Toyota Tacoma 2002-06

CV-Joints

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Overhaul



Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle.
  4.  
  5. Remove the large clamp from the inboard joint.
  6.  
  7. Remove the small clamp, using side cutters, from the inboard joint.
  8.  
  9. Slide the inboard joint boot toward the outboard joint.
  10.  
  11. Matchmark the inboard joint to the halfshaft.
  12.  
  13. Remove the inboard joint housing from the halfshaft.
  14.  
  15. Remove the snapring from the end of the halfshaft.
  16.  
  17. Matchmark the halfshaft to the tri-pot joint.
  18.  
  19. Remove the tri-pot from the halfshaft, using a brass bar and a hammer.
    WARNING
    Do not tap on the tri-pot joint.

  20.  
  21. Remove the inboard and outboard boots from the halfshaft.
    WARNING
    Do not disassemble the outboard joint.

  22.  

To assemble:

  1. Wrap vinyl tape around the halfshaft splines to prevent damaging the boots.
  2.  
  3. Install the outboard and inboard boots to the halfshaft with the small end clamps.
  4.  
  5. Assemble the tri-pot joint to the halfshaft with the beveled side facing the outboard joint and align the matchmarks.
  6.  
  7. Install the tri-pot joint, using a brass bar and a hammer.
    WARNING
    Do not tap on the roller.

  8.  
  9. Install the snapring.
  10.  
  11. Lubricate the outboard joint with 1 / 2 of the grease supplied with the kit.
  12.  
  13. Assemble the boot to the outboard joint
  14.  
  15. Assemble the inboard joint housing to the halfshaft by aligning the matchmarks.
  16.  
  17. Temporarily install the boot onto the tri-pot housing.
  18.  
  19. Make sure the boots are positioned in the shaft grooves.
  20.  
  21. On 2001-2004 vehicles, with the halfshaft positioned at the standard length of 17.094-17.252 in. (434.2-438.2mm), make sure that the boots are not stretched or contracted.
  22.  
  23. On 2005-2006 vehicles, with the halfshaft positioned at the standard length of 19.071-19.226 in. (484.4-488.4mm), make sure that the boots are not stretched or contracted.
  24.  
  25. Install a new inboard joint clamp.
  26.  
  27. Crimp the large clamp so that the crimp clearance is 0.039-0.059 in. (1.0-1.5mm) on 2001-2004 vehicles and 0.039-0.197 in. (1.0-5.0mm) on 2005-2006 vehicles.
  28.  
  29. Install the halfshaft.
  30.  

Outer Joint

The outboard joint is replaced with halfshaft; no overhaul is possible or necessary.

 
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