Drive/Propeller Shaft: Service and Repair

REAR PROPELLER SHAFT ASSEMBLY (for 2WD)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REMOVAL
1. REMOVE NO. 2 ENGINE UNDER COVER
2. REMOVE FRONT FLOOR BRACE CENTER
3. REMOVE REAR FLOOR NO. 1 PANEL BRACE (for 3UZ-FE)
4. REMOVE HEATED OXYGEN SENSOR (for Sensor 2)
(a) for 2GR-FSE:
Disconnect the sensor from the front exhaust pipe.
(b) for 3UZ-FE:
Disconnect the sensor from the front exhaust pipe.
5. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE)
6. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 3UZ-FE)
7. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR
(a) for 2GR-FSE:
Remove the 4 nuts, grommet and front floor No. 1 heat insulator.
(b) for 3UZ-FE:
Remove the 4 nuts and front floor No. 1 heat insulator.

8. REMOVE AIR GUIDE PLATE OUTSIDE RH
(a) Remove the 4 nuts and air guide plate outside RH.

9. REMOVE REAR PROPELLER SHAFT ASSEMBLY
(a) Using SST, loosen the adjusting nut until it can be turned by hand.
SST 09922-10010

HINT:
Use 2 same type of SST.

(b) Put matchmarks on the transmission companion flange, flexible coupling and intermediate shaft.
(c) Remove the 3 bolts, 3 washers and 3 nuts.

NOTICE:
The propeller shaft and flexible coupling should not be separated.

(d) Put matchmarks on the differential companion flange, flexible coupling and propeller shaft.
(e) Remove the 3 bolts, 3 washers and 3 nuts.

NOTICE:
The propeller shaft and flexible coupling should not be separated.

(f) Remove the 2 bolts and 2 center support bearing washers.

HINT:
Some vehicles are not equipped with the center support bearing washers.

(g) 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.

HINT:
If it is difficult to separate the flange from the flexible coupling, pry it using a screwdriver.

(h) Pull the propeller shaft outward from the vehicle's rear.

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

INSTALLATION

1. INSTALL REAR PROPELLER SHAFT ASSEMBLY
(a) Apply grease to the flexible coupling centering bushings.
Grease:
Molybdenum disulphide lithium base, NLGI No. 2

(b) Align the matchmarks on the transmission companion flange and flexible coupling.
(c) Install and tighten the 6 bolts, washers and nuts.
Torque: 79 N*m (805 kgf*cm, 58 ft.*lbf)

NOTICE:
Be careful not to damage the flexible coupling centering bushing.

HINT:
The bolts should be installed from the propeller shaft side.

(d) Align the matchmarks on the differential companion flange and flexible coupling.
(e) Install and torque the 6 bolts, washers and nuts.
Torque: 79 N*m (805 kgf*cm, 58 ft.*lbf)

NOTICE:
Be careful not to damage the flexible coupling centering bushing.

HINT:
The bolts should be installed from the propeller shaft side.

(f) Temporarily install the 2 center support bearing set bolts with the adjusting washers.

HINT:
Use the adjusting washers which were removed.

2. FULLY TIGHTEN CENTER SUPPORT BEARING ASSEMBLY NO. 1
(a) Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) respectively as shown in illustration.

(b) Check that the center line of the bracket is at right angles to the shaft axial direction.

(d) Using SST, tighten the adjusting nut.
SST 09922-10010
Torque:
69 N*m (700 kgf*cm, 51 ft.*lbf)
51 N*m (520 kgf*cm, 38 ft.*lbf) for use with SST

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

3. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 3UZ-FE)
(a) Stabilize the propeller shaft and differential.
(1) Turn the propeller shaft several times by hand to stabilize the center support bearing.
(b) Check the No. 2 and No. 3 joint angles.
(1) Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
SST 09370-50010

HINT:
The SST should be set directly underneath the shaft.

(2) Using SST, measure the installation angle of the differential.

SST 09370-50010

HINT:
Measure the installation angle by placing the SST in the positions, shown in the illustration.

(3) Calculate the No. 2 joint angle.
No. 2 joint angle:
A - B = 0°11' to 1°11'
A: Intermediate shaft installation angle
B: Propeller shaft installation angle
(4) Calculate the No. 3 joint angle.
No. 3 joint angle:
B - C = 0°53' to 1°53'
B: Propeller shaft installation angle
C: Differential installation angle

HINT:
If the measured angle is not within the specified range, adjust it with the center support bearing washers.

(c) Adjust the No. 2 joint angle.
(1) Select the center support bearing washers for adjustment.

Adjustment washer:

NOTICE:
The 2 washers should be of the same thickness.

4. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2GR-FSE)
(a) Stabilize the propeller shaft and differential.
(1) Turn the propeller shaft several times by hand to stabilize the center support bearing.
(b) Check the No. 2 and No. 3 joint angles.
(1) Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
SST 09370-50010

HINT:
The SST should be set directly underneath the shaft.

(2) Using SST, measure the installation angle of the differential.

SST 09370-50010

HINT:
Measure the installation angle by placing the SST in the positions, shown in the illustration.

(3) Calculate the No. 2 joint angle.
No. 2 joint angle:
A - B = 0° 11' to 1°11'
A: Intermediate shaft installation angle
B: Propeller shaft installation angle
(4) Calculate the No. 3 joint angle.
No. 3 joint angle:
B - C = 0°53' to 1°53'
B: Propeller shaft installation angle
C: Differential installation angle

HINT:
If the measured angle is not within the specified range, adjust it with the center support bearing washers.

(c) Adjust the No. 2 joint angle.
(1) Select the center support bearing washers for adjustment.

Adjustment washer:

NOTICE:
The 2 washers should be of the same thickness.

5. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
(a) for 2GR-FSE:
Install the front No. 1 floor heat insulator with the 4 nuts and grommet.
Torque: 5.4 N*m (55 kgf*cm, 48 ft.*lbf) for nut
(b) for 3UZ-FE:
Install the front No. 1 floor heat insulator with the 4 nuts.
Torque: 5.4 N*m (55 kgf*cm, 48 ft.*lbf)

6. INSTALL AIR GUIDE PLATE OUTSIDE RH
(a) Install the air guide plate outside RH with the 4 nuts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 3UZ-FE)
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE)
9. INSTALL HEATED OXYGEN SENSOR (for Sensor 2)
(a) for 2GR-FSE:
Install the sensor.
(b) for 3UZ-FE:
Install the sensor.
10. INSTALL REAR FLOOR NO. 1 PANEL BRACE (for 3UZ-FE)
11. INSTALL FRONT FLOOR BRACE CENTER
12. INSTALL NO. 2 ENGINE UNDER COVER
13. CHECK FOR EXHAUST GAS LEAKS