TOYOTA AVENSIS 2005 Service Repair Manual

F40647
SST
C68337
C68338
F40208SST

F45151
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±11
AVENSIS REPAIR MANUAL (RM1018E)
(b) 3ZZ±FE, 1ZZ±FE:
(1) Using SST and a press, remove the drive shaft dust
cover RH.
SST 09950±00020
24. REMOVE CASE SUB ASSY, DRIVE SHAFT BEARING
SNAP RING
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using a screwdriver, remove the bearing case snap ring.
25. REMOVE DRIVE SHAFT BEARING CASE SUB ASSY
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using a press, remove the drive shaft bearing case.
NOTICE:
Be careful not to drop the inboard joint assy.
26. REMOVE FRONT DRIVE SHAFT DUST COVER
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using SST and a press, remove the drive shaft dust cover.
SST 09950±00020
NOTICE:
Be careful not to drop the inboard joint assy.
27. REMOVE FRONT DRIVE SHAFT BEARING
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using a snap ring expander, remove the drive shaft hole
snap ring.

F40210SST

F40211
SST
C68341
F40212
SST
F40213
30±12
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using SST and a press, remove the drive shaft bearing.
SST 09527±10011
(c) Remove the snap ring.
28. INSTALL FRONT DRIVE SHAFT BEARING
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using SST and a press, install a new drive shaft bearing.
SST 09950±60020 (09951±00710), 09950±70010
(09951±07100)
29. INSTALL CASE SUB ASSY, DRIVE SHAFT BEARING
SNAP RING
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using a screwdriver, install a new bearing case snap ring.
30. INSTALL DRIVE SHAFT BEARING CASE SUB ASSY
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using SST and a press, install the drive shaft bearing
case to the inboard joint assy RH.
SST 09527±10011, 09710±04081
NOTICE:
Bearing should be installed completely.
(b) Using a snap ring expander, install a new drive shaft hole
snap ring.

F40214
SST
SST(A)
F02277
SST
(A)

F45152
SST
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±13
AVENSIS REPAIR MANUAL (RM1018E)
31. INSTALL FRONT DRIVE SHAFT DUST COVER
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Using SST and a press, install a new drive shaft dust cov-
er.
SST 09726±40010, 09527±10011
Distance (A): 0.5 0.5 mm (0.020  0.020 in.)
NOTICE:
Be careful not to damage the dust cover.
32. INSTALL FRONT DRIVE SHAFT DUST COVER RH
(a) 1AZ±FSE, 1AZ±FE, 1CD±FTV:
(1) Using SST and a press, install a new drive shaft
dust cover RH until the distance from the tip of cen-
ter drive shaft to the drive shaft dust cover RH
reaches the specification, as shown in the illustra-
tion.
SST 09527±10011
Distance (A): 91.5  0.5 mm (3.602  0.020 in.)
(b) 3ZZ±FE, 1ZZ±FE:
(1) Using SST and a press, install a new drive shaft
dust cover RH.
SST 09527±10011
NOTICE:

Dust cover should be installed completely.

Be careful not to damage the dust cover.
33. INSTALL FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, install a new drive shaft dust cover LH.
SST 09527±10011
NOTICE:

Dust cover should be installed completely.

Be careful not to damage the dust cover.
HINT:
Install the LH side by the same procedures as the RH (3ZZ±FE, 1ZZ±FE) side.
34. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new hole snap ring.
HINT:
Except RH (1AZ±FSE, 1AZ±FE, 1CD±FTV)

W01994
Vinyl Tape
R10425
SSTHold
Turn
R10426
SST
30±14
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
35. 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) Install new parts to the outboard joint shaft assy in the fol-
lowing order.
(1) Outboard joint boot LH No.2 clamp
(2) Outboard joint boot
(3) Outboard joint boot LH clamp
(b) Pack the outboard joint shaft and boot with grease in the
boot kit.
Grease capacity:
Engine typeGrease capacity g (oz.)
1AZ±FSE, 1AZ±FE, 1CD±FTV152 ± 162 g
(5.4 ± 5.7 oz.)
3ZZ±FE, 1ZZ±FE85 ± 105 g
(3.0 ± 3.7 oz.)
36. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Hold the front drive shaft in a soft vise.
(b) Secure 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 (0.031 in.) or less
(f) Install the outboard joint boot LH clamp by the same pro-
cedures as the outboard joint boot LH No.2 clamp.
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.

F40646Distance
C86267
SSTHold
Turn
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±15
AVENSIS REPAIR MANUAL (RM1018E)
37. INSTALL DAMPER, DRIVE SHAFT
HINT:

Except 1AZ±FSE, FE (MT)/ 1CD±FTV

Perform the above procedure only when reassembling
the RH side
(a) Temporarily install a new damper clamp.
(b) Set the distance, as described below.
Engine typeDistance mm (in.)
3ZZ FE
RH422.0
2.0
(16.61
0.08)
3ZZ±FE
LH176.0
2.0
(6.93
0.08)
1ZZ FE
RH416.0
2.0
(16.38
0.08)
1ZZ±FE
LH176.0
2.0
(6.93
0.08)
1AZ FSE FE
RH212.0
2.0
(8.35
0.08)
1AZ±FSE, FELH
(AT)183.0
2.0
(7.20
0.08)
1CD±FTVRH192.0
2.0
(7.56
0.08)
1CD FTV
LH±
(c) Install the damper clamp.
HINT:

Install the damper clamp to inboard joint side.
(1) Hold the front drive shaft in a soft vise.
(2) Secure the damper clamp onto the damper.
(3) Place SST onto the damper clamp.
SST 09521±24010
(4) Tighten the SST so that the damper clamp is
pinched.
NOTICE:
Do not overtighten the SST.

C86268
SST
C67417
Matchmarks
30±16
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
(5) Using SST, adjust the clearance of the damper
clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
HINT:

Install the damper clamp to inboard joint side.

Except 1AZ±FSE, FE (MT)/ 1CD±FTV

Perform the above procedure only when reassembling
the RH side
38. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Wrap the spline of the outboard joint shaft assy LH with
vinyl tape to prevent them from being damaged.
(b) Install new parts to the outboard joint shaft assy LH in the
following order.
(1) Inboard joint boot LH clamp
(2) Inboard joint boot
(3) Inboard joint boot LH No.2 clamp
(c) Place the beveled side of the tripod axial spline toward the
outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap in the tripod joint assy
to the drive shaft assy LH.
NOTICE:

Do not tap the roller.

Be sure to install the tripod joint assy in the correct
direction.
(f) Pack the inboard joint shaft and boot with grease in the
boot kit.
Engine typeGrease capacity g (oz.)
1AZ±FSE, 1AZ±FE, 1CD±FTV170 ± 190 g
(6.0 ± 6.7 oz.)
3ZZ±FE, 1ZZ±FE125.5 ± 135.5 g
(4.4 ± 4.8 oz.)

G24058

F45461
Matchmarks
C86269
SST
Hold
Turn
C86270SST
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±17
AVENSIS REPAIR MANUAL (RM1018E)
(g) Using a snap ring expander, install a new shaft snap ring.
(h) Aligning the matchmarks, install the inboard joint assy LH
to the outboard joint shaft assy LH.
39. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy LH and outboard joint shaft assy LH.
40. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) Install the inboard joint boot clamp.
(1) Hold the drive shaft in a soft vise.
(2) Secure the 2 inboard joint boot clamps onto the
boot.
(3) Place SST onto the inboard joint large boot clamp.
SST 09521±24010
(4) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(5) Using SST, adjust the clearance of the large clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
(b) Install the inboard joint boot LH clamp by the same proce-
dures as the inboard joint boot LH No.2 clamp.

C91598

F45254
(A)
C83851
C83155
1AZ±FSE/
1AZ±FE:
F44774
1CD±FTV: 30±18
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
41. INSPECT FRONT DRIVE SHAFT
(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.
NOTICE:
Keep the drive shaft assy level during inspection.
HINT:
For dimension (A), refer to the following table.
Engine typeLH mm (in.)RH mm (in.)
3ZZ±FE583.8 (22.98)
5.0 (0.20)856.3 (33.71)
5.0 (0.20)
1ZZ±FE582.9 (22.94)
5.0 (0.20)855.4 (33.68)
5.0 (0.20)
1AZ±FSE, 1AZ±FE559.8 (22.03)
5.0 (0.20)876.0 (34.49)
5.0 (0.20)
1CD±FTV546.8 (21.53)
5.0 (0.20)889.0 (35.00)
5.0 (0.20)
42. INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Coat the spline of the inboard joint shaft assy LH with gear
oil.
(b) Aligh the shaft splines and install the drive shaft assy LH
with a brass bar and hammer.
NOTICE:

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

Be careful not to damage the oil seal, boot and dust
cover.
43. INSTALL FRONT DRIVE SHAFT ASSY RH
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Coat the spline of the inboard joint shaft assy RH with
gear oil.
(b) Aline the shaft splines and install the drive shaft assy RH
with the 2 bolts.
Torque: 64 N
m (650 kgf
cm, 47 ft
lbf)
NOTICE:
Do not damage the oil seal, boot and dust cover.

C80293
F44775
C80291
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±19
AVENSIS REPAIR MANUAL (RM1018E)
44. INSTALL FRONT AXLE ASSY LH
(a) Install the 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.
45. INSTALL FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Install the lower ball joint to the front suspension arm sub±
assy lower No.1 LH with the bolt and 2 nuts.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
46. INSTALL TIE ROD END SUB±ASSY LH
(a) Install the tie rod end sub±assy LH to the steering knuckle with the nut.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
47. 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.

F13686
HoldTurn
C68609
30±20
±
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
48.INSTALL FRONT STABILIZER LINK ASSY LH
(a)Install the front stabilizer link assy LH with the nut. Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
49.INSTALL FRONT AXLE HUB LH NUT
(a)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.
50.INSTALL ENGINE UNDER COVER LH
51.INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
52.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
53.INSPECT AND ADJUST AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
54. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
55.INSPECT MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See page 41±2)
56.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
57. 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)