Drivetrain - Rear Driveshaft Clunk/Thump Noise

DRIVELINE & DIFFERENTIAL
DL001-06
REVISED

April 19, 2006

Title:
REAR DRIVESHAFT/PROPELLER SHAFT CLUNK/THUMP NOISE

Models:
'03 - '06 GX 470

TSIB REVISION NOTICE:
^ June 19, 2006: Images have been added to steps 3 and 4 of the Repair Procedure.

^ May 5, 2006: Warranty Information has been updated: Op Code DL5003 has been changed to "Combo A" and two OFPs have been deleted.

^ Previous versions of this TSIB should be discarded.

TSIB UPDATE NOTICE:

The information contained in this TSIB supercedes TSIB No. DL001-04. TSIB No. DL001-04 is now obsolete and should be discarded.

Introduction

Some 2003 - 2006 model year GX 470 vehicles may experience a clunk/thump noise from the rear of the vehicle or a bump-from-behind sensation just before or after coming to a stop. A new rear propeller shaft assembly and revised rear suspension control arms have been developed to improve this condition.

Applicable Vehicles:
^ 2003 - 2006 model year GX 470 vehicles.





Required Tools & Material





Warranty Information

Applicable Warranty:

^ Op Code 370011 is covered under the Lexus Powertrain Warranty. This warranty is in effect for 72 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date.

^ Op Code DL5002 is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.





Parts Information

Repair Procedure

1. Test drive vehicle and confirm noise condition.





NOTE:
Check for the painted match marks on the transfer flange and differential flange when installing the NEW propeller shaft assembly. If the match marks are NOT visible, be sure to install the NEW propeller shaft in the same direction as the original propeller shaft.

2. Remove and replace the 2-piece propeller shaft assembly.

For more information, refer to the Technical Information System (TIS), 2003 - 2006 model year GX 470 Repair Manual: Driveshaft/Propeller Shaft: Propeller Shaft Assy: Overhaul.

A. Remove the propeller shaft assembly.

a. Remove the 4 nuts and 4 washers.





b. Remove the 4 nuts, 4 bolts, and 4 washers and then the propeller shaft assembly.





B. Install the NEW propeller shaft assembly.

a. Align the matchmarks on the yoke and the differential flange.

b. Install the propeller shaft assembly with the 4 bolts, 4 nuts, and 4 washers.

Torque: 88 N.m

(898 kgf.cm, 65 ft.-lbf)





C. Align the matchmarks on the yoke and the transfer flange.

d. Install the propeller shaft assembly with the 4 nuts and 4 washers.

Torque: 88 N.m

(898 kgf.cm, 65 ft.-lbf)





3. Remove and replace the LH and RH upper control arm assemblies one side at a time. Refer to TIS, 2003 - 2006 model year GX 470 Repair Manual: Rear Suspension: Upper Control Arm Assy: Replacement.





4. Remove and replace the LH and RH lower control arm assemblies one side at a time. Refer to TIS, 2003 - 2006 model year GX 470 Repair Manual: Rear Suspension: Lower Control Arm Assy LH: Replacement.

5. Test drive vehicle and confirm repair effectiveness.