1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

2nd gen lower steering shaft rebuild DIY :)

Discussion in 'Technical Chat' started by Jon G, Apr 10, 2018.

  1. Apr 10, 2018 at 4:43 AM
    #1
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    REMEMBER this is for entertainment :) this is how i did it, what YOU DO IS UP TO YOU !!! I DO NOT want you to try this at home your truck will explode in to little pieces. I am not a mechanic nor do i pretend to be one i do not know your mechanical abilities or your judgement on what is safe or not. SO AGAIN DO NOT DO THIS AT HOME OR WORK OR AT YOUR PARENTS HOUSE take it to a PROFESSIONAL to have any work completed on your truck



    Second gen Tacomas have a lower intermediate shaft with a u joint and yokes close to the steering rack end. This u joint is not protected from the elements and tends to fail often causing the steering to become sticky or bind causing unwanted results. Seen in pink highlighted area



    24129919_10159457397680417_8877964581642_73d8ed831b1ccff817562229901df1765da02fc0.jpg

    If your not having problems with it now i would suggest to spray the u joint with penetrating oil every oil change.

    The u joint is NOT a serviceable part through the dealer, they want to sell you the complete assembly. The caps for the u joint are staked into place ( metal bent over )

    I am in CANADA my dealer wanted $600 the best price i could get out of the OEM part was just under $400. There is a aftermarket shaft for $150 the same price as some of the local machine shops charge to rebuild my old one.

    Pictures of a new one my local dealer had in stock


    24899734_10159483266965417_1887755191958_e224f0ac4850fdbbc121f6df72af71c74532a656.jpg
    24862494_10159483267335417_7816726489122_0907afa3398e79429858199f4d98522d5b2d1e22.jpg
    24862272_10159483267865417_5470284888739_6a215364d1bd2dda7007b330a603adc534a32b10.jpg

    24232588_10159965994735122_5315416832305_9688a7e82ebab7d3de984ba90bd00ef7750353d4.jpg





    SOOOOOO This is my DIY on how i rebuilt the old one, I did my research and asked questions i was told that a ALL BALLS 19-1010 kit for a BRP atv will work. I ordered one through my local Honda dealer for around $30.

    REMEMBER this is for entertainment :) this is how i did it, what YOU DO IS UP TO YOU !!! i do not want you to try this at home.



    24774963_10159475550370417_4732334825716_e5c325c92b4e4a014f5db4606d4ea136c7350ce4.jpg


    A mechanic friend called me and said he had a shaft that was replaced out of a 2011 and it was seized and the owner did not want it back, he kept it for me to try my rebuild on.
    Once i had the old shaft I took the steering shaft into work and ran it across the wire wheel to clean the rust and crap off of it. The u joint is seized in one direction.


    30264802_10160012804730417_2865273760921_18d62acd4b84fdd9dd7063bc196d1e6d742870f2.jpg

    30415690_10160012804765417_6777754475248_ff859a8177a78e11e3f8715eb57cc5f23aec8059.jpg

    30515900_10160012804760417_4923711084629_bb41cac5f5834804608faed477a00c20bc3b54ba.jpg



    30441586_10160015599930417_4368923196863_f981bbb54177d4b8335272d8602997f9e7e03f20.jpg


    Picture for reference Flat spot in shaft up and treads for bolt down or you could make a mark on the two yokes so it will go back together the same way.. Cleaned up with wire wheel


    Untitled.jpg



    I took a grinder with a cutting disk and cut into the u joint cap careful not to damage the yoke 1st red line. I rotated the joint so i had the cut cap in and the uncut one out to be able to access to make the second cut.

    Once removed you will have the u joint held in with the two opposite caps in the other yoke this will provide lots of room to be able to cut into what is remaining of the u joint. Red line 3 and 4.

    After the center section of the u joint is removed i put the ear of the yoke into a vice and used a hammer and a punch to knock the caps down into the center to remove.


    Untitled 2.jpg


    30441425_10160015608590417_7460502053081_81379dc7a1a8f67143e664a8fb20bfd4d44a40ad.jpg

    30515996_10160015608790417_2458624251586_003c8eecaba8c951f7ec3fb61b12712898529a1c.jpg

    30594535_10160015609075417_8252315399069_1aec517c086482f546eba4925e93d493f4bfa49e.jpg

    30443496_10160015609675417_8575468137124_831f1f270bdc91f7e5509340c927a425d101202a.jpg

    30441044_10160015610015417_8745559579464_9e66ca7ed4144f68925b497b3454a2a3a16097f8.jpg


    To reinstall you will need to file out the stakes that held the old cap in. I used a chainsaw round file, made a few passes to clean it up.

    Installation of new u joint, I put one new cap 1/2 way in then took the u joint and put it in the yoke cap. took the opposite cap and installed 1/2 way, then moved the u joint so both ends were in the bearing caps, I did this so the bearings would be held in place.

    I put the joint into the vice and tightened the jaws to squeeze the caps into the yoke slowly. Care is needed here to make sure your are drawing them in straight re positing might be needed to fair up one side of the cap. Draw the cap into the yoke until the retaining clip can be inserted into its slot. Once one clip is in I used a socket on that side in the vice so the pressure would be on the yoke not the joint as i did not want to push the cap in further. I also used a socket on the other side to push on the cap only to bring the retaining slot into place.

    EDIT *** I also plan to stake the yoke as a second way of keeping the cap in place.

    The thought of putting RED locktight on the cap before installing in the yoke also crossed my mind :bananadead:


    30442997_10160016153535417_3523343753752_f0c62769254d7eadb7ebb7590a8904450c796950.jpg

    30442810_10160016153675417_8988602432896_f12dbaaff2d94d9f05288b4ea8bbb2a72b7c5ea5.jpg

    30440800_10160016153880417_5813551381201_8d5bfba3bddc3c4a7f97380abdbc0f10765c844e.jpg

    30442959_10160016154155417_2717276480756_7324c1699c31f4008134673ae4f6abf783d50503.jpg

    30441406_10160016847820417_4993950507341_1a6bc72852656669bec27a278284f4c5cb398cec.jpg

    30571401_10160016847955417_2193917999725_ddd8378bb3d00b0f7c408f99ad43cc20f9c995fb.jpg

    I installed the provided grease nipple and tested the rebuilt joint for
    clearance.

    I also plan to cut a length of HD dirt bike tube to slide over the joint to protect it from the elements. This will be held in place with zip ties. When it comes time to grease under carriage, just cut one zip tie slide up grease and reinstall the zip tie.


    EDIT !!!

    For added surface area contact the clips will be rotated

    [​IMG]

    I hope someone gets use out of this DIY and saves $$$$

    Tacoma World is a awesome place with a excellent group of members

    AGAIN THIS IS YOUR STEERING MAKE SURE IT IS SAFE TO USE

    shameless plug for my 07 taco pro build where this and many more wrenching adventures can be found :)

    have a look


    https://www.tacomaworld.com/threads/canadian-family-taco-build-and-bs.527692/


    Jon
     
    Last edited: Apr 11, 2018
  2. Apr 10, 2018 at 4:51 AM
    #2
    Spintly

    Spintly Well-Known Member

    Joined:
    Mar 2, 2014
    Member:
    #124416
    Messages:
    721
    Gender:
    Male
    First Name:
    Greg
    Home of the Groundhog
    Vehicle:
    85 Single Cab Pickup & 2000 911
    Totally awesome! I had toyota replace mine when they did the frame recall. Thanks for posting this :thumbsup:
     
    lynyrd3, ODNAREM and Jon G [OP] like this.
  3. Apr 10, 2018 at 5:11 AM
    #3
    gearcruncher

    gearcruncher Well-Known Member

    Joined:
    Nov 1, 2012
    Member:
    #90305
    Messages:
    6,100
    Gender:
    Male
    First Name:
    Canadain bumper technician
    Great white North 51.0333° N, 93.8333° W
    Vehicle:
    2010.TRD.SportDCLB4x4Limited leather package
    TRD Sport Rally -5 speed automatic Limited ,Factory heated leather seats ,chrome package,Super white with front windows tinted to 35 % Dick Cepek DC-2 wheels Summer tires - Good year silent armor P265/65R17 Winter tires - Good year P265/65R17 Ultra Ice studded Illuminated 4x4 switch TRD 3rd brake light cover ($20) TRD seat belt shoulder protectors (5). ($50) TRD ...B pillar emblems ($20) TRD rear slider sticker with devil horns ( $6) TRD summer floor matts ($60) TRD steering wheel emblem ($20) TRD floor pedals .($95) TRD shorty antenna ($14) TRD front Windshield emblems ($17) TRD head pillows .($60) TRD head rest protectors TRD door scuff protection $20 TRD floor matt emblems ($40) TRD tow plug emblem . ($40) TRD cigarette lighter with LED.($35) TRD tissue dispenser ($12) TRD front bezel emblems ($9) TRD door emblems ($6) TRD lanyards($9) TRD lisence plates with TRD bolts($50) TRD fender emblems TRD center caps Part Number:PT904-35070-CC ($80) TRD cd
    Thanks for the write up !! :thumbsup:

    This is going to save members a lot of time and money .

    Good job sourcing the greaseable universal joint
     
  4. Apr 10, 2018 at 7:03 AM
    #4
    Kemosabe

    Kemosabe Little bitty life

    Joined:
    Apr 2, 2015
    Member:
    #152362
    Messages:
    6,182
    Gender:
    Male
    First Name:
    Louis
    Western Quebec, Canada
    Vehicle:
    2010, 2.7l, 4x4, M/T
    URD STS, Spidertrax spacers, AFE Pro dry
    Excellent write up @Jon G !


    @tcBob Can we make this thread a sticky to get more visibility?
     
  5. Apr 10, 2018 at 7:34 AM
    #5
    ravenlord

    ravenlord Well-Known Member

    Joined:
    Mar 12, 2010
    Member:
    #33087
    Messages:
    173
    Gender:
    Male
    First Name:
    Scott
    Nova Scotia
    You sir are a scholar and a gentleman.
     
    Jon G [OP] likes this.
  6. Apr 10, 2018 at 8:05 AM
    #6
    madsand

    madsand wanderer

    Joined:
    Oct 26, 2012
    Member:
    #89874
    Messages:
    3,356
    Gender:
    Male
    First Name:
    sandz
    Costa Mesa, CA
    Vehicle:
    2012 DBLCB LB sports 4x4 SC
    Icon 2.5" Remote Reservoir Extended Travel CDCV Icon tubular UCA Icon add a leaf Method NV wheels Nitto trail grappler MT 285/70/17 Weather Tech floor mat All Pro rock slider
    Thanks for sharing! great info, well done sir!
     
    Jon G [OP] and ODNAREM like this.
  7. Apr 10, 2018 at 8:12 AM
    #7
    tcBob

    tcBob Gringo Bandito Moderator

    Joined:
    Sep 6, 2006
    Member:
    #1
    Messages:
    14,489
    Gender:
    Male
    First Name:
    Bob
    Vehicle:
    07 PreRunner SR5 V6 Black
    I added it to the 2nd gen mod list and will give it a shout out w/ link in the upcoming newsletter
     
    TacoTRD78, Crom, inesshell and 6 others like this.
  8. Apr 10, 2018 at 8:21 AM
    #8
    ODNAREM

    ODNAREM MEMBER Of The Church Of @ODNAREM

    Joined:
    Feb 28, 2015
    Member:
    #149762
    Messages:
    41,301
    Gender:
    Male
    First Name:
    Ron
    Huntington Beach,CA.
    Vehicle:
    2012 TRD Sport Prerunner
    TRD catback exhaust,FJ Cruiser trail team wheels,BFG All Terrain K02 tires,Grillcraft front grill,Pelfreybilt IFS/Mid skids,sliders,standard rear bumper,Total Chaos bed stiffeners.TRD Pro Bilstein front/rear suspension.
    @Jon G Great Information,Thank You!
     
    Jon G [OP] likes this.
  9. Apr 10, 2018 at 8:49 AM
    #9
    Kemosabe

    Kemosabe Little bitty life

    Joined:
    Apr 2, 2015
    Member:
    #152362
    Messages:
    6,182
    Gender:
    Male
    First Name:
    Louis
    Western Quebec, Canada
    Vehicle:
    2010, 2.7l, 4x4, M/T
    URD STS, Spidertrax spacers, AFE Pro dry
    Awesome thanks!
     
    Jon G [OP] likes this.
  10. Apr 10, 2018 at 9:18 AM
    #10
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    just added this edit :bananadead:

    I also plan to cut a length of HD dirt bike tube to slide over the joint to protect it from the elements. This will be held in place with zip ties. When it comes time to grease under carriage, just cut one zip tie slide up grease and reinstall the zip tie.
     
    Kemosabe likes this.
  11. Apr 10, 2018 at 9:20 AM
    #11
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    D2. likes this.
  12. Apr 10, 2018 at 9:28 AM
    #12
    D2.

    D2. Well-Known Member

    Joined:
    Dec 1, 2016
    Member:
    #203759
    Messages:
    1,221
    Gender:
    Male
    First Name:
    Dan
    Nova Scotia, Canada
    Vehicle:
    2009 Tacoma - access cab 4x4 2TR-FE
    Cruise Control install. WeatherTech Mats Intermittent wipers Hood lights Bed Lights
    x2

    also Just posted this to the NSBS thread, a few guys in there had some steering shaft issues.
     
    Kemosabe and Jon G [OP] like this.
  13. Apr 10, 2018 at 10:01 AM
    #13
    Toy4me

    Toy4me Well-Known Member

    Joined:
    Aug 19, 2012
    Member:
    #85061
    Messages:
    3,534
    Gender:
    Male
    First Name:
    Tom
    NNJ
    Vehicle:
    '10 DCLB TRD Sport MGM
    Sorry everyone, I’m going to be that guy. Nice work op, but I don’t like the way the retaining circlips aren’t captured. They only touch the shaft in a couple of spots and I would be very concerned that they will wear and fall out. At least humor me op and keep checking them. I would only do this if I could replace the circlips into the oem recesses.
     
  14. Apr 10, 2018 at 10:18 AM
    #14
    D2.

    D2. Well-Known Member

    Joined:
    Dec 1, 2016
    Member:
    #203759
    Messages:
    1,221
    Gender:
    Male
    First Name:
    Dan
    Nova Scotia, Canada
    Vehicle:
    2009 Tacoma - access cab 4x4 2TR-FE
    Cruise Control install. WeatherTech Mats Intermittent wipers Hood lights Bed Lights
    I don't think there is any OEM Recesses. It looks like the U-Joint was designed this way on purpose, so I would trust the manufacturer to know what they are doing. These are ATV U-joints and are going to see a lot more stress in an ATV then a steering shaft of a vehicle. if you really wanted to do it "OEM" style, then could could un-steak the caps, then re-steak. Honestly if you check these everytime you change your oil, I'd think you'll be fine
     
  15. Apr 10, 2018 at 10:39 AM
    #15
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    @Toy4me no its good to bring this kind of thing up

    The OEM caps did not have any clips holding them in, only two areas per a cap top and bottom that were staked in the yoke ( metal bent over the top of the cap) as shown in the below picture. This picture was after I drove the cap into the yoke so the amount of bent over metal is the same as what Toyota deemed safe to hold the caps. The Circlip that came with the ATV u joint snaps into the slot to provide a solid stop from the cap backing off. This circlip also has way more surface area making contact with the yoke. Also this is a pressed fit once you go through the process of putting the new caps in using the force from the jaws of the vice you will see it needs a fair amount of force to drive the caps in.

    The caps stay stationary in the yoke circlip does not move so there would no wear, u joint pin that goes in cap is what moves the cap has needle bearings in it

    The circlip and u joint set up is for a ATV drive daft that spins at unknown RPM and holds the cap in place

    The amount of rotation that this u joint will see is slow ( same speed as you turn the wheel)

    But yes as with ANYTHING and EVERYTHING it could fail so i do plan on checking it

    Untitled3.jpg
     
    Last edited: Apr 10, 2018
    Kemosabe, Toy4me and Tacotj like this.
  16. Apr 10, 2018 at 12:29 PM
    #16
    tcBob

    tcBob Gringo Bandito Moderator

    Joined:
    Sep 6, 2006
    Member:
    #1
    Messages:
    14,489
    Gender:
    Male
    First Name:
    Bob
    Vehicle:
    07 PreRunner SR5 V6 Black
    Every so often we send out an email newsletter highlighting the good info on the site they might've missed (things fly by fast on here) and things like new TSBs and such.

    If you want to confirm you'll receive it, top-right of the page click You > Contact Details and make sure "Receive site mailings" is checked.
     
    Jon G [OP] and D2. like this.
  17. Apr 10, 2018 at 3:44 PM
    #17
    tmj41765

    tmj41765 Active Member

    Joined:
    Mar 20, 2014
    Member:
    #125736
    Messages:
    30
    Gender:
    Male
    First Name:
    Todd
    Monongahela, Pennsylvania
    Vehicle:
    2010 Tacoma TRD Off Road Super White
    Jon G i bow at your feet. I'm so glad i found this write up because my 2010 DoubleCab steering shaft is acting up right now. I so want to do this and i searched for that All Balls 237-191010 kit on the internet and not one single link showed up. I can call a Honda shop tomorrow but it just seems strange you cant find any online. I'm puzzled
     
  18. Apr 10, 2018 at 4:19 PM
    #18
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    @tmj41765

    AD56EFEE-FD13-4764-96BE-BA4D58FF3A3C.jpg

    Hummmm this is the packaging it came in with the part # the supplier is les import thibault (French)but I am sure other aftermarket suppliers can order it using this #
     
    tacoma16 likes this.
  19. Apr 10, 2018 at 4:28 PM
    #19
    Jon G

    Jon G [OP] Hoarding Tacomas one at a time,

    Joined:
    Jan 25, 2017
    Member:
    #208594
    Messages:
    1,776
    Gender:
    Male
    First Name:
    Jon
    St John's Newfoundland Canada
    Vehicle:
    02, 04 & 07 Tacoma
    Magnaflow 2.5 Catback Exhaust K&N filter
    FE7FE620-6471-42DD-B94A-BB1F12867323.jpg


    Did a search on thibault’s atv catalog for the number and it says it fits a bayou :)
     
  20. Apr 10, 2018 at 4:31 PM
    #20
    tmj41765

    tmj41765 Active Member

    Joined:
    Mar 20, 2014
    Member:
    #125736
    Messages:
    30
    Gender:
    Male
    First Name:
    Todd
    Monongahela, Pennsylvania
    Vehicle:
    2010 Tacoma TRD Off Road Super White
    My bad, the part number 19-1010 is on Amazon. So sorry for my confusion, and thank you again!!!
     

Products Discussed in

To Top