GROUP 26 FRONT AXLE

SPECIFICATIONS ............................................................................. 26-2

STRUCTURE AND OPERATION

1. Wheel Hub and Brake Drum ........................................................ 26-2
2. Front Axle, Knuckle and Kingpin ................................................. 26-3

TROUBLESHOOTING ...................................................................... 26-4

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Inspection and Adjustment of Wheel Alignment ......................... 26-6
2. Inspection and Adjustment of Steering Angle ............................. 26-9
3. Inspection of Side Slip .............................................................. 26-10
4. Adjustment of Side Slip and Axle Slip <FS> .................................. 26-11
5. Inspection of Tie Rod End Ball Joint ............................................. 26-13
6. Inspection of Wheel Bearing for Play ............................................. 26-14
7. Inspection of Knuckle Joint for Play .............................................. 26-14

WHEEL HUB AND BRAKE DRUM ................................................. 26-16

FRONT AXLE, KNUCKLE AND KINGPIN ..................................... 26-28

TIE ROD .......................................................................................... 26-36

26-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Specifications
Item FS FS
FP-R, FV
(front 1st axle) (front 2nd axle)
Model F090T F090TR F090T (M)
Front axle
Type Reverse Elliot, “I” beam
Kingpin outer diameter ×
50 × 243
length mm
Tread mm 2045
Mass kg Approx.410

STRUCTURE AND OPERATION

1. Wheel Hub and Brake Drum

26-2
 26
2. Front Axle, Knuckle and Kingpin

26-3
TROUBLESHOOTING
Symptoms

Uneven wear or early wear of front tires

Unable to steer the steering wheel
Continuous noise while cruising
Intermittent noise while cruising

Steering wheel return poor

Steering pulls to one side

Reference Gr

Steering wheel shakes

Steering feels stiff
Possible causes
Wheel alignment misaligned O O O O
Steering angle adjustment faulty O
Wheel hub bearing seized, worn or rotation
O O
faulty
Wheel hub bearing broken O
Kingpin worn O
Clearance between kingpin and bushing ex-
O O
cessive
Greasing to kingpin insufficient O
Kingpin bearing seized, worn or rotation
Wheel hub, knuckle and O
faulty
kingpin, front axle
Vertical clearance between knuckle and
O
front axle excessive
Knuckle arm and tie rod arm tightening nuts
O
loose
Ball stud tightening nut of tie rod end loose O
Tie rod end ball stud worn O
Tie rod bent O
Knuckle bent O
Front axle bent O
Various parts of front axle overtightened O
U-bolt nut of front suspension loose O
Front air spring and radial rod bracket
O
Front suspension mounting nut loose Gr33
One of front springs worn-out or broken O
One of front air spring faulty O
Tire inflation pressure uneven O O
Tire inflation pressure too little O
Inflation pressure uneven for right and left
O
tires
Tire Gr31
Size and type of right and left tires different O O
Outer diameters of right and left tires re-
O
markably different
Handling of tires inadequate O

26-4
 26
M E M O

26-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection and Adjustment of Wheel Alignment
Before performing inspection and adjustment of wheel alignment, set the vehicle to the following condition.
• Park the vehicle unloaded on a level place.
• The vehicle needs to be equipped with proper size tires.
• If the wear condition of tires on the right is remarkably different from that of tires on the left, replace tires.
• Tires need inflation to specified pressure.
• Correct if the vehicle tilts due to faulty suspension.
• Service all parts of the front axle and ensure that there is no fault such as the following.
• Play at or loose kingpin
• Loose front wheel hub
• Loose bolts used for tightening various parts of tie rod arm, knuckle arm and tie rod
• Bend of knuckle and front axle
• Adjust play at steering wheel properly.
• For wheel alignment, which is related to the side slip amount, both wheel alignment and the side slip amount must
conform to the standard values.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Front 1st axle 1 to 3 – Adjust
FS
Toe-in Front 2nd axle 1 to 3 (toe-out) – Adjust
FP-R, FV 1 to 3 – Adjust
–
Camber 1° ± 1° – Replace
Caster 2°08’ – Replace
Kingpin inclination angle 7° ± 30’ – Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Nut (tie rod end tightening) 78 ± 12 {8.0 ± 1.2} Wet

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Chassis grease
– Clamp nut thread of tie rod end As required
[NLGI No. 1 (Li soap)]

1.1 Inspection and adjustment of toe-in

[Inspection]
• Direct the front wheels exactly to forward running position.
• Put a mark on both the right and left tires at the height of the
front wheel axis in the center of the tire width.

• Align the two points of the toe-in gauge with respective marks
and measure distance A between the marks.

26-6
 26
• Push the vehicle to roll the tires 180 degrees.
• Measure distance B between the marks that have moved to the
rear of the vehicle.
• If toe-in (difference between A and B) deviates from the stan-
dard value, adjust.

[Adjustment]
• Loosen the right and left nuts of tie rod.
• Turn the tie rod with a pipe wrench to adjust the toe-in.
C: When adjusting to the toe-out direction
D: When adjusting to the toe-in direction
• After adjustment, tighten the nut to the specified torque.

• Hold down the tie rod toward the front or rear of the vehicle with
the front wheels directed to forward running position so that the
right and left tie rod ends are in contact with the ball studs at the
same time.
• In this state adjust the toe-in and tighten the clamp nut to secure
the tie rod end.

• After adjustment, turn the steering wheel to the extreme left (the
state in which the knuckle stopper bolt is contacted), and move
the tie rod in the longitudinal direction of the vehicle by hand to
make sure that the tie rod moves.
Do the same for right steering.
(If the tie rod swings, the tie rod ends should be in contact with
the ball studs at the same time.)
WARNING
• When turning the steering wheel to the left and right, be
careful not allow your hand to be pinched because the tie
rod moves.

26-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
• If the tie rod does not swing, repeat the work from the item
marked with .

1.2 Inspection of camber

• Direct the front wheels exactly to forward running position.
• Remove the wheel hub cap.
• Wipe off grease from the knuckle end, and bring the camber/
caster/kingpin gauge into intimate contact with the front wheel
hub.
• Place the level so that the bubble remains in the middle, and
read center of bubbles on camber scale in this state to find the
camber. Do the same for the right and left front tires.
• If the measured value deviates from the standard value, abnor-
malities such as wear of kingpin and bushing, loose hub bearing,
and bend of knuckle and front axle are suspected. Inspect each
part and replace defective parts.

1.3 Inspection of caster and kingpin inclination angle

• Prepare a platform with the same height as the turning radius
gauge and place it under the rear wheels so that the vehicle may
be placed level.
• Apply chocks to the rear wheels.
WARNING
• Do not remove chocks until the entire operation is complet-
ed.

• Keep the turning radius gauge locked.

• Jack up the vehicle and set the right and left front wheels so that
respective ground contact area centers of the two wheels and
turn table centers may meet.
• Unfasten locking of the turning radius gauge, and set the scale
to 0 degrees.
• As with the camber measurement in Section 1.2, attach the
camber/caster/kingpin gauge and set the level so that the bub-
ble remains in the middle.

• Apply brake pedal, and with brake applied to the front wheels,
turn steering wheel slowly from the point of 0 degrees on the
turning radius gauge until the direction is changed by 20 de-
grees to the right side in the case of the right front wheel and to
20 degrees to the case of the left front wheel.
NOTE
• It is not possible to make exact measurements unless the
brake remains applied, otherwise the wheels will turn slight-
ly.

26-8
 26
• After setting the steering at 20 degrees, set the caster scale and
the center of the bubble of the kingpin scale to 0 degrees by
turning the adjuster.
NOTE
• Pay attention to the kingpin scale because it has scales for
right and left: align the right kingpin scale in the case of the
right front wheel, and left kingpin scale in the case of the
left front wheel.

• Reverse this position, turn the steering wheel slowly until the di-
rection of the front wheels changes by 20 degrees in the oppo-
site direction.
• Read the center of the bubbles at this position of the caster
scale and kingpin scale to find caster and kingpin inclination an-
gles.
• If the measured value deviates from the standard value, abnor-
malities such as wear of kingpin and bushing, loose hub bearing,
and bend of knuckle and front axle are suspected. Inspect each
part and replace defective parts.

2. Inspection and Adjustment of Steering Angle

• Perform steering angle inspection and adjustment only after wheel alignment inspection and adjustment has been
completed.

Service standards
Location Maintenance item Standard value Limit Remedy
0°
Inside Front 1st axle 45° –2° (37° 22’)
(outside steer- FS 0°
– Steering angle Front 2nd axle 28° –2° (23° 31’) – Adjust
ing angle is for
0°
reference only) FP-R, FV 49° –2° (39° 42’)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Lock nut (knuckle stopper bolt tightening) 71 ± 12 {7.3 ± 1.3} –

• Set the turning radius gauge and a platform on the vehicle in the
same manner as in the case of the caster and kingpin inclination
angle measurement performed in Section 1.3.
• Turn the steering wheel right or left completely from the position
where the turning radius gauge is set to 0 degrees, and read the
scale of the turning radius gauge to measure the steering angle.
• If the measured value deviates from the standard value, adjust
with the knuckle stopper bolt and tighten the lock nut to the
specified torque.

26-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Inspection of Side Slip
• Perform side slip inspection only after wheel alignment inspection and adjustment has been completed.
• For the side slip amount, which is related to wheel alignment, both the side slip amount and wheel alignment must
conform to the standard values.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Side slip amount (per 1 m) 3 or less – Adjust

• Set the front wheels exactly to forward running position.

• Move the vehicle forward past the side slip tester as slowly as
possible to inspect side slip.
NOTE
• Pay attention to the following when moving over the side
slip tester.
• Be sure to hold steering exactly at the forward running
position, and make no turn.
• Do not apply brake.
• Keep the speed constant.

• If the measured value deviates from the standard value, inspect

and adjust wheel alignment.

26-10
 26
4. Adjustment of Side Slip and Axle Slip <FS>
• Measure the axle slip after adjustment of wheel alignment is completed.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Axle slip amount (per 1 m) 3 or less – Adjust

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Nut (connecting link end tightening) 55 ± 9 {5.6 ± 0.9} –

<Side slip inspection using side slip tester>

• The tires installed are tubeless radial tires having low flat ratio. This type of tires is greatly different in characteris-
tics from the conventional type. It does not allow the axle slip to be measured by the conventional method which
involves a vehicle simply passing over a side slip tester.
To take accurate axle slip measurements on a vehicle having tires of this type, it is necessary to have the vehicle
go and back over the side slip tester one time so that the strain accumulated in the tires may be released.

[Inspection]
• Place the front wheels exactly in the straight ahead position.
• While maintaining the straight ahead position, drive forward as
slowly as possible to pass over side slip tester. Stop the vehicle
immediately after the front 1st wheels have rolled to a position
just beyond the board of the side slip tester.
• Drive backward as slowly as possible to have the vehicle pass
over side slip tester again. Stop the vehicle immediately after the
front 1st wheels have no longer ridden on the board of the side
slip tester.
• Drive forward as slowly as possible across side slip tester. Mea-
sure the slip amounts of the right and left wheels using the tester
at this time. The average of these measurements is the axle slip
for the front 1st axle.
• Measure the side slip of the rear axle of the tandem front axle by
repeating the steps starting with one with the mark.
• The side slip of the front and rear axles of the tandem front axle
can be obtained using the following formula.
FfL + FfR – FrL + FrR
2 2
FfL: Side slip of the LH wheel of the front axle of the tandem
front axle
FfR: Side slip of the RH wheel of the front axle of the tandem
front axle
FrL: Side slip of the LH wheel of the rear axle of tandem
front axle
FrR: Side slip of the RH wheel of the rear axle of tandem
front axle
• If the axle side slip deviates from the standard value, adjust as
follows.

26-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
[Adjustment]
• Loosen clamping nuts at the connecting link end, then turn the
connecting link gently. Before turning connecting link, put align-
ment marking as a reference for adjustment.
• After adjustment is completed, tighten clamping nuts at the con-
necting link end.

<Side slip inspection without using side slip tester>

• Hold gauge against the tire side walls as shown to check for
alignment of four front wheels.

• Measure the gauge-to-side wall distance at portions A to D and

adjust the dimensions using connecting link so that the following
relationship can be achieved:
A=B
C=D

• Loosen clamping nuts at the connecting link end, then turn the
connecting link gently. Before turning connecting link, put align-
ment marking as a reference for adjustment.
• After adjustment is completed, tighten clamping nuts at the con-
necting link end.

26-12
 26
5. Inspection of Tie Rod End Ball Joint

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Play in tie rod end ball joint (displacement) 0 to 0.4 0.8 Replace

• With the engine shut down, raise the front axle with a jack until
both front wheels are clear of the ground.

5.1 Play
• Install a knuckle stopper bolt on the front side of the left wheel.
• Adjust the knuckle stopper bolt such that it touches the front axle
before the knuckle stopper bolt on the right wheel does.

• Set the dial indicator on the tie rod as shown in the illustration.
• Apply the dial indicator’s probe in line with the axis of the ball
joint.
• Zero-adjust the dial indicator in the following method.
• Lightly turn the steering wheel to the right from the point where
the knuckle stopper bolt comes in contact with the front axle and
then release the steering wheel. Repeat this operation a few
times and check that the dial indicator reading returns to zero
each time the steering wheel is released.
CAUTION
• Release the steering wheel slowly.

• After completing zero adjustment, turn the steering wheel to the

right by 36 degrees (or through 6 bosses on the inner periphery
of the steering wheel) and read the resulting displacement on
the dial indicator.
• If the measurement value exceeds the limit, replace the tie rod
end. If the measurement value is more than the standard value
and less than the limit, remove the tie rod and inspect it.
(See “TIE ROD”.)
• Perform the above measurement for the left and right ends of
the tie rod (2 places in total).
• After necessary adjustment, remove the knuckle stopper bolt
from the front side of the left wheel.

5.2 Dust cover

• Check that there are no wear, cracks or damage. These abnor-
malities can cause water to enter the ball joint, resulting in pre-
mature wear.
• If wear, crack, or damage is present, inspect traces of water en-
try and occurrence of rust in the ball joint. If any abnormality is
found, replace the tie rod end. If no abnormality is found, replace
the dust cover and reapply grease. (See “TIE ROD”.)

26-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
6. Inspection of Wheel Bearing for Play
• Jack up the vehicle.
• Try to move the top and bottom of the front tire by hands in the il-
lustrated directions to inspect the wheel bearing for play.
• If play is found with the feel of hands, repeat the inspection pro-
cedure while having the brake pedal pressed by another person-
nel. When the play is removed by operating the brake pedal, the
symptom indicates that there is play in the wheel bearing, not in
the suspension or other related parts. Then inspect the turning
torque of the wheel bearing and adjust it as required. (See
“WHEEL HUB AND BRAKE DRUM”.)
• If the turning torque of the wheel bearing cannot be adjusted
correctly or the play still remains after the adjustment, replace
the wheel bearing with a new one. (See “WHEEL HUB AND
BRAKE DRUM”.)

7. Inspection of Knuckle Joint for Play

• Jack up the vehicle.
• Try to move the top and bottom of the front tire by hands in the il-
lustrated directions to inspect the knuckle joint for play.
• If play is found with the feel of hands, repeat the inspection pro-
cedure while having the brake pedal pressed by another person-
nel. If there is any play, it may be caused by the play in the
knuckle joint. Check each part and replace a defective part. (See
“KNUCKLE AND KING PIN, FRONT AXLE”.)

26-14
 26
M E M O

26-15
WHEEL HUB AND BRAKE DRUM

Disassembly sequence
1 Brake hose (for service brake) 8 Outer bearing inner race 15 Front drum brake (See Gr35.)
2 Brake hose (for breather) 9 Oil seal 16 Inner bearing inner race
3 Wheel hub cover 10 Inner bearing outer race
4
5
Gasket
Lock plate
11
12
Outer bearing outer race
Brake drum (See Gr35.)
*a:: Knuckle
Locating pin
6 Lock nut 13 Hub bolt : Non-reusable parts
7 Lock washer 14 Wheel hub

• Plug the brake hose to prevent entry of dust and dirt after it has been removed.

Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Make sure that the brake lining surface and inner surface of the brake drum of the wheel hub and brake
drum are free from grease to avoid malfunction of brakes.
• Make sure that the brake hose is not twisted when you install it.
• Do not damage the oil seal when mounting the wheel hub and brake drum on the knuckle.

NOTE
• Adjust brake shoe clearance after assembly. (See Gr35.)

26-16
 26
Service standards
Location Maintenance item Standard value Limit Remedy
2.5 to 5.5 N·m
{0.25 to 0.55 kgf·m}
Starting torque of wheel hub bearing (tangential force at
– (tangential force: – Adjust or replace
hub bolt position with oil seal assembled)
15 to 32 N {1.5 to 3.3
kgf})

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (front drum brake mounting) 216 ± 32 {22 ± 3.3} –
Nut (front drum brake mounting) 515 ± 123 {52.5 ± 12.5} –
Brake hose (for service brake) tightening (frame side) 41.7 ± 2.5 {4.25 ± 0.25}
–
Brake hose (for breather) tightening (frame side) 31.9 ± 2.5 {3.25 ± 0.25}
Bolt (wheel hub cover mounting) 23 ± 4 {2.35 ± 0.45} –
Bolt (lock plate mounting) 9 ± 2 {0.9 ± 0.2} –
Back-off angle 22.5°
Lock nut 200 {20}
(1/16 of a turn)
Nut (brake drum and wheel hub mounting) 422 {43} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Pack space between rollers of bearing inner race
As required
Lip area of oil seal
Wheel hub body 570 g *1
Pack inside of wheel hub Total
Wheel bearing grease
Around outer bearing 90 g *2 660 ±
[NLGI No. 2 (Li soap)]
20 g *1
Spindle of knuckle 90 g *2
Pack outside of wheel hub 150 ± 10 g *1
Nut thread As required
*1: For a wheel
*2: For a wheel, either outer bearing neighborhood or knuckle spindle part

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Socket wrench

A
MH061530 Removal and installation of lock nut
75

Wheel hub puller

MH061433 or Removal of wheel hub and brake
A B MH061458 drum
φ130 φ120

26-17
WHEEL HUB AND BRAKE DRUM
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Inner bearing
installer
03723-22000 Installation of inner bearing outer race
A B C
φ138 φ125 φ120

Outer bearing
installer

A B C Installation of outer bearing outer

03723-23000
φ108 φ98 φ92.5 race

Removal of inner bearing inner race

Gear puller MH061102
and oil seal retainer

Inner bearing installer

Installation of inner bearing inner race
A B C MH061473
and oil seal retainer
φ76.2 φ67 186

Removal procedure
Removal: Brake hose
• When removing the brake hose, remove it from the frame side
first, and then from the wheel brake side.

Removal: Lock nut

26-18
 26
Removal: Wheel hub and brake drum
• If the brake drum has stepped wear and the wear prevents the
wheel hub and brake drum from being removed, the removal
can still be effected by taking the following procedure. After re-
moval, repair or replace brake drum.

• Remove the dust cover.

• Turn the adjusting screw of the expander using a flat-blade
screwdriver or other similar tool in the direction of the arrow to
increase the clearance between the brake drum and shoe.
Then, remove the wheel hub and brake drum.
CAUTION
• When inserting a flat-blade screwdriver, be careful not to
damage the expander boot.

Removal: Inner bearing outer race

• Drive out the inner bearing outer race by tapping evenly at notch
in the wheel hub.

Removal: Outer bearing outer race

• Drive out the outer bearing outer race by tapping evenly at notch
in the wheel hub.

Removal: Inner bearing inner race

• Insert two bolts (M14 × 1.5 mm) into the knuckle stopper bolt or
screw plug mounting hole of the knuckle evenly to push out the
inner bearing inner race.

26-19
WHEEL HUB AND BRAKE DRUM
• Hook the tab of to the clearance between the knuckle and
inner bearing race to remove.

Inspection procedure
Inspection: Outer bearing inner race
• Inspect the outer bearing inner race after cleaning the bearing to
remove grease completely.
• If any damage, wear, or poor rotating condition is evident in the
inner race, replace it with a new one.
• The inner race and the outer race should be replaced as a set.

26-20
 26
Inspection: Wheel hub
(1) Visual inspection
• Check the disc wheel mounting surface of the wheel hub by
watching and touching. If there is damage or crack on it, replace
the wheel hub.
• Make sure that there is not rust, dust, paint or foreign body on
the disc wheel mounting surface of the wheel hub to prevent the
wheel nut to loosen.
• If any abnormality is found, remove it with sandpaper.
(2) Wear in disc wheel mounting part of wheel hub
• Clean the wheel mounting surface of the wheel hub before in-
spection.
• Place a straightedge on the hub so as to contact to the two hub
bolts on the disc wheel mounting surface.
CAUTION
• Make sure that the straightedge does not run onto the hub
bolt.

• Using feeler gauges to measure the amount of wear at the outer

periphery of the wheel hub.
Measure the amount of wear in the area of every hub bolt.
• If the amount of wear at any point exceeds the following stan-
dard value, inspect the crack check of wheel hub.
Wear standard value: 0.8 mm
(3) Crack check
• Check if there is not crack on the entire rounded corner on the
root of flange of the wheel hub by magnetic particle or liquid pen-
etrant testing. If crack is found, replace the wheel hub.
• If crack is found on the wheel hub bolt, replace it.
• If there is crack or stepped wear on the wheel hub mounting sur-
face of wheel disc, replace it. (See Gr31.)

Inspection: Inner bearing inner race

• Inspect the inner bearing inner race in the same manner as for
the outer bearing inner race.
(See “ Inspection: Outer bearing inner race”.)

Inspection: Knuckle
• To ensure accurate starting torque adjustment, if the lock nut
mating screw thread (A) of the knuckle spindle is damaged, be
sure to repair the damaged screw thread using an appropriate
thread cutting die.
• If abnormal wear (stepped, slanting or irregular) or damage is
evident in the bearing fitting area (B), replace the knuckle.

26-21
WHEEL HUB AND BRAKE DRUM
Installation procedure
Installation: Packing of grease in inner bearing inner race
• Insert the grease pump nozzle into the space between rollers of
the outer and inner bearing inner race to pack grease sufficient-
ly.

Installation: Inner bearing inner race

• Using press-fit inner bearing inner race.

Installation: Hub bolts

• As for hub bolt, tighten nut at specified torque, and caulk at 4 po-
sitions for prevention of loosening.

Installation: Outer bearing outer race

Installation: Inner bearing outer race

26-22
 26
Installation: Packing of grease to inside of wheel hub
• Apply grease following Manner 1 or Manner 2 shown below.
CAUTION
• Wheel bearing seized may be caused unless following these
manners.
• Apply the specific amount of grease measured by measure-
ment cup or etc.

<Manner 1>
• As shown in the illustrations at the left, fill grease inside of the
hub body in such a manner that grease covers the outer bearing
and inner bearing outer races. Make sure that grease reaches
the outer bearing and inner bearing.
• After installing the hub onto the knuckle and before installing the
outer bearing inner race, place the pump nozzle into the hub and
fill grease in the neighborhood of the outer bearing.

<Manner 2>
• As shown in the illustrations at the left, fill grease inside of the
hub body in such a manner that grease covers the outer bearing
and inner bearing outer races. Make sure that grease reaches
the outer bearing and inner bearing.
• Before installing the hub onto the knuckle, apply grease to the
knuckle spindle part.

26-23
WHEEL HUB AND BRAKE DRUM
Installation: Packing of grease in outer bearing inner race
• Follow the same procedure as for packing the inner bearing in-
ner race with grease.
(See “ Installation: Packing of grease in inner bearing in-
ner race”.)

Adjustment: Starting torque of wheel hub bearing

CAUTION
• Unless this adjustment procedure is performed, seizure of
the wheel hub bearing can be caused.

[Adjustment]
• Temporarily tighten the lock nut and make sure that the brake
drum and brake shoe do not drag.
• If they drag, make adjustment with the adjuster of the wheel cyl-
inder.
• Gradually tighten the lock nut while turning the wheel hub and
brake drum. Tighten the lock nut so that the specified torque is
achieved when the wheel hub and brake drum are turned three
times or more.
CAUTION
• Do not tighten the lock nut without turning the wheel hub
and brake drum, or tighten it to the specified torque within
three turns. Failure to observe the above will make the in-
stalled condition of the inner bearing faulty, causing poor
rotation and seizure.

• Perform the following work to pull the outer bearing inner race
toward the lock nut side.
• Loosen the lock nut to create clearance between the outer bear-
ing inner race and lock nut.
• Apply a block of wood to the end face of the axle housing, and
tap it twice or three times while turning the wheel hub and brake
drum.

• Tighten the lock nut to the specified torque again, and then back
it off as follows.
22.5° (1/16 turn)

26-24
 26
• Fit lock plate into place check to ensure that all of the mounting
holes in lock nut and the lock plate are in alignment, and tighten
mounting bolts.
• If the mounting holes of lock nut and lock plate are out of align-
ment, align them by the procedures shown in the following table.

Lock nut hole position How to align lock plate hole

Range A Loosen lock nut and align holes.
Range B Turn over lock plate, loosen lock nut and
align holes.
On line C–C Turn over lock plate and align holes.
(Hole position changes from D´ to D.)

• Perform the following work to pull the outer bearing inner race
toward the lock nut side again.
• Apply a block of wood to the end face of the axle housing, and
tap it twice or three times while turning the wheel hub and brake
drum.
• Make sure that there is no looseness in the axial direction.

[Inspection]
• After assembly of the lock nut, fasten a spring balance to hub
bolt and measure tangential force.
• If the tangential force meets the specified value, starting torque
will become the standard value.
• If the measurement deviates from the specified value, repeat the
work from the item marked with , since adjustment of the lock
nut may be insufficient.
• If the result is found to be abnormal, replace outer and inner
bearings.

Installation: Packing of grease in outside of wheel hub

CAUTION
• Unless this packing procedure is performed, seizure of the
wheel hub bearing can be caused.
• For a grease amount, pack the specified amount using a
measuring cup.

• Pack grease up to the lock plate using a grease pump nozzle so

that a wall is formed outside the outer bearing as shown in the il-
lustration.
CAUTION
• Do not pile grease in the wheel hub cap. Otherwise, grease
does not reach the outer bearing, causing poor lubrication
of the bearing.

26-25
WHEEL HUB AND BRAKE DRUM
Installation: Wheel hub cover
CAUTION
• Adhesion of grease to the mounting surface with the wheel
hub causes water entry and grease leakage.

Installation: Brake hose

• To install the brake hose, follow the removal procedure in re-
verse. (See “ Removal: Brake hose”.)
• After installing, make sure that the brake hose does not interfere
in the peripheral parts.
CAUTION
• Make sure that the brake hose is not twisted when you in-
stall it.

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 26
M E M O

26-27
FRONT AXLE, KNUCKLE AND KINGPIN

Disassembly sequence
1 U-bolt 9 Lower cover 17 Screw plug
2 Tie rod (See later section.) 10 Dust seal 18 Knuckle
3 Tie rod arm 11 Kingpin 19 Front axle
4 Knuckle arm 12 Thrust washer
5 Set bolt 13 Thrust bearing
*a: Drag link
6 Grease nipple 14 Oil seal
*b: Front spring
7 Upper cover 15 Bushing : Non-reusable parts
8 O-ring 16 Knuckle stopper bolt

CAUTION
• Do not damage the dust cover of the tie rod when removing the tie rod.
Damaging the dust cover may cause water infiltration and wear-out at the early stage.
• Kingpin may have a blackend surface, but this is due to transcription of the resin of bushing and does not
present any problem.

Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Kingpin kit

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 26
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
10 Outer diameter of kingpin 49.985 to 49.998 49.9 Replace
10, 15 Clearance between kingpin and bushing 0.02 to 0.06 0.3 Replace
10, 19 Clearance between kingpin and front axle 0.002 to 0.04 0.1 Replace
Inner diameter of bushing (after having been pressed
15 50.018 to 50.045 – Replace
into knuckle)
18, 19 Vertical clearance between knuckle and front axle 0 to 0.1 0.2 Adjust
Horizontal bend 0 to 2.5 7
19 Front axle Vertical bend 0 to 3 7 Replace
Kingpin inclination angle 7° ± 30’ –

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (drag link mounting) 353 ± 88 {36 ± 9} –
Nut (U-bolt mounting) 440 to 540 {45 to 55} –
Nut (tie rod mounting) 353 ± 88 {36 ± 9} –
Nut (tie rod arm mounting) 515 ± 123 {52.5 ± 12.5} Wet
Nut (knuckle arm mounting) 466 ± 74 {47.5 ± 7.5} Wet
Nut (set bolt tightening) 29 {3} –
Bolt (upper cover mounting) 41.2 ± 7.8 {4.2 ± 0.8} –
Lower cover 137 ± 29 {14 ± 3} –
Lock nut (knuckle stopper bolt mounting) 71 ± 12 {7.3 ± 1.3} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Nut thread
Outer surface of kingpin and fill through-hole As required
Pack inside of thrust bearing
Wheel bearing grease
Until grease
[NLGI No. 2 (Li soap)]
starts overflow-
Packing from grease nipple
ing from dust
plug
Oil seal lip As required

26-29
FRONT AXLE, KNUCKLE AND KINGPIN
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Set bolt remover MH061688 Removal of set bolt

Kingpin puller
MH061684 Removal of kingpin

A B C
M16 × 1.5 M22 × 1.5 M27 × 1.5

Oil seal installer

A
MH062203 Installation of oil seal
φ50

Kingpin bushing
remover
Removal of oil seal and removal and
A B C MH061792
installation of bushing
φ45 φ50 φ54.5

Removal procedure
Removal: Set bolt

Removal: Kingpin
• Screw into the kingpin threads to remove the kingpin.

26-30
 26
Inspection procedure
Inspection: Outer diameter of kingpin
• Take measurement at a total of four levels on the kingpin: two
levels for the axle fitting portion and one level each for the upper
and lower knuckle fitting portions.
• If the measured value is under the limit, replace the kingpin with
a new one.

Inspection: Clearance between kingpin and bushings

• Using a cylinder gauge, measure the bores of the upper and
lower kingpin bushings. Obtain the kingpin-to-bushing clearance
for each bushing by subtracting the measured kingpin diameter
from the measured bore of the bushing. If the calculated clear-
ance exceeds the limit, replace the kingpin bushings.

Replacement of bushing
[Removal]
• Using , remove the bushing together with the oil seal.

[Installation]
• Install a new bushing into the knuckle bore for the kingpin. En-
sure that the oil hole in the bushing is aligned with that in the
knuckle, and that the bushing is flush with the knuckle at A.

• Apply grease to the oil seal lip. Then, install the oil seal to .

26-31
FRONT AXLE, KNUCKLE AND KINGPIN
• Then install the onto the knuckle in the illustrated direction.
• Insert a rod through the knuckle bore for the kingpin until it is
against .
• Using a hammer, tap the top of the rod until the flange of is
against the knuckle face.
• Ensure that the bushing is flush with the knuckle at B.
• Ensure that the top face of the oil seal is lower than the knuckle
face at C.

Inspection: Thrust bearing

• Check the thrust bearing for integrity including proper rotation.
Replace the bearing if it has cracks or other damage, or rotation
faulty.

Inspection: Front axle

(1) Bend of front axle in the longitudinal direction and vertical
direction
• Put a piece of thread through kingpin holes of the front axle and
hang weights at both ends.
• Use a square to find bend to each of longitudinal and vertical di-
rections.
• If the measured value exceeds the limit, replace the front axle.

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 26
(2) Kingpin inclination angle
• Set the kingpin on the front axle as illustrated to measure the an-
gle.
• If the measured value deviates from the standard value, replace
the front axle.

(3) Clearance between kingpin and axle

• Using a cylinder gauge, measure the front axle bores for king-
pins. Obtain the kingpin-to-axle clearance for each bore by sub-
tracting the measured kingpin diameter from the measured axle
bore. If the calculated clearance exceeds the limit, replace the
front axle or kingpin.

Installation procedure
Inspection: Thrust washer, bearing, knuckle and front axle
[Inspection]
• Provisionally assemble kingpin and bearing, move 2 or 3 times
knuckle to have them fit.
• Measure clearance between front axle upper surface and knuck-
le downside.
• Adjust if the measured value exceeds the limit.

[Adjustment]
• Kinds of adjusting thrust washers
2.9 to 3.6 mm (8 kinds with every 0.1 mm difference)
• Select a thrust washer so as to make clearance as small as pos-
sible.
• After assembly, make sure that the knuckle moves smoothly.

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FRONT AXLE, KNUCKLE AND KINGPIN
Installation: Set bolt
• Install the set bolt so that the taper part of the set bolt is aligned
with the notch of the kingpin.

Work after assembly

Greasing: Grease nipple
• Supply grease through the grease nipple of the upper cover.
• Supply grease until it overflows from the thrust washer and
press portion of the bearing.

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 26
M E M O

26-35
TIE ROD
Disassembly sequence
1 Dust cover
2 Tie rod end
3 Tie rod

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Play
– 0.7
(560 N {57 kgf} loaded)
2 Ball joint of tie rod end Replace
0.5 to 12 N·m
Rotation torque –
{0.05 to 1.2 kgf·m}
Correct or
3 Bend of tie rod – 2
replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (tie rod end tightening) 78 ± 12 {8.0 ± 1.2} Wet

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Lip area of dust cover Molybdenum disulfide grease As required
Pack inside of the dust cover [NLGI No. 2 (Li soap)] 23 to 24 g
Nut thread Chassis grease [NLGI No. 1 (Li soap)] As required

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Dust cover installer

A B C MH062729
φ70 φ55 100

Installation of dust cover

End holder

MH062730

A B C D
φ70 φ61.7 φ35 25

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 26
Inspection procedure
Inspection: Tie rod end
(1) Play
• Fix the tie rod end with a vise.
CAUTION
• Take care not to deform or damage the dust cover when fix-
ing it with a vise.

• If measured value deviates from the standard value with apply-

ing the specified load (pushing) to the ball joint, replace the tie
rod end.

(2) Rotation torque

• Install the tie rod mounting nut on the tie rod end.
• Install the socket, adapter and torque wrench to measure the ro-
tation torque.
• If the measured value deviates from the standard value, replace
the tie rod end.

(3) Dust cover

• Check that there are no wear, cracks or damage. These abnor-
malities can cause water to enter the ball joint, resulting in pre-
mature wear.
• If wear, crack, or damage is present, inspect traces of water en-
try and occurrence of rust in the ball joint. If any abnormality is
found, replace the tie rod end. If no abnormality is found, replace
the dust cover and reapply grease.

Inspection: Bend of tie rod

• Measure the bend of the tie rod at its center.
• Give the tie rod one complete turn and read the dial gauge at
this time. The bend is one half of the reading.
• If the measured value exceeds the limit, correct or replace the
tie rod.

Installation procedure
Installation: Tie rod end
• Install the tie rod end on the tie rod so that the distance between
centers of the ball joints of tie rod ends is to the dimension be-
low, and tighten nuts to the specified torque.

A: 1810.92 mm <FP-R, FS (front 1st axle), FV>

1759.09 mm <FS (front 2nd axle)>

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TIE ROD
Installation: Dust cover
• Seal grease in the inside of the dust cover and apply grease to
the lip area. Pinch the dust cover with and , and install
it using a vise so that the reinforcing collar is brought into inti-
mate contact with the tie rod end.
NOTE
• Install the dust cover so that it is vertical.

26-38