Toyota Celica, Corolla, ECHO & MR2 1999-05

Overhaul 2

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5S-FE, 1zz-FE And 2zz-GE Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Place matchmarks on the tri-pot and inboard joint tulip or center driveshaft. Do not punch the marks.



    Halfshaft
     
    On the inboard joint tulip, the boot clamps. Slide the inboard joint boot toward the outboard joint.
     



    Inboard joint tulip or center driveshaft from the driveshaft

    Click image to see an enlarged view

    Fig. Place matchmarks on the tri-pot and outboard joints

     

  4.  
  5. On the tri-pot, use snapring expander, temporarily, slide the snapring toward the outboard joint side.
    NOTE
    Place matchmarks on the driveshaft and tri-pot. Do not punch the marks.

  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not disassemble the outboard joint.



    Tri-pot from the driveshaft
     
    Snapring

    Click image to see an enlarged view

    Fig. With matchmarks on the tri-pot, tap the joint for the driveshaft

     
    Inboard joint boot
     
    On the right side with dynamic damper, the clamps from the damper and extract the unit
     
    Clamps from the outboard joint
     
    Boot from the outboard joint
     



    On the left side, the dust cover from the inboard joint tulip
     
    On the right side, the dust cover from the center driveshaft

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

     
    On the right side, the snapring and bearing from the case
     
    The dust cover and snapring
     
    The bearing from the shaft and the other snapring
     
    The straight pin
     
    The No. 2 dust deflector

    Click image to see an enlarged view

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

     

  8.  

To assemble:

  1. Install or connect the following:

    On the right side, assemble the center driveshaft by inserting the straight pin into the bearing case
     
    A new bearing into the case
     
    A new snapring
     
    A new bearing into the case assembly on the center driveshaft
     
    A new snapring
     
    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. Press the new No. 2 deflector and seat it properly



    Click image to see an enlarged view

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

     
    On the left side, use a press and insert the new dust cover
     
    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

    Click image to see an enlarged view

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

     

  2.  
  3. 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.
  4.  
  5. Install or connect the following:

    Temporarily, the new outboard boot onto the driveshaft
     
    On the dynamic damper, temporarily install the damper to the driveshaft.
     
    Temporarily, a new inboard joint to the driveshaft

    Click image to see an enlarged view

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

     

  6.  
  7. Install as follows:
    NOTE
    Do not tap the roller.



    A new snapring on the tri-pot joint
     
    Place the beveled side of the tri-pot joint axial spline toward the outboard joint. Align the matchmarks placed before removal
     
    The tri-pot joint to the driveshaft
     



    A new snapring
     
    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)
     
    Inboard joint tulip to the front driveshaft. Pack grease (usually yellow) into the boot and inboard joint tulip.
     
    Inboard joint tulip onto the driveshaft
     
    Boot to the inboard joint tulip

    Click image to see an enlarged view

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

     
    Boot clamps to both boots
     

  8.  

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)
 

  1. Bend the band of the clamp and lock onto the boot.
  2.  
  3. On the dynamic damper attach the clamp 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).
  4.  
  5. Using a screwdriver, tighten the band of the clamp and lock it.
  6.  

 
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