2005 TOYOTA AVENSIS boot

C81167
C57543
F40647
SST
C67101
30±10
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
19. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Using pliers and remove the outboard joint boot LH No.2
clamp, as shown in the illustration.
(b) Remove the outboard joint boot LH clamp by the same
procedures as outboard joint boot LH No.2 clamp.
20. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft assy LH.
(b) Remove the old grease from the outboard joint.
21. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Using a screwdriver, remove the hole snap ring.
HINT:
Except RH (1AZ±FSE, 1AZ±FE, 1CD±FTV)
22. REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, remove the front drive shaft dust
cover LH.
SST 09950±00020
NOTICE:
Be careful not to drop the inboard joint assy.
23. REMOVE FRONT DRIVE SHAFT DUST COVER RH
(a) 1AZ±FSE, 1AZ±FE, 1CD±FTV:
(1) Using a press, remove the drive shaft dust cover
RH.

W01994
Vinyl Tape
R10425
SSTHold
Turn
R10426
SST
30±14
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
35. 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.
(a) Install new parts to the outboard joint shaft assy in the fol-
lowing order.
(1) Outboard joint boot LH No.2 clamp
(2) Outboard joint boot
(3) Outboard joint boot LH clamp
(b) Pack the outboard joint shaft and boot with grease in the
boot kit.
Grease capacity:
Engine typeGrease capacity g (oz.)
1AZ±FSE, 1AZ±FE, 1CD±FTV152 ± 162 g
(5.4 ± 5.7 oz.)
3ZZ±FE, 1ZZ±FE85 ± 105 g
(3.0 ± 3.7 oz.)
36. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Hold the front drive shaft in a soft vise.
(b) Secure the 2 outboard joint boot clamps onto the boot.
(c) Place SST onto the outboard joint large boot clamp.
SST 09521±24010
(d) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(e) Using SST, adjust the clearance of the large clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
(f) Install the outboard joint boot LH clamp by the same pro-
cedures as the outboard joint boot LH No.2 clamp.
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.

C86268
SST
C67417
Matchmarks
30±16
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
(5) Using SST, adjust the clearance of the damper
clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
HINT:

Install the damper clamp to inboard joint side.

Except 1AZ±FSE, FE (MT)/ 1CD±FTV

Perform the above procedure only when reassembling
the RH side
38. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Wrap the spline of the outboard joint shaft assy LH with
vinyl tape to prevent them from being damaged.
(b) Install new parts to the outboard joint shaft assy LH in the
following order.
(1) Inboard joint boot LH clamp
(2) Inboard joint boot
(3) Inboard joint boot LH No.2 clamp
(c) Place the beveled side of the tripod axial spline toward the
outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap in the tripod joint assy
to the drive shaft assy LH.
NOTICE:

Do not tap the roller.

Be sure to install the tripod joint assy in the correct
direction.
(f) Pack the inboard joint shaft and boot with grease in the
boot kit.
Engine typeGrease capacity g (oz.)
1AZ±FSE, 1AZ±FE, 1CD±FTV170 ± 190 g
(6.0 ± 6.7 oz.)
3ZZ±FE, 1ZZ±FE125.5 ± 135.5 g
(4.4 ± 4.8 oz.)

G24058

F45461
Matchmarks
C86269
SST
Hold
Turn
C86270SST
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±17
AVENSIS REPAIR MANUAL (RM1018E)
(g) Using a snap ring expander, install a new shaft snap ring.
(h) Aligning the matchmarks, install the inboard joint assy LH
to the outboard joint shaft assy LH.
39. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy LH and outboard joint shaft assy LH.
40. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) Install the inboard joint boot clamp.
(1) Hold the drive shaft in a soft vise.
(2) Secure the 2 inboard joint boot clamps onto the
boot.
(3) Place SST onto the inboard joint large boot clamp.
SST 09521±24010
(4) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(5) Using SST, adjust the clearance of the large clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
(b) Install the inboard joint boot LH clamp by the same proce-
dures as the inboard joint boot LH No.2 clamp.

C91598

F45254
(A)
C83851
C83155
1AZ±FSE/
1AZ±FE:
F44774
1CD±FTV: 30±18
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
41. INSPECT FRONT DRIVE SHAFT
(a) Check that there is no remarkable play in the radial direc-
tion 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 direc-
tion of the inboard joint.
(d) Check the boots for damage.
NOTICE:
Keep the drive shaft assy level during inspection.
HINT:
For dimension (A), refer to the following table.
Engine typeLH mm (in.)RH mm (in.)
3ZZ±FE583.8 (22.98)
5.0 (0.20)856.3 (33.71)
5.0 (0.20)
1ZZ±FE582.9 (22.94)
5.0 (0.20)855.4 (33.68)
5.0 (0.20)
1AZ±FSE, 1AZ±FE559.8 (22.03)
5.0 (0.20)876.0 (34.49)
5.0 (0.20)
1CD±FTV546.8 (21.53)
5.0 (0.20)889.0 (35.00)
5.0 (0.20)
42. INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Coat the spline of the inboard joint shaft assy LH with gear
oil.
(b) Aligh the shaft splines and install the drive shaft assy LH
with a brass bar and hammer.
NOTICE:

Set the snap ring with the opening side facing down-
wards.

Be careful not to damage the oil seal, boot and dust
cover.
43. INSTALL FRONT DRIVE SHAFT ASSY RH
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only.
(a) Coat the spline of the inboard joint shaft assy RH with
gear oil.
(b) Aline the shaft splines and install the drive shaft assy RH
with the 2 bolts.
Torque: 64 N
m (650 kgf
cm, 47 ft
lbf)
NOTICE:
Do not damage the oil seal, boot and dust cover.

C80293
F44775
C80291
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±19
AVENSIS REPAIR MANUAL (RM1018E)
44. INSTALL FRONT AXLE ASSY LH
(a) Install the drive shaft assy LH to the front axle assy LH.
NOTICE:

Be careful not to damage the outboard joint boot.

Be careful not to damage the speed sensor rotor.
45. INSTALL FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Install the lower ball joint to the front suspension arm sub±
assy lower No.1 LH with the bolt and 2 nuts.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
46. INSTALL TIE ROD END SUB±ASSY LH
(a) Install the tie rod end sub±assy LH to the steering knuckle with the nut.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
47. CONNECT SPEED SENSOR FRONT LH
(a) Install the speed sensor front LH to the steering knuckle
with the bolt.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the speed sensor wire and flexible hose to the
shock absorber with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Be careful not to damage the speed sensor.

Keep the speed sensor clean.

Do not twist the sensor wire when installing the sen-
sor.


F45574Non±reusable parts

Front Drive Shaft Dust Cover LH
Front Drive Inboard Joint Assy LH
Front Drive Inner Shaft
Inner LH Shaft Snap Ring
Front Axle Inboard Joint Boot LH Clamp
Drive Shaft Damper Drive Shaft Damper Clamp Front Drive Shaft Inboard
Joint Boot Front Axle Inboard Joint Boot LH No.2 ClampTripod Joint Assy








Front Drive Shaft Out board Joint Boot
Front Axle Outboard Joint Boot LH No.2 Clamp


Front Drive Outboard Joint Shaft Assy LH
Front Axle Outboard
Joint Boot LH Clamp
LH:
Except
1AZ±FSE (MT)/
1AZ±FE (MT)/
1CD±FTV:



30±4
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)


F45575Non±reusable parts
Front Axle Outboard Joint Boot RH No.2 Clamp
Drive Shaft Outboard Joint Boot
Front Axle Out board Joint Boot RH Clamp
Drive Shaft DamperFront Axle Inboard Joint Boot RH Clamp
Drive Shaft Inboard Joint Boot
Front Axle Inboard Joint
Boot RH No.2 Clamp




Front Drive Outboard Joint Shaft Assy RH
RH:
3ZZ±FE/
1ZZ±FE:1AZ±FSE/
1AZ±FE/
1CD±FTV:
Front Drive Inboard
Joint Assy RH
Front Drive Shaft
Dust Cover RHTripod Joint Assy
Front Drive Inner
Shaft Inner RH
Shaft Snap Ring Drive Shaft Bearing
Case Snap Ring
Front Drive Shaft Bearing
Straight Pin
Drive Shaft Bearing Case
Front Drive Shaft
Hole Snap Ring
Front Drive Shaft
Dust Cover
Front Drive Shaft
Dust Cover RH













3ZZ±FE/
1ZZ±FE:
1AZ±FSE/
1AZ±FE/
1CD±FTV:
Front Drive Inboard
Joint Assy RH








± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±5
AVENSIS REPAIR MANUAL (RM1018E)