Toyota Avalon, Camry, Camry Solara 2001-06

Overhaul

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Click image to see an enlarged view

Fig. Exploded view of the right-hand halfshaft



Click image to see an enlarged view

Fig. Exploded view of the left-hand halfshaft

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle and mount securely in a vise.
  4.  
  5. Using a suitable pry tool, remove the front drive inner shaft outer LH shaft snap ring.
  6.  
  7. Using pliers, remove the inboard joint boot No.2 clamp and inboard joint boot clamp, as shown in the illustration.

    Click image to see an enlarged view

    Fig. Removing the boot clamps

  8.  
  9. Separate the inboard joint boot from the inboard joint.
  10.  
  11. Matchmark the inboard joint and outboard joint shaft.
  12.  
  13. Remove the inboard joint from the outboard joint shaft.
  14.  
  15. Using a snap ring expander, remove the shaft snap ring.
  16.  
  17. Matchmark the outboard joint shaft and tripod joint.
  18.  
  19. Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft.
  20.  
  21. Using pliers, remove the drive shaft damper clamp, as shown in the illustration.

    Click image to see an enlarged view

    Fig. Removing the halfshaft damper clamp-Automatic transmission models

  22.  
  23. Remove the drive shaft damper.
  24.  
  25. Using pliers, remove the outboard joint boot LH No.2 clamp and outboard joint boot LH clamp, as shown in the illustration.
  26.  
  27. Remove the outboard joint boot from the outboard joint shaft.
  28.  
  29. Remove the grease from the outboard joint.
  30.  
  31. Use Special Tool 09950-0020 and a press, remove the drive shaft dust cover
  32.  
  33. Using a snap ring expander, remove the drive shaft hole snap ring.
  34.  
  35. On the right side, use Special Tool 09527-10011 and a press, remove the bearing.
  36.  
  37. Remove the bearing bracket hole snap ring.
  38.  

To install:

  1. Install a new bearing bracket hole snap ring to the right side halfshaft.
  2.  
  3. Using Special Tool 09527-30010 and a steel plate, install a new front drive shaft bearing.
  4.  
  5. Using a snap ring expander, install a new halfshaft hole snap ring.
  6.  
  7. Using Special Tool 09527-10011 and a press, install a new right side halfshaft dust cover until the distance from the tip of the center halfshaft to the halfshaft dust cover meets the specification, as shown in the illustration.
    1. 2.4L (2AZ-FE) Engine: 3.60+/-0.02 in. (91.5+/-0.5 mm)
    2.  
    3. 1MZ-FE, 3.3L (3MZ-FE) Engine: 4.3+/-0.02 in. (110.5+/-0.5 mm)
    4.  
    5. 3.5L (2GR-FE) Engine: 4.331-4.370 in. (110-111 mm)

      Click image to see an enlarged view

      Fig. Install the right halfshaft dust cover to the specified distance

    6.  

  8.  
  9. Using Special Tool 09527-10011 and a press, install a new left side halfshaft dust cover.
    NOTE
    Wrap the splines of the halfshaft with tape to prevent the boots from being damaged.

  10.  
  11. Secure the halfshaft lightly in a soft vise.
  12.  
  13. Temporarily install a new outboard joint boot to the halfshaft with 2 clamps.
  14.  
  15. Pack the outboard joint shaft and boot with grease:
    1. 2GR-FE: 4.2-4.9 oz.
    2.  
    3. 2.4L (2AZ-FE) (AT): 3.5-4.2 oz.
    4.  
    5. 2.4L (2AZ-FE) (MT): 3.7 to 4.4 oz.
    6.  
    7. 1MZ-FE, 3MZ-FE: 6.9-7.9 oz.
    8.  

  16.  
  17. Using Special Tool 09521-24010, tighten the outboard joint large boot clamp.
  18.  
  19. Using Special Tool 09240-00020, measure the clearance of the outboard joint large boot clamp. Clearance should be as follows:
    1. 3.5L (2GR-FE) Engine: 0.0472-0.1575 in. (1.2-4.0 mm)
    2.  
    3. All others: Clearance: 0.118-0.157 in. (3-4 mm)
    4.  

  20.  
  21. Install the halfshaft damper to the halfshaft groove, if equipped with automatic transmission. Set the distance, as specified:
    1. 2GR-FE: 8.051-8.209 in. (204.5 to 208.5 mm)
    2.  
    3. All others: 8.15+/-.08 in. (207+/-2 mm)
    4.  

  22.  
  23. Using pliers, install a new halfshaft damper clamp.
  24.  
  25. Temporarily install a new inboard joint boot with 2 clamps to the halfshaft.
  26.  
  27. Place the beveled side of the tripod joint axial spline toward the outboard joint shaft and align the matchmarks.

    Click image to see an enlarged view

    Fig. Correct orientation of the tripod joint for installation

  28.  
  29. Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.
  30.  
  31. Using a snap ring expander, install a new shaft snap ring.
  32.  
  33. Pack the outboard joint shaft and boot with grease:
    1. 3.5L (2GR-FE) Engine: 6.7 -7.4 oz.
    2.  
    3. 2.4L (2AZ-FE) Engine: 6.0-6.7 oz.
    4.  
    5. 1MZ-FE, 3.3L (3MZ-FE) Engines: 5.5 to 6.2 oz.
    6.  

  34.  
  35. Align the matchmarks and install the inboard joint to the outboard joint shaft.
  36.  
  37. Install the inboard joint boot to the inboard joint.
  38.  
  39. Using pliers, install the new inboard joint boot No.2 clamp and inboard joint boot clamp.
  40.  
  41. Install the front drive inner shaft outer LH shaft snap ring.
  42.  
  43. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
    1. 1MZ-FE, 3.3L (3MZ-FE) Engine:

      Left side: 22.864+/-0.08 in. (580.76+/-2.0 mm)
       
      Right side: 35.354+/-0.08 in. (898.0+/-2.0 mm)
       

    2.  
    3. 2.4L (2AZ-FE) Engine:

      Left side: 23.276+/-0.08 in. (591.2+/-2.0 mm)
       
      Right side: 35.039+/-0.08 in. (890.0+/-2.0 mm)
       

    4.  
    5. 3.5L (2GR-FE) Engine:

      Left side: 23.150-23.307 in. (588.0-592.0 mm)
       
      Right side: 35.677-35.835 in. (906.2-910.2 mm)

      Click image to see an enlarged view

      Fig. Standard length of the halfshaft should be measured as shown in the illustration.

       

    6.  

  44.  
  45. Check to see that there is no play in the inboard and outboard joints and that the inboard joint slides smoothly in the thrust direction.
  46.  

 
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