Center Bearing Housing & Rear Side Of Cushion
      G02865592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check that the center line of the bracket is at right angles at the shaft axial direction.
    7. In case of being a strange sound or noise:

      Select the center support bearing washer No.2 for adjusting.

      NOTE:
      • Make sure to use the washer of the same thickness on both right and left sides.
      • Do not use 2 or more washers on a bolt.

      Washer thickness: 

      WASHER THICKNESS

      Thickness mm (in.) Thickness mm (in.)
      3.6 (0.142) 6.5 (0.256)
      4.5 (0.177) 9.0 (0.354)
  11. Tighten the 2 bolts.

    Torque: 36.8 N.m (374 kgf.cm, 27 ft.lbf) 

    Fig 24: Tightening Propeller W/Center Bearing Shaft Assy Bolts
    G02865593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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