Toyota Prius: Front Drive Shaft Assembly

• Removal
• Disassembly
• Inspection
• Reassembly
• Installation

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during front drive shaft assembly removal/installation are shown below.

CAUTION / NOTICE / HINT

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*1: Also necessary after performing a tire rotation. *2: It is not necessary to perform this procedure if the tire pressure warning valve and transmitters are installed to the same location. *3: The Toyota Prius vehicle height changes because of tire replacement.
Front wheel alignment adjustment	Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system disabled or malfunctions
Suspension parts	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization	Panoramic View Monitor System
		Advanced Park
Tires	Initialization*1*2 Tire Position Identification*1*2	Tire Pressure Warning System	Refer to Procedures Necessary When Replacing Parts (for Tire Pressure Warning System) table below
	Rear television camera assembly optical axis (Back camera position setting)*3	Parking Assist Monitor System
	Parking assist ECU initialization*3	Panoramic View Monitor System
		Advanced Park

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	FRONT WHEELS	-	-	-	-
2	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
3	REAR ENGINE UNDER COVER LH	51444A		-	-
4	REAR ENGINE UNDER COVER RH	51443C	-	-	-
5	HYBRID TRANSAXLE FLUID	-	-		-

Procedure		Part Name Code
6	FRONT AXLE SHAFT NUT	43502H		-	-
7	FRONT SPEED SENSOR	89543		-	-
8	TIE ROD END SUB-ASSEMBLY	45047		-	-
9	FRONT STABILIZER LINK ASSEMBLY	48810		-	-
10	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY	48069	-	-	-
11	FRONT DRIVE SHAFT ASSEMBLY	43420		-	-

*1	FRONT FLEXIBLE HOSE	*2	FRONT AXLE ASSEMBLY
*3	COTTER PIN	-	-
●	Non-reusable part	-	-

Procedure		Part Name Code
12	FRONT DRIVE SHAFT ASSEMBLY	43420		-	-
13	FRONT DRIVE SHAFT HOLE SNAP RING	43420G	-	-	-

●

Non-reusable part

-

-

PROCEDURE

1. REMOVE FRONT WHEELS

Click here

2. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

for M20A-FXS: Click here

for 2ZR-FXE: Click here

3. REMOVE REAR ENGINE UNDER COVER LH

Use the same procedure as for the RH side. for M20A-FXS: Click here for 2ZR-FXE: Click here

4. REMOVE REAR ENGINE UNDER COVER RH

for M20A-FXS: Click here

for 2ZR-FXE: Click here

5. DRAIN HYBRID TRANSAXLE FLUID

Click here

6. REMOVE FRONT AXLE SHAFT NUT

(1) Using SST and a hammer, release the staked part of the front axle shaft nut.

SST: 09930-00010

NOTICE:

Loosen the staked part of the front axle shaft nut completely, otherwise the threads of the drive shaft may be damaged.

(2) While applying the brakes, remove the front axle shaft nut.

7. SEPARATE FRONT SPEED SENSOR

Click here

8. SEPARATE TIE ROD END SUB-ASSEMBLY

Click here

9. SEPARATE FRONT STABILIZER LINK ASSEMBLY

Click here

10. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

Click here

11. SEPARATE FRONT DRIVE SHAFT ASSEMBLY

Click here

12. REMOVE FRONT DRIVE SHAFT ASSEMBLY

(1) Using SST, remove the front drive shaft assembly.

SST: 09520-01011

SST: 09520-20010

09521-02010

09521-02040

09521-02060

13. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (DISASSEMBLY)

Procedure		Part Name Code
1	FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP	43448G		-	-
2	FRONT AXLE INBOARD JOINT BOOT CLAMP	43448F		-	-
3	FRONT AXLE INBOARD JOINT BOOT	-	-	-	-
4	FRONT DRIVE INBOARD JOINT ASSEMBLY	43040		-	-
5	FRONT DRIVE SHAFT DAMPER CLAMP	43474G		-	-
6	FRONT DRIVE SHAFT DAMPER	43474E	-	-	-

*1	TRIPOD JOINT	*2	FRONT AXLE INBOARD JOINT GROMMET
*3	FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY	*4	SHAFT SNAP RING
●	Non-reusable part	-	-

Procedure		Part Name Code
7	FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP	43447F		-	-
8	FRONT AXLE OUTBOARD JOINT BOOT CLAMP	43447E		-	-
9	FRONT AXLE OUTBOARD JOINT BOOT	-		-	-

*A	for LH Side	-	-
*1	FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY	-	-
●	Non-reusable part	-	-

PROCEDURE

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

(1) Using a screwdriver, release the staked part of the front No. 2 axle inboard joint boot clamp and separate the front No. 2 axle inboard joint boot clamp.

2. SEPARATE FRONT AXLE INBOARD JOINT BOOT CLAMP

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

3. SEPARATE FRONT AXLE INBOARD JOINT BOOT

4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY

*a

Matchmark

-

-

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

(2) 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.

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

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

(5) Put matchmarks on the front drive outboard joint shaft assembly and tripod joint.

NOTICE:

Do not use a punch for the marks.

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

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

(8) Remove the front axle inboard joint grommet from the front drive inboard joint assembly.

5. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP

*a

Claw

-

-

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

6. REMOVE FRONT DRIVE SHAFT DAMPER

7. SEPARATE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

(1) Using a screwdriver, release the staked part of the front No. 2 axle outboard joint boot clamp and separate the front No. 2 axle outboard joint boot clamp.

8. SEPARATE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

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

9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)

(1) 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.

(2) Remove the old grease from the front drive outboard joint shaft assembly.

Inspection

INSPECTION

PROCEDURE

1. INSPECT FRONT DRIVE SHAFT ASSEMBLY

(a) Check that there is no excessive play in the radial direction of the outboard joint.

(b) Check that the inboard joint slides smoothly in the thrust direction.

(c) Check that there is no excessive play in the radial direction of the inboard joint.

(d) Check the boots for damage.

(e) Check whether each drive shaft dimension (A) is within specification. NOTICE: Keep the drive shaft assembly level during inspection. Dimension (A) (for M20A-FXS): Installation Position Specified Condition Result for LH Side 587.2 to 595.2 mm 1.93 to 1.95 ft. mm ft. for RH Side 891.2 to 899.2 mm 2.92 to 2.95 ft. mm ft. Dimension (A) (for 2ZR-FXE): Installation Position Specified Condition Result for LH Side 592.2 to 600.2 mm 1.94 to 1.97 ft. mm ft. for RH Side 891.2 to 899.2 mm 2.92 to 2.95 ft. mm ft.

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	FRONT AXLE OUTBOARD JOINT BOOT	-		-	-
2	FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP	43447F		-	-
3	FRONT AXLE OUTBOARD JOINT BOOT CLAMP	43447E		-	-

*A	for LH Side	-	-
*1	FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY	-	-
●	Non-reusable part	-	-

Procedure		Part Name Code
4	FRONT DRIVE SHAFT DAMPER	43474E		-	-
5	FRONT DRIVE SHAFT DAMPER CLAMP	43474G		-	-
6	FRONT DRIVE INBOARD JOINT ASSEMBLY	43040		-	-
7	FRONT AXLE INBOARD JOINT BOOT	-		-	-
8	FRONT AXLE INBOARD JOINT BOOT CLAMP	43448F		-	-
9	FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP	43448G		-	-
10	INSPECT FRONT DRIVE SHAFT ASSEMBLY	43420		-	-

*1	TRIPOD JOINT	*2	FRONT AXLE INBOARD JOINT GROMMET
*3	FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY	*4	SHAFT SNAP RING
●	Non-reusable part	-	-

PROCEDURE

1. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)

	Outboard Joint Side		Inboard Joint Side
	Parts insertion direction		Grease

(1) Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

(2) Install new parts to the front drive outboard joint shaft assembly in the following order:

1. Front No. 2 axle outboard joint boot clamp

2. Front axle outboard joint boot

3. Front axle outboard joint boot clamp

(3) Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

Standard Grease Capacity:

135 to 145 g (4.76 to 5.11 oz.)

(4) Install the front axle outboard joint boot to the front drive outboard joint shaft assembly groove.

2. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

CAUTION: When installing the front No. 2 axle outboard joint boot clamp, do not perform the work without wearing protective gloves. If work is performed without using protective gloves, injuries may occur.

*a	Fulcrum Point	*b	Lever Push Position
*c	Band Support Position	-	-

(1) Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot and temporarily fold back the lever at the fulcrum point.

*a	Press down	*b	Contact Point
*c	Turn	*d	Temporary Claw
*e	Fulcrum Point	-	-

(1) As shown in the illustration, while pressing the outboard joint area against the work surface, firmly press the lever into place by rolling the outboard joint area forward from the folded fulcrum point to the temporary claw area until a click sound is heard.

*a

Buckle

-

-

(1) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

CAUTION: When installing the front axle outboard joint boot clamp, do not perform the work without wearing protective gloves. If work is performed without using protective gloves, injuries may occur.

*a

Place the tip near the center of the lever

*b

Buckle

(1) Install the front axle outboard joint boot clamp to the front axle outboard joint boot and provisionally bend the lever.

(2) Using water pump pliers, temporarily secure the front axle outboard joint boot clamp by pinching the front axle outboard joint boot clamp until a click sound is heard.

NOTICE:

Do not damage the front axle outboard joint boot.

(3) Using a plastic hammer, tap the buckle to fix it while adjusting the clearance between the lever and groove to make the clearances between the buckle edge and lever end even.

4. INSTALL FRONT DRIVE SHAFT DAMPER

(1) Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

Dimension (A) (for M20A-FXS):

for LH Side	211.7 to 215.7 mm (8.33 to 8.49 in.)
for RH Side	488 to 492 mm (1.60 to 1.61 ft.)

Dimension (A) (for 2ZR-FXE):

for LH Side	243.4 to 247.4 mm (9.58 to 9.74 in.)
for RH Side	488 to 492 mm (1.60 to 1.61 ft.)

5. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP

*a

Claw

-

-

(1) Using needle-nose pliers, install the 2 front drive shaft damper clamps as shown in the illustration.

6. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY

*a	Matchmark	*b	Groove
	Outboard Joint Side		Inboard Joint Side
	Install in this Direction		Grease

(1) Install new parts to the front drive outboard joint shaft assembly in the following order:

1. Front axle inboard joint boot clamp

2. Front axle inboard joint boot

3. Front No. 2 axle inboard joint boot clamp

(2) Remove the protective tape.

(3) Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

Face the serrated side of the tripod joint outward and install it to the outboard joint end.

(4) Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.

(5) Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

(6) Pack the front drive inboard joint assembly and front axle inboard joint boot with grease.

Standard Grease Capacity:

168 to 178 g (5.93 to 6.28 oz.)

(7) Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

(8) Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

7. INSTALL FRONT AXLE INBOARD JOINT BOOT

(1) Install the front axle inboard joint boot to the front drive inboard joint assembly.

8. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

CAUTION: When installing the front axle inboard joint boot clamp, do not perform the procedure without wearing protective gloves. Performing the procedure without wearing protective gloves could result in injury.

*a

Place the tip near the center of the lever

*b

Buckle

(1) Install the front axle inboard joint boot clamp to the front axle inboard joint boot and temporarily fold back the lever.

(2) Using water pump pliers, temporarily secure the front axle inboard joint boot clamp by pinching the front axle inboard joint boot clamp until a click sound is heard.

NOTICE:

Do not damage the front axle inboard joint boot.

(3) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

9. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

CAUTION: When installing the front No. 2 axle inboard joint boot clamp, do not perform the work without wearing protective gloves. Performing the procedure without wearing protective gloves could result in injury.

*a

Indented Portion

*b

Support Point

(1) Check whether the dimension (A) of each drive shaft is within specification.

Dimension (A) (M20A-FXS):

for LH Side	587.2 to 595.2 mm (1.93 to 1.95 ft.)
for RH Side	891.2 to 899.2 mm (2.92 to 2.95 ft.)

Dimension (A) (2ZR-FXE):

for LH Side	592.2 to 600.2 mm (1.94 to 1.97 ft.)
for RH Side	891.2 to 899.2 mm (2.92 to 2.95 ft.)

(2) While holding dimension (A) to the specified length, pull the indented portion of the inboard joint grommet outward with your finger, etc. to release air from inside the inboard joint and equalize the air pressure with the atmospheric pressure.

(3) Set the folding support point of the clamp so that it is aligned with any of the B portions indicated by arrows in the illustration.

*a	Fulcrum Point	*b	Lever Push Position
*c	Band Support Position	-	-

(1) Temporarily fold back the lever at the fulcrum point.

*a	Press down	*b	Contact Point
*c	Turn	*d	Temporary Claw
*e	Fulcrum Point	-	-

(1) As shown in the illustration, while pressing the outboard joint area against the work surface, firmly press the lever into place by rolling the outboard joint area forward from the folded fulcrum point to the temporary claw area until a click sound is heard.

*a

Buckle

-

-

(1) Using a plastic hammer, tap the buckle to secure it while adjusting the clearance between the lever and the groove to make the clearance between the buckle edge and the lever end even.

10. INSPECT FRONT DRIVE SHAFT ASSEMBLY

Click here

Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	FRONT DRIVE SHAFT HOLE SNAP RING	43420G		-	-
2	FRONT DRIVE SHAFT ASSEMBLY	43420		-	-

*1	FRONT DRIVE SHAFT OIL SEAL	-	-
●	Non-reusable part		MP grease
	Toyota Genuine e-Transaxle Fluid TE		Toyota Genuine Oil Seal Side Lip Grease

Procedure		Part Name Code
3	FRONT DRIVE SHAFT ASSEMBLY	43420		-	-
4	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY	48069	-	-	-
5	FRONT STABILIZER LINK ASSEMBLY	48810		-	-
6	TIE ROD END SUB-ASSEMBLY	45047		-	-
7	FRONT SPEED SENSOR	89543		-	-
8	FRONT AXLE SHAFT NUT	43502H		-	-

*1	FRONT FLEXIBLE HOSE	*2	FRONT AXLE ASSEMBLY
*3	COTTER PIN	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)	●	Non-reusable part
	Toyota Body Grease W		Do not apply lubricants to the threaded parts

Procedure		Part Name Code
9	ADD HYBRID TRANSAXLE FLUID	-	-		-
10	INSPECT HYBRID TRANSAXLE FLUID	-	-	-
11	INSPECT FOR HYBRID TRANSAXLE FLUID LEAK	-	-	-
12	FRONT WHEELS	-	-	-	-
13	INSPECT AND ADJUST FRONT WHEEL ALIGNMENT	-	-	-
14	REAR ENGINE UNDER COVER LH	51444A	-	-	-
15	REAR ENGINE UNDER COVER RH	51443C	-	-	-
16	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
17	CHECK FOR SPEED SENSOR SIGNAL	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

PROCEDURE

1. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING

(1) Install a new front drive shaft hole snap ring.

NOTICE:

Face the end gap of the front drive shaft hole snap ring downward.

2. INSTALL FRONT DRIVE SHAFT ASSEMBLY

	MP grease		Toyota Genuine e-Transaxle Fluid TE
	Toyota Genuine Oil Seal Side Lip Grease	-	-

(1) Coat the snap ring of the front drive inboard joint assembly with MP grease.

(2) Coat the splines of the front drive inboard joint assembly with Toyota Genuine e-Transaxle Fluid TE.

(3) Coat the lip of the front drive shaft oil seal LH with MP grease and Toyota genuine oil seal side lip grease as shown in the illustration.

HINT:

Apply a light coat of MP grease and Toyota genuine oil seal side lip grease to the entire circumference of the front drive shaft oil seal LH.

(4) Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

HINT:

Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

3. CONNECT FRONT DRIVE SHAFT ASSEMBLY

*a	Matchmark	-	-
	Toyota Body Grease W	-	-

(1) Apply 0.1 to 0.3 g (0.00353 to 0.0105 oz.) of Toyota Body Grease W to each of the 4 areas shown in the illustration.

(2) Align the matchmarks and install the front drive shaft assembly to the front axle assembly.

4. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

Click here

5. INSTALL FRONT STABILIZER LINK ASSEMBLY

Click here

6. CONNECT TIE ROD END SUB-ASSEMBLY

Click here

7. INSTALL FRONT SPEED SENSOR

Click here

8. INSTALL FRONT AXLE SHAFT NUT

(1) Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using non-residue solvent.

(2) Using a 30 mm deep socket wrench, install the front axle shaft nut.

HINT:

Keep depressing the brake pedal to prevent the drive shaft from rotating.

Torque:

216 N·m {2203 kgf·cm, 159 ft·lbf}

(3) Using a chisel and a hammer, stake the front axle shaft nut.

9. ADD HYBRID TRANSAXLE FLUID

Click here

10. INSPECT HYBRID TRANSAXLE FLUID

Click here

11. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK

Click here

12. INSTALL FRONT WHEELS

Click here

13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

14. INSTALL REAR ENGINE UNDER COVER LH

15. INSTALL REAR ENGINE UNDER COVER RH

16. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

for M20A-FXS: Click here

for 2ZR-FXE: Click here

17. CHECK FOR SPEED SENSOR SIGNAL

Click here

18. PERFORM INITIALIZATION

Parking Assist Monitor System
Panoramic View Monitor System
Advanced Park