Drive/Propeller Shaft: Service and Repair

Propeller Shaft Replacement

Removal Procedure




1. Depress the brake pedal and hold it.

Note:
* Put a piece of cloth or equivalent (1) into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.
* Do not remove the bolts.

2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.




3. Place matchmarks (1, 2) on the rear propeller shaft and the electromagnetic control coupling assembly.
4. Remove the nuts and washers.
5. Using a brass bar and a hammer, separate the rear propeller shaft with the center bearing shaft assembly.





Note: When removing the bolts and washers, do not apply excessive force to the universal joint.

6. Remove the bolts (1, 2, 3, 4) and No. 2 center support bearing washers.

Note:
* When removing the propeller shaft, do not apply a large force to the universal joint.
* During and after the removal of the propeller shaft, keep the universal joint angle straight (within 15 degrees).
* Be careful not to damage the oil seal.

7. Pull out the propeller with center bearing shaft assembly from the transfer.




8. Insert a suitable seal installer (1) into the transfer to prevent oil leakage.

Installation Procedure




1. Remove the seal installer (1) from the transfer.

Note:
* Be careful not to damage the oil seal.
* Be careful not to damage the universal joint boot when installing the propeller shaft.

2. Install the propeller with center bearing shaft assembly.




3. Align matchmarks (1, 2) on the rear propeller shaft and the electromagnetic control coupling assembly and install the nuts and washers temporarily.





Note: Use the removed washers when installation.

4. Install the 2 No. 1 center support bearing assembly with the bolts (1, 2, 3, 4) and No. 2 center support bearing washers.




5. Align the matchmarks (1, 2).

Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the center support bearing nuts and tighten to 37 Nm (27 lb ft).




7. Remove the piece of cloth (1) from the universal joint.
8. Depress the brake pedal and hold it.
9. Using a hexagon wrench (6 mm), tighten the bolts to 26 Nm (19 lb ft).




10. With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft.

Length A - 65.5 to 70.5 mm (2.579 to 2.776 in)




11. With the vehicle unloaded, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown, and then tighten the bolts.

Length A - 11.5 to 13.5 mm (0.453 to 0.532 in)

12. Check that the center line of the bracket is at a right angle to the shaft axial direction.




13. Tighten the bolts (1) to 37 Nm (27 lb ft).
14. If any vibration or noise occurs, perform joint angle check as follows and replace the No. 2 center support bearing washer with a proper one.
15. Turn the propeller shaft several times by hand to stabilize the center support bearings.
16. Using a jack, raise and lower the differential to stabilize the differential mounting cushion.
17. Remove the transfer dynamic damper.




18. Using an angle meter or equivalent, measure the propeller shaft installation angle (6) and intermediate shaft installation angle (5).

No. 1 joint angle (1) - (6) - (5) = -1.74 degrees to +0.26 degrees

Note: Make sure to use a washer of the same thickness on both right and left sides. Do not use 2 or more washers on a bolt.

19. Using an angle meter or equivalent, measure the rear propeller shaft installation angle (4) and rear differential installation angle (3).

No. 2 joint angle (2) - (4) - (3) = 1.20 degrees to 2.20 degrees
If the calculated amount is not within the specification, adjust it with the No. 2 center support bearing washer.
20. Install the transfer dynamic damper and tighten to 26 Nm (19 lb ft).