boot LEXUS ES300 2005 User Guide

F47192
Non-reusable partSupply Parts:
Front Axle Outboard
Joint Boot RH
No.2 Clamp

Front Drive Outboard
Joint Shaft Assy RHFront Axle Outboard Joint
Boot RH Clamp
Front Drive Shaft
Damper RH Clamp
Front Axle Inboard
Joint Boot RH Clamp
Front Drive Shaft
Dust Cover RH Front Drive Shaft
Dust CoverFront Drive Shaft Hole
Snap Ring RH
Front Drive Inboard
Joint Assy RH
Front Drive Inner Shaft Inner
RH Shaft Snap Ring Front Drive
Shaft Bearing
Front Axle Inboard
Joint Boot
Front Axle Inboard
Joint Boot RH No.2 Clamp













Front Drive Shaft
Dust Cover LH Front Drive Inboard
Joint Assy LH








Front Drive Shaft LH
Hole Snap Ring


Front Drive Shaft
Damper RH
Outboard Joint Boot
LH:
Front Drive Inboard
Joint Assy RH




- DRIVE SHAFT / PROPELLER SHAFTDRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)30-5
2408 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

C92142
SST
HoldTurn
F40142
D27403
C83850
SST
C66549
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-9
2412 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
6. DISCONNECT TIE ROD ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end from the steering
knuckle.
SST 09628-6201 1
7. DISCONNECT FRONT SUSPENSION ARM
SUB-ASSY LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and disconnect the front sus-
pension arm sub-assy lower No.1 LH from the lower ball
joint.
8. DISCONNECT FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the drive shaft from the
axle hub.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
9. REMOVE FRONT DRIVE SHAFT ASSY LH
(a) Using SST, remove the front drive shaft assy LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:

Be careful not to damage the transaxle case oil seal,
inboard joint boot and drive shaft dust cover.

Be careful not to drop the drive shaft assy.
10. REMOVE FRONT DRIVE SHAFT ASSY RH
(a) Using pliers, remove the drive shaft bearing bracket hole
snap ring.
(b) Remove the bolt and front drive shaft assy RH from the
drive shaft bearing bracket.

C92143
SST
C91598
C67412
F07391
30-10
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2413 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
11. FIX FRONT AXLE ASSY LH
SST 09608-16042 (09608-02021, 09608-02041)
NOTICE:
The hub bearing could be damaged if it is subjected to the
vehicle's full weight, such as when moving the vehicle with
the drive shaft removed.
Therefore, if it is absolutely necessary to place the vehicle
weight on the hub bearing, first support it with SST.
12. INSPECT FRONT DRIVE SHAFT ASSY LH
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no remarkable play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
13. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, remove the front axle inboard
joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.
(b) Claw Engagement type
(1) Using pliers, remove the front axle inboard joint
boot LH clamp and front axle inboard joint boot LH
No.2 clamp, as shown in the illustration.
14. DISCONNECT FR AXLE INBOARD JOINT BOOT
(a) Separate the inboard joint boot from the inboard joint assy.

C91600
Matchmarks
C67414F45046
N00194
Matchmarks
C57543
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-1 1
2414 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. REMOVE FRONT DRIVE INBOARD JOINT ASSY LH
(a) Put matchmarks on the inboard joint assy and outboard
joint shaft.
NOTICE:
Do not use a punch for the marks.
(b) Remove the inboard joint assy from the outboard joint
shaft.
(c) Using a snap ring expander, remove the front drive inner
shaft inner RH shaft snap ring.
(d) Put matchmarks on the outboard joint shaft and tripod
joint.
NOTICE:
Do not use a punch for the marks.
(e) Using a brass bar and hammer, remove the tripod joint
from the outboard joint shaft.
NOTICE:
Do not tap the roller.
16. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Using a screwdriver, remove the front drive shaft damper LH clamp.
(b) Remove the front drive shaft damper LH.
17. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
(a) Using a screwdriver, remove the front axle outboard joint boot LH clamp and front axle outboard joint
boot LH No.2 clamp.
18. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft.
(b) Remove the old grease from the outboard joint.
19. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Using a screwdriver, remove the hole snap ring.

W01994
Vinyl Tape
R10425
SST
R10426
F40646
225.4
2.0 mm
(8.87
0.079 in.) 30-14
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2417 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new front drive shaft LH hole snap ring.
29. INSTALL OUTBOARD JOINT BOOT
HINT:
Before installing the boots, wrap the spline of the drive shaft
with vinyl tape to prevent the boots from being damaged.
(a) Hold the drive shaft lightly in a soft vise.
(b) Temporarily install a new outboard joint boot with 2 new
clamps to the drive shaft.
(c) Pack the outboard joint shaft and boot with grease.
Grease capacity:
205 - 215 g (7.2 - 7.6 oz.)
30. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Hold the drive shaft lightly in a soft vise.
(b) Install the 2 outboard joint boot clamps onto the boot.
(c) Place SST onto the outboard joint large boot clamp.
SST 09521-24010
(d) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(e) Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm (0.032 in.) or less
(f) Employ the same manner to the outboard joint small boot
clamp.
31. INSTALL FRONT DRIVE SHAFT DAMPER LH
(a) Install the drive shaft damper LH to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Distance: 225.4
2.0 mm (8.87
0.079 in.)
(d) Install a new front drive shaft damper LH clamp to the front
drive shaft damper LH.

C67417
C67414F45046
F40222
Matchmarks
C83397
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-15
2418 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Temporarily install a new inboard joint boot with 2 new
clamps to the drive shaft.
(b) Place the beveled side of the tripod joint axial spline to-
ward the outboard joint shaft.
(c) Align the matchmarks.
(d) Using a brass bar and hammer, tap in the tripod joint to the
outboard joint shaft.
NOTICE:

Do not tap the roller.

Be sure to install the tripod joint assy in the correct
direction.
(e) Using a snap ring expander, install a new shaft snap ring.
(f) Pack the outboard joint shaft and boot with grease.
Grease capacity: 175 to 185 g (6.25 to 6.61 oz.)
(g) Aligning the matchmarks, install the inboard joint assy to
the outboard joint shaft assy.
33. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy.
34. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, install the front axle inboard
joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.

F07391
C91598
R00764
C83851
30-16
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2419 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Claw Engagement type
(1) Using pliers, install the front axle inboard joint boot
LH clamp and front axle inboard joint boot LH No.2
clamp, as shown in the illustration.
35. INSPECT FRONT DRIVE SHAFT
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no remarkable play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
(e) Make sure that the 2 boots are on the shaft groove.
(f) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length: mm (in.)
LH576.9
2.0 (22.713
0.079)
RH896.4
2.0 (35.291
0.079)
36. INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Install a new front drive shaft LH hole snap ring.
(b) Coat the spline of the inboard joint shaft assy with ATF.
(c) Align the shaft splines and install the drive shaft assy with
a brass bar and hammer.
NOTICE:

Set the snap ring with the opening side facing down-
ward.

Be careful not to damage the oil seal, boot and dust
cover.

Move the drive shaft assy while keeping it level.

C66548
F40142
C83022
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-17
2420 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37. INSTALL FRONT DRIVE SHAFT ASSY RH
(a) Using a screwdriver, install a new bearing bracket hole
snap ring.
NOTICE:
Do not damage the oil seal and boot.
(b) Install the bolt.
Torque: 32 NVm (330 kgfVcm, 24 ftVlbf)
38. INSTALL FRONT AXLE ASSY LH
(a) Install the front drive shaft assy LH to the front axle assy LH.
NOTICE:

Be careful not to damage the outboard joint boot.

Be careful not to damage the speed sensor rotor.
39. INSTALL FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Install the lower ball joint to the front suspension arm sub-
assy lower with the bolt and nuts.
Torque: 75 NVm (765 kgfVcm, 55 ftVlbf)
40. INSTALL TIE ROD ASSY LH
(a) Install the tie rod end to the steering knuckle with the nut.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
41. INSTALL SPEED SENSOR FRONT LH
(a) Install the flexible hose and the speed sensor to the shock
absorber with the bolt and set the clip of sensor on
knuckle.
Torque: 19 NVm (192 kgfVcm, 14 ftVlbf)
NOTICE:

Be careful not to damage the speed sensor.

Do not twist the sensor wire when installing the speed
sensor.

300M6-02
C91612
C83023
F40153
SST
- DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB-ASSY LH (From July, 2003)
30-19
2422 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
REPLACEMENT
HINT:

Replace the RH side using the same procedures as for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT AXLE HUB LH NUT (SEE PAGE 30-8)
SST 09930-00010
3. DISCONNECT SPEED SENSOR FRONT LH (SEE PAGE 30-8)
4. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the front disc brake cali-
per assy LH from the steering knuckle LH.
NOTICE:
Use a string or other device to keep the brake caliper from
hanging down by the flexible hose.
5. REMOVE FRONT DISC
6. SEPARATE TIE ROD ASSY LH (SEE PAGE 30-8)
SST 09628-6201 1
7. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-8)
8. REMOVE FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the front drive shaft
assy LH from the front axle hub sub-assy LH.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
(b) Remove the 2 bolts, nuts and steering knuckle with the
axle hub.
9. REMOVE LOWER BALL JOINT ASSY FRONT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint assy front LH.
SST 09628-6201 1

C83852F45465
C97690F45054
C83023
30-22
- DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB-ASSY LH (From July, 2003)
2425 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. INSTALL FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, install a new front axle hub LH hole
snap ring.
19. INSTALL FRONT WHEEL BEARING DUST
DEFLECTOR NO.1 LH
(a) Using SST and a hammer, install the bearing dust deflec-
tor No.1 LH.
SST 09316- 60011 (09316- 00011, 09316- 00031),
09608-32010
HINT:
Aligh the hole for the speed sensor in the bearing dust deflector
No.1 LH with the steering knuckle.
20. INSTALL LOWER BALL JOINT ASSY FRONT LH
(a) Install the lower ball joint assy front LH and tighten the nut.
Torque: 123 NVm (1,254 kgfVcm, 90 ftVlbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
21. INSTALL FRONT AXLE ASSY LH
(a) Install the front axle assy LH with the 2 bolts and nuts to
the shock absorber assy front LH.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:

Only when reusing the bolts and nuts, apply the small
amount of engine oil to the screw part of the nuts.

Do not excessively push out the front axle assy LH.

Be careful not to damage the outboard joint boot.

Be careful not to damage the speed sensor rotor.
22. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-8)
23. INSTALL TIE ROD ASSY LH (SEE PAGE 30-8)
24. INSTALL FRONT DISC