105 Series Overhaul - Suspension and Axle

SA−1
SUSPENSION AND AXLE − TROUBLESHOOTING (Rigid Front Suspension)
TROUBLESHOOTING (Rigid Front Suspension)

SA140−04
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
(w/ Differential locking system):
S Check that the transfer shift lever is shifted to the L4 position.
S When switching differential Free « Lock, the indicator light will blink if the gears of the differen-
tial lock sleeve are not meshed. If this occurs, when the tires are rotated to apply differential
power to the differential, the differential locks and the indicator light lights up.
Symptom Suspect Area See page
1. Tire (Worn or improperly inflated) SA−5
2. Wheel alignment (Incorrect) SA−7
3. Steering linkage (Loosen or worn) −
Wanders/pulls
4. Hub bearing (Loosen or worn) SA−14
5. Suspension parts (Worn out) −
6. Steering gear (Out of adjustment or broken) −
1. Vehicle (Overloaded) −
2. Spring (Weak) SA−119
Bottoming SA−269
3. Shock absorber (Worn out) SA−122
SA−272
2. Stabilizer bar (Bent or broken) SA−148
Sways/pitches SA−297
SA−272
2. Wheel (Out of balance) SA−5
Front wheel shimmy 5. Ball joint (Worn) −
−
1. Tire (Improperly inflated) SA−5
Abnormal tire wear 3. Suspension parts (Worn out) −
SA−272
1. Oil level (Low or wrong grade) SA−57
2. Excessive backlash between pinion and ring gear SA−67
Noise in front differential 3. Ring, pinion or side gears (Worn or chipped) SA−67
4. Pinion shaft bearing (Worn) SA−67
5. Side bearing (Worn) SA−67
1. Oil level (Too high or wrong grade) SA−57
2. Front differential rear oil seal (Worn or damaged) SA−57
Oil leak from front differential 3. Side gear oil seal (Worn or damaged) SA−67
4. Companion flange (Loose or damaged) SA−67
5. Side gear shaft (Damaged) SA−67
1. Oil seal (Worn or damaged) SA−154
Oil leak from rear axle
2. Rear axle housing (Cracked) −
SA−2
SUSPENSION AND AXLE − TROUBLESHOOTING (Rigid Front Suspension)

SA−210
SA−233
3. Ring, pinion or side gears (Worn or chipped) SA−187
Noise in rear differential SA−210
SA−233
SA−210
SA−233
5. Axle shaft bearing (Worn) SA−154
Oil leak from rear differential 3. Companion flange (Loosen or damaged) SA−187
SA−210
SA−233
1. Fusible link (Blown) −
2. GAUGE fuse (Blown) −
Diff. lock Indicator lights do not light up
3. Bulb (Burned out) −
4. Wiring or ground (Faulty) −
1. Diff. fuse (Blown) −

Diff. lock Indicator lights do not light up 2. Diff. lock control switch (Faulty) SA−253
(Diff. lock control switch RR or FR/RR position) 3. Diff. lock ECU (Faulty) SA−253
1. Diff. lock control switch (Faulty) SA−253

2. Diff. lock actuator (Faulty) SA−253
Differential lock does not operate 3. Diff. lock ECU (Faulty) SA−253
4. Differential carrier (Faulty) −
1. Speed sensor (Faulty) SA−253
After differential lock, lock is not released
2. Diff lock ECU (Faulty) SA−253
When vehicle speed is higher than approx. 8 km/h (5 mph)
SA−3
SUSPENSION AND AXLE − TROUBLESHOOTING (Independent Front Suspension)
TROUBLESHOOTING (Independent Front Suspension)

SA1A1−01
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
(w/ Differential locking system):
S Check that the transfer shift lever is shifted to the L4 position.
S When switching differential Free « Lock, the indicator light will blink if the gears of the differen-
tial lock sleeve are not meshed. If this occurs, when the tires are rotated to apply differential
power to the differential, the differential locks and the indicator light lights up.
Symptom Suspect Area See page
Wanders/pulls
5. Suspension parts (Worn out) −
1. Vehicle (Overloaded) −
2. Spring (Weak) SA−125
Bottoming SA−275
SA−279
2. Stabilizer bar (Bent or broken) SA−151
Sways/pitches SA−300
SA−279
2. Wheel (Out of balance) SA−5
Front wheel shimmy 5. Ball joint (Worn) SA−131
SA−136
1. Tire (Improperly inflated) SA−5
Abnormal tire wear 3. Suspension parts (Worn out) −
SA−279
Noise in front differential 3. Ring, pinion or side gears (Worn or chipped) SA−92
5. Side bearing (Worn) SA−92
2. Front differential rear oil seal (Worn or damaged) SA−92
Oil leak from front differential 3. Side gear oil seal (Worn or damaged) SA−92
4. Companion flange (Loose or damaged) SA−92
5. Side gear shaft (Damaged) SA−92
Oil leak from rear axle
2. Rear axle housing (Cracked) −
SA−4
SUSPENSION AND AXLE − TROUBLESHOOTING (Independent Front Suspension)

SA−210
SA−233
3. Ring, pinion or side gears (Worn or chipped) SA−187
Noise in rear differential SA−210
SA−233
SA−210
SA−233
5. Axle shaft bearing (Worn) SA−159
Oil leak from rear differential 3. Companion flange (Loosen or damaged) SA−187
SA−210
SA−233
1. Fusible link (Blown) −
2. GAUGE fuse (Blown) −
Diff. lock Indicator lights do not light up
3. Bulb (Burned out) −
1. Diff. fuse (Blown) −

Diff. lock Indicator lights do not light up 2. Diff. lock control switch (Faulty) SA−262
(Diff. lock control switch RR position) 3. Diff. lock ECU (Faulty) SA−262
1. Diff. lock control switch (Faulty) SA−262

2. Diff. lock actuator (Faulty) SA−262
Differential lock does not operate 3. Diff. lock ECU (Faulty) SA−262
4. Differential carrier (Faulty) −
1. Speed sensor (Faulty) SA−262
After differential lock, lock is not released
2. Diff lock ECU (Faulty) SA−262
When vehicle speed is higher than approx. 8 km/h (5 mph)
SA−1
SUSPENSION AND AXLE − TROUBLESHOOTING
SA2BJ−02
VEHICLE PULLING DIAGNOSIS

START
Preliminary Check * ROAD TEST NO Is the steering NO

COMPLETE
S Tire pressure Does the vehicle pull? off center?
S Vehicle height YES YES
S Brake dragging
YES Steering wheel off−center (See page DI−419)

Are the tires uni−directional type?
NO NO
Cross switch front tire & wheel ROAD TEST
assemblies (left & right). Does the vehicle still pull?
YES
Choose the position of front tire & wheel YES Does the vehicle pull in
assemblies where there is least amount of pull. same direction as before?
NO
Check front wheel alignment. YES NO Is the pull stronger

Is it within specification? than before?
NO YES
Adjust front wheel alignment.
Reverse the front left side
tire and rebalance it.
ROAD TEST
Does the vehicle still pull?
NO YES ROAD TEST NO
Is the steering
off center? YES
NO YES Does the vehicle
COMPLETE pull to the left?
NOTICE : Do not exceed 1˚ of cross camber.
Steering wheel off−center YES NO Do not exceed adjustment range.
(See page DI−419)
Increase right front camber and decrease Increase left front camber and decrease
left front camber until pull is eliminated. right front camber until pull is eliminated.
NO ROAD TEST YES

Contact your local retail tire distributor.
* Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed
of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page DI−419)
(2) The vehicle cannot keep straight.
STEERING PULL
LAND CRUISER (W/G) SUP (RM970E)

SA−1
SUSPENSION AND AXLE − TROUBLESHOOTING
TROUBLESHOOTING
SA2BJ−03
VEHICLE PULLING DIAGNOSIS

START
Preliminary Check * ROAD TEST NO Is the steering NO

COMPLETE
S Tire pressure Does the vehicle pull? off center?
S Vehicle height YES YES
S Brake dragging
YES Steering wheel off−center (See page DI−162)

Are the tires uni−directional type?
NO NO
Cross switch front tire & wheel ROAD TEST
assemblies (left & right). Does the vehicle still pull?
YES
Choose the position of front tire & wheel YES Does the vehicle pull in
assemblies where there is least amount of pull. same direction as before?
NO
Check front wheel alignment. YES NO Is the pull stronger

Is it within specification? than before?
NO YES
Adjust front wheel alignment.
Reverse the front left side
tire and rebalance it.
ROAD TEST
NO YES ROAD TEST NO
Is the steering
off center? YES
NO YES Does the vehicle
COMPLETE pull to the left?
NOTICE : Do not exceed 1˚ of cross camber.
Steering wheel off−center YES NO Do not exceed adjustment range.
(See page DI−162)
Increase right front camber and decrease Increase left front camber and decrease
left front camber until pull is eliminated. right front camber until pull is eliminated.
NO ROAD TEST YES

Contact your local retail tire distributor.
* ofSelect a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed
56 km/h (35mph). Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page DI−162)
(2) The vehicle cannot keep straight.
STEERING PULL

SA−5
SUSPENSION AND AXLE − TIRE AND WHEEL
TIRE AND WHEEL SA1A2−01
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure
Front Rear
Tire size
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)
LT235/85R16 108/104N 260 (2.6, 38) 375 (3.75, 54)

275/70R16 114H
220 (2.2, 32) 220 (2.2, 32)
114S
7.50R16−6PRLT 260 (2.6, 38) 375 (3.75, 54)
(b) Check the tire runout.

Tire runout: 3.0 mm (0.118 in.) or less
R03031
Full−time 4WD: Part−time 4WD: 2. ROTATE TIRE

HINT:
See the illustration for where to rotate each tire when you in-
clude the spare tire in rotation.
Front
W03082
3. INSPECT WHEEL BALANCE

(a) Check and adjust the Off−the car balance.
(b) If necessary, check and adjust the On−the car balance.
Imbalance after adjustment: 14.0 g (0.031 lb) or less
R07928
SA−6
4. CHECK FRONT SUSPENSION FOR LOOSENESS

5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
7. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check for oil leak
S Check the mounting bushings for wear
S Bounce front and rear of the vehicle
SA−1
TIRE AND WHEEL SA1A2−03
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure
Front Rear
Tire size
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)
LT235/85R16 108/104N 260 (2.6, 38) 375 (3.75, 54)

275/70R16 114H
200 (2.0, 29) 220 (2.2, 32)
114S
7.50R16−6PRLT 260 (2.6, 38) 375 (3.75, 54)
(b) Check the tire runout.

Tire runout: 3.0 mm (0.118 in.) or less
R03031
Full−time 4WD: Part−time 4WD: 2. ROTATE TIRE

HINT:
See the illustration for where to rotate each tire when you in-
clude the spare tire in rotation.
Front
W03082
3. INSPECT WHEEL BALANCE

(a) Check and adjust the Off−the car balance.
(b) If necessary, check and adjust the On−the car balance.
Imbalance after adjustment: 14.0 g (0.031 lb) or less
R07928

SA−2
4. CHECK FRONT SUSPENSION FOR LOOSENESS

5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
7. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check for oil leak
S Check the mounting bushings for wear
S Bounce front and rear of the vehicle

SA−7
SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT (Rigid Front Suspension)
FRONT WHEEL ALIGNMENT (Rigid

Front Suspension) SA1A3−01
INSPECTION
1. MEASURE VEHICLE HEIGHT
Clearance:
A B
A: Distance from the front axle housing to the follow
spring
F05800
B: Distance from the rear axle housing to the bumper
stopper
Clearance
D ti ti
Destination
Front mm (in.) Rear mm (in.)
G.C.C. 36.8 (1.45) 86.7 (3.41)
AUSTRALIA 47.1 (1.85) 110.0 (4.33)
OTHERS 34.8 (1.37) 113.0 (4.45)
If the clearance of the vehicle is not standard, try to level the ve-
hicle by rocking it down.
If still not correct, check for bad springs or suspension parts.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR

POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber 1˚ ± 45’ (1˚ ± 0.75˚)
Left−right error 45’ (0.75˚) or less
Z03382 Caster (G.C.C.) 2˚30’ ± 45’ (2.5˚ ± 0.75˚)
Left −right error 45’ (0.75˚) or less
Caster (AUSTRALIA) 1˚40’ ± 45’ (1.67˚ ± 0.75˚)

Caster (OTHERS) 2˚10’ ± 45’ (2.17˚ ± 0.75˚)
Steering axis inclination 13˚ ± 45’ (13˚ ± 0.75˚)

Camber, caster and steering axis inclination are not adjustable.
If measurements are not within the specification, inspect the
suspension parts for damaged and/or worn out and replace
them as necessary.
B 4. INSPECT TOE−IN
A
D Toe−in A + B: 0˚12’ ± 12’ (0.2˚ ± 0.2˚)
Front (total) C − D: 2 ± 2 mm (0.08 ± 0.08 in.)
If the toe−in is not within the specification, adjust by the tie rod
ends.
C
SA3213
SA−8
SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT (Rigid Front Suspension)
5. ADJUST TOE−IN
(a) Loosen the clamp bolts and nuts.
(b) Adjust toe−in to the correct value by turning the tie rod.
A B HINT:
Make sure that the lengths of the left and right tie rod ends are
A=B
the same.
(c) Torque the clamp bolts and nuts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
R05628
HINT:
60˚ The clamps opening must be positioned at the rear of the tie rod
+ 10˚
and faced within 60˚ ± 10˚ from the vehicle axis.
− 10˚
Front
Side
R05626
6. INSPECT WHEEL ANGLE

(a) Remove the caps of the knuckle stopper bolts and check
the steering angles.
FA0507
A B B A (b) Turn the steering wheel fully, and measure the turning
angle.
Front
Inside wheel 32˚ − 35˚
Outside wheel (Reference) 31˚
HINT:
A: Inside When the steering wheel is fully turned, make sure that the
B: Outside wheel is not touching the body or brake flexible hose.
If the maximum steering angle differs from the standard value,
FA0018
adjust the wheel angle with the knuckle stopper bolts.
If the wheel angle still cannot be adjusted within the limit, in-
spect and replace damaged or worn steering parts.
SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT (Independent Front SA−9
Suspension)
FRONT FRONT WHEEL ALIGNMENT

(Independent Front Suspension) SA17I−03
INSPECTION
1. MEASURE VEHICLE HEIGHT
Vehicle height
A B EUROPE
Engine Front Rear
2UZ−FE A − B: 75.0 mm (2.953 in.) C − D: 40.0 mm (1.575 in.)
REAR
1HD−FT A − B: 76.0 mm (2.992 in.) C − D: 41.0 mm (1.614 in.)
GENERAL
Engine Front Rear
C 1HD−T A − B: 76.0 mm (2.992 in.) C − D: 34.0 mm (1.339 in.)

D
G.C.C.
Engine Front Rear
F05219
1FZ−FE A − B: 71.0 mm (2.795 in.) C − D: 64.0 mm (2.520 in.)
AUSTRALIA
Front A − B: 75.0 mm (2.953 in.)
Rear C − D: 39.0 mm (1.535 in.)
w/ AHC System
Front A − B: 83.0 mm (3.268 in.)
Rear C − D: 71.0 mm (2.795 in.)
Measuring points:
A: Ground clearance of spindle center
B: Ground clearance of lower suspension arm front bolt center
C: Ground clearance of rear axle shaft center
D: Ground clearance of lower control arm front bolt center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not within the specification, try to adjust
it by pushing down on or lifting the body.

TER
Z03382
SA−10 SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT (Independent Front
Suspension)

INCLINATION
EUROPE AND GENERAL (2UZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

Steering axis inclination 12˚10’ ± 45’ (12.17˚ ± 0.75˚)
GENERAL (1HD−T)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚25’ ± 45’ (2.42˚ ± 0.75˚)

G.C.C. (2UZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚15’ ± 45’ (2.25˚ ± 0.75˚)

G.C.C. (1FZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚50’ ± 45’ (2.83˚ ± 0.75˚)

AUSTRALIA
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

w/ AHC System
Camber 0˚00’ ± 45’ (0˚ ± 0.75˚)
Caster 3˚05’ ± 45’ (3.08˚ ± 0.75˚)

If the steering axis inclination is not within the specification, after

the camber and caster have been correctly adjusted, recheck
the steering knuckle front wheel for bearing or looseness.
Suspension)
B 4. INSPECT TOE−IN
A
D w/ AHC System
Front Toe−in A + B: 0˚00’ ± 12’ (0˚ ± 0.2˚)
(total) C − D: 0 ± 2 mm (0 ± 0.08 in.)
OTHERS
Toe−in A + B: 0˚06’ ± 12’ (0.1˚ ± 0.2˚)
(total) C − D: 1 ± 2 mm (0.04 ± 0.08 in.)
C
If the toe−in is not within the specification, adjust the rack ends.
SA3213
5. ADJUST CAMBER AND CASTER
NOTICE:
After the camber has been adjusted, inspect the toe−in.
(a) Loosen the front and/or rear adjusting cam nuts.
(b) Adjust the camber and caster by front and/or rear adjust-
ing cams.
HINT:
Try to adjust the camber and caster to the center value.
Front
Front cam (LH) Front cam (RH)

(Longer) (Shorter) (Shorter) (Longer)

(Shorter) (Longer) (Longer) (Shorter)
Rear cam (LH) Rear cam (RH)
F05207
SA−12 SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT (Independent Front
Suspension)
(Example) (c) How to read adjustment chart (using examples).

(1) Measure the present alignment.
Camber: −0˚20’ (−0.33˚)
Caster: 3˚15’ (3.25˚)
Camber (2) Mark the difference between the standard value (A)
Caster
and the measured value (B) on the adjustment
f = Calculated value
F = 0 point chart.
Standard value:
Camber: 0˚00’ (0˚)
0˚00’ 0˚20’
0˚00’
Caster: 3˚05’ (3.08˚)
(0.0˚) (0.34˚)
(0.0˚) Formula: A − B = C
−0˚10’ Camber: 0˚00’ − (−0˚20’) = 0˚20’
(−0.17˚)
Caster: 3˚05’ − 3˚15’ = −0˚10’
−3.2 −0˚20’ (3) As shown in the chart, read the distance from the
(−0.34˚) marked point to 0 point, and adjust the front and/or
−1.6
rear adjusting cams accordingly.
Front cam: − (Shorter) 1.6
0˚10’
(0.17˚)
Rear cam: − (Shorter) 3.2
F05095
(+) Front Cam Graduation
Camber
Caster −0˚30’ −0˚20’ −0˚10’ 0˚00’ 0˚10’ 0˚20’ 0˚30’ 0˚40’ 0˚50’ 1˚00’
(−0.5˚) (−0.34˚) (−0.17˚) (0.0˚) (0.17˚) (0.34˚) (0.5˚) (0.67˚) (0.83˚) (1.0˚)
−0˚10’
(−0.17˚)
−0˚20’
1˚40’ (−0.34˚)
(1.67˚)
−0˚30’
1˚30’ (−0.5˚)
(1.5˚)
−0˚40’
1˚20’ (−0.67˚)
Rear Cam (1.34˚)
−0˚50’
Graduation 1˚10’ (−0.83˚)
(1.17˚)
−1˚00’
(−) 1˚00’ (−1.0˚) (+)
(1.0˚)
−1˚10’
0˚50’ (−1.17˚)
(0.83˚)
−1˚20’
0˚40’ (−1.34˚)
(0.67˚)
−1˚30’
0˚30’
(−1.5˚)
(0.5˚)
0˚20’ −1˚40’
(0.34˚) (−1.67˚)
0˚10’
(0.17˚)
0˚00’
(0.0˚)
−1˚00’ −0˚50’ −0˚40’
(−1.0˚) (−0.83˚) (−0.67˚)
(−) F05209
Suspension)
(d) Torque the front and/or rear adjusting cam nuts.

Torque: 98 N·m (1,000 kgf·cm, 72 ft·lbf)
6. ADJUST TOE−IN
(a) Check or adjust the lengths of the rack ends, then adjust
the toe−in.
Rack end length difference: 3.0 mm (0.118 in.) or less
(b) Remove the boot clamps.
(c) Loosen the tie rod lock nuts.
(d) Turn the left and right rack ends an equal amount to adjust
the toe−in.
F05208 HINT:
Try to adjust the toe−in to the center value.
(e) Tighten the tie rod lock nuts.
(f) Place the boot on the seat and clamp it.
HINT:
Make sure that the boots are not twisted.
A B B A 7. INSPECT AND ADJUST WHEEL ANGLE

(a) Turn the steering wheel fully, and measure the turning
Front angle.
36˚42’ (33˚42’ − 36˚42’)
Inside wheel
36.7˚ (33.7˚ − 36.7˚)
32˚36’
Reference: Outside wheel
A: Inside 32.6˚
B: Outside If the wheel angles differ from the standard of the specification,
SA0028 inspect the toe−in.
(b) When toe−in is normal after inspection, adjust wheel

angle with the knuckle stopper bolt of the lower suspen-
sion arm.
F05200
SA−2
SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT SA17I−05
INSPECTION
NOTICE:
After adjusting wheel alignment perform the VGRS calibra-
tion.
HINT:
S For the steering wheel off−center, perform the ”steering
off−center” (See page DI−419).
S Check that the ”STRAIGHT ANG FLG” is ”VALID” in the
DATA LIST (See page DI−348 step 5.).
FRONT 1. MEASURE VEHICLE HEIGHT
Vehicle height
EUROPE
Engine Front Rear
A B GENERAL
Engine Front Rear
REAR
1HD−T A − B: 76.0 mm (2.992 in.) C − D: 34.0 mm (1.339 in.)
G.C.C.
Engine Front Rear
C 1FZ−FE A − B: 71.0 mm (2.795 in.) C − D: 64.0 mm (2.520 in.)
D
AUSTRALIA
Front A − B: 75.0 mm (2.953 in.)
F05219 Rear C − D: 39.0 mm (1.535 in.)

w/ AHC System
Front A − B: 83.0 mm (3.268 in.)
Rear C − D: 71.0 mm (2.795 in.)
Measuring points:
NOTICE:

SA−3

TER

INCLINATION
Z03382 Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

GENERAL (1HD−T)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚25’ ± 45’ (2.42˚ ± 0.75˚)

G.C.C. (2UZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚15’ ± 45’ (2.25˚ ± 0.75˚)

G.C.C. (1FZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚50’ ± 45’ (2.83˚ ± 0.75˚)

AUSTRALIA
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

w/ AHC System
Camber 0˚00’ ± 45’ (0˚ ± 0.75˚)
Caster 3˚05’ ± 45’ (3.08˚ ± 0.75˚)

SA−4

A B 4. INSPECT TOE−IN
D w/ AHC System
Front Toe−in A + B: 0˚00’ ± 12’ (0˚ ± 0.2˚)
(total) C − D: 0 ± 2 mm (0 ± 0.08 in.)
OTHERS
Toe−in A + B: 0˚06’ ± 12’ (0.1˚ ± 0.2˚)
(total) C − D: 1 ± 2 mm (0.04 ± 0.08 in.)
C
SA3213
NOTICE:
ing cams.

SA−5
HINT:
Front


F05207

SA−6

Camber: −0˚20’ (−0.33˚)
Caster: 3˚15’ (3.25˚)
Caster
F = 0 point chart.
Standard value:
Camber: 0˚00’ (0˚)
0˚00’ 0˚20’
0˚00’
Caster: 3˚05’ (3.08˚)
(0.0˚) (0.34˚)
−0˚10’ Camber: 0˚00’ − (−0˚20’) = 0˚20’
(−0.17˚)
Caster: 3˚05’ − 3˚15’ = −0˚10’
−1.6
0˚10’
(0.17˚)
F05095
Camber
Caster −0˚30’ −0˚20’ −0˚10’ 0˚00’ 0˚10’ 0˚20’ 0˚30’ 0˚40’ 0˚50’ 1˚00’
(−0.5˚) (−0.34˚) (−0.17˚) (0.0˚) (0.17˚) (0.34˚) (0.5˚) (0.67˚) (0.83˚) (1.0˚)
−0˚10’
(−0.17˚)
−0˚20’
1˚40’ (−0.34˚)
(1.67˚)
−0˚30’
1˚30’ (−0.5˚)
(1.5˚)
−0˚40’
1˚20’ (−0.67˚)
Rear Cam (1.34˚)
−0˚50’
(1.17˚)
−1˚00’
(−) 1˚00’ (−1.0˚) (+)
(1.0˚)
−1˚10’
0˚50’ (−1.17˚)
(0.83˚)
−1˚20’
0˚40’ (−1.34˚)
(0.67˚)
−1˚30’
0˚30’
(−1.5˚)
(0.5˚)
0˚20’ −1˚40’
(0.34˚) (−1.67˚)
0˚10’
(0.17˚)
0˚00’
(0.0˚)
−1˚00’ −0˚50’ −0˚40’
(−1.0˚) (−0.83˚) (−0.67˚)
(−) F05209

SA−7

6. ADJUST TOE−IN
NOTICE:
tion.
the toe−in.
F05208 (c) Loosen the tie rod lock nuts.
the toe−in.
HINT:
HINT:
(g) Perform the VGRS system calibration (See page
DI−357).

Front angle.
36˚42’ (33˚42’ − 36˚42’)
Inside wheel
36.7˚ (33.7˚ − 36.7˚)
32˚36’
A: Inside 32.6˚

sion arm.
F05200

SA−2
FRONT WHEEL ALIGNMENT SA17I−09
INSPECTION
NOTICE:
tion.
HINT:
S For the steering wheel off−center, perform the ”steering
off−center” (See page DI−162).
S Check that the ”STRAIGHT ANG FLG” is ”VALID” in the
DATA LIST (See page DI−91 step 5.).
FRONT 1. MEASURE VEHICLE HEIGHT
Vehicle height
EUROPE
Engine Front Rear
A B GENERAL
Engine Front Rear
REAR
1HD−T A − B: 76.0 mm (2.992 in.) C − D: 34.0 mm (1.339 in.)
G.C.C.
Engine Front Rear
C 1FZ−FE A − B: 71.0 mm (2.795 in.) C − D: 64.0 mm (2.520 in.)
D
AUSTRALIA
Front A − B: 75.0 mm (2.953 in.)
F05219 Rear C − D: 39.0 mm (1.535 in.)

w/ AHC System
Front A − B: 83.0 mm (3.268 in.)
Rear C − D: 71.0 mm (2.795 in.)
Measuring points:
NOTICE:

SA−3

TER

INCLINATION
Z03382 Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

GENERAL (1HD−T)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚25’ ± 45’ (2.42˚ ± 0.75˚)

G.C.C. (2UZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚15’ ± 45’ (2.25˚ ± 0.75˚)

G.C.C. (1FZ−FE)
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚50’ ± 45’ (2.83˚ ± 0.75˚)

AUSTRALIA
Camber 0˚05’ ± 45’ (0.08˚ ± 0.75˚)
Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

w/ AHC System
Camber 0˚00’ ± 45’ (0˚ ± 0.75˚)
Caster 3˚05’ ± 45’ (3.08˚ ± 0.75˚)

SA−4

A B 4. INSPECT TOE−IN
D w/ AHC System
Front Toe−in A + B: 0˚00’ ± 12’ (0˚ ± 0.2˚)
(total) C − D: 0 ± 2 mm (0 ± 0.08 in.)
OTHERS
Toe−in A + B: 0˚06’ ± 12’ (0.1˚ ± 0.2˚)
(total) C − D: 1 ± 2 mm (0.04 ± 0.08 in.)
C
SA3213
NOTICE:
ing cams.

SA−5
HINT:
Front


F05207

SA−6

Camber: −0˚20’ (−0.33˚)
Caster: 3˚15’ (3.25˚)
Caster
F = 0 point chart.
Standard value:
Camber: 0˚00’ (0˚)
0˚00’ 0˚20’
0˚00’
Caster: 3˚05’ (3.08˚)
(0.0˚) (0.34˚)
−0˚10’ Camber: 0˚00’ − (−0˚20’) = 0˚20’
(−0.17˚)
Caster: 3˚05’ − 3˚15’ = −0˚10’
−1.6
0˚10’
(0.17˚)
F05095
Camber
Caster −0˚30’ −0˚20’ −0˚10’ 0˚00’ 0˚10’ 0˚20’ 0˚30’ 0˚40’ 0˚50’ 1˚00’
(−0.5˚) (−0.34˚) (−0.17˚) (0.0˚) (0.17˚) (0.34˚) (0.5˚) (0.67˚) (0.83˚) (1.0˚)
−0˚10’
(−0.17˚)
−0˚20’
1˚40’ (−0.34˚)
(1.67˚)
−0˚30’
1˚30’ (−0.5˚)
(1.5˚)
−0˚40’
1˚20’ (−0.67˚)
Rear Cam (1.34˚)
−0˚50’
(1.17˚)
−1˚00’
(−) 1˚00’ (−1.0˚) (+)
(1.0˚)
−1˚10’
0˚50’ (−1.17˚)
(0.83˚)
−1˚20’
0˚40’ (−1.34˚)
(0.67˚)
−1˚30’
0˚30’
(−1.5˚)
(0.5˚)
0˚20’ −1˚40’
(0.34˚) (−1.67˚)
0˚10’
(0.17˚)
0˚00’
(0.0˚)
−1˚00’ −0˚50’ −0˚40’
(−1.0˚) (−0.83˚) (−0.67˚)
(−) F05209

SA−7

6. ADJUST TOE−IN
NOTICE:
tion.
the toe−in.
F05208 (c) Loosen the tie rod lock nuts.
the toe−in.
HINT:
HINT:
(g) Perform the VGRS system calibration (See page
DI−100).
(h) Perform the zero point calibration of yaw rate and decel-
eration sensor (See Pub No. RM970E, page DI−185).

Front angle.
36˚42’ (33˚42’ − 36˚42’)
Inside wheel
36.7˚ (33.7˚ − 36.7˚)
32˚36’
A: Inside 32.6˚

SA−8

sion arm.
F05200

SA−14
SUSPENSION AND AXLE − FRONT AXLE HUB (Rigid Front Suspension)
FRONT AXLE HUB (Rigid Front Suspension)

SA1A4−01
COMPONENTS
123 (1,250, 90)
z Gasket
Brake Caliper
30 (310, 22)
z Oil Seal
z Bearing Disc
Hub Bolt
Axle Hub
x5
x5
74 (750, 51)
z Outer Bearing
z Lock Washer
Thrust Washer Lock Nut
64 (650, 47)
z Gasket
Flange
z Snap Ring
z Bearing Cap
Adjusting Nut x6
Cone Washer
z 33 (335, 24)
N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part F05782
SA−1
FRONT AXLE HUB (Rigid Front Suspension)

SA1A4−02
COMPONENTS
123 (1,250, 90)
z Gasket
Brake Caliper
30 (310, 22)
Flexible Hose
z Oil Seal
z Inner Bearing Disc
Hub Bolt
Axle Hub
x5
x5
74 (750, 51)
z Gasket
Adjusting Nut
z Outer Bearing See page SA−3
Spindle Washer
55 (559, 40)
Brake Set* Snap Ring

x6
Dual Mode Automatic

Locking Hub*
*: Make sure to the replace the dual auto
matic locking hub and brake set together.
LAND CRUISER SUP (RM695E)

SA−15
SA1A5−01
REMOVAL
1. REMOVE FRONT WHEEL
2. REMOVE BRAKE CALIPER
(a) Remove the bolt and 2 gaskets from the brake caliper and
disconnect the flexible hose.
(b) Remove the 2 bolts, washers and brake caliper.

3. w/ Free Wheel Hub:
REMOVE FREE WHEEL HUB (See page SA−28)
4. w/o Free Wheel Hub:
REMOVE FLANGE
(a) Using a screwdriver and hammer, remove the grease cap
from the flange.
(b) Using a snap ring expander, remove the snap ring.
F05936 (c) Loosen the 6 mounting nuts.
(d) Using a brass bar and hammer, tap on the 6 bolts heads
and remove the 6 cone washers, plate washers and nuts.
(e) Remove the flange.
(f) Remove the gasket.
5. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.
F05763
(b) Using SST, remove the lock nut.

SST 09607−60020
(c) Remove the lock washer.
(d) Using SST, remove the adjusting nut and thrust washer.
SST
SST 09607−60020
(e) Remove the hub and disc together with the outer bearing.
F05769
SA−2
SA1IF−01
REMOVAL
(a) Remove the bolt and 2 gaskets from the brake caliper and
disconnect the flexible hose.
(b) Remove the 2 bolts, washers and brake caliper from the
steering knuckle.
3. REMOVE DUAL MODE AUTOMATIC LOCKING HUB
(See page SA−10)
4. REM O VE SNAP RI NG , SPI NDLE WASHER AND
BRAKE SET FORM SPINDLE
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spindle washer and brake set.
F05936
5. REMOVE AXLE HUB WITH DISC FROM SPINDLE

(a) Using SST, remove the adjusting nut.
SST 09607−60020
(b) Remove the axle hub with disc together with the outer
bearing.
SST
F07616

SA−16
SA1A6−01
DISASSEMBLY
1. REMOVE OIL SEAL AND BEARING
SST (a) Using SST, remove the oil seal.
SST 09308−00010
(b) Remove the bearing from the axle hub.
SA2635
2. REMOVE BEARING OUTER RACES

Using a brass bar and hammer, remove the 2 bearing outer
races.
3. INSPECT BEARINGS
Clean the 2 bearings and outer races and inspect them for wear
or damage.
FA0076
4. REMOVE DISC
Matchmarks (a) Place matchmarks on the axle hub and disc.
(b) Remove the 5 bolts and disc from the axle hub.
SA0498
SA−17
SA1A7−01
Matchmarks
REASSEMBLY
1. INSTALL DISC
(a) Align the matchmarks on the axle hub and disc.
(b) Install the 5 bolts to the axle hub.
SA0498
2. INSTALL BEARING OUTER RACES

(a) Using SST and a hammer, carefully install a new outside
bearing outer race.
SST 09950−60020 (09951−00720),
SST 09950−70010 (09951−07150)
(b) Using SST and a hammer, carefully install a new inside
bearing outer race.
SST 09950−60020 (09951−00810),
F05768 09950−70010 (09951−07150)
3. PACK BEARING WITH MP GREASE

(a) Place MP grease in the palm of your hand.
(b) Pack grease into the bearing, continuing until the grease
oozes out from the other side.
(c) Do the same around the bearing circumference.
RA0009
4. COAT INSIDE OF AXLE HUB WITH MP GREASE

5. INSTALL INNER BEARING AND OIL SEAL
(a) Place the inner bearing into the axle hub.
Grease
SA2636
(b) Using SST, install a new oil seal into the hub.
SST 09950−60020 (09951−00910),
09950−70010 (09951−07150)
(c) Coat the oil seal lip with MP grease.
SST
F06163
SA−18
SA1A8−01
INSTALLATION
1. INSTALL AXLE HUB WITH DISC TO SPINDLE
(a) Place the axle hub with disc to the spindle.
(b) Install the outer bearing.
(c) Install the thrust washer.
2. ADJUST PRELOAD
(a) Using SST, torque the adjusting nut.
SST 09607−60020
SST Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(b) Turn the hub right and left 2 or 3 times.
(c) Loosen the nut until it can be turned by hand.
(d) Using SST, torque the adjusting nut again.
SST 09607−60020
F05767 Torque: 5.4 N·m (55 kgf·cm, 48 ft·lbf)
NOTICE:
Check that the bearing has no play.
(e) Using a spring tension gauge, measure the preload.

Preload (at starting):
26 − 52 N (2.7 − 5.3 kgf, 6.0 − 11.7 lbf)
3. INSTALL LOCK WASHER AND LOCK NUT
(a) Install a new lock washer and lock nut.
90 ˚
F05776
(b) Using SST, torque the lock nut.

SST 09607−60020
SST (c) Check that axle hub turns smoothly and that the bearing
has no play.
F05767
SA−19
(d) Using a spring tension gauge, check the preload.

26 − 52 N (2.7 − 5.3 kgf, 6.0 − 11.7 lbf)
If it is not within the specification, adjust it with the adjusting nut
after removing the lock washer and lock nut.
90 ˚ (e) Secure the lock nut by bending one of the lock washer
teeth inward and the other lock washer teeth outward.
4. w/ Free Wheel Hub:
F05776 INSTALL FREE WHEEL HUB (See page SA−30)
5. w/o Free Wheel Hub:
INSTALL FLANGE
(a) Place a new gasket in position on the axle hub.
(b) Apply MP grease to the inner flange splines.
(c) Install the flange to the axle hub.
(d) Install the 6 cone washers, plate washers and new nuts.
(e) Install the bolt in the axle shaft and pull it out.
(f) Using a snap ring expander, install a new snap ring.
(g) Remove the bolt.
(h) Coat inside of the new cap with MP grease.
(i) Install the cap to the flange.
6. INSTALL BRAKE CALIPER
(a) Install the brake caliper, 2 bolts and washers.
R08416 (b) Connect the flexible hose and install 2 new gaskets and
bolt.
7. INSTALL FRONT WHEEL
8. BLEED BRAKE LINE (See page BR−10 or BR−5)
SA−3
SA1IG−01
INSTALLATION
1. INSTALL AXLE HUB WITH DISC TO SPINDLE
(a) Place the axle hub with disc to the spindle.
2. ADJUST PRELOAD
(a) Install the adjusting nut and tighten it using SST.
SST 09607−60020
(d) Using SST, retighten the adjusting nut.
SST 09607−60020
F07616 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(e) Tighten the adjusting nut in the tightening direction so that

Spindle Key Grooves the grooves of the adjusting nut are aligned with on the
SST
key grooves before and after spindle.
Torque: 49 − 79 N·m (500 − 800 kgf·cm, 36 − 58 ft·lbf)
NOTICE:
Adjusting Nut Grooves F07618
(f) Using a spring tension gauge, measure the preload.

42 − 67 N (4.3 − 6.8 kgf, 9.5 − 15.0 lbf)
HINT:
Make sure to check preload in the direction of rotation.
90˚ If the preload is not within the specified value, adjust it again
with the adjusting nut.
F07622
Brake Wire Brake Set Mark 3. INSTALL BRAKE SET, SPINDLE WASHER AND SNAP
RING TO SPINDLE
(a) Check that the brake wire is within the range of 60˚ of the
brake outer raised portion on the opposite side to the
60˚
brake set mark.
Brake Outer
Raised Portion
F07619

SA−4
Spindle Key Grooves (b) Align the claws of the brake set with the key grooves of
the spindle and assemble the brake set.
(c) Install the spindle washer and using a snap ring expan-
der, install the snap ring.
(d) Install the bolt to the axle shaft.
Brake Set
Claws
F07620
(e) Using a dial indicator, check the backlash near the center
of the axle shaft, while pulling the bolt with pliers.
Maximum: 0.2 mm (0.008 in.) or less
If the backlash is not within the specified value, replace the
snap ring.
Snap ring thickness:
1.80 mm (0.0709 in.) 2.40 mm (0.0945 in.)
2.00 mm (0.0787 in.) 2.60 mm (0.1024 in.)
F07621
2.20 mm (0.0866 in.) 2.80 mm (0.1102 in.)
(f) Remove the bolt from the axle shaft.
4. INSTALL DUAL MODE AUTOMATIC LOCKING HUB
(See page SA−11)
(a) Install the brake caliper with the 2 bolts and washers to the
steering knuckle.
(b) Connect the flexible hose and install 2 new gaskets and
bolt.
7. BLEED BRAKE LINE (See Pub. No. RM616E on page
BR−5 or BR−10)

SA−20
SUSPENSION AND AXLE − FRONT AXLE HUB (Independent Front Suspension)
FRONT AXLE HUB (Independent Front Suspension)

SA143−03
COMPONENTS
123 (1,250, 90)

28 (290, 21)
Brake Caliper
z Bearing Disc
z Oil Seal
x5
Axle Hub
74 (750, 54)
z Bearing
Claw Washer
Adjusting Nut
z Lock Washer
Lock Nut
64 (650, 47)
z Gasket
Flange
z Snap Ring
Hub Bolt
z Grease Cap
x6
Cone Washer
N·m (kgf·cm, ft·lbf) : Specified torque z 33 (335, 24)

SA−5
FRONT AXLE HUB (Independent Front Suspension)

SA143−05
COMPONENTS
Flexible Hose Bracket

123 (1,250, 90)
28 (290, 21)
Brake Caliper
Disc
z Bearing
z Oil Seal
x5
74 (750, 54)
Axle Hub
z Bearing Adjusting Nut

See page SA−7
Spindle Washer
x5
Hub Bolt z Gasket
Brake Set* 55 (559, 40)
Snap Ring
*: Make sure to the replace the dual auto x6
matic locking hub and brake set together. Dual Mode Automatic
N·m (kgf·cm, ft·lbf) : Specified torque Locking Hub*

SA−21
SA144−03
REMOVAL

(a) Remove the bolt and disconnect the flexible hose from
the steering knuckle.
(c) Support the brake caliper securely.
3. REMOVE FLANGE
(a) Using a screwdriver and hammer, remove the grease cap
from the flange.
F04367

(c) Remove the 6 nuts and washers.
(d) Install the nuts temporarily to protect the threads of the
stud bolts.
F04368
(e) Using a brass bar and hammer, tap on the bolt heads and
remove the 6 nuts and cone washers.
(f) Remove the flange and gasket.
4. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.
F04369

SST 09607−60020
(c) Remove the lock washer.
(d) Using SST, remove the adjusting nut.
SST 09607−60020
(e) Remove the axle hub with disc.
NOTICE:
Be careful not to damage the ABS speed sensor rotor (w/
SST
F04370 ABS) and oil seal.
(f) Remove the claw washer and bearing from the axle hub.
SA−6
SA1IH−01
REMOVAL

(a) Remove the bolt and disconnect the flexible hose bracket
from the steering knuckle.
(See page SA−10)
4. REMOVE SNAP RING, SPINDLE WASHER AND
F04367 BRAKE SET FROM STEERING KNUCKLE
5. REMOVE AXLE HUB WITH DISC FROM STEERING

KNUCKLE
(a) Using SST, remove the adjusting nut.
SST 09607−60020
(b) Remove the axle hub with disc together with the outer
bearing.
NOTICE:
SST
F05525 ABS) and oil seal.

SA−22
SA145−03
DISASSEMBLY
1. REMOVE OIL SEAL AND BEARING
(a) Using a screwdriver, pry out the oil seal.
(b) Remove the bearing from the axle hub.
2. REMOVE BEARING OUTER RACES

(a) Using a brass bar and hammer, remove the outside bear-
ing outer race.
NOTICE:
w/ ABS:
Be careful not to damage the ABS speed sensor rotor.
F04408
(b) Using a brass bar and hammer, remove the inside bearing
outer race.
3. INSPECT BEARINGS
Clean the bearings and outer races and inspect them for wear
or damage.
F04339
4. REMOVE DISC
(a) Mount the axle hub with the disc in a soft jaw vice.
NOTICE:
Close vice until it holds disc, do not tighten further.
(b) Place matchmarks on the axle hub and disc.
(c) Remove the 5 bolts and separate the axle hub and disc.
Matchmarks
F04340
SA−23
SA146−03
REASSEMBLY
1. INSTALL DISC
(a) Mount the disc in a soft jaw vice.
NOTICE:
(b) Align the matchmarks on the axle hub and disc.
(c) Install the 5 bolts to the axle hub.
Matchmarks Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
F04340
2. INSTALL NEW BEARING OUTER RACES

(a) Using SST and a hammer, carefully install a new outside
bearing outer race.
SST 09950−60020 (09951−00730),
SST
09950−70010 (09951−07100)
F04341
(b) Using SST and a hammer, carefully install a new inside

bearing outer race.
SST SST 09950−60020 (09951−00890),
09950−70010 (09951−07100)
NOTICE:
w/ ABS:
F04342

(a) Place MP grease in the palm.
(b) Pack grease into the bearing, continuing until the grease
oozes out from the other side.
(c) Employ the same manner around the bearing circumfer-
ence.
RA0009
4. COAT INSIDE OF AXLE HUB WITH MP GREASE

5. INSTALL INNER BEARING AND NEW OIL SEAL
(a) Place the inner bearing into the axle hub.
MP Grease
SA0412
SA−24
(b) Using SST and a hammer, install a new oil seal into the
axle hub.
SST SST 09950−60020 (09951−01030),
09950−70010 (09951−07100)
NOTICE:
w/ ABS:
(c) Coat the lip of the oil seal with MP grease.
F04343
SA−25
SA147−03
INSTALLATION
1. INSTALL AXLE HUB TO STEERING KNUCKLE
(a) Place the axle hub to the steering knuckle.
NOTICE:
ABS) and oil seal.
(c) Install the claw washer.
2. ADJUST PRELOAD
SST 09607−60020
(b) Turn the axle hub several times to settle down the bear-
ing.
(c) Using SST, retighten the adjusting nut to then loosen it un-
SST til it can rotate by hand.
F04370 SST 09607−60020
SST 09607−60020
Torque: 4.3 − 6.5 N·m (44 − 66 kgf·cm, 38 − 57 in.·lbf)
HINT:
Check that there is no looseness on the bearing.
(e) Using a spring tension gauge, measure the preload.

42 − 67 N (4.3 − 6.8 kgf, 9.5 − 15.0 lbf)
3. INSTALL LOCK WASHER AND LOCK NUT
(a) Install a new lock washer and the lock nut.
90˚
F04362
(b) Using SST, torque the lock nut.

SST 09607−60020
(c) Check that the axle hub rotates smoothly and there is no
looseness on the bearing.
SST
F04370
SA−26
(d) Using a spring tension gauge, check the preload.

42 − 67 N (4.3 − 6.8 kgf, 9.5 − 15.0 lbf)
HINT:
90˚
If the preload is not within the specification, adjust it again with
the adjusting nut.
(e) Secure the lock nut by bending one of the lock washer
F04362 teeth inward and the other lock washer teeth outward.
4. INSTALL FLANGE
(b) Install the flange to the axle hub.
(c) Install the 6 cone washers, washers and new nuts.
(d) Pull out the drive shaft outside the vehicle and select the
snap ring which ensures the clearance between the tip of
the flange and the snap ring is less than 0.2 mm (0.008
in.).
Snap ring thickness
1.8 mm (0.0709 in.) 2.4 mm (0.0945 in.)
2.0 mm (0.0787 in.) 2.6 mm (0.1024 in.)
2.2 mm (0.0866 in.) 2.8 mm (0.1102 in.)
F04363
(e) Using a snap ring expander, install a new snap ring to the
drive shaft.
(f) Install a new grease cap to the flange.
(a) Install the brake caliper with 2 bolts.
(b) Install the flexible hose and bolt to the steering knuckle.
Torque:
Steel wheel: 209 N·m (2,131 kgf·cm, 154 ft·lbf)
Aluminum wheel: 131 N·m (1,340 kgf·cm, 97 ft·lbf)
7. w/ ABS:
CHECK ABS SPEED SENSOR SIGNAL
(See page DI−312)
SA−7
SA1II−01
INSTALLATION
1. INSTALL AXLE HUB TO STEERING KNUCKLE
(a) Place the axle hub to the steering knuckle.
NOTICE:
ABS) and oil seal.
2. ADJUST PRELOAD
SST 09607−60020
SST 09607−60020
F05525
(e) Tighten the adjusting nut in the tightening direction so that

Spindle Key Grooves the grooves of the adjusting nut are aligned with on the
key grooves before and after spindle.
SST
Torque: 49 − 79 N·m (500 − 800 kgf·cm, 36 − 58 ft·lbf)
NOTICE:
Adjusting Nut Grooves F07618
(f) Using a spring tension gauge, measure the preload.

42 − 67 N (4.3 − 6.8 kgf, 9.5 − 15.0 lbf)
HINT:
90˚
If the preload is not within the specified value, adjust it again
with the adjusting nut.
F07617
Brake Wire Brake Set Mark 3. INSTALL BRAKE SET, SPINDLE WASHER AND SNAP
RING TO STEERING KNUCKLE
(a) Check that the brake wire is within the range of 60˚ of the
brake outer raised portion on the opposite side to the
60˚ brake set mark.
Brake Outer
Raised Portion
F07619

SA−8
Spindle Key Grooves (b) Align the claws of the brake set with the key grooves of
the spindle and assemble the brake set.
(c) Install the spindle washer and using a snap ring expan-
der, install the snap ring.
(d) Install the bolt to the drive shaft.
Brake Set
Claws
F07620
(e) Using a dial indicator, check the backlash near the center
of the drive shaft, while pulling the bolt with pliers.
Maximum: 0.2 mm (0.008 in.) or less
If the backlash is not within the specified value, replace the
snap ring.
Snap ring thickness:
1.80 mm (0.0709 in.) 2.40 mm (0.0945 in.)
2.00 mm (0.0787 in.) 2.60 mm (0.1024 in.)
F07621
2.20 mm (0.0866 in.) 2.80 mm (0.1102 in.)
(f) Remove the bolt from the drive shaft.
4. INSTALL DUAL MODE AUTOMATIC LOCKING HUB
(See page SA−11)
(a) Install the brake caliper with the 2 bolts and washers.
(b) Connect the flexible hose bracket to the steering knuckle
with the bolt.
Torque:
7. w/ ABS:
CHECK ABS SPEED SENSOR SIGNAL (See Pub. No.
RM616E on page DI−312)

SA−27
SUSPENSION AND AXLE − FREE WHEEL HUB
FREE WHEEL HUB

SA1A9−01
COMPONENTS
z Gasket
Cone Washer
z 33 (335, 24)
x6
z Snap Ring
z Gasket
Wheel Cover
x6
Free Wheel Hub Body
10 (100, 7)
Free Wheel Hub Cover

z Non−reusable part
F05958
SA−28
SA1AA−01
REMOVAL
1. REMOVE WHEEL COVER
2. REMOVE FREE WHEEL HUB COVER
(a) Set the control handle to FREE.
(b) Remove the 6 bolts and pull off the free wheel hub cover.
(c) Remove the gasket.
3. REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.
4. REMOVE FREE WHEEL HUB BODY
(a) Remove the 6 nuts and washers.
(b) Using a brass bar and hammer, tap on the bolt heads and
remove the 6 cone washers.
(c) Pull off the free wheel hub body.
(d) Remove the gasket.
Z03690
SA−29
SA1AB−01
INSPECTION
1. INSPECT FREE WHEEL HUB COVER
Check the handle moves smoothly.
2. INSPECT INNER HUB
Place the cover in the body and check that the inner hub turns
smoothly.
R13348
SA−30
SA1AC−01
INSTALLATION
1. INSTALL FREE WHEEL HUB BODY
(b) Install the body with 6 cone washers, washers and new
nuts.
(c) Select the snap ring which ensures the clearance be-
tween the tip of the body and the snap ring is less than 0.2
mm (0.008 in.).
Snap ring thickness
1.8 mm (0.0709 in.) 2.4 mm (0.0945 in.)
2.0 mm (0.0787 in.) 2.6 mm (0.1024 in.)
2.2 mm (0.0866 in.) 2.8 mm (0.1102 in.)
(d) Using a snap ring expander, install a new snap ring.
2. INSTALL FREE WHEEL HUB COVER

(a) Apply MP grease to inner hub splines.
(b) Set the control handle to FREE.
(c) Place a new gasket in position on the body.
FA0070
(d) Install the cover to the body with the tabs of the pawl
aligned with the non−toothed portions of the body.
(e) Install the 6 bolts.
3. INSTALL WHEEL COVER
R13434
SA−31
SUSPENSION AND AXLE − FRONT WHEEL HUB BOLT (Rigid Front Suspension)
FRONT WHEEL HUB BOLT (Rigid

Front Suspension) SA1AD−01
REPLACEMENT
1. REMOVE FRONT AXLE HUB (See page SA−15)
2. REPLACE HUB BOLTS

Matchmarks (a) Place matchmarks on the axle hub and disc.
(b) Remove the 5 bolts and disc from the axle hub.
(c) Install the nut to the hub bolt.
(d) Using an extension bar and press, remove the hub bolt.
F06164
(e) Using an extension bar and press, install a new hub bolt.
Matchmarks (f) Align the matchmarks on the axle hub and disc.
(g) Install and torque the 5 bolts.
3. INSTALL FRONT AXLE HUB (See page SA−18)
F06165
SA−32 SUSPENSION AND AXLE − FRONT WHEEL HUB BOLT (Independent Front
Suspension)
FRONT WHEEL HUB BOLT

(Independent Front Suspension) SA148−03
REPLACEMENT
2. REMOVE HUB BOLT

(a) Mount the axle hub with the disc in a soft jaw vice.
NOTICE:
(b) Place matchmarks on the axle hub and disc.
(c) Remove the 5 bolts and separate the axle hub from the
disc.
Matchmarks F04340
(d) Using a press, remove the hub bolt.
F04344
3. INSTALL HUB BOLT

(a) Using an extension bar and press, install a new hub bolt.
F04345
(b) Align the matchmarks and install the axle hub to the disc,
and install the 5 bolts.
Matchmarks F04340
SA−33
SUSPENSION AND AXLE − STEERING KNUCKLE (Independent Front Suspension)
STEERING KNUCKLE (Independent Front Suspension)

SA149−03
COMPONENTS
w/ ABS 28 (290, 21)

ABS Speed Sensor
and Wire Harness 28 (290, 21)
110 (1,125, 81) 13 (130, 9)
z Cotter Pin
z Cotter Pin Steering Knuckle
122 (1,250, 90) Brake Caliper
8.0 (82, 71 in.·lbf)
123 (1,250, 90)
159(1,625,118)
Dust Cover
z Cotter Pin
z Gasket
z Oil Seal
Axle Hub with Disc
Tie Rod End

Bearing
Claw Washer
18 (185, 13)
z Lock Washer
Lock Nut
64 (650, 47)
z Gasket
Flange
Adjusting Nut z Snap Ring

z Oil Seal z Grease Cap
Steering Knuckle
x6
z 33 (335, 24)
z Bushing
z Bearing
L 147 (1,500, 108)
Steering Knuckle Arm

L Precoated part F05160
SA−34
SA14A−03
REMOVAL
2. REMOVE OIL SEAL, GASKET AND DUST COVER

Remove the 4 bolts, oil seal, gasket and dust cover.
F04371
3. w/ ABS:
DISCONNECT ABS SPEED SENSOR AND WIRE HAR-
NESS
Remove the 3 bolts and disconnect the ABS speed sensor and
wire harness.
4. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE ARM
(a) Remove the cotter pin and nut.
F04372
(b) Using SST, disconnect the tie rod end from the steering
SST knuckle arm.
SST 09628−62011
5. DISCONNECT LOWER SUSPENSION ARM FROM
STEERING KNUCKLE
F04373
(b) Using SST, disconnect the lower suspension arm from the
steering knuckle.
SST 09628−62011
6. REMOVE STEERING KNUCKLE
SST (b) Temporarily install the nut to the lower suspension arm.
F04374
SA−35
(c) Using SST, disconnect the steering knuckle from the up-
per suspension arm.
SST 09628−62011
(d) Remove the nut and steering knuckle from the lower sus-
SST pension arm.
F04375
SA−36
SA14B−03
DISASSEMBLY
1. REMOVE STEERING KNUCKLE ARM
Remove the 2 bolts and steering knuckle arm.
2. REMOVE OIL SEAL
Using a screwdriver and hammer, remove the oil seal.
3. REMOVE BEARING AND BUSHING

Using a brass and hammer, remove the bearing and bushing.
F04346
SA−37
SA14C−03
REASSEMBLY
1. INSTALL BEARING AND BUSHING
SST
(a) Using SST and a press, install a new bearing and bush-
ing.
SST 09950−60010 (09951−00540),
09950−70010 (09951−07100)
(b) Apply synthetic oil and lithium soap base chassis grease,
NLGI No.1 to the steering knuckle inner side of bushing.
F04348
2. INSTALL OIL SEAL

(a) Using SST and a press, install a new oil seal.
SST
SST 09950−60020 (09951−00910),
09950−70010 (09951−07100)
(b) Coat the lip of the oil seal with MP grease.
3. INSTALL STEERING KNUCKLE ARM
(a) Clean the threads of the 2 bolts and steering knuckle with
toluene or trichloroethylene.
F04349 (b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833−00070, THREE BOND 1324
or equivalent
(c) Install the steering knuckle arm with 2 bolts.
SA−38
SA14D−03
INSTALLATION
1. INSTALL STEERING KNUCKLE
(a) Apply synthetic oil and lithium soap base chassis grease,
NLGI No.1 to the drive shaft.
(b) Support the lower suspension arm with jack and connect
the steering knuckle to the lower suspension arm.
NOTICE:
Be careful not to damage the oil seal.
F04405
(c) Temporarily install the nut to lower suspension arm.
(d) Raise up the lower suspension arm using a jack and
install the steering knuckle to the upper suspension arm
with a nut.
(e) Install a new cotter pin.
(f) Torque the nut of the lower suspension arm.
(g) Install a new cotter pin.
2. CONNECT TIE ROD END
(a) Connect the tie rod end to steering knuckle with nut.
(b) Install a new cotter pin.
3. w/ ABS:
CONNECT ABS SPEED SENSOR AND WIRE HAR-
NESS
Install the 3 bolts.
B C
Torque:
A: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
A
B: 13 N·m (130 kgf·cm, 9 ft·lbf)
C: 28 N·m (290 kgf·cm, 21 ft·lbf)
F04372 4. INSTALL DUST COVER, GASKET AND OIL SEAL
Install the dust cover, gasket and oil seal with 4 bolts.
SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT (Rigid Front SA−39
Suspension)
STEERING KNUCKLE AND AXLE SHAFT (Rigid Front

Suspension)
SA1AE−01
COMPONENTS
96 (980, 71)
Oil Seal Set 8.0 (82, 71 in.·lbf)
Bearing Cap
Oil Seal Shim
End Retain-
er Felt Dust Bearing
x6 Seal Rubber ABS Speed
5.4 (55, 48 in.·lbf) Steel
Seal Steering Knuckle Sensor
Ring
z Bearing z Gasket
Outer Race Bushing
Knuckle
z Snap Ring Bearing Spindle
z
Tie Rod End
z Oil Seal Knuckle Arm
Front Axle Shaft
91 (925, 67)
z Gasket Cone Washer
z Cotter Pin
96 (980, 71)
30 (310, 22)
123 (1,250, 90)
Dust Cover
Brake Caliper
47 (475, 34)
x8
Outer Adjusting Nut
Bearing z Lock Washer
Lock Nut
z Gasket z Gasket
Flange
Dust Seal
z Snap Ring
z Bearing Cap
Thrust Washer
x6
Cone Washer
z 33 (335, 24)
F05783
SA−40 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT (Rigid Front
Suspension)
SA1AF−01
REMOVAL
2. w/ ABS:
REMOVE ABS SPEED SENSOR
Remove the 2 bolts and disconnect the ABS speed sensor from
the steering knuckle.
3. REMOVE DUST SEAT AND DUST COVER

Remove the 8 bolts, dust seal, dust cover and gasket.
4. REMOVE KNUCKLE SPINDLE
(a) Using a brass bar and hammer, tap the knuckle spindle
of the steering knuckle.
(b) Remove the knuckle spindle and gasket.
5. REMOVE AXLE SHAFT
Position one flat part of the outer shaft upward and remove the
W00495 axle shaft.
6. DISCONNECT TIE ROD FROM KNUCKLE ARM
(b) Using SST, disconnect the tie rod from the knuckle arm.
SST 09611−22012
SST
SA2644
7. REMOVE OIL SEAL END RETAINER

Remove the 6 bolts from the oil seal end retainer.
R08383
Suspension)
8. REMOVE KNUCKLE ARM AND BEARING CAP

(a) Remove the 2 bolts and plate washers from the bearing
cap.
(b) Remove the 4 nuts from the knuckle arm.
(c) Using a brass bar and hammer, tap on the 4 bolts heads
and remove the 4 cone washers.
R13137
(d) Using SST and wooden plate, remove the bearing cap
SST and shim from the steering knuckle.
SST 09606−60020
HINT:
S Use the SST without a collar.
S In some cases, to satisfy the standard value of preload,
more than one shims are used.
Wooden Plate F05793
Wooden Plate (e) Using SST and wooden plate, remove the knuckle arm
from the steering knuckle.
SST 09606−60020
HINT:
S Use the SST without a collar.
S In some cases, to satisfy the standard value of preload,
more than one shims are used.
SST
F05794
9. REMOVE STEERING KNUCKLE AND BEARING

HINT:
Mark the removed adjusting shim and bearings so as to enable
reassembling them to their proper positions.
10. REMOVE OIL SEAL SET
Remove the steel ring, rubber seal and felt dust seal.
SA2780
11. REMOVE OIL SEAL TO AXLE HOUSING

Using SST, remove the oil seal.
SST 09308−00010
SST Q07149
Suspension)
SA1AG−01
DISASSEMBLY
REMOVE OUTER SHAFT
(a) Hold the inner shaft in a vise.
(b) Place a brass bar against the joint inner race and remove
the outer shaft.
HINT:
When removing the outer shaft, the snap ring will be broken.
FA0203
Suspension)
SA1AH−01
REPLACEMENT
1. REPLACE BUSHING
(a) Using SST, remove the bushing.
SST
SST 09612−65014 (09612−01010, 09612−01050)
SST (b) Using SST and a press, install a new bushing into the
spindle.
SST 09618−60010
R08435
2. REPLACE BEARING OUTER RACE

(a) Using a brass bar and hammer, remove the bearing outer
SST
race.
(b) Using SST and a hammer, carefully install a new bearing
outer race.
SST 09605−60010
Z06889
Suspension)
SA1AI−01
REASSEMBLY
INSTALL OUTER SHAFT
(a) Hold the outer shaft in a vise and while compressing a
new snap ring, install the inner shaft to the outer shaft.
(b) Make sure that the inner shaft cannot be pulled out.
FA0107
Suspension)
SA1AJ−01
INSTALLATION
1. INSTALL OIL SEAL TO AXLE HOUSING
Using SST and a hammer, install a new oil seal into the axle
housing.
SST SST 09618−60010
2. TEMPORALLY INSTALL OIL SEAL SET TO AXLE
HOUSING
Place the felt dust seal, rubber seal and steel ring to the axle
SA2650
housing.
Lithium Base Wheel Bearing 3. PACK BEARINGS WITH LITHIUM BASE WHEEL
Grease, NLGI No. 2 BEARING GREASE, NLGI NO. 2
(a) Place lithium base wheel bearing grease, NLGI No. 2 on
your hand.
(b) Pack grease into the bearing until the grease oozes out
from the outer side.
4. INSTALL STEERING KNUCKLE AND BEARINGS
Z15221 (a) Place the bearings in positions on the knuckle and axle
housing.
(b) Install the knuckle on the axle housing.
5. INSTALL KNUCKLE ARM AND BEARING CAP

SST
(a) Using SST and wooden plate, support the upper bearing
inner race.
SST 09606−60020
HINT:
Use the SST with a collar.
(b) Install the bearing cap over the used shim.
(c) Using a hammer, install the bearing cap into the bearing
Wooden Plate
F04029 inner race.
Wooden Plate (d) Using SST and wooden plate, support the lower bearing
inner race.
SST 09606−60020
HINT:
Use the SST with a collar.
(e) Using a hammer, tap the knuckle arm and shim into bear-
ing inner race.
(f) Remove the SST from the knuckle.
SST
F04030
Suspension)
(g) Install the 4 cone washers and nuts.

(h) Install the 2 plate washers and bolts.
6. MEASURE BEARINGS PRELOAD

Using a spring tension gauge, measure the preload.
25 − 44 N (2.5 − 4.5 kgf, 5.6 − 9.9 lbf)
7. ADJUST BEARING PRELOAD
90˚ (a) Remove the bearing cap and knuckle arm.
(b) Select the adjusting shim.
Adjusting shim thickness
R13138 Thickness mm (in.) Thickness mm (in.)
0.1 (0.004) 0.5 (0.020)
0.2 (0.008) 1.0 (0.039)
(c) Install the bearing cap and knuckle arm.
8. CONNECT TIE ROD TO KNUCKLE ARM
Torque the nut and secure it with a new cotter pin.
9. INSTALL OIL SEAL END RETAINER TO KNUCKLE
ARM
Install the steel ring, rubber seal, felt dust seal and oil seal end
retainer to steering knuckle with the 6 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
10. INSTALL AXLE SHAFT
Position one flat part of the outer shaft upward and install the
shaft.
11. PACK MOLYBDENUM DISULFIDE LITHIUM BASE

GREASE, NLGI NO. 2
Pack molybdenum disulfide lithium base grease, NLGI No. 2
Molybdenum into the knuckle to about 3 fourths of the knuckle.
Disulfied
Lithium
Base Grease,
NLGI No. 2
Z15222
Suspension)
12. INSTALL KNUCKLE SPINDLE, DUST COVER WITH

GASKETS AND DUST SEAL
(a) Place a new gasket in position on the knuckle and install
the spindle.
(b) Place the dust cover, dust seal and a new gasket on the
spindle.
(c) Torque the 8 bolts.
13. w/ ABS:
CONNECT ABS SPEED SENSOR
Connect the ABS speed sensor and 2 bolts to the steering
knuckle.
15. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)
16. w/ ABS:
(See page DI−312)
SA−48
SUSPENSION AND AXLE − FRONT DRIVE SHAFT (Independent Front Suspension)
FRONT DRIVE SHAFT (Independent Front Suspension)

SA14E−03
COMPONENTS
w/ ABS 28 (290, 21)

ABS Speed Sensor
and Wire Harness
28 (290, 21)
13 (130, 9)
110 (1,125, 81)
z Cotter Pin 8.0 (82, 71in.·lbf)
123 (1,250, 90)

Drive Shaft Brake Caliper
Steering Knuckle
with Axle Hub
159 (1,625, 118)
z Cotter Pin z Snap Ring
z Grease Cap
L 147 (1,500, 108)

z Snap Ring
Supply Parts
z Dust Cover
z Boot Clamp
Inboard Joint Tulip
Snap Ring
Cage
Inner Race
Ball
Snap Ring
z Boot z Boot Clamp
z Boot
Outboard Joint Shaft
z Dust Seal

SA−49
SA14F−03
REMOVAL
Torque:

(a) Remove the bolt and flexible hose from the steering
knuckle.
3. REMOVE SNAP RING
F04367 (a) Using a screwdriver and hammer, remove the grease cap
from the flange.
(b) Using snap ring pliers, remove the snap ring.
F04368
4. w/ ABS:
DISCONNECT ABS SPEED SENSOR AND WIRE HAR-
NESS
C Remove the 3 bolts and disconnect the ABS speed sensor and
B wire harness.
Torque:
A A: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
B: 13 N·m (130 kgf·cm, 9 ft·lbf)
F05795 C: 28 N·m (290 kgf·cm, 21 ft·lbf)
5. DISCONNECT STEERING KNUCKLE ARM

Remove the 2 bolts and disconnect the steering knuckle arm.
HINT:
At the time of installation, please refer to the following items.
S Clean the threads of the 2 bolts and steering knuckle with
F05161
SA−50
S Apply sealant to the bolt threads.

Sealant:
or equivalent
6. DISCONNECT STEERING KNUCKLE FROM LOWER
SUSPENSION ARM
(b) Using SST, disconnect the steering knuckle from the low-
er suspension arm.
SST 09628−62011
7. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Support the lower suspension arm with a jack.
SST
(b) Remove the cotter pin and nut.
(c) Temporarily install the nut to the lower suspension arm.
F05162
(d) Using SST, disconnect the steering knuckle from the up-
per suspension arm.
SST 09628−62011
(e) Remove the nut and steering knuckle with axle hub.
SST
F04375
LH Side 8. REMOVE DRIVE SHAFT

(a) Using a brass bar and hammer, remove the drive shaft.
NOTICE:
Be careful not to damage the boot, dust cover and oil seal.
(b) Using a screwdriver, remove the snap ring.
HINT:
S Coat the oil seal lip with MP grease.
RH Side S Before installation, set a new snap ring with opening side
facing downward.
S After installation, check that the drive shaft cannot be
pulled out by hand.
F04376
SA−51
SA14G−03
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no remarkable play in the out-
board joint.
(b) Check to see that inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
F05255
(d) Check for damage to boots.
2. UNSTAKE INBOARD JOINT BOOT CLAMPS
Using a screwdriver, unstake the 2 inboard joint boot clamps.
Matchmarks 3. REMOVE INBOARD JOINT TULIP

(a) Place matchmarks on the inboard joint tulip and outboard
joint shaft.
NOTICE:
Do not punch the marks.
(b) Using a screwdriver, remove the snap ring.
(c) Remove the inboard joint tulip from the outboard joint
shaft.
W05076
4. DISASSEMBLE INBOARD JOINT

(a) Place matchmarks on the outboard joint shaft, inner race
and cage.
Matchmarks
NOTICE:
Do not punch the marks.
(b) Remove the 6 balls.
(c) Slide the cage to the outboard joint side.
(d) Using a snap ring expander, remove the snap ring.
F05242 (e) Using a brass bar and hammer, remove the inner race.
NOTICE:
Be careful not to damage the inner race.
(f) Remove the cage.
5. REMOVE INBOARD JOINT BOOT AND CLAMPS
6. REMOVE OUTBOARD JOINT BOOT CLAMPS
(a) Using a screwdriver, unstake the 2 outboard joint boot
clamps.
HINT:
When the supplied part is used, using a side cutter, cut the 2
outboard joint boot clamps and remove them.
SA−52
(b) Remove the 2 outboard joint boot clamps and outboard

joint boot.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER
Using a screwdriver and hammer, remove the dust cover from
the inboard joint tulip.
8. REMOVE DUST SEAL
Using a screwdriver and hammer, remove the dust seal from the
outboard joint shaft assembly.
SA−53
SA14H−03
REASSEMBLY
1. INSTALL DUST SEAL
Using SST and a press, install a new dust seal to the outboard
SST joint shaft assembly.
SST 09950−00020
NOTICE:
Be careful not to damage the dust seal.
F05097
2. INSTALL DUST COVER

Using SST a steel plate and press, install a new dust cover to
the inboard joint tulip.
SST 09316−20011
NOTICE:
Be careful not to damage the dust cover.
3. INSTALL OUTBOARD JOINT BOOT AND CLAMPS
(a) Place 2 new boot clamps to boot.
SST F05096 HINT:
Before installing the boot, wrap vinyl tape around the spline of
the shaft to prevent damaging the boot.
(b) Temporarily install a new boot to the outboard joint shaft
assembly.
(c) Position the inside clamp onto the boot.
(d) Using SST, pinch the inside clamp.

SST
SST 09521−24010
NOTICE:
Do not overtighten SST.
(e) Coat the outboard joint and boot with grease in the boot
kit.
Grease capacity: 368 − 378 g (13 − 13.3 oz.)
(f) Position the outside clamp onto the boot.
R10353
(g) Using SST, pinch the outside clamp.

SST SST 09521−24010
NOTICE:
Do not overtighten SST.
F05098
SA−54
(h) Using SST, adjust the clearance of the clamp.

SST 09240−00020
Clearance Clearance: 0.8 mm (0.031 in.)
4. TEMPORARILY INSTALL INBOARD JOINT BOOT AND
CLAMPS
Temporarily install 2 new boot clamps and boot to the outboard
SST joint shaft assembly.
R10354
5. ASSEMBLE INBOARD JOINT

(a) Install the cage to the outboard joint shaft assembly.
Outboard NOTICE:
side Insert the cage with its smaller inner diameter side facing
to the outboard joint.
(b) Align matchmarks placed before removal.
(c) Install the inner race.
(d) Using a snap ring expander, install a new snap ring.
F05099 (e) Align matchmarks placed before removal, and install the
cage to the inner race.
(f) Install the 6 balls.
HINT:
Apply grease onto the balls to keep them from falling.
(g) Coat the inboard joint tulip and boot with grease in the
boot kit.
Grease capacity: 293 − 303 g (10.3 − 10.7 oz.)
(h) Align matchmarks placed before removal, and install the
inboard joint tulip to the outboard joint shaft assembly.
(i) Install a new snap ring.
(j) Temporarily install the boot to the inboard joint tulip.
(k) Make sure that the boot is on the shaft groove.
(l) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
573.9 ± 5 mm (22.594 ± 0.197 in.)
(m) Using a screwdriver, bend the clamp and lock it.
6. CHECK DRIVE SHAFT (See page SA−51)
F05237
SA−55
SA14I−02
INSTALLATION
Installation is in the reverse order of removal (See page SA−49).
w/ ABS:
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−312)
SA−56 SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front
Suspension)
FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front

Suspension)
SA1BR−01
COMPONENTS
80(820,59)
Companion Flange
Front Propeller
Shaft
z Oil Seal
Rear Bearing
z Bearing Spacer z See page SA−74
Oil Slinger
z Oil Storage Ring

SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front SA−57
Suspension)
SA1BS−01
REPLACEMENT
Matchmarks 1. DISCONNECT FRONT PROPELLER SHAFT
(a) Place matchmarks on the flanges.
(b) Remove the 4 bolts and nuts.
(c) Disconnect the front propeller shaft.
2. DRAIN HYPOID GEAR OIL
SA1958
3. REMOVE COMPANION FLANGE

(a) Using a chisel and hammer, loosen the staked part of the
SST nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
Z15176
SST (c) Using SST, remove the companion flange.

SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
R13186
4. REMOVE OIL SEAL AND SLINGER

SST 09308−10010
(b) Remove the oil slinger.
SA1973
5. REMOVE REAR BEARING

SST
Using SST, remove the rear bearing from the drive pinion.
SST 09556−22010
SA1969
SA−58 SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front
Suspension)
6. REMOVE REAR BEARING OUTER RACE

Using SST, remove the bearing outer race.
SST SST 09308−00010
NOTICE:
Do not scratch the taper surface of the outer race.
SA2430
7. REMOVE OIL STORAGE RING

Using a screwdriver, bend the oil storage ring and drive it out.
8. REMOVE BEARING SPACER
SA2271
Oil Storage Ring 9. INSTAL NEW BEARING SPACER

10. INSTALL OIL STORAGE RING
Using SST, install a new oil storage ring.
SST 09316−60011 (09316−00011), 09506−35010
SST 11. INSTALL REAR BEARING
Rear Bearing Outer Race
(a) Using SST, install the bearing outer race.
SST 09316−60011 (09316−00011), 09506−35010
(b) Install the rear baring.
SST R13155
12. INSTALL OIL SLINGER AND OIL SEAL

SST (a) Install the oil slinger.
(b) Using SST, install a new oil seal, as shown.
SST 09214−76011
Oil seal drive in depth: 1.0 mm (0.039 in.)
(c) Coat the lip of the oil seal with MP grease.
1.0 mm (0.039 in.)

SA2411
SST 13. INSTALL COMPANION FLANGE

(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
(b) Apply light coat of gear oil on threads of a new nut.
R13139
SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front SA−59
Suspension)
(c) Using SST to hold the flange, torque the nut.

SST
SST 09330−00021
14. ADJUST DRIVE PINION PRELOAD
(See page SA−74)
15. STAKE DRIVE PINION NUT
SA1960
16. CONNECT FRONT PROPELLER SHAFT

Matchmarks (a) Align the matchmarks and connect the propeller shaft to
the companion flange with the 4 bolts, washers and nuts.
(b) Torque the bolts and nuts.
SA1958
17. FILL DIFFERENTIAL WITH HYPOID GEAR OIL

Oil type: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18 ˚C (0 ˚F) SAE 90
Below −18 ˚C (0 ˚F) SAE 80W−90 or 80W
Capacity:
Filler Hole
Oil w/o Diff. lock:
0 − 5 mm (0 − 0.20 in.) RA1072 2.80 liters (2.9 US qts, 2.5 lmp. qts)
w/ Diff. lock:
2.65 liters (2.8 US qts, 2.3 lmp. qts)
SA−60 SUSPENSION AND AXLE − FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(Independent Front Suspension)
FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

SA14J−03
COMPONENTS
w/ ABS
ABS Speed Sensor 28 (290, 21)
and Wire Harness
13 (130, 9)
8.0 (82, 71 in.·lbf) 28 (290, 21)
123 (1,250, 90)
z Oil Seal
110 (1,125, 81)
Brake Caliper
z Cotter Pin
Steering Knuckle
with Axle Hub
Drive Shaft
159 (1,625, 118)

z Snap Ring
L 147 (1,500, 108) z Cotter Pin
z Grease Cap

L Precoated part
F05165
SUSPENSION AND AXLE − FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL SA−61
SA14K−03
REPLACEMENT
1. REMOVE FRONT DRIVE SHAFT
(See page SA−49)
2. REPLACE OIL SEAL

(a) Using SST, remove the oil seal.
SST 09308−00010
(b) Coat the hypoid gear oil to a new oil seal periphery.
SST
F05234
(c) Using SST and a hammer, install a new oil seal.

SST 09550−00032, 09950−70010 (09951−07100)
(d) Coat the MP grease to the oil seal lip.
3. INSTALL FRONT DRIVE SHAFT
(See page SA−55)
SST
F05235

Oil type: Hypoid gear oil API GL−5
Less than 5 mm (0.20 in.) Recommended oil viscosity:
Above −18˚C (0˚F) SAE 90
Below −18˚C (0˚F) SAE 80W−90 or 80W
Capacity: 1.70 liters (1.80 US qts, 1.50 lmp.qts)
F05233
SA−62 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (Rigid Front
Suspension)
FRONT DIFFERENTIAL CARRIER (Rigid Front Suspension)

SA1BX−01
COMPONENTS
w/ Diff. Lock
Front Differential
x11
Tie Rod
Front Propeller Shaft
Front Differential
z Gasket
80 (820, 59)
z Gasket x10
Filler Plug 27 (280, 20)

49 (500, 36)
z Gasket
91 (925, 67)
z Cotter Pin
Drain Plug
49 (500, 36)
Front Axle Shaft
Steering Knuckle Spindle
N·m (kgf·cm, ft·lbf) : Specified torque z Gasket

F05945
SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (Rigid Front SA−63
Suspension)
w/o Diff. Lock
Side Gear Thrust Washer

Pinion Gear
Side Gear
Pinion Shaft
Straight Pin
Side Bearing Pinion Gear Thrust Washer
Adjusting Nut
Outer Race z Bearing Spacer

Differential Case
Ring Gear Plate Washer
Driven Pinion
x10
Outer Race
97 (985, 71) x5
z Lock Plate Front Bearing
z Dust Deflector
z See page SA−74
Oil Slinger
Bearing Cap z Oil Storage Ring
78 (800, 58)
z Oil Seal
Outer Race Companion Flange
Rear Bearing
13 (130, 9)
z Adjusting Nut Lock
Differential Carrier
78 (800, 58)

W00530
Suspension)
w/ Diff. Lock
L Straight Screw Plug
22 (220, 16)
Spring Seat
Position Switch
Compression Spring 40 (410, 30)
Ball z Gasket Actuator

L 24 (240, 17)
z O−Ring 26 (270, 20)
Shaft Retainer Slotted Spring Pin z See page SA−74

z Dust Deflector
Shift Fork Shaft
Shift Fork z Oil Storage Ring
Oil Slinger
Bearing Cap

Companion Flange
78 (800, 58)
Outer Race z Oil Seal
Sleeve Rear Bearing

13 (130, 9)
Side Bearing z Bearing Spacer
78 (800, 58)
Outer Race Front Bearing
LH Differential Case
47 (480, 35) Drive Pinion Outer Race
RH Differential Case
x8
Adjusting Nut
Ring Gear
97 (985, 71) x10
z Lock Plate
x5
Plate Washer
Pinion Gear
Adjusting Nut
Pinion Gear
Thrust Washer
Side Gear
Thrust Washer
Spider
Side Gear
L Precoated part
W00531
Suspension)
SA1BY−01
REMOVAL
1. w/ DIFF. LOCK:
SHIFT FRONT DIFFERENTIAL TO LOCK CONDITION
(a) Turn the ignition switch to the ON position.
(b) Shift the transfer shift lever to L4 position.
(c) Turn the differential lock control switch to the FR/RR posi-
tion and lock the front differential.
HINT:
Rotating the tires, check they are in the differential lock condi-
tion.
(d) Disconnect the cable from the negative terminal of the
battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE FRONT AXLE SHAFTS (See page SA−40)
4. DISCONNECT FRONT PROPELLER SHAFT
Matchmarks (a) Place matchmarks on the flanges.
(b) Remove the 4 bolts, washers and nuts.
(c) Disconnect the front propeller shaft.
SA1958
5. w/ DIFF. LOCK:
DISCONNECT CONNECTORS AND TUBE
HINT:
S When connecting the tube of the harness side to the hose
of the actuator side, its depth of insertion is 15 mm (0.59
in.).
S Take care that water or equivalent does not adhere to the
FA2038 connector and hose.
Suspension)
6. REMOVE DIFFERENTIAL CARRIER ASSEMBLY

w/o Diff. Lock
(a) Remove the 10 nuts (w/o Diff. lock) 11 nuts (w/ Diff. lock),
washers and differential carrier assembly.
NOTICE:
Be careful not to damage the installation surface.
(b) Remove the gasket.
HINT:
w/ Diff. lock:
w/ Diff. Lock S Before installation, check differential lock operation con-
necting the connector of the actuator to the connector of
the vehicle side.
S Before installation, check that the sleeves on work with
switching over the differential lock control switch.
After checking, lock the front differential.
Z10092
Suspension)
SA1BZ−01
DISASSEMBLY
1. SET DIFFERENTIAL CARRIER TO OVERHAUL STAND
ETC.
2. CHECK RUNOUT OF COMPANION FLANGE

Using a dial indicator, measure the vertical and lateral runout of
the companion flange.
Maximum runout: 0.10 mm (0.0039 in.)
If the runout is not within the specification, replace the compan-
ion flange.
30 mm
(1.18 in.) W00493
3. CHECK RING GEAR RUNOUT

Using a dial indicator, measure the ring gear runout.
If the runout is greater than the maximum, replace the ring gear
and driven pinion as a set.
SA2465
4. CHECK RING GEAR BACKLASH

Using a dial indicator, while holding the drive pinion flange mea-
sure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
Measure at 3 or more places on the circumference of the ring
gear.
If the backlash is not within the specification, adjust the side
SA2462 bearing preload or repair as necessary.
5. MEASURE DRIVE PINION PRELOAD

Using a torque wrench, measure the drive pinion preload using
backlash of the drive pinion and ring gear.
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
SA2403
Suspension)
6. CHECK TOTAL PRELOAD

Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
If necessary, disassemble and inspect the differential.
7. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−74)
8. w/o DIFF. LOCK:

CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash while
holding one pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washers (See page SA−74).
9. w/ DIFF. LOCK:
SA2442 REMOVE ACTUATOR
(a) Remove the bolt and actuator from the differential carrier.
(b) Remove the O−ring.
10. w/ DIFF. LOCK:
REMOVE POSITION SWITCH
Remove the position switch and gasket.
11. w/ DIFF. LOCK:

REMOVE SHIFT FORK SHAFT
(a) Using a hexagon wrench, remove the 2 straight screw
plugs.
(b) Remove the spring seat, compression spring and ball.
R13332
(c) Using a pin punch and hammer, remove the slotted spring
pin.
SA2206
Suspension)
(d) Remove the 2 bolts from the shaft retainer.

(e) Using a plastic hammer, tap out the shaft retainer.
(f) Remove the shift fork shaft.
HINT:
Pull out the shift fork shaft with a screwdriver turned round.
(a) Using a chisel and hammer, unstake the nut.
Z10098

SST SST 09330−00021
SA2405
(c) Using SST, remove the companion flange.

SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
SST
R13141
13. REMOVE OIL SEAL AND OIL SLINGER

(a) Using SST, remove the oil seal from the differential carrier.
SST SST 09308−10010
SA2402

SST 09556−22010
If the rear bearing is damaged or worn, replace the rear bearing.
SST
Z00641
Suspension)
15. REMOVE DIFFERENTIAL CASE

(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 2 bolts and adjusting nut locks.
(c) Remove the 4 bolts and 2 bearing caps.
(d) w/o Diff. lock:
Matchmarks Remove the 2 adjusting nuts.
(e) w/o Diff. lock:
R13142 Remove the differential case with the side bearing outer
races from the carrier.
HINT:
Tag the disassembled parts to show the location for reassemb-
ly.
(f) w/ Diff. lock:
Remove the differential case with the side bearing outer
race, 2 adjusting nuts and sleeve from the differential car-
rier.
(g) w/ Diff lock:
Remove the shift fork.
16. REMOVE DRIVE PINION AND BEARING SPACER
FROM DIFFERENTIAL CARRIER
17. REMOVE DRIVE PINION FRONT BEARING

(a) Using SST and a press, remove the front bearing from the
SST drive pinion.
SST 09950−00020
If the drive pinion or ring gear is damaged, replace them as a
set.
(b) Remove the plate washer from the drive pinion.
FA2045
Rear Bearing Outer Race 18. REMOVE DRIVE PINION FRONT AND REAR BEARING
OUTER RACES AND OIL STORAGE RING
SST (a) Using SST, remove the rear bearing outer race.
SST 09308−00010
SA2431
Suspension)
Oil Storage Ring Front Bearing Outer Race (b) Using a brass bar and hammer, remove the oil storage
ring and front bearing outer race.
SA2410
19. REMOVE RING GEAR

(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the 5 lock
plates.
(c) Remove the 10 bolts and 5 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
Matchmarks it from the differential case.
20. CHECK DIFFERENTIAL CASE RUNOUT
Z15178 (a) Install the differential case in the differential carrier and
tighten the adjusting nut just to where there is no play in
the bearing.
(b) Using a dial indicator, measure the differential case run-

out.
Maximum case runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the differen-
tial case and side bearing as a set.
(c) Remove the differential case.
SA2464
21. REMOVE SIDE BEARINGS FROM DIFFERENTIAL

SST CASE
Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40011 (09951−04010, 09952−04010,
09953−04020, 09954−04010, 09955−04010,
09957−04010, 09958−04010),
09950−60010 (09951−00480)
SST W03472 HINT:
Fix the claws of SST to the notches in the differential case.
Suspension)
22. w/o DIFF. LOCK:

DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove the pinion shaft, 2 pinion gears, pinion gear
thrust washers, side gears and side gear thrust washers
from the differential case.
RA0997
23. w/ DIFF. LOCK:

DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the LH and RH cases.
(b) Remove the 8 bolts uniformly, a little at a time.
(c) Using a plastic hammer, separate the LH and RH cases.
(d) Remove the spider, 2 side gears, side gear thrust wash-
Matchmarks ers, 4 pinion gears and pinion gear thrust washers from
the RH differential case.
FA2046
Suspension)
SA1C0−01
SST
REPLACEMENT
REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950−00020
SA2419
(b) Using SST and a press, install a new dust deflector.

SST 09726−40010
SST
SA2418
Suspension)
SA1C1−01
REASSEMBLY
HINT:
S Using a shop rag, clean off any foreign object from the
parts.
S Apply all of the sliding and rotating surfaces with hypoid
gear oil.
1. w/o DIFF. LOCK:

MEASURE SIDE GEAR BACKLASH AND ASSEMBLE
DIFFERENTIAL CASE
(a) Install the 2 thrust washers to the side gears.
(b) Install the 2 side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT:
Align the hole of the differential case and pinion shaft.
SA0510
(c) Using a dial indicator, measure the side gear backlash

while holding one pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install side gear
thrust washers with different thickness.
Thrust washer thickness
Thickness mm (in.) Thickness mm (in.)
1.60 (0.0630) 1.80 (0.0709)
Z06893
1.70 (0.0669) −
(d) Using a pin punch and hammer, install the straight pin
through the holes in the differential case and hole of the
pinion shaft.
(e) Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.
Z06894
2. w/ DIFF. LOCK:
INSPECT SLEEVE
(a) Install the sleeve to the differential case (LH) and check
it moves smoothly.
(b) Install the sleeve to the side gear check it moves smooth-
ly.
R08149
Suspension)
3. w/ DIFF. LOCK:
MEASURE CLEARANCE OF SHIFT FORK AND
SLEEVE
Using a feeler gauge, measure the clearance between the shift
fork and sleeve.
Clearance: 0.15 − 0.35 mm (0.006 − 0.014 in.)
SA1987
4. w/ DIFF. LOCK:
MEASURE SIDE GEAR BACKLASH AND ASSEMBLE
DIFFERENTIAL CASE
(a) Install the side gear thrust washer to the side gear.
(b) Install the side gear to the RH case.
(c) Install the 4 pinion gears and pinion gear thrust washers
to the spider.
(d) Install the pinion gear with the spider to the RH case.
SA1978
(e) Using a dial indicator, holding the side gear and spider,
measure the side gear backlash,
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
HINT:
S Measure at all 4 locations.
S Measure the backlash at the RH case and at the LH case.
If the backlash is not within the specification, install a thrust
washer of a different thickness.
SA1976 Thrust washer thickness
0.9 (0.035) 1.2 (0.047)
1.0 (0.039) 1.3 (0.051)
1.1 (0.043) −
(f) Install the side gear and side gear thrust washer to the RH
case.
(g) Install the pinion gears and spider to the RH case.
(h) Install the side gear and side gear thrust washer to the RH
case.
(i) Align the matchmarks on the LH and RH cases.

(j) Torque the 8 bolts uniformly a little at a time.
Matchmarks
FA2037
Suspension)
5. INSTALL SIDE BEARINGS

(a) w/o Diff. lock:
SST Using SST and a press, install the 2 side bearings to the
differential case.
SST 09950−60010 (09951−00480)
SST SA2415
(b) w/ Diff. lock:

Using SST and a press, install the 2 side bearings to the
SST
differential case.
SST 09223−15020, 09950−60010 (09951−00480)
6. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
SST
SA2150
(b) Heat the ring gear to about 100 ˚C (212 ˚F) in boiling wa-
Boiling Water ter.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the ring gear and differential case.
(e) Temporarily install 5 new lock plates and 10 bolts so that
SA2160 the bolt holes in the ring gear and differential case are not
misaligned.
(f) After the ring gear has cooled sufficiently, torque the 10
bolts.
(g) Using a drift punch hammer, stake the 5 lock plates.

HINT:
Stake the claws of the lock plates to fix the bolts.
For the claw contacting the protruding portion of the bolt, stake
only the half of it along the tightening direction.
SA2182
Suspension)

(a) Place the bearing outer races on their respective bear-
ings. Check that the left and right outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
(c) When there is no play left in the side bearings.
(d) Align matchmarks on the bearing cap and differential car-
rier.
(e) Install and uniformly tighten the 4 bearing cap bolts in sev-
eral passes.
(f) Using a dial indicator, check the ring gear runout.
(g) Remove the differential case.
SA2465
8. INSTALL OIL STORAGE RING

Using SST and a hammer, install a new oil storage ring.
SST 09316−60011 (09316−00011, 09316−00021)
SST
SA2406
REAR FRONT 9. INSTALL DRIVE PINION FRONT AND REAR BEARING

SST OUTER RACES
SST
(a) Using SST and a press, install the front bearing outer
race.
SST 09316−60011 (09316−00011, 09316−00051)
(b) Using SST and a press, install the rear bearing outer race.
SST 09316−60011 (09316−00011, 09316−00021)
10. INSTALL DRIVE PINION FRONT BEARING
SA2203 (a) Install the plate washer on the drive pinion with the cham-
fered end facing the pinion gear.
(b) Using SST and a press, install the front bearing onto the
drive pinion.
SST SST 09506−30012
11. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion, rear bearing and oil slinger.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
FA2042
Suspension)
(b) Using SST, install the companion flange.

SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
SST
R13140
(c) Using SST to hold the flange, adjust the drive pinion pre-
SST load by tightening the nut.
SST 09330−00021
NOTICE:
S Coat the nut and threads of the drive pinion with gear
oil.
S As there is no spacer, tighten the nut a little at a time,
being careful not to overtighten.
SA2401
(d) Using a torque wrench, measure the preload.

New bearing
0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
HINT:
Measure the total preload after first turning the bearing clock-
SA2403 wise and counterclockwise several times to make the bearing
smooth.
12. w/o DIFF. LOCK:
INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear-
ings. Make sure the left and right outer races are not inter-
changed.
13. w/ DIFF. LOCK:

INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Apply MP grease on the rack of the shift fork and connect-
ing part of the indicator switch.
(b) Insert the shift fork into the differential carrier, as shown.
MP Grease
SA2161
Suspension)
(c) Install outer races, adjusting nuts and sleeve to left side.
HINT:
Check that the sleeve moves smoothly.
(d) Install the shift fork in the groove of the sleeve holding it
by hand and install the case in the carrier.
Z10100
14. w/o DIFF. LOCK:

INSTALL ADJUSTING NUTS
Install the 2 adjusting nuts on the carrier, making sure the nuts
are engaged properly.
Z06898
15. INSTALL BEARING CAPS

Matchmarks Align the matchmarks on the bearing cap and carrier. Tighten
the 2 bearing cap bolts 2 or 3 turns and press down the bearing
cap by hand.
HINT:
If the bearing cap does not fit tightly on the carrier, the adjusting
nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
SA2458
16. ADJUST SIDE BEARING PRELOAD

(a) Torque the 4 bearing cap bolts to the specified torque,
and loosen them to the point where the adjusting nuts can
be turned by SST.
SST 09504−00011
Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf)
(b) Fully tighten the 4 bearing cap bolts by hand.
SST (c) Using the SST, torque the adjusting nut on the ring gear
SA2467 side until the ring has a backlash of about 0.2 mm (0.008
in.).
(d) While turning the ring gear, use the SST to fully tighten the
adjusting nut on the drive pinon side. After the bearings
are settle, loosen the adjusting nut on the drive pinion
side.
SST
Z10281
Suspension)
(e) Place a dial indicator on the top of the adjusting nut on the
ring gear side.
(f) Adjust the side bearing for 0 preload by tightening the oth-
SST
er adjusting nut until the pointer on the indicator bearings
to move.
(g) Torque the adjusting nut 1 − 1.5 notches from the 0 pre-
load position.
SA2308
(h) Using a dial indicator, adjust the ring gear backlash until
it is within the specification.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
The backlash is adjusted by turning the left and right adjusting
nuts equal amounts. For example, loosen the nut on left side 1
notch and torque the nut on the right side 1 notch.
(i) Torque the 4 bearing cap bolts.
SST
SA2443 Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(j) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(k) Using a torque wrench, measure the preload.

Total preload (at starting ):
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
SA2403

AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Turn the companion flange in both directions to inspect
the ring gear for proper tooth contact.
SA2463
Suspension)
Heel Contact Face Contact
Proper Contact
Select an adjusting washer that will bring the drive

pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting washer that will shift drive pinion

away from the ring gear.
FA2013
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Washer thickness
1.70 (0.0669) 2.03 (0.0799)
1.73 (0.0681) 2.06 (0.0811)
1.76 (0.0693) 2.09 (0.0823)
Washer
1.79 (0.0705) 2.12 (0.0835)
FA2041
1.82 (0.0717) 2.15 (0.0846)
1.85 (0.0728) 2.18 (0.0858)
1.88 (0.0740) 2.21 (0.0870)
1.91 (0.0752) 2.24 (0.0882)
1.94 (0.0764) 2.27 (0.0894)
1.97 (0.0776) 2.30 (0.0906)
2.00 (0.0787) 2.33 (0.0917)
(See page SA−67)
19. REMOVE OIL SLINGER AND REAR BEARING

20. REMOVE REAR BEARING OUTER RACE AND OIL
STORAGE RING (See page SA−67)
21. INSTALL BEARING SPACER AND REAR BEARING
(a) Install a new bearing spacer on the shaft.
(b) Install a new oil storage ring and rear bearing outer race
(See page SA−74).
(c) Install the rear bearing and oil slinger.
W00529
Suspension)
22. INSTALL OIL SEAL

(a) Using SST, install a new oil seal.
SST 09214−76011
(b) Coat the MP grease to the oil seal lip.
SST
SA2407
23. INSTALL COMPANION FLANGE

(a) Install the companion flange with SST.
SST 09950−30010 (09951−03010, 09953−03010,
SST
09954−03010, 09955−03030, 09956−03020)
(b) Install a new nut.
HINT:
Coat the threads of a new nut with gear oil.
R13140
(c) Using SST to hold the flange, tighten the nut.

SST 09330−00021
SA2390
24. ADJUST DRIVER PINION PRELOAD

Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
New bearing
0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
SA2403 If the preload is greater than the specification, replace the bear-
ing spacer.
If the preload is less than the specification, retighten the nut with
a force of 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the speci-
fied preload is reached.
Torque: 343 N·m (3,500 kgf·cm, 253 ft·lbf) or less
If the maximum torque is exceeded while retightening the nut,
replace the bearing spacer and repeat the preload procedure.
Do not loosen the pinion nut to reduce the preload.
Suspension)
25. RECHECK RING GEAR BACKLASH

(See page SA−67)
26. RECHECK TOOTH CONTACT BETWEEN RING GEAR
(See page SA−67)
29. INSTALL ADJUSTING NUT LOCKS

(a) Install 2 new nut locks on the bearing caps.
(b) After tightening bolts, bend the nut locks.
SA2471
30. w/ DIFF. LOCK:

Holes INSTALL SHIFT FORK SHAFT
(a) Apply MP grease onto the outer circuit of the fork shaft.
(b) Install the fork shaft to match the hole of the shift fork and
that of the shift fork shaft.
Groove
SA2417
(c) Remove any FIPG material and be careful not to drop oil
FIPG Width Approx. on the contacting surface of the differential carrier and
1 − 2 mm (0.04 − 0.08 in.)
shaft retainer.
(d) Apply FIPG to the carrier, as shown.
FIPG:
or equivalent
HINT:
Z15179 Install the shaft retainer within 10 minutes after applying FIPG.
(e) Clean the threads of the bolts and retainer bolts holes with
(f) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
Adhesive (g) Tighten the shaft retainer with the 2 bolts.
Z10101
Suspension)
(h) Using a pin punch and hummer, install the slotted spring
pin to the shift fork.
SA2205
(i) Shift the fork deeply and keep the differential lock condi-
tion.
Lock SA1979
(j) Install the ball, compression spring and spring seat.

(k) Clean the threads of 2 plugs and plug holes with toluene
or trichloroethylene.
(l) Apply adhesive to the plug threads.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(m) Using a hexagon wrench, install and tighten the screw
Adhesive R13413 plugs.
31. w/ DIFF. LOCK:
MEASURE DISTANCE BETWEEN SLEEVE AND DIF-
FERENTIAL CASE END SIDE
Measure distance between the sleeve and tip of the differential
case when the differential is free and locked.
Standard distance:
LOCK: 17.44 − 18.86 mm (0.6866 − 0.7425 in.)
FREE: 32.40 − 33.90 mm (1.2756 − 1.3346 in.)
R08152
32. w/ DIFF. LOCK:

INSTALL POSITION SWITCH
Install the position switch with a new gasket.
SA1993
Suspension)
33. w/ DIFF. LOCK:

INSTALL ACTUATOR
(a) Check that the outermost positioned rack tooth of the shift
Outside fork is virtually above the center line of the actuator instal-
Shift Fork
lation hole.
Actuator Installation
Hole
R08153
(b) Ensure that the matchmarks of the pinion of the actuator

is between 0 and 5 degrees clockwise above the center
line of the actuator.
3 2 NOTICE:
S If the matchmarks is not within the above range, ro-
1.5V
tate the pinion to be matched.
S Do not supply the battery voltage directly between
terminals.
S If the matchmarks come to the extension limit of the
rotation, do not electrify moreover.
5˚
108˚
Matchmark
(Groove)
R08154
(c) Install a new O−ring to the actuator.

(d) Apply a light coat of gear oil on the O−ring.
(e) Coat the MP grease to the gear part.
SA2306
(f) Insert the actuator so that the long hole on the actuator
Knock side fits with the knock pin on the carrier side.
Pin HINT:
Do not damage the O−ring of the actuator.
(g) Align the actuator with the long hole and rotate the actua-
tor counterclockwise when the knock pin reaches the
right−hand side.
SA1992
Suspension)
(h) Install the actuator to the differential carrier with the bolt
so that the outermost positioned rack tooth of the shift fork
will fit the matchmarks of the pinion of the actuator.
34. REMOVE DIFFERENTIAL CARRIER FROM OVER-
HAUL STAND ETC.
R08218
Suspension)
SA1C2−01
INSTALLATION
AFTER INSTALLATION, FILL DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA−57)
SA−88 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (Independent Front
Suspension)
FRONT DIFFERENTIAL CARRIER (Independent Front

Suspension)
SA14L−04
COMPONENTS
w/ ABS
ABS Speed Sensor 28 (290, 21)
and Wire Harness
13 (130, 9)
28 (290, 21)
8.0 (82, 71 in.·lbf)
123 (1,250, 90)
Brake Caliper
110 (1,125, 81)
z Cotter Pin
Drive Shaft
Steering Knuckle with

Axle Hub
159 (1,625, 118) z Snap Ring
z Cotter Pin z Grease Cap
L 147 (1,500, 108)
Steering Arm

SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (Independent Front SA−89
Suspension)
80 (820, 59)
17 (173, 13)
Breather Hose
Front Propeller Shaft
Mount Stopper
Mount Stopper
Mount Stopper
186 (1,900, 137)
Mount Differential
Differential Support Support
Stopper
186 (1,900, 137)
186 (1,900, 137)
78 (800, 58)
68 (695, 50)
No. 3 Frame
Crossmember
68 (695, 50) 186 (1,900, 137)

F05231
Suspension)
z See page SA−99

Filler Plug Companion Flange
49 (500, 36)
z Rear Bearing Oil Slinger
z Gasket
Drain Plug
49 (500, 36) Dust Deflector
z Gasket z Oil Seal
Washer z Oil Storage Ring
z Bearing Spacer
L 105 (1,070, 77)
Front Bearing Differential Tube

Drive Pinion
Oil Deflector 47 (475, 34)
Breather Plug 7.3 (74, 64 in.·lbf)
Differential
Carrier Cover
Side Gear Shaft Snap Ring

x8
47 (475, 34) z Oil Seal
Bearing
z Lock Plate
Snap Ring
x5
Differential Case
Thrust Washer x10 Ring Gear
Side Gear
Side Bearing
97 (985, 71)
Pinion Shaft Straight Pin
85 (870, 63)
Pinion Gear
Thrust Washer Plate Washer
Bearing Cap

Suspension)
FRONT DIFFERENTIAL CARRIER (Independent Front

Suspension)
SA1S9−01
COMPONENTS
Filler Plug z See page SA−8
49 (500, 36) Rear Bearing Dust Deflector
z z Gasket z Bearing Spacer Oil Slinger
Drain Plug
49 (500, 36)
z Gasket
Front Bearing Companion Flange
Washer z Oil Seal
z Oil Storage Ring
Breather Plug L 105 (1,070, 77)
7.3 (74, 64 in.·lbf)
Drive Pinion
Differential Tube
Differential
Carrier Cover
Bearing
Oil Deflector
x8 Side Gear Shaft Snap Ring
z Oil Seal
x8
47 (475, 34)
97 (985, 71) x10
Thrust Washer
x5
Side Bearing
Side Gear
Ring Gear
Spider
Pinion Gear
Thrust Washer
Pinion Gear 85 (870, 63)
Plate Washer
Bearing Cap

Suspension)
SA14M−03
REMOVAL
1. REMOVE FRONT WHEELS
Torque:
2. REMOVE DRIVE SHAFTS (See page SA−49)
3. DISCONNECT FRONT PROPELLER SHAFT

(a) Place matchmarks on the front propeller shaft and com-
panion flange.
(b) Remove the 4 nuts, washers, bolts and disconnect the
front propeller shaft.
(c) Support the propeller shaft securely.
Matchmarks 4. DRAIN HYPOID GEAR OIL
5. REMOVE NO. 3 FRAME CROSSMEMBER

Remove the 5 bolts, nuts and No. 3 frame crossmember.
Torque:
B B A: 186 N·m (1,900 kgf·cm, 137 ft·lbf)
B B: 68 N·m (695 kgf·cm, 50 ft·lbf)
A B
6. REMOVE FRONT DIFFERENTIAL CARRIER AS-
SEMBLY
(a) Support the front differential carrier assembly with a jack.
F05232 (b) Remove the bolt and disconnect the breather hose.
(c) Remove the 3 nuts, 4 mount stoppers, 6 bolts, 2 differen-
tial supports and front differential carrier.
Torque:
A
B B A: 186 N·m (1,900 kgf·cm, 137 ft·lbf)
B: 78 N·m (800 kgf·cm, 58 ft·lbf)
A A
A
F04404
Suspension)
SA14N−03
DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 9 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover from
carrier.
(c) Remove the breather plug from the differential carrier cov-
er.
(d) Remove the 2 bolts and oil deflector from the differential
carrier cover.
ETC.

Maximum: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, replace the compan-
ion flange.
30 mm
(1.18 in.) W00493

and drive pinion as a set.
F05229

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
gear.
If the backlash is not within the specification, adjust the back-
F05228 lash.
Suspension)

the backlash of the drive pinion and ring gear.
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
Using a torque wrench, measure the total preload.
SA2352 Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
9. CHECK SIDE GEAR BACKLASH

Using a dial indicator, measure the side gear backlash while
holding one pinion gear toward the differential case.
Maximum backlash: 0.15 mm (0.0059 in.)
If the backlash is out of the specification, install the correct
thrust washers (See page SA−99).
F05220
10. REMOVE SIDE GEAR SHAFT OIL SEALS

Using SST, remove the 2 side gear shaft oil seals.
SST 09308−00010
SST
F05221
11. REMOVE DIFFERENTIAL TUBE ASSEMBLY

(a) Using SST, remove the snap ring.
SST SST 09350−30020 (09350−07060)
(c) Remove the 4 bolts and differential tube with side gear
shaft from the differential carrier.
(d) Remove the side gear shaft from the differential tube.
F05222
Suspension)
12. REMOVE SIDE GEAR BEARING

Using SST and a press, remove the bearing from side gear
shaft.
SST 09950−60010 (09951−00410),
SST
09950−70010 (09951−07100)
F05223

SST 09330−00021
SST
SA2349

SST 09950−30010 (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03020)
R11391

SST SST 09308−10010
SA2348

SST 09556−22010
SST
Z00641
Suspension)
16. REMOVE DIFFERENTIAL CASE ASSEMBLY

Matchmarks (a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.
F05224
(c) Using SST and a hammer, remove the 2 side bearing

plate washers.
SST SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case with the bearing outer races
from the differential carrier.
HINT:
F05225 Tag the bearing outer races to show the location for reassem-
bling.

drive pinion.
SST 09950−00020
HINT:
SST If the drive pinion or ring gear is damaged, replace them as a
set.
(b) Remove the washer.
R02482
19. REMOVE DRIVE PINION FRONT AND REAR BEARING

SST
(a) Using SST, remove the rear bearing outer race.
SST 09308−00010
F05168
Suspension)
Oil Storage Ring Outer Race (b) Using a brass bar and hammer, remove the oil storage
F05169

plates.
it from the differential case.
Matchmarks FA1998 (a) Place the bearing outer races on their respective bear-
changed.
(b) Install the assembled plate washers onto the side bear-
ing.
(c) Install the differential case in the differential carrier.
HINT:
If it is difficult to install the differential case into the carrier, re-
place the plate washer with a thinner one.
However, select a plate washer that allows no clearance be-
tween it and the carrier.
rier.
(e) Install and uniformly tighten the 4 bolts a little at a time.
(f) Using a dial indicator, measure the differential case run-

out.
tial case and side bearings as a set.
F05210
Suspension)
22. REMOVE SIDE BEARINGS

SST Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04060,
09957−04010, 09958−04010),
09950−60010 (09951−00480)
HINT:
SST R11392 Fix the claws of SST to the notches in the differential case.
23. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove the pinion shaft, 2 pinion gears, pinion gear
thrust washers, side gears and side gear thrust washers
Suspension)
SA14N−09
DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 9 bolts and nut from the carrier cover.
(b) Using a brass bar and hammer, separate the cover from
carrier.
(c) Remove the breather plug from the differential carrier cov-
er.
(d) Remove the 2 bolts and oil deflector from the differential
carrier cover.
2. SET DIFFERENTIAL CARRIER TO OVERHAUL
STAND, ETC.

Maximum: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, replace the compan-
ion flange.
30 mm
(1.18 in.) W00493

and drive pinion as a set.
F05229

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
gear.
If the backlash is not within the specification, adjust the back-
F05228 lash.

Suspension)

0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
SA2352 Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
9. REMOVE SIDE GEAR SHAFT OIL SEALS

Using SST, remove the 2 side gear shaft oil seals.
SST 09308−00010
SST
F05221
10. REMOVE DIFFERENTIAL TUBE ASSEMBLY

(a) Using SST, remove the snap ring.
SST SST 09350−30020 (09350−07060)
(c) Remove the 4 bolts and differential tube with side gear
shaft from the differential carrier.
(d) Remove the side gear shaft from the differential tube.
F05222
11. REMOVE SIDE GEAR BEARING

Using SST and a press, remove the bearing from side gear
shaft.
SST 09950−60010 (09951−00410), 09950−70010
SST
(09951−07100)
F05223

Suspension)

SST 09330−00021
SST
SA2349

SST 09950−30011 (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03020)
R11391

SST SST 09308−10010
SA2348

SST 09556−22010
SST
Z00641

rier.
F11453

Suspension)
(c) Using SST and a hammer, remove the 2 side bearing

plate washers.
SST SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case with the bearing outer races
from the differential carrier.
HINT:
F11454 Tag the bearing outer races to show the location for reassem-
bling.

drive pinion.
SST 09950−00020
HINT:
SST If the drive pinion or ring gear is damaged, replace them as a
set.
(b) Remove the washer.
R02482
18. REMOVE DRIVE PINION FRONT AND REAR BEARING

SST
(a) Using SST, remove the rear bearing outer race.
SST 09308−00010
F05168
Oil Storage Ring Outer Race (b) Using a brass bar and hammer, remove the oil storage
F05169

Suspension)

plates.
it from the differential case.
Matchmarks FA1998 (a) Place the bearing outer races on their respective bear-
changed.
ing.
HINT:
rier.

out.
F05210
21. REMOVE SIDE BEARINGS

SST Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04061,
09957−04010, 09958−04011), 09950−60010
(09951−00480)
HINT:
SST R11392 Fix the claws of SST to the notches in the differential case.

Suspension)
22. DISASSEMBLE DIFFERENTIAL CASE

(d) Remove the spider, 2 side gears, side gear thrust wash-
ers, 4 pinion gears and pinion gear thrust washers from
Matchmarks the RH differential case.
FA2046

Suspension)
SA14O−03
REPLACEMENT
SST REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950−00020, 09950−60010 (09951−00400),
09950−70010 (09951−07100)
F02521
(b) Using SST and a press, install a new dust deflector.

SST 09223−00010
SST
F05956
Suspension)
SA14P−03
REASSEMBLY
HINT:
parts.
gear oil.
1. MEASURE SIDE GEAR BACKLASH AND ASSEMBLE

DIFFERENTIAL CASE
(a) Install the 2 thrust washers to the 2 side gears.
(b) Install the 2 side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT:
Align the holes of the differential case and pinion shaft.
SA0510

Maximum backlash: 0.15 mm (0.0059 in.)
If the backlash is not within the specification, install side gear
thrust washers with different thicknesses.
1.50 (0.0591) 1.75 (0.0689)
FA1123
1.55 (0.0610) 1.80 (0.0709)
1.60 (0.0630) 1.85 (0.0729)
1.65 (0.0650) 1.90 (0.0748)
1.70 (0.0669) −
2. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL

CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.
FA1124
Suspension)

ring gear.
(b) Heat the ring gear to approx. 100˚C (212˚F) in boiling wa-
Boiling Water ter.
HINT:
misaligned.
ring gear set bolts.
(g) Using a chisel and hammer, stake the 5 lock plates.

HINT:
Stake the claws of the lock plates to fix the bolts. For the claw
contacting the protruding portion of the bolt, stake only the half
of it along the tightening direction.
Z02483

Using SST and a press, install the 2 bearings to the differential
SST case.
SST 09315−00022
F05211
Suspension)

changed.
ing.
HINT:
rier.
(f) Using a dial indicator, measure the ring gear runout.

(g) Remove the differential carrier.
F05229
FRONT REAR 6. INSTALL DRIVE PINION FRONT AND REAR BEARING

OUTER RACES
SST SST (a) Using SST and a press, install the front bearing outer
race.
SST 09950−60020 (09951−00780),
09950−70010 (09951−07150)
SST 09950−60020 (09951−00710),
F05212 09950−70010 (09951−07150)
(a) Install the washer on the drive pinion.
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with one of a different thickness if necessary.
Suspension)
drive pinion.
SST 09506−30012
(a) Install the drive pinion and rear bearing.
HINT:
SST
tact pattern.
SA3102 (b) Install the oil slinger.
(c) Using SST, install the companion flange.

SST 09950−30010, (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03020)
R13414
(d) Using SST to hold the flange and adjust the drive pinion
preload by tightening the nut.
SST NOTICE:
oil.
SA2450
(e) Using a torque wrench, measure the preload.

New bearing
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
HINT:
Measure the total preload after turning the bearing clockwise
SA2446 and counterclockwise several times to make the bearing
smooth.
9. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
changed.
Suspension)
10. ADJUST RING GEAR BACKLASH

(a) Install the plate washer on the ring gear back side.
HINT:
Make sure that the ring gear has backlash.
FA0743
(b) Tap on the ring gear with a plastic hammer so that the
washer fits to the bearing.
FA0744

Backlash (Reference): 0.13 mm (0.0051 in.)
FA0746
(d) Select a plate washer for back side ring gear, using the
backlash as reference.
FA0743
Suspension)
Side plate washer thickness

2.58 (0.1016) 3.04 (0.1197)
2.60 (0.1024) 3.06 (0.1205)
2.62 (0.1031) 3.08 (0.1213)
2.64 (0.1039) 3.10 (0.1220)
2.66 (0.1047) 3.12 (0.1228)
2.68 (0.1055) 3.14 (0.1236)
2.70 (0.1063) 3.16 (0.1244)
2.72 (0.1071) 3.18 (0.1252)
2.74 (0.1079) 3.20 (0.1260)
2.76 (0.1087) 3.22 (0.1268)
2.78 (0.1094) 3.24 (0.1276)
2.80 (0.1102) 3.26 (0.1283)
2.82 (0.1110) 3.28 (0.1291)
2.84 (0.1118) 3.30 (0.1299)
2.86 (0.1126) 3.32 (0.1307)
2.88 (0.1134) 3.34 (0.1315)
2.90 (0.1142) 3.36 (0.1323)
2.92 (0.1150) 3.38 (0.1331)
2.94 (0.1157) 3.40 (0.1339)
2.96 (0.1165) 3.42 (0.1346)
2.98 (0.1173) 3.44 (0.1354)
3.00 (0.1181) 3.46 (0.1362)
3.02 (0.1189) 3.48 (0.1370)
(e) Select a ring gear teeth side plate washer so that is no

clearance between the outer race and case.
FA0742
(f) Remove the plate washers and differential case.

(g) Install the plate washer into the ring gear back side of the
carrier.
FA0752
Suspension)
Plate Washer (h) Place the other plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Tap on the ring gear with a plastic hammer so that the
washers fit to the bearing.
Plate Washer
Z03861
(j) Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
If the backlash is not within the specification, adjust by either in-
creasing or decreasing the thickness of washers on both sides
by an equal amount.
HINT:
There should be no clearance between the plate washer and
case.
FA0754 Make sure that there is ring gear backlash.
(a) Remove the ring gear teeth side plate washer and mea-
sure the thickness.
(b) Using the backlash as a reference, install a new washer

of 0.06 − 0.09 mm (0.0024 − 0.0035 in.) thicker than the
washer removed.
Plate
HINT:
Washer
Select a washer which can be pressed in 2/3 of the way with
your finger.
(c) Using a plastic hammer, install the plate washer.
Z03863 rier.
(e) Tighten the 4 bolts.
Suspension)
(f) Using a dial indicator, adjust the ring gear backlash until
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
by an equal amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) corre-
F05213 sponding to 0.03 mm (0.0012 in.) change in the plate washer.
12. MEASURE TOTAL PRELOAD
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)

AND DRIVE PINION
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
Z03852
Select an adjusting shim that will bring the drive

pinion closer to the gear.
Proper Contact
Select an adjusting shim that will shift the drive

pinion gear away from the ring gear.
R02495
Suspension)
If the teeth are not contacting properly, use the following table
Washer thickness
1.70 (0.0669) 2.03 (0.0799)
1.73 (0.0681) 2.06 (0.0811)
1.76 (0.0693) 2.09 (0.0822)
Washer
1.79 (0.0704) 2.12 (0.0835)
FA2008
1.82 (0.0717) 2.15 (0.0847)
1.85 (0.0729) 2.18 (0.0858)
1.88 (0.0740) 2.21 (0.0870)
1.91 (0.0752) 2.24 (0.0882)
1.94 (0.0764) 2.27 (0.0894)
1.97 (0.0776) 2.30 (0.0906)
2.00 (0.0787) 2.33 (0.0918)
14. REMOVE COMPANION FLANGE (See page SA−92)
15. REMOVE OIL SLINGER
16. REMOVE REAR BEARING (See page SA−92)
(See page SA−92)
18. INSTALL BEARING SPACER AND OIL STORAGE

RING
(a) Install a new bearing spacer.
(b) Using SST and a hammer, install a new oil storage ring.
SST 09316−60011 (09316−00011), 09506−35010
SST
F05159
19. INSTALL REAR BEARING OUTER RACE

Using SST and a hammer, install the bearing outer race.
SST 09316−60011 (09316−00011), 09506−35010
20. INSTALL REAR BEARING AND OIL SLINGER
(a) Coat the hypoid gear oil to a new oil seal periphery.
SST
F05964
Suspension)
(b) Using SST and a hammer, install a new oil seal.

SST 09554−30011
(c) Coat MP grease to the oil seal lip.
SST
Z00698

(a) Using SST, install the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
(b) Coat the thread of a new nut with hypoid gear oil LSD.
SST
R11163

SST SST 09330−00021
SA2351

New bearing
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
ing spacer.
If the preload is less than the specification, retighten the nut a
SST force of 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the specified
preload is reached.
SST 09330−00021
SA2351
Suspension)
24. RECHECK TOTAL PRELOAD (See page SA−92)

(See page SA−92)
(See page SA−92)
29. INSTALL SIDE GEAR BEARING

Using SST and a press, install the bearing to side gear shaft.
SST SST 09502−12010, 09950−60020 (09951−00730),
09950−70010 (09951−07100)
30. INSTALL DIFFERENTIAL TUBE ASSEMBLY
(a) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(b) Apply FIPG to the differential tube.
F05214 FIPG:
Part No. 08826 − 00090, THREE BOND 1281
or equivalent.
HINT:
Install the differential tube within 10 minutes after applying
FIPG.
(c) Install the differential tube with 4 bolts to the differential
tube.
(d) Install the side gear shaft.
(e) Using a snap ring expander, install the snap ring.
(f) Using SST, install the snap ring.

SST 09350−30020 (09350−07060)
SST
31. INSTALL SIDE GEAR SHAFT OIL SEALS
F05222
(b) Using SST and a hammer, install 2 new oil seals.

SST 09550−00032, 09950−70010 (09951−07150)
SST HAUL STAND ETC.
F05215
Suspension)
33. INSTALL DIFFERENTIAL CARRIER COVER

(a) Install the oil deflector with 2 bolts to the carrier cover.
(b) Install the breather plug to the carrier cover.
(c) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
carrier cover.
(d) Clean surfaces with FIPG with material attached to using
gasoline or alcohol.
(e) Apply FIPG to the carrier cover, as shown.

FIPG:
Seal Width or equivalent.
Approx. HINT:
1 − 2 mm
Install the carrier cover within 10 minutes after applying FIPG.
(0.04 − 0.08 in.)
(f) Install the differential carrier cover with the 9 bolts.
F05216
Suspension)
SA14P−05
REASSEMBLY
HINT:
parts.
gear oil.
1. MEASURE SIDE GEAR BACKLASH AND ASSEMBLE

DIFFERENTIAL CASE
(a) Install the 2 side gear thrust washers to the side gears.
(b) Install the 2 side gears to the RH case.
(c) Install the 4 pinion gears and pinion gear thrust washers
to the spider.
(d) Install the pinion gears with the spider to the RH case.
SA1978
(e) Using a dial indicator, holding the side gear and spider,
measure the side gear backlash,
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
HINT:
S Measure the backlash at the RH case and at the LH case.
SA1976 Thrust washer thickness
0.9 (0.035) 1.2 (0.047)
1.0 (0.039) 1.3 (0.051)
1.1 (0.043) −
(f) Align the matchmarks on the LH and RH cases.

(g) Torque the 8 bolts uniformly a little at a time.
Matchmarks
FA2037

Suspension)

ring gear.
(b) Heat the ring gear to approx. 100˚C (212˚F) in boiling wa-
Boiling Water ter.
HINT:
misaligned.
ring gear set bolts.
(g) Using a chisel and hammer, stake the 5 lock plates.

HINT:
Stake the claws of the lock plates to fix the bolts. For the claw
contacting the protruding portion of the bolt, stake only the half
of it along the tightening direction.
Z02483

Using SST and a press, install the 2 side bearings to the differ-
SST ential case.
SST 09223−15020, 09950−60010 (09951−00480)
SST SA2415

Suspension)

changed.
ing.
HINT:
rier.
(f) Using a dial indicator, measure the ring gear runout.

(g) Remove the differential carrier.
F05229

OUTER RACES
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
SST 09950−60020 (09951−00710), 09950−70010
F05212 (09951−07150)
HINT:

Suspension)
drive pinion.
SST 09506−30012
(a) Install the drive pinion and rear bearing.
HINT:
SST
tact pattern.

SST 09950−30010, (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03020)
R13414
SST NOTICE:
oil.
SA2450

New bearing
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
HINT:
smooth.
8. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
changed.

Suspension)

(a) Install the plate washer on the ring gear back side.
HINT:
Make sure that the ring gear has backlash.
FA0743
(b) Tap on the ring gear with a plastic hammer so that the
washer fits to the bearing.
FA0744

F11455
(d) Select a plate washer for back side ring gear, using the
backlash as reference.
FA0743

Suspension)

2.58 (0.1016) 3.04 (0.1197)
2.60 (0.1024) 3.06 (0.1205)
2.62 (0.1031) 3.08 (0.1213)
2.64 (0.1039) 3.10 (0.1220)
2.66 (0.1047) 3.12 (0.1228)
2.68 (0.1055) 3.14 (0.1236)
2.70 (0.1063) 3.16 (0.1244)
2.72 (0.1071) 3.18 (0.1252)
2.74 (0.1079) 3.20 (0.1260)
2.76 (0.1087) 3.22 (0.1268)
2.78 (0.1094) 3.24 (0.1276)
2.80 (0.1102) 3.26 (0.1283)
2.82 (0.1110) 3.28 (0.1291)
2.84 (0.1118) 3.30 (0.1299)
2.86 (0.1126) 3.32 (0.1307)
2.88 (0.1134) 3.34 (0.1315)
2.90 (0.1142) 3.36 (0.1323)
2.92 (0.1150) 3.38 (0.1331)
2.94 (0.1157) 3.40 (0.1339)
2.96 (0.1165) 3.42 (0.1346)
2.98 (0.1173) 3.44 (0.1354)
3.00 (0.1181) 3.46 (0.1362)
3.02 (0.1189) 3.48 (0.1370)
(e) Select a ring gear teeth side plate washer so that is no

clearance between the outer race and case.
FA0742
(f) Remove the plate washers and differential case.

(g) Install the plate washer into the ring gear back side of the
carrier.
FA0752

Suspension)
Plate Washer (h) Place the other plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Tap on the ring gear with a plastic hammer so that the
washers fit to the bearing.
Plate Washer
Z03861
(j) Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
by an equal amount.
HINT:
case.
F11755 Make sure that there is ring gear backlash.
(a) Remove the ring gear teeth side plate washer and mea-
sure the thickness.
(b) Using the backlash as a reference, install a new washer

of 0.06 − 0.09 mm (0.0024 − 0.0035 in.) thicker than the
washer removed.
Plate
HINT:
Washer
Select a washer which can be pressed in 2/3 of the way with
your finger.
(c) Using a plastic hammer, install the plate washer.
Z03863 rier.
(e) Tighten the 4 bolts.
HINT:
Turn the ring gear several times to make the side bearings
smooth.

Suspension)
(f) Using a dial indicator, adjust the ring gear backlash until
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
by an equal amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) corre-
F11477 sponding to 0.03 mm (0.0012 in.) change in the plate washer.
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)

AND DRIVE PINION
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
F11478

Proper Contact

R02495

Suspension)
If the teeth are not contacting properly, use the following table
Washer thickness
1.70 (0.0669) 2.03 (0.0799)
1.73 (0.0681) 2.06 (0.0811)
1.76 (0.0693) 2.09 (0.0822)
Washer
1.79 (0.0704) 2.12 (0.0835)
FA2008
1.82 (0.0717) 2.15 (0.0847)
1.85 (0.0729) 2.18 (0.0858)
1.88 (0.0740) 2.21 (0.0870)
1.91 (0.0752) 2.24 (0.0882)
1.94 (0.0764) 2.27 (0.0894)
1.97 (0.0776) 2.30 (0.0906)
2.00 (0.0787) 2.33 (0.0918)
14. REMOVE OIL SLINGER
15. REMOVE REAR BEARING (See page SA−2)
(See page SA−2)
17. INSTALL BEARING SPACER AND OIL STORAGE

RING
(a) Install a new bearing spacer.
(b) Using SST and a hammer, install a new oil storage ring.
SST 09316−60011 (09316−00011), 09506−35010
SST
F05159
18. INSTALL REAR BEARING OUTER RACE

SST 09316−60011 (09316−00011), 09506−35010
19. INSTALL REAR BEARING AND OIL SLINGER
SST
F05964

Suspension)

SST 09554−30011
SST
Z00698

SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03020)
(b) Coat the thread of a new nut with hypoid gear oil LSD.
SST
R11163

SST SST 09330−00021
SA2351

New bearing
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
ing spacer.
If the preload is less than the specification, retighten the nut a
SST force of 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the specified
preload is reached.
SST 09330−00021
SA2351

Suspension)
23. RECHECK TOTAL PRELOAD (See page SA−2)

(See page SA−2)
(See page SA−2)
28. INSTALL SIDE GEAR BEARING

Using SST and a press, install the bearing to side gear shaft.
SST SST 09502−12010, 09950−60020 (09951−00730),
09950−70010 (09951−07100)
29. INSTALL DIFFERENTIAL TUBE ASSEMBLY
(a) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(b) Apply FIPG to the differential tube.
F05214 FIPG:
Part No. 08826 − 00090, THREE BOND 1281
or equivalent.
HINT:
Install the differential tube within 10 minutes after applying
FIPG.
(c) Install the differential tube with 4 bolts to the differential
tube.
(d) Install the side gear shaft.
(e) Using a snap ring expander, install the snap ring.
(f) Using SST, install the snap ring.

SST 09350−30020 (09350−07060)
SST
30. INSTALL SIDE GEAR SHAFT OIL SEALS
F05222
(b) Using SST and a hammer, install 2 new oil seals.

SST 09550−00032, 09950−70010 (09951−07150)
SST HAUL STAND, ETC.
F05215

Suspension)
32. INSTALL DIFFERENTIAL CARRIER COVER

(a) Install the oil deflector with 2 bolts to the carrier cover.
(b) Install the breather plug to the carrier cover.
(c) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
carrier cover.
(d) Clean surfaces with FIPG with material attached to using
(e) Apply FIPG to the carrier cover, as shown.

FIPG:
Seal Width or equivalent.
Approx. HINT:
1 − 2 mm
Install the carrier cover within 10 minutes after applying FIPG.
(0.04 − 0.08 in.)
(f) Install the differential carrier cover with the 9 bolts.
F05216

Suspension)
SA14Q−03
INSTALLATION
AFTER INSTALLATION, FILL FRONT DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA−61)
SA−112 SUSPENSION AND AXLE − FRONT SHOCK ABSORBER (Independent Front
Suspension)
FRONT SHOCK ABSORBER (Independent Front

Suspension)
SA17Y−02
COMPONENTS
w/ AHC System
18 (185, 13)
Pressure Hose
z O−ring
Front Fender Apron z Back Up Ring
z 68 (700, 51)
Cushion
z 68 (700, 51)
Retainer
Cushion
Cushion
Retainer
Retainer
Cushion
Retainer
Shock
Absorber
Shock
Absorber z Bushing
135 (1,400, 101)

SUSPENSION AND AXLE − FRONT SHOCK ABSORBER (Independent Front SA−113
Suspension)
SA1C5−01
REMOVAL
1. w/ AHC System:
DRAIN SUSPENSION FLUID AHC
(a) Connect the hose to the bleeder plug for damping force
control actuator and loosen the bleeder plug.
CAUTION:
While the fluid is being discharged, vehicle height is low-
ered suddenly.
F05121
(b) After the fluid pressure has dropped and oil has drained
out, tighten the bleeder plug and remove the hose.
Torque:
3. REMOVE FRONT FENDER APRON
4. w/o AHC System:

REMOVE SHOCK ABSORBER
(a) Remove the bolt, nut and disconnect the shock absorber
from the lower suspension arm.
F04382
(b) While holding the piston rod, remove the nut, retainer,
cushion and shock absorber.
(c) Remove the retainer and cushion from the shock absorb-
er.
F04407
5. w/ AHC System:
(a) Remove the bolt, nut and disconnect the shock absorber
from the lower suspension arm.
F04382
Suspension)
(b) Remove the 2 bolts and disconnect the pressure hose.

(c) Remove the O−ring and back up ring from the pressure
hose.
HINT:
At the time of installation, replace the used O−ring and back up
ring with new ones.
(d) While holding the cushion, remove the nut, cushion, re-
F05151 tainer and shock absorber.
(e) Remove the cushion and retainer from the shock absorb-
er.
Suspension)
SA180−02
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sounds.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
w/o AHC System:
SA0627
When disposing the shock absorber, see DISPOSAL on
page SA−116.
Suspension)
SA14U−02
DISPOSAL
w/o AHC System:
DISCARD SHOCK ABSORBER
Before discarding the shock absorber, drill a hole of 2 − 3 mm
(0.079 − 0.118 in.) in diameter at the location shown in the il-
lustration to discharge the gas inside.
CAUTION:
S When drilling, chips may fly out, work carefully.
F05250
S The gas is colorless, odorless and non−poisonous.
Suspension)
SA181−02
REPLACEMENT
w/ AHC System:
SST
REPLACE BUSHING
(a) Using SST and a press, remove the bushing.
SST 09623−36010, 09710−28021 (09710−08031)
F05251
(b) Using SST and a press, install a new bushing.

SST 09623−36010, 09710−28021 (09710−08031)
SST
F05251
Suspension)
SA182−04
INSTALLATION
w/ AHC System:
AFTER INSTALLATION, FILL AHC PUMP & MOTOR RESERVOIR WITH SUSPENSION FLUID AHC,
BLEED AHC SYSTEM (See page SA−303) AND CHECK FOR LEAKS (See page SA−305)
SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER SA−119
(Rigid Front Suspension)
COIL SPRING AND FRONT SHOCK ABSORBER (Rigid Front

Suspension)
SA1AK−01
COMPONENTS
9.2 (94, 82 in.·lbf)
69 (700, 51)
Follow Spring Retainer

Cushion
Retainer
Cushion
Shock Absorber Retainer
Coil Spring
Retainer
Cushion
Retainer
Cushion
Retainer
69 (700, 51)

F05784
SA−120 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER
SA1AL−01
REMOVAL
2. JACK UP AND SUPPORT AXLE HOUSING
3. REMOVE FRONT SHOCK ABSORBER

(a) Hold the piston rod and remove the upper mounting nut,
2 retainers and cushion.
SA2662
(b) Hold the shock absorber and remove the lower mounting
nut, shock absorber, 3 cushions and 4 retainers.
SA2663
4. DISCONNECT STABILIZER BAR FROM AXLE HOUS-

ING
Remove the bolt, nut and disconnect the stabilizer bar from the
axle housing.
HINT:
At the time of installation, after stabilizing the suspension,
torque the nut.
R08394 5. JACK DOWN AND SUPPORT AXLE HOUSING
6. REMOVE COIL SPRING

(a) Using SST, compress the coil spring.
SST
SST 09727−30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Remove the coil spring.
HINT:
At the time of installation, please refer to the following item.
R13152 Align the coil spring end with the lower seat and install the coil
spring.
7. REMOVE FOLLOW SPRING

Remove the 2 nuts and following spring.
SA1AM−02
INSPECTION
there is no abnormal resistance or unusual sound during opera-
tion.
new one.
NOTICE:
FA0530
page SA−123.
SA1AN−01
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER
Using a drill, make a hole on the top of the shell as shown to dis-
charge the gas inside.
CAUTION:
50 mm 30 mm The gas coming out is harmless, but be careful of chips
(1.97 in.) (1.18 in.) which may fly up when drilling.
SA2667
SA1AO−01
INSTALLATION
SUSPENSION AND AXLE − FRONT TORSION BAR SPRING (Independent Front SA−125
Suspension)
FRONT TORSION BAR SPRING (Independent Front

Suspension)
SA17J−02
COMPONENTS
Anchor Arm Swivel
Anchor Arm
Torsion Bar Spring
Anchor Arm Adjusting Seat
Anchor Arm Adjusting Bolt
225 (2,300, 166)
225 (2,300, 166)
Torque Arm
Engine Under Cover

F05243
SA−126 SUSPENSION AND AXLE − FRONT TORSION BAR SPRING (Independent Front
Suspension)
SA17K−02
REMOVAL
2. REMOVE ENGINE UNDER COVER
3. REMOVE TORSION BAR SPRING WITH ANCHOR

ARM
(a) Place matchmarks on the torsion bar spring, anchor arm
and torque arm.
Matchmarks
F05247
(b) Measure the dimension ”A” between the anchor arm bolt
end and the frame as shown.
HINT:
Use the measurement for a reference when installing the an-
chor arm.
F05246
(c) Loosen the anchor arm bolt until the spring tension is free
and measure the anchor arm bolt ”B”.
HINT:
Use the measurement for a reference when installing the an-
chor arm.
(d) Remove the anchor arm bolt, anchor arm swivel and an-
chor arm adjusting seat.
B (e) Remove the torsion bar spring with anchor arm.
F05245 (f) Remove the anchor arm from the torsion bar spring.
4. REMOVE TORQUE ARM
Remove the bolt, 2 nuts and torque arm.
SUSPENSION AND AXLE − FRONT TORSION BAR SPRING (Independent Front SA−127
Suspension)
SA17L−02
INSTALLATION
1. INSTALL TORQUE ARM
Install the torque arm and bolt with 2 nuts.
2. INSTALL TORSION BAR SPRING WITH ANCHOR ARM

HINT:
S There are left and right matchmarks on the rear end of the
torsion bar springs.
S Apply a light coat of MP grease to the spline of the torsion
bar springs.
(a) New torsion bar spring:
(1) Install the anchor arm to the torsion bar spring.
F05244 (2) Install the torsion bar spring with the anchor arm to
the torque arm.
(3) Install the anchor arm adjusting seat, anchor arm
swivel and anchor arm bolt.
(4) Check that the length of anchor arm bolt end is al-
most same as dimension ”B” measured when the
torsion bar was removed.
B
F05245
(5) Tighten the anchor arm bolt so that the dimension

”A” is within the specifications in the table below.
(Reference)
LH 8 − 25 mm (0.315 − 0.984 in.)
RH 2 − 18 mm (0.079 − 0.709 in.)
(b) Reused torsion bar spring:
A (1) Align matchmarks on the torsion bar spring and an-
chor arm and install them.
F05246
SA−128 SUSPENSION AND AXLE − FRONT TORSION BAR SPRING (Independent Front
Suspension)
(2) Align matchmarks on the torsion bar spring and

torque arm and install them.
(3) Install the anchor arm adjusting seat, anchor arm
swivel and anchor arm bolt.
(4) Tighten the anchor arm bolt so that the dimension

”A” is almost same as the dimension measured
when the torsion bar spring was removed.
3. INSTALL ENGINE UNDER COVER
Torque:
A
F05246 5. CHECK VEHICLE HEIGHT (See page SA−9)
HINT:
After stabilizing the suspension, adjust the vehicle height by
turning the anchor arm bolt.
SUSPENSION AND AXLE − FRONT UPPER SUSPENSION ARM (Independent SA−129
Front Suspension)
FRONT UPPER SUSPENSION ARM (Independent Front

Suspension)
SA183−02
COMPONENTS
Front Fender Apron
w/ ABS
No. 1 Camber Adjust Cam ABS Speed Sensor
Wire Harness
13 (130, 9)
98 (1,000, 72) Upper Suspension

Arm
No. 2 Camber Adjust Cam
w/ AHC System
Height Control
Sensor Link 5.6 (57, 49 in.·lbf)
110 (1,125, 81)

z Cotter Pin z Bushing
Upper Suspension Arm
z Bushing
z Wire
z Dust Cover

F05155
SA−130 SUSPENSION AND AXLE − FRONT UPPER SUSPENSION ARM (Independent
Front Suspension)
SA184−02
REMOVAL
Torque:
3. w/ AHC System:
Matchmarks DISCONNECT HEIGHT CONTROL SENSOR LINK
(a) Place matchmarks on the height control sensor link and
upper suspension arm.
(b) Remove the nut and disconnect the height control sensor
link.
F04364
4. w/ ABS:
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the 2 bolts and disconnect the ABS speed sensor wire
harness.
5. DISCONNECT STEERING KNUCKLE FROM UPPER
SUSPENSION ARM
(a) Support the lower suspension arm with a jack.
F04377 (b) Remove the cotter pin and nut.
(c) Using SST, disconnect the steering knuckle from the up-
per suspension arm.
SST SST 09628−62011
F04378
6. REMOVE UPPER SUSPENSION ARM

Matchmarks
(a) Place matchmarks on the front and rear No. 2 adjust cams
and body.
(b) Remove the 2 nuts, No. 1 and No. 2 camber adjust cams
and upper suspension arm.
HINT:
F04379 torque the nuts.
Front Suspension)
SA185−02
INSPECTION
INSPECT UPPER SUSPENSION ARM BALL JOINT FOR
ROTATION CONDITION
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously 1 turn
per 3 − 5 seconds and take the torque reading on the 5th
turn.
F04380
Turning torque:
1.0 − 4.4 N·m (10 − 45 kgf·cm, 8.7 − 39 in.·lbf)
SA−132 SUSPENSION AND AXLE − FRONT UPPER SUSPENSION ARM (Independent
Front Suspension)
SA186−02
REPLACEMENT
1. REPLACE BUSHING
(a) Using a chisel and hammer, pry up the flange of the bush-
ing.
(b) Using SST, a steel plate and press, remove the bushing.
SST 09527−17011, 09710−28021 (09710−08031),
09950−00020
SST
SST
F04350
(c) Using SST, a steel plate and press, install a new bushing.
SST 09316−20011, 09710−28012 (09710−07062)
SST
SST
F04351
2. REPLACE DUST COVER

(a) Remove the wire and dust cover.
(b) Coat the ball joint with grease in the boot kit.
(c) Install a new dust cover and wire.
F04352
Front Suspension)
SA187−02
INSTALLATION
AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA−9)
SA−134 SUSPENSION AND AXLE − FRONT LOWER SUSPENSION ARM (Independent
Front Suspension)
FRONT LOWER SUSPENSION ARM (Independent Front

Suspension)
SA17M−02
COMPONENTS
Anchor Arm Swivel
Torsion Bar Spring Anchor Arm
Anchor Arm Adjusting Seat

Anchor Arm Adjusting Bolt
Front Shock 135 (1,400, 101)

Absorber z No. 2 Bushing
225 (2,300, 166)
230 (2,350, 170)
230 (2,350, 170) 225 (2,300, 166)
Torque 52 (530, 38)

Arm
Stabilizer
Bar Link
z No. 1 Bushing z Wire
Lower Suspension Arm
z Dust Cover
159 (1,625, 118)
z Cotter Pin
Engine Under Cover

SUSPENSION AND AXLE − FRONT LOWER SUSPENSION ARM (Independent SA−135
Front Suspension)
SA17N−02
REMOVAL
Torque:
3. REMOVE FRONT TORSION BAR SPRING
(See page SA−126)
4. DISCONNECT STABILIZER BAR LINK FROM LOWER

SUSPENSION ARM
Remove the bolt and disconnect the stabilizer bar link from the
lower suspension arm.
F04381
5. DISCONNECT SHOCK ABSORBER FROM LOWER

SUSPENSION ARM
Remove the bolt, nut and disconnect the shock absorber from
the lower suspension arm.
6. DISCONNECT STEERING KNUCKLE FROM LOWER
SUSPENSION ARM
F04382 Torque: 159 N·m (1,625 kgf·cm, 118 ft·lbf)
(b) Using SST, disconnect the steering knuckle from the low-
er suspension arm.
SST 09628−62011
SST
F04383
7. REMOVE LOWER SUSPENSION ARM

Remove the 2 nuts, 3 bolts and lower suspension arm.
F04384
Front Suspension)
SA17O−02
INSPECTION
INSPECT LOWER SUSPENSION ARM BALL JOINT FOR
ROTATION CONDITION
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously 1 turn
per 3 − 5 seconds and take the torque reading on the 5th
turn.
F04385
Turning torque:
0.29 − 2.94 N·m (3 − 30 kgf·cm, 2.6 − 26 in.·lbf)
Front Suspension)
SA17P−02
REPLACEMENT
1. REPLACE NO. 1 BUSHING
(a) Using a chisel and hammer, pry up the flange of the No.
1 bushing.
(b) Using SST, remove the No. 1 bushing.

SST 09710−30021 (09710−03101),
SST
09950−00020, 09950−00030,
09950−40011 (09957−04010)
SST F04353
(c) Using SST and a press, install a new bushing.

SST 09726−36010
SST
F04354
2. REPLACE NO. 2 BUSHING

(a) Using SST, remove the No. 2 bushing.
SST
SST 09710−22021 (09710−01071),
09726−35011 (09726−05021),
09830−36010
F05253
(b) Using SST, install a new bushing.

SST SST 09631−32020, 09830−36010
F05254
Front Suspension)
3. REPLACE DUST COVER

(a) Remove the wire and dust cover.
(b) Coat the ball joint with grease in the boot kit.
(c) Install a new dust cover and wire.
F04355
Front Suspension)
SA17Q−02
INSTALLATION
AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA−9)
SA−140 SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD (Rigid Front
Suspension)
FRONT LATERAL CONTROL ROD (Rigid Front Suspension)

SA1AP−01
COMPONENTS
z Bushing
z 171 (1,750, 127)
Lateral Control
Rod
z Bushing
z 171 (1,750, 127)

SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD (Rigid Front SA−141
Suspension)
SA1AQ−01
REMOVAL
2. DISCONNECT LATERAL CONTROL ROD FROM AXLE

HOUSING
Remove the bolt, washer and disconnect the lateral control rod
from the axle housing.
HINT:
torque the bolt.
SA2675
3. REMOVE LATERAL CONTROL ROD FROM FRAME

Remove the nut, bolt and lateral control rod.
HINT:
torque the bolt.
SA2676
SA−142 SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD (Rigid Front
Suspension)
SA1AR−01
REPLACEMENT
1. REMOVE BUSHING
SST Using SST and a press, remove the bushing from the lateral
control rod.
SST
SST 09710−22042 (09710−02051, 09710−02071),
SST 09950−70010 (09951−07150)
FA0533
2. INSTALL BUSHING
Using SST and a press, install a new bushing into the lateral
SST
control rod.
SST 09710−22042 (09710−02051, 09710−02071)
HINT:
SST Do not use a lubricant when pressing in the bushing.
FA0534
SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD (Rigid Front SA−143
Suspension)
SA1AS−01
INSTALLATION
SA−144
SUSPENSION AND AXLE − FRONT LEADING ARM (Rigid Front Suspension)
FRONT LEADING ARM (Rigid Front Suspension)

SA1AT−01
COMPONENTS
Leading Arm
z Bushing
z Bushing
z 177 (1,800, 130)
z Bushing
z 177 (1,800, 130)

SA−145
SA1AU−01
REMOVAL
2. REMOVE LEADING ARM

(a) Remove the bolt, washer and nut from the leading arm on
the frame side.
HINT:
torque the bolt.
SA2677
(b) Remove the 2 bolts and nuts from the leading arm on the
axle housing side.
HINT:
torque the bolt.
(c) Remove the leading arm.
SA2678
SA−146
SA1AV−01
REPLACEMENT
REPLACE BUSHINGS
(a) Front side:
SST Using SST and a press, replace the bushing from the
leading arm.
SST 09710−30050
(b) Rear side:
Using SST and a press, replace the bushing from the
R13847
leading arm.
SST 09710−22042 (09710−02061)
HINT:
Assemble a new bushing, as shown in the illustration.
W02079
SA−147
SA1AW−01
INSTALLATION
SA−148
SUSPENSION AND AXLE − FRONT STABILIZER BAR (Rigid Front Suspension)
FRONT STABILIZER BAR (Rigid Front Suspension)

SA1AX−01
COMPONENTS
Stabilizer Bar Link
Cushion 103 (1,050, 76)
Cover
18 (185, 13)
Collar
30 (310, 23)
z Stabilizer Bar Bushing

F05787
SA−149
SA1AY−01
REMOVAL
2. REMOVE STABILIZER BAR

(a) Remove the nut and disconnect the stabilizer bar with the
link from the bracket.
HINT:
torque the nut.
R07756
(b) Remove the bolt, nut and stabilizer bar from the axle
housing.
HINT:
torque the nut.
R08394
(c) Remove the 4 bolts, 2 covers, 2 cushions and 2 stabilizer

Paint Line bar links from the stabilizer bar.
HINT:
At the time of installation, please refer to the following item.
Install the cushions on the lines painted on the stabilizer bar and
install the covers onto cushions.
(d) Remove the 2 collars, bushings from the stabilizer bar.
R13153
SA−150
SA1AZ−01
INSTALLATION
SUSPENSION AND AXLE − FRONT STABILIZER BAR (Independent Front SA−151
Suspension)
FRONT STABILIZER BAR (Independent Front Suspension)

SA188−02
COMPONENTS
z
Stabilizer Bar
Cushion
25 (250, 18)
Retainer
Cushion Bracket
z 18 (185, 13)
Cushion
Retainer
52 (530, 38)
Stabilizer Bar Link
Engine Under Cover

F05236
SA−152 SUSPENSION AND AXLE − FRONT STABILIZER BAR (Independent Front
Suspension)
SA189−03
REMOVAL
2. REMOVE LH AND RH STABILIZER BAR LINKS

Remove the 2 nuts, 2 bolts, 4 retainers, 4 cushions and 2 stabi-
lizer bar links.
Torque:
Bolt: 52 N·m (530 kgf·cm, 38 ft·lbf)
Nut: 25 N·m (250 kgf·cm, 18 ft·lbf)
F05117

(a) Remove the 4 bolts, 2 brackets and 2 cushions.
HINT:
S Install the cushion with its opening facing the back side of
the vehicle.
S Install the bracket properly so that its flange will face the
F04402 outside of the vehicle.
(b) Remove the stabilizer bar.
SUSPENSION AND AXLE − FRONT STABILIZER BAR (Independent Front SA−153
Suspension)
SA18A−02
INSTALLATION
SA−154
SUSPENSION AND AXLE − REAR AXLE SHAFT (Rigid Front Suspension)
REAR AXLE SHAFT (Rigid Front Suspension)

SA1B0−01
COMPONENTS
z Oil Seal
Rear Axle Shaft
z Gasket
33 (335, 24)
x6
Cone Washer

SA−155
SA1B1−01
REMOVAL
REMOVE REAR AXLE SHAFT
(a) Remove the 6 nuts and washers.
(b) Using a brass bar and hammer, strike the center part of
the axle shaft to remove the 6 cone washers.
F05773
(c) Install and gradually tighten 2 bolts evenly and pull the
axle shaft.
(d) Remove the 2 bolts from the rear axle shaft.
(e) Remove the rear axle shaft and gasket.
NOTICE:
F05766
SA−156
SA1B2−01
INSPECTION
INSPECT REAR AXLE SHAFT
(a) Check for wear or damage.
(b) Using a dial indicator, check the runout of axle shaft.

If the runout is greater than the maximum, replace the axle
shaft.
RA0377
SA−157
SA1B3−01
REPLACEMENT
SST REPLACE OIL SEAL
SST 09308−00010
F05765
hub.
SST 09517−36010
SST
(c) Coat the MP grease to the oil seal lip.
F05764
SA−158
SA1B4−01
INSTALLATION
SA−159
SUSPENSION AND AXLE − REAR AXLE SHAFT (Independent Front Suspension)
REAR AXLE SHAFT (Independent Front Suspension)

SA1C6−01
COMPONENTS
DRUM BRAKE
15 (155, 11)
z Hub Bolt
z O−ring
Drum Brake Assembly
Axle Shaft Assembly
z Oil Seal
123 (1,250, 90)
DISC BRAKE
123 (1,250, 90)
15 (155, 11)
Drum
Axle Shaft Assembly

Parking Brake Assembly
z Oil Seal
z O−ring
103 (1,050, 76)
Brake Caliper
Disc

z Non−reused part
F05949
SA−160
DISC BRAKE
Backing Plate
z Bearing Retainer Serration Bolt

z ABS Speed Sensor Rotor
z Snap Ring
z Bearing Retainer
z Plate Washer
z Bearing
Bearing Case
DRUM BRAKE
Backing Plate
Serration Bolt
z Hub Bolt
x5 z Oil Seal
Oil Deflector
z Gasket
Axle Shaft
z Non−reused part
F05946
SA−161
SA1C7−01
REMOVAL
1. REMOVE REAR WHEEL
Torque:
2. DISCONNECT BRAKE LINE

(a) DRUM BRAKE:
Using SST, disconnect the brake line.
SST 09023−00100
SST
F05406
(b) DISC BRAKE:

Using SST, disconnect the brake line and remove the clip.
SST
SST 09023−00100
3. DRUM BRAKE:
REMOVE DRUM
F04386
4. DISC BRAKE:
REMOVE BRAKE CALIPER AND DISC
Remove the 2 bolts, brake caliper and disc.
F04387
5. CHECK BEARING BACKLASH AND AXLE SHAFT

DEVIATION
(a) Using a dial indicator, check the backlash in the bearing
shaft direction.
Maximum: 0.6 mm (0.024 in.)
If the backlash exceeds the maximum, replace the bearing.
(b) Using a dial indicator, check the deviation at the surface
of the axle shaft outside the hub bolt.
F04388 Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle shaft.
SA−162
6. DRUM BRAKE:
REMOVE REAR BRAKE ASSEMBLY
(See page BR−44)
7. DISC BRAKE:
REMOVE PARKING BRAKE ASSEMBLY
(See page BR−57)
8. REMOVE AXLE SHAFT ASSEMBLY

(a) Remove the 4 nuts.
(b) Pull out the axle shaft assembly.
NOTICE:
(c) Remove the O−ring from the bearing case.
F04406
SA−163
SA17T−02
DISASSEMBLY
1. REMOVE BEARING RETAINER (DIFFERENTIAL SIDE)
AND ABS SPEED SENSOR ROTOR
(a) Attach 4 nuts to the serration bolts and remove the serra-
tion bolts from the backing plate using a hammer.
NOTICE:
Do not reuse the nuts previously removed from the vehicle.
F05100
(b) Grind the retainer and sensor rotor surfaces using a grind-
er, then pry them out with a chisel and hammer.
2. REMOVE SNAP RING FROM AXLE SHAFT
Using a snap ring expander, remove the snap ring.
F05101
3. REMOVE REAR AXLE SHAFT FROM BACKING

PLATE
Washer (a) Attach washers and nut to the serration bolts, then torque
the nuts to install the serration bolts to the backing plate.
(b) Remove the 4 nuts from the serration bolts.
Nut
F05102
(c) Position SST on the backing plate with 4 nuts.

SST 09521−25011, 09521−25021
SST (d) Using a press, remove the rear axle shaft, plate washer
and bearing retainer from the backing plate.
(e) Remove the SST.
SST 09521−25011, 09521−25021
F05103
4. REMOVE OIL DEFLECTOR AND GASKET

Using a brass bar and hammer, remove the 5 hub bolts, oil de-
flector and gasket.
F05104
SA−164
5. REMOVE OUTER OIL SEAL

Using SST, remove the oil seal.
SST 09308−00010
SST
F05107
6. REMOVE BEARING CASE

Attach 4 nuts to the serration bolts and remove the serration
bolts from the backing plate using a hammer.
NOTICE:
Do not reuse the nuts previously removed from the vehicle.
F05108
7. REMOVE REAR AXLE BEARING

Using SST and a press, remove the bearing.
SST 09950−60020 (09951−00810),
SST
09950−70010 (09951−07100)
F05109
SA−165
SA17U−02
INSPECTION
INSPECT AXLE SHAFT
Using a dial indicator, measure the runout of the shaft and
flange.
Maximum shaft runout: 2.0 mm (0.079 in.)
Maximum flange runout: 0.05 mm (0.0020 in.)
If the rear axle shaft or flange are damaged or worn, or if runout
is greater than the maximum, replace the rear axle shaft.
R12254
SA−166
SA17V−02
REPLACEMENT
REPLACE OIL SEAL (INNER SIDE)
SST
SST 09308−00010
F05105

SST SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
F05106
SA−167
SA17W−03
REASSEMBLY
SST 1. INSTALL REAR AXLE BEARING
Using SST and a press, install a new bearing to the bearing
case.
SST 09950−60020 (09951−00890)
F05110
2. INSTALL BEARING CASE

Position the backing plate on the bearing case and using a
press and 2 socket wrenches, install the serration bolts.
F05118
3. INSTALL OUTER OIL SEAL

(a) Using SST and a hammer, install a new oil seal.
SST 09950−60020 (09951−00810),
09950−70010 (09951−07100)
SST (b) Coat MP grease to the oil seal lip.
F05111
4. INSTALL OIL DEFLECTOR AND GASKET

Position a new gasket on the axle shaft and install a washer and
nut to a new hub bolt, as shown in the illustration, and install the
Washer hub bolt by torquing the nut.
5. INSTALL REAR AXLE SHAFT TO BACKING PLATE
(a) Install the backing plate, plate washer and bearing retain-
er on the rear axle shaft.
Nut
F05112
SST (b) Using SST and a press, install the rear axle shaft into the
backing plate.
SST 09631−12090, 09950−60020 (09951−01030)
6. INSTALL SNAP RING TO AXLE SHAFT
Using a snap ring expander, install a new snap ring.
SST
F05113
SA−168
SST 7. INSTALL ABS SPEED SENSOR ROTOR AND BEAR-

ING RETAINER (DIFFERENTIAL SIDE)
Using SST and a press, install a new ABS speed sensor rotor
and bearing retainer.
SST 09631−12090, 09950−60020 (09951−01030)
Standard length: 170.7 ± 1.0 mm (6.720 ± 0.039 in.)
SST F05114
SA−169
SA17X−02
INSTALLATION
AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See
page BR−5 or BR−10) AND CHECK FOR LEAKS
w/ ABS:
SA−170
SUSPENSION AND AXLE − REAR AXLE HUB (Rigid Front Suspension)
REAR AXLE HUB (Rigid Front Suspension)

SA1B5−01
COMPONENTS
z Oil Seal
Hub Bolt
Rear Axle Hub
x5
z Bearing
x6 Lock Nut Plate

Lock Nut Screw
5.4 (55, 48 in.·lbf)
z Bearing
z Oil Seal
Rear Axle Shaft
Straight Pin
z Gasket Lock Nut
Drum
33 (335, 24)
x6
Cone Washer
Disc Brake
103 (1,050, 76)
Brake Caliper
Disc

SA−171
SA1B6−01
REMOVAL
2. REMOVE REAR AXLE SHAFT (See page SA−155)
3. DRUM BRAKE:
REMOVE DRUM
4. DISC BRAKE:
(a) Remove the 2 bolts, washers and brake caliper.
(b) Support the brake caliper securely.
5. REMOVE REAR AXLE BEARING LOCK NUT
(a) Remove the 2 screws from the lock nut.

SST 09509−25011
6. REMOVE REAR AXLE HUB
Pull out the axle hub, remove the lock nut plate and outer bear-
ing.
SST
F05779
SA−172
SA1B7−01
DISASSEMBLY
1. REMOVE OIL SEAL AND INNER BEARING
SST 09308−00010
(b) Remove the inner bearing from the hub.
SST
F05777
Brass Bar 2. IF NECESSARY, REMOVE 2 BEARING OUTER RACES

Positions Using a brass bar and hammer, remove the 2 bearing outer
races.
NOTICE:
R13157
SA−173
SA1B8−01
REASSEMBLY
1. IF NECESSARY INSTALL 2 BEARING OUTER RACES
SST
(a) Using SST and a press, install a new outside bearing out-
er race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
(b) Using SST and a press, install a new inside bearing outer
race.
R13158
SST 09950−60020 (09951−00810),
09950−70010 (09951−07150)

(a) Place MP grease on the palm of your hand.
(b) Pack grease into the bearing until the grease ooze out
from the other side.
RA0009
3. COAT INSIDE OF HUB WITH MP GREASE

4. INSTALL INNER BEARING AND OIL SEAL
(a) Place inner bearing into the hub.
Grease
R13159
hub.
SST 09223−15020, 09950−70010 (09951−07150)
(c) Apply MP grease to the oil seal lip.
SST
F05778
SA−174
SA1B9−01
INSTALLATION
1. INSTALL REAR AXLE HUB
(a) Clean the hub installation position of the axle housing and
apply light coat of MP grease.
(b) Place the axle hub to the axle housing.
NOTICE:
(c) Install the outer bearing.
2. INSTALL LOCK NUT PLATE AND REAR AXLE BEAR-

ING LOCK NUT
(a) Place the lock nut plate on the axle housing, making sure
the tongue lines up with the key groove.
Lock Nut (b) Temporarily install the lock nut.
3. DRUM BRAKE:
INSTALL DRUM
Lock Nut Plate
4. DISC BRAKE:
F05772 INSTALL DISC AND BRAKE CALIPER
(a) Install the disc.
(b) Install the brake caliper with 2 bolts and washers.
5. ADJUST PRELOAD
(a) Using SST, torque the bearing lock nut.
SST 09509−25011
(b) Make the bearing smooth by turning the hub several
times.
(c) Using SST, retighten the bearing lock nut.
SST
F05771 (d) Using SST, loosen the nut until it can be turned by hand.
(e) Using a spring tension gauge, check the preload and

tighten the nut until the preload is within the specification.
24 − 52 N (2.4 − 5.3 kgf, 6.4 − 11.7 lbf)
NOTICE:
90 ˚ Make sure that there is no contact with the parking brake
shoe.
F05770
SA−175
(f) Align the mark on the bearing lock nut and tip of axle
Lock Nut Mark housing under the above preload range.
Axle Housing
Mark
R08001
(g) Check the distance between the top surface of axle hous-
OK
ing and lock nut.
Standard distance:
−0.2 mm − 0.9 mm (−0.0079 − 0.0354 in.)
−0.2 − 0.9 mm If the distance is greater than the specification, reassemble the
lock nut plate.
(h) Check that the hub with disc rotates smoothly and hub
has no axial play.
W00498 6. INSTALL BEARING LOCK NUT SCREW
Tighten the 2 lock nut screws.
7. INSTALL REAR AXLE SHAFT (See page SA−158)
8. INSTALL REAR WHEEL
9. w/ ABS:
(See page DI−312)
SA−176
SUSPENSION AND AXLE − REAR WHEEL HUB BOLT (Rigid Front Suspension)
REAR WHEEL HUB BOLT (Rigid

Front Suspension) SA1BA−01
REPLACEMENT
1. REMOVE REAR AXLE HUB (See page SA−171)
2. REMOVE HUB BOLT

Using SST and a press, remove the hub bolt from the axle hub.
SST 09950−70010 (09951−07150)
SST NOTICE:
F05781
3. INSTALL HUB BOLT

Using SST and a press, install a new hub bolt.
SST 09950−70010 (09951−07150)
4. INSTALL REAR AXLE HUB (See page SA−174)
SST
F05780
SUSPENSION AND AXLE − REAR WHEEL HUB BOLT (Independent Front SA−177
Suspension)
REAR WHEEL HUB BOLT

(Independent Front Suspension) SA18B−03
REPLACEMENT
2. DRUM BRAKE:
REMOVE DRUM
3. DISC BRAKE:
(a) Remove the 2 bolts, brake caliper and disc.
(b) Support the brake caliper securely.
F04387
4. REMOVE HUB BOLT

Using a brass bar and hammer, remove the hub bolt.
F04389
5. INSTALL HUB BOLT

Install a washer and nut to a new hub bolt, as shown in the il-
lustration, and install the hub bolt by torquing the nut.
6. DISC BRAKE:
INSTALL DISC AND BRAKE CALIPER
Nut Install the disc and brake caliper with the 2 bolts.
Washer Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
7. DRUM BRAKE:
F04390 INSTALL DRUM
8. INSTALL REAR WHEEL
Torque:
SA−178
SUSPENSION AND AXLE − REAR DIFFERENTIAL FRONT OIL SEAL
REAR DIFFERENTIAL FRONT OIL SEAL

SA15K−03
COMPONENTS
Rear Propeller Shaft

Companion Flange
z Oil Seal z Bearing Spacer
106 (1,080, 78) Oil Slinger
Outer Race
Bearing
z Normal: See page SA−192
w/ Diff. Lock: See page SA−216
w/ LSD: See page SA−240

F05115
SA−179
SA15L−03
REPLACEMENT
1. DISCONNECT REAR PROPELLER SHAFT
(a) Place matchmarks on the rear propeller shaft and com-
panion flange.
(b) Remove the 4 nuts, washers, bolts and disconnect the
propeller shaft.
(c) Support the propeller shaft securely.
2. DRAIN HYPOID GEAR OIL
Matchmarks F05080

SST 09330−00021
SST
Z15218

SST
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
F05920

SST 09308−10010
F05921
5. REMOVE FRONT BEARING

SST
Using SST, remove the front bearing from the drive pinion.
SST 09556−22010
Z06902
SA−180
6. REMOVE BEARING OUTER RACE

SST 09308−00010
NOTICE:
Do not scratch the taper surface of the outer race.
7. REMOVE BEARING SPACER
8. INSTALL NEW BEARING SPACER
SST
SA2395
9. INSTALL BEARING OUTER RACE

SST 09316−60011 (09316−00011, 09316−00021)
10. INSTALL FRONT BEARING
11. INSTALL OIL SLINGER AND NEW OIL SEAL
(a) Install the oil slinger.
SST (b) Coat the hypoid gear oil to a new oil seal periphery.
Z06903
(c) Using SST and a hammer, install a new oil seal.

SST
SST 09214−76011
(d) Coat the MP grease to the oil seal lip.
F05922

SST
(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
(b) Coat the threads of a new nut with hypoid gear oil LSD.
F05923
SST (c) Using SST to hold the flange, install the nut.
SST 09330−00021
SA1966
SA−181

(See page SA−192, SA−216 or SA−240)
15. CONNECT REAR PROPELLER SHAFT
(a) Align the matchmarks on the rear propeller shaft and
companion flange.
(b) Install the 4 bolts, washers and nuts.

HINT:
w/ AHC System:
Less than 5 mm Set the vehicle height select switch to the ”N” mode.
(0.20 in.)
Oil type:
w/o LSD: Hypoid gear oil API GL−5
w/ LSD: Hypoid gear oil LSD API GL−5
Z06905 Recommended oil viscosity:
Above −18˚C (0˚F) SAE 90
Below −18˚C (0˚F) SAE 80W−90 or 80W
Capacity:
w/ Diff. Lock: 3.20 liters (3.38 US qts, 2.82 lmp.qts)
Others: 3.30 liters (3.49 US qts, 2.90 lmp.qts)
SA−182
SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER
REAR DIFFERENTIAL CARRIER

SA1C9−01
COMPONENTS
RIGID FRONT SUSPENSION
z Gasket
Filler Plug
49 (500, 36)
z Gasket
Drain Plug
49 (500, 36)
z Gasket
Rear Axle Shaft
x6
Rear Propeller Shaft Cone Washer
33 (335, 24)
z Gasket
106 (1,080, 78) x10
72 (740, 53)

F05924
SA−183
INDEPENDENT FRONT SUSPENSION
Pin
z Parking Brake Cable

Clip
Filler Plug
49 (500, 36)
z Gasket
Clip
DISC BRAKE 123 (1,250, 90)

Rear Axle Shaft (RH)
15 (155, 11)
z Gasket
Drain Plug Clip

49 (500, 36)
DRUM BRAKE
Rear Axle Shaft (RH) z O−ring
Rear Propeller Shaft z Gasket
DRUM BRAKE
Rear Axle Shaft (LH)
x10
72 (740, 53)
106 (1,080, 78)
DISC BRAKE

F05925
SA−184
Side Gear
Pinion Gear Thrust Washer
Side Gear Thrust
Washer
Pinion Gear
Adjusting Nut
Bearing
Spider
47 (480, 35)
x8
Ring Gear
Bearing
L 137 (1,400, 101)
Drive Pinion x12

Plate Washer
z Bearing Spacer
13 (130, 9)
z
Oil Slinger
83 (850, 61)
z Oil Seal
Companion Flange
Bearing Cap
Bearing Differential Carrier
z Dust Deflector z
z See page SA−192

L Precoated part
F05942
SA−185
SA1CA−01
REMOVAL
1. RFS:
REMOVE DIFFERENTIAL CARRIER
(a) Drain the hypoid gear oil.
(b) Remove the rear axle shafts (See page SA−155).
(c) Disconnect the rear propeller shaft.

Matchmarks (1) Place matchmarks on the propeller shaft and differ-
ential flange.
(2) Remove the 4 nuts, washers, bolts and disconnect
the propeller shaft.
(3) Support the propeller shaft.
F05080
(d) Remove the differential carrier assembly.

(1) Remove the 10 nuts, washers and differential carri-
er assembly.
NOTICE:
(2) Remove the gasket.
F05932
2. IFS:
(a) Remove the rear wheels.
Torque:
(b) Drain the hypoid gear oil.
(c) Drum Brake:

Disconnect the brake lines.
(1) Using SST, disconnect the brake line and remove
the clip.
SST 09023−00100
(2) Employ the same manner described above to the
other side.
F05406
SA−186
(d) Disc Brake:

SST (1) Using SST, disconnect the brake line and remove
the clip.
SST 09023−00100
other side.
F04386 (e) Disconnect the parking brake cables.
(1) Remove the 2 clips, pin and disconnect the parking
brake cable from the bellcrank.
other side.
(f) Remove the rear axle shafts.

(1) Remove the 4 nuts.
(2) Pull out the axle shaft assembly.
NOTICE:
other side.
F05217
(g) Disconnect the rear propeller shaft.

ential flange.
(3) Support the propeller shaft securely.
F05080
(h) Remove the differential carrier assembly.

er assembly.
NOTICE:
F05932
SA−187
SA15O−04
DISASSEMBLY
ETC.

ion flange.
30 mm
(1.18 in.) W00493

If the runout is greater than the maximum, replace the ring gear.
F05201

Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
Perform the measurements at 3 or more positions around the
circumference of the ring gear.
bearing preload or repair as necessary.
F05202

Using a torque wrench, measure the preload of backlash be-
tween the drive pinion and ring gear.
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
SA2446
SA−188

Using a torque wrench, measure the preload with the teeth of
the drive pinion and ring gear in contact.
0.38 − 0.63 N·m (3.8 − 6.4 kgf·cm, 3.3 − 5.6 in.·lbf)
7. CHECK TOOTH CONTACT BETWEEN RING GEAR

SST SST 09330−00021
SA2448

SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
SST
R13166

SST SST 09308−10010
SA2348
SA−189

SST 09556−22010
If the front bearing is damaged or worn, replace the bearing.
SST
Z00641

rier.
(b) Remove the 2 bolts and 2 adjusting nut locks.
(c) Remove the 4 bolts, 2 bearing caps and 2 adjusting nuts.
HINT:
ly.
F05203 (d) Remove the differential case with the bearing outer races
from the carrier.
HINT:
ly.
(a) Remove the drive pinion with the rear bearing.
(b) Remove the bearing spacer.
13. REMOVE DRIVE PINION REAR BEARING

(a) Using SST and a press, remove the rear bearing from the
SST drive pinion.
SST 09950−00020
HINT:
set.
Z06911
FRONT REAR 14. REMOVE FRONT AND REAR BEARING OUTER

RACES
Using a brass bar and hammer, remove the outer races.
F05803
SA−190

(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
Matchmarks 16. CHECK DIFFERENTIAL CASE RUNOUT
F05204 changed.
(b) Install the differential case in the differenital carrier.
(c) Tighten the adjusting nut just to where there is no play in
the bearing.
rier.
(e) Install and uniformly tighten the 4 bearing cap bolts a little
at a time.

out.
F05205

CASE
case.
SST SST 09950−00020, 09950−00030,
09950−40011 (09957−04010),
09950−60010 (09951−00480)
F05206

(a) Place matchmarks on the LH and RH differential cases.
Matchmarks
(c) Using a plastic hammer, separate the LH and RH differen-
tial cases.
(d) Remove the 2 side gear thrust washers, 2 side gears, spi-
der, 4 pinion gears and 4 pinion gear thrust washers.
F05190
SA−191
SA15P−03
REPLACEMENT
1. REMOVE COMPANION FLANGE DUST DEFLECTOR
Using SST a steel plate and press, remove the dust deflector.
SST 09950−00020
SST SA2419
2. INSTALL DUST DEFLECTOR

Using SST a steel plate and press, install a new dust deflector.
SST 09726−40010
SST
SA2418
SA−192
SA15Q−08
REASSEMBLY
HINT:
parts.
gear oil.
1. MEASURE SIDE GEAR BACKLASH

(a) Install the 2 thrust washers to the side gears.
(b) Install the side gear assembly to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Install the spider assembly to the differential case.
HINT:
Install the spider to the differential case tightly.
SA0510
(e) Using a dial indicator, measure the side gear backlash

holding the side gear and spider.
Backlash: 0.02 − 0.15 mm (0.0008 − 0.0059 in.)
HINT:
S Measure the backlash at the LH and RH differential
cases.
F05191 washer of a different thickness.
1.55 (0.0610) 1.85 (0.0728)
1.60 (0.0630) 1.90 (0.0748)
1.65 (0.0650) 1.95 (0.0768)
1.70 (0.0669) 2.00 (0.0787)
1.75 (0.0689) 2.05 (0.0807)
1.80 (0.0709) 2.10 (0.0827)
2. ASSEMBLE DIFFERENTIAL CASE
(a) Reinstall the spider assembly to the differential case.
HINT:
Install the spider to the differential case tightly.
SA−193
(b) Align the matchmarks and assemble the LH and RH dif-

ferential cases.
(c) Tighten the 8 bolts uniformly, a little at a time.
Matchmarks
F05190
3. INSTALL SIDE BEARING

(a) Using SST and a press, install the RH side bearing on the
SST differential case.
SST 09710−30050, 09950−70010 (09951−07100)
F05192
(b) Using SST and a press, install the LH side bearing on the
differential case.
SST SST 09710−30050, 09950−60010 (09951−00480),
09950−70010 (09951−07100)
(a) Clean the threads of the bolts and differential case with
the white gasoline.
SST (b) Clean the contact surfaces of the differential case and
F05193 ring gear.
(c) Heat the ring gear to about 100 ˚C (212 ˚F) in boiling wa-
Boiling Water ter.
(d) Carefully take the ring gear out of the boiling water.
(e) After the moisture on the ring gear has completely evapo-
SA1143
(f) Align the matchmarks on the ring gear and differential

case.
(g) Temporarily install the 12 set bolts.
(h) After the ring gear cools down enough, torque the 12 set
bolts to which thread lock has been applied.
Matchmarks Thread lock: Part No. 08833−00100, THREE BOND
1360 K or equivalent
F05204
SA−194

changed.
(b) Install the differential case onto the carrier and tighten the
adjusting nut just to where there is no play in the bearings.
(c) Using a dial indicator, check the ring gear runout.

(d) Remove the differential case.
F05194
FRONT REAR 6. INSTALL FRONT AND REAR BEARING OUTER

RACES
race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
SST 09950−60020 (09951−00890),
F05804 09950−70010 (09951−07150)
7. INSTALL DRIVE PINION REAR BEARING
HINT:
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506−35010
SST 8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
tact pattern.
SA−195

SST 09950−30010 (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03040)
R13414
SST
SST 09330−00021
NOTICE:
oil.
SA2450

New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
HINT:
smooth.
9. INSTALL DIFFERENTIAL CASE IN CARRIER
ings. Make sure that the left and right outer races are not
interchanged.
(b) Install the differential case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
10. INSTALL ADJUSTING NUTS

F05195
SA−196

Align the matchmarks on the bearing cap and carrier. Screw in
the 2 bearing cap bolts 2 or 3 turns and press down the bearing
cap by hand.
HINT:
If the bearing cap does not fit tightly on the carrier, the adjust
nuts are not engaged properly.
Matchmarks
Reinstall the adjusting nuts if necessary.
F05196

(a) Torque the 4 bolts.
F05197
(b) Then loosen them to the point where the adjusting nuts
can be turned by SST.
SST 09504−00011
(c) Tighten the 4 bolts.
(d) Using SST, torque the adjusting nut on the ring gear side
until the ring gear has a backlash of about 0.2 mm (0.008
in.).
SST
Z06953
(e) While turning the ring gear, use the SST to fully tighten the
adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
SST
F05198
(f) Place a dial indicator on the top of the adjusting nut on the
ring gear side.
(g) Adjust the side bearing to zero preload by tightening the
SST
other adjusting nut until the pointer on the indicator be-
gins to move.
SA2444
SA−197
(h) Using SST, torque the adjusting nut 1 − 1.5 notches from
the zero preload position.
SST
F05198
(i) Using a dial indicator, adjust the ring gear backlash until
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
nuts by equal amount. For example, loosen the nut on the left
SST
side 1 notch and torque the nut on the right side 1 notch.
Z06918
(j) Torque the 4 bearing cap bolts.

(k) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
F05197

0.38 − 0.63 N·m (3.8 − 6.4 kgf·cm, 3.3 − 5.6 in.·lbf)
SA2446

AND DRIVE PINION
(b) Turn the companion flange, in both directions to inspect
F05199
SA−198
Proper Contact

Select an adjusting washer that will shift the drive pinion

FA2013
1.050 (0.04134) 1.325 (0.05217)
1.075 (0.04232) 1.350 (0.05315)
1.100 (0.04331) 1.375 (0.05413)
1.125 (0.04429) 1.400 (0.05512)
Washer
1.150 (0.04528) 1.425 (0.05610)
FA2041
1.175 (0.04626) 1.450 (0.05709)
1.200 (0.04724) 1.475 (0.05807)
1.225 (0.04823) 1.500 (0.05906)
1.250 (0.04921) 1.525 (0.06004)
1.275 (0.05020) 1.550 (0.06102)
1.300 (0.05118) −
16. REMOVE OIL SLINGER AND FRONT BEARING
(See page SA−187)

SST 09308−00010
SST 18. INSTALL NEW BEARING SPACER
F05116
SA−199

SST 09316−60011 (09316−00011, 09316−00021)
20. INSTALL FRONT BEARING AND OIL SLINGER
SST
Z06903

SST 09214−76011
SST
SA2454

SST SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
R13414

SST SST 09330−00021
SA2351

New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
ing spacer.
SA−200
SST a force of 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the speci-
SST 09330−00021
SA2351 24. RECHECK RING GEAR BACKLASH
(See page SA−192)
(See page SA−192)

(b) Tightening 2 bolts, bend the nut locks.
HAUL STAND ETC.
F05180
SA−201
SA15R−03
INSTALLATION
AFTER INSTALLATION, FILL REAR DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA−179), FILL
BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR−5 or BR−10) AND
CHECK FOR LEAKS
w/ ABS:
SA−202
SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
REAR DIFFERENTIAL CARRIER (w/ Diff. Lock)

SA1C3−01
COMPONENTS
z Gasket
Filler Plug
49 (500, 36)
z Gasket
Drain Plug
49 (500, 36)
35 (360, 26)
z Gasket
Actuator Protector Rear Axle Shaft
20 (200, 14)
x6
33 (335, 24)
z Gasket
106 (1,080, 78)

x10
72 (740, 53)

F05926
SA−203
Filler Plug Pin

DISC BRAKE 49 (500, 36)
Rear Axle Shaft (RH) z Gasket
Clip Clip
15 (155, 11)
z Gasket
Clip
DRUM BRAKE
Drain Plug
49 (500, 36)
z O−ring
123 (1,250, 90)
15 (150, 11)
No. 1 Differential
Actuator Carrier
No. 2
Protector
Actuator
Protector
15 (150, 11)
z Gasket
36 (367, 27)
DRUM BRAKE
Rear Propeller Shaft
x10
106 (1,080, 78) 72 (740, 53)
DISC BRAKE

F05927
SA−204
Pinion Shaft
Pinion Shaft
Holder
Side Gear
Side Gear Thrust

Pinion Gear
Washer
Ring Gear
L 58 (590, 43)
L 58 (590, 43)
Bearing
x3 x5
z Bearing Spacer
L 137 (1,400, 101)

Drive Pinion x12
Washer Differential Cover
Bearing
Differential Case
Shift Fork Plate Washer
Actuator
24 (240, 17)
Sleeve
113 (1,150, 83)

L 20 (200, 14)
Rear Diff. Lock
Position Switch
40 (410, 30) Cover
z Gasket 18 (185, 13) Bearing
Companion Flange
z See page SA−216 Bearing Cap
Oil Slinger Differential Carrier

z Oil Seal
z Dust Deflector

SA−205
Pinion Shaft
Pinion Shaft
Holder
Side Gear
Pinion Gear Side Gear Thrust

Washer
Ring Gear
L 58 (590, 43)
L 58 (590, 43)
Bearing
x3
x5
z Bearing Spacer
L 137 (1,400, 101)

Drive Pinion x12
Washer Differential Cover
Bearing
Differential Case
Shift Fork Plate Washer
Actuator
24 (240, 17)
Sleeve
L 20 (200, 14) 113 (1,150, 83)

Rear Diff. Lock
Position Switch
40 (410, 30) Cover
z Gasket 18 (185, 13)
Bearing
Companion Flange
z See page SA−216
Bearing Cap
Oil Slinger Differential Carrier

z Oil Seal
z Dust Deflector

SA−206
SA1C4−01
REMOVAL
1. RFS:
(a) Lock the rear differential.
(1) Turn the ignition switch to the ON position.
(2) Shift the transfer shift lever to L4 position.
(3) Turn the differential lock control switch to the RR or

FR/RR position and lock the rear differential.
HINT:
While rotating the rear wheels, check they are in the differential
lock condition.
(4) Disconnect the cable from the negative terminal of
the battery.
(c) Remove the rear axle shafts (See page SA−155).
(d) Remove the actuator protector.
Remove the bolt, 2 nuts and protector.
Torque:
Nut: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf)
(e) Disconnect the connectors and hose.
Z07261
(f) Disconnect the rear propeller shaft.

(1) Place matchmarks on the rear propeller shaft and
companion flange.
Matchmarks
F05080
(g) Remove the differential carrier assembly.

er assembly.
NOTICE:
F05932
SA−207
HINT:
S Before installation, connect the connectors of the actua-
tor to the connector on the vehicle side, check the differ-
ential lock is in operation.
S Before installation, check that the sleeves are in opera-
tion while switching over the differential lock control
switch.
S After installation, check that the rear differential lock is in
operation.
2. IFS:
(a) Lock the rear differential.
(3) Turn the differential lock control switch to the RR

position and lock the rear differential.
HINT:
While rotating the rear wheels, check they are in the differential
lock condition.
(4) Disconnect the cable from the negative terminal of
the battery.
(b) Remove the rear wheels.
F05181 Torque:
(c) Drain the hypoid gear oil.
(d) Drum Brake:

the clip.
SST 09023−00100
other side.
F05406
SA−208
(e) Disc Brake:

the clip.
SST 09023−00100
other side.
F04386 (f) Disconnect the parking brake cables.
other side.
(g) Remove the rear axle shafts.

NOTICE:
other side.
F05217
(h) Disconnect the rear propeller shaft.

ential flange.
(i) Remove the No. 1 and No. 2 actuator protectors.
F05080 (1) Remove the nut, bolt and No. 1 actuator protector.
(2) Remove the 2 nuts and No. 2 actuator protector.
(j) Disconnect the connectors and hose.
SA−209
(k) Remove the differential carrier assembly.

er assembly.
NOTICE:
HINT:
F05932 At the time of installation, please refer to the following items.
S Before installation, connect the connectors of the actua-
tor to the connector on the vehicle side, check the differ-
ential lock is in operation.
S Before installation, check that the sleeves are in opera-
tion while switching over the differential lock control
switch.
S After installation, check that the rear differential lock is in
operation.
SA−210
SA15U−06
DISASSEMBLY
ETC.

ion flange.
30 mm
(1.18 in.) W00493

F05182

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
F05183
SA−211

Using a torque wrench, measure the preload of the drive pinion
using the backlash between the drive pinion and ring gear.
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
SA2446 Total preload (at starting):
0.3 − 0.5 N·m (3 − 5 kgf·cm, 2.6 − 4.3 in.·lbf)
8. REMOVE REAR DIFF. LOCK POSITION SWITCH
Remove the rear diff. lock position switch and gasket.
9. REMOVE COVER
(a) Remove the 3 bolts.
(b) Using a brass bar and hammer, tap on the cover to re-
move it.
10. REMOVE ACTUATOR, SHIFT FORK AND SLEEVE
F05801
(b) Remove the shift fork shaft bolt.

(c) Using a screwdriver, pull out the actuator and remove the
sleeve and shift fork.
F05802

SST SST 09330−00021
SA2448
SA−212

SST 09950−30010 (09951−03010, 09953−03010,
SST
09954−03010, 09955−03030, 09956−03040)
R13166

SST SST 09308−10010
SA2348

SST 09556−22010
SST
Z00641

rier.
Matchmarks
SA2437
(c) Using SST and a hammer, remove the plate washers.

SST SST 09504−22011
HINT:
Measure the plate washer thickness and note down it.
(d) Remove the differential case with the side bearing outer
races from the differential carrier.
HINT:
Tag the bearing outer races to show the location for reassembly.
R08254
SA−213


SST drive pinion.
SST 09950−00020
HINT:
set.
Z06911

RACES
F05803

Matchmarks
F05184 changed.
ing.
HINT:
rier.
SA−214

out.
F05185

(a) Place matchmarks on the differential case and differential
cover.
(b) Using a torx socket (E10), remove the 5 set bolts and 3
pinion shaft pins.
Matchmarks
(c) Separate the cover and case.
(d) Remove the 2 side gears, side gear thrust washers, 4 pin-
ion gears, 4 pinion gear thrust washers, 3 pinion shafts
F05953 and holder from the differential case.
21. REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE
Using SST, remove the side bearing.
SST SST 09950−40011 (09951−04010, 09952−04010,
09953−04020, 09955−04060, 09957−04010,
09958−04010), 09950−60010 (09951−00580)
HINT:
Fix the claws of SST to the notches in the differential case.
SST
F05186
22. REMOVE SIDE BEARING FROM DIFFERENTIAL COV-

ER
Using SST, 4 bolts and a press, remove the side bearing.
SST
SST 09950−60010 (09951−00580),
09950−70010 (09951−07100)
F05187
SA−215
SA15V−03
REPLACEMENT
SST 1. REMOVE COMPANION FLANGE DUST DEFLECTOR
Using SST a steel plate and press, remove the dust deflector.
SST 09950−00020
SA2419
2. INSTALL DUST DEFLECTOR

Using SST a steel plate and press, install a new dust deflector.
SST 09726−40010
SST
SA2418
SA−216
SA15W−07
REASSEMBLY
HINT:
parts.
gear oil.
1. MEASURE SIDE GEAR BACKLASH

(a) Install the 2 thrust washers to the 2 side gears.
(b) Install the 4 thrust washers to the 4 pinion gears.
SA0510
(c) Install the 2 side gears into the differential case.

(d) Install the holder into the differential case.
(e) Install the 4 pinion gears with the thrust washers.
(f) Align the holes of the differential case and pinion shaft,
and install the 3 pinion shafts.
(g) Install the side gear to the differential cover.
(h) Align the matchmarks and install the differential case and
differential cover.
R08274 (i) Using a torx socket (E10), install the 5 bolts and 3 pinion
shaft pins.
SA−217
(j) Using a dial indicator, while holding the side gear mea-
sure the backlash.
Backlash: 0.02 − 0.15 mm (0.0008 − 0.0059 in.)
If the backlash is not within the specification, install the thrust
HINT:
S Try to select washers of the same size for both sides.
R08276 Thrust washer thickness
1.55 (0.0610) 1.85 (0.0728)
1.60 (0.0630) 1.90 (0.0748)
1.65 (0.0650) 1.95 (0.0768)
1.70 (0.0669) 2.00 (0.0787)
1.75 (0.0689) 2.05 (0.0807)
1.80 (0.0709) 2.10 (0.0827)
(k) After measuring backlash, remove the 5 set bolts and 3
pinion shaft pins.
(a) Clean the threads of the bolts, pinion shaft pins, case and
cover with the white gasoline.
(b) Coat the threads of the bolts and pinion shaft with adhe-
sive.
Adhesive: Part No. 08833−00070, THREE BOND 1324
or equivalent
(c) Align the matchmarks, install the case and cover.
(d) Using a torx socket (E10), install the 5 bolts and 3 pinion
shaft pins.
Adhesive Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
Matchmarks R13246

SST (a) Differential cover side:
Using SST and a press, install the side bearing on the dif-
ferential cover.
SST 09550−60010
F05178
SA−218
(b) Ring gear side:

Using SST and a press, install the side bearing on the dif-
SST ferential case.
SST 09550−60010
the white gasoline.
(b) Clean the contact surfaces of the differential case and
F05179 ring gear.
Boiling Water ter.
rated, quickly install the ring gear on the differential case.
SA1143

case.
(h) After the ring gear has cooled down enough, torque the
12 set bolts to which thread lock has been applied.
Thread lock: Part No.08833−00100, THREE BOND
F05188 5. CHECK RING GEAR RUNOUT
changed.
ing.
HINT:
rier.
SA−219
(f) Using a dial indicator, check the ring gear runout.

F05182

OUTER RACES
SST SST
race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
SST 09950−60020 (09951−00890),
F05804 09950−70010 (09951−07150)
HINT:
drive pinion.
SST 09506−35010
HINT:
SST
tact pattern.

SST 09950−30010, (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03040)
R13414
SA−220
SST preload by tightening the nut.
SST 09330−00021
NOTICE:
oil.
SA2450

New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
HINT:
smooth.
ings. Make sure that the left and right races are not inter-
changed.
(b) Install the assembled plate washer onto the side bearing.
(c) Install the differential case in the carrier.
R08261
(d) Settle down the plate washer and bearing snugly by tap-
ping on the ring gear with a plastic hammer.
HINT:
R08262

(a) Using a dial indicator, while holding the side bearing of the
ring gear side measure the backlash.
R08263
SA−221
(b) Select a case cover side plate washer using the backlash
as a reference.
Mark Thickness mm (in.) Mark Thickness mm (in.)
1 2.67 (0.1051) 13 3.03 (0.1193)
2 2.70 (0.1063) 14 3.06 (0.1205)
3 2.73 (0.1075) 15 3.09 (0.1217)
4 2.76 (0.1087) 16 3.12 (0.1228)
5 2.79 (0.1098) 17 3.15 (0.1240)
6 2.82 (0.1110) 18 3.18 (0.1252)
7 2.85 (0.1122) 19 3.21 (0.1264)
8 2.88 (0.1134) 20 3.24 (0.1276)
9 2.91 (0.1146) 21 3.27 (0.1287)
10 2.94 (0.1157) 22 3.30 (0.1299)
11 2.97 (0.1169) 23 3.33 (0.1311)
12 3.00 (0.1181) − −
(c) Select a ring gear teeth side plate washer so that there is
no clearance between the outer race and case.
R08264
(d) Remove the 2 plate washers and differential carrier.

(e) Install the plate washer into the lower part of the carrier.
(f) Place the plate washer onto the differential case together
with the outer races, and install the differential case with
the outer race into the carrier.
(g) Settle down the plate washer and bearing snugly by tap-
ping on the ring gear with a plastic hammer.
R08265
(h) Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness of washers on both sides by an
equal amount.
HINT:
case.
R08263 Ensure that there is ring gear backlash.
SA−222

(a) After adjustment using the backlash as reference, re-
move the ring gear side plate washer.
(b) Using a micrometer, measure the thickness of the re-

moved plate washer.
(c) Install a new washer 0.06 − 0.09 mm (0.0024 − 0.0035 in.)
thicker than the removed washer.
HINT:
Select a washer which can be pressed in 2/3 of the way with fin-
ger.
RA0090
(d) Using SST, tap in the plate washer.

SST 09504−22010
(e) Align the matchmarks on the cap and carrier.
SST (f) Tighten the 4 bearing cap bolts to the specified torque.
R08269
(g) Using a dial indicator, adjust the ring gear backlash until
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
by an equal amount.
(h) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
F05183

0.3 − 0.5 N·m (3 − 5 kgf·cm, 2.6 − 4.3 in.·lbf)
SA2446
SA−223

(b) Turn the companion flange, in both directions to inspect
F05170
Proper Contact

Select an adjusting washer that will shift the drive pinion

FA2013
1.050 (0.04134) 1.325 (0.05217)
1.075 (0.04232) 1.350 (0.05315)
1.100 (0.04331) 1.375 (0.05413)
1.125 (0.04429) 1.400 (0.05512)
Washer 1.150 (0.04528) 1.425 (0.05610)
FA2041
1.175 (0.04626) 1.450 (0.05709)
1.200 (0.04724) 1.475 (0.05807)
1.225 (0.04823) 1.500 (0.05906)
1.250 (0.04921) 1.525 (0.06004)
1.275 (0.05020) 1.550 (0.06102)
1.300 (0.05118) −
(See page SA−210)
SA−224

SST 09308−00010
SST
F05116

SST 09316−60011 (09316−00011, 09316−00021)
SST
Z06903
(b) Using SST and a hammer, install a new oil seal, as shown.
SST 09214−76011
SST
SA2454

SST SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
R13414

SST SST 09330−00021
SA2351
SA−225

Using a torque wrench, measure the preload of the drive pinion
using the backlash between the drive pinion and ring gear.
New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
ing spacer.
SST 09330−00021
(See page SA−210)
(See page SA−210)
27. INSTALL ACTUATOR, SHIFT FORK AND SLEEVE
(a) Clean contacting surfaces of any FIPG material using
(b) Apply FIPG to the actuator.

FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
FIPG Width Approx. HINT:
1 − 2 mm (0.04 − 0.08 in.) Install the actuator within 10 minutes after applying FIPG.
Z15220
(c) Install the shift fork and actuator to the differential and
match the shift fork hole with the shift fork.
(d) Clean the threads of the set bolt and fork shaft with the
white gasoline.
F05912
SA−226
(e) Coat the threads of the set bolt with adhesive.

or equivalent
Adhesive (f) Tighten the shift fork shaft set bolt.
F05910
(g) Engage the sleeve with the dog clutch of the differential
case.
F05911
(h) Tighten the 4 bolts.

28. INSTALL COVER
F05801
(b) Apply FIPG to the cover.

equivalent
HINT:
Install the cover within 10 minutes after applying FIPG.
FIPG Width Approx. 29. INSTALL REAR DIFF. LOCK POSITION SWITCH
1 − 2 mm (0.04 − 0.08 in.) Z15219 Install the rear diff. lock position switch with a new gasket.
HAUL STAND ETC.
SA−227
SA15X−03
INSTALLATION
CHECK FOR LEAKS
w/ ABS:
SA−228
SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (w/ LSD)
REAR DIFFERENTIAL CARRIER (w/ LSD)

SA1CB−01
COMPONENTS
z Gasket
Filler Plug
49 (500, 36)
z Gasket
Drain Plug
49 (500, 36)
z Gasket
Rear Axle Shaft
x6
33 (335, 24)
z Gasket
106 (1,080, 78) x10
72 (740, 53)

F05924
SA−229
Pin
z Parking Brake Cable

Clip
Filler Plug
49 (500, 36)
z Gasket
Clip
DISC BRAKE 123 (1,250, 90)

15 (155, 11)
z Gasket
Drain Plug Clip

49 (500, 36)
DRUM BRAKE
Rear Axle Shaft (RH) z O−ring
Rear Propeller Shaft z Gasket
DRUM BRAKE
x10
72 (740, 53)
106 (1,080, 78)
DISC BRAKE

F05925
SA−230
#: If the side gear backlash has been adjusted

Pinion Gear Thrust Washer by TOYOTA dealer, adjusting shims are
installed between the side gear thrust washer
and the differential case.
Pinion Gear
Spider
Compression Spring Spring Retainer
Side Gear
L 137 (1,400, 101)
Adjusting Nut
x12
Bearing
Ring Gear
Bearing
47 (480, 35)
# Adjusting Shim
Drive Pinion x8 Clutch Plate

Plate Washer
RH Differential
z Bearing Spacer
Case
Side Gear Thrust Washer
z
z
83 (850, 61)
Bearing Cap
Bearing
z Oil Seal
Companion Flange
z See page SA−240 13 (130, 9)
z z Adjusting Nut Lock
Oil Slinger
z Dust Deflector

SA−231
SA1CC−01
REMOVAL
1. RFS:
(a) Drain the hypoid gear oil.
(b) Remove the rear axle shafts (See page SA−155).
(c) Disconnect the rear propeller shaft.

ential flange.
(3) Support the propeller shaft.
F05080
(d) Remove the differential carrier assembly.

er assembly.
NOTICE:
F05932
2. IFS:
(a) Remove the rear wheels.
Torque:
(c) Drum Brake:

the clip.
SST 09023−00100
other side.
F05406
SA−232
(d) Disc Brake:

the clip.
SST 09023−00100
other side.
F04386 (e) Disconnect the parking brake cables.
other side.
(f) Remove the rear axle shafts.

NOTICE:
other side.
F05217
(g) Disconnect the rear propeller shaft.

ential flange.
F05080
(h) Remove the differential carrier assembly.

er assembly.
NOTICE:
F05932
SA−233
SA160−04
DISASSEMBLY
ETC.

ion flange.
30 mm
(1.18 in.) W00493

F05201

Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
SA3242
SA−234

Using a torque wrench, measure the preload of backlash be-
tween the drive pinion and ring gear.
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
SA2446 Total preload (at starting):
0.38 − 0.63 N·m (3.8 − 6.4 kgf·cm, 3.3 − 5.6 in.·lbf)

SST
SST 09330−00021
SA2448

SST 09950−30010 (09951−03010, 09953−03010,
SST
09954−03010, 09955−03030, 09956−03040)
R13166

SST SST 09308−10010
SA2348
SA−235

SST 09556−22010
SST
Z00641
11. REMOVE DIFFERENTIAL CASE

rier.
(b) Remove the 2 bolts and 2 adjusting nut locks.
(c) Remove the 4 bolts, 2 bearing caps and adjusting nuts.
HINT:
ly.
Matchmarks R15928 (d) Remove the differential case with the bearing outer races.
HINT:
ly.

SST
drive pinion.
SST 09950−00020
HINT:
set.
FA2045

RACES
F05803
SA−236

Matchmarks 16. CHECK DIFFERENTIAL CASE RUNOUT
F05204 changed.
(c) Tighten the adjusting nut just to where there is no play in
the bearing.
(d) Align the matchmarks on the bearing cap and differential
carrier.
(e) Install and uniformly tighten the bearing cap bolts a little
at a time.

out.
SA3243

CASE
case.
SST 09950−00020, 09950−00030,
SST
09950−40011 (09957−04010),
09950−60010 (09951−00480)
F05206

Matchmarks
F05190
SA−237
(d) Remove the 2 side gears, 6 side gear thrust washers, 4

clutch plates, 2 spring retainers, compression spring, 4
pinion gears, 4 pinion gear thrust washers and spider
HINT:
S Keep the disassembled parts in order.
S If the side gear backlash has been adjusted by TOYOTA
dealer, adjusting shims are installed between the side
gear thrust washer and the differential case.
SA−238
SA161−03
INSPECTION
1. REPLACE PARTS THAT ARE DAMAGED OR WORN
HINT:
If replacing the side gear, also replace the thrust washer that
contact with it.
RA0225
2. INSPECT SIDE GEAR THRUST WASHERS FOR WEAR

OR DAMAGE
Using a micrometer, measure that the contact surface of the
thrust washer is even and check that no bare metal is showing.
Thickness (Reference):
1.97 − 2.06 mm (0.0776 − 0.0811 in.)
If necessary, replace the thrust washers.
HINT:
Z15288 If replacing the thrust washer, also replace the clutch plate that
contacts with it.
3. INSPECT CLUTCH PLATE FOR WEAR OR DAMAGE
Using a micrometer, measure the contact surface of the clutch
plate and check that there is no abnormal wear.
Thickness (Reference):
1.97 − 2.03 mm (0.0776 − 0.0799 in.)
If necessary, replace the clutch plate.
R13849
4. INSPECT COMPRESSION SPRING FREE LENGTH

Using vernier calipers, measure the free length of the spring.
Length (Reference): 32.8 mm (1.291 in.)
RA0192
SA−239
SA162−03
SST
REPLACEMENT
REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST a steel plate and press, remove the dust de-
flector.
SST 09950−00020
SA2419
(b) Using SST a steel plate and press, install a new dust de-
SST flector.
SST 09726−40010
SA2418
SA−240
SA163−04
REASSEMBLY
HINT:
S When reusing the side gear, thrust washers and clutch
plates, skip the STEP 1.
parts.
S Apply all of the sliding and rotating surfaces with LSD oil.
LH Case 1. SELECT ADJUSTING SHIM

RH Case
(a) Measure the LH and RH differential case dimensions ”X”,
as shown in the illustration.
X X
F05258
(b) Install the thrust washers and clutch plates on the side
gear.
(c) Using SST to press down the thrust washers and clutch
plates with about pressure of 10 kgf (22 lbf), measure di-
SST mension ”Y”, as shown in the illustration.
SST 09649−17010
(d) Referring to the following selection table on the next
Y page, select the proper adjusting shim.
F05259 Adjust shim thickness = X − Y − 19.08 mm (0.7511 in.)
SA−241
®
X mm
Y mm
¬
46.05 46.06 46.07 46.08 46.09 46.10 46.11 46.12 46.13 46.14 46.15 46.16 46.17 46.18 46.19 46.20 46.21 46.22
26.45
26.46
26.47 C+D
26.48
26.49
26.50
C+C
26.51
26.52
26.53
B+C
26.54
26.55
26.56
26.57
B+B
26.58
26.59
26.60
26.61
A+B
26.62
26.63
26.64
26.65
26.66 A+A
26.67
26.68
26.69
26.70 D
26.71
26.72
26.73
26.74
C
26.75
26.76
26.77
26.78 B
26.79
26.80
26.81
26.82 A
26.83
26.84
26.85
#
26.86
26.87
26.88
#: Reassemble another type shim or check the backlash after assembling A shim.
F05260
SA−242
®
X in.
Y in.
¬
1.8129 1.8133 1.8137 1.8141 1.8145 1.8149 1.8153 1.8157 1.8161 1.81651.8169 1.8173 1.8177 1.8181 1.8185 1.8188 1.8192 1.8196
1.0413
1.0417
1.0421
C+D
1.0425
1.0429
1.0433
C+C
1.0436
1.0440
1.0444
B+C
1.0448
1.0452
1.0456
1.0460
B+B
1.0464
1.0468
1.0472
1.0476
A+B
1.0480
1.0484
1.0488
1.0492
1.0496 A+A
1.0499
1.0503
1.0507
1.0511 D
1.0515
1.0519
1.0523
1.0527
C
1.0531
1.0535
1.0539
1.0543 B
1.0547
1.0551
1.0555
1.0559 A
1.0562
1.0566
1.0570
#
1.0574
1.0578
1.0582
#: Reassemble another type shim or check the backlash after assembling A shim.
F05260
SA−243
Adjust shim thickness

Mark Thickness mm (in.) Mark Thickness mm (in.)
A 0.20 (0.0079) C 0.30 (0.0118)
B 0.25 (0.0098) D 0.35 (0.0138)
2. CHECK SIDE GEAR BACKLASH
(a) Install the thrust washers, clutch plates and adjusting
shim to side gear.
HINT:
Install the adjusting shim with its surface having no oil groove
facing to the differential case side.
(b) Install the side gear assembly to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Align the spring retainer holes with the straight pins and
install the retainer.
(e) Install the spider assembly to the differential case.
HINT:
Install the spider to the differential case tightly and do not move
the spring retainer.
F05929
(f) Using a dial indicator, measure the side gear backlash

while holding the side gear and spider.
Backlash: 0.02 − 0.15 mm (0.0008 − 0.0059 in.)
HINT:
S Measure the backlash at the LH and RH differential
cases.
If the backlash is not within the specification, select the adjust-
W01878 ing shim.
(a) Reinstall the spider assembly to the LH differential case.
HINT:
Install the spider to the LH differential case tightly and do not
move the spring retainer.
(b) Install the compression spring and RH spring retainer.
(c) Install the RH side gear assembly.
(d) Align the matchmarks and assemble the LH and RH dif-
ferential cases.
SA−244
HINT:
S Be careful not to drop the side gear.
S Check the pinion and side gear alignment.
(e) Tighten the 8 bolts uniformly, a little at a time.
the white gasoline.
(b) Clean the contact surfaces of the differential case and
ring gear.
Boiling Water ter.
SA1143

case.
(h) After the ring gear has cooled down enough, torque the
12 set bolts to which thread lock has been applied.
Thread lock: Part No. 08833−00100, THREE BOND
Matchmarks Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
F05204 5. CHECK RING GEAR RUNOUT
changed.
(b) Install the differential case onto the carrier and tighten the
adjusting nut just to where there is no play in the bearings.
(c) Using a dial indicator, measure the ring gear runout.

(d) Remove the differential case.
F05194
SA−245

SST SST OUTER RACE
race.
SST 09950−60020 (09951−00710)
09950−70010 (09951−07150)
SST 09950−60020 (09951−00890),
F05804 09950−70010 (09951−07150)
HINT:
drive pinion.
SST 09506−35010
HINT:
SST
tact pattern.

SST 09950−30010, (09951−03010, 09953−03010,
SST 09954−03010, 09955−03030, 09956−03040)
R13414
SST
SST 09330−00021
NOTICE:
S Coat the nut and threads of the drive pinon with gear
oil.
SA2450
SA−246

New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
HINT:
smooth.
(a) Place the 2 bearing races on their respective bearings.
Make sure that the left and right outer races are not inter-
changed.
(b) Install the differential in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
10. INSTALL ADJUSTING NUTS

F05195

Align the matchmarks on the bearing cap and carrier. Screw in
Matchmarks the 2 bearing cap bolts 2 or 3 turns and press down the bearing
cap by hand.
HINT:
If the bearing cap does not fit tightly on the carrier, the adjusting
nuts are not engaged properly. Reinstall the adjusting nuts if
necessary.
W01783 12. ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bolts.
SA−247
(b) Then loosen them to the point where the adjusting nuts
can be turned by SST.
SST 09504−00011
(d) Using SST, torque the adjusting nut on the ring gear side
until the ring gear has a backlash of about 0.2 mm (0.008
in.).
SST
Z06953
(e) While turning the ring gear, use the SST to fully tighten the
adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
SST SA3245
(f) Place a dial indicator on the top of the adjusting nut on the
ring gear side.
SST (g) Adjust the side bearing to zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.
SA2444
(h) Using SST, torque the adjusting nut 1 − 1.5 notches from
the zero preload position.
SST SA3245
(i) Using a dial indicator, adjust the ring gear backlash until
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
nuts equal amounts. For example, loosen the nut on the left
side 1 notch and torque the nut on the right side 1 notch.
SST
Z06918
SA−248
(j) Torque the 4 bolts.

(k) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)

0.38 − 0.63 N·m (3.8 − 6.4 kgf·cm, 3.3 − 5.6 in.·lbf)
SA2446

AND DRIVE PINION
(b) Turn the companion flange, and pin to both directions to
inspect the ring gear for proper tooth contact.
SA3248

Proper Contact

R02495
SA−249
1.050 (0.04134) 1.325 (0.05217)
1.075 (0.04232) 1.350 (0.05315)
1.100 (0.04331) 1.375 (0.05413)
1.125 (0.04429) 1.400 (0.05512)
Washer 1.150 (0.04528) 1.425 (0.05610)
FA2041
1.175 (0.04626) 1.450 (0.05709)
1.200 (0.04724) 1.475 (0.05807)
1.225 (0.04823) 1.500 (0.05906)
1.250 (0.04921) 1.525 (0.06004)
1.275 (0.05020) 1.550 (0.06102)
1.300 (0.05118) −
(See page SA−233)

SST 09308−00010
SST
F05116

SST 09316−60011 (09316−00011, 09316−00021)
SST
Z06903
(b) Using SST and a hammer, install a new oil seal, as shown.
SST 09214−76011
Oil seal driven in depth: 0.5 mm (0.020 in.)
SST
SA2454
SA−250

SST SST 09950−30010 ( 09951−03010, 09953−03010,
09954−03010, 09955−03030, 09956−03040)
R13414

SST SST 09330−00021
SA2351

New bearing
1.3 − 1.8 N·m (13 − 19 kgf·cm, 11.3 − 16.4 in.·lbf)
Reused bearing
0.64 − 0.92 N·m (6.5 − 9.4 kgf·cm, 5.6 − 8.2 in.·lbf)
ing spacer.
SST 09330−00021
(See page SA−233)
(See page SA−233)
SA−251

(b) After tightening 2 bolts, bend the nut locks.
HAUL STAND ETC.
SA3241
SA−252
SA164−03
INSTALLATION
CHECK FOR LEAKS
w/ ABS:
SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (Rigid Front SA−253
Suspension)
DIFFERENTIAL LOCKING SYSTEM

(Rigid Front Suspension) SA1BT−01
ON−VEHICLE INSPECTION
1. INSPECT DIFFERENTIAL LOCK SYSTEM
(a) Inspect the indicator light.
Check that the indicator light lights up for approx. 1 se-
cond when the ignition switch is turned ON.
(b) Inspect the differential lock operation.
(1) Jack up the vehicle then start the engine.
(2) Keep the L4 condition.
(3) When the Diff. lock control switch is set to the RR
position, the indicator light (rear side) is turned on.
Differential lock is applied to the rear wheels at this
time.
HINT:
If the gears of the differential lock system are not meshed, the
indicator light remains blinking, so rotate the tires to mesh the
F05158
gear.
(4) When the Diff. lock control switch is at the OFF posi-
tion, the indicator light goes off.
Differential lock is released for the rear wheel at this
time.
(5) When the Diff. lock control switch is set to the FR/
RR position, the indicator lights (front side and rear
side) are turned on.
Differential lock is applied for the both front wheels
and rear wheels at this time.
(6) Check the voltage between the terminals of the

4WD control ECU when switching the Diff. lock con-
M3 M4 M1 M2
trol switch with the speedometer, registering
approx. 8 km/h (5 mph) or more.
Switch position Terminal Specified value
0.5 V or less
RR M1 − M2
(No change)
0.5 V or less
FR/RR M3 − M4
Z07254 (No change)
(7) Check that the indicator lights blink when the trans-
fer shift lever is shifted to a position other than L4.
(8) Return the Diff. lock control switch to OFF.
(9) Stop the engine and lower the vehicle.
2. INSPECT DIFF. LOCK SYSTEM CIRCUIT
(a) Inspect the battery voltage.
Battery voltage: 10 − 14 V
SA−254 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (Rigid Front
Suspension)
Wire Harness Side (b) Inspect the system circuit with the connector discon-
M2 RLP M1 SPD M4 RF M3
nected.
Disconnect the connector from the 4WD control ECU and
inspect the connector on the wire harness side, as shown
in the table.
IG FLP R GND 4WD

Z07255
Symbols (Terminal No.) Trouble part Condition Specified value

M1 − M2 RR Diff. Lock Actuator
L
Less than
th 100 W
M3 − M4 FR Diff. Lock Actuator −
GND − Body ground Body ground Continuity
1 pulse each
SPD − Body ground Speed Sensor Vehicle moves slowly
40 cm (15.75 in.)
IG − Body ground DIFF. Fuse Ignition switch ON 10 − 14 V
Rear Diff. Lock Ignition switch ON with indicator light (Rear) ON About 0 V
RLP − Body
B d ground
d
Position Switch Ignition switch ON with indicator light (Rear) OFF 10 − 14 V
Front Diff. Lock Ignition switch ON with indicator light (Front) ON About 0 V
FLP − Body
B d ground
d
Position Switch Ignition switch ON with indicator light (Front) OFF 10 − 14 V
Ignition switch ON with transfer L4 position About 0 V
4WD − Body
B d ground
d L4 Position
P iti Switch
S it h
Ignition switch ON with transfer without L4 position 10 − 14 V
Ignition switch ON with Diff. lock control switch RR or FR/RR 10 − 14 V
R − Body
B d ground
d
Differential Lock Ignition switch ON with Diff. lock control switch OFF About 0 V
Control Switch Ignition switch ON with Diff. lock control switch FR/RR 10 − 14 V
RF − Body
B d ground
d
Ignition switch ON with Diff. lock control switch OFF or RR About 0 V
HINT:
When the signals that lock the front differential and free the rear
differential enter the ECU from the Diff. lock control switch,
(when battery voltage is inputted to terminal 6 (RF) of ECU and
about 0 V is inputted to terminal 12 (R)), the indicator lights keep
blinking until the ignition switch is turned OFF, or the ECU re-
ceives other signals which set both differentials free and identi-
fies that those differential are free (Fail−safe function).
If the circuit is not as specified, check and repair or replace the
trouble part shown in the table above.
(c) Inspect the system circuit with the connector connected.
(3) Remove the Diff. lock ECU.
Suspension)
ECU Side (4) Using a voltmeter, measure the voltage when the
M3 M4 M1 RLP M2 differential lock control switch is in the position, as
shown below.
Tester Connection
Switch position Specified value
−
4WD − GND − 0.5 V or less

RLP − GND ON
4WD M1 − M2 OFF ® RR 0.5 V or less ® 10 − 14 V

Z07256
M2 − M1 RR ® OFF (Approx. 1 sec.) ® 0.5 V
M3 − M4 OFF or RR ® FR/RR or less
M4 − M3 FR/RR ® OFF or RR
Heater Main Relay 3. INSPECT DIFF. LOCK COMPONENTS

Relay Housing (a) Inspect the relay operation.
2 Metallic Parts
(1) Jack up the vehicle.
3 (2) Use a heater main relay and connect it, as shown
1
below.
5 4 NOTICE:
Connect the terminals being careful not to touch the neigh-
boring terminals or metallic parts of the relay housing.
W02075 (3) Rotate the tire and check that differential lock has
occurred.
If operation is not as specified, replace the actuator.
Free ® Lock Lock ® Free
2 2
4 5 4 5
1 3 1 3
Heater Main Heater Main

3 2 3 2
6 4
Relay 5 4 Relay
Battery Battery
Z07257
Suspension)
4 2 1
(b) Inspect the Diff. lock control switch continuity.
(1) Inspect the switch continuity between terminal 1
Ohmmeter and terminal 4.
(2) Inspect the switch continuity between terminal 2
and terminal 4.
HINT:
If continuity dose not exist, replace the switch.
SA1948
(c) Inspect the Diff. lock position switch.

Ohmmeter (1) Check that continuity exists between terminals
when the switch is pushed (differential connected
position).
(2) Check that no continuity exists when the switch is
free (differential disconnected position).
HINT:
If operation is not as specified, replace the switch.
Z07264 (d) Inspect the L4 position switch
(See page TR−53 or TR−51).
(e) Inspect the vehicle speed sensor (See page BE−78).
Suspension)
SA1BU−01
LOCATION
DIFF LOCK Indicator Light Diff. Lock Control Switch Rear Diff. Lock Actuator
Front Diff. Lock Position Switch
Rear Diff. Lock Position Switch
Vehicle Speed Sensor
L4 Position Switch
Front Diff. Lock Actuator Differential Lock ECU
F05943
Suspension)
SA1BV−01
REMOVAL
1. SHIFT FRONT AND REAR DIFFERENTIAL TO LOCK
CONDITION
(c) Turn the differential lock control switch to the FR/RR posi-
tion and lock the rear differential.
HINT:
While rotating the tires, check that they are in the differential
lock condition.
battery.
2. REMOVE FRONT ACTUATOR
F05157 (a) Disconnect the connector and tube.
(b) Remove the 2 nuts, bolt and actuator.

(c) Remove the O−ring from the actuator.
3. REMOVE REAR ACTUATOR
(a) Remove the bolt, 2 nuts and protector.
(b) Disconnect the connectors and tube.
(c) Remove the rear Diff. lock position switch.
Z07258
(d) Remove the 3 bolts.

(e) Using a brass bar and hammer, remove the cover.
SA2619
(f) Remove the shift fork set bolt.

(g) Remove the 4 bolts.
(h) Using a screwdriver, pry out the actuator.
SA2621
Suspension)
SA1BW−01
INSTALLATION
1. INSTALL FRONT ACTUATOR
(a) Check that the outermost positioned rack tooth of the shift
Outside fork is virtually above the center line of the actuator instal-
Shift Fork lation hole.
Actuator Installation
Hole
Z07259
(b) Using a dry cell battery, align the matchmark on the actua-
tor pinion with the center line of the actuator.
NOTICE:
3 2 S If the pinion of the actuator is not is the specified
place, the actuator is difficult to be installed.
1.5 V
S Do not supply the battery voltage between terminals.
S If the matchmark comes to the extension limit of the
rotation, do not electrify moreover.
5˚
108˚
Matchmark
(Groove)
R08154
(c) Install a new O−ring to the actuator.

(d) Apply a light coat of gear oil on the O−ring.
(e) Coat the MP grease to the gear part of the actuator.
SA2306
(f) Install the actuator to the differential with the 2 nuts and
bolt, so that the outermost positioned rack tooth of the
shift fork shall fit matchmark of the pinion of the actuator.
HINT:
Do not damage the O−ring of the actuator.
SA2420
Suspension)
(g) Connect the connector and tube.

HINT:
S The depth of the insertion of the bleeder tube into the
hose is approx. 15 mm (0.59 in.).
S Take care that water or an equivalent shall not adhere to
the connector and hose.
2. INSTALL REAR ACTUATOR

FIPG Width Approx. (b) Apply FIPG to the actuator.
1 − 2 mm (0.04 − 0.08 in.) FIPG:
or equivalent
HINT:
Z15220 Install the actuator within 10 minutes after applying FIPG.
(c) Install the actuator to the differential and match the shaft
with the shaft fork hole.
(d) Clean the threads of the set bolt and shaft fork with the
white gasoline.

Adhesive:
or equivalent
(f) Tighten the shift fork set bolt.
Adhesive Z07262
(g) Tighten the 4 bolts uniformly, a little at time.

SA2620
Suspension)
3. INSTALL COVER
(a) Clean the contacting surfaces of any FIPG material using
FIPG:
or equivalent
FIPG Width Approx. HINT:
1 − 2 mm (0.04 − 0.08 in.) Z15219 Install the actuator within 10 minutes after applying FIPG.
4. INSTALL REAR DIFF. LOCK POSITION SWITCH
Install the position switch with a new gasket.
5. CONNECT CONNECTORS AND TUBE
HINT:
S Take care that the water or an equivalent will not adhere
to the connectors and hose.
6. INSTALL ACTUATOR PROTECTOR
Install the protector with the nut and bolt.
7. CANCEL REAR DIFFERENTIAL LOCK
With the ignition switch ON, turn the differential lock control
switch OFF to cancel the differential lock.
SA−262 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (Independent Front
Suspension)
DIFFERENTIAL LOCKING SYSTEM

(Independent Front Suspension) SA165−04
1. INSPECT DIFFERENTIAL LOCK SYSTEM
(a) Inspect the indicator light.
Check that the indicator light lights up for approx. 1 se-
cond when the ignition switch is turned ON.
(b) Inspect the differential lock operation.
(1) Jack up the vehicle then start the engine.
(3) When the diff. lock control switch is set to the RR
position, the indicator light is turned on.
Differential lock is applied to the rear wheel at this
time.
HINT:
If the gears of the differential lock system are not meshed, the
indicator light remains blinking, so rotate the tires to mesh the
F05176
gear.
(4) When the diff. lock control switch is at the OFF posi-
tion, the indicator light goes off.
Differential lock is released for the rear wheel at this
time.
(5) Check the voltage between the terminals of the rear

diff. lock control ECU when switching the diff. lock
M1 M2
control switch with the speedometer, registering
approx. 8 km/h (5 mph) or more.
Swith position Terminal Specified value
0.5 V or less
ON M1 − M2
(No change)
(6) Return the diff. lock control switch to OFF.

Z16659
(7) Stop the engine and lower the vehicle.
2. INSPECT DIFF. LOCK SYSTEM CIRCUIT
(a) Inspect the battery voltage.
Battery voltage: 10 − 14 V
SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (Independent Front SA−263
Suspension)
WIRE HARNESS (b) Inspect the system circuit with the connector discon-
RLP M2 M1 R nected.
Disconnect the connector from the rear diff. lock control
ECU and inspect the connector on the wire harness side,
as shown in the table.
IG GND 4WD SPD

Z16462
Symbols (Terminals No.) Trouble part Condition Specified value

M1 − M2 RR Diff. Lock Actuator − Less than 100 W
GND − Body ground Body ground − Continuity
1 pulse each
SPD − Body ground Speed sensor Vehicle moves slowly
40 cm (15.75 in.)
IG − Body ground DIFF Fuse Ignition switch ON 10 − 14 V
Rear Diff. Lock Posi

Posi- Ignition switch ON with indicator light ON About 0 V
RLP − Body
B d ground
d
tion Switch Ignition switch ON with indicator light OFF 10 − 14 V
Ignition switch ON with T/F shift lever except L4 About 0 V
4WD − Body
B d ground
d L4 position
iti Switch
S it h
Ignition switch ON with T/F shift lever L4 10 − 14 V
Differential Lock Con-

Con Ignition switch ON with differential lock control switch RR 10 − 14 V
R − Body
B d ground
d
trol Switch Ignition switch ON with differential lock control switch OFF About 0 V
HINT:
If the circuit is not as specified, check and repair or replace the
trouble part shown in the table above.
ECU (c) Inspect the system circuit with the connector connected.
M1 M2 RLP (1) Turn the ignition switch to the ON position.
(3) Using a voltmeter, measure the voltage when the
differential lock control switch is in the position, as
shown in the table.
Tester Connection
Switch position Specified valve
−
4WD GND
Z16461 4WD − GND − 10 − 14 V
RLP − GND RR* 0.5 V or less
M1 − M2 OFF ® RR 0.5 V or less ® 10 − 14 V

(A
(Approx. 1 sec.)) ® 0.5
05V
M2 − M1 RR ® OFF or less
*: The rear differential should be locked mechanically.
If the circuit is not as specified, replace the ECU.
Suspension)
HEATER MAIN RELAY 3. INSPECT DIFF. LOCK COMPONENTS

Relay Housing (a) Inspect the relay operation.
2 Metallic Parts
(1) Jack up the vehicle.
3 (2) Use a heater main relay and connect it, as shown
1
below.
5 4 NOTICE:
Connect the terminals being careful not to touch the neigh-
boring terminals or metallic parts of the relay housing.
W02075 (3) Rotate the tire and check that differential lock has
occurred.
If operation is not as specified, replace the actuator.
Free ® Lock Lock ® Free
2 2
4 5 4 5
1 3 1 3
Heater Main Heater Main

3 2 3 2
6 4
Relay 5 4 Relay
Battery Battery
Z07257
(b) Inspect the diff. lock control switch continuity.

1 Inspect the switch continuity between terminal 1 to termi-
nal 4.
(+) HINT:
If continuity dose not exist, replace the switch.
(−)
4
F05957
(c) Inspect the rear diff. lock position switch.

(1) Check that continuity between exists terminals
when the switch is pushed (differential connected
position).
(2) Check that no continuity exists when the switch is
free (differential disconnected position).
HINT:
If operation is not as specified, replace the switch.
F05962 (d) Inspect the L4 position switch (See page TR−53).
(e) Inspect the vehicle speed sensor (See page BE−78).
Suspension)
SA166−04
LOCATION
Rear Differential Lock Actuator
Combination Meter
Rear Diff. Lock Control ECU
Rear Differential Lock Position Switch
Differential Lock Control Switch
L4 Position Switch
F05954
Suspension)
SA167−04
REMOVAL
1. SHIFTING REAR DIFF. LOCK POSITION
(c) Turn the differential lock control switch to the RR position

and lock the rear differential.
HINT:
While rotating the tires, check they are in the differential lock
condition.
battery.
2. REMOVE NO. 1 ACTUATOR PROTECTOR
F05181 Remove the nut, bolt and No. 1 actuator protector.
3. REMOVE NO. 2 ACTUATOR PROTECTOR
Remove the 2 nuts and No. 2 actuator protector.
4. DISCONNECT CONNECTORS AND TUBE
5. REMOVE REAR DIFF. LOCK POSITION SWITCH
6. REMOVE COVER
(b) Using a brass bar and hammer, remove the cover.
F05083
7. REMOVE ACTUATOR
(a) Remove the shift fork set bolt.
(b) Remove the 4 bolts.
(c) Using a screwdriver, pry out the actuator.
F04360
Suspension)
SA168−04
INSTALLATION
1. INSTALL ACTUATOR
FIPG Width Approx. gasoline or alcohol.
1 − 2 mm (0.04 − 0.08 in.)
(b) Apply FIPG to the actuator.
equivalent
HINT:
Z15220
Install the actuator within 10 minutes after applying FIPG.
(c) Install the actuator to the differential and match the shaft
with the shaft fork hole.
(d) Clean the threads of the set bolt and shaft fork with the
white gasoline.

or equivalent
(f) Tighten the shift fork set bolt.
Adhesive
F05081
(g) Tighten the 4 bolts uniformly, a little at time.

F05082
2. INSTALL COVER
(a) Clean the contacting surfaces of any FIPG material using
equivalent
HINT:
FIPG Width Approx. Install the actuator within 10 minutes after applying FIPG.
1 − 2 mm (0.04 − 0.08 in.) Z15219
Suspension)

3. INSTALL REAR DIFF. LOCK POSITION SWITCH
Install the rear diff. lock position switch with a new gasket.
4. CONNECT CONNECTORS AND TUBE
HINT:
S Take care that the water or the equivalent will not adhere
to the connectors and hose.
5. INSTALL NO. 2 ACTUATOR PROTECTOR
Install the No. 2 actuator protector with 2 nuts.
6. INSTALL NO. 1 ACTUATOR PROTECTOR
Install the No. 1 actuator protector with the nut and bolt.
7. CANCEL REAR DIFFERENTIAL LOCK POSITION
(a) Connect the cable to the negative terminal of the battery.
(b) Turn the ignition switch to the ON position.
(c) Turn the differential lock control switch to the OFF position
and cancel the differential lock.
(d) Shift the transfer shift lever to H4 position.
SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER (Rigid SA−269
Front Suspension)
COIL SPRING AND REAR SHOCK ABSORBER (Rigid Front

Suspension)
SA1BB−01
COMPONENTS
z 177 (1,800, 130)
z 69 (700, 51)
Retainer
Cushion
Retainer
Insulator
Bracket
50 (510, 37)
Lateral Control Rod Follow
Cushion Spring
Retainer
Shock 28 (290, 21)
Absorber
Breather Hose
Coil Spring
Cushion
Cushion
Retainer
Stabilizer Bar Bracket
64 (650, 47)
18 (185, 13)

F05792
SA−270 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER (Rigid
Front Suspension)
SA1BC−01
REMOVAL
2. SUPPORT AXLE HOUSING WITH JACK
3. REMOVE REAR SHOCK ABSORBER
(a) Remove the lower bolt holding the shock absorber from
the rear axle housing.
(b) Remove the retainer and 2 cushions, disconnect the
shock absorber.
(c) Remove the 2 upper bolts and shock absorber.
(d) Remove the nut, 2 cushions, 3 retainers and bracket from
the shock absorber.
4. DISCONNECT LH AND RH STABILIZER BAR BRACK-

ETS
Remove the 4 bolts and disconnect the LH and RH stabilizer bar
brackets.
F05959
5. DISCONNECT LATERAL CONTROL ROD

Remove the nut, washer, bolt and disconnect the lateral control
rod.
HINT:
torque the nut and bolt.
6. DISCONNECT BREATHER HOSE
F04394 7. REMOVE COIL SPRING
(a) Begin to lower the axle housing.
NOTICE:
Be careful not to snap the brake line and parking cable.
Front Suspension)
(b) While lowering the axle housing, remove the coil spring
and insulator.
HINT:
S Check that the coil spring end is installed correctly.
S If the coil spring end is not in the correct position, reinstall
the coil spring.
F04396
(c) Remove the bolt and follow spring from the frame.
F04395
Front Suspension)
SA1BD−01
INSPECTION
new one.
NOTICE:
SA0627
page SA−273.
Front Suspension)
SA1BE−01
DISPOSAL
CAUTION:
F04361
Front Suspension)
SA1BF−01
INSTALLATION
SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER SA−275
COIL SPRING AND REAR SHOCK ABSORBER (Independent

Front Suspension)
SA172−02
COMPONENTS
w/ AHC System
18 (185, 13)
Pressure Hose
z 68 (700, 51)
z O−ring
z Back Up Ring
Retainer 68 (700, 51)
Cushion
z 150 (1,530, 111) Cushion
Retainer
Retainer
Retainer
Cushion
Retainer Cushion
Retainer
Shock Absorber
z Bushing
Insulator
Follow
Spring
Breather Hose 28 (290, 21)
Coil
Spring
18 (185, 13)
z 98 (1,000, 72)
18 (185, 13)

F05951
SA−276 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER
SA1C8−01
REMOVAL
1. w/ AHC System:
DRAIN SUSPENSION FLUID AHC
CAUTION:
ered suddenly.
F05121
2. REMOVE REAR WHEELS
Torque:
3. SUPPORT REAR AXLE HOUSING WITH JACK
4. w/o AHC System:

(a) Remove the bolt and disconnect the shock absorber from
the axle housing.
F04391
(b) While holding the pison rod, remove the nut, 2 retainers
cushion and shock absorber.
(c) Remove the 2 retainers and cushion from the shock ab-
sorber.
F04392
5. w/ AHC System:
(a) Remove the bolt and disconnect the shock absorber from
the axle housing.
F04391
(b) Remove the 2 bolts and disconnect the pressure hose.

(c) Remove the O−ring and back up ring from the pressure
hose.
HINT:
At the time of installation, replace the used O−ring and back up
ring with new ones.
(d) While holding the cushion, remove the nut, cushion, re-
F05153 tainer and shock absorber.
(e) Remove the cushion and retainer from the shock absorb-
er.

ETS
brackets.
F04393
7. DISCONNECT LATERAL CONTROL ROD

Remove the nut, washer, bolt and disconnect the lateral control
rod.
HINT:
S Replace the used nut with a new one.
S After stabilizing the suspension, torque the nut.
F04394 8. DISCONNECT BREATHER HOSE
9. REMOVE COIL SPRING
(a) Begin to lower the axle housing.
NOTICE:
Be careful not to snap the brake line and parking brake
cable.
(b) While lowering the axle housing, remove the coil spring
and insulator.
HINT:
S Check that the coil spring end is installed correctly.
S If the coil spring end is not in the correct position, reinstall
the coil spring.
F04396
(c) Remove the bolt and follow spring from the frame.
F04395
SA174−02
INSPECTION
new one.
NOTICE:
w/o AHC System:
SA0627
page SA−280.
SA16C−02
DISPOSAL
w/o AHC System:
CAUTION:
F04361
SA175−02
REPLACEMENT
REPLACE BUSHING
SST (a) Using SST and a press, remove the bushing.
SST 09710−14013 (09710−00061),
09710−28012 (09710−07031),
09950−70010 (09951−07100)
SST
F05063

SST 09710−14013 (09710−00061),
09710−28012 (09710−07031),
SST
09950−70010 (09951−07100)
SST
F05063
SA176−03
INSTALLATION
w/ AHC System:
SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Rigid Front SA−283
Suspension)
REAR LATERAL CONTROL ROD (Rigid Front Suspension)

SA1BG−01
COMPONENTS
z 177 (1,800, 130)

z Bushing
Lateral Control Rod
z Bushing
245 (2,500, 181)

F05790
SA−284 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Rigid Front
Suspension)
SA1BH−01
REMOVAL
2. REMOVE LATERAL CONTROL ROD

B
Remove the 2 bolts, nut, washer and lateral control rod.
A Torque:
A: 245 N·m (2,500 kgf·cm, 181 ft·lbf)
B: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
HINT:
S Replace the used nut with a new one.
F04399 S After stabilizing the suspension, torque the nut and bolt.
SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Rigid Front SA−285
Suspension)
SA1BI−01
REPLACEMENT
REPLACE LATERAL CONTROL ROD BUSHING
SST
SST 09550−10012 (09553−10010),
09710−22021 (09710−01071)
SST
R13240

SST 09550−10012 (09553−10010),
SST
09710−22021 (09710−01071)
SST
R13241
SA−286 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Rigid Front
Suspension)
SA1BJ−01
INSTALLATION
SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Independent Front SA−287
Suspension)
REAR LATERAL CONTROL ROD (Independent Front

Suspension)
SA177−02
COMPONENTS
z 150 (1,530, 111)
Lateral Control Rod
z 149 (1,520, 110)

SA−288 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Independent Front
Suspension)
SA178−02
REMOVAL
2. REMOVE LATERAL CONTROL ROD

B
Remove the 2 bolts, nut, washer and lateral control rod.
Torque:
A
A: 149 N·m (1,520 kgf·cm, 110 ft·lbf)
B: 150 N·m (1,530 kgf·cm, 111 ft·lbf)
HINT:
S Replace the used nut and bolt with new ones.
F04399 S After stabilizing the suspension, torque the nut and bolt.
SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD (Independent Front SA−289
Suspension)
SA179−02
INSTALLATION
SA−290 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM (Rigid
Front Suspension)
REAR UPPER AND LOWER CONTROL ARM (Rigid Front

Suspension)
SA1BK−01
COMPONENTS
Upper Control Arm

z
z z Bushing
z Bushing 177 (1,800, 130)
177 (1,800, 130)
z Lower Control Arm
z Bushing
177 (1,800, 130)
z Bushing
177 (1,800, 130)

F05791
SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM (Rigid SA−291
Front Suspension)
SA1BL−01
REMOVAL
3. DISCONNECT ABS SPEED SENSOR WIRE HARNESS
4. REMOVE UPPER CONTROL ARM

Remove the 2 nuts, washers, bolts and upper control arm.
HINT:
torque the nuts.
F04397
5. REMOVE LOWER CONTROL ARM

Remove the 2 nuts, washers, bolts and lower control arm.
HINT:
torque the nuts.
F04398
SA−292 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM (Rigid
Front Suspension)
SA1BM−01
REPLACEMENT
SST 1. REPLACE UPPER CONTROL ARM BUSHING
SST 09226−10010, 09950−60010 (09951−00490),
09950−70010 (09951−07100)
SST
R13242

SST 09226−10010, 09506−35010
SST
SST
R13243
2. REPLACE LOWER CONTROL ARM BUSHING

SST SST 09506−35010, 09950−60010 (09951−00540),
09950−70010 (09951−07100)
SST
R13244
(b) Using SST and a press, install a new busing, as shown.

Frame Side
SST 09316−20011, 09506−35010
SST
SST Axle Side

W02078
SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM (Rigid SA−293
Front Suspension)
SA1BN−01
INSTALLATION
SA−294 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM
REAR UPPER AND LOWER CONTROL ARM (Independent

Front Suspension)
SA17B−02
COMPONENTS
w/ AHC System
ABS Speed Sensor

Wire Harness
Height Control
Sensor Link
Heat Insulator
18 (185, 13)
Upper Control Arm
z 150 (1,530, 110)
5.6 (57, 49 in.·lbf)

z 150 (1,530, 110)
z 150 (1,530, 110)
w/ ABS
ABS Speed Sensor
Wire Harness
z 150 (1,530, 110)
z 150 (1,530, 110)
Lower Control Arm

F05952
SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM SA−295
SA17C−02
REMOVAL
Torque:
3. w/ AHC System − LH Side:

DISCONNECT HEIGHT CONTROL SENSOR LINK
Matchmarks (a) Place matchmarks on the height control sensor link and
upper control arm.
(b) Remove the nut and disconnect the height control sensor
link.
4. REMOVE UPPER CONTROL ARM
F04365 (a) w/ ABS:
Disconnect the ABS speed sensor wire harness.
(b) RH side:
Remove the bolt from the heat insulator.
(c) Remove the 2 nuts, washers, bolts, and upper control

arm.
HINT:
S Replace the used 2 nuts with new ones.
S After stabilizing the suspension, torque the nuts.
F04397
5. REMOVE LOWER CONTROL ARM

Remove the 2 nuts, washers, bolts and lower control arm.
HINT:
S Replace the used 2 nuts with new ones.
S After stabilizing the suspension, torque the nuts.
F04398
SA−296 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM
SA17D−02
INSTALLATION
SA−297
SUSPENSION AND AXLE − REAR STABILIZER BAR (Rigid Front Suspension)
REAR STABILIZER BAR (Rigid Front Suspension)

SA1BO−01
COMPONENTS
z
Retainer
Cushion
z 15 (150, 11)
Stabilizer Bar Bracket
Retainer
Cushion
Retainer
Collars Stabilizer 18 (185, 13)

Bar Link
18 (185, 13)
Bushing
Bracket
18 (185, 13)
Stabilizer Bar
Cushion
26 (270, 19)

SA−298
SA1BP−01
REMOVAL

ETS
brackets.
F05959

(a) Remove the 4 bolts and stabilizer bar with bushings and
brackets.
(b) Remove the 2 brackets and 2 bushings from the stabilizer
bar.
5. REMOVE BOTH STABILIZER BAR LINKS FROM STA-
BILIZER BAR
F04400 (a) Remove the 2 nuts, 6 retainers, 4 cushions and discon-
nect the stabilizer bar link from the bracket.
(b) Remove the 2 nuts, bolts and stabilizer bar links.
(c) Remove the 2 collars and 2 cushions.
SA−299
SA1BQ−01
INSTALLATION
SA−300 SUSPENSION AND AXLE − REAR STABILIZER BAR (Independent Front
Suspension)
REAR STABILIZER BAR (Independent Front Suspension)

SA17E−02
COMPONENTS
z
Retainer
Cushion
Stabilizer Bar Bracket z 15 (150, 11)
Retainer
Cushion
Retainer
18 (185, 13)
Collar Bushing
18 (185, 13)
Bracket
18 (185, 13)
Stabilizer Bar
Cushion
26 (270, 19)
Stabilizer Bar Link

F05239
SUSPENSION AND AXLE − REAR STABILIZER BAR (Independent Front SA−301
Suspension)
SA17F−02
REMOVAL
Torque:

ET
brackets.
F04393

(a) Remove the 4 bolts and stabilizer bar with bushings and
brackets.
(b) Remove the 2 brackets and 2 bushings from the stabilizer
bar.
5. REMOVE BOTH STABILIZER BAR LINKS FROM STA-
BILIZER BAR
F04400 (a) Remove the 2 nuts, 6 retainers, 4 cushions and discon-
nect the stabilizer bar link from the bracket.
HINT:
At the time of installation, replace the used 2 nuts with new
ones.
(b) Remove the 2 nuts, bolts and stabilizer bar links.
(c) Remove the 2 collars and 2 cushions.
SA−302 SUSPENSION AND AXLE − REAR STABILIZER BAR (Independent Front
Suspension)
SA17G−02
INSTALLATION
SUSPENSION AND AXLE − ACTIVE HEIGHT CONTROL SYSTEM (Independent SA−303
Front Suspension)
ACTIVE HEIGHT CONTROL

SYSTEM (Independent Front
Suspension) SA18C−03
BLEEDING
HINT:
If any work is done on the AHC system or if air is suspected in
the AHC lines, bleed the system of air.
1. FILL RESERVOIR WITH SUSPENSION FLUID AHC
While the vehicle is stopped, pour the suspension fluid AHC in
the reservoir tank.
Fluid: Suspension fluid AHC (08886−01805)
NOTICE:
Do not start the engine until the fluid is poured in the reser-
voir tank.
2. BLEED AHC FLUID LINES
(a) Start the engine and push the vehicle height select switch
to select the ”N” mode.
NOTICE:
When the reservoir tank is empty, or after the AHC pump &
motor is replaced or removed, starting engine may cause
air inflow in the AHC fluid line. In this condition, the AHC
system can not be operated even if the fluid is poured into
the tank. If this happens, raise the vehicle height of the
front or rear wheel by conducting the active test and acti-
vate the AHC pump & motor for about 10 seconds (See
page DI−208).
(b) After vehicle height adjustment is completed, check that
the AHC pump & motor is stopped, then stop the engine.
(c) Connect the hose to the bleeder plug for either right or left
front damping force control actuator.
(d) Loosen the bleeder plug.
CAUTION:
While the fluid is being discharged, the vehicle height is
lowered suddenly.
(e) When the emulsified fluid containing air is discharged, re-
tighten the bleeder plug.
F05121 Torque: 8.3 N·m (84 kgf·cm, 73 in.·lbf)
SA−304 SUSPENSION AND AXLE − ACTIVE HEIGHT CONTROL SYSTEM (Independent
Front Suspension)
(f) Perform steps (c) to (e) for damping force control actuator
on the right or left rear side.
(g) Repeat the step (b) to (f) for left and right damping force
control actuators alternately.
(h) Start the engine on a level place. Adjust the vehicle height
to ”N” position with the vehicle unloaded.
(i) Check that the fluid level in the reservoir tank is within the
standard range.
NOTICE:
Temperature should be normal (20 ˚C, 68 ˚F).
Front Suspension)
SA18D−03
1. INSPECT FLUID LEVEL
(a) Start the engine on a level place. Adjust the vehicle height
to ”N” position with the vehicle unloaded.
NOTICE:
After adjusting the vehicle height to control the fluid pres-
sure in the height control accumulator, do not turn the en-
gine OFF.
F05120
(b) Check that the fluid level in the reservoir tank of the AHC
pump & motor is within the standard range.
2. OPERATE HEIGHT SELECT SWITCH AND CHECK
CHANGE OF VEHICLE HEIGHT
(a) Check the tires for the proper inflation pressure (See
page SA−5).
(b) Check the vehicle height (See page SA−9).
(c) Start the engine.
(d) Push the height select switch to change from ”N” to the
”HI” mode.
(e) Check the time required for the height change and the
changed amount of the vehicle height.
Standard value
Up time 15 secs. less than
Down time 10 secs. less than
Amount of change in vehicle height
F05122
Front 30 − 45 mm (1.18 − 1.77 in.)
Rear 40 − 55 mm (1.57 − 2.17 in.)
NOTICE:
After vehicle height control has been completed, wait for
approx. 5 secs. until the height is fixed securely, then
check the changed amount of vehicle height.
Front Suspension)
(f) Push the height select switch to change from ”N” to the
”LO” mode.
(g) Check the time required for the height change and the
changed amount of the vehicle height.
Standard value
Up time 15 secs. less than
Down time 10 secs. less than
Amount of change in vehicle height
F05122
Front 40 − 55 mm (1.57 − 2.17 in.)
Rear 30 − 45 mm (1.18 − 1.77 in.)
NOTICE:
After vehicle height control has been completed, wait for
approx. 5 secs. until the height is fixed securely, then
check the changed amount of vehicle height.
3. INSPECT VEHICLE SPEED SENSING FUNCTION
(a) When vehicle height is in the ”LO” position:
(1) Start the engine and push the height select switch
to select the ”LO” mode.
(2) Drive the vehicle at 5 km/h (3 mph) or more and
check with an indicator that the vehicle height
changes from ”LO” to the ”N” position.
(b) When vehicle height is in the ”HI” position:
(1) Start the engine and push the height select switch
to select the ”HI” mode.
(2) Drive the vehicle at 50 km/h (31 mph) or more and
check with an indicator that the vehicle height
changes from ”HI” to the ”N” position.
(c) When the height control switch is operated:
(1) Push the height control switch to turn off the height
control.
(2) Drive the vehicle and check with the indicator that
the height control is activated automatically.
Standard value
Vehicle Height Vehicle Speed
HI More than 30 km/h (19 mph)
N More than 80 km/h (50 mph)
LO More than 30 km/h (19 mph)
4. INSPECT PRESSURE VALUE OF FRONT SHOCK AB-

SORBER (IN CASE OF USING HAND−HELD TESTER)
NOTICE:
Perform the operation with vehicle unloaded (with the fuel
tank and sub fuel tank filled up).
Front Suspension)
Hand−held Tester (a) Connect the hand−held tester to DLC3 on the vehicle.
(b) Start the engine and push the height select switch to ad-
just the vehicle height to the ”N” position.
(c) Push the height select switch to adjust the vehicle height
from the ”N” to ”LO” then back to ”N” position.
NOTICE:
Adjust it with no passengers are in.
DLC3
(d) Stop the engine.
D01634 (e) Read the pressure value of the front shock absorber with
hand−held tester at this time.
Pressure:
6.9 ± 0.5 MPa (70 ± 5 kgf/cm2, 996 ± 71 psi)
HINT:
The cylinder pressure read by the hand−held tester is estimated
by the pump emitted pressure so the pressure is approx. 1.2
MPa (12 kgf/cm2, 171 psi) higher than the pressure read by the
LSPV gauge (SST).
If the value is not within the specified value, adjust the torsion
bar spring (See page SA−313).
(f) Start the engine and push the height select switch to ad-
(g) Check the fluid level (See page SA−305).
5. INSPECT PRESSURE VALUE OF FRONT SHOCK AB-

SORBER (IN CASE OF NOT USING HAND−HELD TES-
TER)
NOTICE:
S Perform the operation with the vehicle unloaded (with
the fuel tank and sub fuel tank filled up).
S After and before using LSPV gauge (SST), make sure
to clean the hose, gauge and adopter.
(a) Start the engine and push the height select switch to ad-
just the vehicle height to the ”LO” position.
(b) With the ignition switch OFF, discharge the suspension
fluid AHC from the bleeder plug of the either front right or
left wheel dumping force control actuator.
CAUTION:
The fluid gushes out because of high pressure, so dis-
charge the fluid in the same way as air bleeding.
Front Suspension)
(c) Remove the bleeder plug of either right or left dumping

force control actuator and install the LSPV gauge (SST)
SST
and bleed air.
SST 09709−29018
(d) Start the engine and push the height select switch to ad-
(e) Push the height select switch to adjust the vehicle height
F05128 (f) Stop the engine.
(g) Read the pressure value with LSPV gauge (SST) at this
time.
SST 09709−29018
Pressure:
5.7 ± 0.3 MPa (58 ± 3 kgf/cm2, 825 ± 43 psi)
bar spring (See page SA−313).
(h) Start the engine and push the height select switch to ad-
(i) With the ignition switch OFF, discharge the suspension
fluid AHC from the bleeder plug of LSPV gauge (SST).
SST 09709−29018
CAUTION:
(j) Remove the LSPV gauge (SST).
SST 09709−29018
(k) Install the bleeder plug.
(l) Bleed the air (See page SA−303).
HINT:
Bleed the bleeder plug with LSPV gauge (SST) installed to only
once.
(m) Check the fluid level (See page SA−305).
6. INSPECT PRESSURE VALUE OF REAR SHOCK AB-

SORBER (IN CASE OF USING HAND−HELD TESTER)
NOTICE:
Perform the operation with the vehicle unloaded (with the
fuel tank and sub fuel tank filled up).
Front Suspension)
(b) Disconnect the fluid temperature sensor connector.
(c) Start the engine and push the height select switch to ad-
just the vehicle height from the ”N” to ”LO” then back to ”N”
position.
NOTICE:
DLC3
(d) Stop the engine.
D01634 (e) Read the pressure value of the rear shock absorber with
Pressure:
w/o Sub fuel tank:
5.6 − 6.7 MPa (57 − 68 kgf/cm2, 811 − 967 psi)
w/ Sub fuel tank:
5.9 − 7.0 MPa (60 − 71 kgf/cm2, 853 − 1,010 psi)
If the pressure is not within the specified range, its cause may
be that a load object is either installed or removed.
HINT:
LSPV gauge (SST).
(f) Connect the fluid temperature sensor connector.
(g) Check the DTC (See page DI−208).
If a DTC is displayed, clear the DTC (See page DI−208).
just the vehicle height to the ”LO” then to ”N” position.
At this time, check that the 4 wheels are raised simulta-
neously.
7. INSPECT PRESSURE VALUE OF REAR SHOCK AB-

SORBER (IN CASE OF NOT USING HAND−HELD TES-
TER)
NOTICE:
fluid AHC from the bleeder plug of the either rear right or
CAUTION:
Front Suspension)

SST
and bleed air.
SST 09709−29018
(e) Push the height select switch to adjust the vehicle height
F05128 (f) Stop the engine.
(g) Read the pressure value with LSPV gauge (SST) at this
time.
SST 09709−29018
Pressure:
w/o Sub fuel tank:
4.4 − 5.5 MPa (45 − 56 kgf/cm2, 640 − 797 psi)
w/ Sub fuel tank:
4.7 − 5.8 MPa (48 − 59 kgf/cm2, 683 − 839 psi)
If the pressure is not within the specified range, its cause may
be that a load object is either installed or removed.
(i) With the ignition switch OFF, discharge the suspension
SST 09709−29018
CAUTION:
(j) Remove the LSPV gauge (SST).
SST 09709−29018
(k) Install the bleeder plug.
(l) Bleed the air (See page SA−303).
HINT:
once.
(m) Check the fluid level (See page SA−305).
Front Suspension)
8. CHECK FLUID LEAKAGE

Check the connections of tube and parts for fluid leakage.
F05123
Front Suspension)
SA18E−03
LOCATION
RH Rear Damping
Force Control Actuator
Combination Meter Control Valve Assembly

DLC3
Rear Height Control
Suspension Control ECU Sensor
AHC Pump & Motor
RH Front Height
Control Sensor
Pump Attenuator
LH Rear Damping
LH Front Height Force Control Actuator
Control Sensor Height Control Accumulator
RH Front Damping
Force Control Actuator LH Front Damping
Height Control Switch
and Height Select Switch
F05124
Front Suspension)
SA18F−03
ADJUSTMENT
HINT:
After adjusting the height control sensor, adjust the torsion bar
spring of the front wheel because the neutral fluid pressure of
the absorber is changed.
Hand−held Tester 1. ADJUST HEIGHT CONTROL SENSOR (IN CASE OF

USING HAND−HELD TESTER)
(a) Connect the hand−held tester to DLC3 on the vehicle.
(b) Start the engine and push the height control select switch
to adjust the vehicle height to the ”LO” then to ”N” position.
DLC3
D01634
FRONT (c) Inspect the vehicle height.

Vehicle height
Front A − B: 83.0 mm (3.268 in.)
Rear C − D: 71.0 mm (2.795 in.)
Measuring points:
A B B: Ground clearance of lower suspension arm front bolt center
REAR (d) Inspect and adjust the height control sensor to the neutral
position.
(1) Read the value of height control sensor on the
hand−held tester.
Standard value:
D
C Actual vehicle height ± 5 mm (0.20 in.)
HINT:
(Example)
When the measurement value of the front vehicle height is 85.0
F05219
mm (3.35 in.), the actual value of height control sensor is −2.0
mm (−0.08 in.).
Front Suspension)
(2) Loosen the nut and adjust the positions of the

FRONT
height control sensor link and front upper suspen-
sion arm or rear lower control arm by moving them
up and down to install them.
(3) Tighten the nut.
REAR
F05125
(4) Front sensor:

When adjustment cannot be done by performing
step (2), loosen the 2 nuts of height control sensor
link and turn the link.
HINT:
S To raise the vehicle, turn the link clockwise.
S To lower the vehicle, turn the link counterclockwise.
(5) Tighten the 2 nuts.
(6) Coat the threads of the link with sealer.
Sealer: Part No. 08833−00070, THREE BOND 1324 or
equivalent
Front Suspension)
FRONT 2. ADJUST HEIGHT CONTROL SENSOR (IN CASE OF

NOT USING HAND−HELD TESTER)
(a) Inspect the vehicle height.
Vehicle height
Front A − B: 83.0 mm (3.268 in.)
Rear C − D: 71.0 mm (2.795 in.)
A B Measuring points:
REAR C: Ground clearance of rear axle shaft center
(b) Inspect and adjust the height control sensor to the neutral
position.
(1) Disconnect the connector of front and rear height
D
C control sensors.
F05219
FRONT (2) Connect 3 dry cell batteries of 1.5 V to SHB terminal

and its negative to SHG terminal and apply approx.
4.5 V voltage between the terminals.
SHFL (3) Measure the voltage between terminals SHB and
(SHFR) SHB
SHG. The target voltage (Voltage between SHFL,
SHFR, SHRR and SHB) can be obtained by dividing
this value by 2.
SHG HINT:
(Example)
REAR Terminal voltage between SHB and SHG: 4.5 V
Target voltage: 2.25 V
SHRR
(4) Measure the voltage between SHFL (SHFR,
SHG SHB SHRR) and SHG terminals when voltage is applied.
Standard value:
Front sensor: Target voltage ± 0.08 V
Rear sensor: Target voltage ± 0.07 V
F05127
Front Suspension)
(5) Loosen the nut and adjust the positions of the

FRONT
height control sensor link and front upper suspen-
sion arm or rear lower control arm by moving them
up and down to install them.
(6) Tighten the nut.
REAR
F05125
(7) Front sensor:

When adjustment cannot be done by performing
step (5), loosen the 2 nuts of height control sensor
link and turn the link.
HINT:
S To raise the vehicle, turn the link clockwise.
S To lower the vehicle, turn the link counterclockwise.
(8) Tighten the 2 nuts.
(9) Coat the threads of the link with sealer.
Sealer: Part No. 08833−00070, THREE BOND 1324 or
equivalent
3. ADJUST TORSION BAR SPRING (IN CASE OF USING

HAND−HELD TESTER)
NOTICE:
S Perform the operation with vehicle unloaded (with the
fuel tank and sub fuel tank filled up).
S Temperature should be normal.
(10 − 50 ˚C, 50 − 122 ˚F in the engine compartment)
S Perform this on a level place.
Front Suspension)
(b) Start the engine and push the height select switch to ad-
(c) With the ignition switch OFF, adjust the torsion bar spring
so that the difference between right and left in vehicle
height is less than 10 mm (0.39 in.).
HINT:
DLC3
To eliminate the height difference between the right and left tor-
D01634 sion bar springs, tighten the lower one and loosen the other one
by the same amount.
(Example)
When the vehicle height of the right wheel side is too high, loos-
en the torsion bar spring of the right wheel side and tighten the
one of the left wheel by same amount.
NOTICE:
position.
(e) Stop the engine.
(f) Read the pressure value of the front shock absorber with
Pressure:
6.9 ± 0.5 MPa (70 ± 5 kgf/cm2, 996 ± 71 psi)
HINT:
LSPV gauge (SST).
bar spring.
NOTICE:
Make sure to turn the ignition OFF when adjusting the tor-
sion bar spring.
HINT:
S Approx. 0.2 MPa (2 kgf/cm2, 28 psi) changes when both
right and left adjusting bolts are turned one turn.
S The pressure rises when the adjusting bolts are loos-
ened.
Pressure:
6.9 ± 0.3 MPa (70 ± 3 kgf/cm2, 996 ± 43 psi)
(g) Start the engine and push the height select switch to ad-
(h) Check the fluid level (See page SA−305).
Front Suspension)
4. ADJUST TORSION BAR SPRING (IN CASE OF NOT

USING HAND−HELD TESTER)
NOTICE:
fluid AHC from the bleeder plug of the either front right or
CAUTION:

SST
and bleed air.
SST 09709−29018
(e) With the ignition switch OFF, adjust the torsion bar spring
so that the difference between right and left in vehicle
F05128 height is less than 10 mm (0.39 in.).
HINT:
To eliminate the height difference between the right and left tor-
sion bar springs, tighten the lower one and loosen the other one
by the same amount.
(Example)
When the vehicle height of the right wheel side is too high, loos-
en the torsion bar spring of the right wheel side and tighten the
one of the left wheel by same amount.
(f) Start the engine and push the height select switch to ad-
position.
(g) Stop the engine.
Front Suspension)
(h) Read the pressure value with LSPV gauge (SST) at this
time.
SST 09709−29018
Pressure:
5.7 ± 0.3 MPa (58 ± 3 kgf/cm2, 825 ± 43 psi)
bar spring.
NOTICE:
Make sure to turn the ignition OFF when adjusting the tor-
sion bar spring.
HINT:
S Approx. 0.2 Mpa (2 kgf/cm2, 28 psi) changes when both
right and left adjusting bolts are turned one turn.
S The pressure rises when the adjusting bolts are loos-
ened.
(i) Start the engine and push the height select switch to ad-
(j) With the ignition switch OFF, discharge the suspension
SST 09709−29018
CAUTION:
(k) Remove the LSPV gauge (SST).
SST 09709−29018
(l) Install the bleeder plug.
(m) Bleed the air (See page SA−303).
HINT:
once.
(n) Check the fluid level (See page SA−305).
SA−320 SUSPENSION AND AXLE − ACTIVE HEIGHT CONTROL PUMP & MOTOR
ACTIVE HEIGHT CONTROL PUMP & MOTOR (Independent

Front Suspension)
SA19W−02
COMPONENTS
LHD
AHC Pump & Motor
15 (155, 11)
Collar
Bracket
5.5 (55, 48 in.·lbf)
Cushion
5.5 (55, 48 in.·lbf)
18 (185, 13)
Holder
AHC Pump & Motor Bracket
Cushion
Cushion Bolt
6.9 (70, 61 in.·lbf)
18 (185, 13)
18 (185, 13)
5.5 (55, 48 in.·lbf)

F05129
SUSPENSION AND AXLE − ACTIVE HEIGHT CONTROL PUMP & MOTOR SA−321
RHD
15 (155, 11)
AHC Pump & Motor
Cushion Bolt
6.9 (70, 61 in.·lbf)
Holder
Cushion
5.5 (55, 48 in.·lbf)
Collar
Cushion
18 (185, 13)
18 (185, 13)
18 (185, 13)
5.5 (55, 48 in.·lbf)

F05931
Cap
Strainer
Reservoir
6.9 (70, 61 in.·lbf)
z Grommet
12 (120, 8)
12 (120, 8) Pump Cover
5.6 (58, 50 in.·lbf)

Cushion
Reservoir Bracket
z O−ring
z O−ring
5.2 (53, 46 in.·lbf) Housing
Fluid Temperature
Sensor
22 (220, 16)
Pump Sub−assembly
Motor Joint
Fluid Pressure Sensor
z Oil Seal z O−ring 44 (450, 33)
z Ring
Pump Motor

F05130
ACTIVE HEIGHT CONTROL PUMP & MOTOR (Independent

Front Suspension)
SA19W−03
COMPONENTS
LHD
AHC Pump & Motor
15 (155, 11)
Collar
Bracket
5.5 (55, 48 in.·lbf)
Cushion
5.5 (55, 48 in.·lbf)
18 (185, 13)
Holder
Cushion
Cushion Bolt
6.9 (70, 61 in.·lbf)
18 (185, 13) 18 (185, 13)
5.5 (55, 48 in.·lbf)
N·m (kgf·cm, ft·lbf) : Specified torque F13419

RHD
15 (155, 11)
AHC Pump & Motor
Cushion Bolt
6.9 (70, 61 in.·lbf)
Holder
Cushion
5.5 (55, 48 in.·lbf)
Collar
Cushion
18 (185, 13)
18 (185, 13)
18 (185, 13)
5.5 (55, 48 in.·lbf)

F13966

Cover
Cap
Strainer
Reservoir
6.9 (70, 61 in.·lbf)
z Grommet
12 (120, 8)
Pump Cover
12 (120, 8)
5.6 (58, 50 in.·lbf)

Cushion
Reservoir Bracket
z O−ring
z O−ring
Housing
5.2 (53, 46 in.·lbf)
Fluid Temperature
Sensor
22 (220, 16)
Pump Sub−assembly
Motor Joint
Fluid Pressure Sensor
44 (450 33)
z Oil Seal
Pump Motor

F13420

SA19X−02
REMOVAL
1. DRAIN SUSPENSION FLUID AHC
(a) Connect the hose to the bleeder plug for height control ac-
cumulator and loosen the bleeder plug.
2. DISCONNECT CONNECTORS
F05131
3. DISCONNECT AHC FLUID LINE

Using SST, disconnect the AHC fluid line from the AHC pump
SST & motor.
SST 09023−00100
4. REMOVE AHC PUMP & MOTOR
(a) Remove the bolt, 3 nuts and AHC pump & motor.
F05132 (b) Remove the bolt, collar, cushion, 2 nuts and AHC pump
& motor from the AHC pump & motor bracket.
(c) Remove the 2 holders, cushions and cushion bolts from
the AHC pump & motor.
(d) LHD:
Remove the bolt and bracket.
SA19X−02
REMOVAL
2. DISCONNECT CONNECTORS
F05131
3. DISCONNECT AHC FLUID LINE

Using SST, disconnect the AHC fluid line from the AHC pump
SST & motor.
SST 09023−00100
4. REMOVE AHC PUMP & MOTOR
(a) Remove the bolt, 3 nuts and AHC pump & motor.
F05132 (b) Remove the bolt, collar, cushion, 2 nuts and AHC pump
& motor from the AHC pump & motor bracket.
(c) Remove the 2 holders, cushions and cushion bolts from
the AHC pump & motor.
(d) LHD:
Remove the bolt and bracket.

SA19Y−02
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the 2 bolts and pull out the reservoir.
(b) Remove the cap, strainer and grommet from the reservoir.
2. REMOVE RESERVOIR BRACKET
(a) Remove the 2 bolts and reservoir bracket from the hous-
ing.
(b) Remove the 3 cushions from the reservoir bracket.
3. REMOVE FLUID PRESSURE SENSOR
(a) Remove the fluid pressure sensor from the housing.
(b) Remove the O−ring and ring from the fluid pressure sen-
sor.
4. REMOVE FLUID TEMPERATURE SENSOR
Remove the fluid temperature sensor from the housing.
5. REMOVE PUMP COVER
Remove the 3 bolts, pump cover and O−ring.
6. REMOVE PUMP SUB−ASSEMBLY

(a) Using a hexagon wrench, remove the 2 bolts and pump
sub−assembly.
7. REMOVE PUMP MOTOR
Remove the 2 bolts and pump motor from the housing.
8. REMOVE MOTOR JOINT
F05134
9. REMOVE OIL SEAL

Using a screwdriver, remove the oil seal.
NOTICE:
Be careful not to damage the housing.
F05133
SA226−01
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the 2 bolts and pull out the reservoir.
(b) Insert the flat−head screwdriver into the slit of the cover
to the extent that it reaches the reservoir cap.
Turn the cap and the cover together.
Remove the cover and the cap.
(c) Remove the cover from the cap.
(d) Remove the strainer and grommet from the reservoir.
2. REMOVE RESERVOIR BRACKET
(a) Remove the 2 bolts and reservoir bracket from the hous-
F13957 ing.
(b) Remove the 3 cushions from the reservoir bracket.
3. REMOVE FLUID PRESSURE SENSOR
Remove the fluid pressure sensor from the housing.
4. REMOVE FLUID TEMPERATURE SENSOR
Remove the fluid temperature sensor from the housing.
5. REMOVE PUMP COVER
Remove the 3 bolts, pump cover and O−ring.
6. REMOVE PUMP SUB−ASSEMBLY

(a) Using a hexagon wrench, remove the 2 bolts and pump
sub−assembly.
7. REMOVE PUMP MOTOR
Remove the 2 bolts and pump motor from the housing.
8. REMOVE MOTOR JOINT
F05134
9. REMOVE OIL SEAL

Using a screwdriver, remove the oil seal.
NOTICE:
Be careful not to damage the housing.
F05133

SA19Z−02
REASSEMBLY
1. INSTALL OIL SEAL
Using SST and a hammer, install a new oil seal.
SST 09950−60010 (09951−00310),
09950−70010 (09951−07100)
2. INSTALL PUMP MOTOR
SST Install the pump motor with 2 bolts.
F05136
3. INSTALL MOTOR JOINT
4. INSTALL PUMP SUB−ASSEMBLY
(a) Install a new O−ring to the housing.
(b) Align the pin of pump sub−assembly and housing.

NOTICE:
Be careful not so that the shaft portion does not interfere
with other portions.
(c) Using a hexagon wrench, install the 2 bolts.
5. INSTALL PUMP COVER
Install a new O−ring and the pump cover with 3 bolts.
6. INSTALL FLUID TEMPERATURE SENSOR
Install the fluid temperature sensor to the pump cover.
7. INSTALL FLUID PRESSURE SENSOR
(a) Install a new ring and O−ring to the fluid pressure sensor.
(b) Install the fluid pressure sensor to the housing.
8. INSTALL RESERVOIR BRACKET
(a) Install the 3 cushions to the reservoir bracket.
(b) Install the reservoir bracket with the 2 bolts to the housing.
9. INSTALL RESERVOIR
(a) Install a new grommet to the reservoir.
(b) Install the strainer and cap.
(c) Install the reservoir with 2 bolts.
SA227−01
REASSEMBLY
1. INSTALL OIL SEAL
Using SST and a hammer, install a new oil seal.
SST 09950−60010 (09951−00310),
09950−70010 (09951−07100)
2. INSTALL PUMP MOTOR
SST Install the pump motor with 2 bolts.
F05136
3. INSTALL MOTOR JOINT
4. INSTALL PUMP SUB−ASSEMBLY
(a) Install a new O−ring to the housing.
(b) Align the pin of pump sub−assembly and housing.

NOTICE:
Be careful not so that the shaft portion does not interfere
with other portions.
(c) Using a hexagon wrench, install the 2 bolts.
5. INSTALL PUMP COVER
Install a new O−ring and the pump cover with 3 bolts.
6. INSTALL FLUID TEMPERATURE SENSOR
Install the fluid temperature sensor to the pump cover.
7. INSTALL FLUID PRESSURE SENSOR
Install the fluid pressure sensor to the housing.
8. INSTALL RESERVOIR BRACKET
(a) Install the 3 cushions to the reservoir bracket.
(b) Install the reservoir bracket with the 2 bolts to the housing.
9. INSTALL RESERVOIR
(a) Install a new grommet to the reservoir.
(b) Install the strainer.
(c) Instal the cover to the cap.

(d) Insert the flat−head screwdriver into the slit of the cover
to the extent that it reaches the reservoir cap.
Turn the cap and the cover together to install them.
(e) Install the reservoir with 2 bolts.
F13984

SA1A0−02
INSTALLATION
SA1A0−03
INSTALLATION
BLEED AHC SYSTEM (See Pub No. RM616E on page SA−303) AND CHECK FOR LEAKS (See Pub.
No. RM616E on page SA−305).

SUSPENSION AND AXLE − CONTROL VALVE ASSEMBLY (Independent Front SA−327
Suspension)
CONTROL VALVE ASSEMBLY (Independent Front

Suspension)
SA18L−02
COMPONENTS
Bracket
15 (155, 11)
Cushion Bolt
7.8 (80, 69 in.·lbf)
Cushion
Holder
Control Valve Assembly
z Gasket 5.5 (55, 48 in.·lbf)
15 (155, 11)
Cover
4.4 (45, 38 in.·lbf)

SA−328 SUSPENSION AND AXLE − CONTROL VALVE ASSEMBLY (Independent Front
Suspension)
SA18M−02
REMOVAL
1. DISCONNECT CONNECTOR
2. DISCONNECT AHC FLUID LINES

Using SST, disconnect the 5 AHC fluid lines from the control
SST
valve assembly.
SST 09023−00100
3. REMOVE CONTROL VALVE ASSEMBLY
(a) Remove the 3 nuts and control valve assembly.
F05137 (b) Remove the 3 holders, cushions and cushion bolts from
the control valve assembly.
(c) Remove the 4 bolts and cover.
(d) Remove the gasket.
HINT:
At the time of installation, replace the used gasket with a new
one.
SUSPENSION AND AXLE − CONTROL VALVE ASSEMBLY (Independent Front SA−329
Suspension)
SA18N−03
INSTALLATION
SA−330 SUSPENSION AND AXLE − HEIGHT CONTROL ACCUMULATOR (Independent
Front Suspension)
HEIGHT CONTROL ACCUMULATOR (Independent Front

Suspension)
SA18O−02
COMPONENTS
15 (155, 11)
44 (450, 33)
29 (300, 22)
LH Front Damping
30 (310, 22)
*24 (245, 18)
Height Control Accumulator

15 (155, 11)
29 (300, 22) 29 (300, 22)
29 (300, 22)
29 (300, 22)
Cover
Bleeder Plug
6.9 (70, 61 in.·lbf)
Cap
29 (300, 22)
28 (290, 21) 29 (300, 22)

* For use with SST F05142
SUSPENSION AND AXLE − HEIGHT CONTROL ACCUMULATOR (Independent SA−331
Front Suspension)
SA18P−02
REMOVAL
2. REMOVE FRONT LH DAMPING FORCE CONTROL
F05131
ACTUATOR (See page SA−340)
SST
4. REMOVE HEIGHT CONTROL ACCUMULATOR
(a) Using SST, disconnect the inlet fluid line from the height
control accumulator.
SST 09631−22020
HINT:
Fulcrum S Use a torque wrench with a fulcrum length of 300 mm
Length
F05961 (11.81 in.).
S This torque value is effective in case that SST is parallel
to a torque wrench.
(b) Using SST, disconnect the outlet fluid line from the height
SST control accumulator.
SST 09751−36011
(c) Remove the nut, 3 bolts and height control accumulator.
F05143
SA−332 SUSPENSION AND AXLE − HEIGHT CONTROL ACCUMULATOR (Independent
Front Suspension)
SA18Q−02
DISPOSAL
A B
DISPOSAL HEIGHT CONTROL ACCUMULATOR
Place the accumulator in a vise and saw a hole between ”A” and
”B” shown in the illustration using a saw to discharge the gas
inside.
CAUTION:
S Before the gas discharging, loosen the bleeder plug
to bleed high pressure oil.
F05144
S The gas discharging is colorless, odorless and harm-
less.
S Saw a hole while covering the saw with a shop rug be-
cause chips may fly up.
SUSPENSION AND AXLE − HEIGHT CONTROL ACCUMULATOR (Independent SA−333
Front Suspension)
SA18R−03
INSTALLATION
SA−334
SUSPENSION AND AXLE − PUMP ATTENUATOR (Independent Front Suspension)
PUMP ATTENUATOR (Independent Front Suspension)

SA18S−02
COMPONENTS
18 (185, 13)
15 (155, 11)
Pump Attenuator
Cushion
30 (310, 22) Collar
*24 (245, 18)
Front Fender Apron

SA−335
SA18T−02
REMOVAL
F05131
3. REMOVE PUMP ATTENUATOR

(a) Using SST, disconnect the inlet fluid line from the pump
attenuator.
SST 09751−36011
F05140
(b) Using SST, disconnect the outlet fluid line from the pump
attenuator.
SST 09631−22020
HINT:
Fulcrum At the time of installation, please refer to the following items.
Length S Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
F05139 S This torque value is effective in case that SST is parallel
to a torque wrench.
(c) Remove the 2 bolts and pump attenuator.
(d) Remove the 2 collars and cushions.
SA−336
SA18U−02
A B DISPOSAL
DISPOSAL PUMP ATTENUATOR
Place the pump attenuator in a vise and saw a hole between ”A”
and ”B” shown in the illustration using a saw to discharge the
gas inside.
CAUTION:
S As the gas is contained inside a metal bellows saw up
to the metal bellows.
F05141
less.
SA−337
SA18V−03
INSTALLATION
SA−338 SUSPENSION AND AXLE − DAMPING FORCE CONTROL ACTUATOR
DAMPING FORCE CONTROL ACTUATOR (Independent

Front Suspension)
SA18W−03
INSPECT GAS CHAMBER
HINT:
Before conducting this inspection, check that front and rear shock absorber neutral pressure are within the
specified range (See page SA−305).
(a) Start the engine with the vehicle unloaded (with fuel tank full) and adjust the vehicle height to the ”LO”
position.
(b) Record the graduation on the reservoir tank. (A)
(c) Adjust the vehicle height from ”LO” position to ”HI” position.
(d) Note the graduations on the reservoir tank (B). Inspect that the value (A − B) is within the standard
value.
Standard value:
Australia: A − B = 8 graduations or more
Others: A − B = 7 graduations or more
NOTICE:
Perform the inspection 30 secs. after ”HI” indicator light has changed flushing to light up.
If the value is not within the specification, replace all the gas chambers with new ones.
SUSPENSION AND AXLE − DAMPING FORCE CONTROL ACTUATOR SA−339
SA18X−02
COMPONENTS
44 (450, 33)
15 (155, 11)
29 (300, 22)
90 (918, 66)
Damping Force Control *65 (663, 48)
Actuator z Back Up Ring
z O−ring
Gas Chamber
Cover
29 (300, 22)
Bleeder Plug
8.3 (84, 73 in.·lbf)
Cap
28 (290, 21)
SA18Y−02
REMOVAL
CAUTION:
ered suddenly.
F05121
2. REMOVE COVER
Remove the 2 bolts and cover.
4. REMOVE DAMPING FORCE CONTROL ACTUATOR
(a) Disconnect the 2 fluid lines from the damping force control
actuator.
Torque:
Inlet: 15 N·m (155 kgf·cm, 11 ft·lbf)
Outlet: 44 N·m (450 kgf·cm, 33 ft·lbf)
(b) Remove the nut, 2 bolts and damping force control actua-
tor.
SA18Z−02
DISPOSAL
DISPOSAL GAS CAMBER
Place the gas camber in a vise and saw a hole in the hatched
area shown in the illustration using a saw to discharge the gas
inside.
CAUTION:
less.
F05147
SA190−03
REPLACEMENT
1. REMOVE GAS CHAMBER
(a) Place damping force control actuator in a vise.
(b) Using SST, remove the gas camber.
SST 09922−10010
(c) Remove the O−ring and back up ring from the gas cham-
ber.
SST
2. INSTALL GAS CHAMBER
F05148
(a) Install a new back up ring and O−ring to the gas chamber.
NOTICE:
S Be careful not to damage the O−ring.
S Care should be taken for installing order of the back
up ring and O−ring.
(b) Coat the O−ring with suspension fluid AHC.
(c) Using SST, install the gas chamber.

SST
SST 09922−10010
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
Fulcrum NOTICE:
Length Use SST (09922−10010) in direction shown in the illustra-
F05960 tion.
SA191−03
INSTALLATION
SA−344 SUSPENSION AND AXLE − HEIGHT CONTROL SENSOR (Independent Front
Suspension)
HEIGHT CONTROL SENSOR (Independent Front

Suspension)
SA192−02
COMPONENTS
FRONT
5.6 (57, 49 in.·lbf)
REAR
Height Control Sensor
28 (285, 21)
28 (285, 21)
Height Control Sensor 5.6 (57, 49 in.·lbf)

F05150
SUSPENSION AND AXLE − HEIGHT CONTROL SENSOR (Independent Front SA−345
Suspension)
SA193−02
REMOVAL
1. REMOVE FRONT HEIGHT CONTROL SENSOR
(a) Remove the front wheel.
(b) Disconnect the connector.
(c) Remove the front height control sensor.

Matchmarks (1) Place matchmarks on the height control sensor link
and front upper suspension arm.
(2) Remove the nut and disconnect the height control
sensor link.
(3) Remove the 2 bolts and height control sensor.
F04364 2. REMOVE REAR HEIGHT CONTROL SENSOR
(a) Remove the rear wheel.
(b) Disconnect the connector.
(c) Remove the rear height control sensor.

(1) Place matchmarks on the height control sensor link
and rear upper control arm.
Matchmarks
(2) Remove the nut and disconnect the height control
sensor link from the rear upper control arm.
(3) Remove the 2 bolts and height control sensor.
F04365
SA−346 SUSPENSION AND AXLE − HEIGHT CONTROL SENSOR (Independent Front
Suspension)
SA194−02
INSTALLATION
SA−9
SUSPENSION AND AXLE − DUAL MODE AUTOMATIC LOCKING HUB (DALH)
DUAL MODE AUTOMATIC LOCKING HUB (DALH)

SA1IJ−01
COMPONENTS
z Gasket
Spindle Washer
Dual Mode Automatic

Locking Hub*
Brake Set*
Snap Ring
x6
55 (559, 40)
Wheel Cover
*: Make sure to the replace the dual auto

matic locking hub and brake set together.
F05520

SA−10
SA1IK−01
REMOVAL
1. SET KNOB OF DUAL MODE AUTOMATIC LOCKING
HUB
Using a hub nut wrench, set the knob of the dual mode automat-
ic locking hub to ”LOCK” position.
2. REMOVE WHEEL COVER
F05521

Using a 8 mm hexagon wrench, remove the 6 hexagon bolts
and locking hub.
4. REMOVE SNAP RING, SPINDLE WASHER AND
BRAKE SET FORM SPINDLE (OR STEERING
KNUCKLE)
F05522 5. REMOVE GASKET

SA−11
SA1IL−01
Identification Marks INSTALLATION

(No. 0 to 8) HINT:
S Replace the rocking hub assembly for right and left at the
same time, while matching the identification marks
(No. 0 to 8) on both rocking hubs.
S After assembling the dual automatic rocking hub to the
axle hub, when the knob of the rocking hub is turned to
”AUTO”, the rocking hub might be either locked or free.
F05463
Therefore, it is necessary to turn the axle hub to free. Also
it is necessary to move the vehicle back and forth with
2WD to turn the rocking hub free.
1. INSTALL BRAKE SET, SPINDLE WASHER AND SNAP
RING TO SPINDLE (OR STEERING KNUCKLE)
RFS: (See page SA−3)
IFS: (See page SA−7)
2. INSTALL NEW GASKET
3. CHECK KNOB OF DUAL MODE AUTOMATIC LOCK-
ING HUB IN ”LOCK” POSITION
Align 4. INSTALL DUAL MODE AUTOMATIC LOCKING HUB

(a) Align the marks on the brake set and notch on the locking
hub.
HINT:
Check that the brake wire of the brake set does not touch the
claw on the release plate of the rocking hub.
Claw of (b) Insert the gear drive of the locking hub into the drive shaft
Release (or axle shaft) and push the locking hub into the axle hub.
Plate HINT:
While holding the rocking hub to the axle hub, ensure that there
is no gap between the axle hub and rocking hub.
If there is a gap, the brake wire and claw of the release plate
might touch. Check and repair it and confirm that there is no
gap.
Brake Wire F05523
(c) Using a 8 mm hexagon wrench, install the 6 hexagon

bolts.
5. INSTALL WHEEL COVER
F05522

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SA−1

SUSPENSION AND AXLE − TROUBLESHOOTING (Rigid Front Suspension)

TROUBLESHOOTING (Rigid Front Suspension)

PROBLEM SYMPTOMS TABLE

1. Oil level (Low or wrong grade) SA−179

1. Diff. fuse (Blown) −

1. Diff. lock control switch (Faulty) SA−253

TROUBLESHOOTING (Independent Front Suspension)

PROBLEM SYMPTOMS TABLE

1. Oil level (Low or wrong grade) SA−179

1. Diff. fuse (Blown) −

1. Diff. lock control switch (Faulty) SA−262

VEHICLE PULLING DIAGNOSIS

Preliminary Check * ROAD TEST NO Is the steering NO

YES Steering wheel off−center (See page DI−419)

Check front wheel alignment. YES NO Is the pull stronger

NO ROAD TEST YES

LAND CRUISER (W/G) SUP (RM970E)

VEHICLE PULLING DIAGNOSIS

Preliminary Check * ROAD TEST NO Is the steering NO

YES Steering wheel off−center (See page DI−162)

Check front wheel alignment. YES NO Is the pull stronger

NO ROAD TEST YES

LAND CRUISER (W/G) SUP (RM1072E)

TIRE AND WHEEL SA1A2−01

LT235/85R16 108/104N 260 (2.6, 38) 375 (3.75, 54)

7.50R16−6PRLT 260 (2.6, 38) 375 (3.75, 54)

(b) Check the tire runout.

Full−time 4WD: Part−time 4WD: 2. ROTATE TIRE

3. INSPECT WHEEL BALANCE

4. CHECK FRONT SUSPENSION FOR LOOSENESS

TIRE AND WHEEL SA1A2−03

LT235/85R16 108/104N 260 (2.6, 38) 375 (3.75, 54)

7.50R16−6PRLT 260 (2.6, 38) 375 (3.75, 54)

(b) Check the tire runout.

Full−time 4WD: Part−time 4WD: 2. ROTATE TIRE

3. INSPECT WHEEL BALANCE

LAND CRUISER (W/G) SUP (RM793E)

4. CHECK FRONT SUSPENSION FOR LOOSENESS

LAND CRUISER (W/G) SUP (RM793E)

FRONT WHEEL ALIGNMENT (Rigid

2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR

Caster (AUSTRALIA) 1˚40’ ± 45’ (1.67˚ ± 0.75˚)

Steering axis inclination 13˚ ± 45’ (13˚ ± 0.75˚)

6. INSPECT WHEEL ANGLE

FRONT FRONT WHEEL ALIGNMENT

C 1HD−T A − B: 76.0 mm (2.992 in.) C − D: 34.0 mm (1.339 in.)

2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR

3. INSPECT CAMBER, CASTER AND STEERING AXIS

Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

Caster 2˚25’ ± 45’ (2.42˚ ± 0.75˚)

Steering axis inclination 12˚10’ ± 45’ (12.17˚ ± 0.75˚)

Caster 2˚50’ ± 45’ (2.83˚ ± 0.75˚)

Caster 2˚10’ ± 45’ (2.17˚ ± 0.75˚)

Steering axis inclination 12˚15’ ± 45’ (12.25˚ ± 0.75˚)

If the steering axis inclination is not within the specification, after

Front cam (LH) Front cam (RH)

(Shorter) (Longer) (Longer) (Shorter)

Rear cam (LH) Rear cam (RH)