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    Toyota Tacoma 2002-06

    Upper Ball Joints

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    Removal & Installation




    NOTE
    The upper ball joint is removed with the upper control arm.

    2-Wheel Drive
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove the wheels.
    4.  
    5. Support the lower control arm with a floor jack.
    6.  
    7. Remove or disconnect the following:

      Anti-lock Brake System (ABS) speed sensor wire from the upper control arm
       
      2 bolts and camber adjusting shims from the upper control arm
       

    8.  


    NOTE
    Before removing the shims from the upper control arm, make a note of each shim size and position.



    Upper control arm cotter pin and nut.
     
    Upper ball joint from the steering knuckle, using SST 09628-62011
     
    Upper control arm
     
    4 upper control arm-to-upper ball joint nuts and bolts.
     
    Upper control arm from the upper ball joint
     



    Click image to see an enlarged view

    Fig. Upper control arm and related parts-2wd

    To install:

    1. Install or connect the following:

      New ball joint to the upper control arm. Tighten the 4 nuts/bolts to 29 ft. lbs. (39 Nm).
       
      Upper control arm
       
      Camber adjusting shims to the upper control arm. Tighten the 2 bolts to 94 ft. lbs. (130 Nm).
       
      Upper ball joint to the steering knuckle. Tighten the nut to 80 ft. lbs. (110 Nm).
       
      ABS speed sensor wire to the upper control arm. Tighten the ABS bolt to 71 inch lbs. (8 Nm).
       
      Wheels
       

    2.  
    3. Check the wheel alignment.
    4.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove the wheels.
    4.  
    5. Support the lower control arm with a floor jack.
    6.  
    7. Remove or disconnect the following:
      NOTE
      Before removing the shims from the upper control arm, make a note of each shim size and position.



      Anti-lock Brake System (ABS) speed sensor wire from the upper control arm
       
      2 bolts and camber adjusting shims from the upper control arm
       



      Upper control arm cotter pin and nut.
       
      Upper ball joint from the steering knuckle, using SST 09628-62011
       
      Upper control arm
       
      4 upper control arm-to-upper ball joint nuts and bolts.
       
      Upper control arm from the upper ball joint

      Click image to see an enlarged view

      Fig. Upper control arm and related parts-2wd

       

    8.  

    To install:

    1. Install or connect the following:

      New ball joint to the upper control arm. Tighten the 4 nuts/bolts to 29 ft. lbs. (39 Nm).
       
      Upper control arm
       
      Camber adjusting shims to the upper control arm. Tighten the 2 bolts to 94 ft. lbs. (130 Nm).
       
      Upper ball joint to the steering knuckle. Tighten the nut to 80 ft. lbs. (110 Nm).
       
      ABS speed sensor wire to the upper control arm. Tighten the ABS bolt to 71 inch lbs. (8 Nm).
       
      Wheels
       

    2.  
    3. Check the wheel alignment.
    4.  

    4-Wheel Drive
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Wheel
       
      Strut
       

    4.  
    5. If not equipped with a FREE wheeling hub, disconnect the halfshaft from the steering knuckle, as follows:

      Grease cap
       
      Cotter pin and lockcap from the halfshaft
       
      Locknut from the halfshaft, while having an assistant apply the brakes
       

    6.  
    7. If equipped with free wheeling hub, remove the free wheel hub, as follows:

      Set the control handle to FREE
       
      Cover bolts and pull off the cover
       
      Center bolt with washer
       
      Hub body nuts and washer
       
      Cone washer, using a brass bar and hammer to tap on the bolt heads
       
      Free wheel hub body and gasket
       
      Snapring and spacer from the halfshaft end, using a snapring expander
       
      Anti-lock Brake System (ABS) speed sensor from the steering knuckle, if equipped with ABS
       
      Brake hose from the steering knuckle
       
      Brake caliper support bracket and support it on a wire
       

    8.  


    WARNING
    Do not allow the caliper to hang from the brake hose.

    1. Remove or disconnect the following:

      Rotor
       
      Lower ball joint from the steering knuckle
       
      Upper control arm cotter pin and nut
       
      Steering knuckle from the upper control arm, using SST 09950-40010
       
      Steering knuckle from the vehicle
       

    2.  


    NOTE
    If it is difficult to remove the halfshaft from the steering knuckle, use a rubber hammer to tap the halfshaft from the steering knuckle.



    Wire and boot from the upper ball joint
     
    Snapring from the ball joint, using a snapring expander
     
    Upper ball joint from the steering knuckle, using SST 09950-40010 (puller set) and a deep socket wrench
     



    Click image to see an enlarged view

    Fig. Upper ball joint and related parts-4wd, exc. PreRunner



    Click image to see an enlarged view

    Fig. Upper ball joint and related parts-PreRunner

    To install:

    1. Install or connect the following:

      Press in a new upper ball joint, using SST 09309-37010 and a socket wrench
       
      New snapring, using a snapring expander
       
      New boot, secured with a new piece of wire
       
      Steering knuckle to the halfshaft
       
      Steering knuckle to the lower ball joint by installing the 4 bolts; do not tighten the bolts at this time.
       
      Upper control arm
       
      Upper ball joint to the arm. Tighten the nut to 80 ft. lbs. (105 Nm).
       
      New cotter pin
       
      Tighten the lower ball joint-to-steering knuckle bolts to 59 ft. lbs. (80 Nm).
       
      Brake rotor
       
      Caliper support bracket to the steering knuckle. Tighten both bolts to 90 ft. lbs. (123 Nm).
       
      Brake hose clamp to the steering knuckle. Tighten the bolt to 13 ft. lbs. (18 Nm).
       
      ABS speed sensor and wiring harness to the steering knuckle, if equipped with ABS
       
      Spacer and snapring to the halfshaft, using a snapring expander
       

    2.  
    3. If equipped with a free wheeling hub, install the hub, as follows:

      New front axle hub gasket
       
      Free wheeling hub body with the 6 cone washers and nuts. Tighten the 6 nuts to 23 ft. lbs. (31 Nm).
       
      Bolt with the washer. Tighten the bolt to 13 ft. lbs. (18 Nm).
       
      Apply multi-purpose grease to the inner hub splines
       
      Set the control handle and clutch to the FREE position
       
      New gasket on the cover
       
      Cover to the hub body with the follower pawl tabs aligned with the non-toothed portions of the hub body
       
      Tighten the cover bolts to 84 inch lbs. (10 Nm).
       

    4.  
    5. If equipped without a free wheeling hub, install the halfshaft to the steering knuckle, as follows:

      Locknut to the halfshaft. Tighten the nut to 174 ft. lbs. (235 Nm).
       
      Halfshaft lockcap and cotter pin
       
      Grease cab
       
      Strut. Tighten the strut-to-lower control arm nut to 101 ft. lbs. (135 Nm) and the upper 3 nuts to 47 ft. lbs. (64 Nm).
       
      Front wheels
       

    6.  
    7. Check the wheel alignment.
    8.  



    Click image to see an enlarged view

    Fig. Upper ball joint and related components-4WD 2001-2004 except PreRunner



    Click image to see an enlarged view

    Fig. Upper ball joint and related components-2001-2004 PreRunner

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Wheel
       
      Strut
       

    4.  
    5. If not equipped with a FREE wheeling hub, disconnect the halfshaft from the steering knuckle, as follows:

      Grease cap
       
      Cotter pin and lockcap from the halfshaft
       
      Locknut from the halfshaft, while having an assistant apply the brakes
       

    6.  
    7. If equipped with free wheeling hub, remove the free wheel hub, as follows:
      WARNING
      Do not allow the caliper to hang from the brake hose.



      Set the control handle to FREE
       
      Cover bolts and pull off the cover
       
      Center bolt with washer
       
      Hub body nuts and washer
       
      Cone washer, using a brass bar and hammer to tap on the bolt heads
       
      Free wheel hub body and gasket
       
      Snapring and spacer from the halfshaft end, using a snapring expander
       
      Anti-lock Brake System (ABS) speed sensor from the steering knuckle, if equipped with ABS
       
      Brake hose from the steering knuckle
       
      Brake caliper support bracket and support it on a wire
       

    8.  
    9. Remove or disconnect the following:
      NOTE
      If it is difficult to remove the halfshaft from the steering knuckle, use a rubber hammer to tap the halfshaft from the steering knuckle.



      Rotor
       
      Lower ball joint from the steering knuckle
       
      Upper control arm cotter pin and nut
       
      Steering knuckle from the upper control arm, using SST 09950-40010
       
      Steering knuckle from the vehicle
       



      Wire and boot from the upper ball joint
       
      Snapring from the ball joint, using a snapring expander
       
      Upper ball joint from the steering knuckle, using SST 09950-40010 (puller set) and a deep socket wrench
       

    10.  

    To install:

    1. Install or connect the following:

      Press in a new upper ball joint, using SST 09309-37010 and a socket wrench
       
      New snapring, using a snapring expander
       
      New boot, secured with a new piece of wire
       
      Steering knuckle to the halfshaft
       
      Steering knuckle to the lower ball joint by installing the 4 bolts; do not tighten the bolts at this time.
       
      Upper control arm
       
      Upper ball joint to the arm. Tighten the nut to 80 ft. lbs. (105 Nm).
       
      New cotter pin
       
      Tighten the lower ball joint-to-steering knuckle bolts to 59 ft. lbs. (80 Nm).
       
      Brake rotor
       
      Caliper support bracket to the steering knuckle. Tighten both bolts to 90 ft. lbs. (123 Nm).
       
      Brake hose clamp to the steering knuckle. Tighten the bolt to 13 ft. lbs. (18 Nm).
       
      ABS speed sensor and wiring harness to the steering knuckle, if equipped with ABS
       
      Spacer and snapring to the halfshaft, using a snapring expander
       

    2.  
    3. If equipped with a free wheeling hub, install the hub, as follows:

      New front axle hub gasket
       
      Free wheeling hub body with the 6 cone washers and nuts. Tighten the 6 nuts to 23 ft. lbs. (31 Nm).
       
      Bolt with the washer. Tighten the bolt to 13 ft. lbs. (18 Nm).
       
      Apply multi-purpose grease to the inner hub splines
       
      Set the control handle and clutch to the FREE position
       
      New gasket on the cover
       
      Cover to the hub body with the follower pawl tabs aligned with the non-toothed portions of the hub body
       
      Tighten the cover bolts to 84 inch lbs. (10 Nm).
       

    4.  
    5. If equipped without a free wheeling hub, install the halfshaft to the steering knuckle, as follows:

      Locknut to the halfshaft. Tighten the nut to 174 ft. lbs. (235 Nm).
       
      Halfshaft lockcap and cotter pin
       
      Grease cab
       
      Strut. Tighten the strut-to-lower control arm nut to 101 ft. lbs. (135 Nm) and the upper 3 nuts to 47 ft. lbs. (64 Nm).
       
      Front wheels
       

    6.  
    7. Check the wheel alignment.
    8.  

     
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