TROUBLESHOOTING PROBLEM SYMPTOMS TABLE

TROUBLESHOOTING PROBLEM SYMPTOMS TABLE TROUBLESHOOTING Use the table below to help find the cause of problems. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. 2WD: Symptom Suspected Area See page PR1 PR01F05 Noise Vibration 4WD: 1. Center support bearing (Worn) 1. Sleeve yoke spline (Worn) 2. Spider bearing (Worn or stuck) 1. Transmission extension housing rear bushing (Runout) 2. Sleeve yoke spline (Stuck) 3. Propeller shaft (Runout) 4. Propeller shaft (Imbalance) PR5 PR5 PR5 PR5 Symptom Suspected Area See page Noise Vibration 1. Center support bearing (Worn) 2. Sleeve yoke spline (Worn) 3. Spider bearing (Worn or stuck) 1. Transmission extension housing rear bushing (Runout) 2. Sleeve yoke spline (Stuck) 3. Propeller shaft (Runout) 4. Propeller shaft (Imbalance) PR12 PR12 PR12 PR12 4038

PR2 ASSEMBLY (2WD) COMPONENTS ASSEMBLY (2WD) PR01G07 Dust Cover Snap Ring Spider Bearing Center Support Bearing Spacer Intermediate Shaft Spacer See page PR6 Center Yoke Spider 40 (410, 30) Sleeve Yoke Flange Yoke Snap Ring Spider Bearing Snap Ring Spider Bearing Spider Spider Propeller Shaft 88 (897, 65) DoubleCab: 88 (897, 65) N m (kgf cm, ft lbf) : Specified torque Nonreusable part Apply MP grease F19958 4039

Except DoubleCab model: DoubleCab model: REMOVAL ASSEMBLY (2WD) PR3 PR01H05 REMOVE (a) Place matchmarks on the differential and propeller shaft flanges. (b) Except DoubleCab model: Remove the 4 bolts, washers and nuts. (c) DoubleCab model: Remove the 4 nuts and washers. (d) Remove the 2 mounting bolts and center support bearing from the frame crossmember. (e) Pull out the propeller shaft yoke from the transmission. F19350 SST (f) Insert SST in the transmission to prevent oil leakage. SST 0932540010 R04164 4040

PR4 Q10882 ASSEMBLY (2WD) DISASSEMBLY NOTICE: PR05K02 Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. SEPARATE AND INTERMEDI ATE SHAFT (a) Place matchmarks on the yoke and propeller shaft. (b) Disassemble the center yoke (See SPIDER BEARING REPLACEMENT on page PR17 ). Q10880 2. REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE SHAFT (a) Using a hammer and chisel, loosen the staked part of the nut. (b) Clamp the yoke in a vise and remove the spacer and nut. (c) Place matchmarks on the yoke and shaft. (d) Using a brass bar and hammer, remove the center yoke, dust cover, spacer and center support bearing from the intermediate shaft. 4041

Z04240 Z04241 INSPECTION NOTICE: ASSEMBLY (2WD) PR5 PR01J03 Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. INSPECT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT Using a dial indicator, check the runout of each shaft. Maximum runout: 0.8 mm (0.031 in.) If shaft runout is greater than the maximum, replace it. 2. INSPECT SPIDER BEARING (a) Inspect the spider bearing for wear or damage. (b) Using a dial indicator, check the spider bearing axial play by turning the yoke of the flange while holding the shaft tightly. Maximum bearing axial play: 0.05 mm (0.0020 in.) If the spider bearing axial play exceeds the maximum, replace the spider bearing (See page PR17 ). 3. INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. R04478 4042

PR6 REASSEMBLY NOTICE: ASSEMBLY (2WD) PR05L02 Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. When removing or installing any part, make sure that each joint is facing the correct direction, as shown in the illustration below. F08477 Front 1. INSTALL CENTER SUPPORT BEARING ON INTER MEDIATE SHAFT Install the center support bearing in the direction shown. 2. INSTALL CENTER YOKE ON INTERMEDIATE SHAFT (a) Coat the splines of the intermediate shaft with MP grease. (b) Install the spacer and dust cover. Q07493 Q10880 (c) Place the center yoke on the shaft and align the matchmarks. If replacing either the center yoke or intermediate shaft, reassemble them so that the front side yoke of the intermediate shaft and the center yoke are facing the same direction. (d) Install the spacer. (e) Clamp the yoke in a vise, and press in the bearing by tightening with a new nut. Torque: 181 N m (1,845 kgf cm, 133 ft lbf) (f) Loosen the nut. (g) Torque the nut again. Torque: 82 N m (835 kgf cm, 60 ft lbf) (h) Using a hammer and punch, stake the nut. 4043

ASSEMBLY (2WD) PR7 3. CONNECT AND INTERMEDIATE SHAFT Assemble the center yoke aligning matchmarks (See SPIDER BEARING REPLACEMENT on page PR17 ). Q10882 4044

PR8 ASSEMBLY (2WD) INSTALLATION 1. INSTALL (a) Remove SST from the transmission. SST 0932540010 (b) Insert the yoke into the transmission. PR05M03 Except DoubleCab model: DoubleCab model: (c) Temporarily install the center support bearing with the 2 mounting bolts. Make sure the bearing is installed with the drain hole facing downwards. (d) Except DoubleCab model: Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. (e) Torque the 4 bolts. Torque: 88 N m (897 kgf cm, 65 ft lbf) (f) DoubleCab model: Align the matchmarks on the flanges and connect the flanges with the 4 washers and nuts. (g) Torque the 4 nuts. Torque: 88 N m (897 kgf cm, 65 ft lbf) F19350 90 Bracket Center Line 2. ADJUST CENTER SUPPORT BEARING With the vehicle unloaded, adjust the center support bearing to keep the angles, as shown. Under the same conditions, check the center line in the axial direction. Adjust the bearing if necessary. Shaft Axial Direction F07983 Center Bearing Center Line The center bearing center line and center bearing housing center line must be adjusted to within 6.0 ± 1.0 mm (0.236 ± 0.039 in.) of each other in the vehicle s longitudinal direction with the vehicle unloaded. Torque the 2 bolts. Torque: 40 N m (410 kgf cm, 30 ft lbf) 6.0 ± 1.0 mm (0.236 ± 0.039 in.) Center Bearing Housing Center Line Q07263 4045

Front propeller shaft: ASSEMBLY (4WD) COMPONENTS ASSEMBLY (4WD) PR9 PR01M06 88 (897, 65) Spider Bearing Snap Ring Spider Front Propeller Shaft Flange Yoke Flange Yoke Spider Spider Bearing Snap Ring 74 (754, 54) Rear propeller shaft: Snap Ring Spider Bearing Spider Center Support Bearing Spacer See page PR13 Flange Yoke Spacer Companion Flange 88 (897, 65) Grease Fitting Intermediate Shaft Sleeve Yoke 40 (410, 30) 88 (897, 65) Flange Yoke Spider Spider Bearing Grease Fitting Snap Ring Rear Propeller Shaft Grease Fitting 74 (754, 54) N m ( kgf cm, ft lbf ) : Specified torque Nonreusable part Apply MP grease F19352 4046

PR10 ASSEMBLY (4WD) Z15303 REMOVAL PR05N05 1. REMOVE FRONT (a) Place matchmarks on the differential and propeller shaft flange. (b) Remove the 4 bolts, washers and nuts, and disconnect the propeller shaft from the differential. (c) Use a rope to suspend the front edge of the propeller shaft. (d) Place matchmarks on the transfer and propeller shaft flanges. (e) Remove the 4 nuts and washers. (f) Remove the propeller shaft from the transfer flange. 2. REMOVE REAR (a) Place matchmarks on the transfer and propeller shaft flanges. (b) Remove the 4 nuts and washers, and disconnect the propeller shaft from the transfer flange. (c) Use a rope to suspend the front edge of the propeller shaft. Q07228 (d) (e) (f) (g) Remove the 2 mounting bolts and center support bearing. Place matchmarks on the differential and propeller shaft flanges. Remove the 4 bolts, washers and nuts. Remove the propeller shaft from the differential. Z15304 4047

R04445 ASSEMBLY (4WD) DISASSEMBLY NOTICE: PR1 1 PR05O03 Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. Rear propeller shaft: SEPARATE AND INTERMEDI ATE SHAFT (a) Place matchmarks on the flanges. (b) Remove the 4 nuts, bolts and washers. SST Z04243 2. Rear propeller shaft: REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE SHAFT (a) Using a hammer and chisel, loosen the staked part of the nut. (b) Using SST to hold the flange, remove the nut and spacer. SST 0933000021 (c) Place matchmarks on the flange and shaft. SST (d) (e) Using SST, remove the flange from the intermediate shaft. SST 09950 30012 (09951 03010, 09953 03010, 0995403010, 0995503030, 0995603020) Remove the spacer and center support bearing from the intermediate shaft. Q06613 4048

PR12 Z04240 INSPECTION NOTICE: ASSEMBLY (4WD) PR01P03 Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. INSPECT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT Using a dial indicator, check the runout of each shaft. Maximum runout: 0.8 mm (0.031 in.) If shaft runout is greater than the maximum, replace it. Z04241 2. INSPECT SPIDER BEARING (a) Inspect the spider bearing for wear or damage. (b) Using a dial indicator, check the spider bearing axial play by turning the yoke of the flange while holding the shaft tightly. Maximum bearing axial play: Front propeller shaft: 0.05 mm (0.0020 in.) Rear propeller shaft: 0 mm (0 in.) If the spider bearing axial play exceeds the maximum, replace it (See page PR17 ). 3. Rear propeller shaft: INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. R04478 Double Cardan Joint 4. Rear propeller shaft: INSPECT DOUBLE CARDAN JOINT PROPELLER SHAFT (a) Inspect the shaft for wear or damage. (b) Inspect the double cardan joint for wear or damage. If any problem is found, replace the propeller shaft assembly. A double cardan joint is used on the rear propeller shaft. R04479 4049

ASSEMBLY (4WD) PR13 REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. When removing or installing any part, make sure that each joint is facing the correct direction, as shown in the illustration below. PR01Q03 Front propeller shaft: Rear propeller shaft: F19335 Front 1. Rear propeller shaft: INSTALL CENTER SUPPORT BEARING ON INTER MEDIATE SHAFT Install the center support bearing in the direction shown. Q07493 PR0011 2. Rear propeller shaft: INSTALL FLANGE ON INTERMEDIATE SHAFT (a) Coat the splines of the intermediate shaft with MP grease. (b) Install the spacer. (c) Place the flange on the shaft and align the matchmarks. If replacing either the center flange or intermediate shaft, reassemble it so that the front side flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing in the same direction. 4050

PR14 ASSEMBLY (4WD) SST PR0034 (d) Install the spacer. (e) Using SST to hold the flange, press in the bearing by tightening with a new nut. SST 0933000021 Torque: 181 N m (1,845 kgf cm, 133 ft lbf) (f) Loosen the nut. (g) Torque the nut again. Torque: 82 N m (835 kgf cm, 60 ft lbf) (h) Using a hammer and punch, stake the nut. 3. Rear propeller shaft: INSTALL (a) Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. If replacing either the center flange or intermediate shaft, reassembly it so that the front side flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing in the same direction. (b) Torque the bolts. Torque: 74 N m (754 kgf cm, 54 ft lbf) 4051

Z15303 ASSEMBLY (4WD) INSTALLATION PR15 PR05P02 1. INSTALL FRONT (a) Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges with the 4 bolts, nuts and washers. (b) Torque the 4 bolts. Torque: 74 N m (754 kgf cm,54 ft lbf) (c) Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with the 4 nuts and washers. (d) Torque the 4 nuts. Torque: 88 N m (897 kgf cm, 65 ft lbf) Z15304 2. INSTALL REAR (a) Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges with the 4 bolts, washers and nuts. (b) Torque the 4 bolts. Torque: 88 N m (897 kgf cm, 65 ft lbf) (c) Temporarily install the center support bearing with the 2 mounting bolts. Make sure the bearing is installed with the drain hole facing downwards. (d) (e) Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with the 4 nuts and washers. Torque the 4 nuts. Torque: 88 N m (897 kgf cm, 65 ft lbf) Q07228 4052

PR16 ASSEMBLY (4WD) 90 Bracket Center Line 3. ADJUST CENTER SUPPORT BEARING With the vehicle unloaded, adjust the center support bearing to keep the angles, as shown. Under the same conditions, check the center line in the axial direction. Adjust the bearing if necessary. Shaft Axial Direction F07986 Center Bearing Center Line The center bearing center line and center bearing housing center line must be adjusted to within 0 ±1.0 mm of each other in the vehicle s longitudinal direction with the vehicle unloaded. Torque the 2 bolts. Torque: 40 N m (410 kgf cm, 30 ft lbf) 0 ± 1.0 mm (0 ± 0.039 in.) Center Bearing Housing Center Line Q07263 4053

SPIDER BEARING SPIDER BEARING REPLACEMENT 1. PLACE MATCHMARKS ON SHAFT AND YOKE PR17 PR08F01 Z04244 Z16099 2. REMOVE SNAP RING (a) Using a brass bar and hammer, slightly tap in the bearing outer race. (b) 4WD rear propeller shaft: Using 2 screwdrivers, remove the 4 snap rings from the grooves. (c) 2WD and 4WD front propeller shaft: Using needle nose pliers, remove the 4 snap rings from the grooves. SST A PR0019 3. REMOVE SPIDER BEARING (a) Using SST, push out the bearing from the flange yoke. SST 0933225010 Sufficiently raise the part indicated by A so that it does not come into contact with the bearing. (b) Clamp the bearing outer race in a vise and tap off the flange with a hammer. Remove the bearing on the opposite side using the same procedure. SST Z04246 (c) Install the 2 removed bearing outer races to the spider, and clamp them in a vise. (d) Using SST, push out the bearing from the sleeve yoke. SST 0933225010 (e) Clamp the outer bearing race in a vise and tap off the yoke with a hammer. Remove the bearing on the opposite side using the same procedure. 4054

PR18 SPIDER BEARING 4. INSTALL SPIDER BEARING (a) Apply MP grease to a new spider and bearings. Be careful not to apply too much grease. (b) Align the matchmarks on the yoke and shaft. (c) Fit the spider to the yoke. Z00735 SST (d) Using SST, install the bearing to the spider. SST 0933225010 PR0027 (e) Using SST, adjust both bearings so that the snap ring grooves are at maximum and are equal in width. PR0028 4055

SPIDER BEARING PR19 5. INSTALL SNAP RINGS (a) Install 2 new snap rings of equal thickness which will allow for 0 to 0.05 mm (0 to 0.0020 in.) axial play. Do not reuse the snap rings. 4WD rear propeller shaft: Color Mark Thickness mm (in.) F07987 2.44 to 2.46 (0.0961 to 0.0969) 10 2.46 to 2.48 (0.0969 to 0.0976) 1 2.28 to 2.30 (0.0898 to 0.0906) 2 2.30 to 2.32 (0.0906 to 0.0913) None 2.32 to 2.34 (0.0913 to 0.0921) Brown 2.34 to 2.36 (0.0921 to 0.0929) Blue 2.36 to 2.38 (0.0929 to 0.0937) 6 2.38 to 2.40 (0.0937 to 0.0945) 7 2.40 to 2.42 (0.0945 to 0.0953) 8 2.42 to 2.44 (0.0953 to 0.0961) J 2.18 to 2.20 (0.0858 to 0.0866) K 2.20 to 2.22 (0.0866 to 0.0874) F 2.22 to 2.24 (0.0874 to 0.0882) G 2.24 to 2.26 (0.0882 to 0.0890) H 2.26 to 2.28 (0.0890 to 0.0898) A 2.48 to 2.50 (0.0976 to 0.0984) B 2.50 to 2.52 (0.0984 to 0.0992) C 2.52 to 2.54 (0.0992 to 0.1000) D 2.54 to 2.56 (0.1000 to 0.1008) E 2.56 to 2.58 (0.1008 to 0.1016) F19941 4056

PR20 SPIDER BEARING 2WD and 4WD front propeller shaft: R16053 (b) Color Thickness mm (in.) Blue 1.638 (0.0645) Yellow 1.588 (0.0625) Silver 1.537 (0.0605) Copper 1.511 (0.0595) Black 1.486 (0.0585) Red 1.435 (0.0565) Green 1.384 (0.0545) Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. R04428 6. CHECK SPIDER BEARING (a) Check that the spider bearing moves smoothly. (b) Check the spider bearing axial play. Maximum bearing axial play: 4WD rear propeller shaft: 0 mm (0 in.) 2WD and 4WD front propeller shaft: 0.05 mm (0.0020 in.) Install new spider bearings on the flange side using the procedure described above. 4057

SPIDER BEARING PR21 When replacing the rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly holes are facing in the direction shown in the illustration below. SPIDER GREASE FITTING ASSEMBLY DIRECTION FOR 4WD REAR No. 1 No. 2, No. 3, No. 4 and No. 5 Sleeve Yoke The figure on the left shows the locations of the grease fittings from the rear. No. 1 No. 2 No. 4 No. 5 No. 3 Sleeve Yoke F19336 4058