boot TOYOTA PRIUS 2001 Service User Guide

Z12938
RH
LH
F12937
Type A:
Type B:
R10425
SST
R10426
SST
F11615
SA±22
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
2001 PRIUS (RM778U)
(b) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
RH836.9 ± 5.0 mm (32.949 ± 0.197 in.)
LH579.9 ± 5.0 mm (22.831 ± 0.197 in.)
(c) Bend the band and lock the 2 inboard joint boot clamps
with a screwdriver.
(d) Install either A or B type boot clamp.
(e) Type A clamp:
Bend the band and lock the 2 outboard joint boot clamps
with a screwdriver.
(f) Type B clamp:
Pinch the 2 outboard joint boot clamps.
(1) Secure the 2 outboard joint boot clamps onto the
boot.
(2) Place SST onto the outboard joint large boot clamp.
SST 09521±24010
(3) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(4) Using SST, adjust the clearance of the large clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
(5) Employ the same manner to the outboard joint
small boot clamp.
7. RH drive shaft:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Set the distance, as described below.
Distance: 500.1 ± 2.0 mm (19.689 ± 0.079 in.)
(b) Type A clamp:
Bend the band and lock the dynamic damper clamp with
a screwdriver.
(c) Type B clamp:
Using pliers, compress the clamp and attach the claws.
8. CHECK DRIVE SHAFT (See page SA±19)

F12630
Clevis Clevis Lock Nut
Cylinder Boot
No. 2 Piston
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)
Master Cylinder Body

Non±reusable part
No. 1 Piston

Plug
Snap Ring
26 (265, 19)
± BRAKEBRAKE MASTER CYLINDER
BR±17
1532 Author: Date:
2001 PRIUS (RM778U)

F09780
F12390
SST
BR±34
± BRAKEREAR DRUM BRAKE
2001 PRIUS (RM778U)
(b) Using needle±nose pliers, disconnect the parking brake
cable from the parking brake lever, and remove the rear
shoe.
6. REMOVE PARKING BRAKE LEVER
(a) Remove the C±washer.
(b) Remove the parking brake lever from the rear shoe.
7. REMOVE WHEEL CYLINDER
(a) Using SST, disconnect the brake line. Use container to
catch the brake fluid.
SST 09751±36011
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Remove the bolt and the wheel cylinder.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. DISASSEMBLE WHEEL CYLINDER
(a) Remove the 2 boots from the wheel cylinder.
(b) Remove the 2 pistons from the wheel cylinder.
(c) Remove the spring from the wheel cylinder.
(d) Remove the 2 piston cups from each piston.

F12262
Tie Rod End
Clip
Rack Boot
Clamp
Rack End
PS Gear Assembly
with Motor
Claw Washer


83 (850, 61)
* 62 (630, 46)
Claw Washer


Rack End83 (850, 61)
* 62 (630, 46)
Clamp
Rack Boot
Clip
Tie Rod End
Lock Nut56 (570, 41)
Lock Nut56 (570, 41)
N´m (kgf´cm, ft´lbf) : Specified torque
Non±reusable part
* For use with SST

5.5 (60, 52 in.´lbf)
Earth
Wire
SR±18
± STEERINGELECTRIC POWER STEERING GEAR
1591 Author: Date:
2001 PRIUS (RM778U)

SR1BM±01
F12264
SST
F07501
Matchmarks
F12265
F12266
SST
± STEERINGELECTRIC POWER STEERING GEAR
SR±21
2001 PRIUS (RM778U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE ELECTRIC POWER STEERING GEAR AS-
SEMBLY IN VISE
Using SST, secure the electric power steering gear assembly
in a vise.
SST 09612 ± 00012
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
(a) Place matchmarks on the tie rod end, lock nut and rock
end.
(b) Loosen the lock nut and remove the tie rod end and lock
nut.
(c) Employ the same manner described above to the other
side.
3. REMOVE RH AND LH CLAMPS, CLIPS AND RACK
BOOTS
(a) Remove the clamp, clip and rack boot.
NOTICE:
Be careful not to damage the boot.
HINT:
Mark the RH and LH rack boots.
(b) Employ the same manner described above to the other
side.
4. REMOVE RH AND LH RACK ENDS CLAW WASHERS
(a) Using a screwdriver and a hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
(b) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST 09922 ± 10010
NOTICE:
Use SST 09922 ± 10010 in the direction shown in the il-
lustration.
HINT:
Mark the RH and LH rack ends.
(c) Remove the claw washer.

SR1BN±01
F12267
F12268
Fulcrum LengthSST
F12269
± STEERINGELECTRIC POWER STEERING GEAR
SR±23
2001 PRIUS (RM778U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL EARTH WIRE
Install the earth wire with the bolt.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
2. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new claw washer and temporarily install the rack
end.
HINT:
Align the claws of the claw washer with the steering rack
grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922 ± 10010
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
NOTICE:
Use SST 09922 ± 10010 in the direction shown in the il-
lustration.
HINT:
Use a torque wrench with a fulcrum length of 380 mm (14.96
in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact on the steering rack.
(d) Employ the same manner described above to the other
side.
3. INSTALL RH AND LH RACK BOOTS, CLIPS AND
CLAMPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot, clip and clamp.
NOTICE:
Be careful not to damage or twist the boot.