Toyota Celica, Corolla, ECHO & MR2 1999-05

Halfshafts

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CV-Joints



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

    Inboard joint boot clips
     
    Inboard joint tulip from the driveshaft
     
    Snapring
     
    Using a brass rod and hammer, the tri-pot joint off the driveshaft without hitting the joint roller
     
    Inboard joint boot
     
    Clamp and driveshaft damper
     
    Clamps and the outboard drive boot. DO NOT disassemble the outboard joint.
     

  4.  

To assemble:

  1. Install or connect the following:
    NOTE
    Before installing the boot, wrap the spline end of the shaft with masking tape to prevent damage to the boot.


    NOTE
    The inboard boot and clamp are larger than those of the outboard boot.






    Driveshaft damper with a new clamp
     
    Temporarily, the inboard boot with new clamp to the drive joint
     



    The tri-pot onto the driveshaft with a brass rod and hammer without hitting the joint roller
     
    The snapring
     

  2.  
  3. Pack the outboard tulip joint and the outboard boot with about 0.26-0.33 lbs. ounces of grease that was supplied with the boot kit.
  4.  
  5. Install or connect the following:

    Boot onto the outboard joint
     
    Inboard tulip joint and boot with 1 / 2 lb. of grease that was supplied with the boot kit
     
    Inboard tulip joint onto the driveshaft
     
    Boot onto the driveshaft
     

  6.  
  7. Before checking the standard length, bend the band and lock it. Make sure that the boot is not stretched or squashed when the driveshaft is at standard length. Standard driveshaft length: LH: 540.2 mm (21.268 in.); RH: 857.4 mm (33.756 in.)
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The outboard joint cannot be disassembled.

  2.  
  3. Remove or disconnect the following:
    NOTE
    Paint-mark the inboard joint shaft and tri-pot joint.



    The 2 inboard boot clamps and slide the clamp down the shaft
     



    Inboard joint shaft from the outboard joint shaft
     
    Snapring from the tri-pot joint, and paint-mark the tri-pot and outboard joint shaft
     
    Tri-pot joint from the shaft with a brass hammer
     
    Inboard boot and clamps
     
    Damper (right shaft)
     
    Outboard joint boot
     
    Dust cover from the inboard joint shaft (press)
     

  4.  

To assemble:

  1. Install or connect the following:
    NOTE
    Toyota recommends different types of grease for the joints. OEM replacement boot kits have the grease color coded. The outboard grease is black; the inboard, yellow.



    Dust cover
     
    Boots and clamps, loosely
     
    Damper (right shaft)
     
    Tri-pot joint, beveled edge toward the outboard shaft. Align the matchmarks and drive it into place
     
    New snapring
     
    Outboard boot. The grease capacity is 5.5-6 ounces (155-170 g).
     
    Inboard shaft to outboard shaft
     
    Inboard boot. The grease capacity is 4.4-4.8 ounces (125-135 g).
     

  2.  
  3. Check the boots at standard halfshaft length. The right shaft should be 32.02 inches +/- 0.197 in. (813.3mm +/- 5mm); the left shaft should be 22.61 inches +/- 0.197 in. (574.3mm +/- 5mm).
  4.  
  5. Check the position of the damper before installing the clamp. Distance from the outer face of the damper to the outer face of the outer joint should be 16.835 inches +/- 0.079 in. (427.6mm +/- 2mm).
  6.  

5S-FE, 1zz-FE & 2zz-Ge Engines
  1. Before servicing the vehicle, refer to the Precautions 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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