Front Shock Absorber With Coil Spring: Overhaul

HINT:

• COMPONENTS: See FRONT SUSPENSION 
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.

1. REMOVE FRONT WHEEL 
2. REMOVE FRONT WIPER ARM HEAD CAP (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
3. REMOVE FR WIPER ARM RH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
4. REMOVE FR WIPER ARM LH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
5. REMOVE HOOD TO COWL TOP SEAL (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
6. REMOVE COWL TOP VENTILATOR LOUVER LH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
7. REMOVE COWL TOP VENTILATOR LOUVER RH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
8. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
9. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  REPLACEMENT  ) 
   Fig 1: Removing Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. SEPARATE FRONT STABILIZER LINK ASSY 
    1. Place a wooden block on a jack, and support the front suspension lower arm No.1 LH with the jack.
    2. Remove the nut and separate the front stabilizer link assy from the shock absorber with coil spring.

    HINT:

    Use a hexagon wrench (6 mm) to hold the stud if the ball joint turns together with the nut.

11. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING 
    1. Remove the bolt and disconnect the front flexible hose No.1 and speed sensor front LH wire harness.
       NOTE: Be sure to completely disconnect the speed sensor front LH from the front shock absorber assy  .
    2. Remove the 2 nuts on the lower side of the front shock absorber with coil spring.
       NOTE: Keep the bolts inserted. 
       Fig 2: Disconnecting Speed Sensor Front LH From Front Shock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 3: Locating Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 nuts.
    4. Lower the jack slowly. Remove the 2 bolts on the lower side and the front shock absorber with coil spring.
       NOTE: Ensure that the speed sensor front LH is completely disconnected from the front shock absorber with coil spring. 
       Fig 4: Locating Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. FIX FRONT SHOCK ABSORBER WITH COIL SPRING 
    1. Secure the front shock absorber with coil spring in a vise by clamping onto a double nutted bolt affixed to the bracket at the bottom of the absorber, as shown in the illustration to the left.
    Fig 5: Securing Front Shock Absorber

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT 
    1. Attach the SST to the coil spring so that the upper and lower hooks of the installed area are as wide as possible.

       SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)

    2. Fully compress the coil spring.
       NOTE: Do not use an impact wrench. It will damage the SST. 

       HINT:

       The coil spring can also be installed/removed using the hydraulic spring compressor.

    3. Remove the front suspension support dust cover.
    4. Secure the front coil spring seat upper with SST and remove the front suspension support to front shock absorber LH nut.

    SST 09729-22031

    Fig 6: Attaching SST To Coil Spring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Removing Front Suspension Support Dust Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT SUSPENSION SUPPORT SUB-ASSY LH 
15. REMOVE FRONT SUSPENSION SUPPORT LH DUST SEAL 
16. REMOVE FRONT COIL SPRING SEAT UPPER LH 
17. REMOVE FRONT COIL SPRING INSULATOR UPPER LH 
18. REMOVE FRONT COIL SPRING LH 
19. REMOVE FRONT SPRING BUMPER LH 
20. REMOVE FRONT COIL SPRING INSULATOR LOWER LH 
21. REMOVE SHOCK ABSORBER ASSY FRONT LH 
    Fig 8: Compressing Shock Absorber Rod

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSPECT SHOCK ABSORBER ASSY FRONT LH 
    1. Compress and extend the shock absorber rod 4 or more times. Check that there is no abnormal resistance or sound.

    If there is any abnormality, replace the shock absorber assy front LH with a new one.

    NOTE: When disposing of the shock absorber assy front LH, see DISPOSAL  DISPOSAL 
23. INSTALL SHOCK ABSORBER ASSY FRONT LH 
    Fig 9: Installing Front Coil Spring Insulator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL FRONT COIL SPRING INSULATOR LOWER LH 
    1. Install the front coil spring insulator lower to the front shock absorber assy so that both recessed parts are aligned.
25. INSTALL FRONT SPRING BUMPER LH 
    Fig 10: Compressing Coil Spring Using SST

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT COIL SPRING LH 
    1. Using SST, compress the coil spring.

       SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)

       NOTE: Do not use an impact wrench. It will damage the SST. 

       HINT:

       The coil spring can also be installed/removed using the hydraulic spring compressor.

    2. Fit the lower end of the front coil spring LH into the recessed part of the spring lower seat.

    HINT:

    Install the spring with the smaller diameter on top.

27. INSTALL FRONT COIL SPRING INSULATOR UPPER LH 
    1. Install the front coil spring insulator upper to the front shock absorber assy with the protruding part facing to the outside of the vehicle.
    Fig 11: Installing Front Coil Spring Insulator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT COIL SPRING SEAT UPPER LH 
    1. Install the front coil spring seat upper with the recess facing to the outside of the vehicle.
       Fig 12: Installing Front Coil Spring Seat

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Fit the protruding part of the front coil spring insulator upper LH to the recess of the front coil spring seat upper LH. 
    • Ensure that the width across flats of the piston rod and the front coil spring seat upper LH are fitted. 
29. INSTALL FRONT SUSPENSION SUPPORT LH DUST SEAL
30. INSTALL FRONT SUSPENSION SUPPORT SUB-ASSY LH
    Fig 13: Installing Front Suspension Support LH Dust Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT
    1. Secure the front coil spring seat upper with SST and tighten it with a new nut.

       Torque: 47 N.M (479 kgf.cm, 35 ft.lbf)

    2. Release the SST while aligning the protruding part of the front coil spring insulator upper, the recess of the spring front coil spring seat upper and the shock absorber lower bracket and then remove the SST from the coil spring.

       SST 09729-22031

       NOTE: Do not use an impact wrench when removing the SST. 
    3. Apply MP grease No.2 to the parts indicated in the illustration and install the front suspension support dust cover.
    Fig 14: Applying MP Grease

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING 
    1. Insert the 2 bolts from the front side of the vehicle and install the front shock absorber with coil spring to the steering knuckle assy.
    2. Place a wooden block between the front shock absorber with coil spring and a jack. Slowly raise the jack and install the front shock absorber with coil spring (upper side) to the vehicle.
    3. Install the front shock absorber with coil spring (upper side) with the 3 nuts.

       Torque: 39 N.M (398 kgf.cm, 29 ft.lbf) 

       Fig 15: Locating Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front shock absorber with coil spring to the steering knuckle with the 2 nuts.

       Torque: 153 N.M (1560 kgf.cm, 113 ft.lbf) 

       Fig 16: Installing Front Shock Absorber

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the front flexible hose No.1 and the speed sensor front LH to the shock absorber assy with the bolt.

    Torque: 19 N.M (192 kgf.cm, 14 ft.lbf) 

    NOTE: Do not twist the speed sensor front while installing. 
    Fig 17: Connecting Front Flexible Hose

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. CONNECT FRONT STABILIZER LINK ASSY 
    1. Connect the front stabilizer link assy to the front shock absorber with coil spring with the nut.

    Torque: 74 N.M (755 kgf.cm, 55 ft.lbf) 

    HINT:

    Use a hexagon wrench (6 mm) to hold the stud if the ball joint turns together with the nut.

    Fig 18: Connecting Front Stabilizer Link Assy To Front Shock Absorber

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  REPLACEMENT  ) 
35. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
36. INSTALL COWL TOP VENTILATOR LOUVER RH 
37. INSTALL COWL TOP VENTILATOR LOUVER LH 
38. INSTALL HOOD TO COWL TOP SEAL 
39. INSTALL FR WIPER ARM RH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
40. INSTALL FR WIPER ARM LH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
41. INSTALL FRONT WIPER ARM HEAD CAP 
42. INSTALL FRONT WHEEL 

    Torque: 103 N.M (1,050 kgf.cm, 76 ft.lbf) 

43. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE  FRONT WHEEL ALIGNMENT   )