Toyota Tacoma 2002-06

Halfshafts

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the differential oil from the differential.
  4.  
  5. If not equipped with a free-wheeling hub, disconnect the halfshaft from the steering knuckle, as follows:

    Grease cap
     
    Cotter pin and lockcap, from the halfshaft
     
    Locknut from the halfshaft, while having an assistant apply the brakes
     

  6.  
  7. If equipped with free-wheeling hub, remove the free wheel hub, as follows:

    Set the control handle to FREE
     
    Cover bolts and pull off the cover
     
    Center bolt with washer
     
    Mounting nuts and washer to the hub body
     
    Cone washer, using a brass bar and hammer to tap on the bolt heads
     
    Free wheel hub body and gasket
     
    Snapring from the end of the halfshaft, using a snapring expander

    Click image to see an enlarged view

    Fig. Free wheeling hub assembly and related components-2001-2004

     

  8.  
  9. Remove or disconnect the following:
    NOTE
    If it is difficult to remove the halfshaft from the steering knuckle, use a rubber hammer and tap the halfshaft from the steering knuckle.



    Halfshaft from the differential, using a brass bar and hammer
     
    Cotter pin and nut, from the lower ball joint
     
    Lower control arm from the lower ball joint
     
    Halfshaft
     



    Snapring from the inboard shaft
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Push the steering knuckle inwards and at the same time, push the halfshaft into the differential with the snapring opening facing downward. Be sure the halfshaft is fully installed to the differential by checking that it cannot be pulled out by hand.



    New snapring to the inboard shaft
     
    Halfshaft to the steering knuckle
     



    Lower control arm to the lower ball joint. Tighten the nut to 112 ft. lbs. (152 Nm).
     
    New cotter pin
     

  2.  
  3. If equipped with a free wheeling hub, install the hub, as follows:

    Spacer
     
    Snapring to the halfshaft, using a snapring expander
     
    New gasket on the front axle hub
     
    Fee wheeling hub body, with the 6 cone washers and nuts. Tighten the 6 nuts to 23 ft. lbs. (31 Nm).
     
    Bolt with the washer. Tighten the bolt to 13 ft. lbs. (18 Nm).
     
    Apply multi purpose grease to the inner hub splines
     
    Set the control handle and clutch to the FREE position
     
    New gasket on the cover
     
    Cover to the hub body, with the follower pawl tabs aligned with the non-toothed portions of the hub body.
     
    Tighten the cover bolts to 84 inch lbs. (10 Nm).
     

  4.  
  5. If equipped without a free wheeling hub, install the halfshaft to the steering knuckle, as follows:

    Locknut to the halfshaft. Tighten the locknut to 174 ft. lbs. (235 Nm).
     
    Lockcap and cotter pin to the halfshaft
     
    Grease cap
     
    Wheels
     

  6.  
  7. Fill the differential with gear oil.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-4WD 2001-2004



    Click image to see an enlarged view

    Fig. Halfshaft and related components-4WD 2005-2006

  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely. Remove the tire and wheel assembly.
  6.  
  7. Drain the differential.
  8.  
  9. Remove the bolt and separate the front speed sensor. Disengage the two clamps. Remove the bolt and separate the speed sensor wire harness from the steering knuckle.
  10.  
  11. Remove the cotter pin and nut. Using tool SST09628-62011 or equivalent, separate the tie rod end from the steering knuckle.
  12.  
  13. Using a suitable tool and hammer, remove the front axle hub grease cap. Remove the cotter pin and adjusting cap. Remove the front axle hub nut.
  14.  
  15. Remove the two bolts and separate the front lower ball joint attachment front from the steering knuckle.
  16.  
  17. Using tool SST09520-01010, and SST09520-24010 remove the halfshaft. Be careful not to damage the oil seal.
  18.  

To install:

  1. Coat the spline of the inboard joint shaft with clean ATF.
  2.  
  3. Align the shaft splines and install the halfshaft.
    NOTE
    Set the snapring with the opening side facing downward. Be careful not to damage the oil seal.

  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Tighten the hub nut to 173 ft. lbs.
  8.  
  9. Be sure to fill the differential with the proper type and grade lubricant.
  10.  
  11. Check and correct leaks, as required.
  12.  
  13. Check and adjust the alignment, as required.
  14.  

 
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