Toyota Previa 1991-1997 Repair Information

Front Driveshaft and U-Joints

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REMOVAL & INSTALLATION



See Figures 1 through 10



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Fig. Fig. 1: View of the common 4WD front driveshaft



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Fig. Fig. 2: A grease fitting is used to insert grease into the U-joint

Only 4WD models are equipped with a front driveshaft.



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Fig. Fig. 3: Common view of the 4WD front and rear driveshaft assemblies

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Place matchmarks on the flanges of the driveshaft and the differential carrier.
  6.  



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Fig. Fig. 4: Place matchmarks on the flange and carrier

  1. Remove the four nuts, bolts and washers and disconnect the front driveshaft from the differential housing.
  2.  



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Fig. Fig. 5: Two wrenches are needed to remove the four bolts, and sometimes an air wrench



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Fig. Fig. 6: Once the four bolts are removed, pull the front portion of the driveshaft down and allow it to rest

  1. Remove the center support bearing by removing the two bolts.
  2.  



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Fig. Fig. 7: Unbolt the center support bearing ...



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Fig. Fig. 8: ... and using two hands pull the unit up and out of the ...



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Fig. Fig. 9: ... .transmission yoke

  1. Pull out the driveshaft yoke from the transfer case.
  2.  
  3. Remove the driveshaft from the vehicle.
  4.  
  5. Install a transfer case output shaft plug into the transfer case to prevent fluid loss.
  6.  

To install:
  1. Remove the transfer case output shaft plug.
  2.  
  3. Slide the driveshaft into the transfer case.
  4.  
  5. Connect the center support bearing by installing the two bolts. Make sure the bearing is installed with the drain holes facing down. Tighten the bolts to 27 ft. lbs. (36 Nm).
  6.  
  7. Align the matchmarks on the driveshaft and differential flanges.
  8.  



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Fig. Fig. 10: Align the drive shaft match marks and secure all bolts

  1. Install the four washers, bolts and nuts to the driveshaft and differential carrier. Tighten the bolts to 31 ft. lbs. (42 Nm).
  2.  
  3. Adjust the center support bearing to keep the intervals, as shown with the vehicle unladen condition. At the same condition, check that the center line of the axle direction. Adjust the bearing if necessary. Tighten the bolts to 27 ft. lbs. (36 Nm).
  4.  
  5. Lower the vehicle and connect the negative battery cable to the battery.
  6.  

U-JOINT REPLACEMENT



See Figures 11 through 19

  1. Place matchmarks on the shaft and yoke.
  2.  



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Fig. Fig. 11: Place matchmarks on the shaft and yoke

  1. Using a brass bar and hammer, slightly tap in the bearing and outer race.
    1. Using 2 screwdrivers, carefully remove the 4 snaprings from the grooves as shown.
    2.  

  2.  



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Fig. Fig. 12: Removing the snaprings from the U-joint grooves

  1. Using a puller, push out the bearing from the flange. Sufficiently raise the part indicated as A so that it does not come into contact with the bearing.
    1. Clamp the bearing outer race in a vise, then tap off the flange with a hammer. Remove the bearing on the opposite side in the same procedure.
    2.  
    3. Install the 2 removed bearing outer races to the spider. With the special tool, push out the bearing from the yoke.
    4.  
    5. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. remove the bearing on the opposite side in the same procedure.
    6.  

  2.  



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Fig. Fig. 13: Separating the bearing from the flange using a puller and vise



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Fig. Fig. 14: Extract the bearing from the spider

  1. Select the bearing according to whether or not there is a drill mark in the yoke selection.

    Yoke with a drill mark-red color bearing
     
    Yoke with no drill mark-no color mark bearing
     

  2.  



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Fig. Fig. 15: Select the bearing according to the cap color

To assemble:
  1. Apply MP grease to the new bearing and spider. Be careful not to apply too much grease.
    1. Align the matchmarks on the yoke and shaft. fit the spider into the yoke. Using a press, install the new bearing on the spider.
    2.  
    3. Adjust both bearing so that the snapring grooves are at maximum and equal widths.
    4.  

  2.  



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Fig. Fig. 16: Always apply MP grease (but not too much) when installing a new bearings to the spider gear



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Fig. Fig. 17: Adjust the snaprings so that they are at maximum and equal widths

  1. Install the 2 snaprings of equal thickness which will allow 0-0.0020 inch (0-0.05mm) axial play.
  2.  

Do not reuse the old snaprings. check the charts for sizes.

  1. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snapring.
  2.  



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Fig. Fig. 18: TMC made snapring chart



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Fig. Fig. 19: DANA made snapring chart

  1. Make sure the spider bearing moves smoothly. Inspect the spider bearing axial play, 0.0020 inch (0.05mm).
  2.  

Only install new spider bearings on the flange side in the procedure described.

 
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