Toyota CH-R Service Manual: Disassembly

DISASSEMBLY

PROCEDURE

1. SEPARATE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Using pliers, separate the front No. 2 axle inboard joint boot clamp.

2. SEPARATE FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Separate the front axle inboard joint boot clamp.

HINT:

Perform the same procedure as for the front No. 2 axle inboard joint boot clamp.

3. SEPARATE FRONT AXLE INBOARD JOINT BOOT

(a) Separate the front axle inboard joint boot from the front drive inboard joint assembly.

4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY

(a) Remove the old grease from the front drive inboard joint assembly.

(b) Put matchmarks on the front drive inboard joint assembly and front drive outboard joint shaft assembly. NOTICE: Do not use a punch for the marks.

*a Matchmark

(c) Remove the front drive inboard joint assembly from the front drive outboard joint shaft assembly.

(d) Remove the 3 rollers from the tripod joint.

(e) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(f) Using a snap ring expander, remove the front drive inner shaft inner shaft snap ring from the front drive outboard joint shaft assembly.

(g) Put matchmarks on the front drive outboard joint shaft assembly and tripod joint. NOTICE: Do not use a punch for the marks.

*a Matchmark

(h) Using a brass bar and a hammer, tap out the tripod joint from the front drive outboard joint shaft assembly.

5. REMOVE FRONT AXLE INBOARD JOINT BOOT

(a) Remove the front No. 2 axle inboard joint boot clamp, front axle inboard joint boot and front axle inboard joint boot clamp.

6. REMOVE FRONT DRIVE SHAFT DAMPER LH

(a) Using needle-nose pliers, separate the 2 front drive shaft damper clamps.

(b) Remove the front drive shaft damper and 2 front drive shaft damper clamps from the front drive outboard joint shaft assembly.

7. SEPARATE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP

(a) Using pliers, separate the front No. 2 axle outboard joint boot clamp as shown in the illustration.

8. SEPARATE FRONT AXLE OUTBOARD JOINT BOOT CLAMP

(a) Separate the front axle outboard joint boot clamp.

HINT:

Perform the same procedure as for the front No. 2 axle outboard joint boot clamp.

9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT

(a) Remove the front axle outboard joint boot clamp, front axle outboard joint boot and front No. 2 axle outboard joint boot clamp from the front drive outboard joint shaft assembly.

(b) Remove the old grease from the outboard joint.

10. REMOVE FRONT DRIVE SHAFT DUST COVER LH

HINT:

Only perform the following procedure if the front drive shaft dust cover LH is deformed.

(a) Using SST and a press, remove the front drive shaft dust cover LH. SST: 09950-00020 NOTICE: Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

11. REMOVE FRONT DRIVE SHAFT DUST COVER RH

(a) Using a press, remove the front drive shaft dust cover RH. NOTICE: Be careful not to drop the front drive inboard joint assembly.