PR-1

PROPELLER SHAFT - TROUBLESHOOTING

TROUBLESHOOTING
PR01F-05

PROBLEM SYMPTOMS TABLE

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
1. Center support bearing (Worn) PR-5
Noise 1. Sleeve yoke spline (Worn) -
2. Spider bearing (Worn or stuck) PR-5
1. Transmission extension housing rear bushing (Runout) -
2. Sleeve yoke spline (Stuck) -
Vibration
3. Propeller shaft (Runout) PR-5
4. Propeller shaft (Imbalance) PR-5

4WD:
Symptom Suspected Area See page
1. Center support bearing (Worn) PR-12
Noise 2. Sleeve yoke spline (Worn) -
3. Spider bearing (Worn or stuck) PR-12
1. Transmission extension housing rear bushing (Runout) -
2. Sleeve yoke spline (Stuck) -
Vibration
3. Propeller shaft (Runout) PR-12
4. Propeller shaft (Imbalance) PR-12

Author
: Date
: 4038

PR-2
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)

PROPELLER SHAFT ASSEMBLY (2WD)

PR01G-07

COMPONENTS
Dust Cover

Center Support
Spacer
Bearing
Spacer
Intermediate Shaft

Snap Ring

Spider Bearing
See page PR-6

Center Yoke

40 (410, 30)

Spider
Sleeve Yoke

Flange Yoke

Snap Ring

Spider Bearing

Snap Ring Double-Cab:

Spider Bearing 88 (897, 65)

Spider
Spider
Propeller Shaft 88 (897, 65)

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

Non-reusable part
Apply MP grease
F19958

Author
: Date
: 4039

 PR-3
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)
PR01H-05

Except Double-Cab REMOVAL

Double-Cab model: REMOVE PROPELLER SHAFT
model:
(a) Place matchmarks on the differential and propeller shaft
flanges.
(b) Except Double-Cab model:
Remove the 4 bolts, washers and nuts.
(c) Double-Cab model:
Remove the 4 nuts and washers.
(d) Remove the 2 mounting bolts and center support bearing
Matchmarks Matchmarks from the frame crossmember.
(e) Pull out the propeller shaft yoke from the transmission.

F19350

(f) Insert SST in the transmission to prevent oil leakage.

SST SST 09325-40010

R04164

Author
: Date
: 4040

PR-4
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)
PR05K-02

DISASSEMBLY
Matchmarks
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. SEPARATE PROPELLER SHAFT AND INTERMEDI-
ATE SHAFT
(a) Place matchmarks on the yoke and propeller shaft.
(b) Disassemble the center yoke
Q10882
(See SPIDER BEARING REPLACEMENT on page
PR-17 ).

2. REMOVE CENTER SUPPORT BEARING FROM IN-

Matchmarks 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 in-
Q10880 termediate shaft.

Author
: Date
: 4041

 PR-5
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)
PR01J-03

INSPECTION
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. INSPECT PROPELLER SHAFT 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.)
Z04240
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 PR-17 ).
Z04241

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

Author
: Date
: 4042

PR-6
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)
PR05L-02

REASSEMBLY
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
HINT:
When removing or installing any part, make sure that each joint
is facing the correct direction, as shown in the illustration below.

F08477

1. INSTALL CENTER SUPPORT BEARING ON INTER-

Front MEDIATE SHAFT
HINT:
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

(c) Place the center yoke on the shaft and align the match-
Matchmarks marks.
HINT:
If replacing either the center yoke or intermediate shaft, reas-
semble 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 tight-
Q10880 ening 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.

Author
: Date
: 4043

 PR-7
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)

3. CONNECT PROPELLER SHAFT AND INTERMEDIATE

Matchmarks SHAFT
Assemble the center yoke aligning matchmarks (See SPIDER
BEARING REPLACEMENT on page PR-17 ).

Q10882

Author
: Date
: 4044

PR-8
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (2WD)
PR05M-03

INSTALLATION
1. INSTALL PROPELLER SHAFT
(a) Remove SST from the transmission.
SST 09325-40010
(b) Insert the yoke into the transmission.

Except Double-Cab (c) Temporarily install the center support bearing with the 2
Double-Cab model: mounting bolts.
model: HINT:
Make sure the bearing is installed with the drain hole facing
downwards.
(d) Except Double-Cab model:
Align the matchmarks on the flanges and connect the
flanges with the 4 bolts, washers and nuts.
(e) Torque the 4 bolts.
Matchmarks Matchmarks Torque: 88 N·m (897 kgf·cm, 65 ft·lbf)
(f) Double-Cab 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

2. ADJUST CENTER SUPPORT BEARING

Bracket Center HINT:
90 Line
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 hous-
ing center line must be adjusted to within 6.0 ± 1.0 mm
(0.236 ± 0.039 in.) of each other in the vehicle’s longitudi-
nal 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

Author
: Date
: 4045

 PR-9
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)

PROPELLER SHAFT ASSEMBLY (4WD)

PR01M-06

COMPONENTS
Front propeller shaft:

88 (897, 65)

Flange Yoke

Snap Ring
Front Propeller Shaft

Spider Bearing

Spider

Flange Yoke
Spider

Spider Bearing

Snap Ring

74 (754, 54)

Rear propeller shaft: Spacer

See page PR-13

Snap Ring Center Support Bearing

Spider Bearing

Spider
Flange Yoke
Spacer
Companion Flange
Intermediate Shaft
40 (410, 30)
88 (897, 65)
Grease Fitting
88 (897, 65)
Sleeve Yoke
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

Non-reusable part
Apply MP grease
F19352

Author
: Date
: 4046

PR-10
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)
PR05N-05

REMOVAL
1. REMOVE FRONT PROPELLER SHAFT
(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
Matchmarks shaft.
Z15303
(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 PROPELLER SHAFT

(a) Place matchmarks on the transfer and propeller shaft
flanges.
(b) Remove the 4 nuts and washers, and disconnect the pro-
peller shaft from the transfer flange.
Matchmarks (c) Use a rope to suspend the front edge of the propeller
shaft.

Q07228

(d) Remove the 2 mounting bolts and center support bearing.

(e) Place matchmarks on the differential and propeller shaft
flanges.
(f) Remove the 4 bolts, washers and nuts.
(g) Remove the propeller shaft from the differential.

Matchmarks
Z15304

Author
: Date
: 4047

 PR-1 1
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)
PR05O-03

Matchmarks
DISASSEMBLY
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. Rear propeller shaft:
SEPARATE PROPELLER SHAFT AND INTERMEDI-
ATE SHAFT
(a) Place matchmarks on the flanges.
R04445
(b) Remove the 4 nuts, bolts and washers.

2. Rear propeller shaft:

REMOVE CENTER SUPPORT BEARING FROM IN-
TERMEDIATE SHAFT
(a) Using a hammer and chisel, loosen the staked part of the
Matchmarks
nut.
(b) Using SST to hold the flange, remove the nut and spacer.
SST 09330-00021
SST
(c) Place matchmarks on the flange and shaft.
Z04243

(d) Using SST, remove the flange from the intermediate

shaft.
SST
SST 09950- 30012 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03020)
(e) Remove the spacer and center support bearing from the
intermediate shaft.

Q06613

Author
: Date
: 4048

PR-12
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)
PR01P-03

INSPECTION
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. INSPECT PROPELLER SHAFT 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.)
Z04240
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:
Front propeller shaft: 0.05 mm (0.0020 in.)
Rear propeller shaft: 0 mm (0 in.)
Z04241 If the spider bearing axial play exceeds the maximum, replace
it (See page PR-17 ).

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

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.
Double Cardan HINT:
Joint A double cardan joint is used on the rear propeller shaft.
R04479

Author
: Date
: 4049

 PR-13
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)

REASSEMBLY
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
HINT:
When removing or installing any part, make sure that each joint
is facing the correct direction, as shown in the illustration below.

PR01Q-03

Front propeller shaft:

Rear propeller shaft:

F19335

1. Rear propeller shaft:

INSTALL CENTER SUPPORT BEARING ON INTER-
Front
MEDIATE SHAFT
HINT:
Install the center support bearing in the direction shown.

Q07493

2. Rear propeller shaft:

Matchmarks 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.
HINT:
If replacing either the center flange or intermediate shaft, reas-
semble it so that the front side flange yoke of the intermediate
PR0011 shaft and the rear side flange yoke of the propeller shaft are fac-
ing in the same direction.

Author
: Date
: 4050

PR-14
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)

SST (d) Install the spacer.

(e) Using SST to hold the flange, press in the bearing by tight-
ening with a new nut.
SST 09330-00021
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)
PR0034 (h) Using a hammer and punch, stake the nut.
3. Rear propeller shaft:
INSTALL PROPELLER SHAFT
(a) Align the matchmarks on the flanges and connect the
flanges with the 4 bolts, washers and nuts.
HINT:
If replacing either the center flange or intermediate shaft, reas-
sembly it so that the front side flange yoke of the intermediate
shaft and the rear side flange yoke of the propeller shaft are fac-
ing in the same direction.
(b) Torque the bolts.
Torque: 74 N·m (754 kgf·cm, 54 ft·lbf)

Author
: Date
: 4051

 PR-15
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)
PR05P-02

INSTALLATION
1. INSTALL FRONT PROPELLER SHAFT
(a) Align the matchmarks on the propeller shaft and differen-
tial 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)
Matchmarks (c) Align the matchmarks on the propeller shaft and transfer
Z15303
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)

2. INSTALL REAR PROPELLER SHAFT

(a) Align the matchmarks on the propeller shaft and differen-
tial 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
Matchmarks mounting bolts.
Z15304 HINT:
Make sure the bearing is installed with the drain hole facing
downwards.

(d) Align the matchmarks on the propeller shaft and transfer

flanges, and connect the flanges with the 4 nuts and
washers.
(e) Torque the 4 nuts.
Torque: 88 N·m (897 kgf·cm, 65 ft·lbf)
Matchmarks

Q07228

Author
: Date
: 4052

PR-16
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY (4WD)

3. ADJUST CENTER SUPPORT BEARING

Bracket Center
Line HINT:
90

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 hous-
ing 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

Author
: Date
: 4053

 PR-17
PROPELLER SHAFT - SPIDER BEARING

SPIDER BEARING PR08F-01

Matchmarks
REPLACEMENT
1. PLACE MATCHMARKS ON SHAFT AND YOKE

Matchmarks

Z04244

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
Z16099 the grooves.

3. REMOVE SPIDER BEARING

(a) Using SST, push out the bearing from the flange yoke.
SST 09332-25010
SST HINT:
Sufficiently raise the part indicated by ”A” so that it does not
A
come into contact with the bearing.
(b) Clamp the bearing outer race in a vise and tap off the
flange with a hammer.
PR0019 HINT:
Remove the bearing on the opposite side using the same pro-
cedure.

(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 SST 09332-25010
(e) Clamp the outer bearing race in a vise and tap off the yoke
with a hammer.
HINT:
Remove the bearing on the opposite side using the same pro-
Z04246 cedure.

Author
: Date
: 4054

PR-18
PROPELLER SHAFT - SPIDER BEARING

4. INSTALL SPIDER BEARING

(a) Apply MP grease to a new spider and bearings.
HINT:
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 09332-25010

PR0027

(e) Using SST, adjust both bearings so that the snap ring
grooves are at maximum and are equal in width.

PR0028

Author
: Date
: 4055

 PR-19
PROPELLER SHAFT - SPIDER BEARING

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.
HINT:
Do not reuse the snap rings.
4WD rear propeller shaft:
Color Mark Thickness mm (in.)
2.44 to 2.46
F07987
-
(0.0961 to 0.0969)
2.46 to 2.48
- 10
(0.0969 to 0.0976)
2.28 to 2.30
- 1
(0.0898 to 0.0906)
2.30 to 2.32
- 2
(0.0906 to 0.0913)
2.32 to 2.34
- None
(0.0913 to 0.0921)

2.34 to 2.36
Brown -
(0.0921 to 0.0929)
2.36 to 2.38
Blue -
(0.0929 to 0.0937)
2.38 to 2.40
- 6
(0.0937 to 0.0945)
2.40 to 2.42
- 7
(0.0945 to 0.0953)
2.42 to 2.44
- 8
(0.0953 to 0.0961)

2.18 to 2.20
- J
(0.0858 to 0.0866)
2.20 to 2.22
- K
(0.0866 to 0.0874)
2.22 to 2.24
- F
(0.0874 to 0.0882)
2.24 to 2.26
- G
(0.0882 to 0.0890)
2.26 to 2.28
- H
(0.0890 to 0.0898)

2.48 to 2.50
- A
(0.0976 to 0.0984)
2.50 to 2.52
- B
(0.0984 to 0.0992)
2.52 to 2.54
- C
(0.0992 to 0.1000)

D 2.54 to 2.56
-
(0.1000 to 0.1008)
2.56 to 2.58
- E
(0.1008 to 0.1016)

F19941

Author
: Date
: 4056

PR-20
PROPELLER SHAFT - SPIDER BEARING

2WD and 4WD front propeller shaft:

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)
R16053
Green 1.384 (0.0545)
(b) Using a hammer, tap the yoke until there is no clearance
between the bearing outer race and snap ring.

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.)
HINT:
R04428
Install new spider bearings on the flange side using the
procedure described above.

Author
: Date
: 4057

 PR-21
PROPELLER SHAFT - SPIDER BEARING

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 PROPELLER SHAFT

No. 2, No. 3, No. 4 and No. 5

The figure on the left shows the locations
Sleeve Yoke of the grease fittings from the rear.
No. 1
No. 2
No. 1 No. 4 No. 5
No. 3 Sleeve Yoke

F19336

Author
: Date
: 4058