Toyota Sienna 2000-06

Overhaul

Print

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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:

    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     

  16.  


WARNING
Be careful not to punch the roller.



Inboard joint boot
 
Outboard joint boot clamps and boot
 


WARNING
Do not disassemble the outboard joint.



Click image to see an enlarged view

Fig. Place matchmarks on the inboard joint outer race and shaft



Click image to see an enlarged view

Fig. Use snapring expanders to extract the snapring from the end



Click image to see an enlarged view

Fig. With a brass bar and hammer, tap the joint hard enough to remove

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
  2.  


NOTE
Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  1. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  2.  
  3. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  4.  
  5. Install a new snapring.
  6.  
  7. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 4.2-4.6 oz. (120-130 g).
  8.  


NOTE
Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  1. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 7.6-7.9 oz. (215-225 g).
  2.  
  3. Install or connect the following:

    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  4.  


NOTE
Be sure the boot is on the shaft groove and inboard joint outer race groove.

  1. Set the length of the shaft to 19.146-19.546 in. (486.4-496.41mm).
  2.  
  3. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft
     

  4.  


    Click image to see an enlarged view

    Fig. Set the length of the halfshaft at the points shown here


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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:

    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     

  16.  


WARNING
Be careful not to punch the roller.



Inboard joint boot
 
Outboard joint boot clamps and boot
 


WARNING
Do not disassemble the outboard joint.

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
  2.  


NOTE
Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  1. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  2.  
  3. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  4.  
  5. Install a new snapring.
  6.  
  7. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 3.7-4.4 oz. (105-125 g).
  8.  


NOTE
Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  1. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 4.2-4.6 oz. (120-130 g) for the joint side; 2.1-2.3 oz. (52.5-57.5 g) for the boot side.
  2.  
  3. Install or connect the following:

    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  4.  


NOTE
Be sure the boot is on the shaft groove and inboard joint outer race groove.

  1. Set the length of the shaft (inboard end to outboard joint flange) to 23.071 in. (586mm) +/- 2mm for left side; 34.709 in. (881.6mm) +/- 2mm for the right side..
  2.  
  3. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft
     

  4.  

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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:

    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     

  16.  


WARNING
Be careful not to punch the roller.



Inboard joint boot
 
Outboard joint boot clamps and boot
 


WARNING
Do not disassemble the outboard joint.

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
  2.  


NOTE
Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  1. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  2.  
  3. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  4.  
  5. Install a new snapring.
  6.  
  7. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 1.2-1.9 oz. (35-55 g) for 2wd; 1.4-2.1 oz. (40-60 g) for 4wd.
  8.  


NOTE
Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  1. Install the damper on the left shaft. The distance from the outer end flange of the damper to the outer end flange of the outer joint should be 8.7 inches (221mm) +/- 2mm.
  2.  
  3. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 3.4-4.1 oz. (95-115 g) for 2wd; 3.9-4.6 oz. (110-130 g) for 4wd.
  4.  
  5. Install or connect the following:

    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  6.  


NOTE
Be sure the boot is on the shaft groove and inboard joint outer race groove.

  1. Set the length of the shaft (inboard end to outboard joint flange) to 25.134 in. (638.4mm) +/- 5mm for 2wd left side; 37.678 in. (957mm) +/- 5mm for the 2wd right side; 21.797 in. (553.6mm) for 4wd left side; 39.065 in. (992.2mm) for 4wd right side.
  2.  
  3. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:
    WARNING
    Be careful not to punch the roller.


    WARNING
    Do not disassemble the outboard joint.



    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     



    Inboard joint boot
     
    Outboard joint boot clamps and boot
     



    Click image to see an enlarged view

    Fig. Place matchmarks on the inboard joint outer race and shaft



    Click image to see an enlarged view

    Fig. Use snapring expanders to extract the snapring from the end



    Click image to see an enlarged view

    Fig. With a brass bar and hammer, tap the joint hard enough to remove

  16.  

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
    NOTE
    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  2.  
  3. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  4.  
  5. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  6.  
  7. Install a new snapring.
  8.  
  9. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 4.2-4.6 oz. (120-130 g).
    NOTE
    Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  10.  
  11. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 7.6-7.9 oz. (215-225 g).
  12.  
  13. Install or connect the following:
    NOTE
    Be sure the boot is on the shaft groove and inboard joint outer race groove.



    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  14.  
  15. Set the length of the shaft to 19.146-19.546 in. (486.4-496.41mm).
  16.  
  17. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft

    Click image to see an enlarged view

    Fig. Set the length of the halfshaft at the points shown here

     

  18.  

Rear Halfshaft



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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:
    WARNING
    Be careful not to punch the roller.


    WARNING
    Do not disassemble the outboard joint.



    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     



    Inboard joint boot
     
    Outboard joint boot clamps and boot
     



    Click image to see an enlarged view

    Fig. Place matchmarks on the inboard joint outer race and shaft



    Click image to see an enlarged view

    Fig. Use snapring expanders to extract the snapring from the end



    Click image to see an enlarged view

    Fig. With a brass bar and hammer, tap the joint hard enough to remove

  16.  

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
    NOTE
    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  2.  
  3. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  4.  
  5. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  6.  
  7. Install a new snapring.
  8.  
  9. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 4.2-4.6 oz. (120-130 g).
    NOTE
    Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  10.  
  11. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 7.6-7.9 oz. (215-225 g).
  12.  
  13. Install or connect the following:
    NOTE
    Be sure the boot is on the shaft groove and inboard joint outer race groove.



    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  14.  
  15. Set the length of the shaft to 19.146-19.546 in. (486.4-496.41mm).
  16.  
  17. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft

    Click image to see an enlarged view

    Fig. Set the length of the halfshaft at the points shown here

     

  18.  

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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:
    WARNING
    Be careful not to punch the roller.


    WARNING
    Do not disassemble the outboard joint.



    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     



    Inboard joint boot
     
    Outboard joint boot clamps and boot
     

  16.  

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
    NOTE
    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  2.  
  3. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  4.  
  5. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  6.  
  7. Install a new snapring.
  8.  
  9. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 3.7-4.4 oz. (105-125 g).
    NOTE
    Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  10.  
  11. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 4.2-4.6 oz. (120-130 g) for the joint side; 2.1-2.3 oz. (52.5-57.5 g) for the boot side.
  12.  
  13. Install or connect the following:
    NOTE
    Be sure the boot is on the shaft groove and inboard joint outer race groove.



    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  14.  
  15. Set the length of the shaft (inboard end to outboard joint flange) to 23.071 in. (586mm) +/- 2mm for left side; 34.709 in. (881.6mm) +/- 2mm for the right side.
  16.  
  17. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft
     

  18.  

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

    Halfshaft
     
    Inboard joint boot clamps
     

  4.  
  5. Clean the joint before removing the boot.
  6.  
  7. Slide the inboard joint boot toward the outboard joint.
  8.  
  9. Place matchmarks on the inboard joint tulip and the shaft.
  10.  
  11. Remove the inboard joint tulip from the driveshaft.
  12.  
  13. Clamp the halfshaft in a vise.
  14.  
  15. Remove or disconnect the following:
    WARNING
    Be careful not to punch the roller.


    WARNING
    Do not disassemble the outboard joint.



    Snapring and disassemble the tri-pot joint
     
    Tri-pot joint from the halfshaft, using a brass bar and hammer
     



    Inboard joint boot
     
    Outboard joint boot clamps and boot
     

  16.  

To assemble:

  1. Temporarily, install the new boot and new boot clamps to the outboard joint.
    NOTE
    Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

  2.  
  3. Temporarily, install the new boot and the new boot clamps for the inboard joint to the halfshaft.
  4.  
  5. Assemble the tri-pot joint, as follows:
    1. Place the beveled side of the tri-pot axial spline toward the outboard joint.
    2.  
    3. Align the matchmarks placed before disassembly.
    4.  
    5. Using a brass bar and hammer, tap in the tri-pot joint onto the driveshaft. Do not punch the roller.
    6.  

  6.  
  7. Install a new snapring.
  8.  
  9. Before assembling the boot to the outboard joint, pack the boot with grease. The capacity is 1.2-1.9 oz. (35-55 g) for 2wd; 1.4-2.1 oz. (40-60 g) for 4wd.
    NOTE
    Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

  10.  
  11. Install the damper on the left shaft. The distance from the outer end flange of the damper to the outer end flange of the outer joint should be 8.7 inches (221mm) +/- 2mm.
  12.  
  13. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. The capacity is 3.4-4.1 oz. (95-115 g) for 2wd; 3.9-4.6 oz. (110-130 g) for 4wd.
  14.  
  15. Install or connect the following:
    NOTE
    Be sure the boot is on the shaft groove and inboard joint outer race groove.



    Outer race, by aligning the matchmarks on the shaft
     
    Inboard joint boot, without twisting it
     

  16.  
  17. Set the length of the shaft (inboard end to outboard joint flange) to 25.134 in. (638.4mm) +/- 5mm for 2wd left side; 37.678 in. (957mm) +/- 5mm for the 2wd right side; 21.797 in. (553.6mm) for 4wd left side; 39.065 in. (992.2mm) for 4wd right side.
  18.  
  19. Install or connect the following:

    Both clamps to the inboard joint boot; bend back the band and lock it
     
    Halfshaft
     

  20.  

 
label.common.footer.alt.autozoneLogo