Toyota Prius 2002-06

Overhaul

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Click image to see an enlarged view

Fig. Exploded view of tripod joint and drive shaft assembly-Right side shown

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the drive shaft.
  4.  
  5. Remove the large seal retaining clamp from the inboard joint. Discard the clamp.
  6.  
  7. Remove the small seal retaining clamp from the inboard joint. Discard the clamp.
  8.  
  9. Separate the joint housing from the boot.
  10.  
  11. Remove grease from the inboard joint.
  12.  
  13. Put match marks on the inboard joint and outboard joint, but do not make the match marks with a punch and hammer.
  14.  
  15. Remove the inboard joint from the outboard joint.
  16.  
  17. Hold the outboard joint with vise with aluminum plates in between. Do not overtighten the vise.
  18.  
  19. Using a snap ring expander, remove the front drive inner shaft snap ring.
  20.  
  21. Put match marks on the tripod joint and outboard joint. Do not make match marks with a punch and hammer.
  22.  
  23. Using a brass bar and hammer, tap out the tripod joint but do not hit the roller position.
  24.  
  25. Remove the No. 2 inboard joint boot clamp, inboard joint boot and inboard joint boot clamp.
  26.  
  27. Remove the drive shaft damper setting clamp (right drive shaft) and remove the drive shaft damper from the right outboard joint.
  28.  
  29. Using a flat-head screwdriver, remove the No. 2 outboard joint boot clamp.
  30.  
  31. Using a flat-head screwdriver, remove the outboard joint boot clamp.
  32.  
  33. Remove the outboard joint boot from the outboard joint.
  34.  
  35. Remove grease from the outboard joint.
  36.  
  37. Using a flat-head screwdriver, remove the front drive shaft hole snap ring.
  38.  
  39. Using SST 09950-00020 and a press, press out the front drive shaft dust cover. Be careful not to drop the inboard joint.
  40.  

To install:

Click image to see an enlarged view

Fig. Staking the one touch clamp-Tripod joint



Click image to see an enlarged view

Fig. Locking the hook type clamp using needle-nose pliers-Tripod joint

  1. When installing new boot and damper clamps, observe the following:
    NOTE
    Do not scratch the boots. Do not deform the claw of the hook.



    When using a one touch clamp: After installing the new clamp, stake the clamp using a flat-head screwdriver.
     
    When using a hook type: Using needle-nose pliers, align the concave part and protrusion of the new clamp in order to lock it.
     

  2.  
  3. Using a press, install a new dust cover to the inboard joint shaft.
  4.  
  5. Install a new front drive shaft hole snap ring.
  6.  
  7. Wrap protective tape around the spline of the outboard joint.
  8.  
  9. Install a new No. 2 outboard joint boot clamp.
  10.  
  11. Install the outboard joint boot
  12.  
  13. Install a new outboard joint boot clamp.
  14.  
  15. Apply 4.9-5.3 oz. (125-135g) grease to the joint of the outboard joint and outboard joint boot.
    NOTE
    Do not apply grease in the groove.

  16.  
  17. Install the outboard joint boot into the outboard joint groove.
  18.  
  19. Hold the front drive shaft in a vise between 2 aluminum plates. Do not overtighten the vise.
  20.  
  21. Set SST 09521-24010 to the No. 2 outboard joint boot clamp and slightly tighten the SST bolt while pushing the outboard joint on.
  22.  
  23. Hold SST and tighten the SST bolt so that the clearance is within 0.031 in. (0.8mm) or less. Do not damage the outboard joint.
  24.  
  25. Remove SST.
  26.  
  27. Using SST 09240-00020, measure the clearance of the No. 2 outboard joint boot clamp. The clearance should measure within 0.031 in. (0.8mm) or less.
    NOTE
    If the clearance exceeds the maximum, retighten it.

  28.  
  29. Set SST 09521-24010 to the outboard joint boot clamp and slightly tighten the SST bolt while pushing the outboard joint on.
  30.  
  31. Hold SST and tighten the SST bolt so that the clearance is within 0.031 in. (0.8mm) or less. Do not damage the outboard joint.
  32.  
  33. Remove SST.
  34.  
  35. Using SST 09240-00020, measure the clearance of the outboard joint boot clamp. The clearance should measure within 0.031 in. (0.8mm) or less.
    NOTE
    If the clearance exceeds the maximum, retighten it.



    Click image to see an enlarged view

    Fig. Standard distance measurement for drive shaft damper (right drive shaft)-Tripod joint

  36.  
  37. Install the drive shaft damper to the right drive shaft outboard joint. The standard distance should measure 16.81+/-0.079 inches (427+/-2.0mm). Be sure to install in the correct direction.
  38.  
  39. Install a new drive shaft damper clamp.
  40.  
  41. Install a new inboard joint boot clamp
  42.  
  43. Install inboard joint boot
  44.  
  45. Install a new No. 2 inboard joint boot clamp
  46.  
  47. Hold the drive shaft in a vise between 2 aluminum plates. Do not overtighten the vise.
  48.  
  49. Remove the protective tape.
  50.  
  51. Align the match marks and install the tripod joint onto the outboard joint. Face the serration side of the tripod joint outward and install it to the outboard joint end.
  52.  
  53. Using a brass bar and hammer, drive the tripod joint in.
    CAUTION
    Do not hit the roller portion. Do not attach any foreign matter on the tripod joint.

  54.  
  55. Using a snap ring expander, install a new front drive inner shaft snap ring.
  56.  
  57. Apply 4.9-5.3 oz. (125-135g) grease in the joint of the inboard joint and outboard joint boot.
  58.  
  59. Align the match marks and install the inboard joint onto the outboard joint.
  60.  
  61. Install the inboard joint boot into the inboard joint and outboard joint grooves. Do not apply grease in the groove.
  62.  
  63. Install a new No. 2 front axle inboard joint boot clamp.
    NOTE
    Do not scratch the boots.

  64.  
  65. Install a new front axle inboard joint boot clamp.
    NOTE
    Do not scratch the boots.



    Click image to see an enlarged view

    Fig. Measuring the drive shaft dimension-Tripod joint

  66.  
  67. Check if the front drive shaft is within the following standard dimension:

    Left drive shaft: 22.216 inches (564.3mm)
     
    Right drive shaft: 33.319 inches (846.3mm)
     

  68.  
  69. Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction.
  70.  
  71. Check for cracks, damage or grease leaks on the joint boot.
    NOTE
    Always carry the drive shaft levelly.

  72.  
  73. Install the drive shaft.
  74.  

 
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