How to replace a driveshaft

Gearboxs, Transfers, Tailshafts, Diffs, axles and CVs

How to replace a driveshaft

Postby Hilux Max on Thu, 16 Jun 2011 7:20 +0000

This thread is going to be your number one resource on how to replace a front driveshaft on your hilux.

To better understand your front end here is a layout of components.
Front Suspension Layout showing location of front driveshaft
Image

Driveshaft Assembly Diagram
Image


And here is the exerpt from the Toyota Workshop Manual that shows you how to do it going by the book.

Front Driveshaft Removal Instructions

1. REMOVE FRONT WHEEL

2. DRAIN DIFFERENTIAL OIL

3. REMOVE FRONT AXLE HUB GREASE CAP

Image

4. REMOVE FRONT AXLE HUB NUT

a - Remove the cotter pin and adjusting cap.
b - Remove the axle hub nut.

Image

5. REMOVE FRONT SPEED SENSOR LH

a - Remove the bolt and speed sensor.
b - Disconnect the 2 clamps.
c - Remove the bolt and disconnect the speed sensor wire harness from the steering knuckle.

Image

6. DISCONNECT TIE ROD END SUB-ASSEMBLY

a - Remove the cotter pin and nut.
b - Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011

Image

7. DISCONNECT FRONT SUSPENSION LOWER ARM ASSEMBLY WITH ATTACHMENT

a - Remove the 2 bolts and disconnect the suspension arm from the steering knuckle.

Image

8. REMOVE FRONT DRIVE SHAFT ASSEMBLY

a - Using SST, tap out the drive shaft.
SST 09520-01010 09520-24010 (09520-32040)
NOTICE: Be careful not to damage the oil seal.

Image


How to replace your front driveshaft when offroad?

Pretty much the same method as above but you improvise a little.

Tools Required to be carried -

1. Replacement Driveshaft
2. Some sort of Jack to raise vehicle
3. Small Crowbar or Long chisel/Cold Punch of some form or Flat head Screwdriver.
4. Medium Sized Hammer
5. Small Flathead Screwdriver
6. 10mm spanner/socket for speed sensor nut
7. 17mm spanner with a 6mm Allen Key to remove Sway Bar Link from Steering Knuckle
8. 19mm single Hex socket and breaker bar for 2 x lower bolt joint to hub bolts.
9. 35mm Single Hex socket
10. 21mm socket for wheel nuts.

Process for Changing Driveshaft Offroad

1. Find some flat clear ground to park your vehicle where your not going to bother anyone and is safe.
2. Jack up the side of the vehicle that needs the driveshaft replaced.
3. Remove Wheel on that side and place below the vehicle chassis rails as a safety precaution in case the jack lets go.
4. With hammer and small flathead screwdriver gently tap off the grease cap off the hub.
5. With the same screwdriver straighten out the cotter pin and gently tap it ou with the hammer and screwdriver.
6. Remove cotter pin and adjusting cap.
7. Get someone to put their foot on the brake pedal and with the 35mm single hex nut and breaker bar, very carefully put pressure and loosen driveshaft nut.
Note: you will be using considerable force/leverage to loosen this nut, be careful not to slip as you risk knocking yourself out on the disc brake!
8. Remove 10mm bolt holding speed sensor and carefully place speed sensor on the side, even tie it up. Do not touch the face of the sensor.
9. Use 17mm spanner over the nut whilst holding the 6mm allen key within the nut to loosen it and remove swaybar link.
10. Use breaker bar and 19mm single hex socket to remove lower 2 balljoint to hub bolts.
Note: as the bolts come loose the lower control arm "may" jerk downwards with pressure from the coil over releasing.
11. Using a piece of wood, rest it onto the end of the driveshaft and give the wood a couple taps with the hammer to loosen the outer stub in the hub.
12. Get someone to leverage the hub, out and forwards whilst you pull the outer stub out of the hub from the inner side.
13. Use the hammer and chisel/screwdriver etc and place the chisel/screwdriver against the ribs on the inner driveshaft cup angled outwards. Give a couple hard taps, and driveshaft should come loose out of the diff housing.

Note:
- Be careful not to damage the driveshaft seal on the diff housing.
- Do not drop the driveshaft so as to damage the splines on rocks.
- Reverse is the same except to note that the C-Clip at the end of the driveshaft on the inner stub should be positioned with the open end facing downwards as you push it back into the diff housing. Do not attempt to fit outer stub through hub until inner stub has seated fully.



Appendices

Toyota GSIC link - http://toyota.esealtd.com/toyota/hilux/repair2/html/frame_rm000000zz9000x.html

Pdf File Link to workshop manual Instructions (05+Tacoma-USA) - http://www.ncttora.com/fsm/05+/data/ileaf/06toyrm/06toypdf/06rmsrc/rm2006ta/03600.pdf
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Re: How to replace a driveshaft

Postby Hilux Max on Thu, 16 Jun 2011 7:25 +0000

Just to add....the Monster Rides Driveshaft Tool is an awesome bit of gear to have in your offroad toolkit aswell. It is very strong and can be used as both a breaker bar, chisel, and has a 35mm single hex cutout thats perfect for the driveshaft nut -

Image
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Re: How to replace a driveshaft

Postby Jack S on Thu, 16 Jun 2011 7:42 +0000

You da man Max :D
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Re: How to replace a driveshaft

Postby kyle300exc on Thu, 16 Jun 2011 7:48 +0000

Ah mmaaxx your a champion, Im going to print this off and stick it in my glove box thanks a lot.
Hey Jack dont need to take you with me now ;) ;) ;) ;)
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Re: How to replace a driveshaft

Postby jap on Thu, 16 Jun 2011 8:08 +0000

Im gonna take mine out for the drags :twisted:
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How to replace a driveshaft

Postby KTM525EXC on Thu, 16 Jun 2011 8:10 +0000

Nice one max :D like Alby said I'm taking a print out and keeping it In my lux ;)
D4D THE WAY TO BE!!!!!!
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Re: How to replace a driveshaft

Postby seb on Thu, 16 Jun 2011 8:12 +0000

Great work max. 8-)
Cheers Seb.
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Re: How to replace a driveshaft

Postby danmcccc on Fri, 17 Jun 2011 8:09 +0000

veeeeeeeeery good thread, im diesel fitter so you thought i would know it already but i didnt, sad aye haha.....sooooo easy tho, i rekon theres about 30-40mins work there for someone not mechanical and doing it for the first time, easy as

cheers
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Re: How to replace a driveshaft

Postby Bushbound on Fri, 17 Jun 2011 5:39 +0000

Max,
How much is the Drive shaft tool ???
Geoff
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Re: How to replace a driveshaft

Postby Hilux Max on Fri, 17 Jun 2011 5:44 +0000

Which one? the genuine SST slide hammer or the Monster Rides Driveshaft Nut breaker bar tool?
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Re: How to replace a driveshaft

Postby danmcccc on Fri, 17 Jun 2011 6:44 +0000

mmaaxx wrote:Which one? the genuine SST slide hammer or the Monster Rides Driveshaft Nut breaker bar tool?

lets go with MR tool, coz that would be handy if it was cheap
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Re: How to replace a driveshaft

Postby Hilux Max on Fri, 17 Jun 2011 7:11 +0000

$55 delivered....and you can leave it in your vehicle for "personal protection" aswell :roll:
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Re: How to replace a driveshaft

Postby fourby4diesel on Mon, 01 Aug 2011 3:09 +0000

Excellent maxx, now I need a 35mm socket, my workshop, Burson and Repco don't have one!
Anyone in hillside vic, want to lend mr theirs for a day?
Any ideas who stocks them????
New DENSO Injectors are the go! New genuine parts.
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WARNING check oil pickup screen is clear
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Re: How to replace a driveshaft

Postby dermy on Sat, 06 Aug 2011 11:49 +0000

hey guys I just snapped the inner part of the cv.. so the inner boots still on the cv but the bit the goes into the diff is still in the diff should I just remove outer part of the cv so I can drive?
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Re: How to replace a driveshaft

Postby fourby4diesel on Sat, 06 Aug 2011 11:57 +0000

Ring me if u need to 0416111155
New DENSO Injectors are the go! New genuine parts.
Cheers, Anth - Technician - 1KD-FTV

Check your injectors about every 10,000k.
WARNING check oil pickup screen is clear
no chips no tune ups - why increase risk of piston cracking?
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Re: How to replace a driveshaft

Postby fourby4diesel on Sat, 06 Aug 2011 12:06 +0000

Yes. Inner cup must be locked in so oil doesn't puss out.
Outer hold hub together.
I just made sure inner tripod was in cup and drove anyway, still had 4x4.
U just loose your bearings.
A bit if jingle bells.
But easy to keep mobile.
New DENSO Injectors are the go! New genuine parts.
Cheers, Anth - Technician - 1KD-FTV

Check your injectors about every 10,000k.
WARNING check oil pickup screen is clear
no chips no tune ups - why increase risk of piston cracking?
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Re: How to replace a driveshaft

Postby dermy on Sat, 06 Aug 2011 3:07 +0000

Image
Image
Image

I seemed to have done a good job lol
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Re: How to replace a driveshaft

Postby fourby4diesel on Sat, 06 Aug 2011 3:36 +0000

That looks like me a week ago, difference is u have 3 inch lift I have one inch lift.
And mine is 4 months old, not 2006, just goes to show, there's no real pattern to when they go kaput!
New DENSO Injectors are the go! New genuine parts.
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Check your injectors about every 10,000k.
WARNING check oil pickup screen is clear
no chips no tune ups - why increase risk of piston cracking?
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Re: How to replace a driveshaft

Postby danmcccc on Sat, 06 Aug 2011 3:39 +0000

rough :o
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Re: How to replace a driveshaft

Postby dute on Sat, 06 Aug 2011 3:50 +0000

dermy wrote:hey guys I just snapped the inner part of the cv.. so the inner boots still on the cv but the bit the goes into the diff is still in the diff should I just remove outer part of the cv so I can drive?



How did you do it Dermy ? . . . .
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