Avalon 1995-1996

CV-Joints

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Overhaul



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the center drive shaft or side gear shaft:
    1. Using an 8 mm hexagon wrench, remove the 6 hexagon bolts and 3 washers. Do not compress the inboard boot.

      Click image to see an enlarged view

      Fig. Using an 8 mm hexagon wrench, remove the 6 hexagon bolts and 3 washers

    2.  
    3. Remove the joint end cover gasket from the drive shaft.
    4.  
    5. Use bolts, nuts and washers to keep the inboard joint together. Tighten the bolts by hand to avoid scratching the flange surface.

      Click image to see an enlarged view

      Fig. Use bolts, nuts and washers to keep the inboard joint together

    6.  

  4.  
  5. Remove the inboard and outboard joint boot clamps:
    1. Using pliers, draw the hooks together and remove the clamps.

      Click image to see an enlarged view

      Fig. Using pliers, draw the hooks together and remove the clamps

    2.  
    3. Using a side cutter, cut the small boot clamps and remove them.
    4.  

  6.  
  7. Disassemble the inboard joint:
    1. Place matchmarks on the inboard joint and drive shaft.
    2.  
    3. Using a snap ring expander, remove the snap ring.
    4.  
    5. Using SST [SST 09726-10011 (09726-00031)] or equivalent tool, a socket wrench and press, remove the inboard joint from the drive shaft.

      Click image to see an enlarged view

      Fig. Remove the inboard joint from the drive shaft

    6.  
    7. Remove the bolts, nuts and washers.
    8.  
    9. Using a screwdriver and hammer, pry around the whole perimeter of the inboard joint cover.
    10.  
    11. Using a screwdriver, remove the inboard joint from the inboard joint cover. When lifting the inboard joint, hold onto the inner race and outer race.
    12.  

  8.  
  9. Remove the inboard and outboard joint boots.
  10.  
  11. Disassemble the side gear shaft. Using a screwdriver, remove the dust cover.
  12.  
  13. Disassemble the center drive shaft:
    1. Using a press, remove the transaxle side dust cover.

      Click image to see an enlarged view

      Fig. Remove the transaxle side dust cover

    2.  
    3. Using SST (SST 09950-00020) or equivalent tool, and a press, remove the bearing side dust cover.

      Click image to see an enlarged view

      Fig. Remove the bearing side dust cover

    4.  
    5. Using a snap ring expander, remove the snap ring.
    6.  
    7. Using a press, remove the bearing.
    8.  
    9. Remove the snap ring.
    10.  

  14.  

To install:

  1. Assemble the center drive shaft:
    1. Place the snap ring to the center drive shaft.
    2.  
    3. Using a press and extension bar, install a new bearing.
    4.  
    5. Using a snap ring expander, install a new snap ring.
    6.  
    7. Using a press, install a new bearing side dust cover. The clearance between the dust cover and the bearing should be kept in the range shown in the illustration.

      Click image to see an enlarged view

      Fig. The clearance between the dust cover and the bearing should be kept in the range shown

    8.  
    9. Using a press, install a new transaxle side dust cover.
    10.  

  2.  
  3. Assemble the side gear shaft. Using a press, install a new dust cover.
  4.  
  5. Temporarily install the boots and boot clamps to drive shaft. Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boot. Place new clamps on the small ends of the boots and install the boots to the drive shaft.
  6.  
  7. Assemble the inboard joint cover:
    1. Clean contacting surfaces of any FIPG material using a cleaner.
    2.  
    3. Apply FIPG to the inboard joint cover, as shown in the illustration. FIPG: Part No. 08826-00801, THREE BOND 1121 or equivalent.

      Click image to see an enlarged view

      Fig. Sealant application

    4.  
    5. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts.
    6.  
    7. Use a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times.

      Click image to see an enlarged view

      Fig. Tap the rim of the inboard joint cover in the order shown

    8.  
    9. Use bolts, nuts and washers to keep the inboard joint together. Tighten the bolts by hand to avoid scratching the flange surface.
    10.  

  8.  
  9. Assemble the inboard joint:
    1. Align the matchmarks placed before disassembly.
    2.  
    3. Using a brass bar and hammer, tap the inboard joint onto the drive shaft. Check that the brass bar is touching the inner race, and not the cage.
    4.  
    5. Using a snap ring expander, install a new snap ring. Work carefully so that the outer race does not come off.
    6.  

  10.  
  11. Assemble the boot or outboard joint. Before assembling the boot, pack in grease. Grease capacity: 4.8-5.5 oz. (135-155 g)
  12.  
  13. Assemble the inboard joint boot to the inboard joint. Pack the inboard joint and boot with grease. Use the grease supplied in the boot kit. Grease capacity: 5.0-5.3 oz. (142-150 g)
  14.  
  15. Assemble boot clamps to both boots:
    1. Make sure that the boots are in the shaft groove.
    2.  
    3. Make sure that the boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: 17.809 plus or minus 0.079 in. (452.4 plus or minus 2.0 mm)

      Click image to see an enlarged view

      Fig. Drive shaft length

    4.  
    5. Holding the clamp near the closing hooks, using pliers, position the holes in the clamp-s free end over the closing hooks.
    6.  
    7. Secure clamps by drawing the closing hooks together.
    8.  
    9. Secure the clamp onto the boot.
    10.  
    11. Place SST (SST 09521-24010) or equivalent tool onto the clamp.
    12.  
    13. Tighten the SST so that the clamp is pinched. Do not overtighten the SST.

      Click image to see an enlarged view

      Fig. Tighten the SST so that the clamp is pinched

    14.  
    15. Using SST [SST 09240-00020 (09242-00190)] or equivalent tool, adjust the clearance of the clamp. Clearance: 0.075 in. (1.9 mm) or less

      Click image to see an enlarged view

      Fig. Adjust the clearance of the clamp

    16.  

  16.  
  17. Pack the center drive shaft or side gear shaft with grease. Use the grease supplied in the boot kit.
  18.  
  19. Grease capacity: 1.8-2.1 oz. (50-60 g)
  20.  
  21. Temporarily connect the center drive shaft or side gear shaft to the drive shaft.
  22.  
  23. Check the drive shaft:
    1. Check to see that there is no play in the outboard joint shaft.
    2.  
    3. Check to see that the inboard joint shaft slides smoothly in the thrust direction.
    4.  
    5. Check to see that there is no remarkable play in the radial direction of the inboard joint shaft.
    6.  
    7. Check for damage to boots.
    8.  

  24.  

 
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