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Suspension & Axle
Suspension & Axle
Page Page
UBLESHOOTING SA-2 REAR AXLE SHAFT
(Semi-Floating Type) SA-110
EL ALIGNMENT SA-3
REAR AXLE SHAFT AND AXLE HUB
WHEELING HUB SA-6
(Full-Floating Type) SA-1 18
ER LOCKING HUB
REAR DIFFERENTIAL / 8 INCH TYPE
it Location SA-15
On-Vehicle Replacement of
firing Diagram SA-16 Front Oil Seal SA-127
nnectors SA-17 Removal and Installation of
roubleshooting SA-18 Rear Differential SA- 129
it Inspection SA-20 Differential Carrier SA-132
war Locking Hub Actuator SA-23 Differential Case (4 Pinion Type) . . . SA-133
TROUBLESHOOTING
Page
Problem Possible cause Remedy
Front Rear
I
Wanders/pulls Tire worn or improperly inflated Replace tire or inflate tires to A-15 A-15
proper pressure
Alignment incorrect Check front wheel alignment SA-3 -
Front or rear suspension parts Tighten or replace suspension SA-89, 98 SA-194, 200
loosen or broken parts
Steering linkage loosen or worn Tighten or replace steering link- SR-72, 76 -
age
Steering gear out of adjustment Adjust or repair steering gear SR-20, 62 -
or broken
WHEEL ALIGNMENT
1. MAKE FOLLOWING CHECKS AND CORRECT ANY PROB-
LEMS
(a) Check the tires for wear, size and proper inflation
pressure .
Cold tire inflation pressure : See page A-15
B1286
C2718
FA0184
SA- 4 SUSPENSION AND AXLE - Wheel Alignment
Caster : 4°05' ± 1 °
If caster is not as specified, inspect and replace damaged
or worn suspension parts .
7. ADJUST TOE-IN
(a) Make sure the wheels are positioned straight ahead .
(c) Advance the vehicle until the marks on the rear sid
of the tires come to the front .
HINT : The toe-in should be measured at the same poi
on the tire at the same level .
t t Toe in = B-A
B
SA1777
(f) Loosen the nuts holding the clamps to the tie rod .
(g) Adjust toe-in to the correct value by turning the tie
')~IIIII ~ rod .
(h) Insure that the lengths of the tie rod ends are the
same .
B -- (i) Torque the nuts holding the clamps .
A=B ,., ∎ Torque : 375 kg-cm (27 ft-Ib, 37 N •m )
,."-
SA2627
FA0568
B1292
• Gasket
100 (7,10)
Spring
(b) Remove the six cover mounting bolts and pull off
the cover .
(b) Using a brass bar and hammer, tap on the bolt heads
and remove the cone washers .
(c) Pull off the free wheeling hub body .
SA-8 SUSPENSION AND AXLE - Free Wheeling Hub
(b) Using snap ring pliers, remove the snap ring from
the free wheeling hub cover .
(c) Remove the control handle from the free wheeling
hub cover .
(d) Remove the steel ball, spring and seal from the con-
trol handle .
(b) Remove the free wheeling hub ring and spacer from
the inner hub .
FA0064
SUSPENSION AND AXLE - Free Wheeling Hub SA-1 1
(b) Compress the spring and install the clutch with the
pawl tab fit to the handle cam .
(b) Using snap ring pliers, install the snap ring to the
free wheeling hub ring .
(b) Insert the cover to the body and check that the inn
hub turns smoothly .
(c) Remove the cover from the body .
-_~ SA0808
SA2847
xqm
MP Grease 11111h,
* 44~h.hqwlb
FA0070
FA0060 FA0066
(c) Install the cover to the body with the follower pawl
tabs aligned with the non-toothed portions of the
body .
SA0807
SA-14 SUSPENSION AND AXLE - Free Wheeling Hub
Adjusting Nut
Lock Nut
• Oil Seal 650 (47, 64)
Inner Bearing
C0)
(w/ Free Wheeling Hub)
Outer Bearing
Thrust Washer
• Lock Washer
(w/o Free Wheeling Hub)
• Gasket •G asket
Cone Washer
Washer
315(23,3 )
m (ft-lb, N •m ) torque
SA2880,
Non-reusable part SA2881&.
SA2489
a
71
(b) Using snap ring pliers, remove the snap ri .
(d) Using a brass bar and hammer, tap the bolt heads
and remove the cone washers .
(e) Pull out the flange .
~t=
1. INSPECT BEARING
Clean the bearings and outer races and inspect them
wear or damage .
6. ADJUST PRELOAD
(a) (w/ Power Locking Hub)
Remove the vinyl tape from the tip of spindle .
(b) Using SST, torque the bearing adjusting nut .
SST 09607-60020
Torque : 600 kg-cm (43 ft-lb, 59 N •m )
HINT : Be careful not to damage the oil seal .
(c) Turn the hub right and left two or three times .
(d) Loosen the nut until it can be turned by hand .
SST 09751-36011
Torque : 155 kg-cm (11 ft-lb, 15 N •m )
SHAFT
COMPONENTS
980 (71,96)
Cone Washer
Shim
(w/ Coil Spring Type)
(c) Using SST, push out the knuckle arm and shims
from the steering knuckle .
SST 09606-60020
HINT : Use the SST without a collar .
(d) Using SST, push out the bearing cap from the steer-
ing knuckle .
SST 09606-60020
2. REPLACE BUSHING
(a) Using SST, remove the bushing .
SST 09612-65014 (09612-01020, 09612-01050)
SST (b) Using SST, press a new bushing into the spindle .
SST
SST 09618-60010
W
i
FA0202 SA2838
(c) Tilt the inner race and cage, then take out the bear-
ing balls one by one .
(d) Fit the two large openings in the cage against the
protruding parts of the outer shaft, and pull out the
cage and inner race .
(e) Take out the inner race from the cage through the
large opening .
(f) Clean and inspect the joint inner parts for wear or
damage .
(g) Coat the joint inner parts and outer shaft inside with
molybdenum disulphide lithium base grease .
(h) Insert the inner race in the cage through the large
opening .
(i) Position the protruding end of the inner race toward
the wide side of the cage .
(j) Assemble the cage and inner race to the outer shaft
by fitting the two large openings in the cage against
the protruding parts of the outer shaft .
(k) Make sure to position the wide side of the cage and
Narrow Wide
the inner race protruding end outward .
(I) Fit in the inner race and cage, and install the six
jeolm
bearing balls in the outer shaft . (See step (c))
(m) Pack molybdenum disulphide lithium base grease in
49
the outer shaft .
Protruding End
SA2733
FA0107
SST 09618-60010
SA2506
SA2507
FA0009
SA-48 SUSPENSION AND AXLE - Steering Knuckle and Axle Shaft
Molybdenum
Disulphide
Lithium
Base Grease
SA0280
SA2497
FRONT DIFFERENTIAL
On-Vehicle Replacement of Rear Oil
Seal
1. DISCONNECT FRONT PROPELLER SHAFT
(a) Place matchmarks on the flanges .
(b) Remove the four bolts and nuts .
SA1972
SAZ969
Front
SUSPENSION AND AXLE (On-Vhicle Replacement of Rear Oil Seal)
(On-Vehicle SA-53
SA2430
SA2917
SA2309
SST
SA2416
SST
SA2918
Front Differential
SUSPENSION AND AXLE (On-Vehicle Replacement of Rear Oil Seal)
SA-54
SA2411
1111110
(b) Place the plate washer on the companion flange .
SA1971
Capacity :
RJ, LJ
1 .9 liters (2 .1 US qts, 1 .7 Imp .qts)
FJ, PZJ, HZJ
2 .6 liters (2 .7 US qts, 2 .3 Imp .gts)
Front Differential
SA-56 SUSPENSION AND AXLE - (Removal and Installation of Front Differential)
500 t36,49)
kg-cm (ft-lb, N • m)
Front Differential
SUSPENSION AND AXLE (Removal and Installation of Front Differential) SA-57
4. (RJ, LJ)
REMOVE TIE ROD AND STEERING DAMPER
(a) Using SST, disconnect the tie rod from the knucle
arm .
SST 09611-22012
Front Differential
SA-58 SUSPENSION AND AXLE - (Removal and Installation of Front Differential)
Front Differential
SA-60 SUSPENSION AND AXLE
(Removal and Installation of Front Differential)
7. (RJ, LJ)
INSTALL TIE ROD AND STEERING DAMPER
(a) Install the steering damper with the two bolts .
Torque : 195 kg-cm (14 ft-lb, 19 N •m )
(b) Torque the castle nut and secure it with a new cot-
ter pin .
Torque : 925 kg-cm (67 ft-lb, 91 N-m)
Differential Carrier
COMPONENTS
Washer
D ust Deflector
Bearing Outer Race
Oil Slinger
Washer
Drive Pinion
Ring Gear
Spring Seat
Compression Spring Actuator
Indicator Switch
Ball See page SA-79
410 f30,40)
270 (20, 26)
*1 240 (17, 24) -~ • Gasket --ED
Shaft Retainer Straight Screw
* 220 (16, 22)
Front Bearing
Drive Pinion
6. (2 PINION TYPE)
CHECK SIDE GEAR BACKLASH
Measure the side gear backlash while holding one pun
gear toward the case .
Standard backlash : 0 .05 - 0 .20 mm
(0 .0020 - 0 .0079 in .)
If the backlash is out of specification, install the corr
thrust washers . (See page SA-85)
SA2898
((I
~rrro ~~Ilfff
~ftrl
SA1993
SST SA2922
(c) Using a pin punch and hammer, drive out the slotted
spring pin .
SA2206
SA1986 SA1985
SA-66 SUSPENSION AND AXLE - Front Differential (Differential Carrier)
SA2405
(c) Remove the four bolts and the two bearing caps .
(d) (2 pinion type only)
Remove the two adjusting nuts .
SA2405
(c) Remove the four bolts and the two bearing caps .
(d) (2 pinion type only)
Remove the two adjusting nuts .
FA2045
i
10 .-2 (FJ, PZJ, HZJ)
REMOVE FRONT, REAR BEARING OUTER RACE
OIL STORAGE RING
(a) Using SST, remove the bearing outer race .
SST 09308-00010
SUSPENSION AND AXLE - Front Differential (Differential Carrier) SA-69
Outer Race (b) Using a hammer and brass bar, drive out the oil stor-
age ring and outer race from the carrier .
l
SA2410
SA2176
Match marks
SA2177
SA2464
SA-70 SUSPENSION AND AXLE - Front Differential (Differential Carrier)
SST
SST
Aft
/ D7935 D7936
SA2203
HINT : If the bearing cap does not fit tightly on the car-
rier, the adjusting nuts are not threaded properly . Rein-
stall the adjusting nuts if necessary .
(c) Using SST, tighten the adjusting nut on the ring gear
side until the ring gear has a backlash of about 0 .2
mm (0 .008 in .) .
SST 09504-00011 or 09616-30020
SA-76 SUSPENSION AND AXLE - Front Differential (Differential Carrier)
(d) While turning the ring gear, use 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 09504-0001 1
SA2472
SA2403
(b) Hold the companion flange firmly and rotate the ring
gear in both directions .
SA2463
Proper Contact
FA2013
SA-78 SUSPENSION AND AXLE - Front Differential (Differential Carrier)
FA2043
EM3555 SA1986
Iff i
SA2205
(i) Shift the shift fork deeply and keep the differential
lock condition .
a
LOCK
SA1979
(j) Clean the threads of the plugs and plug holes with
toluene or trichoroethylene .
(k) Install the ball, compression spring and spring seat .
I Ire
(I) Apply adhesive to the plug threads .
Adhesive : Part No . 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(m) Using SST, install and tighten the screw plugs .
I
r SST SST 09313-30021
1-4
SA1980 SA2922 Torque : 220 kg-cm (16 ft-lb, 22 N •m )
X4003
(f) Insert the actuator so that the long hole on the actu-
ator side fits with the knock pin on the carrier side .
HINT : Do not damage the O-ring of the actuator .
(g) Align the actuator with the long hole and rotate the
actuator counterclockwise when the knock pin
reaches the right-hand side .
SA-84 SUSPENSION AND AXLE - Front Differen tia l (Differential Case / 2 Pinion Type)
Differential Case
(2 Pinion Type)
COMPONENTS
Pinion Gear
Straight Pin
Thrust Washer
Differential Case
0 Side Gear
Pinion Shaft
Thrust Washer
C,
0
0
SA2580
SUSPENSION AND AXLE - Front Differential (Differential Case / 2 Pinion Type) SA-85
IL
CJ
K1882
K1883
K1884
INSTALLATION OF DIFFERENTIAL
1. INSTALL DIFFERENTIAL CASE IN CARRIER
(See page SA-62)
2. INSTALL DIFFERENTIAL
(See page SA-56)
K1B85
ON
C
ro
NkL-I/
41?)
SA2575
SA2891
(d) Align the coil spring end with the lower seat h~
Coil Spring Type Front Suspension
SUSPENSION AND AXLE (Coil Spring and Shock Absorber) SA-101
do
SA2539
(d) Hold the mounting bolt, and install the upper mount-
ing bolt, nut and washer .
Torque : 1,800 kg-cm (130 ft-lb, 177 N •m )
FA0533
2. INSTALL BUSHING
Using SST and a press, press a new bushing into the
eral control rod .
SST 09710-22041 (09710-02050, 09710-02070)
HINT : Do not use a lubricant when pressing in the bu
ing .
Coil Spring Type Front Suspension
SUSPENSION AND AXLE (Lateral Control Rod) SA-103
.~,
SA2892
3. STABILIZE SUSPENSION
(a) Lower the vehicle .
(b) Boucnce the vehicle up and down to stabilize the,,
suspension .
I!,
∎ WA
SA2888
SA2893 FA0538
Leading Arm
(See page SA-98)
(c) Remove the two bolts and nuts of the axle housing
side, then remove the leading arm .
SST
FA0539
2. INSTALL BUSHINGS
Using SST and a press, press new bushings into the le
SST ing arm .
v
SST 09228-22020, 09710-30030 (09710-03180)
SST
FA0539
Coil Spring Type Front Suspension
SUSPENSION AND AXLE ( LeadinArm) S A- 10 5
4. STABILIZE SUSPENSION
Bounce the vehicle up and down to stabilize the suspen-
sion .
5. TORQUE NUTS
(a) Jack up the axle housing .
HINT : For safety, place stands under either side of the
vehicle's frame .
Stabilizer Bar
REMOVAL OF STABILIZER BAR
(See page SA-98)
SA2534
SA2542
SA2543
SA2544
2. STABILIZE SUSPENSION
(a) Lower the vehicle .
(b) Bounce the vehicle up and down to stabilize the su
pension .
Coil Spring Type Front Suspension
SUSPENSION AND AXLE (Stabilizer Bar) SA-109
SA2539
w
SA2547
130(9, 13)
G asket
Differential Cover
G asket
Bearing
O il Seal
(w/ Disc Brake)
Oil Deflector
G asket
29 .0 (1 .142)
29 .4 (1 .157)
29 .8 (1 .173)
30 .2 (1 .189)
30 .6 (1 .205)
(a) Install the spacer and the pinion shaft to the differ-
ential .
Thickness mm (in .)
29 .0 (1 .142)
29 .4 (1 .157)
29 .8 (1 .173)
30 .2 (1 .189)
30 .6 (1 .205)
(b) Install the brake cylinder with the torque plate to the
rear axle carrier with the two bolts .
Torque : 900 kg-cm (65 ft-lb, 88 N •m )
(c) Install the wheel .
11 . LOWER VEHICLE
(a) Lower the vehicle .
(b) Bounce the vehicle up and down to stabilize the sus-
pension .
WA
6. LOWER VEHICLE
Rear Differential / 8 Inch Type
SUSPENSION AND AXLE (On-Vehicle Replacement of Front Oil Seal) SA-127
Gasket
0--ft-h-re
e Frame Wire >''~ <J
~ .{' ,,10 \ ® ~--500 (36,49)
O-Ring
91 1~1 • Gasket
250 8,25)
500 (36, 49)
IV 700 (51, 69)
G asket /
J ~~ 1
Rear Differential
750 (54, 74)
250(18,25)
Rear Propeller Shaft Rear Axle Shaft
SA2919
SA2920
SA-132 SUSPENSION AND AXLE - Rear Differential / 8 Inch Type (Differential Carrier)
M
Differential Carrier
COMPONENTS
4 Pinion (w/o Differential Lock) and LSD Types
• Dust Deflector
Front Bearing
*Oil Seal Differential Carrier
Washer
w/ Differential Lock
130(9,13)
22006,22)
Bearing Outer
Oil Slinger
• Dust Deflector
240 (17, 24)
Actuator
1
kg-cm (ft-lb, N •m ) Specified torque
• Non-reusable part
SA2583
Precoated part SA2582
Rear Differential / 8 Inch Type
SUSPENSION AND AXLE (Differential Carrier), (Differential Case / 4 Pinion Type) SA-133
Differential Case
(4 Pinion Type)
COMPONENTS (w/o DIFFERENTIAL LOCK)
INSTALLATION OF DIFFERENTIAL
1. INSTALL DIFFERENTIAL CASE IN CARRIER
(See page SA-132)
I Differential Case
w (Limited Slip Differential)
COMPONENTS
INSPECTION OF COMPONENTS
1. REPLACE PARTS THAT ARE DAMAGED OR WORN
HINT : If replacing the side gear, also replace the thrust
washer contacting it .
A Dimension
45 .00
.00 .01 .02 .03 .04 .05 .06 .07
B Dimension (1 7717) (1 .7720) (1 7724) (1 .7728) (1 .7732) (1 .7736) (1 .7740) (1 .7744)
28 .10 (1 .1063)
.12 (1 .1071)
14 (1 .1079)
.16 (1 .1087)
.18 (1 .1094)
.20 (1 .1102)
.22 (1 .1110)
.24 (1 .1118)
.26 (1 .1126)
.28 (1 .1134)
.30 (1 .1142)
.32 (1 .1150)
.34 (1 .1157) © a
.36 (1 .1165)
.38 (1 .1173)
.40 (1 .1181)
.42 (1 .1189)
.44 (1 .1197) © a'
.46 (1 .1205)
.48 (1 .1213)
.50 (1 .1220)
.52 (1 .1228)
54 (1 .1236)
.56 (1 .1244)
58 (1 .1252)
.60 (1 .1260)
.62 (1 .1268)
.64 (1 .1276)
.66 (1 .1283)
.68 (1 .1291)
70 (1 1299)
SA0428
SA-138 SUSPENSION AND AXLE - Rear Differential / 8 Inch Type (Differential Case / LSD)
SUSPENSION AND AXLE - Rear Differential / 8 Inch Type (Differential Case / LSD) SA-139
(e) Hold the side gear and spider, measure the side gear
backlash .
Backlash : 0 .05 - 0 .20 mm (0 .0020 - 0 .0079 in .)
HINT :
• Measure the backlash at the RH case and at the LH
case .
• Measure at all four locations .
If the backlash is not within specification, select an ad-
justi,pg shim .
INSTALLATION OF DIFFERENTIAL
1. INSTALL DIFFERENTIAL CASE IN CARRIER
(See page SA-132)
2. INSTALL DIFFERENTIAL
(See page SA-129)
Cushion
320(23,31)
kg-cm (ft-lb, N •m )
• Non-reusable part
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Coil Spring and Shock Absorber) SA-201
a NOTICE :
• When drilling, chips may fly out work carefully .
• The gas is colorless, odorless, and non-poisonous .
50 mm 30 mm
(1 .97 in .) 0 .18 in .)
SA2575
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Coil Spring and Shock Absorber) SA- 2 0 3
Ap
IN
SA2940
4. STABILIZE SUSPENSION
(a) Lower the vehicle .
(b) Bounce the vehicle up and down to stabilize the sus-
pension .
ROW
iW41 ~ M
SA2941
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Trailing Arm) SA-205
Trailing Arm
(See page SA-200)
(b) Remove the two rear mounting nuts and bolts from
the axle housing .
(c) Lower and remove the trailing arm .
RA0638
J
00
410 4
SST
RA0638
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Trailing Arm)
SA-206
2. STABILIZE SUSPENSION
RA0640
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Lateral Control Rod)
SA-208
SA2939
2. INSTALL BUSHING
MWO
Using SST and press, press in a new bushing into the
eral control rod .
RA0656 RA0657
Coil Spring Type Rear Suspension
SUSPENSION AND AXLE (Lateral Control Rod) SA- 2 0 9
RA0614
AP
RA0658
SA2940
3. STABILIZE SUSPENSION
(a) Lower the vehicle .
(b) Bounce the vehicle up and down to stabilize the sus-
pension .
SA2888
RA0641 SA2941
COMPONENTS
Parking Brake
r
• Snap Ring I \
Cable Axle Shaft
Axle Bearing \-/
l
Bearing Retainer
40
Brake Drum
1 700 151, 69)
i10
kg-cm (ft-lb, N •m ) Specified torque
• Non-reusable part
RAGA
RA0615
RA0617 RA0177
I*1
RA0618
SST
RA0619
SA-212 REAR AXLE AND SUSPENSION - Rear Axle Shaft (Light-Duty)
RA0616