Drive/Propeller Shaft: Service and Repair

REMOVAL
1. REMOVE EXHAUST PIPE ASSEMBLY
a. Disconnect the heated oxygen sensor.
b. Remove the 2 bolts and front floor center brace.
c. Disconnect the exhaust pipe assembly from the O-rings.
d. 2JZ-GE Engine: Remove the 3 bolts, nuts and 2 gaskets from the exhaust manifold.
e. 1UZ-FE Engine:Remove the 4 bolts, nuts and 2 gaskets from the exhaust manifold.
f. Remove the exhaust pipe assembly.
2. REMOVE 2 HEAT INSULATORS
a. Remove the 6 bolts and heat insulator.
b. Remove the 4 bolts and heat insulator.
3. REMOVE PROPELLER SHAFT





a. Using SST, loosen the adjusting nut until it can be turned by hand.
SST 09922-10010

HINT: Use 2 of the same type of SST.





b. Place matchmarks on the transmission companion flange and flexible coupling.
c. Remove the 3 bolts installed from the transmission side.

NOTICE: The bolts installed from the propeller shaft side should not be removed.





d. Place matchmarks on the differential companion flange and flexible coupling.
e. Remove the 3 bolts installed from the differential side.

NOTICE: The bolts installed from the propeller shaft side should not be removed.





f. Separate the flexible couplings from the transmission and differential.

HINT: If the flexible coupling cannot be easily separated by hand, insert a screwdriver into the bolt hole of the flexible coupling as shown in the illustration, then pry the coupling out.

NOTICE: Do not bring the screwdriver blade in direct contact with the flexible coupling's rubber portion.





g. Remove the 2 center support bearing set bolts and adjusting washers.

HINT: Some vehicles are not equipped with an adjusting washer.

NOTICE: When removing the set bolts, support the center support bearing by hand so that the transmission and intermediate shaft, and propeller shaft and differential, remain in a straight line.

Maximum joint angle: 5°





h. Push the rear propeller shaft straight forward to compress the propeller shaft and pull out the propeller shaft from the centering pin of the differential.

NOTICE: Press the propeller shaft straight ahead to keep the transmission and intermediate shaft aligned straight.

i. Pull the propeller shaft out toward the vehicle's rear.

NOTICE: The intermediate shaft and propeller shaft should not be separated.

INSPECTION





1. INSPECT CENTER SUPPORT BEARING
a. Check for cracks in or damage to the cushion.
b. Check if the bearing turns smoothly.
If the center support bearing is damaged, worn or does not turn smoothly, replace it.





2. INSPECT FLEXIBLE COUPLINGS
Check for cracks in or damage to the front and rear flexible couplings.
If the flexible coupling is damaged, replace the propeller shaft assembly.
3. INSPECT FLEXIBLE COUPLING CENTERING BUSHING
Check for damage to the bushing.
If the bushing is damaged, replace the propeller shaft assembly.

REPLACEMENT





1. SEPARATE INTERMEDIATE SHAFT AND PROPELLER SHAFT
a. Place matchmarks on the intermediate shaft and propeller shaft.
b. Separate the intermediate shaft and propeller shaft.
c. Remove the dust boot from the propeller shaft.

HINT: If the dust boot is reused, remove it after wrapping vinyl tape around the spline, so it will not be damaged.





2. REMOVE CENTER SUPPORT BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the center support bearing and dust deflector.
SST 09950-00020





3. INSPECT INTERMEDIATE SHAFT AND PROPELLER SHAFT RUNOUT
Using a dial indicator, check the runout of the shafts.
Maximum runout: 0.8 mm (0.031 inch)
If the runout exceeds the maximum, replace the propeller shaft assembly.





4. INSPECT SPIDER BEARING
a. Check if the spider bearing rotates smoothly.
b. Check if there is any play in the spider bearing.
If necessary, replace the propeller shaft.
5. INSTALL CENTER SUPPORT BEARING

NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation.





a. Using SST and a press, install the center support bearing.
SST 0933G-50010





b. Using SST and a press, insert a new dust deflector until it almost touches the rubber of the center support bearing.
SST 09608-00071, 09608-06041





c. Using SST and a press, install a new dust deflector.
SST 09330-50010
d. Using a snap ring expander, install a new snap ring.
6. ASSEMBLE INTERMEDIATE SHAFT AND PROPELLER SHAFT





a. Install the dust boot.

NOTICE: Assemble after wrapping vinyl tape around the spline so it will not damage the boot.

b. Apply grease to the spline.
Grease: Molybdenum disulphide lithium base, NLGI No.2





c. Align the matchmarks and assemble the intermediate shaft and propeller shaft.





d. Cover the adjusting nut with the dust boot.

NOTICE: The directions of the intermediate shaft companion flange and the propeller shaft companion flange should differ by 180°.

e. Tighten the adjusting nut fully by hand.

INSTALLATION
1. INSTALL PROPELLER SHAFT





a. Apply grease to the flexible coupling centering bushings.
Grease: Molybdenum disulphide lithium base, NLGI No.2





b. Install the propeller shaft from the vehicle's rear and connect the transmission and differential.

NOTICE: Support the center support bearing by hand so that the transmission and intermediate shaft, and propeller shaft and differential, remain in a straight line.

c. Temporarily install the 2 center support bearing set bolts with the adjusting washers.

HINT: Use the adjusting washers which were removed.





d. Align the matchmarks and connect the propeller shaft to the transmission/differential.

e. Install and torque the 3 bolts, washers and nuts.

NOTICE: The bolts should be installed from the propeller shaft side.
Torque: 79 Nm (805 kgf-cm, 58 ft. lbs.)





f. If using a new propeller shaft (w/ Phasemarks): Install the propeller shaft phasemarks and differential/ transmission phasemarks so that their respective alignment phasemarks; match.
If the propeller shaft phasemarks and differential/transmission phasemarks do not align, install the propeller shaft and differential alignment phasemarks as close together as possible.
g. If using a new propeller shaft (w/o Phasemarks): Install the propeller shaft.





h. Torque the 2 center support bearing set bolts.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)

HINT: Adjust the center support bearing to keep the intervals as shown with the vehicle in the unladen condition.

Under the same condition, check if the center line of the center support bearing is at right angles to the shaft axial direction.





i. Using SST, tighten the adjusting nut.
SST 09922-10010
Torque: 50 Nm (515 kgf-cm, 37 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 34.5 cm (13.6 inch).

2. INSPECT JOINT ANGLE. Refer to Universal Joint, Drive/Propeller Shaft; Testing and Inspection.

NOTICE: The joint angle should by all means be checked when the propeller shaft is removed and installed.

3. INSTALL 2 HEAT INSULATORS
a. Install the heat insulator and torque the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
b. Install the heat insulator and torque the 6 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. INSTALL EXHAUST PIPE ASSEMBLY
a. Connect the exhaust pipe assembly to the O-rings.
b. 2JZ-GE Engine: Install the 3 bolts, nuts and 2 gaskets to the exhaust manifold. Torque the bolts.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
c. 1UZ-FE Engine: Install the 4 bolts, nuts and 2 gaskets to the exhaust manifold. Torque the bolts.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
d. Install the front floor center brace and torque the 2 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
e. Connect the heated oxygen sensor.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)

HINT:
- Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
- After installing oxygen sensor, check that the sensor wire should not twist. If it is twisted, remove the oxygen sensor and reinstall it.