OEM 2004 Toyota Prius Sway Bar Kit

2004 Toyota Prius Parts Questions & Experts Answers

• Q: How to replace the front Sway Bar Kit on 2004 Toyota Prius?

  A: The front sway bar kit replacement process starts with facing the wheels straight ahead then unfastening the column hole cover silencer sheet. The front wheel removal requires dissolving the connections between the steering sliding yoke sub-assembly and steering column hole cover sub-assembly No.1. You must begin sway bar kit replacement by first detaching the 2 front sway bar link nuts on the left-hand (LH) side. Use a hexagon wrench (6 mm) to keep the ball joint stable when the nut turns with the stud. Perform 5 cycles with the ball joint stud before installation then apply torque to the nut at a 2 to 4 second period using the wrench to measure the 5th turn's torque between 0.05 to 1.96 Nm (0.5 to 20 kgf-cm, 0.4 to 17.4 inch lbs.). Spare the front sway bar link assembly if you find cracks or grease leakage on the dust cover or if the value exceeds the specified limits. The service technician separates the tie rod end sub-assemblies LH and RH through the use of Special Service Tool: 09628-00011 followed by removing the floor panel brace front and the exhaust pipe assembly front. Remove the two bolts that connect the front suspension crossmember sub-assembly on both the LH and RH front sway bar bracket No.1. First separate the steering intermediate shaft from the steering column hole cover sub-assembly No.1 and the steering gear assembly. The sway bar bushes No.1 must be removed from the sway bar kit before extracting the front sway bar kit through the right side of the vehicle. The new front sway bar kit should be placed inside from the right side before installing front sway bar bush No.1 facing the rear side and maintaining 5mm or less deviation of the sway bar kit. Reinstall the steering gear assembly with the steering column hole cover sub-assembly No.1 along with the steering intermediate shaft. Use 2 bolts to install the front sway bar bracket No.1 LH before torquing it to 19 Nm (194 kgf-cm, 14 ft. lbs.) and repeat for the bracket on the RH side. Replace the floor panel brace front along with the exhaust pipe assembly front before installing the front sway bar link assembly LH with its 2 nuts secured at 74 Nm (755 kgf-cm, 55 ft. lbs.) using a 6 mm hexagon wrench if required. The last step requires installation of the front wheel followed by a 103 Nm torque setting then examination of the front wheel alignment.