OEM 2004 Toyota Prius Axle Shaft

2004 Toyota Prius Parts Questions & Experts Answers

• Q: How do you overhaul the front Axle Shaft on 2004 Toyota Prius?

  A: Start front drive shaft overhaul by draining transaxle oil through a #10 socket hexagon wrench to remove the drain plug along with its gasket which should be replaced with a new gasket before retightening it to 39 Nm (400 kgf-cm, 29 ft. lbs.). Special Service Tool: 09930-00010 with the assistance of a hammer helps unstake the front axle hub LH nut which can be removed with a 30 mm socket wrench. The front speed sensor LH will disconnect by removing its bolt and releasing it from the shock absorber assembly and steering knuckle but keep the sensor area free from any foreign objects. You must disassemble the tie rod end sub-assembly LH by removing its clip and castle nut before using Special Service Tool: 09628-00011 to disconnect it from the steering knuckle without damaging any parts of the dust cover or steering knuckle. The front suspension arm sub-assembly lower No.1 LH needs its bolt and two nuts loosened before you can tap the front drive shaft assembly LH end with a plastic hammer to disengage from the front axle assembly LH. Extract the front drive shaft assembly LH by removing its front fender apron seal then use Special Service Tool: 09520-01010 and 09520-24010 (09520-32040) without damaging either the oil seal or boot. Perform the exact steps to eliminate the front drive shaft assembly on the right-hand side. Use Special Service Tool: 09608-16042 (09608-02021, 09608-02041) to fix the LH front axle assembly because this tool prevents hub bearing damage. Examine the LH front drive shaft assembly for all evidence of damage as well as loose parts and grease leakage. Detach the inboard joint boot clamps from the inboard joint assembly LH before extracting grease and creating marks on both inboard and outboard joint assemblies. A snap ring expander tool should be used to remove INN LH front drive inner shaft snap ring while carefully extracting tripod joint. Prior to installation always fill the joints with grease while abstaining from putting grease in the grooves. Check the dimensions of the front drive shaft assembly LH and inspect it for signs of looseness while performing inboard joint boot clamp tightening. Complete the installation of the LH front drive shaft assembly by aligning its spline properly then repeat the procedure for the right side. The technical process ends with reinstallation of the front wheel along with transaxle oil addition and wheel alignment inspection. Before finalizing the process technicians must torque all components to factory specifications within the front axle assembly LH, lower suspension arm, tie rod end, speed sensor, and front axle hub LH nut.