Tài liệu hướng dẫn sửa chữa Hệ thống truyền lực và trục cac đăng trên xe 18 2005 2006 toyota hilux factory service manual propeller and drive shaft truc cac dang va truyen luc. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán sửa chữa nhanh chóng, chính xác, hiệu quả
PR–4 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) DISASSEMBLY Matchmarks Matchmarks INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear and damage (b) Check the spider bearing axial play by turning the yoke with holding the shaft tightly Maximum bearing axial play: to 0.05 mm (0 to 0.002 in.) If the bearing axial play is greater than the maximum, replace the spider bearing REMOVE PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Place matchmarks on the propeller shaft and yoke PR D033919E01 (b) Using a brass bar and a hammer, slightly tap in the spider bearing outer races (c) Using needle-nose pliers, remove the snap rings from the grooves D033918 (d) Using SST, push the spider bearing out of the propeller shaft SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the spider bearing SST (A) F015025E02 Hammering Point F044192E01 (e) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer NOTICE: Do not tap the shaft HINT: Remove the spider bearing on the opposite side in the same procedure PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) PR–5 (f) Install the removed spider bearing outer races onto the spider, and clamp them in a vise (g) Using SST, push the bearing out of the yoke SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the bearing SST (A) F015030E02 (h) Clamp the outer bearing race in a vise and tap off the yoke with a hammer (i) Remove the spider Hammering Point PR F044193E02 INSPECTION INSPECT PROPELLER SHAFT ASSEMBLY (a) Using a dial indicator, check the propeller shaft runout Maximum runout: 0.6 mm (0.024 in.) If the shaft runout is greater than the maximum, replace the shaft C036277 REASSEMBLY INSTALL PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Apply MP grease No to a new spider and bearings (b) Fit the spider into the flange yoke Z004248 A (c) Measure dimension A between the snap ring grooves (d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the universal joint NOTICE: When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together B G038873E01 PR–6 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) (e) Select snap rings to make dimensions A and B the same Snap Ring Type G038874 Color Thickness mm (in.) Green 1.384 (0.0545) Red 1.435 (0.0565) Black 1.486 (0.0585) Copper 1.511 (0.0595) Silver 1.537 (0.0605) Yellow 1.588 (0.0625) Blue 1.638 (0.0645) NOTICE: • Use new snap rings • If possible, use snap rings of the same thickness for both edges (f) Insert the spider into the yoke, and then using SST, press the spider bearing into the snap ring groove (g) Press in the spider bearing on the opposite side in the same way SST 09332-25010 NOTICE: When pressing in the spider bearing, be careful not to damage its lip PR F052205 (h) Using needle-nose pliers, install new snap rings into the grooves of the yoke INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear and damage (b) Check each spider bearing's axial play by turning the yoke while holding the shaft tightly Maximum bearing axial play: to 0.05 mm (0 to 0.002 in.) G038875 INSTALLATION SST D033911E01 INSTALL PROPELLER SHAFT ASSEMBLY (a) Remove SST from the extension housing (b) Install the propeller shaft assembly into the extension housing PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) PR–7 (c) Align the matchmarks on the propeller shaft flange and differential flange (d) Install the propeller shaft assembly with the bolts, nuts and washers Torque: 88 N*m (899 kgf*cm, 65 ft.*lbf) INSPECT TRANSMISSION OIL LEAKAGE Matchmarks C060588E01 PR DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–3 REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE FRONT WHEEL DRAIN DIFFERENTIAL OIL SEPARATE FRONT SPEED SENSOR (a) Remove the bolt and separate the front speed sensor (b) Disengage the clamps (c) Remove the bolt and separate the speed sensor wire harness from the steering knuckle SEPARATE TIE ROD END SUB-ASSEMBLY (a) Remove the cotter pin and nut DS F052163E03 (b) Using SST, separate the tie rod end from the steering knuckle SST 09628-62011 SST F051679E01 F042729 REMOVE FRONT AXLE HUB NUT (a) Using a screwdriver and a hammer, remove the front axle hub grease cap DS–4 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) (b) Remove the cotter pin and adjusting cap (c) Remove the front axle hub nut F042732 DS SEPARATE FRONT SUSPENSION LOWER ARM (a) Remove the bolts and separate the front lower ball joint attachment front from the steering knuckle REMOVE FRONT DRIVE SHAFT (a) Using SST, remove the front drive shaft SST 09520-01010, 09520-24010 (09520-32040) NOTICE: Be careful not to damage the oil seal G020159 SST F042739E01 DISASSEMBLY INSPECT FRONT DRIVE SHAFT (a) Check whether there is no remarkable play in the outboard joint (b) Check whether the inboard joint slides smoothly in the thrust direction (c) Check whether there is no remarkable play in the radial direction of the inboard joint (d) Check the boots for damage NOTICE: Move the drive shaft while keeping it level REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Using pliers, disengage the hooks together and remove the large clamp (b) Using a side cutter, cut the small boot clamp SEPARATE INBOARD JOINT BOOT (a) Slide the inboard joint boot toward the outboard joint F052122 F052123 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) Matchmarks DS–5 REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Place matchmarks on the inboard joint and outboard joint shaft NOTICE: Do not punch the marks (b) Remove the inboard joint from the outboard joint shaft F052150E01 (c) Using a snap ring expander, remove the snap ring DS G022501 (d) Place matchmarks on the outboard joint shaft and tripod NOTICE: Do not punch the marks (e) Using a brass bar and hammer, remove the tripod from the outboard joint shaft NOTICE: Do not tap the roller (f) Remove the inboard joint boot from the outboard joint shaft Matchmarks N000194E02 C057543 REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Using a side cutter, cut the boot clamps REMOVE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint shaft REMOVE FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING (a) Using a screwdriver, remove the snap ring DS–6 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) REMOVE FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, remove the dust cover SST 09950-00020 REMOVE FRONT AXLE HUB OIL SEAL (a) Using a screwdriver and a hammer, remove the oil seal SST F040647E01 DS C034791 REASSEMBLY INSTALL FRONT AXLE HUB OIL SEAL (a) Using a screwdriver and a hammer, install a new oil seal NOTICE: Do not damage the oil seal INSTALL FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, install a new dust cover SST 09527-10011 INSTALL FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING (a) Install a new snap ring INSTALL OUTBOARD JOINT BOOT HINT: • Before installing the boots, wrap the spline of the outboard joint with vinyl tape to prevent the boots from being damaged • Before installing the boot, place new boot clamps on the small boot end and large boot ends (a) Provisionally install a new outboard joint boot with new clamps onto the outboard joint shaft C034792 SST F041033E01 Vinyl Tape F052125E01 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–7 (b) Fill the outboard joint and boot with grease in the boot kit Grease capacity: 260 to 280 g (9.2 to 9.9 oz.) (c) Provisionally install the boot onto the outboard joint SST INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Install the boot clamps onto the boot (b) Place SST onto the large boot clamp SST 09521-24010 (c) Tighten the SST so that the large boot clamp is pinched NOTICE: Do not overtighten the SST F052126E01 (d) Using SST, adjust the clearance of the large boot clamp SST 09240-00020 Clearance: 1.0 to 5.0 mm (0.039 to 0.197 in.) (e) Use the same procedure for the small boot clamp SST INSTALL INBOARD JOINT BOOT HINT: Before installing the boot, place a new boot clamp on the small boot end (a) Provisionally install a new inboard joint boot with a new clamp onto the outboard joint shaft INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Place the beveled side of the tripod toward the inboard joint (b) Align the matchmarks and install the tripod into the inboard joint (c) Using a brass bar and hammer, tap the tripod into the outboard joint shaft NOTICE: Do not tap the roller F052127E01 Beveled Matchmarks C067417E02 (d) Using a snap ring expander, install a new snap ring (e) Pack the inboard joint and boot with grease from the boot kit Grease capacity: 182 to 202 g (6.4 to 7.1 oz.) (f) Align the matchmarks placed before removal and install the inboard joint onto the outboard joint shaft (g) Provisionally install the boot onto the inboard joint G022501 INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Place the large boot clamp DS DS–8 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) (b) Using pliers, compress the large clamp and attach the claws F052128 (c) Secure the boot clamp onto the boot (d) Place SST onto the small boot clamp SST 09521-24010 (e) Tighten the SST so that the small boot clamp is pinched NOTICE: Do not overtighten the SST SST DS F052151E01 (f) Using SST, adjust the clearance of the small boot clamp SST 09240-00020 Clearance: 1.0 to 4.0 mm (0.039 to 0.157 in.) SST F052152E01 F052122 INSPECT FRONT DRIVE SHAFT (a) Check whether there is no remarkable play in the outboard joint (b) Check whether the inboard joint slides smoothly in the thrust direction (c) Check whether there is no remarkable play in the radial direction of the inboard joint (d) Check the boots for damage NOTICE: Move the drive shaft while keeping it level (e) Make sure that the boots are not stretched or contracted when the drive shaft is at standard length Drive shaft standard length: 484.4 to 488.4 mm (19.071 to 19.226 in.) NOTICE: Move the drive shaft keeping it level Length F052216E01 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) DS–9 INSTALLATION INSTALL FRONT DRIVE SHAFT (a) Coat the spline of the inboard joint shaft with ATF (b) Align the shaft splines and install the drive shaft with a brass bar and hammer NOTICE: • Set the snap ring with the opening side facing downward • Be careful not to damage the oil seal HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be confirmed from the sound or feeling when driving it INSTALL FRONT SUSPENSION LOWER ARM (a) Install the front lower ball joint attachment with the bolts Torque: 160 N*m (1,631 kgf*cm, 118 ft.*lbf) F042771 DS G020159 F042732 INSTALL FRONT AXLE HUB NUT (a) Install the hub nut Torque: 235 N*m (2,396 kgf*cm, 173 ft.*lbf) (b) Install the adjusting cap and a new cotter pin (c) Install the front axle hub grease cap INSTALL TIE ROD END SUB-ASSEMBLY (a) Install the tie rod end onto the steering knuckle (b) Install the nut Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf) (c) Install a new cotter pin DS–10 DS DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) INSTALL FRONT SPEED SENSOR (a) Install the speed sensor wire harness onto the steering knuckle with the bolt Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Engage the clamps (c) Install the speed sensor with the bolt Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) INSTALL FRONT WHEEL Torque: 113 N*m (1,152 kgf*cm, 83 ft.*lbf) INSPECT DIFFERENTIAL OIL (See page DF-8) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) (See page IN-5) CHECK VSC SENSOR SIGNAL (w/ VSC) (See page BC-103) 10 CHECK ABS SENSOR SIGNAL (w/o VSC) (See page BC-7) F052163E03 11 CHECK FOR DIFFERENTIAL OIL LEAKAGE 12 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-7) PR–1 PROPELLER SHAFT – PROPELLER SHAFT SYSTEM PROPELLER SHAFT SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem The numbers indicate the ranked order of probability of each of the possible causes Check each part in order If necessary, replace these parts Symptom Noise Vibration Suspected area See page Propeller shaft universal joint spider bearing (Regular Cab 2WD) PR-3 Propeller shaft universal joint spider bearing (Access Cab 2WD and Double Cab 2WD) PR-8 Front propeller shaft universal joint spider bearing (4WD) PR-16 Propeller shaft universal joint spider bearing (Regular Cab 4WD) PR-22 Propeller shaft universal joint spider bearing (Access Cab 4WD and Double Cab 4WD) PR-27 Propeller shaft (Runout) (Regular Cab 2WD) PR-4 Propeller shaft (Runout) (Access Cab 2WD and Double Cab 2WD) PR-11 Front propeller shaft (Runout) (4WD) PR-18 Rear propeller shaft (Runout) (Regular Cab 4WD) PR-23 Rear propeller shaft (Runout) (Access Cab 4WD and Double Cab 4WD) PR-29 Propeller shaft (Imbalance) - PR PR–2 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) DRIVE LINE SHAFT PROPELLER COMPONENTS PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING SNAP RING SPIDER PROPELLER SHAFT ASSEMBLY PR UNIVERSAL JOINT SLEEVE YOKE SPIDER UNIVERSAL JOINT FLANGE YOKE x4 88 (899, 65) PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING SNAP RING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part C114109E02 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Regular Cab 2WD) PR–3 REMOVAL REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange (b) Remove the nuts, bolts, washers and front propeller shaft Matchmarks C060588E01 (c) Remove the propeller shaft (d) Insert SST into the transmission to prevent oil leakage SST 09325-40010 SST PR D033911E01 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double Cab 2WD) PR–7 PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double Cab 2WD) DRIVE LINE SHAFT PROPELLER COMPONENTS SPIDER SNAP RING PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING UNIVERSAL JOINT SLEEVE YOKE SNAP RING PLATE UNIVERSAL WASHER WASHER JOINT YOKE SPIDER PR 1st: 182 (1,850, 134) 2nd: 69 (700, 51) PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING 36 (369, 27) CENTER SUPPORT BEARING ASSEMBLY NO SNAP RING SPIDER x4 88 (899, 65) PROPELLER SHAFT PROPELLER SHAFT UNIVERSAL UNIVERSAL JOINT FLANGE YOKE JOINT SPIDER BEARING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part C114116E04 PR–8 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for Access Cab 2WD and Double Cab 2WD) REMOVAL REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange (b) Remove the nuts, bolts and washers, and remove the propeller shaft Matchmarks C060588E01 (c) Remove the center support bearing bolts from the frame crossmember PR D033912 (d) Pull out the propeller shaft (e) Insert SST into the transmission to prevent oil leakage SST 09325-40010 SST D033911E01 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) PR–15 FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) DRIVE LINE SHAFT PROPELLER COMPONENTS SNAP RING FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING 88 (899, 65) UNIVERSAL JOINT FLANGE YOKE FRONT PROPELLER SHAFT ASSEMBLY SPIDER PR 88 (899, 65) 88 (899, 65) UNIVERSAL JOINT FLANGE YOKE SPIDER FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING 88 (899, 65) SNAP RING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part C114108E03 PR–16 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) REMOVAL REMOVE EXHAUST FRONT PIPE ASSEMBLY NO (for 1GR-FE) (See page EX-3) REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY (a) Remove the bolts and propeller shaft heat insulator bracket REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange (b) Remove the nuts, bolts, washers and front propeller shaft F052217 PR Matchmarks C098708E02 (c) Place matchmarks on the propeller shaft flange and transfer flange (d) Remove the nuts, washers and front propeller shaft Matchmarks C098709E02 PROPELLER SHAFT – REAR PROPELLER SHAFT ASSEMBLY (for Regular Cab 4WD) PR–21 REAR PROPELLER SHAFT ASSEMBLY (for Regular Cab 4WD) DRIVE LINE SHAFT PROPELLER COMPONENTS SNAP RING SPIDER PROPELLER SHAFT ASSEMBLY x4 PR 88 (899, 65) UNIVERSAL JOINT FLANGE YOKE PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING UNIVERSAL JOINT FLANGE YOKE SPIDER x4 88 (899, 65) N*m (kgf*cm, ft*lbf) : Specified torque SNAP RING Non-reusable part C114115E02 PR–22 PROPELLER SHAFT – REAR PROPELLER SHAFT ASSEMBLY (for Regular Cab 4WD) REMOVAL REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange (b) Remove the nuts, bolts, washers and front propeller shaft Matchmarks C060588E01 (c) Place matchmarks on the propeller shaft flange and transfer flange (d) Remove the nuts, washers and front propeller shaft Matchmarks PR C098709E02 PR–26 PROPELLER SHAFT – REAR PROPELLER SHAFT ASSEMBLY (for Access Cab 4WD and Double Cab 4WD) REAR PROPELLER SHAFT ASSEMBLY (for Access Cab 4WD and Double Cab 4WD) DRIVE LINE SHAFT PROPELLER COMPONENTS SNAP RING SPIDER PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY x4 88 (899, 65) PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING UNIVERSAL JOINT FLANGE YOKE SNAP RING PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING PR SPIDER PLATE UNIVERSAL WASHER WASHER JOINT YOKE 1st: 182 (1,850, 134) 2nd: 69 (700, 51) 36 (369, 27) CENTER SUPPORT BEARING ASSEMBLY NO SNAP RING SPIDER x4 88 (899, 65) PROPELLER SHAFT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING UNIVERSAL JOINT FLANGE YOKE N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part C114114E02 PROPELLER SHAFT – REAR PROPELLER SHAFT ASSEMBLY (for Access Cab 4WD and Double Cab 4WD) PR–27 REMOVAL REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential (b) Remove the nuts, bolts, washers and front propeller shaft Matchmarks C060588E01 (c) Remove the center support bearing bolts from the frame crossmember PR D033912 (d) Place matchmarks on the propeller shaft flange and transfer flange (e) Remove the nuts, washers and front propeller shaft Matchmarks C098709E02 DS–1 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) FRONT DRIVE SHAFT (for 4WD) DRIVE SHAFT LINE COMPONENTS FRONT DRIVE SHAFT DS 8.3 (85, 73 in.*lbf) 13 (133, 10) FRONT SPEED SENSOR COTTER PIN 91 (928, 67) 235 (2,396, 173) FRONT AXLE HUB NUT TIE ROD END SUB-ASSEMBLY 160 (1,631, 118) ADJUSTING LOCK CAP COTTER PIN FRONT AXLE HUB GREASE CAP LH N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part C114113E01 DS–2 DRIVE SHAFT – FRONT DRIVE SHAFT (for 4WD) FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING FRONT DRIVE SHAFT DUST COVER FRONT DRIVE INBOARD JOINT ASSEMBLY SNAP RING TRIPOD DS INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT CLAMP OUTBOARD JOINT BOOT FRONT DRIVE OUTBORARD JOINT SHAFT ASSEMBLY FRONT AXLE HUB OIL SEAL Non-reusable part C123603E01