2002 Corolla Front DriverSide Wheel Bearing Replacement

This is one of those deals where Qslm can provide much better information than me, but it is possible that you over-tightened the axle nut. Try backing it off one or two turns.

What is Qslm ? The squealing sound is now becoming more prominent on turns .We had originally tightened the axle nut using impact wrench so as suggested I have backed the nut and simply tightened it by a hand wrench.

Qslsm is a who, not a what. He is a Toyota Master Diagnostic Technician.

You should never use an impact wrench on the axle nut. There is a pretty good chance the tightening the axle nut with the impact wrench ruined the bearings by crushing the race and/or squeezing the grease out. The axle nut should be HAND tightened until it is snug, then backed off about a half-turn before securing with a new cotter pin.

I think you will need a new set of bearings.

Actually, I've never run across a set of bearings that were over-tightened with an impact wrench, so it was a guess on my part ;-)

I got hold of a 2003 Haynes repair manual and it recommends the torque for axle nut to be be 159 ft-lbs which should be same for 2002 model. In comparison the torque recommendation for the lug nuts was much less 75 ft-lbs. Every repair shop seems to use impact wrench to tighten the lug-nuts so I assume it should be okay for the axle nut as well.

InduP

Either the wheel bearing and axle assembly are put together differently than I think or the torque figure in the Haynes manual is incorrect. You may wish to invest $10 to access techinfo.toyota.com and look at the factory repair manual procedures and diagnosis to confirm.

Yes, I have to admit to the same but I do know how sensitive those races are...I had an RX-7 which had bearing noise caused by corrosion circles caused by parking the new vehicle for many months when it was new (or so the dealer said)

I've never heard that excuse before, I'll give it credit for sounding very plausible ;-)