2-1

SUSPE
CONTENTS

AXLE HUB AND FREE-WHEELING HUB ........... 16 Sealant and Adhesive .. . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . .. . . 7

Service Specifications . . . . . . . . . .. .. . . . . . . . . .. .. . . . . . .. . . . . . !?I
DIFFERENTIAL CARRIER ................................... 68
Torque Specifications . . . . . . . .. . . . . . . .. .. . . . . . . . .. . . . . . 6 “‘,-.
DRIVE SHAFT ..................................................... 52
STABlLlZER BAR . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . .. . . . . 51
FRONT DIFFERENTIAL MOUNTING ................ 66
TORSION BAR . . .. . . . . . . . . .. .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . .. . . . . 48
GENERAL INFORMATION ................................. 2
TROUBLESHOOTING .. ..a................................... 11
INNER SHAFT ..................................................... 62 AUTOMATIC FREE WHEELING HUB . . .. .. . . . . . . . 11
Does not lock
KNUCKLE ........................................................... 44 :’
Locks but does not become free ,-,,.t
LOWER ARM
...................................................... 40 Ratcheting readily occurs -$ I ;j;;.
Replacement of Lower Arm Bushing ............. 42 DIFFERENTIAL .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . . . I$’ “-:Y+:
II. ,‘;.
Replacement of Lower Ball Bearing noise while driving or. coasting : ‘, ,.;,
Joint Dust Cover .............................................. 42 ;
Constant noise i t’ ‘.:I
Gear noise while coasting ‘. ,;J.;
SERVICE ADJUSTMENT PROCEDURES .......... 14 .a
*;,*.,‘..‘,.f. .
Checking Drive Shaft End Play ........................ 16 Gear noise while driving :.
Checking Front Axle Total Backlash Heat ’ ‘k
............... 15
Noise while turning j L.t
Checking Gear Oil Level .................................. 16
Inspection and Adjustment of Wheel Oil leakage
Alignment ........................................................ 14 DRIVE SHAFT, INNER SHAFT . . .. . .. . . . . . . .. .. . . . . . . . 12
Replacement of Differential Carrier Oil Seal ... 17 Noise due to excessive play of wheel in ?i
turing direction
SHOCK ABSORBER AND UPPER ARM ............ 35 ,;
Noise due to excessive wheel end play
Replacement of Upper Ball Joint .................... 37 Noise during wheel rotation
SPECIAL TOOLS ................................................ 8 MANUAL FREE WHEELING HUB,
FRONT AXLE HUB, KNUCKLE . . . . . .. .. . . . . . . . . .. .. . . . 11
SPECIFICATIONS ............................................... 4 Noise due to excessive play of wheel in
General Specifications .................................... 4 turning direction
Lubricants ....................................................... 7 Noise due to excessive wheel end play
 2-2 FRONT SUSPENSION - General Information

GENERAL I FORMATION NOZBBAA

The-front suspension is an independent suspension which is a combination of the double-wishbone and

torsion bar spring.
The front axle assembly consists of a front differential, a Ihousing tube, an inner shaft, drive shafts, etc.
For better serviceability of the differential, the spacer for backlash iadjustment of the final drive gear is
placed between the side bearing outer race and the gear carrier.
The double-offset-joint which can slide in the axial direction, is used at the differential carrier side; the
Bit-field joint, with large operation angle, is used at the axle hub side.
To reduce vibration, noise, and fuel consumption when 2WD is applied, manual or automatic free-wheeling
hubs are equipped; in particular, tha automatic one is an outstanding feature in that the driver can switch
between “lock” and “free” without having to leave his seat. R

Drive sh
\
Torsion bar

Shock absorber

Free-wheeling hub

Drive shaft’L.H. Lower arm

i’f. MANUAL FREE-WHEELING HUB OPERA-K)ly

I ‘i Follower Clutch 1

Free State + Locked State

When the control handle is set to the LOCK position, the
follower moves along the oblique groove in the control handle
and causes the clutch (which is always in mesh with the free-
wheeling hub body) to engage the splines of the inner hub,
thus coupling the free-wheeling hub body with the drive shaft.

f . I_...
;,;a F lS063
PJ
>
Locked State + Free State
When the control handle is set to the FREE position, the
follower moves along the oblique groove in the control handle
and uses the tension spring to disengage the clutch from the
splines of the inner hub, thus separating the free-wheeling hub
body from the drive shaft.

Tension/spring
11 SO63

wision I
 FRONT SUSPENSION - General Information 2-3
AUTOMATIC FREE-WHEELING HUB OPERATlq$m
he@ State + Locked State
When the transfer is shifted from 2WD to 4WD and driving is
begun, rotation of the drive shaft is transmitted from the drive
gear to the slide gear to the cam to retainer (A) to brake (A).
When this happens, brake (A) is pressed against brake (6) by
the function of the cam of retainer (A), and friction force is
generated.
Because brake (B) is secured to the knuckle. retainer (A)
ceases to rotate, and therefore, the cam, while compressing
the return spring, rises out of the cam groove of the retainer
(A) and compresses the shift spring. The slide gear is pushed
by the shift spring, and then engages with the gear of the
_.
housing when the two are in phase and enters the locked *,-
state.
The cam turns until the lug of the drive gear contacts the lug of’
brake (A). Because of this contact, brake (A) is turned by the
drive gear, and therefore, there is also no longer any force of
retainer (A) with a tendency to turn brake (A). As a result, there
is also no longer any force which presses brake (A) against
brake (B) and the drive gear causes brake (A) to turn lightly. -
(there is no friction force).
Because the cam remains meshed, it turns until it contacts the
lug of retainer (A), and is locked.

Free state Locked state ~04:

Locked State +Free State
When the transfer is shifted from 4WD to 2WD and the vehicle
is driven in reverse, rotation of the gear of the body is 1,s:
!.
transmitted from the slide gear to cam to retainer (A) to brake J%.C
(A), but retainer .(A) ceases to turn, just as when the shift is?‘<,.,!;
made from the free state to the locked state. The can$ !:i;.‘i
therefore, turns as far as the cam groove of retainer (A)-and is ,t!?
pushed into the cam groove by the return spring. if :!”
The slide gear moves with the cam, disengages from the gear .‘...,.C
of the doby, and enters a free state. “[ ,I:; +,;:
“\:

llWO23

Lug of the retainer (A)

Meshed state
Locked state
llWO44

wision I
2-4 FRONT SUSPENSION - Specifications

SPECIFICATIONS
GENERAL SPECIFICATIONS NOZCA-

Items Specifications

Suspension system Independent double wishbone with torsion bar and telescopic
shock absorber
Kingpin inclination angle 8”
Torsion bar
Length x O.D. mm (in.) 1277.5 x 24.5 (50.29!5 x ,965)
Spring constant N/mm (Ibs./in.) 22 (123)
Shock absorber
Type Hydraulic cylindrical double-acting type
Maximum length mm (in.) 335(13.19)
Compressed length mm (in.) 215 (8.46)
Stroke mm (in.) 120 (4.72)
Damping force [at 0.3m/sec. (.984 ft./set.)]
Expansion N (Ibs.) 1,940-2,560 (428-564)
C,o$Wion N (Ibs.) 900-I ,300 (198-287)
Front axie hub bearing
Type Tapered roller bearing
Dimensions (O.D. x I.D.) mm (in.)
Outer 7:3.431 x 45.242 (2.8910 x 1.7811)
,. Inner 7r3.431 x 45.242 (2.8910 x 1.7811)
Drive shaft
. Joint type Outer B.J. (Birfield Joint)
Inner D.O.J. (Double Offset Joint)
Length Right mm (in.) 267 (10.5)
‘$ (Joint to joint) Left mm (in.) 294(11.6)
Q&-rer shaft
x
;:(Shaft overall length mm (in.) 432 (17.0)
,.&earing
$3s O.D. x I.D. mm (in.) 62 x 35 (2.44 x 1.38)
Differential
Final drive gear type Hypoid gear
Reduction ratio 4.625
Differential gear type Straight bevel gear
Number of teeth
Drive gear 37
Drive pinion 8
Side gear ‘I 4
Pinion gear ‘I 0

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 FRONT SUSPENSION - Specifications 2-5
SERVICE SPECIFICATIONS NOZCE-

Items Specifications
Standard values
Toe-in mm (in.) 2-9 (.08-.35)
Camber l”t30’
Caster 2”57’ i 30’
Drive shaft end play mm (in.) 0.2-0.5 (.008-.020)
Front hub turning resistance Ncm (in.lbs.) 30-I 30 (2.6-l 1.3)
[Spring scale reading] N (Ibs.) 5-18(1.1-4.0)
Front hub play in the axial direction mm (in.) 0.05 (.0020) or less
Automatic free-wheeling hub
Brake contact surface height mm (in.) 11.8-12.2 (.465-,480)
Brake assembly thickness mm (in.) 10.5 (.41)
Upper ball joint starting torque Ncm (in.lbs) 80-350 (7-30)
Clearance between bump stopper and bump stopper bracket mm (in.) 71 (2.80)
Shock absorber attaching dimension mm (in.) 7-8 (.27-.31)
Stabilizer attaching bolt end attaching dimension mm (in.) 6-8 (.24-.31)
..:
Anchor arm attaching dimension mm (in.)
L.H. 135.2-143.2 (5.323-5.638)
R.H. 124.3-l 32.3 (4.894-5.210)
Setting of D.O.J. boot length mm (in.) 77-83 (3.03-3.27)
Differential
Final drive gear backlash mm (in.) 0.1 l-0.16 (.0043-.0063)
Differential gear backlash mm (in.) O-0.076 (O-.0030)
Drive pinion rotation torque
with oil seal Nm (inlbs.) 0.6-0.7 (5.2-6.1)
without oil seal Nm (inlbs.) 0.4-0.5 (3.5-4.3)

Limits
Front axle total backlash mm (in.) 14(.55)
Automatic free-wheeling hub
Free-wheeling hub turning resistance Ncm (in.lbs.) 100 (8.7)
I
[Spring scale reading] N(lbs.) 14(3.1)
Brake assembly thickness mm (in.) 9.6 (.378)
Return spring deterioration mm (in.) 35 (1.38)
Shift spring deterioration mm (in.) 30(1.18)
Upper arm shaft starting torque Nm (ft.lbs.) 15(11)
[Spring scale reading] N (Ibs.) 6.8 (1.5)
Lower ball joint end play mm (in.) 0.5 (.020)
Differential
Drive gear runout mm (in.) 0.05 (.0020)
Differential gear backlash mm (in.) 0.2 (.008)

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2-6 FRONT SUSPENSION - Specifications
TORQUE SPECIFIC NOZCC-

Items Nm ft.lbs

Automatic free-wheeling hub cover 18-35 13-25

Manual free-wheeling hub cover IO-14 7-10
Free wheeling jub body or drive flange 50-60 36-43
Front hub to brake disc 50-60 36-43
Knuckle to front brake assembly 80-100 58-72
Upper arm shaft to crossmember 100-120 72-87
Rebound stopper to upper arm 8-12 6-9
Upper ball joint to knuckle 60-90 43-65
Front shock absorber to crossmember 12-18 9-13
Front shock absorber to lower arm 15-22 11-16
Lower ball joint to knuckle 120-180 87-130
Lower arm shaft 140-160 101-116
Lower arm ball joint to lower arm 54-75 39-54
Bump stopper to lower arm 20-30 14-22
Anchor arm B 95-l 20 69-87
Anchor arm lock nut 40-50 29-36
Stabilizer bar clamp A 8-12 6-9
Knuckle to tie rod assembly 45 33
Right drive shaft to inner shaft 50-60 36-43
Left diffefential mounting bracket to differential carrier 80-100 58-72
Right differential mounting bracket to housing tube 80-100 58-72
Differential mounting brackets to frame 80-110 58-80
Housing tube to differential carrier 80-100 58-72
Bracket to differential carrier 80-110 58-80
kront propeller shaft to differential carrier 50-60 36-43
Faont suspension crossmember mounting bolts 100-120 72-87
Irain plug 60-70 43-51
.. .
zjller plug - 40-60 2943
$mpanion flange 160-220 116-159
jover 15-22 11-16
3earing cap 55-65 40-47
Differential case to drive gear 80-90 58-65
Jnder skid plate to side frame 18-25 13-18
Jnder cover to frame IO-13 7-9
3rake tube flare nut 13-17 9-12

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 FRONT SUSPENSION - Specifications 2-7
LUBRICANTS \ NOZCD-

Items Specified lubricants Quantity

Front axle gear oil

Front differential Hypoid gear oil 1.10 lit.
API classification GL-4 or higher (1.16 U.S. qts., 0.97 Imp. qts.)
SAE viscosity NO. 80 W, SO
Front axle hub bearing Multipurpose grease As required
SAE J310, NLGI No. 2
Oil seal lip Multipurpose grease As required
SAE J310, NLGI No. 2
Automatic free wheeling hub Multipurpose grease As required
SAE J310, NLGI No. 2
Manual free wheeling hub Multipurpose grease As required
SAE J310, NLGI No. 2
Upper and lower ball joints Multipurpose grease As required
SAE J310, NLGI No. 2
Torsion bar serrations, anchor arm Multipurpose grease As required
assembly serrations, anchor arm 6 SAE J310, NLGI No. 2
serrations, dust cover inside and
anchor bolt thread
Needle bearing Multipurpose grease As required
SAE J310, NLGI No. 2
Contact surface of knuckle and Multipurpose grease As required
spacer SAE J310, NLGI No. 2
D.O.J. boot grease Repair kit grease 110g(1.902.) \
B.J. boot grease Repair kit grease 110g(1.90z.)
Housing tube dust seal lip Multipurpose grease As required
SAE J310, NLGI No. 2
Housing tube dust cover Multipurpose grease As required
SAE J310, NLGI No. 2
I
Companion flange contacting Multipurpose grease As required
surface of the washer SAE J310, NLGI No. 2 f

, .,.’ : #I
SEALANTS AND ADHESIVES .I ‘..‘,

Items Specified sealants and adhesives

Slot of the upper or lower ball joint 3M ART Part No. 8663, No. 8661 or equivalent
Contact surface of free-wheeling hub and front axle hub 3M ART Part No. 8661, No. 8663 or equivalent
Drive gear threaded hole 3M Adhesive STUD LOCKING 4170 or equivalent
Gasket 3M ART Part No. 8661, No. 8663 or equivalent

f STB Revision
2-8 FRONT SUSPENSION - Special Took

SPECIAL TOOLS NOZDA-

Tool (Number and name) Use

MB990955-01 Pressing of front a

Oil seal installer hub oil seal
attachment Sliding hammer

Disassembly and
reassembly of
set automatic
free-wheeling hut
Removal of side
bearing inner race

MB990778-01 Removal of knuck

Ball joint remover Disconnection of
upper ball joint

Pressing of differential MB990799-01 Removal and

Ball joint remover installation of upr
Pressing of drive pinion and installer A
bearing outer race
MB990800-01

MB990840-01
Universal joint remover
and installer

ME3990809-01 Removal of knuck

Lock nut wrench ustment of lock Pitman arm puller Disconnection of

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 FRONT SUSPENSION - Special Tools 2-9
Tool (Number and name) Use Tool (Number and name) Use

MB990958-01 Removal and pressing of MD998348-01 Removal and pressing of

Torsion bar bushing remover bushing A Bearing separator inner shaft bearing
and installer

M B990883-0 1 Removal and pressing M B990339-0 1 Removal of side bearing

Arbor of the bushing B Pinion carrier bearing inner race
puller Removal of drive pinion
front bearing inner race

/I

M B990635-0 1 Removal of knuckle MIT3031 73 Removal of side bearing

Steering linkage puller Disconnection of tie rod Insert inner race
Removal of drive pinion
front bearing inner race

Q
BJ

M B990956-0 1 Pressing of knuckle MIT44801 Removal of side bearing

Needle bearing instal1e.r needle bearing Collet set inner race
Removal of drive pinion
front bearing inner race
CJ /
(?
‘\
e!J cc
$
,,,.,J
‘.
.I
M B990985-0 1 Pressing of knuckle M B990767-0 1 Holding of end yoke 7, i
Oil seal installer oil seal End yoke holder 4. ..

6 $..
- .,
63 k,

G2J % Qs!@%l a
Qaz

MB991 150 Pressing of drive MB990901-01 Adjustment of

Dust cover installer shaft dust cover Pinion height gauge set pinion height

/ STB Revision
2-10 FRONT SUSPENSION - Special Tools

Tool (Number and name) Use Tool (Number and name) Use

MB990802-01 Pressing of drive M IT3041 80 Pressing of the drive

Bearing installer pinion front bearing inner Handle pinion oil seal
race
Pressing of side
bearing inner race

klB990031-01 Pressing of drive

Irive pinion oil seal installer pinion oil seal

1 ST6 Revision
 FRONT SUSPENSION-Troubleshooting 2-11
TROUBLESHOOTING NOZEA-

Reference
Symptom Probable cause Remedy
page
MANUAL FREE
WHEELING HUB,
FRONT AXLE HUB,
KNUCKLE

Noise due to exces- Free wheeling hub serration play Replace 2-33
sive play of wheel in
turning direction

Noise due to exces- Front axle hub bearing play, seizure, wear Check and adjust or replace if 2-l 5
sive wheel end play necessary 2-23

Knuckle needle bearing play, seizure, wear Replace 2-46

Free wheeling hub serration play Replace 2-33 F

Free wheeling hub looseness Tighten or replace 2-29

AUTOMATIC FREE
WHEELING HUB

Does not lock Brake sliding portion worn Replace parts and adjust hub 2-2 1
attaching surface shims 2-25

Brake (B) lug portion broken Replace parts 2-25

Housing damaged
Drive gear damaged
Slide gear damaged
Retainer (A) damaged
Cam damaged
Shift spring deteriorated
Slide gear C ring out of position

Automatic free wheeling hub attaching bolt Retighten attaching bolts 2-l 8
loose

Locks but does not Return spring deteriorated Replace parts 2-25
become free Slide gear C ring out of position

Foreign substances on tooth surfaces of Clean tooth surfaces or replace

drive gear and slide gear parts
Foreign substances on tooth surfaces of
slide gear and housing gear

Excessive front power train resistance Adjust differential preload 2-2 1

Ratcheting readily Water in brake portion Clean and then apply grease 2-25
occurs
Retainer (B) worn Replace parts
Slide gear damaged
Housing gear damaged
Shift spring deteriorated
Slide gear C ring out of position

Automatic free wheeling hub attaching Retighten the attaching bolts 2-l 8
bolts loose

1 STB Revision
., ;
-.. 2-12 FRONT SUSPENSION -Troubleshooting

ymptom Probable cause -lizRemedy Reference

we
RIVE SHAFT, INNER
-iAFT

Noise during wheel Housing tube bent Replace 2-62

rotation Inner shaft bent

Inner shaft bearing worn, pounding Replace 2-64

r Drrve shaft assembly worn damaged, bent Check or replace 2-52
---
Noise due to exces- Inner shaft and side gear serration play Replace 2-62
sive play of wheel in 2-74
turning direction
Drive shaft and side gear serration play Replace 2-52
2-74

Drive shaft and drive flange serration play Replace 2-52

2-62

Noise due to exces- Drive shaft and drive flange end play Adjust or replace 2-J 6
sive wheel end play -
Drive flange looseness Tighten or replace 2-62

FFERENTIAL

Constant noise Improper adjustment of drive gear and drive Correct or replace 2-68
pinion (poor meshing)

Loose, worn or damaged side bearing Correct or replace 2-73,76

Loose, worn or damaged drive pinion Correct or replace 2-73,

bearing 2-76

Worn drive gear, drive pinion Correct or replace 2-73,76

Worn side gear thrust washer or pinion Replace 2-73,76

shaft

Deformed drive gear or differential case Replace 2-73, 76

Damaged gear Replace 2-73, 76

Foreign material Eliminate the foreign material 2-73,

and check; replace the parts if 2-76
necessary

No oil Fill or change 2-l 6

Gear noise while Poor gear engagement Correct or replace 2-69

driving
Improper gear adjustment Correct or replace 2-69

Improper drive pinion preload adjustment Correct or replace 2-77

Damaged gear Replace 2-73,76

Foreign material Eliminate the foreign material 2-73,

and check; replace the parts if 2-76
necessary

Insufficient oil Fill or change 2-16

bTB Revision
 .’ T.

FRONT SUSPENSION -Troubleshooting 2-13

Reference
symptom Probable cause Remedy
page
Gear noise while Improper drive pinion rotation torque Correct or replace 2-77
coasting adjustment

Damaged differential gear Replace 2-73,76

Bearing noise while Cracked or damaged drive pinion rear Replace 2-73,
driving or coasting bearing 2-76

Noise while turning Loose side bearing Replace 2-73, 76

Damaged side gear, pinion gear or pinion Replace 2-73,

shaft 2-76

Heat Improper differential gear backlash Adjust 2-69

Excessive preload

Insufficient oil Fill or change 2-16

Oil leakage Clogged vent plug Clean or replace the parts -

Cover tightened not Retighten, apply sealant, or re- 2-73,

Seal malfunction place the gasket 2-76

Worn or damaged oil seal Replace 2-73,76

Excessive oil Adjust the oil level 2-l 6

/ STB Revision
2-14 FRONT SlJSPiENSlON - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES NOZFBAC

INSPECTION AND ADJUSTMENT OF WHEEL

ALI’GNMENT
1. Mea:sure the wheel alignment with the vehicle parked on
level ground and with the front wheels placed in the
straight ahead positions.
2. Front suspension, steering system, wheels and tires
should be serviced to normal condition prior to measure-
ment of wheel alignment.

TOE-IN
1. Measure the toe-in.

Standard value : 2-9 mm (.08-.35 in.)

2. If the toe-in does not agree with the standard value, use
the left and right tie rod turnbuckles to adjust it.
3. Make the adjustment by turning the left and right turnbuck-
les the same amount in opposite directions. The toe-in
value will decrease if the left turnbuckle is turned toward
the front of vehicle and the right one is turned toward the
rear, and vice a half-turn of the turnbuckles will result in an
approximately 15 mm (.59 in.) adjustment in the toe-in.

CAMBER
I. Remove the free-wheeling hub.
2. Measure the camber with a camber/caster/kingpin gauge.

Standard value : 1”30’

3. Make adjustment of the camber by incerasing or decreas-

ing the thickness of the adjusting shims between the
upper arm shaft and the crossmember.
A total of 4 mm (.I6 in.) shim thickness is normally required
for standard camber. A 1.0 mm (.039 in.) adjustment in
thickness of shims will provide about 13 minutes adjust-
ment of camber.

Camber adjustment shim (yellow plating)

1 STB Revision
 FRONT SUSPENSIO - Service Adjustment Procedures 2-15
CASTER
I. Remove the free-wheeling hub.
2. Measure caster with a camber/caster/kingpin gauge and a
turning radius gauge.

Standard value : 257’ t 30’

Leir
To increase
3 If caster does not meet specifications,
arm from the crossmember
upper arm shaft.
remove the upper
and then adjust by turning the
2’
1 To increase caster A half turn of upper arm shaft will cause 1.25 mm (.049 in.),
fore or aft movement of the upper arm shaft, resulting in
about 17 minutes adjustment of caster. *-
The adjustment must be made so that the difference
between the caster’s left side and right side is within 30;‘
minutes. !.
To reduce caster 1

I 12w529

CHECKING FRONT AXLE TOTAL BACKL/iSi

1. If the vehicle vibrates and produces a booming sound due
to the unbalance of the drivetrain, measure the front axle
total backlash as follows to see if the differential carrier
assembly requires removal.
(1) Set the hubs for 4WD.
0
NOTE
On vehicles with manual free-wheeling hubs, place the ,:1
control handles in the LOCK position. < ‘f:. (.I.
>*’
On vehicles with automatic free-wheeling tubs, place;’ ‘*‘..-
the transfer shift lever in 4H position and drive the .“’
vehicle 1 to 2 m (3.3 to 6.5 ft.) to engage the hubs with<‘:,‘.,.
the drive shafts. ii :
:* ,+
(2) Secure the wheels and set the transfer control lever to - Z;
.;$
“2H”.
ii.,..;
NOTE
If the vehicle is raised on a jack, the wheels will turn ‘.:
and it will not be possible to measure the backlash.

(3) Turn the companion flange clockwise until all play is

removed. Make mating marks on the dust cover of the
companion flange and on the differential carrier.

1
2-16 FRONT SUSPENSION - Service Adjustment Procedures

(4) Turn the companion flange counterclockwise until all

play is removed and measure the amount of distance
through which the mating marks moved.
(5) If the backlash exceeds the limit, remove the differen-
tial carrier assembly and adjust the backlash and drive
shaft or inner shaft spline play.

L.imit : 14 mm ($5 in.)

2. If the backlash exceeds the limit, remove the differential

carrier assembly and final drive gear, and check for
differential gear meshing condition and drive shaft or inner
shaft spline looseness.

CHECKING GEAR OIL LEVEL NOZFEAB

Remove the filler plug and check the oil level. The oil level
should be somewhere within 8 mm (.31 in.) from the bottom
of the filler plug hole.

Specified gear oil : Hypoid gear oil API classification GL-4

or higher SAE viscosity No. 8OW, 90
[I.10 lit. (1.16 U.S.qts., 0.97 Imp.qts.)]

CHECKING DRIVE SHAFT END PLAY NOZFFAA

VEHICLES WITH AUTOMATIC FREE-WHEELING HUBS

I. Plac’e the free-wheeling hubs in the free condition.

NOTE
The free condition can be obtained by shifting the transfer
shift lever to the 2H position and then moving in reverse
for ‘1 to 2 m (3.3 to 6.5 ft.).

2. Jack: the vehicle up and remove the front wheels.

3. Remove the free-wheeling hub covers.
4. Rotate the drive shaft forward, and backward and then set
the drive shaft to the position (the position where end play
is maximum) mid-way between where the rotation feels
“heavy” for each (where there is a stopping feeling).
5. Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction and measure the play.

Standard value : 0.2-0.5 mm (.008-.020 in.)

6. If the play is out of standard value, adjust by adding or

removing shims.
llWO2!
VEHICLES WITH MANUAL FREE-WHEELING HUBS
I. Jack the vehicle up and remove the front wheels.
2. Move the control handles for the free-wheeling hub to the
FREE position.
3. Remove the free-wheeling hub covers.
4. Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction and measure the play.

Standard value : 0.2-O-5 mm (.008-.020 in.)

5. If the play is out of standard value, adjust by adding or

removing shims.
I
wision I
FRONT SUSPENSION - Service Adjustment Procedures 2-17
REPLACEMENT OF DIFFERENTIAL CARRIER OIL
SEAL NOZFGAB

1. Remove the under cover. (Refer to 2-40.)

2. Remove the front hub and knunkle assembly.
3. Remove the left drive shaft. (Refer to 2-52.)

Caution
When pulling the left drive shaft from the differential
carrier assembly, be careful that the drive shaft spline
does not damage the oil seal.

4. Remove the right drive shaft from the inner shaft assem-
bly.
5. Remove the inner shaft assembly by using the special ,,,+‘$-
tools.

Caution i
When pulling the inner shaft assembly from the differen;
tial carrier, be careful that the spline of the inner shaft’-!<;,
does not damage the oil seal. l. -I

6. Remove the differential mounting bracket (R.H.) and

housing tube. (Refer to 2-66, 68.)
7. Use the special tool to remove the oil seal.

8. Press-fit the oil seal positively with the special tool and ”
apply a thin coat of specified grease to the lip of the oil : ” .”
seal. .. *,::

Specified grease : Multipurpose grease SAE 5310, NLGI ‘ii

No. 2 ?
9. Install the drive shaft using care not to damage the oil seal
lip.

NOTE
On R.H. side, after installation of the oil seal, install the ‘?
housing tube and differential mounting bracket (R.H.).
Install the inner shaft with care not to damage the oil seal
lip, and install the drive shaft.

Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached to the B.J. side spline with
a new one.

10. Install the front hub and knuckle assembly.

11. Install the under cover.
1 STB Revision
2-18 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub

AXLE HUB AND FREE-WHEELING HUB

REMOVAL AND INSTALLATION (Vehicles, with Automatic Free-Wheeling Hubs) NOZGA--

B&j00 Nm
58-72 ft.lbs.

,13-25 ,“k.
80-100 Nm /
58-72 klbs. 130-200 Nm+ONm+25 Nm
“ -T 94-145 ft.lbs.+Ofit.lbs+lB ft.lbr
_c
.5040 Nm /
3643 ft.lbs. ,

Removal steps
+* 1. Cover
l + Adjustment of drive shaft end play
l * 2. Snap ring
3. Shim
++ 4. Front brake assembly
l + Adjustment of automatic free-wheeling hub
turning resistance
+* 5. Bolts
l + 6. Automatic free-wheeling hub assembly
I)* Height adjustment of brake contact surface
7. Shim
8. Lock washer
l 4 Adjustment of wheel bearing preload
4* 9. Lock nut
4* 10. Front hub assembly

NOTE
(1) Reverse the removal procedures to reinstall.
(2) ++ : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service points of installation”

1 ST6 Revision
 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-19
SERVICE POINTS OF REMOVAL NOZGBAB

1. REMOVAL OF COVER
(1) Place the free-wheeling hub in the free condition.

NOTE
The free condition can be obtained by shifting the
transfer shift lever to the 2H position and then moving
in reverse for 1 to 2 meters (3.3 to 6.5 ft.).

(2) Remove the automatic free-wheeling hub cover.

NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective cloth in between not to ..
damage the cover.

:::

__ ,,#..f
.-..c

r S&f;
2. REMOVAL OF SNAP RING ,+. .
Using a snap ring pliers, remove the sna$ ring from the
drive shaft.

:
4. REMOVAL OF FRONT BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose’ I .-
connected. 3;;: :
(2) Use wire to suspend the front brake assembly from thei,,,* .i
upper arm so that the front brake assembly won’t fall. Ai
.,-iII-1:
Caution I ._1
Do not twist the brake hose. 2.

5. REMOVAL OF BOLTS
Hexagonal wrench
Remove tha automatic free-wheeling hub by using the
/ hexagonal wrench.

1 STB nevlslon
FRONT SUSPENSION - Axle Hub and Free-Wheeling ‘Hub
9. REMOVAL OF LOCK NUT/IO. FRONT HUB ASSEMBLY
/
(1) After the lock washer has been removed, remove the
lock nut with the Ispecial tool.
(2) Remove the front hub assembly from the knuckle
together with the inner and outer bearings.

4
r
5!

INSPECTION N02GCAA

l Check the wheel bearing for seizure, discoloration and

rough raceway surface.
l Check the front hub -for cracks.
l Check the oil seals for cracks and damage.

SERVICE POINTS OF INSTALLATION N02GDAB

. AD.JUSTMENT OF WHEEL BEARING PRELOAD

(1) Using the special tool, tighten the lock nut by the
following procedures.

Tighten to 130-200 Nm (94-145 ft.lbs.)

+

11568 Loosen to 0 Nm (0 ftlbs.)

I Retighten to 25 Nm (18 ft.1b.s.) and then loosen 3P-40 I

(2) Loosen the lock nut approximately 30 to 40 degrees to

adjust the front hub’s turning resistance and play in the
axial direction so that they agree with the standard
*
values.

Standard value : 30-130 Ncm .

(2.6-l 1.3 in.lbs.) .:. ,’
[Spring scale reading]
5-18 N (I.140 Ibs.)
Standard value : 0.05 mm (.0020 in.) or less
FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-21
NOTE
If adjustment is not possible, the bearing may be
incorrectly installed; check and, if necessary, repair.
The lubrication condition should also be checked.

(3) Mount the lock washer. If the lock washer holes do not
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees) to align them.

. HEIGHT ADJUSTMENT OF BRAKE CONTACT SURFACE

Measure the height of brake contact surface. ,p” +
0 Using a depth gauge, measure the dimension A shown f’
in illustration at two points. 1’.
8:.*
T’.
Standard value : 11.8-12.2 mm (.465-.480 in.) 1,

0 If the average of the measured values is out ok .‘.

standard value, adjust by inserting shims. $
vjj 1
‘.%;::

6. INSTALLATION OF AUTOMATIC FREE-WHEELING HUB

ASSEMBLY
(1) Apply a coating of specified sealant, equally all around
and without any missed spots, to the free-wheeling
hub body assembly and front jub contact surfaces.

Specified sealant : 3M ART Part No. 8661 or No.

8663, or equivalent

Caution
Make sure that there is no excess specified sealant
on the hub outside surface, ‘,.
I 2’.
(2) Align the key of the brake (B) and the keyway of,”
knuckle spindle and loosely install the automatic free-l: t !,,..:$
wheeling hub assembly. 5 ;*i;:-
(3) Check that the hub proper and automatic free-wheeling -:I~,,$$+
hub assembly are brought into intimate contact when ‘,,.:
the assembly is fored lightly against the hub proper. If :,;.,
not; turn the hub until intimate. contact is achieved.

. ADJUSTMENT OF AUTOMATIC FREE-WHEELING HUB ’

TURNING RESISTANCE
Check the automatic free-wheeling hub turning resistance
by the following procedure.
0 Use a spring scale to measure the front hub turning
resistance again. Subtract the value measured in step
(1) from that measured here to find the turning
resistance of the free-wheeling hub.

j STB Revision
).i.,
 2-22 RONT SUSPENSION - Axle Hub and Free-Wheeling Hub

L,imit : 100 Ncm (8.7 in. Ibs.)

[Spring scale reading]
14 N (3.1 Ibs.)

0 If the free-wheeling hub turning resistance exceeds the

limit, disassemble and reassemble the free-wheeling
hub again.

. ADJUSTMENT OF DRIVE SHAFT END PLAY

After the installation of shim and snap ring, check the drive
shaft end play by the following procedure.
0 Rotate the drive shaft forward, and backward and then
set the drive shaft to the position (the position where
end play is maximum) mid-way between where the
rotation feels “heavy” for each (where there is a
stopping feeling).
Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction and measure the
play.

!Standard value : 0.2-0.5 mm (.OO&.020 in.)

0 If the play isout of standard value, adjust by adding or

removing shims.

1 STB Revision
DISASSEMBLY AND REASSEMBLY (Front Axle Hub) NOPHA-

50-60 Nm
3643 ft.lb

Disassembly steps
1. Outer bearing c
l 4 2. Oil seal NOTE
3. Inner bearing (1) Reverse the disassembly procedures to reassemble. 1
(2) +e : Refer to “Service Points of Disassembly”.
*I) 4. Brake disc (3) ++ : Refer to “Service Points of Reassembly”. 4’
5. Front hub (4) @I : Non-reusable parts

SERVICE POINTS OF DISASSEMBLY NOZHBAA

4. REMOVAL OF BRAKE DISC

Make the mating marks on the brake disc and front hub,
and then separate the front hub and brake disc, if
necessary.

.’
)uter bearing Inner bearing REPLACEMENT OF BEARING NOZHDAB ;
di,
(1) Remove the oil seal. 4.;
(2) Wipe off grease from the front hub interior.
(3) Using the drift against, drive out the inner and outer CT,,,‘:i
ri ‘,”
bearing outer races by tapping them uniformly.
(4) Apply the specified grease to the outside surface of the ‘. .,
new inner and outer bearing outer races.
T
Specified grease : Multipurpose grease SAE 5310, NLGI
No. 2

(5) Press-fit the inner and outer bearing outer races by using
Iuter bearing Inner bearing the special tools.
f=i

NOTE
The bearing inner race and bearing outer race should be
replaced as an assembly.

evision 1
2-24 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub

SERVICE POINTS OF REASSEMBLY NOMEAB

2. INSTALLATION OF OIL SEAL

(1) Apply the specified grease to the oil seal lip and inside
s’urface of the front hub.

Specified grease : Multipurpose grease SAE 5310,

NLGI No. 2

(2) Apply the specified grease to the inner bearing inner

race and install the inner race into the front hub.

Specified grease : Multipurpose grease SAE 5310,

NLGI No. 2

(3) Press-fit the new oil seal into the front hub by using the
special tools, until it is flush with the front hub end
face.

STB Revision
 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-25
DISASSEMBLY AND REASSEMBLY (Automatic Free-Wheeling Hub) NOWA-

Disassembly steps
1. Cover 4* 15. Drive gear snap ring
2. O-ring 16. Retainer (A)
3. Housing 17. Drive gear
4* 4.Housing C ring 4+ 18. Slide gear C ring
l 4 5.Brake (B) 19.Cam
6. Brake (A) 20. Spring holder
7. Brake spring 21 Shift spring
41) 8.Housing snap ring 22. Slide gear
41) 9.Retainer (B) C ring
4* IO. Drive gear assembly
41) II. Slide gear assembly NOTE
4* +4 12. Return spring (1) Reverse the disassembly procedures to reassemble.
(2) C) : Refer to “Service Points of Disassemblv”.
l 4 13.Retainer (B) i3j 64 : Refer to “Service points of Reassembly”
14. Retainer bearing (4) m : Non-reusable parts

1 STB Revision
2-26 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub
SERVICE POINTS OF DISASSEMBLY NOlJBAA

4. REMOVAL OF HOUSING c RING

Remove the housing C ring.

NOTE
The ring is easily removable by pushing the brake (B) in and
using a’small-end screwdriver, etc.

8. REMOVAL OF HOUSING SNAP RING

Remove the housing snap ring.

9. REMOVAL OF RETAINER (B) C RING

Using a special tool, lightly push the drive gear in and
remove the retainer(B) C ring.

NOTE
Since the return spring relaxes approx. 40 mm (1.57 in.),
the stroke of the press should be set to more than 40 mm
(1.57 in.)

Caution
1. Place a protective cover not to damage the cover
attaching surface of the housing before setting on
the press table.
2. Make sure that the pressing force does not exceed
200 N (44.1 Ibs.).

10. REIMOVAL OF DRIVE GEAR ASSEMBLY/l 1. SLIDE GEAR

ASSEMBLY/lZ. RETURN SPRING
Slowly reduce the pressure of the press until the return
spring fully relaxes.

Caution
When the pressure of the press is removed, make sure
that the retainer (A) is not caught by the retainer (B).

/ J llWO2C

r-
STB I tvision
 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-27 .

15. REMOVAL OF DRIVE GEAR SNAP RING

Remove the drive gear snap ring.

Caution
When the drive gear snap ring is removed, be sure to
replace it with a new one.

18. REMOVAL OF SLIDE GEAR GRING

Push the cam in and remove the slide gear C ring with the ,.3 ”
‘, ‘.
spring compressed.
!-

llWOl8

INSPECTION NOZJCAA

l Check the drive gear and slide gear splines for damage.
l Check the cam portion of retainer (A) for wear and
damage.
o Check the cam for wear and damage.
l Check the slide gear and housing tooth surfaces for
damage.
l Check the retainer B and housing contact surfaces for
wear and damage.
,.?pZ’

c, ‘:‘;’
, Brake (B) 1 I BRAKE ASSEMBLY THICKNESS 4:. . .‘-
./,: t:
Check the brake assembly thickness by following the steps (j,:.:,‘zj-
i’ ,j
E below. ! . ‘.:,’
- (1) Assemble brake (A) and brake (B) and then use slide k;y$
calipers to measure the thickness of the assembly at the ,-,,f
two lugs on brake (A). .$

Standard value : 10.5 mm (.413 in.)

Limit : 9.6 mm (.378 in.)

NOTE
Measure each side separately.

(2) If the measured value is below the limit, replace brake (A)
and brake (B) as a set.

STB Revision
2-28 FRONT SUSPENSION - AxIf: Hub and Free-Wheeling Hub

DETERIORATION OF RETURN SPRING

Check the return spring for deterioration by following the
steps below.
(1) Measure the dimension A shown in illustration at the
opposite side of spring end.

Limit : 35 mm (1.38 in.)

Caut:ion
To measure the dimension A shown in illustration,
llW567 measure the dimension from the outermost extremity of
one wire diameter to that of the other wire diameter.

(2) If the measured value is below the limit, replace the spring.

DETERIORATION OF SHIFT SPRING

Check the shift spring for deterioration by following the steps
below.
(1) Measure the dimension 6 shown in illustration at the
opposite side of spring end.

Limi,t : 30 mm (1.18 in.)

I llW566

Cau,tion
To measure the dimension B shown in illustration,
mealsure the dimension from the outermost extremity of
one wire diameter to that of the other wire diameter.

(2) If the measured value is below the limit, replace the spring.

SERVICE POINTS OF REASSEMBLY NOPJDAB

Apply the specified grease to the attaching surfaces of all

components.

Specified grease : Multipurpose grease SAE J310, NLGI

No. 2

13. AWLICATION OF GREASE TO RETAINER (B)

Pack the grooves of retainer (B) with the specified grease.

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

12. INSTALLATION OF RETURN SPRING

Install the return spring with the smaller coil diameter side
toward the cam.

5. APIPLICATION OF GREASE TO BRAKE (B)

Pack the grooves of brake (B) with the specified grease.

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2
1 STB Revision 1
 FRONT SUSPENSION - Axle Hub and Free-Wheeling IHubS 2-29

REMOVAL AND INSTALLATION (Vehicles with Manual Free-Wheeling Hubs) N02GA-

80-100 Nrb
58-72 ftlbs.
/
130-200 Nm+O Nm+2 5 Nm
94-145 ft.lbs.+Oft.lbss18 ft.lbs.

50-60 Nm’
36-43 ft.lbs. lo-14 Nm
7.10 ftlbs.

Removal steps
*+ 1. Free-wheeling hub cover
2. Gasket
+a Adjustment of drive shaft end play
*I) 3. Snap ring
4. Shim
+I) 5. Front brake assembly
+4 6. Manual free-wheeling hub assembly
+* 7. Lock washer
I)+ Adjustment of wheel bearing preload
l * a. Lock nut
l * 9. Front hub assembly

NOTE
(1) Reverse the removal procedures to reinstall.
(2) +* : Refer to “Service Points of Removal”.
(3) ++ : Refer to “Service Points of Installation”.
(4) m: Non-reusable parts

1 STB Revision
Z-30 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub

SERVICE POINTS OF REMOVAL NOZGBBA

1. ‘REMOVAL OF FREE-WHEELING HUB COVER

(1) Set the control handle to the FREE position.
(2) Remove the free-wheeling hub cover.

3. REMOVAL OF SNAP RING

Using a snap ring pliers, remove the snap ring from the
drive shaft.

5. REMOVAL OF FRONT BRAKE ASSEMBLY

(1) Remove the front brake assembly with the brake hose
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly wont’t fall.

Caution
Do not twist the brake hose.

8. REMOVAL OF LOCK NUT/S. FRONT HUB ASSEMBLY

(1) After the lock washer has been removed, remove the
lock nut with the special tool.
(2) Remove the front hub assembly from the knuckle
together with the inner and outer bearings.

118695

INSPECTION NOZGCAA

l Check the wheel bearing for seizure, discoloration and

rough raceway surface.
l Check the front hub for cracks.
l Check the oil seal for cracks and damage.

1 STB Revision
FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-31
SERVICE POINTS OF INSTALLATION NOZGDBB

Q ADJUSTMENT OF WHEEL BEARING PRELOAD

(1) Using the special tool, tighten the lock nut by the
following procedure.

Tighten to 130-200 Nm (94-145 ft.lbs.)

Loosen to 0 Nm (0 ft.lbs.)

Retighten to 25 Nm (18ft.lbs.) and then loosen 30”40

(2) Loosen the lock nut approximately 30 to 40 degrees to

adjust the front hub’s turning resistance and play in the
axial direction so that they agree with the standard
values.

Standard value : 30-130 Ncm (2.6-l 1.3 in.lbs.)

[Spring scale reading]
5-18 N (1.140 Ibs.)
Standard value : 0.05 mm (.0020 in.) or less

f" ,:I
NOTE : Ii .L
If adjustment is not possible, the bearing may
be{’ “1’:
incorrectly installed; check and, if necessary, repair.
Cc.F
The lubrication condition should also be checked. T :~~~‘~‘T
.’ _*
(3) Mount the lock washer. If the lock washer holes do not ‘L .y
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees) to align them.

6. INSTALLATION OF MANUAL FREE-WHEELING HUB

ASSEMBLY
Apply a coating of specified sealant, equally all around and
without any missed spots, to the free wheeling hub body
assembly and front hub contact surfaces.

Specified sealant : 3M ART Part No. 8661, No. 8663, or

equivalent
Caution
Make sure that there is no excess specified sealant on
the hub outside surface.
--- -
/ STB Revision
2-32 FRONT SUSPENSION - axle Hub and Free-Wheeling Hub

l ADJ’USTMENT OF DRIVE SHAFT END PLAY

After assembly in the order of the shim and then the snap
ring, check the drive shaft end play.

Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction and measure the play.

Standard value : 0.2-0.5 mm (.008-.020 in.)

If the play is out of standard value, adjust by adding or

wo70
removing shims.

~STB Revision /
 FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub 2-33
DISASSEMBLY AND REASSEMBLY (Front Axle ’
Hub) NOZHA-

Refer to P.2-23.

DISASSEMBLY AND REASSEMBLY (Manual free-Wheeling Hub) N02JA-

Disassembly steps ‘90

p
l d 1. Free wheeling hub cover llW574
” “
2. Gasket
L’
l + 3. Free wheeling hub clutch \’
4. Compression spririg i’, ‘. j;
<’ ,..$,Z.f~
5. Follower I
;. :‘?.:i,r‘.
6. Tension spring
~~ 7. Free wheeling hub body :iq;
*I) 8. Wheel snap ring r: .p,
l + 9. Inner hub NOTE 1,:
10. Shaft snap ring (1) Reverse the disassembly procedures to reassemble.
l + (2) +e : Refer to “Service Points of ,Disassembly”.
+4 11. Free wheeling hub ring (3) l + : Refer to “Service Points of Reassembly”.
12. Spacer (4) m: Non-reusable parts
*

SERVICE POINTS OF DISASSEMBLY NOPJBBA

8. REMOVAL OF WHEEL SNAP RING/lo. SHAFT SNAP

RING
(1) Using a screwdriver, remove the snap ring and remove
the inner hub from the free wheeling hub body.
(2) Remove the snap ring from the inner hub with a snap
ring pliers.

1 STB Revision
2-34 NT SUSPENSION - Axle Hub and Free-Wheeling Hub

INSPECTION NOZJCBA

0 Check the free wheeling hub ring, inner hub, free wheeling
hub body, and clutch for wear or seizure.
0 Check the gasket for damage.
0 Check the compression spring and tension spring for
deterioration.

SERVICE POINTS OF REASSEMBLY NOZJDBB

11. APPLICATION OF GREASE TO FREE WHEELING HUB

RING/g. INNER HUB17. FREE WHEELING HUB BODY/3.
FREIE WHEELING HUB CLUTCH/l. FREE WHEELING
HUB COVER
(1) Apply the specified grease to the entire periphery of
the free wheeling hub ring, inner hub and free wheel-
ing hub clutch, free wheeling hub cover and the inside
of the free wheeling hub body.
hub clutch
Specified grease : Multipurpose grease SAE J310,
Hub cover assembly NLGI No. 2
Hub body assembly \
(2) Check to be sure that the hub body assembly and hub
cover assembly ;are coated (at the positions shown in
the figure) with a sufficient coating of the specified
grease.
Grease (3) ,4dd more grease if necessary.

IVOTE
,4 liberal amount of grease should be applied, especial-
ly when grease is wiped away or a new free-wheeling
,Drive shaft llWO7E
hub is installed.

/ STB Revision
 RONT SUSPENSION - Shock Absorber and Upper Arm 2-35
SHOCK ABSORBER AND UPPER ARM
REMOVAL AND INSTALLATION N02MA--

IO&120 Nm
72-87 ft.bls.

8-

6-12 Nm
6-9 ft.lbs. 401
-- 50 Nm
29-36 ft.lbs.
15-22 Nm
11-16 ft.lbs.
60-90 Nm
43-65 ftlbs

Shock absorber removal steps

l + 1. Shock absorber

Upper arm removal steps

l + Adjustment of clearance between bump
stopper and bump stopper bracket
l * 2. Anchor arm assembly adjusting nut
3. Hose clip’
4. Connection of brake hose
5. Cotter pin
6. Connection of upper ball joint and
knuckle
7. Brake hose support NOTE
8. Rebound stopper (1) Reverse the removal procedures to reinstall.
9. Shim (2) l * : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”.
l * l + 10. Upper arm (4) q : Non-reusable parts

STB Revision
2-36 FRONT SUSPENSION - Shock Absorber and Upper Arm

SERVICE POINTS OF REMOVAL NOZMBAA

2. LOOSENING OF ANCHOR ARM ASSEMBLY ADJUST-

ING NUT
Loosen the anchor bolt of the torsion bar all the way.

NOTE
When the anchor arm assembly adjusting nut is loosened,
use a jack to support the lower arm of the side to be
loosened, thus the work easier.

6. DISCONNECTION 1OF UPPER BALL JOINT FROM

KNUCKLE
(1) Loosen the nut tightening the upper ball joint to the
knuckle.

NOTE
The nut should be partially loosened and should not be
removed.

(2) lJsing a special tool, disconnect the upper ball joint

from the knuckle.

Caution
Tie the special tool to the upper arm, for example,
with a string to prevent bouncing.

10. REMOVAL OF UPPER ARM

Remove the upper arm from the crossmember.

NOTE
The camber adjustment shims should be stored for
reference at assembly.
Do not turn the upper arm shaft, as it changes caster.
12W5lC

INSPECTION NOZMCU

l Check the upper arm for cracks or deformation.

l Check the upper arm shaft for cracks or bends.

SHOCK: ABSORBER
Expand and contract the shock absorber to check it for
damage, oil leakage or abnormal noise.

wision I
 FRONT SUSPENSION - Shock Absorber and Upper Arm 2-37
UPPER ARM SHAFT STARTING TORQUE
Check the upper arm shaft starting torque by following the
steps below.
1. With the upper arm shaft held in a vice, measure the upper
arm shaft starting torque with a spring balance.

Limit : 15 Nm (1 lftlbs.)
[Spring scale reading]
6.8 N (1.5 Ibs.)

2. If the upper arm shaft starting torque exceeds the limit,

replace the upper arm assembly

UPPER BALL JOINT STARTING TORQUE f ‘.

Check the upper ball joint starting torque by following the !
steps below.
I. Measure the upper ball joint starting torque with a torque,
wrench. i, 4. .
‘, ‘:
“P
Standard value : 80-350 Ncm (7-30 in.lbs.)
12se21
2. If the upper ball joint starting torque is out of specification,
replace the upper ball joint.
72.5(2.854) 72.5(2.854)
UPPER ARM SHAFT TIGHTENING AMOUNT
Give appropriate amount of turn to the shaft so as to obtain
the specified dimension.

Caution
The dimensions shown in the illustration are important
dimensions that determine the caster.

REPLACEMENT OF UPPER BALL JOINT NOZMDAB t:’

.,: 2;
‘,:. <.i,%
1. Remove the dust cover together with the ring.
2. Remove the snap ring from the upper ball joint by using ax:‘ “,ji
‘8”;
snap ring pliers. q :.‘~
;i :;;.
I;.i jr;‘.
*;
.i ’

120079 128055

3. Press the upper ball joint out of the upper arm by using the
MB990840-01 I special tools.

Upper arm ball joint

STB Revision
2-38 FRONT SUSPENSION - Shlock Absorber and Upper Arm
4. Press-fit the new upper ball joint with special tools aligning
the mating mark with the upper arm center.

,--- .-
-01 C-+-+ MB990800
&tltf$f upper arm= -3-01

5. Using a snap ring pliers, fit the snap ring securely in the
groove of the joint case.

Caution
Limilt the opening of the snap ring to a minimum.

6. Apply the specified grease to both the interior of dust

cover and the upper ball joint.

Specified Specified grease : Multipurpose grease SAE 5310, NLGI

sealant No. 2
i ;/:,,,,
7. Apply the specified sealant to the grooves in the upper ball
joint.

Specified sealant : 3M ART Pat-t No. 8663, No. 8661 or

equivalent

8. Secure the dust cover to the upper ball joint with a ring.

SERVICE POINTS OF INSTALLATION NOZMEAA

10. INSTALLATION OF UPPER ARM

When the upper arm assembly is installed to the cross-
member, insert the upper arm shaft attaching bolts from
outside the crossmember and put adjusting shims be-
tween the crossmember and upper arm shaft.

. ADJUSTMENT OF CLEARANCE BETWEEN BUMP STOP-

PER TO BUMP STOPPER BRACKET
Refer to P.2-49.

1 STB Revision I
FRONT SUSPENSION - Shock Absorber and Upper Arm 2-39
1. INSTALLATION OF SHOCK ABSORBER
(1) Tighten the shock absorber installation nut so that the
dimension shown in the figure is the standard value.

Standard value : 7-8 mm (.27-.31 in.)

12W533

(2) Install the shock absorber so that the white paint mark
at the lower side of the shock absorber faces the outer
side of the vehicle. p :I’
,!’
r”
-1’
‘,.b
t’
i.1

12W54: t

/ STB Revision
 2-40 FRONT SUSPENSllON - Lower Arm

‘. LOWER ARM
REMOVAL AND INSTALLATION NOPNA-

18-25 Nm
13-18 ftlbs.
/

18W654

1 ‘IO-13 Nm u 12W541
15-22 Nm 7-9 ft.lbs.
11-16 ft.lbs.

40-50 Nm
29-36 ft.lbs.
120-180 Nm b%?
87-130 ftlbs. 63
e3

12W556
14-22 ftlbs.

!S4-75 Nm
139-54 ftlbs.

Removal steps 9.Lower arm shaft

1. Under skid plate lO.Anchor arm B
2. Under cover 11. Lower arm
I)+ Adjustment of clearance between bump 12. Bump stopper
stopper and bump stopper bracket 13.Lower ball joint mounting nuts
+I) l + 3. Torsion bar
4. Cotter pin NOTE
l * 5. Connection of lower ball joint and knuckle (1) Reverse the removal procedures to reinstall.
6. Self-locking nut (2) +* : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”.
I)+ 7. Stabilizer bar (4) m : Non-reusable parts
4* 8. Shock absorber mounting bolts (5) * : Must be tightened while vehicle is unladen.

[ STB Revision II
FRONT SUSPENSION - Lower Arm 2-41
SERVICE POINTS OF REMOVAL NOZNBAA

3. REMOVAL OF TORSION BAR

Refer to P.2-48.

5. DISCONNECTION OF LOWER BALL JOINT FROM

KNUCKLE
(1) Loosen the nut tightening the lower ball joint to the A.:*’
knuckle. I.’
+::
*I.
NOTE
The nut should be partially loosened and should not be”
removed. !\4.
5’1 Iii:
‘h
(2) Using a special tool, disconnect the lower ball joint
from the knuckle.

8. REMOVAL OF SHOCK ABSORBER MOUNTING BOLTS

Remove the shock absorber lower part and compress the
shock absorber.

INSPECTION
l Check the lower arm for cracks or deformation.
l Check the anchor arm assembly for wear or damage. i ,.,;,;,Y;;
l Check the lower ball joint dust cover for cracks or ;, $
,. t
deterioration. 4, ..@
\B i;

LOWER BALL JOINT END PLAY

Check the lower ball joint end play by following the steps
below.
1. Measure the lower ball joint end play with a dial indicator.

Limit : 0.5 mm (.020 in.)

2. If the lower ball joint end play exceeds the limit, replace
the lower ball joint.
2-42 FRONT SUSPENSION - Lower Arm

REPLACEMENT OF LOWER ARM BUSHING NOZND~

1. Using a special tool, remove the bushing A from the
bracket.

NOTE
When removing the left hand bushing A, detach the
differential carrier. (Refer to P.2-69.)

2. Using a special tool, press-fit the bushing A into the

bracket.

3. Remove the bushing B from the lower arm by using

special tools.
MB990883-01

12SO71

4. Coat the bushing B and the lower arm with soap solution
and press-fit the bushing B into the lower arm by using
special tools and taking care not to twist or tilt the bushing
B.
NOl-E
Press-fit the bushing again from the opposite side to
equalize bushing projections at both ends.

REPLACEMENT OF LOWER BALL JOINT DUST

COVER NOZNEAB

1. Apply the specified grease to the interior of the dust cover

and the lower ball joint.

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

2. Apply the specified sealant to the grooves in the lower ball

joint.

Specified sealant : 3M ART Part No. 8663, No. 8661 or

equivalent

3. Secure the dust cover to the lower ball joint with a ring.
wision I
FRONT SUSPENSION - Lower Arm 2-43
SERVICE POINTS OF INSTALLATION NOZNFAA

7. INSTALLATION OF STABILIZER BAR

Install the stabilizer bar to the lower arm in such a way that
the amount of protrusion of the stabilizer bar installation
bolt is the standard value.

Standard value : 6-8 mm (.&l-.31 in.)

NOTE ..
The dimension show in figure is the value when a n&V T’.
bushing is used. +. .

3. INSTALLATION OF TORSION BAR

Refer to P.2-48.
. ADJUSTMENT OF CLEARANCE BETWEEN BUMP STbP- ,:’
PER AND BUMP STOPPER BRACKET
Refer to P.2-49 vi

1 STB Revision
2-44
-. FRONT SUSPENSION - Knuckle

KNUCKLE
REMOVAL AND INSTALLATION NOZPA-

60-90 Nm 80-100 Nm
_ 43-65 ft.lbs. 58-72 ftlbs.

33 ftlbs.

18-35 Nm

120-180 Nm
87-130 ft.lbs. 36-43 ftlbs. ’

80-100 Nm
58-72 ft.lbs.

130-200 Nm + 0 Nm i, 25 Nm
94-145 ft.lbs. + 0 ft.lbs. $ 18 ftlbs.

lW14’Nm
7-10 ft.lbs.
Manual free-wheeling
hub
i 11W611

Removal’ steps
+e 1)4 1. Front axle hub and free-wheeling hub
2. Dust cover
3. Cotter pin
4* 4. Connection of tie rod assembly and
knuckle
5. Cotter pin
4* 6. Connection of lower ball joint and knuckle
7. Cotter pin
4* 8. Connection of upper ball joint and knuckle
9. Knuckle

NOTE
(1) Reverse the removal procedures to reinstall.
(2) +* : Refer to “Service Points of Removal”.
(3) I)4 : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts

/ STB Revision /
 FRONT SUSPENSION - Knuckle 2-45
SERVICE POINTS OF REMOVAL NOZPBAA

1. REMOVAL OF FRONT AXLE HUB AND FREE WHEELING

HUB

For models equipped with the automatic .free-wheeling

hub, refer to page 2-18; for models e,quipped with the
manual free-wheeling hub, refer to page 2-29.

.4. DISCONNECTION OF TIE ROD ASSEMBLY FROM

KNUCKLE
Disconnect the tie rod from the knuckle by using the +, :‘
special tool. pf
Q
Caution $i
1. Use cord to bind the special tool closely so it wo&
become separated.
* 2. The nut should be loosened only, not removed.

6. DISCONNECTION OF LOWER BALL JOINT FROM

KNUCKLE/8. UPPER BALL JOINT FROM KNUCKLE
Using the special tool, remove the lower ball joint and
upper ball joint.

Caution
1. Support the lower arm with a jack’when removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed, lower the jack
j663 I/ / 12W524 slowly. I\‘.
‘!
INSPECTION NOZPCAA
./I, ’
l Check the needle bearing for wear or damage.
l Check the knuckle for cracks or bends.
l Check the knuckle spindle for wear or ‘pounding.

‘i
SERVICE POINT OF INSTALLATION NOZPDAA

1. INSTALLATION OF FRONT AXLE HUB AND FREE-

WHEELING HUB

For mddels equipped with the automatic free-wheeling

hub, refer to page 2-18; for models equipped with the
manual free-wheeling hub, refer to page 2-29.

/ STB Revision
2-46 FRONT SUSPENSION - Knuckle

DISASSEMBLY AN REASSEMBLY NOZPE-

Disassembly steps
I)+ 1. Oil seal
** 2. Spacer
+e‘e+ 3. Needle bearing
4. Knuckle

llW605
NOTE
(1) Reverse the disassembly procedures to reassemble
(2) 41) : Refer to “Service Points of Disassembly”.
(3) l rC : Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts

SERVICE POINTS OF DISASSEMBLY NOZPFAA

3. REMOVAL OF NEEDLE BEARING

(1) Remove the oil seal and take out the spacer.
(2) Drive out the needle bearing by tapping needles
uniformly.

Caution
Once removed, the needle bearing must not be
reused.

SERVICE POIINTS OF REASSEMBLY NOZPGAB

3. INSTALLATION OF NEEDLE BEARING

(1) /4pply the specified grease to the roller surface of the
new needle bearing.

Specified grease : Multipurpose grease SAE J310,

NLGI No. 2

(2) Press-fit the needle bearing by using the special tools,

until it is flush with the knuckle end face.

Caution
llse care to prevent driving the needle bearing too
f,ar in.

1 STB Revision 7
 FRONT SUSPENSION - Knuckle 2-47
2. INSTALLATION OF SPACER
(1) Apply the specified grease to the knuckle attaching
surface of the spacer.

Specified grease : Multipurpose grease SAE J310,

NLGI No. 2

(2) Install the spacer to the knuckle with the chamfered

side toward the center or vehicle.

1. INSTALLATION OF OIL SEAL

(1) Press-fit the new oil seal by using the special tools,
until it is flush with the knuckle end face. :.
(2) Pack the specified grease in the oil seal inside and lip,.!,’

Specified grease : Multipurpose grease SAE 5310, NLGI’I:,

No. 2

/ STB Revision
2-48 FRONT SUSPENSION - Torsion Bar

TORSION BAR
REMOVAL AND lNSTALLATlON NOZSA--

iNl-50 Nm

12W558

Removal steps
1. Heat protector (right side only)
I)+ Adjustment of clearance between bump
stopper and bump stopper bracket
l * 2. Anchor arm assembly
NOTE
3. Dust covers (1) Reverse the removal procedures to reinstall.
4. Heat cover (left side only) (2) 4* : Refer to “Service Points of Removal”.
I)+ 5. Torsion bar (3) l + : Refer to “Service Points of Installation”

SERVICE POINTS OF REMOVAL N02SBAA

2. REMOVAL OF ANCHOR ARM ASSEMBLY

Support the lower arm from which the torsion bar is to be
removed, with a jack.

INSPECTION NOZSCAA

l Check the torsion bar for bends or damage.

l Check the dust cover for cracks or damage.

SERVICE POINTS OF INSTALLATION NOZSDAB

Apply the specified grease to the torsion bar serrations, the

anchor arm assembly serrations, the anchor arm B serrations,
the dust cover inside and the anchor bolt thread.

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

1 STB Revision /
 FRONT SUSPEIWION - Torsion Bar 2-49
5. INSTALLATION OF TORSION BAR
Mating mark Identification mark (1) Identify the right and left torsion bars referring to the
identification mark put on the torsion bars.
Face the end having identification mark forward, and
align the mark on anchor arm B with the mating mark
on torsion bar when the torsion bar is inserted in the
anchor arm B.

( Whi’e mark M\ating rn,:,J NOTE

When installing a new torsion bar, align the serration
painted white with the mark on anchor arm 9.

(2) Select the relative position of the torsion bar serrations

and the anchor arm serrations so that the length shown
in the illustration may have specified dimension when :‘I-’
the torsion bar and the anchor arm are assembled, with ‘,
the upper arm rebound stopper in contact with the:;. ’
crossmember.

Standard value : L.H. 135.2-143.2 mm (5.323-5.638 ‘:;:

in.)
R.H. 124.3-132.3 mm (4.894-5.210
12s6oo in.)

. ADJUSTMENT OF CLEARANCE BETWEEN BUMP STOP-

PER AND BUMP STOPPER BRACKET
(1) Use the curb weight to obtain the amount of anchor
bolt projection from the following table.
NOTE
The anchor bolt projection amount is a reference
dimension used when the torsion bar spring is in-
stalled.
Finally, adjust so that the distance to the bump stopper
bracket is the standard value.
This method can also be used to make the adjustment “‘,
on previously sold vehicles. ,!,”
;. !, ai::.
I. ..
Example
For a vehicle with a curb weight of 1,440 kg (3,175 lbs.),’ .;‘?
the table shows the following left and right anchor bolt5 p, .:!“’
projections. h*t!;
‘i; ; ‘$5.
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.) “k,
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 mm (2.80 in.)

NOTE
For curb weights of the various models, refer to “INTRO- .-
DUCTION AND MASTER TROUBLESHOOTING - General :
Date and Specifications”.

I ! ! I r nlgnr s
80 (3.15) I

70 (2 76)

60 (2.36)

50 (1.97)

14wo31
40 (1.57)
1312 1316 141.0 14.4 14:8 1512 15:6 Id.0 Id4 1618 1712 1716 18!.0 1d.4 Curb weigh ItxlOOkg
(29.1 )(30.0)(30.8)(31.7)(32.6)(33.5)(34.4)(35.3~(36.2)(37.0)(37.9)(38.8~~39.7~l40.6 (x 100 Ibs.)
STB Revision
2-50 FRONT SUSPENSION - Torsion Bar

(2) With the vehicle unladen, measure the dimension from

the bump stopper to the bump stopper bracket to
check for conformance with standard value.

Standard value :: 71 mm (2.80 in.)

(3) If it is out of specification. adjust with the adjusting nut

on the anchor bolt.

ii-J 12woo

/ STB Revision ,
 FRONT SUSPENSION - Stabilizer Bar 2-51
STABILIZER BAR
REMOVAL AND INSTALLATION NOZTA-

7-9 ft.lbs.

Removal steps
8-12 r&l
1. Under skid plate 6-9 ftlbs. 12W555
2. Self-locking nut
3. Clamp A
4. Stabilizer bushing
5. Self-locking nut NOTE
(I 1 Reverse the removal procedures to reinstall.
6. Hanger (2) l + : Refer to “Service Points of Installation”.
I)+ 7. Stabilizer bar (3) q : Non-reusable parts.
p”’

$jfJ / ;..
INSPECTION N02T& -.“I‘;j
l Check the stabilizer bar for deformation or damage. 6, .‘:::T. $
l Check the hanger for bends or damage. IJ;t. .; 2.
l Check the rubber parts for cracks, deterioration or wear!. ,:,’ ‘.if
-bk ,.::
e,..
‘&- ,.,’ -:
‘t &
SERVICE POINTS OF INSTALLATION N02TOAA

7. INSTALLATION OF STABILIZER BAR

When installing the hanger to the stabilizer bracket, tighten
the nut so as to obtain the specified dimension.

Standard value : 6-8 mm (.24-.31 in.)

When installing both ends of the stabilizer bar to the lower

arms, tighten the nut so as to obtain the specified
dimension.

Standard value : 6-8 mm (.24-.31 in.)

NOTE
The dimension shown in the figure is the value when a
new bushing is used.
;
2-52 FRONT SUSPENSION - Drive shaft

DRIVE SHAFT
NOPClA-
REMOVAL AND INSTALLATION

Left drive shaft

lo-13 Nm
7-9 ft.lbs.
50-60 Nm
35-43 ft.lbs.
Removal steps
1. Under cover
4* 2. Cover llW581
(automatic free-wheeling hub)
4* 3. Free-wheeling hub cover
(manual free-wheeling hub)
4. Gasket (manual free-wheeling hub)
1)4 Adjustment of driveshaft end play
4* 5: Snap ring
6. Shim
4* 7. Front brake assembly
8. Cotter pin
4* 9. Connection of tie rod assembly and
knuckle
10. Cotter pin
4* 11. Connection of lower ball joint and
knuckle
12. Cotter pin
4* 13. Connection of upper ball joint and
knuckle
14. Front hub and knuckle assembly NOTE
(1) Reverse the removal procedures to reinstall.
+e l + 15. Left drive shaft (2) l e : Refer to “Service Points of Removal”.
16. Circlip (3) l + : Refer to “Service Points of Installation”.
(4) m: Non-reusable parts
17. Right drive shaft

/ STB Revision I
 SUSPENSION - II wive shaft 2-53
SERVICE POINTS OF REMOVAL NOZOBAC

2. REMOVAL OF COVER (Automatic free wheeling hub)

(1) Place the free-wheeling hub in the free condition.

NOTE
The free condition can be obtained by shifting the
transfer shift lever to the .2H position and then moving
in reverse for 1 to 2 meters. (3.3 to 6.5 ft.)

(2) Remove the automatic free wheeling hub cover.

NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective cloth in between not to ,jJ.,JJ,
damage the cover. J3:

3. REMOVAL OF FREE WHEELING HUB COVER (Manual

free wheeling hub)
(1) Set the control handle to the FREE position.
(2) Remove the free wheeling hub cover.

>
,,.. ; y
9,
i9, ; j

5. REMOVAL OF SNAP RING 5

c ,.:
Using a snap ring pliers, remove the snap ring from the’; ~::
drive shaft. 1.
:( ‘,I ”I
.,, 1
‘hr%.
>-.

llWO50

7. REMOVAL OF FRONT BRAKE ASSEMBLY

(1) Remove the front brake assembly with the brake hose
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly won’t fall.

Caution
Do not twist the brake hose.

1 STB Revision
2-54 FRONT SUSPENSION - Drive shaft

9. DISCONNECTION OF TIE ROD ASSEMBLY FROM

KNUCKLE
Disconnect the tie rod from the knuckle by using the
special tool.

Cuation
1. Use cord to bind the special tool closely so it won’t
become separated.
2. The nut should Ibe loosened only, not removed.

11. DISCONNECTION OF LOWER BALL JOINT FROM

KNIUCKLE/13. UPPER BALL JOINT FROM KNUCKLE
Using the special tool, remove the lower ball joint and
upper ball joint.

Caution
1. Support the lower arm with a jack when removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed, lower the jack
slowly.

15. REMOVAL OF LEFT DRIVE SHAFT

Pull the drive shaft out from the differential carrier.

Caution
When pulling the drive shaft out from the differential
carrier, be careful Uhat the spline part of the drive shaft
does not damage the oil seal.

INSPECTION NOZCXAB

l Check the boot for damage or deterioration.

l Check the ball joint for operating condition and excessive
looseness.
l Ch’eck the splines for wear or damage.

SERVICE POINTS OF INSTALLATION NOZQDAC

15. INSTALLATION OF LEFT DRIVE SHAFI-

Drive the drive shaft into the front differential carrier with a
plastic hammer.

Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached to the D.O.J. side spline
part with a new one.

( STB Revision
FRONT SUSPENSION - Drive shaft 2-55
. ADJUSTMENT OF DRIVE SHAFT END PLAY
Vehicles with automatic free-wheeling hubs
(1) Rotate the drive shaft forward, and backward and then
set the drive shaft to the position (the position where
end play is maximum) mid-way between where the
rotation feels “heavy” for each (where there is a
stopping feeling).
(2) Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction and measure the
play.

Standard value : 0.2-0.5 mm (.008-,020 in.)

(3) If the play is out of standard value, adjust by adding or

removing shims. ,L’
r

Vehicles with manual free-wheeling hubs

(1) Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction and measure the
play.

Standard value : 0.2-0.5 mm (.008-.020 in.)

(2) If the play is out of standard value, adjust by adding or

removing shims.

1 STB Revision
2-56 FRONT SUSPENSION - Drive Shaft

DISASSEMBLY AND REASSEMBLY NOZCIE-

Left drive shaft

I In--_ l? 16

11 BOO25
- 17ilj
w llW60E

Drive shaft kit LH

I 6 *5

llW609
11 W602

I D.O.J. kit Boot repair kit (B.J.) Boot repair kit (D.O.J.)

Disassembly steps Reassembly steps

16. Drive shaft and B.J.
1. Boot band A
I)+ 15. B.J. boot
2. Boot band B
~~ 13. Boot band A
3. Circlip
l + 14. Boot band B
4. D.O.J. outer race
l + 2. Boot band B
5. Balls
6. D.O.J. cage l + 9. D.O.J. boot
7. Snap ring l + 1. Boot band A
8. D.O.J. inner race l + 6. D.O.J. cage
l + 8. D.O.J. inner race
9. D.O.J. boot
7. Snap ring
10. Dust cover
11. Boot protector band l a 5. Balls
12. Boot protector e+ 4. D.O.J. outer race
3. Circlip
13. Boot band A
17. Circlip
14. Boot band B
+a 12. Boot protector
15. B.J. boot
e+ 11. Boot protector band
16. Drive shaft and B.J.
17. Circlip l + 10. Dust cover
NOTE (3) ml : Non-reusable parts
(1) +e : Refer to “Service Points of Disassembly”. (4) B.J. : Birfield Joint
(2) e+ : Refer to “Service Points of Reassembly”. (5) D.O.J. : Double Offset Joini

1 STB Revision I
 FRONT SUSPENSION - Drive Shaft 2-57
Right drive shaft

llBOO25

Drive shaft kit RH

a
UJ llW60 llW609
,‘.

D.O.J. kit Boot repair kit (B.J.) Boot repair kit (D.O.J.)
L
I
1 I
,

.*.
Disassembly steps Reassembly steps :i
I-
1. Boot band A 16. Drive shaft and B.J.
2. Boot band B l + 15. B.J. boot
3. Circlip l + 13. Boot band A
4. D.O.J. outer race l + 14. Boot band B
l * 5. Balls l + 2. Boot band B
l * 6. D.O.J. cage l + 9. D.O.J. boot
l * 7. Snap ring ~~ 1. Boot band A
8. D.O.J. inner race l + 6. D.O.J. cage
l * 9. D.O.J. boot e+ 8. D.O.J. inner race
l * IO. Dust cover 7. Snap ring
11. Boot protector band l + 5. Balls
*I) 12. Boot protector l + 4. D.O.J. outer race
13. Boot band A 3. Circlip
14. Boot band B l + 12. Boot protector
c* 15. B.J. boot ~~ 11. Boot protector band
16. Drive shaft and B.J. l + 10. Dust cover

NOTE (3) q : Non-reusable parts

(1) 4I) : Refer to “Service Points of Disassembly”. (4) B.J. : Birfield Joint
(2) ++ : Refer to “Service Points of Reassembly”. (5) D.O.J. : Double Offset Joint

1 STB Revision
 2-58 FRONT SUSPENSION - Drive Shaft
SERVICE POINTS OF DISASSEMBLY NOZQFAB

5. REMOVAL OF BALLS
Rernove the balls from the D.O.J. cage.

6. REMOVAL OF D.O.J. CAGE

Remove the D.O.J. cage from the D.O.J. inner race in the
direction of the B.J.

7. RE’MOVAL OF SNAP RING

Remove the snap ring from the drive shaft with a snap ring
pliers, and then withdraw the D.O.J. Inner race and D.O.J.
cage from the drive shaft.

1 lY09E

9. RElMOVAL OF D.O.J. BOOT

(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the D.O.J. boots are not
damaged when they are removed.
(2) Withdraw the D.O.J. boots from the drive shaft.

i:..
i
llYO97

10. REiMOVAL OF DUST COVER

Remove the dust cover from the drive shaft and B.J.

wision
 FRONT SUSPENSION - Drive Shaft 2-59 (

12. REMOVAL OF BOOT PROTECTOR

After extending the folded over part of the boot protector
and removing the boot protector band, push the boot
protector to the B.J. side and then remove it.

15. REMOVAL OF B.J. BOOT

(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the B.J. boot are not
damaged when they are removed.
(2) Withdraw the B.J. boot from the drive shaft. , :,
_I
;
Caution
Do not disassemble the B.J. e’.

llW604

INSPECTION NOPOGAB

l Check the drive shaft for bending or wear.

l Check the B.J. for entry of water, foreign matter and rust.
0 Check the B.J. ball for damage.
o Check the D.O.J. cage, D.O.J. inner race and ball for rust,
wear and damage.
l Check the circlip for damage or deformation.
l Check the D.O.J. outer race for wear or damage.

h’,‘,.Gi..’
,. i.’

()I;i.‘*(’
SERVICE POINTS OF REASSEMBLY NOZQHAB _ / &,:

15. INSTALLATION OF B.J. BOOT / 13. BOOT BAND A / 14. i. ::;“’

BOOT BAND B / 2. BOOT BAND B / 9. D.O.J. BOOT / 1. 9%;:.:!‘i
BOOT BAND A y:;:: ;*;;
(1) Apply the specified grease to the drive shaft, and wrap ;;>,i<
vinyl tape around the spline part on the D.O.J. side of :,<t
the drive shaft.
::
Specified grease : Repair kit grease ?

1
I (2) Install the B.J. boot, boot bands (new ones), and D.O.J.
boot on the drive shaft, in that order.

Caution
The B.J. and D.O.J. boots are different in size and
shape, so make sure they are correct.

~STB Revision
 2-60 FRONT SUSPENISION - Drive Shaft
(3) Apply all the specified grease, half of it to the inner side
of the B.J., and the other half to the inner side of the
B.J. boot.

Specified grease : Repair kit grease [llO gr (3.9 oz.)]

‘. (4) Secure the B.J. boot to the driveshaft by boot bands A

Driveshaft rotation direction
iI&
during vehicle forward movement and B.
?“p
‘4I,
Caution
‘; Be sure that the installation direction of the boot
:,.: bands is correct.
Boot b
/ ;’
,*A
; I’ (I

1180076

Cage 6. IN’STALLATION OF D.O.J. CAGE / 8. D.0.J INNER RACE

\ (1) Install the D.O.J. cage onto the drive shaft so that the
smaller diameter side of the cage is installed first.
(2) Apply the specified grease to the D.O.J. inner race and
the D.O.J. cage, and then fit them together.

Specified grease : Repair kit grease

D.O.J. inner race

lB075

5. APPLICATION OF GREASE TO BALLS

Apply the specified grease to the ball insertion parts of the
I
D.O.J. inner race and D.O.J. cage, and insert the balls.

Specified grease : Repair kit grease

4. INSTALLATION OF D.O.J. OUTER RACE

(1) Apply the specified grease to the D.O.J. outer race.

Specified grease : Repair kit grease

[55 gr (1.9 oz.)]

(2) Fit the drive shaft into the D.0.J outer race.
(3) Add the specified grease to the D.O.J. outer race.

Specified grease : Repair kit grease

[55 gr (1.9 oz.)]
wision I
 FRONT SUSPENSION - Drive Shaft 2-61
(4) Install the circlip onto the D.O.J. outer race.
Driveshaft rotation direction
during vehicle forward movement (5) Place the D.O.J. boot over the D.O.J. outer race, and
then use boot band B to secure the boot.

Caution
Be sure that the installation direction of the boot
bands is correct.

(6) Replace the boot band A on D.O.J. boot.

Caution
Do not secure the boot band A

(7) Secure the driveshaft, and then move the D.O.J. outer q:
race until it is at the position where the D.O.J. bootgV3 ”
assembly dimension is the standard value. \5
. I.
t,f
Standard value : 77-83 mm (3.03-3.27 in.) .. .
fr’,
(8) Remove a part of the D.O.J. boot from the D.O.J. outer b:,
race and release the air within the boot.
I (9) Secure the boot band A on D.O.J. boot.
I Boot band B Bo band A
llYO99 I
Caution
Be sure that the installation direction of the boot
bands is correct.

g, :,

12. INSTALLATION OF BOOT PROTECTOR / 11. BOOT f:‘ ,:.$:-

j ‘.i>;-
PROTECTOR BAND CA<
(1) After installating the boot protector to the B.J., secure\.‘, : ~~
by the boot protector band. c,
is,.,, ;
Caution
Be sure that the installation direction of the boot “.
bands is correct.

(2) Securely fold over the end of the boot protector.

llB0017

10. INSTALLATION OF DUST COVER

Using the steel pipe as specified below, force the dust
Steel pipe
cover to the drive shaft.

I -

wision I
2-62 FRONT SUSPENSION - Inner Shaft

INNER SHAFT
REMOVAL AND INSTALLATION

80-100 Nm
58-72 ftlbs.

80-110 Nm
58-80 ft.lbs.-

58-72 ftlbs.

\
50-50 Nm
3543 ftlbs,

10-13 Nm
7-9 ftlbs.

Removal steps llW582

1. Under cover
+e l + 2. Front hub and knuckle assembly
3. Shock absorder lower mounting bolts
l * l * 4. Drive shaft assembly (R.H.)
+e ~~ 5. Inner shaft
6. Circlip
7. Self locking nut
8. Differential mounting bracket (R.H.)
9. Housing tube

NOTE
(1) Reverse the removal procedures to reinstall.
(2) l I) : Refer to “Service Points of Removal”.
(3) *+ : Refer to “Service Points of Installation”.
(4) m : Non-reusable pans

1 STB Revision /
FRONT SUSPENSION - Inner Shaft 2-63
SERVICE POINTS OF REMOVAL NOZRBAB

2. REMOVAL OF FRONT HUB AND KNUCKLE ASSEM-

BLY/4. DRIVE SHAFT ASSEMBLY (R.H.)
Refer to 2-44, 52.

5. REMOVAL OF INNER SHAFT

Attach the special tools to the flange of the shaft, and drive
, _.\
the inner shaft out from the front differential carrier. ,‘C ’

Caution
1. Being careful not to scratch or scar the shocki’
absorber with the special tool, remove the lower a
mounting bolts of the shock absorber, and compress
the shock absorber as much as possible.
2. When pulling the inner shaft out from the front
differential carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.

INSPECTION NOZRCAA

l Check the inner shaft for bend.

l Check the bearing for wear or discoloration.
l Check the housing tube for cracks.
l Check the dust seal for cracks or damage.

SERVICE POINTS OF INSTALLATION NO2DAf <

I’.
,
5. INSTALLATION OF INNER SHAFT
Drive the inner shaft into the front differential carrier by ‘d
using the special tools. 7
1
Caution :.
1. Replace the circlip which is attached to the inner ”
shaft spline part with a new one.
2. Be careful not to damage the lip of the dust seal and
oil seal.

4. INSTALLATION OF DRIVE SHAFT ASSEMBLY (R.H.)/2.

FRONT HUB AND KNUCKLE ASSEMBLY
Refer to 2-44, 52.

STB Revision
 2-64 FRONT SUSPENSION - Inner Shaft

DISASSEMBLY AND REASSEMBLY NOZRE-

i .,
“$,
:rrr
? Disassembly steps
llW597
? 1. Inner shaft
1’
+e I)+ 2. Bearing NOTE
_. (1) Reverse the disassembly procedures to reassemble.
: ‘I +e l + 3. Dust cover
\., 4
(2) +e : Refer to “Service Points of Disassembly”.
4. Housing tube (3) I)+ : Refer to “Service Points of Reassembly”.
ae ~b+ 5. Dust seal (4) q : Non-reusable parts

SERVICE POINTS OF DISASSEMBLY NOZRFAB

2. REMOVAL OF BEARING
(1) 13end the outside periphery of dust cover inward with a
hammer.

(2) After the special tool has been installed as shown,

ttghten the nut of the special tool until the portion “A”
of the special tool touches the bearing outer race.

(3) Press out the inner shaft from the bearing.

CZaution
Do not allow the inner shaft to drop.

Q118727

) STB Revision II
 FRONT SUSPENSION - Inner Shaft 2-65
3. REMOVAL OF DUST COVER
Remove the dust cover from the inner shaft.

5. REMOVAL OF DUST SEAL

Remove the dust seal from the housing tube.

l- I I llW56

SERVICE POINTS OF REASSEMBLY NOZRHAD

5. INSTALLATION OF DUST SEAL

(1) Press-fit the new dust seal into the housing tube by
MB990938-01 using the special tools, until it is flush with the housing
tube end face.
(2) Apply the specified grease to the dust seal lip.
MB990955-01

Specified grease : Multipurpose grease SAE J310,

NLGI No. 2
lW561

3. INSTALLATION OF DUST COVER ,“.

Steel pipe
l-l / Using a steel pipe, force a new dust cover onto the inner:’
shaft. i\ ,’

Steel pipe mm (in.)

Overall length 50 (1.97)

Outside diameter / 75 (2.95)
Wall thickness 1 4i.16)

NOTE
After the dust cover has been installed, apply specified
grease to the inside of the dust cover.

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

2. INSTALLATION OF BEARING
Using the special tool, force the bearing onto the inner
shaft.

STB Revision
2-66 FRONT SUSPENSION - Front Differential Mounting

FRONT DIFFERENTIAL MOUNTING

REMOVAL AND INSTALLATION NOZUA-

q 10 ~E;“ft%i. 80-110 Nm
13
CY
8 80-100 Nm
ICE%,& / 58-72 ft.lb’s. ^^ _--
UU-100
_.
Nm
58-72 ftlbs.

3042 Nm
22-30 ft.lbs.

12W554

lo-13 Nm
7-9 ft.lbs.

Removal steps
1. Under cover 13. Differential mounting bracket (R.H.)
+e l + 2. Drive shaft 14. Self-locking nut
3. Circlip 15. Differential mounting rubber C
+e l + 4. Inner shaft 16. Differential mounting rubber D
5. Circlip
6. Self-locking nut
7. Differential mounting rubber A
8. Differential mounting rubber B
l * 9. Differential mounting bracket (L.H.) NOTE
IO. Self-locking nut (‘I) Reverse the removal procedures to reinstall.
11. Differential mounting rubber A
(2) l * : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”.
12. Differential mounting rubber B (4) m : Non-reusable parts

STB Revision 7
FRONT SUSPENSION - Front Differential Mounting 2-67
SERVICE POINTS OF REMOVAL NOZUBAB

2. REMOVAL OF DRIVE SHAFT

Refer to P.2-52.

4. REMOVAL OF INNER SHAFT

Attach the special tools to the flange of the shaft, and drive
the inner shaft out from the front differential carrier.

Caution
1. Being careful not to scratch or scar the shock
absorber with the special tool, remove the lower
mounting bolts of the shock absorber, and compress
the shock absorber as much as possible.
2. When pulling the inner shaft out from the front ,,’ I
differential carrier, be careful that the spline part of $
the inner shaft does not damage the oil seal. d
;’

9. REMOVAL OF DIFFERENTIAL MOUNTING BRACKET:“:

(L.H.) / 13. DIFFERENTIAL MOUNTING BRACKET (R.H.) ” :.
While supporting the differential carrier with a jack, remove
the differential mounting bracket.

NOTE
Support the differential carrier with a jack until installing
the differential mounting bracket.

INSPECTION NOZUCAA

l Check the differential mounting bracket for deformation

and damage.
l Check the bracket for deformation and damage.
l Check the differential mounting rubber for cracks and
damage.
SERVICE POINTS OF INSTALLATION NOPUDAA , :’
l-r’
4. INSTALLATION INNER SHAFT p
Drive the inner shaft into the front differential carrier b\l;.
using the special tools. j’ I ‘.+
1, .‘:
;;, ,yf
Caution
Be careful not to damage the lip of the dust seal and oil ;-i;i”.
seal.

2. INSTALLATION OF DRIVE SHAFT

Refer to P.2-52.

1 STB Revision
2-68 FRONT SUSPENSION - Differential Carrier

DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION NOZVA-

80-I 10 Nm
1 / 58-80 ft.lbs.
mg, Qz&&y 11 El/ 50-60 NIY
PILlIll Nm
-iJ.., /36-43 fds.

100-120 Nm ‘------““---“i
72-87 ft.lbs.
i2

80-100 Nm
58-72 ft.lbs.

80-106 Nm
IO-13 Nm 58-72 ft.lbs.
7-9 ft.lbs.

Removal steps
1. Under cover Pre-removal Operation
l Draining of Gear Oil (Refer to P.2-
I+* l + 2. Drive shaft 16.)
3. Circlip
~~ I)+ 4. Inner shaft Post-installation Operation
5. Circlip l Supplying Gear Oil (Refer to P.2-16.)
4* 6. Front propeller shaft
7. Self-locking nut
4* 8. Differential mounting bracket (L.H.)
9. Self-locking nut
10. Front suspension crossmember and front
differential carrier assembly
11. Self-locking nut
12. Front suspension crossmember NOTE
13. Differential mounting bracket (R.H.) (1) Reverse the removal procedures to reinstall.
(2) +e : Refer to “Service Points of Removal”.
14. Housing tube (3) l * : Refer to “Service Points of Installation”.
15. Front differential carrier assembly (4) q : Non-reusable parts

/ STB Revision 7
 FRONT SUSPENSION - Differential Carrier 2-69
SERVICE POINTS OF REMOVAL NOZVBAB

2. REMOVAL OF KNUCKLE AND DRIVE SHAFT ASSEMBLY

Refer to P.2-44, 52.

4. REMOVAL OF INNER SHAFT

Attach the special tools to the flange of the shaft, and pull
the inner shaft out from the front differential carrier. “,I‘.<I’
...
+,‘.
Caution p
1. Being careful not to scratch or scar the shock q
absorber with the special tool, remove the lower \
mounting bolts of the shock absorber, and compress *ll.
the shock absorber as much as possible. L‘,
2. When pulling the inner shaft out from the front ”
differential carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.

6. REMOVAL OF FRONT PROPELLER SHAFT

Make the mating marks on the flange yoke and the
differential companion flange.
Detach the propeller shaft from the front differential carrier
assembly.
-

,,r:' b’b”
1'

8. REMOVAL OF DIFFERENTIAL MOUNTING BRACKET ;:.” _:

(L.H.) g,. .i,,:‘.,
While supporting the differential carrier with a jack, removei’< *“I.‘.:‘{
the differential mounting bracket. “,5. .)I’
?->
‘::
<5
i ‘,

INSPECTION BEFORE DISASSEMBLY NOZVCAA

Remove the cover and gasket. Hold the working base in a vice,
and install the differential carrier assembly to the working
base.

evision
z-70 FRONT SUSPENSION - Differential Carrier
FINAL DRIVE GEAR BACKLASH
Check the final drive gear backlash by following the steps
below.
(1) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive gear.

NOTE
Measure at four points or more on the circumference of
the drive gear.

llV16i Standard value : 0.11-0.16 mm (.0043-.0063 in.)

(2) If the backlash is not within the standard value, adjust it by

using the side bearing adjustment spacers.

DRIVE GEAR RUNOUT

Check the drive gear runout by following the steps below.
(1) Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.

Limiit : 0.05 mm (.0020 in.)

(2) If the runout exceeds the limit, check for improper

tightening of the drive gear and differential case.

DIFFERIENTIAL GEAR BACKLASH

Check the differential gear backlash by following the steps
below.
(1) While locking the side gear with the wedge, measure the
differential gear backlash with a dial indicator on the pinion
gear.

NOTE
The measurement should be made for both pinion gears
individually.

Standard value : O-0.076 mm (O-.0030 in.)

Limit : 0.2 mm (.0079 in.)

(2) If the backlash exceeds the limit, adjust by using the side
gear thrust spacers.

I STB Revision
FRONT SUSPENSION - Differential Carrier 2-71
FINAL DRIVE GEAR TOOTH CONTACT
Check the tooth contact of the final drive gear by following the
steps below.
(1) Apply a thin, uniform coat of machine blue to both
surfaces of the drive gear teeth.

(2) Insert the brass between the differential carrier and the
differential case, and then rotate the companion flange by
hand (once in the normal direction, and then once in the =”:
reverse direction) while applying a load to the drive gear so +.‘.’
that the revolution torque [approximately 2.5 to 3.0 Nm (1.8 $:
to 2.2 ft.lbs.)] is applied to the drive pinion. II
!!,
Caution F
*‘i-.
If the drive gear is rotated too much, the tooth contact ‘8 4
pattern will become unclear and difficult to check.

(3) Check the tooth contact condition of th drive gear and

drive pinion.

NOTE
1. Checking the tooth contack pattern is the way to
confirm that the adjustments of the pinion height and
backlash have been done properly.
2. Continue to adjust the pinion height and backlash nutil
the tooth contact pattern resembles the standard
pattern.
3. If, even after adjustments have been made, the correct
tooth contact pattern cannot be obtained, it means that
.the drive gear and the drive pinion have become worn ,:
beyond the allowable limit; replace the gear set. :.
i’: :
’
Caution
If either the drive gear or the drive pinion is to be ‘1. ‘: :
replaced, be sure to replace both gears as a set. d
.1’.‘. ‘.
.I , ,a
1, ;,
‘k+ _-

/ ST6 Revision
2-72 FRONT SUSPENSIOPIJ - Differential Carrier

Standard tooth contact pattern

1 Toe
2 Drive-side
3 Heel
4 Coast-side

Problem Solution

Tooth contact pattern resulting from excessive

pinion height

The drive pinion is positioned too far from the center Increase the thickness of the pinion height adjusting
of the drive gear. shim, and position the drive pinion closer to the
center of the drive gear.
Also, for backlash adjustment, position the drive gear
farther from the drive pinion.

Tooth contact pattern resulting from improper

pinion height

The drive pinion is positioned too close to the center Decrease the thickness of the pinion height adjusting
of the drive gear. shim, and position the drive pinion farther from the
center of the drive gear.
Also, for backlash adjustment, position the drive gear
closer to the drive pinion.

118642

SERVICE POINTS OF INSTALLATION N02VDAB

4. INSTALLATION OF INNER SHAFT

Drive the inner shaft into the front differential carrier by
using the special tools.
Caution
Be careful not to damage the lip of the dust seal and oil
seal.
2. INSTALLATION OF DRIVE SHAFT
Refer to P.2-52.
Revision
 FRONT SUSPE SOON - Differential Carrier 2-73

160-220 Nm
116159 ft.lbs.
170
31
I 25 \I*:

\ I \ !

40-60 Nm
2643 ft.lbs.
do-70 Nm
43-51 ft.lbs.

\
15-22 Nm
‘aI
11-16 ft.lbs.

Disassembly steps
1. Cover 21. Drive pinion front shim (for pinion height ,/-’ L
.i .
2. Gasket adjustment) !b<. .’‘:
3. Bearing caps 22. Drive pinion
4. Differential case assembly 23. Companion flange
5. Side bearing adjusting spacers 24. Drive pinion spacer
6. Side bearing outer races 25. Drive pinion rear shim (for preload ad-
7. Side bearing inner races justment)
8. Bolts (IO) 26. Oil seal
9. Drive gear 27. Drive pinion rear bearing inner race
10. Lock pin 28. Drive pinion rear bearing outer race
11. Pinion shaft 29. Drive pinion front bearing outer race
12. Pinion gears 30. Oil seals
13. Pinion washers 31. Gear carrier
14. Side gears 32. Vent plug
15. Side gear thrust spacers
16. Differential case
17. Companion flange self-locking nut
18. Washer NOTE
19. Drive pinion assembly (1) ++ : Refer to “Service Points of Disassembly”.
20. Drive pinion front bearing inner race (2) q : Non-reusable parts

STB Revision I
2-74 FRONT SUSPENSION - Differential Carrier

SERVICE POINTS OF DISASSEMBLY NOZVFAA

4. REM’OVAL OF DIFFERENTIAL CASE ASSEMBLY

Take out the differential case assembly with a hammer
handle.

Caution
When taking out the differential case assembly, be
careful not to drop and damage the side bearing outer
races.

NOTE
Keep the right and left side bearings and side bearing
adjusting spacers separate, so that they do not become
mixed at the time of reassembly.
MB990339-01
7. REMOVAL OF SIDE BEARING INNER RACES
Pull out the side bearing inner races by using the special
tools.

801

9. REMIOVAL OF DRIVE GEAR

(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.

10. REMOVAL OF LOCK PIN

Drive out the lock pin with a punch.

NOl-E
The removed side gears and side gear thrust spacers, left
and right, should be retained for reassembly.

17. REIWIOVAL OF COMPANION FLANGE SELF-LOCKING

NUT
Use the special tool to hold the companion flange and
remove the companion flange self-locking nut.

ST6 Revision
FRONT SUSPENSION - Differential Carrier 2-75
19. REMOVAL OF DRIVE PINION ASSEMBLY
(1) Make mating marks on the drive pinion and companion
flange.

Caution
The mating mark made on the companion flange
must not be on the coupling surface of the flange
yoke and the front propeller shaft.

(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion shims.

20. REMOVAL OF DRIVE PINION FRONT BEARING INNER

RACE I’
Pull out the drive pinion front bearing inner race by using
the special tools.
MIT303173

llS732

28. REMOVAL OF DRIVE PINION REAR BEARING OUTER

ss rod
RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier by using the brass rod

118596

29. REMOVAL OF DRIVE PINION FRONT BEARING OUTER $’ .z

RACE :,
Drive out the drive pinion front bearing outer race from the ”
gear carrier by using the brass rod. 1.

INSPECTION NOZVGAA

l Check the companion flange for wear or damage.

l Check the oil seal for wear or deterioration.
l Check the bearings for wear or discoloration.
l Check the gear carrier for cracks.
l Check the drive pinion and ring gear for wear or cracks.
l Check the side gears, pinion gears and pinion shaft for
wear or damage.
l Check the side gear spline for wear or damage.

1 STB Revision
2-76 FRONT SUSPENSION - Differential Carrier
N02VH.-
EASSEMBLY

160-220 Nm
1%159\ ft.lbs.
16El
3 11 ‘TV \ \

40-60 Nm
26-43 ft.lbs.

\
Pi-22 Nm
11-16 ftlbs.

511134

Differential gear set Final drive gear set

I

Reassembly steps 18. Side gear thrust spacers

1. Vent plug 19. Side gears
2. Gear carrier 20. Pinion washers
l * 3. Oil seals 21. Pinion gears
l + 4. Drive pinion front bearing outer race l * Adjustment of differential gear backlash
~~ 5. Drive pinion rear bearing outer race 22. Pinion shaft
l + Adjustment of pinion height I)+ 23. Lock pin
6. Drive pinion l * 24. Drive gear
7. Drive pinion front shim (for pinion height 25. Bolts (IO)
adjustment) ++ 26. Side bearing inner races
8. Drive pinion front bearing inner race 27. Side bearing outer races
l + Adjustment of drive pinion preload l + Adjustment of fina. drive gear backlash
9. Drive pinion rear bearing inner race 28. Side bearing adjusting spacers
10. Oil seal 29. Differential case assembly
11. Drive pinion rear shim (for preload ad- 30. Bearing caps
justment) l * 31. Gasket
12. Drive pinion spacer 32. Cover
13. Drive pinion assembly
14. Companion flange
15. Washer NOTE
16. Companion flange self-locking nut (1) l + : Refer to “Service Points of Reassembly”.
17. Differential case (2) q : Non-reusable parts

1 STB Revision
 FRONT SUSPENSION - Differential carrier 2-77

w/ MB990938-01

MB990934-01
SERVICE POINTS OF REASSEMBLY
3. INSTALLATION OF OIL SEALS
Install the oil seal with the special tool and apply a thin coat
of specified grease to the lip of the oil seal.
N02VlAB

Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

4. INSTALLATION OF DRIVE PINION FRONT BEARING

OUTER RACE
0938-01 Press-fit the drive pinion front bearing outer races into the J’
gear carrier by using the special tools. ,‘i’
‘.
0936-01
NOTE
Perform press-fitting carefully so as not to tilt the outer”
race. 1..

5. INSTALLATION OF DRIVE PINION REAR BEARING OUT-

4 MB990938-01 ER RACE
MB990934-01 Press-fit the drive pinion rear bearing outer races into the
gear carrier by using the special tools.

NOTE
Perform press-fitting carefully so as not to tilt the outer
race.

11 w593

. ADJUSTMENT OF PINION HEIGHT .I

Adjustment the drive pinion height by the
,’ following
procedures: \
!,
, jj$(%lB990905-4-01 (1) Install special tools and drive pinion front and rear ,
bearing inner races to the gear carrier in the sequence ’
MB990905-3-01 shown in the illustration. ‘!
MB990901-01 .
MB990905-2-01
’ .$
MB990905-l-01 (2) Tighten the handle of the special tool until the standard ”
value of drive pinion rotation torque is obtained.
:g.
llW518
(3) Measure the drive pinion rotation torque (without the
oil seal) by using the special tools.

Standard value : 0.4-0.5 Nm (3.54.3 in. Ibs.)

MB990905-l-01

1 STB Revision
2-78 FRONT SUSPENSION - Differential Carrier

NOTE
‘I, Gradually tighten the hardle of the special tool
while checking the drive pinion preload.
2. Because one rotation can’t be made when the
special tool is in contact with the gear carrier, move
it a few times and, after seating the bearing,
measure the rotation torque.

(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion front shim of
a thickness which corresponds to the gap between the
special tools.

NOTE
‘1. Be sure to clean the side bearing seat thoroughly.
When positioning the special tool, be sure that the
cut-out sections of the special tool are in the
position shown in the illustration, and also confirm
that the special tool is in close contact with the side
bearing seat.
2. When selecting the drive pinion front shims, keep
the number of shims to a minimum.

(5) IFit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
race by using the special tool.

. ADJUSTMENT OF DRIVE PINION PRELOAD

Adjust the drive pinion turning torque by using the
following procedure:
Without Oil Seal
(1) Insert the drive pinion into the gear carrier, and then
install, from the front side of the carrier, the drive
Ipinion spacer, the drive pinion rear shim; the drive
pinion rear bearing inner race, and the companion
flange in that order.

NOTE
Do not install the oil seal.

(2) Tighten the companion flange to the specified torque

by using the special tool.

1 STB Revision I
FRONT SUSPENSION - Differential Carrier 2-79
(3) Measure the drive pinion rotation torque (without the
oil seal).

Standard value : 0.4-0.5 Nm (3.5-4.3 in.lbs.)

(4) If the drive pinion rotation torque is not within the

range of the standard value, adjust the preload by
replacing the drive pinion rear shim(s) or the drive
pinion spacer.

NOTE
When selecting the drive pinion rear shims, if the
number of shims is large, reduce the number of shims
to a minimum by selecting the drive pinion spacers.

(5) Remove the companion flange and drive pinion once T”

again. ?
?

With Oil Seal

(1) After setting the drive pinion rear bearing inner race, drive
the oil seal into the gear carrier front lip by using the
special tool.
(2) Apply the specified grease to the oil seal lip.

MB990031-01 Specified grease : Multipurpose grease SAE 5310, NLGI

No. 2

(3) Apply a thin coat of specified grease to the companion , ”

flange contacting surface of the washer before installing $
drive pinion assembly. 1 s
.-
Specified grease : Multipurpose grease SAE 5310, NLGI :-
No. 2 .
li.,. :
i;?.

(4) Install the drive pinion assembly and companion flange

with mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified
torque by using the special tools.

wision I
 2-80 FRONT SUSPENSION - Differential Carrier

(5) Measure the drive pinion rotation torque (with oil seal)
to verify that the drive pinion preload complies with the
standard value.

!standard value : 0.647 Nm (5.2-6.1 in.lbs.)

(6) If the measured value is not within the standard value

range, check for faulty installation of the oil seal or
faulty tightening of the self-locking nut.

l ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH

(1) Assemble the side gears, side gear thrust spacers,
pinion gears, and pinion washers into the differential
case.
(2) Temporarily install the pinion shaft.

NOTE
Do not drive in the lock pin yet.

(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) Measure the differential gear backlash with a dial
indicator on the pinion gear.

Standard value : O-0.076 mm (O-.0030 in.)

Limit : 0.2 mm (.008 in.)

(5) If the differential gear backlash exceeds the limit,

adjust the backlash by installing thicker side gear thrust
spacers.
(6) Measure the differential gear backlash once again, and
confirm that it is within the limit.
If adjustment is not possible, replace the side gears
and pinion gears as a set,
; ,I

23. INSTALLATION OF LOCK PIN

(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.

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FRONT SUSPENSI h! - Differential Carrier 2-81
24. INSTALLATION OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml0 x 1.25), and
then clean the threaded holes by applying compressed
air.

(3) Apply the specified adhesive to the threaded holes of

the drive gear.

Specified adhesive : 3M Adhesive stud locking 4170 {“*

/.’
or equivalent

(4) Install the drive gear onto the differential case with the ”
mating marks properly aligned. Be sure to tighten the “‘1;
bolts to the specified torque in a diagonal sequence. ‘,(

26. INSTALLATION OF SIDE BEARING INNER RACES

Press-fit the side bearing inner races to the differential
case by using the special tool.

E!-‘.:
.I f-
.i”:
. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH
f :.,:
(1) Install the side bearing adjusting spacers, which areFd, ::;;
tinner than those removed, to the side bearing outer\, ;
races, and then mount the differential case assembly \,,
into the gear carrier. -3’
:;: 2
NOTE ‘I’ ,
Select side bearing adjusting spacers with the same ‘I.
thickness for both the drive pinion side and the drive
gear side.

(2) Push the differential case assembly to one side, and

measure the clearance between the gear carrier and
the side bearing adjusting spacer with a feeler gauge.

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2-82 FRONT SUSPENSIO - Differential Carrier

(3)Measure the thickness of the side bearing adjusting

spacers on one side, select two pairs of spacers which
correspond to that thickness plus one half of the
clearance plus 0.05 mm (.002 in.), and then install one
+ Clearance + 0.05 mm pair each to the drive pinion side and the drive gear
2 (.002 in.) side.
= Thickness of the
spacer on one side

llY241

(4)lnstall the side bearing adjusting spacers and differen-

tial case assembly, as shown in the illustration, to the
gear carrier.

(5)Tap the side bearing adjusting spacers with the brass

bar to fit them to the side bearing outer race.

(6)Align the mating marks on the gear carrier and the

bearing cap, and then tighten the bearing cap.

(7)With the drive pinion locked in place, measure the final

drive gear backlash with a dial indicator on the drive
gear.

NOTE
Mleasure at four points or more on the circumference
of the drive gear.

Standard value : 0.11-0.16 mm (.0043-.0063 in.)

evision I
FRONT SUSPENSION - Differential Carrier 2-83
(8)Change the side bearing adjusting spacers as illus-
trated, and then adjust the final drive gear backlash
between the drive gear and the drive pinion.

NOTE
When increasing the number of side bearing adjusting
spacers, use the same number for each, and as few as
possible.

(9)Check the drive gear and d-rive pinion for tooth contact.
If poor contact is evident, make adjustment.
(Refer to P.2-71)

(lO)Measure the drive gear runout at the shoulder on the

reverse side of the drive gear. 0.
Limit : 0.05 mm (.0020 in.) ..”1’1
..:
(1 l)lf the drive gear runout exceeds the limit, reinstall by t
changing the phase of the drive gear and differential I,
case, and remeasure. i, G

llY168

31. APPLICATION OF SEALANT TO GASKET

Apply the specified sealant to both sides of the gasket and
install the differential cover to the differential carrier.

Specified sealant : 3M ART Part No. 8661 or No. 8663,

or equivalent

llSO58

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