Repair Procedure No. 1

1. Remove the front wheel.

2. 2WD:

Using a screwdriver and hammer remove the grease cap.





3. 4WD:

Disconnect drive shaft.

A. Remove the cotter pin and lock cap.

B. While applying the brakes, remove the lock nut.





4. With ABS:

Disconnect ABS speed sensor and wire harness clamp from steering knuckle.

Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle.





5. Disconnect brake line.

Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.

SST P/N: 09023-00100





6. Remove brake caliper and disc.

A. Remove the bolt and brake line clamp from the steering knuckle.

B. Remove the 2 bolts, brake caliper, and disc.

7. Remove shock absorber.





A. Disconnect shock absorber from lower suspension arm.

B. Remove the shock absorber lower side set nut and washer.

NOTE:
Do not remove the

C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.





D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.

E. Remove the 3 nuts and shock absorber with the coil spring.

NOTE:
Do not damage the





8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.





9. Remove steering knuckle.

A. Remove the cotter pin and loosen the nut.

B. Using the following SSTs, disconnect the steering knuckle.

SST P/N: 09950-40011
(09951-04010,
09952-04010,
09553-04020,
09554-04010
09955-04031,
09958-04011)

C. Remove the nut and steering knuckle.

NOTE:
4WD:
Be careful not to damage the oil seal and drive shaft boot.

HINT:
4WD:
When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer.

10. 2WD:
Remove grease cap.

A. Mount the axle hub in a soft jaw vise.





NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration).

HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration).

B. Using a screwdriver, remove the grease cap.

NOTE:
Be careful not to damage the grease cap.

11. 4WD:
Remove oil seal (inside).

A. Mount the axle hub in a soft jaw vise.

HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above).

B. Using a screwdriver, remove the oil seal (inside).





12. 2WD:
Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS).
Using a chisel and hammer, loosen the staked part of the lock nut.

NOTE:
Be careful not to damage the bushing.

A. Using the following SST, remove the lock nut.
SST P/N: 00002-00909 (09318-12010)

NOTE:
Do NOT use air wrench.

B. Remove the ABS speed sensor rotor or spacer.

NOTE:
Take care not to scratch the serration of the speed sensor rotor.

13. Remove axle hub from steering knuckle.

A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).

B. Using the following SSTs, remove the axle hub from the steering knuckle.

SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011)

HINT:
If necessary, use a press to remove the axle hub from the steering knuckle.

C. Remove the dust cover from the steering knuckle.

D. 4WD:
Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS).

NOTE:
Take care not to scratch the serration of the speed sensor rotor.

14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle.

15. Remove bearing from steering knuckle.





A. Using snap ring pliers, remove the snap ring.

B. Using the following SSTs and a press, remove the bearing from the steering knuckle.

SST P/N: 09950-60020
(09951-00810)

SST P/N: 09950-70010
(09951-07150)





16. Install new bearing.

A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.

SST P/N: 09527-17011
SST P/N: 09950-60020
(09951-00910)

B. Using snap ring pliers, install a NEW snap ring.





17. Install new oil seal (outside).

A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).

SST P/N: 09223-15030

SST P/N: 09527-17011

B. Coat MP grease to the oil seal lip.





18. Install new dust cover and axle hub to steering knuckle.

A. Install the NEW dust cover to the steering knuckle with the 4 bolts.

Torque: 18 N.m
(185 kgf.cm, 13 ft.lbf)

B. Using the following SST and a press, install the axle hub to the steering knuckle.

SST P/N: 09649-17010

19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).

NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely.

20. 2WD:





Install new lock nut.

A. Using the following SST, install and torque a NEW lock nut to the axle hub.

SST P/N: 00002-00909
(09318-12010)

Torque: 274 N.m
(2,800 kgf.cm, 203 ft.lbf)

NOTE:
Do NOT use air wrench.

B. Using a chisel and hammer, stake the lock nut.





21. 4WD:

Using the following SSTs and a press, install the bearing spacer.

SST P/N: 09950-60010
(09951-00650)

SST P/N: 09950-70010
(09951-07150)





22. 4WD:

Install new oil seal (inside).

A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).

SST P/N: 09527-17011

NOTE:
Lightly strike the SST on its circumference evenly.

B. Coat MP grease to the oil seal lip.

23. Install steering knuckle.

A. 4WD:

Insert the drive shaft into the axle hub and temporarily tighten the nut.

NOTE:
Be careful not to damage the oil seal and drive shaft boot.

B. Connect the steering knuckle to the upper suspension arm.

C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600.

Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)

24. Connect the lower ball joint to the steering knuckle with 4 bolts.

Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)

25. Install shock absorber with coil spring.

A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut.

Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)

26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.

A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values

Minimum Thickness: 26.0 mm (1.024 in.)

NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.

B. Install the disc, brake caliper, and 2 NEW bolts.

Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)

C. Install the brake line clamp to the steering knuckle with the bolt.

Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)

27. Install new brake line.

Using the SST, connect NEW brake line.

SST P/N: 09023-00100

Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)

28. With ABS:

Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

29. 4WD:

Install drive shaft lock nut.

A. While applying the brakes, tighten the nut.

Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)

B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600.

30. 2WD:

Install grease cap.

31. Install front wheel.

NOTE:
Do NOT use an air wrench.

Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)

32. Depress brake pedal several times.

33. Fill the brake reservoir with brake fluid and bleed brake system.

34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):

2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).