26-2 FRONT AXLE – General Information

GENERAL INFORMATION 26100010111

2WD
The front hub assembly which uses a double taper For vehicles with ABS, a rotor for detecting the
roller bearing is mounted on the knuckle spindle. wheel speed is press-fitted into the front hub.

4WD
The front axle consists of the hub assembly, drive D A vacuum-type freewheel clutch has been
shaft, inner shaft, front differential, freewheel clutch adopted in the freewheel mechanism. Its
assembly and actuator. The features are: solenoid valve and actuator switch powertrain
D The wheel bearing uses a double taper roller between 2WD and 4WD.
bearing. For vehicles with ABS, a rotor for D There are two types of differential gear. The
detecting the wheel speed is bolted to the brake difference between them is gear ratio.
disc.
D Drive shafts of almost identical length reduce
torque steer. In addition, a D.O.J.-B.J.-type
constant velocity ball joint has high power
transmission efficiency and reduces vibration
and noise.

2WD
Item Specifications

Wheel bearing Type Double taper roller bearing

Inner bearing (O.D. x I.D.) mm 65.1 x 34.9

Outer bearing (O.D. x I.D.) mm 50.0 x 21.4

4WD
<Bearings>
Item Specifications

Wheel bearing Type Double taper roller bearing

Inner bearing (O.D. x I.D.) mm 73 x 45

Outer bearing (O.D. x I.D.) mm 73 x 45

Drive shaft Joint type Outer: B.J.

Inner: D.O.J.

Shaft length (joint to joint) mm Right: 318

Left: 291

Inner shaft O.D. x length mm 31.5 x 304.2

Bearing (O.D. x I.D.) mm 62 x 35

 FRONT AXLE – General Information 26-3
<Gears>
Item 4D56 4G64, 4D56
<Vehicles without wide tyre> <Vehicles with wide tyre>

Reduction gear type Hypoid gear type Hypoid gear type

Reduction ratio 4.636 4.875

Differential Differential Side gear Straight bevel gear x 2 Straight bevel gear x 2
type
gear ty e
(type x piece) Pinion gear Straight bevel gear x 2 Straight bevel gear x 2

Number of Drive gear 51 39

teeth
Drive pinion 11 8

Side gear 14 14

Pinion gear 10 10

Bearing Side 80.0 x 45.2 80.0 x 45.2

(O.D.
(O D x I.D.)
ID)
mm Front 64.3 x 30.2 64.3 x 30.2

Rear 76.2 x 36.5 76.2 x 36.5

CONSTRUCTION DIAGRAM

<4WD> <2WD> Front hub assembly

Rotor

Drive shaft (R.H.)

Actuator

Freewheel clutch assembly Knuckle spindle

Drive shaft (L.H.)

Inner shaft

Front axle hub assembly

D.O.J.

B.J.
26-4 FRONT AXLE – Service Specifications/Lubricants

SERVICE SPECIFICATIONS 26100030131

Item Standard value Limit

Front axle total backlash mm – 11

Drive shaft axial play mm 0.4 – 0.7 –

Solenoid valve resistance Ω 36 – 46 –

Hub rotary sliding resistance N 7 – 26 –

(Hub rotation starting torque) Nm 0.5 – 1.8 –

Amount of movement of far the wheel bearing in an axial 0.05 or less –

direction mm

Setting of D.O.J. boot length mm 80 ± 3 –

Clutch gear play (bearing axial play) mm 0.05 – 0.30 –

Drive gear backlash mm 0.11 – 0.16 –

Differential gear backlash mm 0 – 0.076 –

Drive pinion rotation torque Nm Without oil seal When replacing (with anti-rust agent) –
0.3 – 0.5

When replacing or reusing (with gear oil –

applied) 0.15 – 0.25

With oil seal When replacing (with anti-rust agent) –

0.5 – 0.7

When replacing or reusing (with gear oil –

applied) 0.3 – 0.4

Drive gear runout mm – 0.05

Differential gear backlash mm – 0.2

LUBRICANTS 26100040141

Items Specified lubricants Quantity

Front differential gear oil Hypoid gear oil API classification 0.9

GL-5 or higher SAE viscosity No. 90,
80W

D.O.J. boot grease Repair kit grease 100 g

 FRONT AXLE – Sealants/Special Tools 26-5
SEALANTS 26100050038

Items Specified sealants Remarks

Contact surface of drive flange or freewheel hub 3M ATD Part No. 8661 or equivalent Semi-drying sealant
and front axle hub

Contact surface of hub cap and drive flange

Contact surface of differential cover and

differential carrier

Vent plug

Freewheel clutch assembly

Drive gear threaded hole 3M Stud Locking 4170 or equivalent Anaerobic sealant

SPECIAL TOOLS 26100060123

Tool Number Name Use

B MB990590 Rear axle shaft oil D Removal of differential carrier oil seal
A: MB990212 seal remover D Removal and installation of inner shaft
B: MB990211 A: Adapter (Used together with MB990906)
B: Sliding hammer
A

MB990954 Lock nut wrench Removal and adjustment of lock nut <4WD>

MB990925 Bearing and oil D Press-out and press-fitting of wheel

seal installer set bearing outer race
D Press-fitting of oil seal (front hub)
D Press-fitting of needle bearing (Knuckle)
D Press-fitting of bearing (freewheel clutch)
D Press-fitting of oil seal (freewheel clutch)
D Press-out and press-fitting of drive pinion
front bearing outer race
D Press-out and press-fitting of drive pinion
rear bearing outer race
D Press-fitting of drive shaft
D Tapping in of side bearing outer race
D Checking of drive gear tooth contact
MB991113 Steering linkage D Disconnection of tie rod
or puller D Disconnection of upper ball joint
MB990635 D Disconnection of lower ball joint

MB990804 Knuckle arm puller Disconnection of upper, lower ball joint and
knuckle <2WD>
26-6 FRONT AXLE – Special Tools

Tool Number Name Use

MB990955 Oil seal installer D Press-fitting of housing tube dust seal
D Press-fitting of front axle hub oil seal
(Used together with MB990938)
D Press-fitting of rotor <2WD>
(Used together with MB990938)

MB990956 Needle bearing Press-fitting of knuckle needle bearing (Used

installer together with MB990938)

MB990985 Oil seal installer Press-fitting of knuckle oil seal (Used together
with MB990938)

MB991561 Boot band clipping Resin boot band installation

tool

MB990906 Drive shaft Removal and installation of inner shaft (Used

attachment together with MB990211)

MB990560 Bearing remover Removal and press-fitting of inner shaft

bearing

MB990799 Ball joint remover Installation of freewheel clutch bearing

and installer

MB991168 Differential oil seal Installation of freewheel clutch oil seal

installer

MB990890 Rear suspension Installation of freewheel clutch bearing

or bushing base
MB990891
 FRONT AXLE – Special Tools 26-7

Tool Number Name Use

MB990909 Working base Support of front differential carrier assembly

MB991116 Adapter Support of front differential carrier assembly

MB990810 Side bearing puller Removal of side bearing inner race

MB990811 Differential side

bearing cap

MB990850 End yoke holder Removal and installation of companion flange

MB990339 Bearing puller Removal of drive pinion front bearing inner race

MB990648 Bearing remover

MB990901 Pinion height D Inspection of drive pinion rotation starting

A A: MB990904 gauge set torque
B: MB990552 A: Drive pinion D Measurement of drive pinion height
gauge assembly
B
B: Cylinder gauge

MB990685 Torque wrench Measurement of drive pinion preload

26-8 FRONT AXLE – Special Tools

Tool Number Name Use

MB990326 Preload socket

MB990802 Bearing installer D Press-fitting of drive pinion front bearing

inner race
D Press-fitting of side bearing inner race

MB990031 Drive pinion oil Press-fitting of drive pinion oil seal

or seal installer
MB990699

MB990813 Tap Removal of adhesive

MB990925
Tool box
C Brass bar

B
A Bar (snap-in type)
Installer adapter

Contents of tool O.D. mm Contents of tool O.D. mm

(MB990925) (MB990925)

A MB990926 39 A MB990933 63.5

MB990927 45 MB990934 67.5

MB990928 49.5 MB990935 71.5

MB990929 51 MB990936 75.5

MB990930 54 MB990937 79

MB990931 57 B MB990938 –

MB990932 61 C MB990939 –
 FRONT AXLE – On-vehicle Service 26-9
ON-VEHICLE SERVICE 26100110071

<2WD>
WHEEL BEARING PLAY CHECK
1. Check the play of the bearings while the vehicle is jacked
up.
Caution
Do not confuse this play with the ball joint play.

2. If there is some play in the bearings, tighten the wheel

bearing nuts to 29 Nm, and then turn the front hub
assembly to run in the bearings.
3. Loosen the nuts to 0 Nm.
4. Re-tighten the nuts to 7.8 Nm.
5. If the split pin hole in the wheel bearing nut is not aligned
with that in the knuckle, turn the nut back within 30_.
Then install the split pin.

<4WD>
FRONT AXLE TOTAL BACKLASH CHECK
26100130022

Observe the following procedure in order to switch powertrain

to 4WD.
1. Turn the ignition switch off, and then put the transfer
shift lever to the 2H position.
Caution
Do not jack up the vehicle.

2. Turn the propeller shaft until a click is heard.

Mating marks 3. Turn the companion flange clockwise until all play is
removed. Make mating marks on the dust cover of the
companion flange with that on the differential carrier.

4. Turn the companion flange counterclockwise until all play

is removed and measure the amount of distance through
which the mating marks moved.
Limit: 11 mm
26-10 FRONT AXLE – On-vehicle Service

5. If the amount of movement exceeds the limit value, check

the following.
(1) Final drive gear backlash
(2) Differential gear backlash
(3) Play in the serrations and splines of the side gears,
drive shaft, inner shaft and drive flange

FRONT AXLE GEAR OIL LEVEL CHECK 26200090026

Remove the filler plug, and check the gear oil level. Check
that gear oil level is not 8 mm below the bottom of filler plug
hole.
8 mm
Specified gear oil:
Upper limit Hypoid gear oil API classification GL-5 or higher, SAE
viscosity No. 90, 80W [Quantity: 0.9
]
Lower limit

DRIVE SHAFT AXIAL PLAY CHECK 26100140025

1. Jack the vehicle up and remove the front wheels.

2. Remove the hub cap.
3. Manually push the drive shaft in the direction in which
it will closely contact the knuckle.
4. As shown in the figure, use a thickness gauge to measure
the clearance between the drive flange and snap ring.
Standard value: 0.4 – 0.7 mm
5. If the play is out of standard value, adjust by adding
or removing shims.

DIFFERENTIAL CARRIER OIL SEAL

REPLACEMENT 26200100026

1. Remove the under cover.

2. Remove the shock absorber lower mounting bolts at the
right and left.
3. Remove the front hub and knuckle assembly.
4. Remove the left drive shaft.

5. Remove the right drive shaft from the inner shaft assembly.
6. Remove the inner shaft.
7. Remove the actuator mounting bolt from the housing tube
and remove the harness from the clamp.
8. Remove the differential mounting bracket (R.H.) and
housing tube.
 FRONT AXLE – On-vehicle Service 26-11
9. Use the special tool to remove the oil seal.
MB990590

10. Press-fit the oil seal positively by using the special tools.
MB990934

MB990938

11. Apply multi-purpose grease to the lip of the oil seal and
install the drive shaft (L.H.). For the right side, apply
multi-purpose grease to the lip of the oil seal and install
the housing tube and differential mounting bracket (R.H.).

12. Install the inner shaft and drive shaft (R.H.).

Caution
1. Do not damage the lip of the oil seal.
2. The circlip attached to the B.J. side of the drive
shaft should be replaced with a new clip.
13. Install the actuator and secure the harness with the clamp.
14. Install the shock absorber.
15. Install the hub and knuckle assembly.
16. Install the under cover.

SOLENOID VALVE OPERATION CHECK 26100150028

1. Remove the vacuum hoses (blue stripe, yellow stripe)

from the solenoid valves.
2. Disconnect the harness connectors.

Solenoid valve B
Solenoid valve A
26-12 FRONT AXLE – On-vehicle Service

3. Connect a hand vacuum pump to solenoid valve B and

carry out the following inspections.
(1) Even if the hand pump is operated with no other
operation, no negative pressure develops.
(2) Negative pressure does not develop when battery
Check valve voltage is applied to solenoid valve B. Meanwhile,
negative pressure is maintained when the vacuum
Vacuum tank hose of solenoid valve A is blocked by bending.
(3) When battery voltage is applied to solenoid valves
A and B, negative pressure is maintained.

Solenoid
valve B

Vacuum
hose
Solenoid valve A

4. Connect the hand vacuum pump to solenoid valve A.

Apply negative pressure and carry out the following
inspections.
Check valve (1) With no other operation, negative pressure is
Vacuum tank maintained.
(2) When battery voltage is applied to solenoid valve
B, negative pressure disappears.
(3) When battery voltage is applied to solenoid valve
A, negative pressure disappears.
Solenoid
valve B
5. Measure the resistance of the solenoid valves.
Standard value: 36 – 46 Ω

Solenoid valve A
 FRONT AXLE – Front Hub Assembly <2WD> 26-13
FRONT HUB ASSEMBLY <2WD> 26100170123

REMOVAL AND INSTALLATION

5
4 3
2

88 Nm
29 Nm 0 Nm 7.8 Nm

Removal steps
AA" 1. Caliper assembly "AA 4. Wheel bearing nut
2. Hub cap 5. Washer
3. Split pin AB" 6. Front hub assembly

REMOVAL SERVICE POINTS

AA" CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire so that it
does not fall.

AB" FRONT HUB ASSEMBLY REMOVAL

Do not drop the outer bearing inner race.

Outer bearing
inner race
26-14 FRONT AXLE – Front Hub Assembly <2WD>

INSTALLATION SERVICE POINT

"AA WHEEL BEARING NUT INSTALLATION
1. Tighten the wheel bearing nuts to 29 Nm, and then turn
the front hub assembly to run in the bearings.
2. Loosen the nuts to 0 Nm.
3. Re-tighten the nuts to 7.8 Nm.
4. If the split pin hole in the wheel bearing nut is not aligned
with that in the knuckle, turn the nut back within 30_.
Then install the split pin.

DISASSEMBLY AND REASSEMBLY 26100190075

8
1
5

4 6 4
5
7 7
2 3

6
1

49 – 59 Nm

Disassembly steps
1. Outer bearing inner race 5. Inner bearing inner race
"CA 2. Rotor (Vehicles with ABS) AB" "AA 6. Outer bearing outer race
AA" 3. Brake disc AB" "AA 7. Inner bearing outer race
"BA 4. Oil seal 8. Front hub

Mating
DISASSEMBLY SERVICE POINTS
marks AA" BRAKE DISC REMOVAL
Make the mating marks on the brake disc and front hub,
and then separate the front hub and brake disc, if necessary.
Caution
Lock disc in vise and grip with copper or aluminum board.
 FRONT AXLE – Front Hub Assembly <2WD> 26-15
AB" OUTER BEARING OUTER RACE/INNER BEARING
Outer bearing Inner bearing OUTER RACE REMOVAL
MB990939 outer race
outer race

Inner bearing Outer bearing INSTALLATION SERVICE POINTS

outer race MB990938 outer race
MB990928
"AA INNER BEARING OUTER RACE/OUTER BEARING
MB990933 OUTER RACE INSTALLATION
NOTE
Replace the inner race and outer race assembly as a set.

"BA OIL SEAL INSTALLATION

MB990938
MB990936

MB990955
"CA ROTOR INSTALLATION
MB990938

Rotor
26-16 FRONT AXLE – Front Hub Assembly <4WD>

FRONT HUB ASSEMBLY <4WD> 26100170130

REMOVAL AND INSTALLATION

1 2
8

90 Nm
Sealant: 3M ATD Part No. 8661 or equivalent

7
6
5

90 Nm 4
3 2

8
127 – 196 Nm 0 Nm 25 Nm 49 – 59 Nm

Front hub shim set

Removal steps
AA" 1. Caliper assembly "CA D Hub rotary sliding resistance and
2. Hub cap wheel bearing axial movement
"DA D Drive shaft axial play adjustment adjustment
3. Snap ring "BA 6. Lock washer
4. Shim AB" "AA 7. Lock nut
5. Drive flange AC" 8. Front hub assembly

REMOVAL SERVICE POINTS

AA" CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire so that it
does not fall.

AB" LOCK NUT REMOVAL

MB990954
 FRONT AXLE – Front Hub Assembly <4WD> 26-17
AC" FRONT HUB ASSEMBLY REMOVAL
Do not drop the outer bearing inner race.
Outer
bearing
inner
race

INSTALLATION SERVICE POINTS

MB990954 "AA LOCK NUT INSTALLATION
Using the special tool, tighten the lock nut by the following
procedures.
(1) Tighten the lock nut to 127 – 196 Nm, and then turn
the front hub assembly to run in the bearings.
(2) Loosen the nuts to 0 Nm.
(3) After re-tightening to 25 Nm, loosen the lock nuts by
approximately 30_.

Max. 20_
"BA LOCK WASHER INSTALLATION
Install the lock washer. If the hole position is not aligned
with the lock nut, move it within a range of not more than
20_ until the holes are aligned.

"CA HUB ROTARY SLIDING RESISTANCE AND

WHEEL BEARING AXIAL MOVEMENT
ADJUSTMENT
1. Use a spring balance to measure the hub rotary sliding
resistance (hub rotation starting torque) as shown in the
illustration.
Standard value: 7 – 26 N (0.5 – 1.8 Nm)
2. If the rotary sliding resistance is not within the standard
value, remove the lock washer and adjust by the following
procedure.
(1) If the rotary sliding resistance is lower than the
standard value, use the special tool (MB990954) to
tighten the lock nut.
(2) If the rotary sliding resistance is higher than the
standard value, use the special tool (MB990954) to
loosen the lock nut.
26-18 FRONT AXLE – Front Hub Assembly <4WD>

3. Install a dial gauge as shown in the illustration, and then

move the hub in the axial direction and measure how
far the front wheel bearing moves.
Standard value: 0.05 mm or less
4. If the distance exceeds the standard value, remove the
lock washer and use the special tool (MB990954) to tighten
the lock nut.
5. If adjustment is not possible, disassemble the hub and
inspect each part.

"DA DRIVE SHAFT AXIAL PLAY ADJUSTMENT

1. Push the drive shaft in by hand towards the knuckle until
they touch.
2. Measure the clearance between the drive flange and
the spacer with a thickness gauge as shown in the
illustration.
Standard value: 0.4 – 0.7 mm
3. If the amount of play is outside the standard value, adjust
by selecting a shim that will bring the play to the standard
value.

DISASSEMBLY AND REASSEMBLY 26100190082

5 8
3

2 2
3
5 6 7 1
4
8

1
13 Nm

49 – 59 Nm

Disassembly steps
1. Outer bearing inner race AA" "AA 5. Inner bearing outer race
"BA 2. Oil seal 6. Rotor <Vehicles with ABS>
3. Inner bearing inner race AB" 7. Brake disc
AA" "AA 4. Outer bearing outer race 8. Front hub assembly
 FRONT AXLE – Front Hub Assembly <4WD> 26-19
Outer bearing Inner bearing REMOVAL SERVICE POINTS
outer race MB990939 outer race
AA" OUTER BEARING OUTER RACE/INNER BEARING
OUTER RACE REMOVAL

AB" BRAKE DISC REMOVAL

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

Mating
Caution
marks Lock disc in vise and grip with copper or aluminium board.

Inner bearing MB990938 Outer bearing REASSEMBLY SERVICE POINTS

outer race outer race
"AA INNER BEARING OUTER RACE/OUTER BEARING
MB990935 OUTER RACE INSTALLATION
NOTE
Replace the inner race and outer race assembly as a set.

"BA OIL SEAL INSTALLATION

MB990938

MB990955
26-20 FRONT AXLE – Knuckle <2WD>

KNUCKLE <2WD> 26100240084

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Front Hub Assembly Removal. (Refer to P. 26-13.) D Front Hub Assembly Installation. (Refer to P. 26-13.)
D Wheel Alignment Check and Adjustment. (Refer
to GROUP 33A – On-vehicle Service.)

74 Nm

2 7

39 Nm
1
5
4

147 Nm

6 3
44 Nm

Removal steps
1. Dust cover AB" 4. Lower arm ball joint connection
2. Front speed sensor <Vehicles with AA" 5. Upper arm ball joint connection
ABS> (Refer to GROUP 35B – 6. Stopper bolt
Wheel Speed Sensor.> 7. Knuckle
AA" 3. Tie rod end connection

REMOVAL SERVICE POINTS

MB991113 or
MB990635 AA" TIE ROD END /UPPER ARM BALL JOINT
Nut DISCONNECTION
Caution
Cord 1. Use the special tool to loosen the nut only; do not
remove it from the ball joint.
2. Tie the special tool with a cord not to let it fall off.

Ball joint
 FRONT AXLE – Knuckle <2WD> 26-21
AB" LOWER ARM BALL JOINT DISCONNECTION
MB990804 Caution
Use the special tool to loosen the nut only; do not remove
it from the ball joint.

INSPECTION 26100250049

D Check the knuckle for wear or cracks.

26-22 FRONT AXLE – Knuckle <4WD>

KNUCKLE <4WD> 26100240091

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Front Hub Assembly Removal. (Refer to P. 26-16.) D Front Hub Assembly Installation. (Refer to P. 26-16.)
D Wheel Alignment Check and Adjustment.
(Refer to GROUP 33A – On-vehicle Service.)

7
74 Nm

8 1

34 – 44 Nm

88 – 103 Nm*
6 118 – 177 Nm
12 Nm 3

Removal steps
1. Dust cover AA" 6. Lower arm ball joint connection
2. Front speed sensor <Vehicles with AA" 7. Upper arm ball joint connection
ABS> (Refer to GROUP 35B – 8. Knuckle
Wheel Speed Sensor.>
3. Stabilizer bar connection Caution
4. Shock absorber lower mounting *: Indicates parts which should be temporarily
bolt tightened, and then fully tightened with the
AA" 5. Tie rod end connection vehicle on the ground in the unladen condition.
 FRONT AXLE – Knuckle <4WD> 26-23
REMOVAL SERVICE POINT
MB991113 or
MB990635 AA" TIE ROD END /LOWER ARM BALL JOINT
Nut /UPPER ARM BALL JOINT DISCONNECTION
Caution
Cord 1. Use the special tool to loosen the nut only; do not
remove it from the ball joint.
2. Tie the special tool with a cord not to let it fall off.

Ball joint

INSPECTION 26100250056

D Check the knuckle for wear or cracks.

26-24 FRONT AXLE – Knuckle <4WD>

DISASSEMBLY AND REASSEMBLY 26100320023

2 1
3

1
2
3

Disassembly steps
"CA 1. Oil seal
"BA 2. Spacer
AA" "AA 3. Needle bearing
4. Knuckle
 FRONT AXLE – Knuckle <4WD> 26-25
DISASSEMBLY SERVICE POINT
AA" NEEDLE BEARING REMOVAL

MB990939

MB990938 REASSEMBLY SERVICE POINTS

"AA NEEDLE BEARING INSTALLATION
MB990956 Caution
Use care to prevent driving the needle bearing too far
MB990956 in.

"BA SPACER INSTALLATION

Install the spacer to the knuckle with the chamfered side
toward the center of vehicle.

"CA OIL SEAL INSTALLATION

MB990938

MB990985

MB990985
26-26 FRONT AXLE – Drive Shaft

DRIVE SHAFT 26100350152

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Front Under Cover Removal D Gear Oil Supplying (Refer to P. 26-10.)
D Gear Oil Draining (Refer to P. 26-10.) D Front Under Cover installation
D Wheel Alignment Check and Adjustment.
(Refer to GROUP 33A – On-vehicle Service.)

Left-side drive shaft

90 Nm

13 2

1
10
74 Nm
12

7
34 – 44 5
Nm
4
3
8

12 Nm 88 – 103 Nm* 11
9 118 – 177 Nm
6

Right-side drive shaft

3
12
49 – 59 Nm Front hub shim set Sealant:
3M ATD Part No. 8661 or
equivalent

Removal steps
AA" 1. Caliper assembly AB" 8. Tie rod end connection
2. Front speed sensor <Vehicles with AB" 9. Lower arm ball joint connection
ABS> (Refer to GROUP 35B – AB" 10. Upper arm ball joint mounting bolt
Wheel Speed Sensor.) AC" "BA 11. Knuckle and front hub assembly
3. Hub cap AD" "AA 12. Drive shaft assembly
"CA D Drive shaft axial play adjustment 13. Circlip
4. Snap ring
5. Shim Caution
6. Stabilizer bar connection *: Indicates parts which should be temporarily
7. Shock absorber lower mounting tightened, and then fully tightened with the
bolt vehicle on the ground in the unladen condition.
 FRONT AXLE – Drive Shaft 26-27
REMOVAL SERVICE POINTS
AA" CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire so that it
does not fall.

AB" TIE ROD END /LOWER ARM BALL JOINT

MB991113 or /UPPER ARM BALL JOINT DISCONNECTION
MB990635 Caution
Nut
1. Use the special tool to loosen the nut only; do not
remove it from the ball joint.
Cord
2. Tie the special tool with a cord not to let it fall off.

Ball joint

AC" KNUCKLE AND FRONT HUB ASSEMBLY

REMOVAL
1. Press down lower arm and remove upper knuckle towards
you.
NOTE
Pull the D.O.J. side of the drive shaft assembly out slightly
from the front differential carrier.

2. Slightly back off drive shaft from knuckle. Remove lower

knuckle holding nut from the lower arm ball joint.
3. Disconnect knuckle and lower ball joint.
4. Remove knuckle and front hub assembly from drive shaft
assembly.
Caution
Do not damage knuckle oil seals with drive shaft
spline.

AD" DRIVE SHAFT (LEFT SIDE) REMOVAL

Caution
When pulling the drive shaft out from the differential
carrier, be careful that the spline part of the drive shaft
does not damage the oil seal.
26-28 FRONT AXLE – Drive Shaft

INSTALLATION SERVICE POINTS

"AA DRIVE SHAFT (LEFT SIDE) INSTALLATION
Caution
Do not damage the oil seal of the differential carrier by
the drive shaft splines.

"BA KNUCKLE AND FRONT HUB ASSEMBLY

INSTALLATION
1. Insert knuckle and front hub assembly to drive shaft.
Caution
Do not damage knuckle oil seal with drive shaft spline.
2. Assemble knuckle and lower ball joint and temporarily
tighten slotted nut.
3. Press up lower arm and lock upper ball joint onto upper
arm.
4. Tighten lower ball joint mounting nuts to specified torque.
Tightening torque: 118 – 177 Nm

"CA DRIVE SHAFT AXIAL PLAY ADJUSTMENT

1. Push the drive shaft in by hand towards the knuckle until
they touch.
2. Measure the clearance between the drive flange and
the spacer with a thickness gauge as shown in the
illustration.
Standard value: 0.4 – 0.7 mm
3. If the amount of play is outside the standard value, adjust
by selecting a shim that will bring the play to the standard
value.
NOTE
The shims available range from 0.3 mm thick to 0.6 mm
thick in steps of 0.1 mm, and from 0.9 mm thick to 1.8
mm thick in steps of 0.3 mm.
FRONT AXLE – Drive Shaft 26-29
INSPECTION 26100360087

D Check the boot for damage or deterioration.

D Check the ball joint for operating condition and excessive
looseness.
D Check the splines for wear or damage.
D Check the differential carrier oil seal (L.H.) for damaged.
26-30 FRONT AXLE – Drive Shaft

DISASSEMBLY AND REASSEMBLY 26100370165

11

2 (L.H.)
10
1
7
9
6 8
15 3
14 (R.H.)
4
13 5 12
2 1
8
12
4

B.J. repair kit (B.J.)

11 1 10
79 (L.H.) 8
8 4 12
2 12
2
10
2 6 1
3 3
1 8 12 (R.H.)
3 4

B.J. repair kit L.H. D.O.J. repair kit Boot repair kit (D.O.J.)

Disassembly steps Reassembly steps

1. D.O.J. boot band (large) 12. Circlip
2. D.O.J. boot band (small) 11. B.J. assembly
3. Circlip "AA 9. D.O.J. inner race
4. D.O.J. outer race "AA 8. Snap ring
5. Dust cover "AA 7. D.O.J. cage
AA" 6. Balls "AA 6. Balls
AB" 7. D.O.J. cage "BA 4. D.O.J. outer race
8. Snap ring 5. Dust cover
9. D.O.J. inner race 3. Circlip
AC" 10. D.O.J. boot "CA 10. D.O.J. boot
11. B.J. assembly "CA 2. D.O.J. boot band (small)
12. Circlip "CA 1. D.O.J. boot band (large)
13. B.J. boot band (small)
14. B.J. boot band (large) Caution
15. B.J. boot Never disassemble the B.J. assembly except when
replacing the B.J. boot.
 FRONT AXLE – Drive Shaft 26-31
Lubrication Points

Grease: Repair kit grease Grease:

Repair kit grease 100 g (60 g inside joint, 40 g
inside boot)

Caution
Do not mix old and new or different types of grease, as a special grease is used in the joint.

DISASSEMBLY SERVICE POINTS

AA" BALLS REMOVAL

AB" D.O.J. CAGE REMOVAL

26-32 FRONT AXLE – Drive Shaft

AC" D.O.J. BOOT REMOVAL

Wrap plastic tape around the spline part on the D.O.J. side
Plastic tape of the drive shaft so that D.O.J. boot is not damaged when
they are removed.

Ball REASSEMBLY SERVICE POINTS

Snap ring "AA D.O.J. INNER RACE/SNAP RING/D.O.J.
Shaft
CAGE/BALLS INSTALLATION
Install the cage, balls and inner race to the drive shaft, and
fit the snap ring securely to the groove in the drive shaft.

Inner race
Cage

"BA D.O.J. OUTER RACE INSTALLATION

Fill the inside of the D.O.J. outer race and D.O.J. boot with
the specified grease.
Specified grease: Repair kit grease 100 g
NOTE
The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint use special grease. Do not mix old
and new or different types of grease.

"CA D.O.J. BOOT/D.O.J. BOOT BAND INSTALLATION

A 1. Position the D.O.J. outer race so that the distance
between the boot bands is at the standard value.
Standard value (A): 80 ± 3 mm
2. Remove part of the D.O.J. boot from the D.O.J. outer
race to release the air pressure inside the boot.
Boot band (small)
Boot band (large)
 FRONT AXLE – Drive Shaft 26-33
3. Secure the boot band (large) on D.O.J. boot.
Direction of drive
shaft rotation when Caution
vehicle is moving Be sure that the installation direction of the boot bands
forward is correct.

Boot band

B.J. BOOT (RESIN BOOT) REPLACEMENT

26100520065

1. Remove the boot bands (large and small).

NOTE
The B.J. boot bands cannot be re-used.
2. Remove the B.J. boot.

3. Install the B.J. boot with the part with the smallest diameter
A in a position such that the shaft groove can be seen.

MB991561 4. Turn the adjusting bolt on the special tool so that the
Stopper
size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm>
Tighten the adjusting bolt.
W <If it is smaller than 2.9 mm>
Loosen the adjusting bolt.
Adjusting bolt NOTE
(1) The value of W will change by approximately 0.7
mm for each turn of the adjusting bolt.
(2) The adjusting bolt should not be turned more than
once.
26-34 FRONT AXLE – Drive Shaft

5. Place the B.J. boot band (small) against the projection

B.J. boot at the edge of the boot, and then secure it so that there
A is a clearance left as shown by (A) in the illustration.

B.J. boot band

(small)

Projection

6. Use the special tool to crimp the B.J. boot band (small).
Caution
1. Secure the drive shaft in an upright position and
clamp the part of the B.J. boot band to be crimped
securely in the jaws of the special tool.
2. Crimp the B.J. boot band until the special tool
touches the stopper.

MB991561

7. Check that crimping amount (B) of the B.J. boot band

is at the standard value.
B Standard value (B): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step (4) according
to the following formula, and then repeat the
operation in step (6).
W = 5.5 mm – B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step (4) according to the following
formula, and then repeat the operations in
steps (5) and (6) using a new B.J. boot band.
W = 5.5 mm – B
Example: If B = 2.3, then W = 3.2 mm.
8. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps (5) to (7) using a new
B.J. boot band.
9. Fill the inside of the B.J. boot with the specified amount
of the specified grease.
Specified grease: Repair kit grease
Amount to use: 125 g
 FRONT AXLE – Drive Shaft 26-35
10. Install the B.J. boot band (large) so that there is the
clearance (C) between it and the B.J. housing is at the
C standard value.
C
Standard value (C): 0.1 – 1.55 mm
11. Follow the same procedure as in step (4) to adjust the
size of the opening (W) on the special tool so that it
is at the standard value.
Standard value (W): 3.2 mm

12. Place the B.J. boot band (large) against the projection
at the edge of the boot, and then secure it so that there
Projection is a clearance left as shown by (D) in the illustration.
B.J. boot
13. Use the special tool to crimp the B.J. boot band (large)
B.J. boot band in the same way as in step (6).

14. Check that the crimping amount (E) of the B.J. boot band
is at the standard value.
Standard value (E): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step (11) according
to the following formula, and then repeat the
operation in step (13).
W = 5.8 mm – E
Example: If E = 2.9 mm, then W = 2.9 mm.
E <If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step (11) according to the following
formula, and then repeat the operating in steps
(12) and (13) using a new B.J. boot band.
W = 5.8 mm – E
Example: If E = 2.3 mm, then W = 3.5mm.
15. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps (12) to (14) using a new
B.J. boot band.
26-36 FRONT AXLE – Inner Shaft

INNER SHAFT 26100400031

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Front Under Cover Removal and Installation
D Gear Oil Draining and Supplying (Refer to P. 26-10.)

88 Nm
11 10
17 Nm

1
93 Nm

88 Nm
12
49 – 59 Nm 8
5
4
9 7

6
3

Removal steps
AA" 1. Caliper assembly 9. Differential mounting bracket (R.H.)
2. Hub assembly, knuckle (Refer to P. 10. Pin
26-22.) 11. Actuator assembly
3. Drive shaft (R.H.) (Refer to 12. Housing tube assembly
P.26-26.)
AB" "AA 4. Inner shaft Caution
5. Circlip *: Indicates parts which should be temporarily
6. Pin tightened, and then fully tightened with the
7. Spacer vehicle on the ground in the unladen condition.
8. Rubber
 FRONT AXLE – Inner Shaft 26-37
REMOVAL SERVICE POINTS
AA" CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire so that it
does not fall.

AB" INNER SHAFT REMOVAL

Caution
MB990906 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.

MB990211

INSTALLATION SERVICE POINT

AA" INNER SHAFT INSTALLATION
MB990906 Caution
Be careful not to damage the lip of the dust seal and
oil seal.

MB990211
26-38 FRONT AXLE – Inner Shaft

DISASSEMBLY AND REASSEMBLY 26100420020

4
5
2
3
1

Disassembly steps
AA" 1. Inner shaft 4. Housing tube
"CA 2. Bearing "AA 5. Dust seal
"BA 3. Dust cover

DISASSEMBLY SERVICE POINT

AA" BEARING REMOVAL
1. Bend the outside periphery of dust cover inward with
a hammer.

2. After the special tool has been installed as shown, tighten

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

MB990560
 FRONT AXLE – Inner Shaft 26-39
3. Press out the inner shaft from the bearing.

MB990560

REASSEMBLY SERVICE POINTS

"AA DUST SEAL INSTALLATION
Press-fit the new dust seal into the housing tube by using
MB990938
the special tools, until it is flush with the housing tube end
face.
MB990955

"BA DUST COVER INSTALLATION

Using a steel pipe, force a new dust cover onto the inner
shaft.
Steel pipe
Steel pipe mm
Overall length 50
Outside diameter 75
Wall thickness 4

"CA BEARING INSTALLATION

MB990560
26-40 FRONT AXLE – Differential Carrier

DIFFERENTIAL CARRIER 26200210019

REMOVAL AND INSTALLATION

5 7 17 Nm
5
93 Nm
44 Nm 19
16 6
88 Nm
21
49 – 59 Nm
35 Nm
9
3 Sealant:
4 17
3M ATD Part No. 8661 or
equivalent
14 8
93 Nm
18 15
19 88 Nm
88 Nm
49 Nm 59 – 69 Nm 14 1
70 Nm
14 35 Nm
20
13
12 2
11

14
13
98 – 118 Nm 12
10

98 – 118 Nm

Removal steps
1. Drive shaft (Refer to P. 26-26.) 12. Pin
2. Circlip 13. Spacer
3. Inner shaft (Refer to P.26-36.) 14. Rubber
4. Circlip 15. Differential mounting bracket (L.H.)
"CA 5. Vacuum hose connection 16. Differential mounting bracket (R.H.)
6. Pin 17. Freewheel engage switch
7. Actuator assembly 18. Housing tube
AA" "BA 8. Front propeller shaft connection 19. Freewheel clutch assembly
9. Freewheel engage switch connector 20. Differential support bracket
10. Front suspension crossmember "AA D Clutch gear bearing axial play
11. Differential mount insulator assem- inspection.
bly 21. Front differential carrier assembly
D Support the differential by a
transmission jack.
 FRONT AXLE – Differential Carrier 26-41
REMOVAL SERVICE POINT
Mating marks
AA" FRONT PROPELLER SHAFT REMOVAL
Make the mating marks on the flange yoke and the differential
carrier companion flange and then remove the front propeller
shaft.

INSTALLATION SERVICE POINTS

Spacer
"AA CLUTCH GEAR BEARING AXIAL PLAY
INSPECTION
Check the axial play of the clutch gear bearing by the following
procedure before installing the freewheel clutch assembly.
1. Insert flat washers of the same thickness as the housing
tube (9.0 mm) onto the bolt, and then temporarily install
the freewheel clutch assembly to the front differential.

2. Place a micrometer against the end of the clutch gear

and check the axial play of the clutch gear bearing.
Standard value: 0.05 – 0.30 mm
3. If the play is not within the standard value, disassemble
the bearing and insert a spacer of the appropriate
thickness.
NOTE
The thicknesses of the spacers vary in steps of 0.25
mm.

"BA FRONT PROPELLER SHAFT INSTALLATION

Install the front propeller shaft so that the mating marks of
the flange yoke and the differential carrier companion flange
are aligned.

"CA VACUUM HOSE INSTALLATION

Actuator
Install the vacuum hoses so that they match the identification
colours of the actuator assembly nipple.
Identification
colour (blue)

Identification
colour (yellow)
26-42 FRONT AXLE – Differential Carrier

INSPECTION BEFORE DISASSEMBLY 26200430026

1. Remove the cover and gasket.

MB990909 and
MB991116
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.

DRIVE GEAR BACKLASH

1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 – 0.16 mm
2. If the backlash is not within the standard value, insert
side bearing adjustment spacers, and then inspect the
drive gear tooth contact.

DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.

Attachment DIFFERENTIAL GEAR BACKLASH

Wedge 1. While locking the side gear with the wedge, measure
the differential gear backlash with a dial indicator on the
pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear Repeat the same procedure for both pinion gears.
thrust spacer
Side gear
thrust spacer
FRONT AXLE – Differential Carrier 26-43
2. If the backlash exceeds the limit, adjust by using the
side gear thrust spacers.
3. If adjustment is impossible, replace the side gear and
pinion gear as a set.

DRIVE GEAR TOOTH CONTACT

Check the tooth contact of 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 (approximate 250 –
300 Ncm) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
26-44 FRONT AXLE – Differential Carrier

Standard tooth contact pattern Problem Solution

1 Narrow tooth side Tooth contact pattern resulting from

2 Drive-side tooth surface (the side excessive pinion height
applying power during forward
movement)
3 Wide tooth side
4 Coast-side tooth surface (the 1
side applying power during re- 1
verse movement)

2 4
2 4
3 3

Increase the thickness of the drive

The drive pinion is positioned too far
pinion rear shim, and position the
from the centre of the drive gear.
drive pinion closer to the centre of the
1 drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.
2 4
Tooth contact pattern resulting from
3 insufficient pinion height.

1 1

2 4 2 4
3 3
Decrease the thickness of the drive
The drive pinion is positioned too
pinion rear shim, and position the
close to the centre of the drive gear.
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.

NOTE
Checking the tooth contact pattern is the way to If, even after adjustments have been made, the
confirm that the adjustments of the pinion height correct tooth contact pattern cannot be obtained,
and backlash have been done properly. Continue it means that the drive gear and the drive pinion
to adjust the pinion height and backlash until the have become worn beyond the allowable limit.
tooth contact pattern resembles the standard Replace the gear set.
pattern.
 FRONT AXLE – Differential Carrier 26-45
DISASSEMBLY 26200230039

17 2 16 15
28 29 26 25 24 23
27 21 22
18 19 20

4
5 6
14
7 13 28
12
9
8
11 10
1 3 11
30 12
13 6
31 5
4

Disassembly steps
D Inspection before disassembly 18. Drive pinion
(Refer to P. 26-42.) 19. Drive pinion front shim (for pinion
1. Cover height adjustment)
2. Bearing cap AG" 20. Drive pinion front bearing inner
AA" 3. Differential case assembly race
4. Side bearing spacer 21. Drive pinion spacer
5. Side bearing outer race 22. Drive pinion rear shim (for turning
AB" 6. Side bearing inner race torque adjustment)
AC" 7. Drive gear 23. Companion flange
AD" 8. Lock pin 24. Oil seal
9. Pinion shaft 25. Drive pinion rear bearing inner race
10. Pinion gear AH" 26. Drive pinion rear bearing outer
11. Pinion washer race
12. Side gear AI" 27. Drive pinion front bearing outer
13. Side gear spacer race
14. Differential case 28. Oil seal
AE" 15. Self-locking nut 29. Gear carrier
16. Washer 30. Plug cover
AF" 17. Drive pinion assembly 31. Vent plug
26-46 FRONT AXLE – Differential Carrier

DISASSEMBLY SERVICE POINTS

AA" DIFFERENTIAL CASE ASSEMBLY REMOVAL
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.

MB990810
AB" SIDE BEARING INNER RACE REMOVAL
NOTE
There are two notches provided (at the differential case side)
for the claw part of the special tool; use the special tool at
MB990811
that position.

AC" DRIVE GEAR REMOVAL

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.
Mating marks

AD" LOCK PIN REMOVAL

Punch

AE" SELF-LOCKING NUT REMOVAL

MB990850
 FRONT AXLE – Differential Carrier 26-47
AF" DRIVE PINION ASSEMBLY REMOVAL
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
Mating marks spacer and drive pinion shims.

MB990339
AG" DRIVE PINION FRONT BEARING INNER RACE
REMOVAL

MB990648

MB990939 AH" DRIVE PINION REAR BEARING OUTER RACE

REMOVAL

AI" DRIVE PINION FRONT BEARING OUTER RACE

MB990939 REMOVAL
26-48 FRONT AXLE – Differential Carrier

REASSEMBLY 26200250035

14 3 30 15 16 17
4 6 10 11
78 – 88 Nm
8 9 5 13 12
7

186 Nm

28
27 26
18 4
25 19 54 – 64 Nm
20
23 24
21 22
31 21 20
2 29
19
49 Nm 1 26 27
28

22 21 25
19 Nm
20 19

18 19
7 17
21 22

Differential gear set Final drive gear set

Reassembly steps
1. Vent plug 14. Drive pinion assembly
2. Plug cover 15. Companion flange
3. Gear carrier 16. Washer
"AA 4. Oil seal 17. Self-locking nut
"BA 5. Drive pinion front bearing outer 18. Differential case
race 19. Side gear spacer
"CA 6. Drive pinion rear bearing outer 20. Side gear
race 21. Pinion washer
"DA D Pinion height adjustment 22. Pinion gear
7. Drive pinion "FA D Differential gear backlash adjustment
8. Drive pinion front shim (for pinion 23. Pinion shaft
height adjustment) "GA 24. Lock pin
9. Drive pinion front bearing inner "HA 25. Drive gear
race "IA 26. Side bearing inner race
"EA D Drive pinion turning torque adjustment 27. Side bearing outer race
10. Drive pinion rear bearing inner race 28. Side bearing adjusting spacer
11. Oil seal "JA D Drive gear backlash adjustment
12. Drive pinion rear shim (for turning 29. Differential case assembly
torque adjustment) 30. Bearing cap
13. Drive pinion spacer 31. Cover
 FRONT AXLE – Differential Carrier 26-49
Lubrication, Sealing and Adhesive Points

Adhesive:
3M Stud Locking 4170 or equivalent

Sealant: Sealant:
3M ATD Part No. 8661 or equivalent 3M ATD Part No. 8661 or equivalent
26-50 FRONT AXLE – Differential Carrier

REASSEMBLY SERVICE POINTS

"AA OIL SEAL INSTALLATION
MB990938

MB990934

Oil seal

"BA DRIVE PINION FRONT BEARING OUTER RACE

INSTALLATION
MB990938

MB990936

"CA DRIVE PINION REAR BEARING OUTER RACE

MB990938 INSTALLATION
MB990933

"DA PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
tool.
2. Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.
MB990903
Washer

3. Tighten the nut of the special tool while measuring the

MB990903 rotation torque of the drive pinion. Gradually keep
tightening the nut of the special tool until the rotation
torque of the drive pinion (without oil seal) is at the standard
value.
 FRONT AXLE – Differential Carrier 26-51
Standard value:
MB990685 Bearing division Bearing lubrication Rotation torque
MB990326 New None (With 0.5 – 0.7 Nm
anti-rust agent)
New or reusing Gear oil applied 0.3 – 0.4 Nm
NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to
run in the bearing, and then measure the rotation torque.
4. Clean the side bearing hub.

Notch MB991170 5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
NOTE
Always check that the notch is in the shown position
A
and that the special tools are touching firmly against the
side bearing hub.
6. Use a thickness gauge to measure the clearance (A)
between the special tools.

Thickness gauge MB990904

7. Remove the special tools (MB991170, MB990904).

8. Use a micrometer to measure the special tool in the places
C (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C–1/2D–91.0
26-52 FRONT AXLE – Differential Carrier

11. Fit 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.

MB990802

"EA DRIVE PINION TURNING TORQUE ADJUSTMENT

Adjust the drive pinion rotation torque by using the following
procedure:
Without Oil Seal
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion 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
186 Nm using the special tool.

MB990850

3. Measure the drive pinion rotation torque (without the oil

MB990326
MB990685 seal) by using the special tools.
Standard value:
Bearing division Bearing lubrication Rotation torque
New None (With 0.3 – 0.5 Nm
anti-rust agent)
New/reusing Gear oil applied 0.15 – 0.25 Nm

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
Identification by selecting the drive pinion spacers. Also, select the
colour drive pinion spacer from the following two types.
 FRONT AXLE – Differential Carrier 26-53
Drive pinion spacer Identification colour
height (mm)
46.67 White
47.01 –

5. Remove the companion flange and drive pinion again.

Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990031 the oil seal.
or
MB990699

6. Install the drive pinion assembly and companion flange

with mating marks properly aligned, and tighten the
186 Nm companion flange self-locking nut to the specified torque
MB990850 by using the special tools.

7. Measure the drive pinion rotation torque (with the oil seal)
MB990685 MB990326
by using the special tools.
Standard value:
Bearing division Bearing lubrication Rotation torque
New None (With 0.5 – 0.7 Nm
anti-rust agent)
New/reusing Gear oil applied 0.3 – 0.4 Nm
8. If the drive pinion rotation torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal.
26-54 FRONT AXLE – Differential Carrier

"FA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT

1. Assemble the side gears, side gear 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.

Attachment
3. Insert a wedge between the side gear and the pinion
Wedge shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear
thrust spacer 5. If the differential gear backlash exceeds the limit, adjust
Side gear the backlash by installing thicker side gear spacers.
thrust spacer

6. If adjustment is not possible, replace the side gears and

pinion gears as a set.
7. Measure the differential gear backlash once again, and
confirm that it is within the limit.

"GA LOCK PIN INSTALLATION

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.

"HA DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning the special tool (tap M10
x 1.25), and then clean the threaded holes by applying
compressed air.

MB990813
 FRONT AXLE – Differential Carrier 26-55
3. Apply the specified adhesive to the threaded holes of
the drive gear.
Specified adhesive:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.

"IA SIDE BEARING INNER RACE INSTALLATION

Metal
Metal

MB990802
MB990802

"JA DRIVE GEAR BACKLASH ADJUSTMENT

Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE
Select side bearing spacers with the same 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 thickness gauge.

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, and then install one pair each to the drive
pinion side and the drive gear side.

Clearance/2 + 0.05 mm
= Thickness of the spacer on one
side
26-56 FRONT AXLE – Differential Carrier

4. Install the side bearing adjusting spacers and differential

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

5. Tap the side bearing adjusting spacers with the special

tool to fit them to the side bearing outer race.

MB990939

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 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.
Standard value: 0.11 – 0.16 mm

If backlash is too small 8. Change the side bearing adjusting spacers as illustrated,
Thinner
and then adjust the drive gear backlash between the
Thicker
spacer spacer 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.
Thicker Thinner 9. Check the drive gear and drive pinion for tooth contact.
spacer spacer If poor contact is evident, make adjustment. (Refer to
If backlash is too large P. 26-43.)
FRONT AXLE – Differential Carrier 26-57
10. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
11. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12. If adjustment is not possible, replace the differential case
or replace the drive gear and drive pinion as a set.
26-58 FRONT AXLE – Freewheel Clutch

FREEWHEEL CLUTCH 26200270017

REMOVAL AND INSTALLATION

5 7 17 Nm 5

93 Nm
6 3
2

88 Nm
35 Nm
1
4

10
11
12

10
13
88 Nm
9

Freewheel clutch removal steps

1. Inner shaft (Refer to P. 26-36.) 8. Pin
2. Circlip 9. Spacer
3. Freewheel engage switch connector 10. Rubber
4. Freewheel engage switch 11. Differential mounting bracket (R.H.)
"EA 5. Vacuum hose 12. Housing tube assembly
6. Pin 13. Freewheel clutch assembly
7. Actuator assembly "DA D Clutch gear bearing axial play
D Support the differential by a inspection.
transmission jack.
 FRONT AXLE – Freewheel Clutch 26-59

19

14
14
20
15 20

18
9 Nm
23 16

17
22

12 Nm

21 9 Nm

Solenoid valve assembly removal steps

14. Solenoid valve connector 17. Vacuum tank bracket
"CA 15. Solenoid valve assembly "BA 18. Check valve
Vacuum tank and vacuum hose 19. Vacuum pipe
assembly and vacuum pipe 20. Vacuum hose
assembly removal steps "AA 21. Vacuum hose
"AA 22. Vacuum pipe assembly
16. Vacuum tank "AA 23. Vacuum hose assembly

INSTALLATION SERVICE POINTS

Actuator
"AA VACUUM HOSE ASSEMBLY/VACUUM PIPE
ASSEMBLY/VACUUM HOSE INSTALLATION
Identification Install the vacuum hoses so that the identification colours
colour (Blue) of the vacuum pipe assembly match those of the actuators.
Note that there is no identification colour for the vacuum
hose which is to be connected to the vacuum tank.
Identification
colour (Yellow)
26-60 FRONT AXLE – Freewheel Clutch

"BA CHECK VALVE INSTALLATION

Install so that air direction arrow points to the vacuum side.

Vacuum side Solenoid

valve side

Air direction arrow

Identification
"CA SOLENOID VALVE ASSEMBLY INSTALLATION
colour (blue) Install so that the identification colours of the vacuum hoses
match those of the solenoid valve assembly.
Nipple

Identification
colour (yellow)

"DA CLUTCH GEAR BEARING AXIAL PLAY

INSPECTION
Spacer Check the axial play of the clutch gear bearing by the following
procedure before installing the freewheel clutch assembly.
1. Insert flat washers of the same thickness as the housing
tube (9.0 mm) onto the bolt, and then provisionally install
the freewheel clutch assembly to the front differential.
2. Place a micrometer against the end of the clutch gear
and check the axial play of the clutch gear bearing.
Standard value: 0.05 – 0.30 mm
3. If the axial play of the clutch gear bearing is not within
the standard value, disassemble the bearing and insert
a spacer of the appropriate thickness.
NOTE
The thickness of the spacers vary in steps of 0.25 mm.

"EA VACUUM HOSE INSTALLATION

Actuator
Connect the vacuum hoses so that the identification colours
match those of the actuator assembly nipples.
Identification
colour (blue)

Identification
colour (yellow)
 FRONT AXLE – Freewheel Clutch 26-61
INSPECTION 26200280010

FREEWHEEL ENGAGE SWITCH

Shaft (switch) Terminal No. 1 Terminal No. 2

position
Shaft
Pressed (ON)
OFF ON
Released (OFF)

Contact Pole

DISASSEMBLY AND REASSEMBLY 26200290044

12
5 10
9
8
6

12 7
11 2
10 3
4
1 9
13

Removal steps
AA" 1. Main shaft 8. Shift rod
"FA 2. Spacer "CA 9. Oil seal
AA" "EA 3. Bearing AB" "BA 10. Clutch gear
4. Clutch sleeve AB" "BA 11. Bearing
"DA 5. Spring pin "AA 12. Oil seal
6. Snap ring 13. Clutch housing
7. Shift fork

A
DISASSEMBLY SERVICE POINTS
MB990560 AA" MAINSHAFT/BEARING REMOVAL
1. After the special tool has been installed as shown, tighten
the nut of the special tool until the portion “A” of the
special tool touches the bearing outer race.
26-62 FRONT AXLE – Freewheel Clutch

2. Press out the mainshaft from the bearing.

Caution
MB990560 Do not allow the mainshaft to drop.

AB" CLUTCH GEAR/BEARING REMOVAL

1. Use a press and steel plate to remove the clutch gear
Iron and bearing together.

2. Use a press to hold the supports against the bearing

inner race, and separate the clutch gear and bearing.

REASSEMBLY SERVICE POINTS

MB991168
"AA OIL SEAL INSTALLATION
Use the special tool to tap the oil seal until it is flush with
the clutch housing.

"BA BEARING /CLUTCH GEAR INSTALLATION

1. Use the special tool to press-fit the bearing to the shoulder
MB990799 of the clutch gear.
 FRONT AXLE – Freewheel Clutch 26-63
2. Use the special tool to press-fit the bearing to the side
MB990890 of the clutch housing.
or
MB990891 Caution
Place the special tool against the outer race of the
bearing.

"CA OIL SEAL INSTALLATION

MB990938

MB990926

"DA SPRING PIN INSTALLATION

Tap the spring pin from the chamfered side of the shift rod
until the projection length becomes length shown in the
illustration.
Spring pin

1 – 2 mm Chamfer

"EA BEARING INSTALLATION

Press-fit the bearing to the shoulder of the mainshaft.

"FA SPACER INSTALLATION

1. After installing the freewheel clutch assembly, select a
Spacer spacer so that the clutch gear axial play (bearing
looseness) is within the standard value.
Standard value: 0.05 – 0.30 mm
2. If it is outside the standard value, disassemble and select
the appropriate spacer again.
NOTE
The thickness of the gauge is different 0.25 mm each.
NOTES