OEM 2003 Toyota Prius Axle Shaft

2003 Toyota Prius Parts Questions & Experts Answers

• Q: How to service and repair the axle shaft on 2003 Toyota Prius?

  A: Start the axle shaft service and repair process by inspecting the drive shaft for outboard joint play followed by testing the inboard joint slider movement in thrust direction then sealing the inboard joint to radial direction. Review the state of the boot seals and check the form of the boot clamps. Separate the inboard joint shaft from the outboard joint shaft by first disclamping two boot clamps then sliding the boot toward the outboard joint and marking inboard joint shaft and tripod without punching before finally separating the joints. Use the snap ring expander to uninstall the snap ring before marking the outboard joint shaft and tripod and gently tapping the tripod with a brass bar and hammer but keeping away from the roller. The RH drive shaft requires the disconnection of its dynamic damper by either using a screwdriver to dismount the Type A clamp or pliers to pinch the Type B clamp followed by removing the damper component. Detach the two Type A clamps with a screwdriver from the outboard joint boot while making sure to cut specific portions of Type B clamps using side cutters before removing the boot from its assembly. Special Service Tool: 09950-00020 and a press should be used to extract the dust cover from the inboard joint shaft. To reassemble the drive shaft begin by using a press to install a new dust cover onto the inboard joint shaft followed by affixing boots and clamps and dynamic damper onto the RH drive shaft with vinyl tape wrapping the spline of the outboard joint shaft to protect it. Start by applying two new A or B type boot clamps on fresh outboard joint boots and complete the installation process followed by attaching either a new or recovered type B damper clamp. Then proceed to install two fresh clamps on new inboard joint boots that will be fastened to the outboard joint shaft. It is necessary to install a new snap ring after aligning the matchmarks by tapping the tripod axial spline into position with a brass bar and hammer where the beveled side faces the outboard joint. The outboard joint requires 110 - 120 grams of grease before installing the boot while the inboard joint needs 180 - 190 grams of grease before it is allowed to align matchmarks before installation of the inboard joint shaft to the outboard joint shaft with temporary boot application. Mount the boot clamps to both boots by making sure that the boots fit into the shaft grooves at regular length measurements. Apply a screwdriver to lock the two inboard joint boot clamps before installing A or B type boot clamps on the outboard joint and securely fastening them. To build the RH drive shaft dynamic damper clamp you should adjust it to 500.1 plus or minus 2.0 mm and lock the Type A clamp with a screwdriver or tighten the Type B clamp with pliers. A proper function check of the drive shaft completes the process.