Front Drive Shaft Assembly (For Hatchback) Installation

Coat the spline of the inboard joint with gear oil.

Align the inboard joint splines and install the drive shaft with a screwdriver and hammer.

NOTICE:

1. Face the cut area of the front drive shaft hole snap ring downward.
   
2. Do not damage the oil seal.
   
3. Do not damage the inboard joint boot.
   

HINT:

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

Push the front axle out of the vehicle to align the spline of the drive shaft with the front axle and insert the front axle.

NOTICE:

1. Do not push the front axle further out of the vehicle than is necessary.
   
2. Do not damage the outboard joint boot.
   
3. Check for any foreign matter on the speed sensor rotor and insertion part.
   
4. Do not damage the speed sensor rotor.
   

Install the lower arm onto the steering knuckle with a new castle nut.

Torque:

98 N*m{999 kgf*cm, 72 ft.*lbf}

NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

Install a new clip.

Install the tie rod end sub-assembly onto the steering knuckle with a new castle nut.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

Install a new cotter pin.

Install the front stabilizer link assembly LH with the nut.

Torque:

74 N*m{755 kgf*cm, 55 ft.*lbf}

HINT:

Using a socket hexagon wrench 6 to hold the stud.

Install the speed sensor onto the steering knuckle with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

NOTICE:

1. Check that the speed sensor tip and installation portion are free of foreign matter.
   
2. Install the speed sensor without turning it from its original installation angle.
   

Install the flexible hose and speed sensor with the bolt.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

NOTICE:

Install the flexible hose and speed sensor without twisting them.

Clean the threaded parts on the front drive shaft and axle shaft nut using a non-residue solvent.

NOTICE:

1. Be sure to perform this work for a new front drive shaft.
   
2. Keep the threaded parts free of oil and foreign objects.
   

Using a deep socket wrench 30 mm, install a new front axle shaft nut.

Torque:

216 N*m{2203 kgf*cm, 159 ft.*lbf}

Using a chisel and hammer, stake the axle shaft nut.

Add manual transmission oil until the oil level is within 5 mm (0.197 in.) from the bottom of the manual transmission filler plug opening.

Standard capacity (Reference):

1.9 liters (2.0 US qts, 1.7 Imp. qts)

Gear oil type:

Toyota Genuine Manual Transmission Gear Oil "LV GL-3 and SAE 75W-90" or "API GL-4 and SAE 75W"

Check for oil leakage when the oil level is low.

Install the transmission filler plug and a new gasket.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}