TOYOTA SIENNA 2007 Service Repair Manual

DS–6DRIVE SHAFT – FRONT DRIVE SHAFT
DS
7. SEPARATE TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end from the
steering knuckle.
SST 09628-62011
8. SEPARATE NO. 1 FRONT SUSPENSION ARM SUB-
ASSEMBLY LOWER LH
(a) Remove the bolt and 2 nuts, and separate the No. 1
front suspension arm sub-assembly lower from the
lower ball joint.
9. SEPARATE FRONT AXLE ASSEMBLY LH
(a) Using a plastic hammer, separate the drive shaft
from the axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft assembly
LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft
assembly.
11. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for
2WD)
(a) Using a screwdriver, remove the bearing brake hole
snap ring.
(b) Remove the bolt and front drive shaft assembly RH
from the drive shaft bearing bracket.
F045060E06
F040142
D027403E03
F040148E05
C080304

DRIVE SHAFT – FRONT DRIVE SHAFTDS–7
DS
12. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for
4WD)
(a) Using SST, remove the front drive shaft assembly
RH.
SST 09520-01010, 09520-24010 (09520-32040)
HINT:
Overhaul the side following the same procedures as
for the LH side.
NOTICE:
• When removing and installing the front drive
shaft assembly RH in 4WD vehicle, be sure to
first drain all the transaxle oil and transfer oil.
If removal and installation is carried out
without draining these oils, the transfer oil
will flow into the transaxle side. Extensive
cleaning will be required if the two oils mix.
• Do not damage the oil seal and dust cover.
• Move the drive shaft assembly while keeping
it level.
13. SECURE FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C108268E04
C054583E01

DS–8DRIVE SHAFT – FRONT DRIVE SHAFT
DS
DISASSEMBLY
1. REMOVE NO. 2 FRONT AXLE INBOARD JOINT
BOOT LH CLAMP
(a) Using pliers, remove the No. 2 front axle inboard
joint boot LH clamp, as shown in the illustration.
2. REMOVE FRONT AXLE INBOARD JOINT BOOT LH
CLAMP
(a) Remove the front axle inboard joint boot LH clamp
using the same procedures as for the No. 2 front
axle inboard joint boot LH clamp.
3. SEPARATE FR AXLE INBOARD JOINT BOOT
(a) Separate the inboard joint boot from the inboard
joint assembly.
4. REMOVE FRONT DRIVE INBOARD JOINT
ASSEMBLY LH
(a) Remove the grease from the inboard joint.
(b) Put matchmarks on the inboard joint shaft assembly
and outboard joint shaft.
NOTICE:
Do not use a punch for the marks.
(c) Remove the inboard joint shaft assembly from the
outboard joint shaft.
(d) Using a snap ring expander, remove the snap ring.
(e) Put matchmarks on the outboard joint shaft and
tripod.
NOTICE:
Do not use a punch for the marks.
C160030E01
C108270E01
C108271

DRIVE SHAFT – FRONT DRIVE SHAFTDS–9
DS
(f) Using a brass bar and hammer, remove the tripod
from the outboard joint shaft.
NOTICE:
Do not tap the roller.
5. REMOVE FR AXLE INBOARD JOINT BOOT
(a) Remove the inboard joint boot and inboard joint
boot clamp.
6. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP
(a) Using pliers, remove the front drive shaft damper
clamp, as shown in the illustration.
7. REMOVE FRONT DRIVE SHAFT DAMPER
(a) Remove the drive shaft damper.
8. REMOVE OUTBOARD JOINT BOOT NO. 2 CLAMP
(a) Using pliers, remove the outboard joint boot No. 2
clamp, as shown in the illustration.
9. REMOVE OUTBOARD JOINT BOOT CLAMP
(a) Remove the outboard joint boot clamp perform the
same procedures as for the outboard joint boot No.
2 clamp.
10. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard
joint shaft.
(b) Remove the grease from the outboard joint.
11. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP
RING
(a) Using a screwdriver, remove the front drive shaft LH
hole snap ring.
N000194E03
C108273
C081167
C057543

DS–10DRIVE SHAFT – FRONT DRIVE SHAFT
DS
12. REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, remove the drive shaft dust
cover LH.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint
assembly.
13. REMOVE FRONT DRIVE SHAFT DUST COVER RH
(for 2WD)
(a) Using a press, remove the drive shaft dust cover
RH.
14. REMOVE FRONT DRIVE SHAFT DUST COVER RH
(for 4WD)
(a) Using SST and a press, remove the drive shaft dust
cover RH.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint
assembly.
15. REMOVE FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, remove the drive shaft dust
cover.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint
assembly.
16. REMOVE FRONT DRIVE SHAFT RH HOLE SNAP
RING
(a) Using a snap ring expander, remove the drive shaft
RH hole snap ring.
F040647E06
C067101
F040648E03
F040208E05
C109617

DRIVE SHAFT – FRONT DRIVE SHAFTDS–11
DS
17. REMOVE FRONT DRIVE SHAFT BEARING
(a) Using SST and a press, remove the front drive shaft
bearing.
SST 09527-10011
INSPECTION
1. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH
(a) Check that there is no remarkable play in the radial
direction 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
direction of the inboard joint.
(d) Check the boots for damage.
(e) For dimension (A), refer to the following table.
REASSEMBLY
1. INSTALL FRONT DRIVE SHAFT BEARING
(a) Using SST and a press, install a new front drive
shaft bearing.
SST 09710-30021 (09710-03141), 09527-10011
NOTICE:
Bearing should be completely installed.
2. INSTALL FRONT DRIVE SHAFT RH HOLE SNAP
RING
(a) Using a snap ring expander, install a new front drive
shaft RH hole snap ring.
C108280E02
C091598
F045048E03
DRIVE TYPE LH mm (in.) RH mm (in.)
2WD638.40 +- 5.0 (25.1338 +-
0.20)957.00 +- 5.0 (37.6771 +-
0.20)
4WD553.64 +- 5.0 (21.7968 +-
0.20)992.24 +- 5.0 (39.0645 +-
0.20)
C108281E04
C109617

DS–12DRIVE SHAFT – FRONT DRIVE SHAFT
DS
3. INSTALL FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, install a new drive shaft
dust cover until the distance from the tip of the
center drive shaft to the drive shaft dust cover meets
the specification, as shown in the illustration.
SST 09726-40010, 09527-10011
Distance (A):
26.8 to 27.4 mm (1.0551 to 1.0787 in.)
4. INSTALL FRONT DRIVE SHAFT DUST COVER RH
(for 2WD)
(a) Using SST and a press, install a new drive shaft
dust cover RH until the distance from the tip of the
center drive shaft to the drive shaft dust cover RH
meets the specification, as shown in the illustration.
SST 09527-10011
Distance:
109.5 mm (4.311 in.)
NOTICE:
• Dust cover should be completely installed.
• Be careful not to damage the dust cover.
5. INSTALL FRONT DRIVE SHAFT DUST COVER RH
(for 4WD)
(a) Using SST and a press, install a new drive shaft
dust cover RH.
SST 09527-10011
NOTICE:
• Dust cover should be completely installed.
• Be careful not to damage the dust cover.
6. 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 completely installed.
• Be careful not to damage the dust cover.
7. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP
RING
(a) Install a new hole snap ring to the inboard joint shaft
assembly.
8. 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.
C108282E04
C108283E03
F040215E02
F041033E06

DRIVE SHAFT – FRONT DRIVE SHAFTDS–13
DS
(a) Install new parts to the outboard joint shaft
assembly in the following order.
(1) Outboard joint boot No. 2 clamp (A)
(2) Outboard joint boot (B)
(3) Outboard joint boot clamp (C)
(b) Pack the outboard joint shaft and boot with grease.
9. INSTALL OUTBOARD JOINT BOOT NO. 2 CLAMP
(a) Hold the outboard joint shaft assembly between
aluminium plates in a vise.
NOTICE:
Do not overtighten the vise.
(b) Install the outboard joint boot No. 2 clamp onto the
boot.
(c) Place SST onto the outboard joint boot No. 2 clamp.
SST 09521-24010
(d) Tighten the SST so that the outboard joint boot No.
2 clamp is pinched.
SST 09521-24010
NOTICE:
Do not overtighten the SST.
(e) Using SST, measure the clearance of the outboard
joint boot No. 2 clamp.
SST 09240-00020
Clearance:
0.8 mm (0.031 in.) or less
NOTICE:
When the measured value is greater than the
specified value, retighten the clamp.
10. INSTALL OUTBOARD JOINT BOOT CLAMP
(a) Install the outboard joint boot clamp perform the
same procedures as for the outboard joint boot No.
2 clamp.
11. INSTALL FRONT DRIVE SHAFT DAMPER
(a) Install the drive shaft damper to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
C104547E02
Drive type Grease capacity g (oz.)
2WD 35 to 55 g (1.2 to 1.9 oz.)
4WD 40 to 60 g (1.4 to 2.1 oz.)
C108286E03
C106165E04

DS–14DRIVE SHAFT – FRONT DRIVE SHAFT
DS
(c) Set the distance, as specified below.
Distance:
221.0 +- 2.0 mm (8.701 +- 0.079 in.)
12. INSTALL FRONT DRIVE SHAFT DAMPER RH CLAMP
(a) Hold the outboard joint shaft assembly between
aluminium plates in a vise.
NOTICE:
Do not overtighten the vise.
(b) Install the drive shaft damper clamp to the damper.
NOTICE:
Be sure to install the clamp in the correct
position.
(c) Place SST onto the drive shaft damper clamp.
SST 09521-24010
(d) Tighten the SST so that the clamp is pinched.
SST 09521-24010
NOTICE:
Do not overtighten the SST.
(e) Using SST, measure the clearance of the drive shaft
damper clamp.
SST 09240-00020
Clearance:
0.8 mm (0.031 in.) or less
NOTICE:
Using SST, measure the clearance of the drive
shaft damper clamp.
13. INSTALL INBOARD JOINT ASSEMBLY
(a) Install new parts to the inboard joint shaft assembly
in the following order.
(1) Inboard joint boot clamp (A)
(2) Inboard joint boot (B)
(3) Inboard joint boot No. 2 clamp (C)
(b) Hold the outboard joint shaft assembly between
aluminium plates in a vise.
NOTICE:
Do not overtighten the vise.
(c) Place the beveled side of the tripod axial spline
toward the outboard joint shaft.
D027407E02
D027408E04
C086268E06
C104548E01

DRIVE SHAFT – FRONT DRIVE SHAFTDS–15
DS
(d) Align the matchmarks.
(e) Using a brass bar and hammer, tap in the tripod to
the outboard joint shaft.
NOTICE:
• Do not tap the roller.
• Be sure to install the tripod in the correct
direction.
(f) Using a snap ring expander, install a new front inner
shaft snap ring.
(g) Pack the inboard joint shaft and boot with grease.
(h) Align the matchmarks, install the inboard joint
assembly to the outboard joint shaft assembly.
14. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint
assembly.
15. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT
LH CLAMP
(a) Hold the outboard joint shaft assembly between
aluminium plates in a vise.
NOTICE:
Do not overtighten the vise.
(b) Install the No. 2 front axle inboard joint boot LH
clamp onto the boot.
(c) for Omega Type:
(1) Place SST onto the No. 2 front axle inboard
joint boot LH clamp.
SST 09521-24010
C108291E01
C104525
C108271
Drive type Grease capacity g (oz.)
2WD 95 to 115 g (3.4 to 4.1 oz.)
4WD 100 to 130 g (3.9 to 4.6 oz.)
C108270E01