suspension TOYOTA PRIUS 2001 Service Service Manual

SA20B±01
FA1535
SST
F12940SST
F11576
SST
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±17
2001 PRIUS (RM778U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608±16042 (09608±02021, 09608±02041)

After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ATF
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Using SST and a hammer, unstake the staked part of the
lock nut.
SST 09930±00010
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011

F11617
F13342
F11614SST
SA±18
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
2001 PRIUS (RM778U)
6. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM
Remove the 2 nuts and bolt.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
7. DISCONNECT DRIVE SHAFT FROM AXLE HUB
Using a plastic hammer, disconnect the drive shaft from the axle
hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.
8. REMOVE DRIVE SHAFT
(a) Using SST, remove the drive shaft.
SST 09520±01010, 09520±24010 (09520±32040)
NOTICE:
Be careful not to damage the oil seal and dust cover.
HINT:
At the time of installation, please refer to the following items.

Apply gear oil to the inboard joint shaft and differential
case sliding surfaces.

Before installing the drive shaft, set the snap ring with its
opening side facing downward.

Whether inboard joint shaft is in contact with pinion shaft
or not can be known from the sound or feeling.

After installation, check that there is 2 ± 3 mm (0.08 ± 0.12
in.) of play in the axial direction.

After installation, check that the drive shaft cannot be re-
moved by hand.
(b) Using a screwdriver, remove the snap ring from the in-
board joint shaft.

SA20C±01
N00191
F12937
Type A:
Type B:
R11817
Matchmarks
N00194
Matchmarks
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±19
2001 PRIUS (RM778U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no remarkable play in the out-
board joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
(d) Check the boots for damage.
(e) Check the shape of the boot clamp.
2. REMOVE INBOARD JOINT SHAFT
(a) Using a screwdriver, disclamp the 2 inboard joint boot
clamps.
(b) Slide the inboard joint boot toward the outboard joint.
(c) Place matchmarks on the inboard joint shaft and tripod.
NOTICE:
Do not punch the marks.
(d) Remove the inboard joint shaft from the outboard joint
shaft.
3. 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, tap out the tripod from the
outboard joint shaft.
NOTICE:
Do not tap the roller.
4. REMOVE INBOARD JOINT BOOT AND 2 CLAMPS
5. RH drive shaft:
REMOVE DYNAMIC DAMPER
(a) Type A clamp:
Using a screwdriver, disclamp the dynamic damper clamp
and remove it.

F12935
AB
F13343
R09716
SST SA±20
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
2001 PRIUS (RM778U)
(b) Type B clamp:
Using pliers, pinch the claw A and B to compress the dy-
namic damper clamp and remove it.
(c) Remove the dynamic damper.
6. REMOVE OUTBOARD JOINT BOOT
(a) Type A clamp:
Using a screwdriver disclamp the 2 outboard joint boot
clamps.
(b) Type B clamp:
Using a side cutter, cut the 2 outboard joint boot clamps
and remove it.
NOTICE:
Cut the part shown by the arrow so that the boot will not be
damaged.
(c) Remove the outboard joint boot from the outboard joint
shaft.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard
joint shaft.
SST 09950±00020

SA20D±01
SA1459
W01994
Vinyl Tape
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±21
2001 PRIUS (RM778U)
REASSEMBLY
1. INSTALL DUST COVER
Using a press, install a new dust cover to the inboard joint shaft.
2. TEMPORARILY INSTALL BOOTS, CLAMPS AND DY-
NAMIC DAMPER (RH DRIVE SHAFT)
HINT:
Before installing the boots (and dynamic damper), wrap the
spline of the outboard joint shaft with vinyl tape to prevent them
from being damaged.
(a) Place either 2 new A or B type boot clamps on a new out-
board joint boot and install them to the outboard joint
shaft.
(b) RH drive shaft:
Place either a new A or B type clamp on the dynamic
damper and install them to the outboard joint shaft.
HINT:
For B type only, the used clamp can be employed.
(c) Place 2 new clamps on a new inboard joint boot and install
them to the outboard joint shaft.
3. 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 out-
board joint shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
4. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot
with grease in the boot kit.
Grease capacity: (Color = Yellow ocher)
110 ± 120 g (3.9 ± 4.2 oz.)
5. INSTALL INBOARD JOINT SHAFT TO OUTBOARD
JOINT SHAFT
(a) Pack the inboard joint and boot with grease in the boot kit.
Grease capacity: (Color = Yellow ocher)
180 ± 190 g (6.3 ± 6.7 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.
6. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure that the 2 boots are on the shaft grooves.

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)

SA1P6±02
F11581
SST
F11582
Out
F11583
F08624
SST
± SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA±29
2001 PRIUS (RM778U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the spring low-
er seat.
(c) Install the upper insulator as shown in the illustration.
(d) Install the spring seat to the shock absorber with the º
º
mark facing to the outside of the vehicle.
(e) Install the dust seal and suspension support.
(f) Using SST to hold the suspension support, install a new
nut.
SST 09729±22031
Torque: 47 N´m (475 kgf´cm, 34 ft´lbf)
(g) Remove the SST.
SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)

F11584
MP Grease No.2
SA±30
± SUSPENSION AND AXLEFRONT SHOCK ABSORBER
2001 PRIUS (RM778U)
(h) Apply MP grease No.2 into the suspension support.
CAUTION:
Do not touch grease on rubber surface of upper support.
(i) Install the cap.

SA1ZW±01
F11576
SST
F11616
F11617
F11586
± SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA±33
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. REMOVE LOWER SUSPENSION ARM
(a) Disconnect the RH and LH tie rod ends.
(1) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(2) Using SST, disconnect the tie rod end from the
steering knuckle.
SST 09628±62011
(3) Employ the same manner described above to the
other side.
(b) Disconnect the RH and LH stabilizer bar links.
(1) Remove the nut and disconnect the stabilizer bar
link from the shock absorber.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
(2) Employ the same manner described above to the
other side.
(c) Disconnect the RH and LH lower suspension arms from
the lower ball joints.
(1) Remove the bolt and 2 nuts, and disconnect the
lower suspension arm from the lower ball joint.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
(2) Employ the same manner described above to the
other side.
(d) Loosen the 2 lower suspension arm set bolts.
Torque: 137 N´m (1,397 kgf´cm, 101 ft´lbf)
HINT:
At the time of installation, after stabilizing the suspension,
torque the bolts.
(e) Disconnect the sliding yoke (See page SR±6).
(f) Support the suspension member with a transmission
jack.

F12936
F12933
SA±34
± SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
2001 PRIUS (RM778U)
(g) Remove the bolt and nut, disconnect the torque rod from
the suspension member.
Torque: 100 N´m (1,150 kgf´cm, 83 ft´lbf)
(h) Remove the 4 bolts and disconnect the suspension mem-
ber from the body.
Torque:
Front side: 113 N´m (1,152 kgf´cm, 83 ft´lbf)
Rear side: 157 N´m (1,600 kgf´cm, 116 ft´lbf)
(i) Remove the 2 lower suspension arm set bolts and discon-
nect the lower suspension arm from suspension member.