Replace the inner CV boot on a front drive axle to prevent grease loss and joint damage.

Warnings

Tools required

Parts

• Inner CV boot kit × 1 — Use OEM specification
• CV grease × 1 — Included in boot kit or Toyota part 08885-00105
• Boot clamps × 2 — Included in boot kit
• Cotter pin or axle nut × 1 — If equipped with cotter pin: 90340-12012

Fluids

• Toyota WS ATF — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on the ground
3. Loosen but do not remove the axle nut while vehicle is on the ground (21mm or 30mm depending on year)
4. Raise vehicle and secure on jack stands at frame points
5. Remove wheel and tire assembly
6. Place drain pan under transaxle area to catch ATF fluid

Procedure

1. 1

   Remove axle nut and brake caliper bracket
   Remove the axle nut completely and set aside. If equipped with cotter pin, remove and discard it. Remove the two brake caliper bracket bolts and support the caliper assembly with wire or a bungee cord without stressing the brake hose.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
2. 2

   Separate tie rod and lower ball joint
   Remove the cotter pin from the tie rod end and loosen the castle nut. Use a tie rod separator or pickle fork to separate the tie rod from the steering knuckle. Remove the lower ball joint pinch bolt and separate the lower control arm from the knuckle using a pry bar.
3. 3

   Remove drive axle from hub
   Pull the steering knuckle assembly outward while pushing the drive axle out of the hub. If the axle is stuck in the hub, use a soft-faced mallet to tap it out from behind. Support the axle to prevent it from hanging by the outer CV joint.
4. 4

   Remove axle from transaxle
   For driver side: Use a pry bar between the inner CV joint and transaxle case to pop the axle free. Pry carefully to avoid damaging the seal. For passenger side: Remove the bearing support bracket bolts, then pull the entire intermediate shaft and inner CV joint assembly out together. Expect ATF to drain from the opening.
5. 5

   Secure axle and remove outer boot clamps
   Place the axle on a clean work surface or in a vise with soft jaws. Cut or release the small and large clamps on the outer CV boot and slide the boot away from the inner joint toward the outer joint. Do not remove the outer boot completely unless it also needs replacement.
6. 6

   Remove inner CV joint
   Wipe away excess grease from the inner CV joint. Use snap ring pliers to remove the snap ring or circlip securing the inner CV joint to the axle shaft. Mark the orientation of the joint housing to the shaft. Tap the joint housing with a soft mallet or pull firmly to separate it from the shaft. Remove the inner boot completely.
7. 7

   Clean components
   Thoroughly clean the axle shaft, CV joint housing, tripod bearing, and all components with cleaning solvent and shop rags. Inspect the tripod bearing for wear, pitting, or damage. Check the joint housing for scoring or damage. Replace the entire axle if components are worn beyond specification.
8. 8

   Install new inner boot and clamps
   Slide the new small boot clamp onto the axle shaft, followed by the new inner CV boot. Position the small end of the boot in the groove on the axle shaft and install the small clamp. Do not tighten the clamp yet. Ensure the boot sits properly in the shaft groove.
9. 9

   Pack joint and install CV assembly
   Pack the inner CV joint housing with the specified amount of CV grease from the boot kit (typically 4-5 oz). Also apply grease to the tripod bearing. Align the marks made during disassembly and install the inner CV joint onto the axle shaft. Install the new snap ring or circlip to secure the joint.
10. 10

    Secure boot and clamps
    Slide the large end of the boot over the CV joint housing and seat it in the housing groove. Ensure the boot is not twisted. Adjust the boot length to the specification in the kit instructions to allow proper articulation. Tighten the small clamp using the boot clamp tool, then tighten the large clamp. Verify both clamps are secure.
11. 11

    Reinstall axle into transaxle
    Install a new snap ring on the inner CV joint stub shaft if applicable. Align the axle and push it firmly into the transaxle until you feel it seat and the snap ring clicks into place. For passenger side, install the intermediate shaft and bearing support bracket. Pull on the axle to verify it is locked in place.
12. 12

    Install axle into hub and reconnect suspension
    Guide the outer CV stub shaft through the hub and push it fully into place. Reconnect the lower ball joint to the steering knuckle and install the pinch bolt. Reconnect the tie rod end to the steering knuckle and install the castle nut and new cotter pin. Torque all fasteners to specification.
13. 13

    Install brake caliper and axle nut
    Remove the support wire and install the brake caliper bracket with mounting bolts. Install the axle nut but do not torque it yet. Install the wheel and tire assembly and hand-tighten lug nuts.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Lower vehicle and final torque
    Lower the vehicle until the tire just contacts the ground. Torque the wheel lug nuts to specification in a star pattern. Lower the vehicle completely. Apply the brakes and torque the axle nut to specification. Install a new cotter pin or stake the nut as applicable per vehicle specifications.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. Check transaxle ATF level and top off with Toyota WS ATF as needed
2. Verify all fasteners are torqued to specification
3. Ensure boot clamps are tight and properly positioned
4. Check that no grease is leaking from the new boot

Verification

• Start the engine and turn the steering wheel lock-to-lock while stationary to check for binding or noise
• Test drive the vehicle and verify no clicking, popping, or vibration from the CV joint during acceleration and turning
• Inspect the new boot for any signs of grease leakage after test drive
• Recheck axle nut torque after 50-100 miles of driving
• Verify transaxle fluid level is correct and top off if needed

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