2001 TOYOTA PRIUS Service Repair Manual

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)