SECTION 3A
FRONT DRIVE AXLE
TABLE OF CONTENTS
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Maintenance and Repair . . . . . . . . . . . . . . . 3A-6
General Specifications . . . . . . . . . . . . . . . . . . 3A-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3A-6
Fastener Tightening Specifications . . . . . . . . . 3A-2 Vacuum Line . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Component Locator . . . . . . . . . . . . . . . . . . . 3A-3 Steering Knuckle and Drive Shaft . . . . . . . . . . 3A-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14
Auto-Locking Hub . . . . . . . . . . . . . . . . . . . . . . 3A-4 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Vacuum Circuit . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
Drive Shaft Type CV Joint
Axle Housing Type Build - up
Differential Type Conventional
Differential Gear Hypoid Gear
Reduction Ratio 661NA M/T 4.56
662NA M/T 4.56
A/T (MB) 3.73
661LA M/T 4.56
A/T (BTRA) 5.38
662LA M/T 4.27
A/T (BTRA) 4.89
E20 M/T 4.89
A/T (MB) 4.55
E23 M/T 4.55
A/T (MB) 4.55
A/T (BTRA) 5.86
E32 M/T 3.73
A/T (MB) 3.73
A/T (BTRA) 4.89
Oil Capacity 1.4 L
Oil Specification SAE 80W/90, API GL - 5
3A-2 FRONT DRIVE AXLE
FASTENER TIGHTENING SPECIFICATIONS
Steering Knuckle and Drive Shaft
Application Nlm
Drive Shaft to Front Axle Inner Shaft 25 - 35
Wheel Speed Sensor 85 - 105
Drive Shaft Cover Bolt 50 - 60
Locking Hub Washer Screw 2-4
Hub Flange Bolt 70 - 90
Hub Nut 15
FRONT DRIVE AXLE 3A-3
COMPONENT LOCATOR
FRONT AXLE
1 Drive Shaft 5 Brake Disc
2 Axle Housing Mounting Bolt 6 Hub-Wheel
3 Axle Housing 7 Locking Hub
4 Cross Member
3A-4 FRONT DRIVE AXLE
AUTO-LOCKING HUB
1 Cap 11 Body
2 Filter 12 Return Spring
3 Vacuum Diaphragm 13 Bearing
4 Diaphragm Retainer 14 O-ring
5 Piston 15 Retaining Ring
6 Bolt (M10) 16 Inner Drive Gear
7 Lock Washer 17 Oil Seal
8 O-ring 18 Oil Seal Race
9 Retaining Ring 19 Axle Retaining Ring
10 Clutch Ring
FRONT DRIVE AXLE 3A-5
VACUUM CIRCUIT
1 Engine 6 Auto locking Hub Solenoid Valve
2 Vacuum Pump 7 T-connector Hose
3 3-way Connector 8 Hub Hose (left)
4 T-connector 9 Hub Hose (right)
5 Check Valve
3A-6 FRONT DRIVE AXLE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
VACUUM LINE
1 Vacuum Auto-locking Hub Assembly 12 Check Valve
2 Bolt ...................................................... 50-60 Nm 13 Hose (L :100, green)
3 Cam Washer 14 Auto Locking Hub Solenoid Valve
4 Auto-locking Hub Cap 15 Bolt
5 Retainer Ring 16 Hose (L :100, green)
6 Shim 17 T-connector
7 Locking Hub 18 Hose (L : 720, yellow)
8 Band 19 Hose (L :2, 360 , red)
9 Hose (L : 400) 20 Corrugated Tube
10 T-connector 21 Clip
11 Hose (L : 250, white) 22 Clip
FRONT DRIVE AXLE 3A-7
Removal & Installation Procedure
1. Be careful not to change the valve when connecting the
check valve and each hose.
2. Adjust the clearance between the retainer ring (5) and
locking hub (7) using the shim(6).
Normal Max. 0.2 mm
Notice
Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm
3. Tighten the auto locking hub cap bolt to the specified torque
and order.
Tightening Torque 50 - 60 Nm
3A-8 FRONT DRIVE AXLE
STEERING KNUCKLE AND DRIVE SHAFT
1 Front Axle Inner Shaft 4 Bolt ...................................................... 45-60 Nm
2 Front Axle Drive Shaft 5 Steering Knuckle
3 Spring Washer
FRONT DRIVE AXLE 3A-9
Removal & Installation Procedure
1. Remove the tire.
Installation Notice
Steel Wheel 80 - 120 Nm
Tightening Torque
Aluminum Wheel 110 - 130 Nm
2. Remove the autolocking hub vacuum hose.
3. With ABS
Remove the wheel speed sensor from the steering knuckle.
Installation Notice
Tightening Torque 6 - 8 Nm
4. Remove the mounting bolts and pull off the caliper assembly.
Installation Notice
Hose Bolt 25 - 35 Nm
Tightening Torque
Mounting Bolt 85 - 105 Nm
Notice
Be careful not to damage the brake hose.
3A-10 FRONT DRIVE AXLE
5. With part time transfer case.
5-1. Remove the cover mounting bolts and pull off the cover.
Installation Notice
Tightening Torque 50 - 60 Nm
5-2. Remove the snap ring of the drive shaft and pull off the
hub body.
Notice
For assembly, adjust the clearance between the snap ring
and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2,
0.3, 0.5, 1.0 mm).
5-3. Remove the screws and pull off the locking hub washer.
Installation Notice
Tightening Torque 2 - 4 Nm
6. With full time transfer case
6-1. Detach the hub cap with screw driver and remove the
snap ring on drive shaft.
Installation Notice
Tightening Torque 15 Nm
Notice
For assembly, adjust the clearance between the snap ring
and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2,
0.3, 0.5, 1.0 mm).
FRONT DRIVE AXLE 3A-11
6-2. Unscrew the bolts and remove hub flange.
Installation Notice
Tightening Torque 70 - 90 Nm
Before installation, apply loctite on the mating surface.
7. Remove the hub nut with special tool.
Tightening Torque 15 Nm
8. Remove the hub and disk assembly.
9. Remove the disk brake dust shield.
Installation Notice
Tightening Torque 4 - 6 Nm
3A-12 FRONT DRIVE AXLE
10. Remove the cotter pin and slotted nut and then remove
the steering knuckle arm and tie-rod.
Installation Notice
Tightening Torque 35 - 45 Nm
Replace the cotter pin with new one.
11. Remove the cotter pin and nut from the steering knuckle
arm and upper arm ball joint connection.
Installation Notice
Tightening Torque 80 - 150 Nm
Replace the cotter pin with new one.
12. Remove the cotter pin and nut from the steering knuckle
arm and lower and lower arm boll joint connection.
Installation Notice
Tightening Torque 120 - 180 Nm
13. Carefully remove the knuckle arm.
FRONT DRIVE AXLE 3A-13
14. Remove the drive shaft mounting bolts and remove the
drive shaft.
Installation Notice
Tightening Torque 45 - 60 Nm
Observe the tighening torque and sequence.
15. Installation should follow the removal precedure in the
reverse order.
3A-14 FRONT DRIVE AXLE
FRONT AXLE
Preceding Work : Removal of the front axle drive shaft
Removla of the steering gear box
1 Axle Mounting Bracket 9 Bushing
2 Breather Hose 10 Nut ..................................................... 95-142 Nm
3 Bolt (Rear) 11 Front Axle Assembly
4 Nut ..................................................... 95-142 Nm 12 Nut ....................................................... 70-80 Nm
5 Cross Member 13 Bolt
6 Bolt (Front) 14 Inner Axle Shaft (LH)
7 Bushing 15 Inner Axle Shaft (RH)
8 Spacer
FRONT DRIVE AXLE 3A-15
Removal & Installation Procedure
1. Remove the propeller shaft from the front axle input shaft.
Notice
Before removal, place the alignment marks.
Installation Notice
Tightening Torque 70 - 80 Nm
2. Remove the breather hose.
3. Remove the axle housing mounting nuts (1) from the cross
member.
Installation Notice
Tightening Torque 95 - 142 Nm
4. Remove the cross member mounting nuts (2) from the frame
and remove the cross member.
Installation Notice
Tightening Torque 62 - 93 Nm
5. Support the axle housing on a suitable jack, Remove the
axle housing mounting bracket nuts.
Installation Notice
Tightening Torque 95 - 142 Nm
6. Lowering the jack carefully, remove the axle housing
assembly.
7. Installation should follow the removal precedure in the
reverse order.
3A-16 FRONT DRIVE AXLE
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle housing
FRONT DRIVE AXLE 3A-17
1 Front Axle Housing Mounting Bracket 20 Bearing
2 Inner Shaft (Left) 21 Oil Slinger
3 Bolt ...................................................... 55-65 Nm 22 Drive Pinion
4 Oil Seal .................................................. Replace 23 Oil Filler Plug ....................................... 28-41 Nm
Apply Grease to the Sealing Rib 24 Bolt ...................................................... 39-46 Nm
5 Snap Ring 25 Axle Housing Cover.............. Apply Liquid Gasket
6 Bearing to the Contact Surface
7 Snap Ring 26 Ring Gear
8 Oil Drain Plug ....................................... 28-41 Nm 27 Bearing
9 Front Axle Housing 28 Shim
10 Breather Nipple 29 Shaft Lock Pin
11 Inner Shaft (Right) 30 Differential Case
12 Pinion Lock Nut ................................ 240-310 Nm 31 Bolt ...................................................... 75-90 Nm
13 Washer 32 Bolt ...................................................... 48-69 Nm
14 Companion Flange 33 Washer
15 Oil Seal .................................................. Replace 34 Bearing Cap
Apply Grease to the Sealing Rib 35 Thrust Washer
16 Bearing 36 Side Gear
17 Shim 37 Differential Shaft
18 Bearing Baffle 38 Differential Pinion
19 Shim 39 Thrust Washer
3A-18 FRONT DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
Installation Notice
Tightening Torque 28 - 41 Nm
2. Unscrew the axle housing and housing mounting bracket
bolts and remove the bracket and inner shaft assembly.
3. Remove the bearing fixing snap ring of the inner shaft and
pull out the bearing. Separate the inner shaft and the
mounting bracket.
4. Remove the axle housing cover.
Notice
Clean the cover and housing contact surfaces.
FRONT DRIVE AXLE 3A-19
5. Unscrew the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
6. Disassemble the parts of the differential carrier assembly.
7. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings :
l Check the ring gear and drive pinion for wear and
damage. If damaged, replace it as a set.
l Check the bearing for sticks, wear, noise and turning
resistance.
l Check the side gear, pinion, pinion shaft and thrust
washer for wear and damage.
l Check the differential carrier for crack and wear (bearing
contact surface). Check the gear case for crack.
3A-20 FRONT DRIVE AXLE
2. Assemble the parts of the drive pinion.
Tightening Torque of the
240 - 310 Nm
Lock Nut
3. Assemble the parts of the differential carrier.
Tightening Torque of the
75 - 90 Nm
Ring Gear Bolts
4. Measure backlash of the side gear and pinion.
Standard 0 - 0.05 mm
5. Install the differential carrier assembly into the axle housing.
Tightening Torque of the
48 - 69 Nm
Bearing Cap Bolts
Notice
Be careful not to change the caps. Be sure to keep the
original position of the caps.
FRONT DRIVE AXLE 3A-21
6. Measure backlash of the drive pinion and ring gear.
Specified Value 0.13 - 0.20 mm
7. Install the axle housing cover.
Tightening Torque 39 - 46 Nm
8. Assemble the parts of the front axle shaft and housing
mounting bracket.
Notice
Apply grease to the oil seal rib.
9. Align the axle shaft and differential carrier spline and insert
the axle shaft. Assemble the axle housing mounting bracket
to the axle housing.
Tightening Torque 55 - 65 Nm
3A-22 FRONT DRIVE AXLE
Inspection of Ring Gear Tooth Contact Pattern
Normal Contact
Apply gear-marking compound (prussian blue / red lead) on
the ring gear teeth. Rotate the ring gear and check the tooth
contact pattern.
Abnormal Contact
Tooth Contact pattern Possible Cause Remedy
1. Heel Contact
Excessive backlash (little) Adjust backlash(Decrease backlash)
l Noise can be occurred l Select proper shim(s) to move the
drive pinion toward the ring gear
(toward toe)
2. Toe Contact
Insufficient backlash (little) Adjust backlash(Increase backlash)
l Tooth can be damaged l Select proper shim(s) to move the
or broken under heavy drive pinion against the ring gear
load (toward heel)
3. Face Contact
Excessive backlash (much) Adjust backlash(Increase pinion shim)
l Drive pinion shaft is apart l Move the drive pinion toward the ring
from the ring gear gear (toward center of ring gear)
l Noise can be occurred
4. Flank Contact Insufficient backlash (much)
l Gear contacts on the low
flank Adjust backlash(Decrease pinion shim)
l Gear can be damaged or l Move the ring gear toward the drive
worn pinion (toward ring gear center line)
l Noise can be occurred
