Toyota Celica 1994-1998 Repair Guide

Halfshafts

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REMOVAL & INSTALLATION



See Figures 1 through 13


WARNING
The hub bearing can be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the driveshaft removed. Therefore, if it is not absolutely necessary to place the vehicle weight on the hub bearing, first support it.



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Fig. Fig. 1: View of the driveshaft and related components-5S-FE engine



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Fig. Fig. 2: View of the driveshaft assembly-7A-FE engine

On models with ABS, after disconnecting the driveshaft from the axle hub, work carefully so as not to damage the sensor rotor serration's on the driveshaft.

  1. Jack up the vehicle and remove the front wheel.
  2.  
  3. Remove the engine under covers.
  4.  
  5. Drain the gear oil (manual) or ATF (automatic) from the transaxle.
  6.  
  7. Remove the cotter pin and lock cap nut. loosen the bearing lock nut while depressing the brake pedal/
  8.  



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Fig. Fig. 3: Remove the castellated washer and cotter pin on the axle shaft, discard the cotter pin



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Fig. Fig. 4: Retain the rotor and loosen the shaft nut

  1. Disconnect the tie rod end from the steering knuckle by pulling the cotter pin and nut off. Using a puller, separate the tie rod end from the knuckle.
  2.  
  3. Remove the nut and disconnect the stabilizer bar link from the lower control arm.
  4.  

If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud.

  1. Disconnect the lower ball joint from the lower control arm.
  2.  



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Fig. Fig. 5: Remove the three bolts for the lower control arm, then ...



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Fig. Fig. 6: ... pull the arm away form the steering knuckle

  1. Using a plastic hammer, carefully disconnect the drive shaft from the axle hub.
  2.  

Be careful not to damage the inner seal, boots and ABS speed sensor rotor.

  1. Pull the hub and disc away from the shaft.
  2.  



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Fig. Fig. 7: Carefully tap the end of the halfshaft to separate it from the hub



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Fig. Fig. 8: The rotor and hub assembly can now be pulled away from the shaft

  1. On the left side driveshaft perform the following:
    1. Cover a hub nut wrench with cloth and using the wrench and a hammer handle or equivalent, pry between the shaft and transaxle, then pull out the driveshaft. Be careful not to damage the dust cover.
    2.  
    3. Remove the snapring on the end of the shaft.

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      Fig. Fig. 9: Prying at the groove on the CV joint will ease halfshaft removal



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      Fig. Fig. 10: Use both hands to maneuver the halfshaft from the transaxle



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      Fig. Fig. 11: Inspect the seal and replace it if necessary



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      Fig. Fig. 12: Snaprings are located on the end of the halfshaft

    4.  

  2.  
  3. On the right hand drive shaft perform the following:
    1. Remove the 2 bolts of the center bearing bracket, then pull out the right driveshaft together with the center bearing case and center driveshaft.
    2.  
    3. Remove the center driveshaft with the right driveshaft to the transaxle through the bearing bracket.

      Click image to see an enlarged view

      Fig. Fig. 13: Remove the 2 bolts of the center bracket on the right side driveshaft

    4.  

  4.  

To install:

Whether or not the driveshaft is making contact with the pinion shaft can be know by the sound of the feeling when driving in it.

  1. To install the left side driveshaft perform the following:
    1. Before installing the driveshaft, using a snapring expander, set the snapring opening side facing downward and install the new snapring.
    2.  
    3. Coat gear oil on the inboard joint tulip and differential case sliding surface.
    4.  
    5. Using a brass bar and hammer, tap in the driveshaft until it makes contact with the pinion shaft.
    6.  
    7. Inspect the installation, there should be 0.08-0.12 inch (2-3mm) of play in the axial direction. Check that the driveshaft will not come out by trying to pull it completely out by hand.
    8.  

  2.  
  3. Install the right side driveshaft by performing the following:
    1. Coat gear oil to the inboard joint tulip and differential case sliding surface.
    2.  
    3. Install the center driveshaft with the right side to the transaxle through the bearing bracket.
    4.  
    5. Install the 2 bolts and tighten them to 47 ft. lbs. (64 Nm).
    6.  

  4.  
  5. connect the driveshaft to the axle hub. Attach the outboard joint side of the driveshaft to the axle hub.
  6.  
  7. Connect the lower ball joint to the lower control arm.
  8.  
  9. Attach the stabilizer bar link to the lower control arm.
  10.  
  11. Connect the tie rod end to the steering knuckle and tighten the nut.
  12.  
  13. Connect the tie rod end to the steering knuckle.
  14.  
  15. Install a new bearing lock nut, lock nut cap and new cotter pin. Tighten the lock nut to 159 ft. lbs. (216 Nm).
  16.  
  17. Fill the transaxle with gear oil (manual) or ATF (automatic).
  18.  
  19. Install the engine undercover.
  20.  
  21. Install the front wheel and lower the vehicle.
  22.  
  23. Check and adjust the front wheel alignment.
  24.  
  25. On ABS models, check the speed sensor signal.
  26.  

CV-JOINTS OVERHAUL



5S-FE Engine

See Figures 14 to 25

Whenever the halfshaft is held in a vise, use pieces of wood in the jaws to protect the components from damage or deformation.

  1. Remove the driveshaft.
  2.  
  3. On the inboard joint tulip, using a flatbladed tool, remove the boot clamps. Slide the inboard joint boot toward the outboard joint.
    1. Place matchmarks on the tripod and inboard joint tulip or center driveshaft.Do not punch the marks.
    2.  
    3. Remove the inboard joint tulip or center driveshaft from the driveshaft.

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      Fig. Fig. 14: Place matchmarks on the tripod and outboard joints

    4.  

  4.  
  5. On the tripod, use snapring expander, temporarily, slide the snapring toward the outboard joint side.
    1. Place matchmarks on the driveshaft and tripod.Do not punch the marks.
    2.  
    3. Use a brass bar and hammer, remove the tripod from the driveshaft.
    4.  
    5. Use a snapring expander and remove the snapring.

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      Fig. Fig. 15: With matchmarks on the tripod, tap the joint for the driveshaft

    6.  

  6.  
  7. Remove the inboard joint boot.
  8.  
  9. On the right side with dynamic damper, remove the clamps from the damper and extract the unit.
  10.  
  11. Remove the clamps from the outboard joint. Pull the boot from the outboard joint.
  12.  

Do not disassemble the outboard joint.

  1. Remove the dust cover as follows:
    1. On the left side, press the dust cover from the inboard joint tulip.
    2.  
    3. On the right side, use a press to remove the dust cover from the center driveshaft.

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      Fig. Fig. 16: Using a press, remove the dust cover from the center driveshaft on the left side



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      Fig. Fig. 17: Use a press to drive the old dust cover out of the right side center driveshaft

    4.  

  2.  
  3. On the right side, remove the snapring and press the bearing from the case.
    1. Next press the dust cover and remove the snapring with expanders.
    2.  
    3. Press the bearing from the shaft and remove the other snapring. Using a pin punch and hammer, remove the straight pin.
    4.  

  4.  
  5. On the No. 2 dust deflector, mount the outboard joint shaft in a soft jaw vise. Next, pry out the No. 2 dust deflector.
  6.  



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Fig. Fig. 18: Removing the no. 2 dust deflector on models with and without ABS

Be careful not to damage the ABS speed sensor.

To assemble:
  1. On the right side, assemble the center driveshaft by inserting the straight pin into the bearing case.
    1. Using a press, install a new bearing into the case.
    2.  
    3. Use a flatbladed tool, and install a new snapring.
    4.  
    5. Using a press and retaining devise, insert a new bearing into the case assembly to the center driveshaft.
    6.  
    7. Use a snapring expander and install the new snapring.
    8.  
    9. Press in the new dust cover. The clearance between the dust cover and bearing should be kept in the ranges in the illustration.

      Click image to see an enlarged view

      Fig. Fig. 19: Press the new No. 2 deflector and seat it properly



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      Fig. Fig. 20: When installing the dust cover, the clearance should be within the ranges as specified

    10.  

  2.  
  3. Install the dust cover as follows:
    1. On the left side, use a press and insert the new dust cover.
    2.  
    3. On the right side, using a steel plate and press, press in a new dust cover until the distance from the tip of the center driveshaft to the cover reaches the specification as shown.

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      Fig. Fig. 21: On the right side driveshaft, press the dust cover till the tip of the shaft reaches specifications

    4.  

  4.  
  5. Temporarily install boots and the damper. Before installing the outboard joint, wrap vinyl tape around the spline of the driveshaft to prevent damaging the boots and damper.
    1. Temporarily install the new outboard boot onto the driveshaft.
    2.  
    3. On the dynamic damper, temporarily install the damper to the driveshaft.
    4.  
    5. Temporarily install a new inboard joint to the driveshaft.

      Click image to see an enlarged view

      Fig. Fig. 22: Temporarily install the driveshaft boots on the inboards and outboard and dynamic damper

    6.  

  6.  
  7. Install the tripod joint as follows:
    1. Use a snapring expander and insert a new snapring.
    2.  
    3. Place the beveled side of the tripod joint axial spline toward the outboard joint.
    4.  
    5. Align the matchmarks placed before removal.
    6.  
    7. Using a brass bar and hammer, carefully tap the tripod joint to the driveshaft.Do not tap the roller.
    8.  
    9. Using snapring expanders, install a new snapring.

      Click image to see an enlarged view

      Fig. Fig. 23: Place the beveled side of the tripod axial spline toward the outboard joint ...



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      Fig. Fig. 24: ... then carefully tap the tripod joint on the driveshaft

    10.  

  8.  
  9. Install the boot to the outboard joint. Before assembling the boot, fill grease into the outboard joint and boot. Special grease (usually black) is supplied with the boot kits. Grease capacity is 4.2-4.6 oz (120-130 g).
  10.  
  11. Install the inboard joint tulip to the front driveshaft. Pack grease (usually yellow) into the boot and inboard joint tulip.
    1. Align the matchmarks placed before removal, then install the inboard joint tulip onto the driveshaft.
    2.  
    3. Attach the boot to the inboard joint tulip.

      Click image to see an enlarged view

      Fig. Fig. 25: Measure the driveshaft length at these points and make sure it reaches specifications prior to installation

    4.  

  12.  
  13. Assemble the boot clamps to both boots as follows:
    1. Be sure the boot is on the shaft groove.
    2.  
    3. Insure that the boot is not stretched or contracted when the driveshaft is standard length.The standard driveshaft length is as follows:

      Automatic left-22.516-22.910 inch (571.7-581.7mm)
       
      Automatic right-33.74-34.13 inch (857.0-867.0mm
       
      Manual left-22.34-22.73 inch (525.5-577.4mm)
       
      Manual right-33.56-33.95 inch (852.5-862.5mm)
       

    4.  
    5. Bend the band of the clamp and lock onto the boot.
    6.  

  14.  
  15. On the dynamic damper attach the clamp is on the shaft groove. Check the distance as shown in the illustration. Correct distance should be 7.677-8.071 inch (195.0-205.0mm).
    1. Using a screwdriver, tighten the band of the clamp and lock it.
    2.  

  16.  

7A-FE Engine

  1. Remove the driveshaft.
  2.  
  3. Remove the inboard joint boot clamps as follows:
    1. Using a flatbladed tool, unclasp the clamps.
    2.  
    3. Slide the inboard joint toward the outboard joint.
    4.  

  4.  
  5. Remove the inboard joint tulip as follows:
    1. Place matchmarks on the inboard joint tulip, tripod and driveshaft.
    2.  

  6.  

Do not punch the marks.

  1. Remove the inboard joint tulip from the driveshaft.
  2.  



Remove the tripod joint as follows:
 

  1. Using snapring expanders, remove the snapring.
  2.  
  3. Place a matchmark on the shaft and tripod.
  4.  

Do not place a punch on the mark.

  1. Using a brass bar and hammer, remove the tripod joint from the driveshaft. Do not tap the roller.
  2.  



Remove the inboard joint boot.
 
On the dynamic damper (right side), remove the clamp from the damper.
 

  1. Remove the dynamic damper.
  2.  



Remove the outboard joint boot, but do not disassemble the joint.
 
Separate the dust cover from the inboard joint tulip using a press. To assemble:
 

  1. Press a new dust cover onto the inboard joint tulip.
  2.  
  3. Temporarily install boots and the right damper. Before installing the outboard joint boot, wrap vinyl tape around the spline of the driveshaft to prevent damaging the boots and damper.
    1. Temporarily install a new outboard boot to the driveshaft.
    2.  
    3. On the right side, install the dynamic damper to the driveshaft.
    4.  
    5. Temporarily install the new inboard joint boot to the driveshaft.
    6.  

  4.  
  5. Install the tripod joint as follows:
    1. Place the beveled side of the tripod joint axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before removal.
    4.  
    5. Using a brass bar and hammer, tap the tripod joint to the driveshaft. Do not tap the roller.
    6.  
    7. Using snapring expanders, install a new snapring.
    8.  

  6.  
  7. install the boot to the outboard joint.
    1. Before assembling the boot, fill it with the grease (black), supplied with the kit, into the outboard joint and boot.
    2.  

  8.  
  9. Install the inboard joint tulip to the front driveshaft. Pack grease into the inboard joint tulip and boot. The grease should be yellow in color and supplied with the boot kit.
    1. Align the matchmarks place before removal.
    2.  
    3. Install the inboard joint tulip to the driveshaft.
    4.  
    5. Temporarily install the boot to the inboard joint tulip.
    6.  

  10.  
  11. Assemble the boot clamps on both boots as follows:
    1. Be sure the boots are on the shaft groove. Set the driveshaft length to the standard:

      1994-98 left-21.81-22.21 inch (554.2-564.2mm)
       
      1994 right-33.46-33.85 inch (849.9-859.9mm)
       
      1995-98 right-34.33-34.73 inch (872.25-882.2mm)
       

    2.  
    3. Using a screwdriver, bend the band and lock it.
    4.  

  12.  
  13. On the right side driveshaft, place the clamp on in the shaft groove. Check that the distance is within specifications. Distance should be 15.25-15.65 inch (387.5-397.5mm).
    1. Using a screwdriver, bend the band and lock it.
    2.  

  14.  

 
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