Get SUSPENSION AND AXLE Guide for Toyota Avensis 4 Door First Generation (1997-2003)

SUSPENSION AND AXLE

FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . .

SA–1

FRONT SHOCK ABSORBER . . . . . . . . . . . . . . SA–13

REFER TO FOLLOWING REPAIR MANUALS:

ManualName

Pub. No.

RM599E

AVENSIS/CORONA Chassis and Body Repair Manual

Supplement(Aug.,1999)

RM698E

NOTE: The above pages contain only the points which differ

from the above listed manuals.

SA–1

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

SA109–03

COMPONENTS

1AZ–FSE

Center Bearing Bracket

1ZZ–FE, 1AZ–FSE

RH Drive Shaft

64(650, 47)

1ZZ–FE

Center Bearing Bracket

3ZZ–FE

64(650, 47)

RH Drive Shaft

z Snap Ring

1ZZ–FE, 3ZZ–FE

LH Drive Shaft

1AZ–FSE

LH Drive Shaft

z Cotter Pin

49 (500, 36)

Tie Rod End

8.0(82,71in.·lbf)

ABS Speed Sensor

z Cotter Pin

Lower Suspension Arm

216(2,200,159)

Lock Cap

127(1,300, 94)

N·m (kgf·cm, ft·lbf) : Specifiedtorque

z Non–reusable part

F12734

AVENSIS/CORONA SUP (RM781E)

SA–2

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

Outboard Joint Shaft

z Boot

Dynamic Damper

Dynamic Damper Clamp

z

z Boot Clamp

z Boot

z Snap Ring

Tripod

Straight Pin

1ZZ–FE

z Snap Ring

3ZZ–FE

z Snap Ring

RH Inboard Joint Shaft

Bearing Case

z Snap Ring

z Dust Cover

Bearing

Tripod

LH

RH Inboard Joint Shaft

1AZ–FSE

z Dust Cover

Straight

z Dust Cover

Inboard Joint Shaft

Bearing Case

z Non–reusable part

F02723

AVENSIS/CORONA SUP (RM781E)

SA–3

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

SA10A–03

REMOVAL

NOTICE:

S

The hub bearing could be damaged if it is subjected

to the vehicle weight, such as when moving the ve-

hicle with the drive shaft removed.

SST

Therefore, if it is absolutely necessary to place the ve-

hicle weight on the hub bearing, first support it with

the SST.

SST 09608–16042 (09608–02021, 09608–02041)

w/ ABS:

After disconnecting the drive shaft from the axle hub,

work carefully so as not to damage the ABS speed

sensor rotor serration on the drive shaft.

REMOVE FRONT WHEEL

FA1535

S

1.

Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

DRAIN OUT GEAR OIL (M/T) OR ATF (A/T)

w/ ABS:

2.

3.

REMOVE BOLT AND ABS SPEED SENSOR

Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

4.

REMOVE DRIVE SHAFT LOCK NUT

(a) Remove the cotter pin and lock cap.

(b) While applying the brakes, remove the nut.

Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)

5.

DISCONNECT TIE ROD END FROM STEERING

KNUCKLE (See Pub. No. RM599E on page SA 36)

DISCONNECT LOWER BALL JOINT FROM LOWER

SUSPENSION ARM (See Pub. No. RM599E on page

SA–36)

6.

F02688

F02721

F02724

7.

DISCONNECT DRIVE SHAFT FROM AXLE HUB

(a) Using a plastic hammer, disconnect the drive shaft from

the axle hub.

NOTICE:

Cover the drive shaft boot and ABS speed sensor rotor with

cloth to protect it from being damaged.

(b) Push the front axle hub toward the outside of the vehicle

to separate the drive shaft from the axle hub.

8.

RH drive shaft of 1ZZ–FE and 1AZ–FSE engine:

REMOVE DRIVE SHAFT

Remove the 2 bolts and pull out the drive shaft together with the

center bearing bracket.

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

HINT:

At the time of installation, coat gear oil to the inboard joint shaft

and differential case sliding surface.

AVENSIS/CORONA SUP (RM781E)

SA–4

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

9.

3ZZ–FE engine:

REMOVE DRIVE SHAFT

SST

(a) Using SST, remove the drive shaft.

SST 09520–01010, 09520–24010 (09520–32040)

(b) Using a screwdriver, remove the snap ring.

HINT:

At the time of installation, please refer to the following items.

S

Apply gear oil to the inboard joint shaft and differential

case sliding surface.

Before installing the drive shaft, set the snap ring with its

opening side facing downward.

Whether inboard joint shaft is in contact with pinion shaft

or not can be known from the sound or feeling.

After installation, check that there is 2 – 3 mm (0.08 – 0.12

in.) of play in the axial direction.

After installation, check that the drive shaft cannot be re-

moved by hand.

SST

F02725

AVENSIS/CORONA SUP (RM781E)

SA–5

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

SA10B–03

DISASSEMBLY

1.

CHECK DRIVE SHAFT

(a) Check to see that there is no obvious play in the outboard

joint.

(b) Check to see that the inboard joint slides smoothly in the

thrust direction.

(c) Check to see that there is no obvious play in the radial

direction of the inboard joint.

(d) Check the boots for damage.

N00191

2.

REMOVE INBOARD AND OUTBOARD JOINT BOOT

CLAMPS

Using a side cutter, cut the 4 boots clamps and remove them.

3.

REMOVE INBOARD JOINT SHAFT

Matchmarks

(a) Place matchmarks on the tripod, inboard and outboard

joint shafts.

NOTICE:

Do not punch the marks.

(b) Remove the inboard joint shaft from the outboard joint

shaft.

4.

REMOVE TRIPOD

(a) Using a snap ring expander, remove the snap ring.

(b) Using a snap ring expander, temporarily slide the snap

ring toward the outboard joint shaft side.

FA1615

(c) Place matchmarks on the outboard joint shaft and tripod.

NOTICE:

Do not punch the marks.

Matchmarks

(d) Using a brass bar and hammer, remove the tripod from

the drive shaft.

NOTICE:

Do not tap the roller.

(e) Using a snap ring expander, remove the snap ring.

5.

REMOVE INBOARD JOINT BOOT

SA1443

AVENSIS/CORONA SUP (RM781E)

SA–6

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

6.

REMOVE DYNAMIC DAMPER

(a) Using a side cutter, cut the dynamic damper clamp and re-

move it.

(b) Remove the dynamic damper.

7.

REMOVE OUTBOARD JOINT BOOT

NOTICE:

Do not disassemble the outboard joint.

8.

REMOVE DUST COVER

(a) RH drive shaft of 3ZZ–FE engine and LH drive shaft:

Using SST and a press, remove the dust cover from the

inboard joint shaft.

SST

SST 09950–00020

R09716

SA1446

Z18045

Z18046

(b) RH drive shaft of 1ZZ–FE and 1AZ–FSE engine:

Using a press, remove the dust cover from the inboard

joint shaft.

9.

RH drive shaft of 1ZZ–FE and 1AZ–FSE engine:

DISASSEMBLE INBOARD JOINT SHAFT

(a) Using a screwdriver, remove the snap ring.

(b) Using a press, remove the bearing case.

(c) Using a pin punch and hammer, remove the straight pin

from the bearing case.

(d) Using SST and a press, remove the dust cover.

SST 09950–00020

(e) Using a snap ring expander, remove the snap ring.

SST

AVENSIS/CORONA SUP (RM781E)

SA–7

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

(f)

Using a press, remove the bearing.

SA1451

AVENSIS/CORONA SUP (RM781E)

SA–8

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

SA10C–03

REASSEMBLY

1.

RH drive shaft of 1ZZ–FE and 1AZ–FSE engine:

ASSEMBLE INBOARD JOINT SHAFT

(a) Using a pin punch and hammer, install the straight pin into

the bearing case.

SA1453

W00880

SA1456

FA1971

(b) Using SST and a press, install a new bearing into the

bearing case.

SST 09950–60010 (09951–00640), 09950–70010

(09951–07150)

(c) Using a screwdriver, install a new snap ring.

SST

(d) Using SST and a press, install the bearing case assembly

to the inboard joint shaft.

SST 09710–30021 (09710–03141)

(e) Using a snap ring expander, install a new snap ring.

SST

(f)

Using SST, an extension bar and press, install a new dust

cover.

SST 09506–35010

SST

2.

INSTALL NEW DUST COVER

83 – 84 mm

(3.27 – 3.31 in.)

(a) RH drive shaft of 3ZZ–FE engine:

Using a steel plate and press, install a new dust cover until

the distance from the tip of center drive shaft to the dust

cover reaches the specification, as shown in the illustra-

tion.

SA1459

AVENSIS/CORONA SUP (RM781E)

SA–9

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

(b) RH drive shaft of 1ZZ–FE and 1AZ–FSE engine:

Using a steel plate and press, install a new dust cover until

the distance from the tip of center drive shaft to the dust

cover reaches the specification, as shown in the illustra-

tion.

A:

A

1ZZ–FE Engine M/T:

86 – 87 mm (3.39 – 3.43 in.)

1ZZ–FE Engine A/T:

F02277

83 – 84 mm (3.27 – 3.31 in.)

1AZ–FSE Engine:

87 – 88 mm (3.43 – 3.46 in.)

3.

TEMPORARILY INSTALL NEW OUTBOARD AND IN-

BOARD JOINT BOOTS WITH NEW BOOT CLAMPS

Vinyl Tape

HINT:

S

Before installing the boots (and dynamic damper), wrap

the spline of the outboard joint shaft with vinyl tape to pre-

vent them from being damaged.

S

Before installing the boots (and dynamic damper), place

new clamps to each of them and then install boots to drive

shaft.

W01994

(a) Temporarily install a new outboard joint boot with 2

clamps to the drive shaft.

(b) w/ Dynamic damper:

Temporarily install the dynamic damper with clamp to the

drive shaft.

(c) Temporarily install a new inboard joint boot with 2 clamps

to the drive shaft.

4.

INSTALL TRIPOD

(a) Using a snap ring expander, install a new snap ring.

(b) Place the beveled side of the tripod axial spline toward the

outboard joint.

(c) Align the matchmarks placed before removal.

(d) Using a brass bar and hammer, tap in the tripod to the

drive shaft.

NOTICE:

Do not tap the roller.

(e) Using a snap ring expander, install a new snap ring.

AVENSIS/CORONA SUP (RM781E)

SA–10

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

5.

INSTALL BOOT TO OUTBOARD JOINT

Before assembling the boot, pack the outboard joint shaft and

boot with grease in the boot kit.

Grease capacity: (Color = Black)

85 – 105 g (3.00 – 3.70 oz.)

6.

INSTALL INBOARD JOINT SHAFT TO OUTBOARD

JOINT SHAFT

(a) Pack the inboard joint shaft and boot with grease in the

boot kit.

Grease capacity: (Color = Yellow)

1ZZ–FE engine:

140 – 150 g (4.94 – 5.29 oz.)

3ZZ–FE engine:

125.5 – 135.5 g (4.43 – 4.78 oz.)

1AZ–FSE engine:

120 – 130 g (4.23 – 4.59 oz.)

(b) Align the matchmarks placed before removal.

(c) Install the inboard joint shaft to the outboard joint shaft.

(d) Temporarily install the boot to the inboard joint shaft.

7.

ASSEMBLE BOOT CLAMPS TO BOTH BOOTS

RH Drive shaft of 1ZZ–FE and 1AZ–FSE

(a) Make sure that the 2 boots are on the shaft groove.

(b) Make sure that the 2 boots are not stretched or contracted

when the drive shaft is at standard length.

Drive shaft standard length:

3ZZ–FE

1ZZ–FE engine M/T:

RH

943.60 ± 1.0 mm (37.15 ± 0.039 in.)

657.90 ± 0.8 mm (25.90 ± 0.032 in.)

LH

F02726

1ZZ–FE engine A/T:

RH

943.60 ± 1.0 mm (37.15 ± 0.039 in.)

653.20 ± 0.8 mm (25.72 ± 0.032 in.)

LH

3ZZ–FE engine:

RH

944.70 ± 0.8 mm (37.19 ± 0.032 in.)

655.70 ± 0.8 mm (25.82 ± 0.032 in.)

LH

1AZ–FSE engine:

RH

LH

922.65 ± 1.0 mm (36.32 ± 0.039 in.)

650.85 ± 0.7 mm (25.62 ± 0.028 in.)

(c) Secure the clamps onto the boot.

(d) Place SST onto the clamps.

SST 09521–24010

(e) Tighten the SST so that the clamps are pinched.

NOTICE:

Do not overtighten the SST.

(f)

Using SST, adjust the clearance of the clamps.

SST 09240–00020

Clearance: 1.9 mm (0.075 in.) or less

SST

R10353

AVENSIS/CORONA SUP (RM781E)

SA–11

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

8.

RH drive shaft of 3ZZ–FE engine:

ASSEMBLE DAMPER CLAMP

(a) Make sure that the dynamic damper is on the shaft

groove.

(b) Set the distance, as described below.

Distance: 432.1 ± 2.0 mm (17.012 ± 0.079 in.)

(c) Secure the clamp onto the damper.

R03119

(d) Place SST onto the clamps.

SST 09521–24010

(e) Tighten the SST so that the clamps are pinched.

NOTICE:

Do not overtighten the SST.

(f)

Using SST, adjust the clearance of the clamps.

SST 09240–00020

Clearance: 1.9 mm (0.075 in.) or less

CHECK DRIVE SHAFT (See page SA–5)

SST

9.

F02727

AVENSIS/CORONA SUP (RM781E)

SA–12

SUSPENSION AND AXLE

–

FRONT DRIVE SHAFT

SA02Z–04

INSTALLATION

Installation is in the reverse order of removal (See page SA–3).

HINT:

After installation, check the ABS speed sensor signal and front wheel alignment (See Pub. No. RM599E on

page SA–4).

AVENSIS/CORONA SUP (RM781E)

SA–13

SUSPENSION AND AXLE

–

FRONT SHOCK ABSORBER

SA10J–06

COMPONENTS

Cap

z 47 (475, 34)

80(820, 59)

Suspension Support

Dust Seal

Spring Upper Seat

Upper Insulator

Coil Spring

Shock Absorber

with Coil Spring

Spring Bumper

Lower Insulator

ABS Speed Sensor

Wire Harness

5.5(55,48in.·lbf)

255(2,600,188)

29(300, 22)

Shock Absorber

Flexible Hose

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

F12735

AVENSIS/CORONA SUP (RM781E)

SA–14

SUSPENSION AND AXLE

–

FRONT SHOCK ABSORBER

SA10K–03

REMOVAL

1.

REMOVE FRONT WHEEL

Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

2.

DISCONNECT ABS SPEED SENSOR WIRE HARNESS

CLAMPS FROM SHOCK ABSORBER

Remove the bolt and disconnect the ABS speed sensor wire

harness clamps.

Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)

3.

DISCONNECT FLEXIBLE HOSE

Remove the bolt and disconnect the flexible hose from the

shock absorber bracket.

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

4.

REMOVE SHOCK ABSORBER WITH COIL SPRING

(a) Loosen the 2 nuts on the lower side of shock absorber.

Torque: 255 N·m (2,600 kgf·cm, 188 ft·lbf)

HINT:

Do not remove the 2 bolts.

(b) Remove the 3 nuts.

Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

(c) Remove the 2 nuts and bolts on the lower side of shock

absorber.

HINT:

At the time of installation, coat the nut’s thread with engine oil.

(d) Remove the shock absorber with coil spring.

F12736

AVENSIS/CORONA SUP (RM781E)

SA–15

SUSPENSION AND AXLE

–

FRONT SHOCK ABSORBER

SA10P–05

INSTALLATION

Installation is in the reverse order of removal (See page SA–14).

HINT:

After installation, check the front wheel alignment (See Pub. No. RM599E on page SA–4).

AVENSIS/CORONA SUP (RM781E)

SUSPENSION AND AXLE for Your Toyota Avensis 4 Door First Generation (1997-2003)

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