Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 4

DRIVE SHAFT  –  FRONT DRIVE SHAFT (for 4WD)

DS–7

DS

(c) Pack the joint portion of the outboard joint shaft and 

outboard joint boot with grease.
Grease capacity:

260 to 270 g (9.2 to 9.5 oz.)

(d) Install the outboard joint boot onto the outboard joint 

shaft groove.
NOTICE:
Keep the groove free of grease.

4.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT 
NO. 2 CLAMP
(a) Fix the outboard joint shaft in a vise between 

aluminum plates.
NOTICE:
Do not overtighten the vise.

(b) Place SST onto the boot clamp, press it against the 

boot and slightly tighten SST.
SST

09521-24010

(c) Fix SST and tighten it so that the clearance comes 

to within the specified range.
Clearance:

0.8 mm (0.031 in.) or less

(d) Remove SST.

(e) Using SST, measure the clearance of the boot 

clamp as shown in the illustration.
SST

09240-00020

Clearance:

0.8 mm (0.031 in.) or less

NOTICE:
If the clearance is outside the specified range, 
retighten it.

5.

INSTALL FRONT AXLE OUTBOARD JOINT BOOT 
CLAMP
(a) Place SST onto the boot clamp, press it against the 

boot and slightly tighten SST.
SST

09521-24010

(b) Fix SST and tighten it so that the clearance comes 

to within the specified range.
Clearance:

0.8 mm (0.031 in.) or less

(c) Remove SST.

SST

F052126E01

SST

F052127E01

SST

C081563E01

DS–8

DRIVE SHAFT  –  FRONT DRIVE SHAFT (for 4WD)

DS

(d) Using SST, measure the clearance of the boot 

clamp as shown in the illustration.
SST

09240-00020

Clearance:

0.8 mm (0.031 in.) or less

NOTICE:
If the clearance is outside the specified range, 
retighten it.

6.

INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
(a) Install new parts onto the outboard joint shaft in the 

following order.

(b) Fix the outboard joint shaft in a vise between 

aluminum plates.
NOTICE:
Do not overtighten the vise.

(c) Remove the protective tape.

(d) Align the matchmarks and install the tripod joint onto 

the outboard joint shaft.
NOTICE:
Place the beveled side of the tripod toward the 
inboard joint.

(e) Using a brass bar and hammer, install the tripod 

joint.
NOTICE:
•

Do not hit the roller portion.

•

Keep the tripod joint free of foreign matter.

(f)

Using a snap ring expander, install a new snap ring.

(g) Pack the inboard joint with grease.

Grease capacity:

231 to 241 g (8.1 to 8.5 oz.)

(h) Align the matchmarks and install the inboard joint 

onto the outboard joint shaft.

7.

INSTALL INBOARD JOINT BOOT
(a) Install the inboard joint boot into the grooves of the 

inboard joint and outboard joint shaft.
NOTICE:
Keep the grooves free of grease.

8.

INSTALL FRONT AXLE INBOARD JOINT BOOT NO. 2 
CLAMP
(a) Install the boot clamp onto the inboard joint boot 

and caulk the boot clamp with a screwdriver.
NOTICE:
Do not damage the boot.

SST

C092627E01

1.

Front axle inboard joint boot clamp

2.

Front axle inboard joint boot

3.

Front axle inboard joint boot No. 2 clamp

Matchmarks

Beveled

C067417E02

G022501

C083397

DRIVE SHAFT  –  FRONT DRIVE SHAFT (for 4WD)

DS–9

DS

9.

INSTALL FRONT AXLE INBOARD JOINT BOOT 
CLAMP
(a) Install the boot clamp onto the inboard joint boot 

and caulk the boot clamp with a screwdriver.
NOTICE:
Do not damage the boot.

10. INSPECT FRONT DRIVE SHAFT

(a) Check whether the drive shaft dimensions are within 

the following specifications.
Dimension (A):

577.5 mm (22.74 in.)

(b) Check for noticeable looseness when turning the 

joint up and down, left and right, and in the thrust 
direction.

(c) Check for cracks, damage and grease leakage on 

the boot joint.
NOTICE:
Keep the drive shaft level while moving it.

INSTALLATION

1.

INSTALL FRONT DRIVE SHAFT
(a) Coat the spline of the inboard joint shaft with ATF.
(b) Align the shaft splines and install the drive shaft with 

a brass bar and hammer.
NOTICE:
•

Set the snap ring with the opening side facing 
downward.

•

Do not damage the oil seal.

HINT:
Whether the inboard joint shaft is in contact with the 
pinion shaft or not can be confirmed from the sound 
or feeling when driving it.

F040962

Dimension (A)

G022110E01

W001721

F042771

DS–10

DRIVE SHAFT  –  FRONT DRIVE SHAFT (for 4WD)

DS

2.

INSTALL FRONT LOWER BALL JOINT ATTACHMENT
(a) Install the front lower ball joint attachment with the 2 

bolts.
Torque: 160 N*m (1,631 kgf*cm, 118 ft.*lbf)

3.

INSTALL TIE ROD END SUB-ASSEMBLY
(a) Install the tie rod end onto the steering knuckle.
(b) Install the nut.

Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf)

(c) Install a new cotter pin.

NOTICE:
If the holes in the cotter pin are not aligned, 
tighten the nut an additional 60

°.

4.

INSTALL FRONT AXLE HUB NUT
(a) Install the hub nut.

Torque: 235 N*m (2,396 kgf*cm, 174 ft.*lbf)

(b) Install the adjusting lock cap and a new cotter pin.

5.

INSTALL FRONT AXLE HUB GREASE CAP

6.

INSTALL FRONT SPEED SENSOR
(a) Install the skid control sensor wire onto the steering 

knuckle with the bolt.
Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)

(b) Engage the 3 clamps.
(c) Using a 5 mm hexagon wrench, install the speed 

sensor with the bolt.
Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)

7.

INSTALL FRONT WHEEL
Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf)

8.

INSPECT DIFFERENTIAL OIL (See page 

DF-3

)

9.

CONNECT CABLE TO NEGATIVE BATTERY 
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

10. CHECK VSC SENSOR SIGNAL

(See page 

BC-28

)

11. CHECK FOR DIFFERENTIAL OIL LEAKAGE

12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

(See page 

SP-2

)

G020159

F043604

F042732

C133044