Front Propeller Shaft Assembly (For Tsam Made) Reassembly

Drivetrain. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
Drive Shaft Propeller Shaft. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. INSTALL UNIVERSAL JOINT SPIDER ASSEMBLY

  2. INSPECT UNIVERSAL JOINT SPIDER ASSEMBLY

  3. INSTALL SLIDING SHAFT BOOT

  4. INSPECT PROPELLER SHAFT GREASE FITTING DIRECTION

Front Propeller Shaft Assembly (For Tsam Made) -- Reassembly


NOTICE:
  1. When using a vise, place aluminum plates between the part and vise.
  2. When using a vise, do not overtighten it.


1. INSTALL UNIVERSAL JOINT SPIDER ASSEMBLY
HINT:
Use the same procedure for both universal joint spiders.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

  1. Apply MP grease to a new spider and 2 new spider bearings.

    NOTICE:
    Be careful not to apply too much grease.

  1. Fit the spider into the flange yoke.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

  1. Using SST, install the 2 spider bearings to the spider.

    SST
    09332-25010


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

  1. Using SST, adjust the spider bearings so that: 1) the flange yoke does not overlap the snap ring grooves of the spider bearings; 2) the grooves are as wide as possible; and 3) the groove width on both sides is the same.

    SST
    09332-25010

  1. Install 2 new snap rings to the installed spider bearings. The snap rings must have equal thickness and allow 0 to 0.05 mm (0 to 0.00196 in.) of axial play.

    Standard Snap Ring Thickness:
    Part No.
    		Thickness
    		Color
    90080-52044
    		1.384 mm (0.0545 in.)
    		Green
    90080-52174
    		1.39 mm (0.0547 in.)
    		Green
    90080-52043
    		1.435 mm (0.0565 in.)
    		Red
    90080-52175
    		1.44 mm (0.0567 in.)
    		Orange
    90080-52041
    		1.486 mm (0.0585 in.)
    		Black
    90080-52176
    		1.49 mm (0.0587 in.)
    		Black
    90080-52042
    		1.511 mm (0.0595 in.)
    		Copper
    90080-52040
    		1.537 mm (0.0605 in.)
    		Silver
    90080-52177
    		1.54 mm (0.0606 in.)
    		White
    90080-52039
    		1.588 mm (0.0625 in.)
    		Yellow
    90080-52178
    		1.59 mm (0.0626 in.)
    		Yellow
    90080-52038
    		1.638 mm (0.0645 in.)
    		Blue
    90080-52179
    		1.64 mm (0.0646 in.)
    		Red
    90080-52180
    		1.69 mm (0.0665 in.)
    		Blue
    NOTICE:
    1. New snap rings must be used.
    2. The snap ring thickness must be the same on both ends.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

  1. Using a plastic-faced hammer, tap the flange yoke until there is no clearance between the spider bearings and snap rings.

    Text in Illustration
    *a
    		Hammering Point

  1. Align the matchmarks on the flange yoke and propeller shaft.

  1. Install new spider bearings on the sleeve yoke side.

    HINT:
    Use the procedure described above.


2. INSPECT UNIVERSAL JOINT SPIDER ASSEMBLY

  1. Clamp the propeller shaft in a vise between aluminum plates.

    NOTICE:
    Do not overtighten the vise.

  1. Check the spider bearings for wear or damage.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Check the axial play of each spider bearing by turning the yoke while holding the shaft tightly.

    Maximum bearing axial play:
    0.05 mm (0.00196 in.)
    If the axial play is more than the maximum, replace the spider bearing.


3. INSTALL SLIDING SHAFT BOOT

  1. Temporarily install the boot to the propeller shaft with 2 new clamps.

  1. Mount the propeller shaft in a soft vise.

  1. Coat the splines of the propeller shaft with MP grease.

  1. Align the matchmarks on the propeller shaft and sleeve yoke.

  1. Install the sleeve yoke to the propeller shaft and connect the boot.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

  1. Secure one of the boot clamps to the boot.

    1. Place SST onto the boot clamp.

      SST
      09521-24010

    2. Tighten SST so that the boot clamp is pinched as shown in the illustration.

      NOTICE:
      Do not overtighten SST.


      3. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly

    3. Using SST, adjust the clearance of the boot clamp.

      SST
      09240-00020
      Standard clearance:
      0.8 mm (0.0314 in.) or less

  1. Secure the remaining boot clamp to the boot.

    HINT:
    Use the procedure described above.


4. INSPECT PROPELLER SHAFT GREASE FITTING DIRECTION


HINT:
  1. When replacing a spider bearing, be sure that the grease fitting hole is facing the direction shown in the illustration.
  2. Fill the grease fittings with MP grease.


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Drive Shaft Propeller Shaft.Drive Shaft System.Front Propeller Shaft Assembly (For Tsam Made) Reassembly


Text in Illustration
*1
No. 1 Grease Fitting
*2
No. 2 Grease Fitting
*a
Spider grease fitting assembly direction for front propeller shaft assembly
*b
Rear Side