TOYOTA AVENSIS 2003 Service Repair Manual

3005B±02
D26919
D26920
C98714
C98715
30±2
±
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT FRONT AXLE HUB BEARING BACKLASH
(a) Using a dial indicator, check the backlash near the center of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
2. INSPECT FRONT AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub.
3. INSPECT REAR AXLE HUB BEARING BACKLASH
(a) Using a dial indicator, check the backlash near the center
of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub as-
sembly.
4. INSPECT REAR AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If the backlash exceeds the maximum, replace the axle hub as-
sembly.
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30091±02

D30592
Speed Sensor Front LH
Lower Ball Joint
Assy Front LH
N
m (kgf
cm, ft
lbf): Specified torque
8.0 (82, 71 in.

lbf)
49 (500, 36)
Tie Rod End Sub±assy LH


Cotter Pin
Front Disc
Front Axle Assy LH
19 (194, 14)
Front Stabilizer Link Assy LH
74 (755, 55)
220 (2,243, 162)
Front Drive Shaft
Assy LH
Front Axle Hub LH Nut
216 (2,200, 159)

Front Axle
LH Hub Bolt
89 (908, 66)
Steering Knuckle LH
Disc Brake Dust Cover Front LH
8.3 (85, 73 in.
lbf)
8.3 (85, 73 in.
lbf)Front Axle
Hub Sub±assy LH
Front Disc Brake
Caliper Assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH

Front Axle Hub
LH Bearing

Cotter Pin
103 (1,050, 76)
102 (1,040, 75)

Non±reusable parts


Front Axle Hub
LH Snap Ring
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
30±21
AVENSIS REPAIR MANUAL (RM1018E)
FRONT AXLE HUB SUB±ASSY LH
COMPONENTS
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300JY±01

F45751
SST
C80291
F44775
C67088
30±22
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replace the RH side by the same procedures as the LH side.
1. REMOVE FRONT WHEEL
2.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6) 3. REMOVE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part of theaxle hub LH nut.
SST 09930±00010
(b) While applying the brakes, remove the axle hub LH nut.
4. DISCONNECT SPEED SENSOR FRONT LH
(a) Remove the bolt, and disconnect the speed sensor wire and flexible hose from the shock absorber.
(b) Remove the bolt, separate the speed sensor front LH from the steering knuckle.
NOTICE:

Be careful not to damage the speed sensor.

Prevent foreign matter from attaching to the speed
sensor.
5. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts, separate the disc brake caliper assy LH from the steering knuckle.
NOTICE:
Use a string or other device to keep the brake caliper from
hanging down.
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F40217
SSTTurn
Hold
C80293
D27403
C83023
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
30±23
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE FRONT DISC
7. SEPARATE TIE ROD END SUB±ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end sub±assy LH from thesteering knuckle.
SST 09628±62011
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the suspension arm sub±assy lower No.1 LH from the lower ball joint.
9. REMOVE FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the drive shaft assy LH from the axle hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.
(b) Remove the 2 bolts, nuts and steering knuckle with the
shock absorber.
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F40228
SST
F40229
F40156
SST

F45153
Turn
SST
SST
Hold
30±24
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE LOWER BALL JOINT ASSY FRONT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the ball joint. SST 09628±62011
11. REMOVE FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, remove the hole snap ring.
12. REMOVE FRONT AXLE HUB SUB±ASSY LH
(a) Using SST, remove the axle hub sub±assy. SST 09520±00031
(b) Using SST, remove the bearing inner race (outside) from the axle hub sub±assy.
SST 09950±40011 (09951±04020, 09952±04010, 09953±04030, 09954±04010, 09955±04061,
09957±04010, 09958±04010), 09950±60010
(09951±00370)
13. REMOVE DISC BRAKE DUST COVER FRONT LH
(a) Remove the 3 bolts and disc brake dust cover front LH.
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F40230
SST
SST
F40231
SST
F40232
SST
SST
F40229
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
30±25
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE FRONT AXLE HUB LH BEARING
(a) Place the bearing inner race (outside) on the axle hub LH
bearing.
(b) Using SST and a press, remove the axle hub LH bearing from the steering knuckle.
SST 09527±17011, 09950±60010 (09951±00640), 09950±70010 (09951±07100)
15. INSTALL FRONT AXLE HUB LH BEARING
(a) Using SST and a press, install a new axle hub LH bearing to the steering knuckle.
SST 09950±60020 (09951±00720), 09950±70010 (09951±07100)
16. INSTALL DISC BRAKE DUST COVER FRONT LH
(a) Install the disc brake dust cover with the 3 bolts. Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
17. INSTALL FRONT AXLE HUB SUB±ASSY LH
(a) Using SST and a press, install the axle hub sub±assy. SST 09608±32010, 09950±60010 (09951±00600), 09950±70010 (09951±07100)
18. INSTALL FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, install the hole snap ring.
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C83023
C80293
30±26
±
DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL LOWER BALL JOINT ASSY FRONT LH
(a)Install the lower ball joint and torque the nut. Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b)Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 6\
0 further.
20.INSTALL FRONT AXLE ASSY LH
(a)Install the 2 bolts, nuts and steering knuckle with 2 boltsand nuts to the shock absorber.
Torque: 220 N
m (2,243 kgf
cm, 162 ft
lbf)
NOTICE:
Only when reusing the bolts and nuts, apply engine oil to
the screw part of the nuts.
(b)Push the front axle assy toward the outside of the vehicle, fit the splined part of the drive shaft assy to that of the front
axle assy and insert the drive shaft assy into the front axle
assy.
NOTICE:

Do not push out the front axle assy excessively.

Be careful not to damage the drive shaft outboard
joint boot.

Be careful not to damage the speed sensor rotor.
21.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the front suspension arm sub±assy lower No.1 LH and lower ball joint with the 2 nuts and bolt.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
22.INSTALL TIE ROD END SUB±ASSY LH
(a)Install the tie rod end sub±assy LH to the steering knuckle.
(b)Install the nut and a new cotter pin. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 6\
0 further.
23.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
24. INSTALL FRONT DISC
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C67088
F44775
C80291
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
30±27
AVENSIS REPAIR MANUAL (RM1018E)
25. INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the disc brake caliper assy with the 2 bolts to the
steering knuckle.
Torque: 104 N
m (1,040 kgf
cm, 75 ft
lbf)
26. INSTALL FRONT AXLE HUB LH NUT
(a) Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 216 N
m (2,200 kgf
cm, 159 ft
lbf)
27. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts, separate the disc brake caliper assy from the stee\
ring knuckle.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
28. REMOVE FRONT DISC
29.INSPECT BEARING BACKLASH (See page 30±2)
30.INSPECT AXLE HUB DEVIATION (See page 30±2)
31. INSTALL FRONT DISC
32. INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the disc brake caliper assy with the 2 bolts to the steering knu\
ckle. Torque: 104 N
m (1,040 kgf
cm, 75 ft
lbf)
33. CONNECT SPEED SENSOR FRONT LH
(a) Install the speed sensor front LH to the steering knuckle with the bolt.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the speed sensor wire and flexible hose to the shock absorber with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Be careful not to damage the speed sensor.

Keep the speed sensor clean.

Do not twist the sensor wire when installing the sen-
sor.
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C68609
30±28
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL FRONT AXLE HUB LH NUT
(a) While applying the brakes, install a new axle hub LH nut. Torque: 216 N
m (2,200 kgf
cm, 159 ft
lbf)
(b) Using a chisel and hammer, stake the axle hub LH nut.
35. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
36.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
37. CHECK ABS SPEED SENSOR SIGNAL
(a)ABD WITH EBD SYSTEM (See page 05±699)
(b)ABD WITH EBD & BA & TRC & VSC SYSTEM ( See page 05±756)
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30092±02
D27405SST
Hold
Turn
D27401
Hold
Turn
Nut
Washer
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE LH HUB BOLT
30±29
AVENSIS REPAIR MANUAL (RM1018E)
FRONT AXLE LH HUB BOLT
REPLACEMENT
HINT:

COMPONENTS: See page 30±21

Replace the RH side by the same procedures as the LH side.
1. REMOVE FRONT WHEEL
2.SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
3. REMOVE FRONT DISC
4. REMOVE FRONT AXLE LH HUB BOLT
(a) Using SST and a hammer handle or an equivalent to holdthe axle hub sub±assy LH, remove the LH hub bolt.
SST 09628±10011
5. INSTALL FRONT AXLE LH HUB BOLT
(a) Install a washer and nut to a new LH hub bolt as shown in the illustration.
(b) Using a hammer handle or an equivalent to hold the axle hub sub±assy LH, install the LH hub bolt by tightening the
nut.
6. INSTALL FRONT DISC
7.INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
8. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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