TOYOTA AVENSIS 1999 Supplement

F02725
SST
SST
SA–4
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
(b) LH drive shaft:
(1) Using SST, remove the drive shaft.
SST 09520–01010, 09520–24010 (09520–32040)
(2) Using a screwdriver, remove the snap ring.

SA10B–02
N00191
FA1615
Matchmarks
SA1443
Matchmarks
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–5
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.
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
(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) Place matchmarks on the outboard joint shaft and tripod.
NOTICE:
Do not punch the marks.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD JOINT BOOT
6. RH drive shaft:
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.

R09716
SST
SA1446
Z18045
Z18046
SST
SA1451
SA–6
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
8. REMOVE DUST COVER
(a) LH drive shaft:
Using SST and a press, remove the dust cover from the
inboard joint shaft.
SST 09950–00020
(b) RH drive shaft:
Using a press, remove the dust cover from the inboard
joint shaft.
9. RH drive shaft:
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.
(f) Using a press, remove the bearing.

SA10C–02
SA1453
W00880
SST
SA1456
SST
FA1971
SST
SA1459
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–7
REASSEMBLY
1. RH drive shaft:
ASSEMBLE INBOARD JOINT SHAFT
(a) Using a pin punch and hammer, install the straight pin into
the bearing case.
(b) Using SST and a press, install a new bearing into the
bearing case.
SST 09950–60020 (09951–00720), 09950–70010
(09951–07150)
(c) Using a screwdriver, install a new snap ring.
(d) Using SST and a press, install the bearing case assembly
to the inboard joint shaft.
SST 09710–30021 (09710–03121)
(e) Using a snap ring expander, install a new snap ring.
(f) Using SST, an extension bar and press, install a new dust
cover.
SST 09316–60011 (09316–00041)
2. INSTALL NEW DUST COVER
(a) LH drive shaft:
Using a press, install a new dust cover.

F02277
89.3 – 90.3 mm
(3.52 – 3.56 in.)
W01994
Vinyl Tape
SA–8
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
(b) RH drive shaft:
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.
3. TEMPORARILY INSTALL NEW OUTBOARD AND IN-
BOARD JOINT BOOTS WITH NEW BOOT CLAMPS
HINT:
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.
Before installing the boots (and dynamic damper), place
new clamps to each of them and then install boots to drive
shaft.
(a) Temporarily install a new outboard joint boot with 2
clamps to the drive shaft.
(b) 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) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
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)
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.

F08950
RH Drive Shaft
LH Drive shaft
R10353
SST
F09070
F02727
SST
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–9
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(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:
RH852.15  2.0 mm (33.55  0.079 in.)
LH548.15  2.0 mm (21.58  0.079 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
8. RH drive shaft:
ASSEMBLE DAMPER CLAMP
(a) Make sure that the dynamic damper is on the shaft
groove.
(b) Set the distance, as described below.
Distance: 267
2.0 mm (10.512
0.079 in.)
(c) Secure the clamp onto the damper.
(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
9. CHECK DRIVE SHAFT (See page SA–5)

SA02Z–03
SA–10
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
INSTALLATION
1. LH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(c) Set the snap ring with opening side facing downward.
(d) Using a brass bar and hammer, install the drive shaft.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
HINT:
Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feel-
ing when driving it in.
(e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
(f) Check that the drive shaft cannot be removed by hand.
2. RH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(b) Install the drive shaft with the center bearing bracket.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
(c) Install the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
3. CONNECT DRIVE SHAFT TO AXLE HUB
NOTICE:
Be careful not to damage the boot and ABS speed sensor rotor.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle.
(b) Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying brakes, install the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(b) Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
7. w/ABS:
INSTALL ABS SPEED SENSOR AND BOLT
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
8. FILL AND CHECK GEAR OIL (See page MX–4)
9. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
10. CHECK FRONT WHEEL ALIGNMENT (See Pub. No. RM599E on page SA–4)
11. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM599E on page DI–115)

BRAKE
BRAKE PEDAL BR–1. . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM PUMP (1CD–FTV) BR–2. . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

BR11N–01
F08962
Brake PedalPedal PadReturn Spring
Cushion Plate Collar
Bushing Brake Pedal BracketStop Light Switch Clevis Pin
Clip
Stop Light Switch Connector

Bushing
: Specified torque
N·m (kgf·cm, ft·lbf)

Non–reusable part
Brake Pedal
Pedal Pad
Clevis Pin
Clip
Stop Light Switch
Stop Light Switch Connector
Brake Pedal Bracket

Bushing
Collar

BushingReturn SpringCushion Plate
Pedal Pad
Brake Pedal
Brake Pedal
Pedal Pad
Lithium soap base glycol grease
RHD M/T
A/T
LHD M/T
A/T
36.8 (375, 27)
36.8 (375, 27)
– BRAKEBRAKE PEDAL
BR–1
BRAKE PEDAL
COMPONENTS