Toyota Prius 2002-06

Strut (MacPherson Strut) Assembly

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. On 2002-03 models, remove the rear seat.
  4.  
  5. On 2004-06 models, remove the following:

    Rear No. 2 floor board
     
    Rear deck floor box
     
    Rear deck trim cover
     
    Tonneau cover assembly
     
    Left rear seatback assembly
     
    Rear No. 1 floor board
     
    Left rear side seatback frame
     
    Rear No. 4 floor board
     
    Left deck floor box
     
    Left deck trim side panel assembly
     
    Battery carrier bracket
     

  6.  
  7. Remove the rear wheel(s).
  8.  
  9. Support the rear axle beam with a jack. Insert a wooden block between the jack and the rear axle beam to prevent damage.
  10.  
  11. Remove the 2 nuts from the rear strut assembly (upper side).
  12.  
  13. Remove the rear strut assembly (upper side) bolt from the under-side of the vehicle.
  14.  
  15. Remove the nut and spacer from the rear strut assembly (lower side).
  16.  
  17. Remove the rear strut assembly while slowly lowering the jack.
    NOTE
    Seat the jack so that no extra load is placed on the strut assembly on the opposite side of the vehicle.



    Click image to see an enlarged view

    Fig. Exploded view of the rear strut assembly and related components



    Click image to see an enlarged view

    Fig. Securing the piston rod of the shock absorber and loosening the nut.



    Click image to see an enlarged view

    Fig. Compressing the coil spring using a coil spring compressor.

  18.  
  19. Separate the coil spring from the strut assembly as follows:


    1. Use a 6mm socket hexagon wrench to secure the piston rod of the shock absorber and loosen the nut.
      NOTE
      Do not remove the nut. Sufficiently insert the hexagon wrench.

    2.  
    3. Attach SST 09727-30021 to the coil spring so that the upper and lower hooks of the installed area are as wide as possible.
    4.  
    5. Compress the coil spring until it moves freely.
      NOTE
      Do not use an impact wrench. It will damage SST.

    6.  
    7. Remove the nut.
    8.  
    9. Remove the No. 1 cushion washer, No. 1 cushion, rear spring front bracket, rear suspension support, rear coil spring insulator upper and rear No. 1 spring bumper. The shock absorber can be replaced without removing the No. 1 cushion and rear suspension support from the rear spring front bracket.
    10.  
    11. Release SST and remove it from the coil spring after removing the coil spring from the strut.
    12.  

  20.  

To install:

  1. Install the coil spring by assembling the strut assembly as follows:


    1. Using SST 09727-30021, compress the coil spring.
      NOTE
      Do not use an impact wrench. It will damage SST.

    2.  
    3. Fit the coil spring end into the recessed part of the strut assembly lower seat.
    4.  
    5. Fit the rear coil spring insulator upper to the rear spring front bracket.
    6.  
    7. Install the rear No. 1 spring bumper, rear suspension support, rear spring front bracket, No. 1 cushion and No. 1 cushion washer.
      NOTE
      Install the rear spring front bracket so that it is aligned with the strut lower bush, as shown in the illustration. Install the No. 1 cushion washer with the protruding portion facing down.

    8.  
    9. Use a 6mm socket hexagon wrench to fix the strut piston rod and tighten the nut to 41 ft. lbs. (56 Nm).
      NOTE
      Sufficiently insert the hexagon wrench.

    10.  
    11. Release SST and remove it from the coil spring.
      NOTE
      Do not use an impact wrench. It will damage SST. Remove SST while confirming the direction of the rear spring front bracket.

    12.  

  2.  
  3. Install the rear strut assembly to the rear axle beam. Place the spacer and temporarily tighten the nut.
  4.  
  5. Install the rear strut assembly (upper side) to the vehicle by slowly raising the rear axle beam on a jack. Insert a wooden block between the jack and the rear axle beam to prevent damage.
  6.  
  7. Do not raise the rear axle beam more than necessary. Securely insert the rear spring front bracket stud bolt into the vehicle.
  8.  
  9. Tighten the bolt and 2 nuts of the rear strut assembly (upper side) to 59 ft. lbs. (80 Nm).
  10.  
  11. Install the rear wheel.
  12.  
  13. After lowering the vehicle, bounce the vehicle up and down to stabilize the rear suspension.
  14.  
  15. Fully tighten the rear strut assembly (lower side) installation nut to 59 ft. lbs. (80 Nm). Ensure the vehicle is lowered to the ground.
  16.  
  17. On 2002-03 models, install the rear seat.
  18.  
  19. On 2004-06 models, install the following:

    Battery carrier bracket
     
    Left deck trim side panel assembly
     
    Left deck floor box
     
    Rear No. 4 floor board
     
    Left rear side seatback frame
     
    Rear No. 1 floor board
     
    Left rear seatback assembly
     
    Tonneau cover assembly
     
    Rear deck trim cover
     
    Rear deck floor box
     
    Rear No. 2 floor board
     

  20.  
  21. Inspect the rear wheel alignment.
  22.  

 
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