FA-1

FRONT AXLE AND

SUSPENSION
(2WD) Page
TROUBLESHOOTING . FA-2
FRONT WHEEL ALIGNMENT . FA-3
FRONT AXLE HUB AND STEERING KNUCKLE . FA-6
Front Axle Hub . FA-7
Steering Knuckle . FA-9
FRONT SUSPENSION . FA-12
Ball Joints , . FA-13
Torsion Bar Spring . FA-15
Lower Suspension Arm and Shock Absorber . FA-17
Upper Suspension Arm . FA-20
Strut Bar . FA-22
Stabilizer Bar . FA-23

(4WD)
TROUBLESHOOTING . FA-24
FRONT WHEEL ALIGNMENT . FA-25
FREE WHEELING HUB .. FA-28
AUTOMATIC LOCKING HUB . FA-34
FRONT AXLE HUB . FA-43
STEERING KNUCKLE AND AXLE SHAFT . FA-48
FRONT DIFFERENTIAL . FA-59
FRONT SUSPENSION . FA-60
Leaf Spring and Shock Absorber . FA-60
Stabilizer Bar . FA-65 ~
Torque Rod . FA-66 ....
FA-2 FRONT AXLE AND SUSPENSION - Troubleshooting (2WD)

TROUBLESHOOTING (2WD)
Problem Possible cause Remedy Page

Wanders/pulls Tires worn or improperly inflated Replace tire or inflate tires to FA-3
proper pressure
Alignment incorrect Check front end alignment FA-3
Wheel bearing adjusted too tight Adjust wheel bearing FA-8
Front or rear suspension parts loose or Tighten or replace suspension
broken part
Steering linkage loosen or worn Tighten or replace steering SR-68
linkage
Steering gear out of adjustment or broken Adjust or repair steering gear SR-3

Bottoming Vehicle overloaded Check loading

Shock absorber worn out Replace shock absorber FA-17
Springs weak Replace spring FA-15

Sways/pitches Tires improperly inflated Inflate tires to proper pressure FA-3

Stabilizer bar bent or broken Inspect stabilizer bar FA-23
Shock absorber worn out Replace shock absorber FA-17

Front wheel shimmy Tires worn or improperly inflated Replace tire or inflate tires FA-3
to proper pressure
Wheels out of balance Balance wheels
Shimmy damper worn out Replace steering damper SR-7';
Shock absorber worn out Replace shock absorber FA-17
Alignment incorrect Check front end alignment FA-3
VVheel bearings worn or improperly Replace or adjust wheel FA-8
adjusted bearings
Ball joints or bushings worn Inspect ball joints and bushings FA-13,18
20
Steering linkage loosen or worn Tighten or replace steering linkage SR-68
Steering gear out of adjustment or broken Adjust or repair steering gear SR-3

Abnormal tire wear Tires improperly inflated Inflate tires to proper pressure FA-3
Shock absorbers worn out Replace shock absorber FA-17
Alignment incorrect Check toe-in FA-5
Suspension parts worn Replace suspension part
 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (2WD) FA-3

FRONT WHEEL ALIGNMENT (2WD)

1. MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(a) Check the tires for wear and proper inflation.
Correct tire pressure: kg/cm 2 (psi, kPa)
Tire Size Front Rear
7.00 - 14 - 6PR 1.7 (24, 167) 2.5 (36, 245)
P195175R 14 2.0 (28, 196) 2.45 (35, 240)
205170 SR 14 1.9 (27, 186) 2.25 (32, 221)
185 R 14 - LT 8 PR 1.8 (26, 177) 4.5 (64, 441)

(b) Check the wheel runout.

Lateral runout: Less than 1.2 mm (0.047 in.)
(c) Check the front wheel bearings for looseness.
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Use the standard bounce test to check that the front
absorbers work properly.
81286

2. MEASURE VEHICLE HEIGHT

If height of the vehicle is not as specified, try to level the
vehicle by shaking it down. If it is still not correct, check
for bad springs and worn or loose suspensions parts.
Front Vehicle height: See page A-21

FAOOO9

FA0010
FA-4 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (2WD)

3. ADJUST WHEEL ANGLE

A B
Remove the caps of the knuckle stopper bolts and che,."
the steering angles.

Wheel angle
Inside wheel 340 + 1 °
Front Max. -2°
A: Inside Outside wheel 30°
B: Outside
Inside wheel 22° 15'
at 20°
Outside wheel 20°
FAOO18

Adjusting Bolt
NOTE: When the steering wheel is fully turned, make sure
that the wheel is not touching the body or brake flexible
hose.
If maximum steering angles differ from standard value, ad-
just the wheel angle with the knuckle stopper bolts.
Torque: 350 kg-em (25 ft-Ib, 34 N em)
If the wheel angle still cannot be adjusted within limits, in-
spect and replace damaged or worn steering parts.
FA0019

4. INSTALL WHEEL ALIGNMENT EQUIPMENT

Follow the specific instructions of the equipment
manufacturer.

M9938

Axis 5. ADJUST CAMBER, STEERING AXIS INCLINATION AND

Inclination Camber CASTER
H ~ Inspection STD Adjustment STD
Camber 0°30' ± 45' 0°30' ± 30'
Left-right error 30' 30'

Steering axis inclination 10°

Caster
1/2 ton short 0°40' ± 45' 0°40' ± 30'
FAOO12
1/2 ton Long 1°10' ± 45' 1 ° 10' ± 30'
1 ton 0°35' ± 45' 0°35' ± 30'
Caster C&C 0°05' ± 45' 0°05' ± 30'
Left-right error 30' 30'

Front . .

FAOO13
 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (2WD) FA-5

If camber caster is not within specification, adjust by

adding or removing shims on the upper arm.
Shim thickness mm (in.)
Thickness
4.0 (0.157)
1.6 (0.063)
1.2 (0.047)

If the steering axis inclination is not as specified after cam-

L-- F-..:.AO;;.:.0--l14 ber and caster have been correctly adjusted, recheck the
steering knuckle and front wheel for bending or looseness.

6. ADJUST TOE-IN
Advance the Vehicle
.- (a)
(b)
Make sure the wheels are positioned straight ahead .
Mark the center of each rear tread at spindle height
and measure the distance between the marks on the
right and left tires.
(c) Advance the vehicle until the marks on the rear side
of the tires come to the front.
NOTE: The toe-in should be measured at the same point
L-- FA_OO--l15 on the tire and at the same level.

(d) Measure the distance between the marks on the front

side of the tires.
Toe-in: mm (in.)
Tire Inspection STD Adjustment STD
1/2 ton Short Bias 4±4 4±1
(0.16 ± 0.16) (0.16 ± 0.04)
Radial 1 ±4 1 ±1
(0.04 ± 0.16) (0.04 ± 0.04)
FAOO16
1/2 ton Long Bias 6±4 6 ± 1
(0.24 ± 0.16) (0.12 ± 0.04)
Radial 3 ± 4 3 ± 1
(0.12 ± 0.16) (0.12 ± 0.04)
...
Front

1 ton, C & C Radial 4±4 4± 1

(0.16 ± 0.16) (0.16 ± 0.04)

(e) Loosen the clamp bolts.

A=B
(f) Adjust toe-in by turning the left and right tie rod tubes
an equal amount.
FAOO17
NOTE: Make sure that the tie rods are the same length.
Left-right error: Less than 3.0 mm (0.118 in.)
(g) Tighten the clamp bolts and torque them.
Torque: 260 kg-em (19 ft-Ib, 25 N·m)

7. INSPECT SIDE SLIP WITH SIDE SLIP TESTER

Side slip limit:
Less than 3.0 mmlm (0.118 in. 13.3 1t)
If the side slip exceeds the limit, the toe-in or other front
wheel alignment may not be correct.

61292
FA-6 FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD)

FRONT AXLE HUB AND STEERING KNUCKLE (2WD)

COMPONENTS

1,100 (80, 108)

t - - - Brake Cylinder

Outer Bearing
Thrust Washer
Nut Lock
Cotter Pin
t
Dust Cover
~'~((j
Nut

.~ ! Cap

Retainer-__
M-----._Nut I 250 (18, 25) I
r------Bushing
,--- ...;...K:..:....:.n...;...uc:,k.l..-e_A_r_m_ _S_t_ee_r_in..,gI Knuckle
270 (20, 26)
1,100 (80, 108)

700 (51, 69)

185 (13, 18)

I kg-cm (ft-Ib, N·m) I : Tightening torque

FAOl83
• : Non-reusable part FA0212
FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD) FA-7

Front Axle Hub

(See page FA-6)

DISASSEMBLY OF FRONT AXLE HUB

1. REMOVE DISC BRAKE CYLINDER AND TORQUE PLATE
(a) Remove the brake cylinder and suspend it with wire.
(b) Remove the torque plate.
NOTE: Do not disconnect the brake tube and hose.
FA0185

2. REMOVE AXLE HUB WITH DISC

(a) Remove the cap, cotter pin, nut lock and nut.
(b) Remove the hub and disc together with the outer bear-
ing and thrust washer.
NOTE: Be careful not to drop the outer bearing.

FAOO20

3. REMOVE INNER BEARING AND OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
(b) Remove the inner bearing from the hub.

FAOO21

INSPECTION AND REPAIR OF FRONT AXLE HUB

1. INSPECT BEARING
Clean the bearings and outer races and inspect them for
wear or damage.

2. REPLACE BEARING OUTER RACE

(a) Using a brass bar and hammer, drive out the bearing
outer race.

(b) Using SST, carefully drive in a new bearing outer race.

SST 09608-30011
I----~SST

Z7798
FA-8 FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD)

ASSEMBLY OF FRONT AXLE HUB

1. PACK BEARINGS 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.

2. COAT INSIDE OF HUB AND CAP WITH MP GREASE

MP Grease

85487

3. INSTALL INNER BEARING AND OIL SEAL

Place inner bearing into the hub. Using SST, drive the oil
seal into the hub. Coat the oil seal with MP grease.
SST 09608-30011

4. INSTALL AXLE HUB ON SPINDLE

(a) Place the axle hub on the spindle.
(b) Install the outer bearing and thrust washer.

85488

5. ADJUST PRELOAD
(a) Install and torque the nut.
Torque: 350 kg-cm (25 ft-Ib, 34 Nom)
(b) Turn the hub right and left two or three times to al-
low the bearings to settle.
(c) Loosen the nut so there is 0.5 - 1.0 mm (0.020 -
0.039 in.) play in the hub axial direction.

FA0022

(d) Using a spring tension gauge, measure the frictional

force of the oil seal.
(e) Adjust the preload by tightening the nut.
Preload (rotating):
Frictional force plus 0.6· - 1.8 kg
(1.3 - 4.0 Ib, 5.9 - 18 Nl

FA0023
FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD) FA-9

(f) Measure the hub axial play.

Limit: 0.05 mm (0.0020 in.)

FAOO24

6. INSTALL LOCK NUT, COTTER PIN AND HUB GREASE CAP

7. INSTALL TORQUE PLATE ONTO STEERING KNUCKLE

Torque: 1,100 kg-em (80 ft-Ib, 108 Nom)

8. INSTALL BRAKE CYLINDER ONTO TORQUE PLATE

Torque: 900 kg-em (65 ft-Ib, 88 Nom)

BR0203

Steering Knuckle
(See page FA-G)

REMOVAL OF STEERING KNUCKLE

1. REMOVE FRONT AXLE HUB AND BRAKE CALIPER
(See page FA-7)

2. REMOVE DUST COVER

FAOO20 (a) Remove the two bolts.
(b) Remove the two cotter pins and bolts and remove the
dust cover.
(c) Remove the knuckle arm from the steering knuckle.

3. REMOVE STEERING KNUCKLE

(a) Support the lower arm with a jack.
(b) Remove the two cotter pins and two nuts.

(c) Using SST, disconnect the steering knuckle from the

lower ball joint.
(d) Using SST, disconnect the steering knuckle from the
upper ball joint.
SST 09628-62011
(e) Remove the steering knuckle.
FA-10 FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD)

INSPECTION OF STEERING KNUCKLE

INSPECT STEERING KNUCKLE
Inspect the knuckle for damage or cracks.
NOTE: It is recommended that a flaw detector or liquid
penetrate be used for this inspection.
If the steering knuckle is damaged or cracked, replace it.

INSTALLATION OF STEERING KNUCKLE

1. INSTALL STEERING KNUCKLE
(a) Support the lower arm with a jack.
(b) Install the steering knuckle to the upper ball joint and
install the nut.
(c) Push the upper arm and steering knuckle down and
install the steering knuckle to the lower ball joint and
install the nut.
FA0028

(d) Torque the upper ball joint nut.

Torque: 1,100 kg-em (80 ft-Ib, 108 Nom)

(e) Torque the lower ball joint nut.
Torque: 1,450 kg-em (105 ft-Ib, 142 Nom)
(f) Install the cotter pins.

FAOO29

2. INSTALL KNUCKLE ARM AND DUST COVER

(a) Install the knuckle arm and the dust cover.
(b) Torque the bolts.
Torque: 1,100 kg-em (80 ft-Ib, 108 Nom)
(c) Secure the nuts with the cotter pins.

FAOO30

3. INSTALL FRONT AXLE HUB AND BRAKE CALIPER

(See pages FA-8, 9)

FA0020
FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD) FA-11

4. CHECK FRONT WHEEL ALIGNMENT

(See page FA-3)

M9938
FA-12 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

FRONT SUSPENSION (2WD)

COMPONENTS

270 (20. 26)

1,280 (93, 126) 1 - 1- - - - - - "

~------UpperArm

1,100 (80, 108)

IUpper Ball Joint

250 (18, 25)

r 130 (9, 13)

~
~
~

t!l
~ Anchor Arm
o
@ ~-_'----_-J 850 (61, 83)

Lower Arm Bushing

\ _
S 500 (36, 49)

2,750 (199,270) tl=J

L-~
;jL:::~:r:::rm
~
~~<n R\ ')

!
Shock Absorber
~--~--!
~. '~~
~ (!) (il

Torsion Bar Spring t

,
Lower Arm----7'

;...A. Lower Ball Joint

~

i~~C:;~'~1 i
1,250 (90. 123)
I~ Strut Bar
970 (70. 95)

\ kg-cm (ft-Ib, N·m) I : Tightening torque

• : Non-reusable part FA0230
 FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-13

Ball Joints
INSPECTION OF BALL JOINTS
1. INSPECT LOWER BALL JOINT FOR EXCESSIVE
LOOSENESS
(a) Jack up the front of the vehicle and support it with
stands.
(b) Make sure the front wheels are in a straight forward
FAOO31
position, and depress the brake pedal.
(c) Move theJower arm up and down and check that the
lower ball joint has no excessive play.
Maximum vertical play: 2.3 mm (O.091 in.)

2. INSPECT UPPER BALL JOINT FOR EXCESSIVE

LOOSENESS
Move the wheel up and down and check that the upper
ball joint has no excessive play.
Maximum vertical play: 2.3 mm {O.091 in.}

FAOO32

3. INSPECT BALL JOINT ROTATION CONDITION

~
~'
'." i f (a) Remove the ball joint. (See pages FA-9,1 0)
..
(b) As shown in the figure, flip the ball joint stud back
.. -. • and forth 5 times before installing the nut.
(c) Using a torque gauge, turn the nut continuously one

~
turn each 2-4 seconds and take the torque reading
on the 5th turn.
Torque (turning):
Lower ball joint 25-50 kg-cm (22-43 in.-Ib, 2.5-4.9 N -m)
84520
Upper ball joint 20-40 kg-cm (18-34 in.-Ib, 2.0-3.9 N-m)

REMOVAL OF BALL JOINTS

1. REMOVE STEERING KNUCKLE
(See page FA-9)

2. REMOVE LOWER BALL JOINT FROM LOWER ARM

FAOO33

3. REMOVE UPPER BALL JOINT FROM UPPER ARM

FAOO34
FA-14 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

INSTALLATION OF BALL JOINTS

1. INSTALL UPPER BALL JOINT TO UPPER ARM
Torque: 270 kg-em (20 ft-Ib, 26 N ·m)

2. INSTALL LOWER BALL JOINT TO LOWER ARM

Torque: 700 kg-em (51 ft-Ib, 69 N·m)

3. INSTALL STEERING KNUCKLE

(See page FA-10)

FAOO28
FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-15

Torsion Bar Spring

(See page FA-12)

A REMOVAL OF TORSION BAR SPRING

1. JACK UP AND SUPPORT FRAME ON STANDS

2. REMOVE lOCK NUT AND MEASURE PROTRUDING BOLT

END "A", AS SHOWN
FAOO37
NOTE: Use this measurement for reference when adjust-
ing the vehicle height.
3. REMOVE DUST COVER

4. LOOSEN ADJUSTING NUT UNTIL NO TENSION ON TOR-

SION BAR

FAQ038

5. REMOVE TORQUE ARM, TORSION BAR SPRING AND

ANCHOR ARM
(a) Remove the torque arm mounting nuts.
(b) Remove the anchor arm from the adjusting bolt and
then remove the torsion bar together with the torque
arm and anchor arm.

INSTALLATION OF TORSION BAR SPRING

NOTE: There are left and right identification marks on the
rear end of the torsion bar springs.
Be careful not to interchange them.

Z7998

1. INSTALL TORSION BAR SPRING AND ANCHOR ARM AND

TORQUE ARM
(a) Apply a light coat of MP grease to the spline of the
torsion bar spring.
(b) Align the toothless portion and install the anchor arm
to the torsion bar spring.
(c) Align the toothless portion and install the torque arm
to the torsion bar spring.
FA-16 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

(d) Install the torsion bar spring torque arm side and in-
stall the anchor arm to the adjusting bolt.
(e) Torque the torque arm nut.
Torque: 500 kg-em (36 ft-Ib, 49 N ·m)

(f) Tighten the adjusting nut so that the bolt protrusion

is equal to that before removal.

FA0037

(g) Install the wheel and remove the stands. Bounce the
vehicle to settle the suspension.
(h) Adjust the vehicle height by turning the adjusting nut.
A Vehicle hight: See page A-21

Front

FAOO37 FAOOO9

2. TORQUE LOCK NUT

Torque: 850 kg-cm (61 ft-Ib, 83 N·m)

3. INSTALL DUST COVER

FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-17

Lower Suspension Arm and Shock

Absorber (See page FA-12)
1. REMOVE TORSION BAR SPRING (See page FA-15)

2. REMOVE SHOCK ABSORBER

FA0042 FA0043

3. DISCONNECT STABILIZER BAR FROM LOWER ARM

4. DISCONNECT STRUT BAR FROM LOWER ARM

5. REMOVE LOWER BALL JOINT

(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the ball joint from the steer-
ing knuckle and remove it.
SST 09628-62011
NOTE: Be careful not to damage the ball joint boot.

FA0026

6. REMOVE LOWER SUSPENSION ARM

(a) Remove the lower arm shaft nut and remove the lower
arm.

FAOO"
FA-18 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

REPLACEMENT OF LOWER ARM BUSHING

1. REMOVE BUSHING
(a) Cut off the bushing rubber as shown in the figure.
(b) Using SST, remove the bushing
SST 09726-35010

FA0046

(c) Apply soapy water on the front rubber part of the

bushing and fit SST on the new bushing.
(d) Using SST, install the new bushing
SST

FA0047
FA0048

INSTALLATION OF LOWER SUSPENSION ARM

AND SHOCK ABSORBER
1. INSTALL LOWER SUSPENSION ARM
(a) Install the torque arm mounting bolts to the lower an.,.
(b) Place the torque arm on the lower arm shaft.
Set the lower arm in installation position, and insert
the lower arm shaft and torque arm.
(c) Temporarily install the torque arm.
FA0049
(d) Finger tighten the lower arm, and remove the torque
arm.
NOTE: Do not torque the nut.

2. INSTALL LOWER BALL JOINT

Install the lower ball joint to the lower arm.
Torque: 700 kg-em (51 ft-Ib, 69 N·m)
 FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-19

3. CONNECT STRUT BAR TO LOWER ARM

Torque: 970 kg-em (70 ft-Ib, 95 N·m)

4. CONNECT STABILIZER BAR TO LOWER ARM

Torque: 130 kg-em (9 ft-Ib, 13 N·m)

FA0050

5. CONNECT BALL JOINT TO STEERING KNUCKLE

(a) Support the lower arm with a jack.
(b) Install the ball joint to the steering knuckle.
(c) Torque the nut.
Torque: 1,450 kg-em (105 ft-Ib, 142 N·m)
(d) Secure the nut with cotter pin.

6. INSTALL SHOCK ABSORBER

(a) Install the shock absorber to the lower arm.
Torque: 185 kg-em (13 ft-Ib, 18 N·m)
(b) Install the shock absorber to the upper bracket.
Torque: 250 kg-em (18 ft-Ib, 25 N·m)

7. INSTALL KNUCKLE ARM, DUST COVER, AXLE HUB AND

BRAKE CALIPER
(See page FA-10)
FA0122

8. INSTALL TORSION BAR SPRING

(See page FA-15)

(~-@J
9. TORQUE LOWER ARM SHAFT NUT
(a) Remove the stands and bounce the vehicle to stabi-
lize the suspension.

FA0123

(b) Torque the nut.

Torque: 2,750 kg-em (199 ft-Ib, 270 N·m)

10. CHECK FRONT WHEEL ALIGNMENT

(See page FA-3)

FA0124
FA-20 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

Upper Suspension Arm

(See page FA-12)

REMOVAL OF UPPER SUSPENSION ARM

1. REMOVE DISC BRAKE CYLINDER
(See Page FA-7)

FA0185

2. DISCONNECT UPPER BALL JOINT FROM STEERING

KNUCKLE
(a) Support the lower arm with a jack.
(b) Using SST, disconnect the ball joint from the steer-
ing knuckle.
SST 09628-62011
NOTE: Be careful not to damage the ball joint boot.

FA0125

3. REMOVE UPPER SUSPENSION ARM

(a) Remove the bolts and camber adjusting shims.
(b) Remove the upper arm.
NOTE: Do not loose the camber adjusting shims. Recc
the position, and the thickness of camber adjusting shims
so that these can be reinstalled to their original location.

FA0126

REPLACEMENT OF UPPER ARM BUSHING

1. REMOVE BUSHING
(a) Remove the bolts and washers.
(b) Using SST, push out the bushings.
SST
SST 09710-30020

FA0127 FA0128

2. INSTALL BUSHING
(a) Using SST, push in the bushings.
SST 09710-30020
(b) Install the washers, and finger tighten the bolts.
NOTE: Do not torque the bolts.

FA0129 FA0130
 FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-21

INSTALLATION OF UPPER SUSPENSION ARM

1. INSTALL UPPER ARM
(a) Install the upper arm together with the camber adjust-
ing shims.
(b) Torque the bolts.
Torque: 1,000 kg-em (72 ft-Ib, 98 Nom)
NOTE: Install an equal number and thickness of shims in
their original position.
FA0135

2. INSTAll UPPER BAll JOINT

(a) Install the upper ball joint to the upper arm.
Torque: 270 kg-em (20 ft-Ib, 26 Nom)
(b) Support the lower arm with a jack and connect the
upper ball joint to the steering knuckle.
Torque: 1,100 kg-em (80 ft-Ib, 108 Nom)
(c) Secure the nut with a new cotter pin.

FA0136

3. CONNECT DISC BRAKE CYLINDER

Torque: 900 kg-em (65 ft-Ib, 88 Nom)

BR0203

4. TORQUE UPPER ARM SHAFT BOLTS

(a) Remove the stands and bounce the vehicle to stabi-
lize the suspension.

(~ @J
FA0123

(b) Torque the upper arm shaft bolts.

Torque: 1,280 kg-em (93 ft-Ib, 126 Nom)

5. CHECK FRONT WHEEL ALIGNMENT

(See page FA-3)

FA0137
FA-22 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)

Match~ Strut Bar

(See page FA-12)

REMOVAL OF STRUT BAR

1. PLACE MATCHMARKS ON STRUT BAR

FA0138

2. REMOVE FRONT NUT FROM STRUT BAR

3. REMOVE STRUT BAR FROM LOWER ARM

Remove the nuts holding the strut bar to the lower arm,
and remove the strut bar.

FA0139

INSTALLATION OF STRUT BAR

1. INSTALL FRONT NUT
Install the front nut and align the matchmarks on the st r
bar.

---------- FA0138

2. INSTALL STRUT BAR TO BRACKET

(a) Install the washer and bushing to the strut bar and
install it to the bracket.
(b) Install the collar, bushing and washer to the strut bar.
(c) Finger tighten the front nut.

3. CONNECT STRUT BAR TO LOWER ARM

Torque: 970 kg-em (70 ft-Ib, 95 N·m)

FAOO50

jC ('I 4. TORQUE FRONT NUT

(a)

(b)
Remove the stands and the vehicle to stabilize the sus-
pension.
Torque the front nut.
Torque: 1,250 kg-em (90 ft-Ib, 123 N ·m)

5. CHECK FRONT WHEEL ALIGNMENT

(See page FA-3)

FA0140
FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-23

Stabilizer Bar
(See page FA-12)

REMOVAL OF STABILIZER BAR

1. REMOVE ONE TORSION BAR SPRING
(See page FA-15)

2. REMOVE STABILIZER BAR FROM LOWER ARMS

(a) Remove the nuts and cushions holding both sides of
the stabilizer bar from the lower arms, and disconnect
the stabilizer bar.

(b) Remove both stabilizer bar bushings and brackets, and

remove the stabilizer bar.

FA0141

INSTALLATION OF STABILIZER BAR

1. PLACE STABILIZER BAR TO FRAME
Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
Finger tighten the bolts.

2. CONNECT STABILIZER BAR TO LOWER ARMS

Connect the stabilizer bar on both sides to the lower arms
with bolts, cushions and new nuts as shown. Torque the
nuts.
Torque: 130 kg-em (9 ft-Ib, 13 Nom)

3. TORQUE BRACKET SET BOLTS

Torque: 130 kg-em (9 ft-Ib, 13 Nom)

4. INSTALL TORSION BAR SPRING

(See page FA-15)
FA-24 FRONT AXLE AND SUSPENSION - Troubleshooting (4WD)

TROUBLESHOOTING (4WD)
Problem Possible cause Remedy Page

Oil leak at front axle Oil seals damaged or worn Replace oil seal FA-49
Front axle housing cracked Repair as necessary

Oil leak at pinion shaft Oil level too high or wrong grade Drain and replace oil A-34
Oil seal worn or damaged Replace oil seal RA-6
Companion flange loose or damaged Tighten or replace flange RA-9

Noises in front axle Oil level low or wrong grade Drain and replace oil A-34
Excessive backlash between pinion and Check backlash RA-8
ring or side gear
Ring, pinion or side gears worn or chipped Inspect gears RA-10
Pinion shaft bearing worn Replace bearing RA-10
Wheel bearing worn Replace bearing FA-45
Differential bearing loose or worn Tighten or replace bearings RA-10
Wanders/pulls Tires worn or improperly inflated Replace tire or inflate tires to FA-25
proper pressure
Alignment incorrect Check front end alignment FA-25
Wheel bearing adjusted too tight Adjust wheel bearing FA-46
Front or rear suspension parts loose or Tighten or replace suspension FA-60
broken part
Steering linkage loosen or worn Tighten or replace steering SR-75
linkage
Steering gear out of adjustment or broken Adjust or repair steering gear SR-3

Bottoming Vehicle overloaded Check loading

Shock absorber worn out Replace shock absorber FA-60
Springs weak Replace spring FA-61
Sways/pitches Tires improperly inflated Inflate tires to proper pressure FA-25
Stabilizer bar bent or broken Inspect stabilizer bar FA-65
Shock absorber worn out Replace shock absorber FA-60
Front wheel shimmy Tires worn or improperly inflated Replace tire or inflate tires FA-25
to proper pressure
Wheels out of balance Balance wheels
Steering damper worn out Replace steering damper SR-77
Shock absorber worn out Replace shock absorber FA-60
Alignment incorrect Check front end alignment FA-25
Wheel bearings worn or improperly Replace or adjust wheel FA-45
adjusted bearings
Steering knuckle bearing worn Replace bearing FA-45
Steering linkage loosen or worn Tighten or replace steering SR-75
linkage
Steering gear out of adjustment or broken Adjust or repair steering gear SR-3
Abnormal tire wear Tires improperly inflated Inflate tire to proper pressure FA-25
Shock absorbers worn out Replace shock absorber FA-60
Alignment incorrect Check toe-in FA-26
 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (4WD) FA-25

FRONT WHEEL ALIGNMENT (4WD)

1. MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(a) Check the tires for wear and proper inflation.
Correct tire pressure:
kg/cm 2 (psi, kPa)
Tire size Front Rear
P225 / 75R 15 1.8 (26,177) 2.0 (28,196)
(b) Check the wheel runout.
Lateral runout: Less than 1.2 mm (0.047 in.)
(c) Check the front wheel bearings for looseness.
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Use the standard bounce test to check that the front
absorbers work properly.

2. INSTALL WHEEL ALIGNMENT EQUIPMENT

Follow the specific instructions of the equipment
manufacturer.

M9938

3. CHECK CAMBER AND KING PIN INCLINATION

Camber
Camber: 1° ± 45'
King Pin Inclination
King pin inclination: go 30' ± 45'
If camber or king pin inclination checks are not within
specification, rechecks the steering knuckle parts and the
front wheel for bending or looseness.

FAO'84

4. CHECK CASTER
Caster (at unloaded):
TRUCK 2° 15' ± 1°
4-RUNNER 3°00' ± 1°
If caster is not as specified, inspect and replace damaged
or worn leaf spring parts.
FA-26 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (4WD)

5. ADJUST TOE-IN
(a) Make sure the wheels are positioned straight ahe? .
. . . . Advance the Vehicle (b) Mark the center of each rear tread at spindle heigrll
and measure the distance between the marks of right
and left tires.
(c) Advance the vehicle until the marks on the rear side
of the tires come to the front.
NOTE: The toe-in should be measured at the same point
on the tire and at the same level.
FAOO1S

(d) Measure the distance between the marks on the front

side of the tires.

Toe-in mm (in.)
Tire
Inspection STD I Adjustment STD
Radial 1 ± 4 (0.04 ± 0.16) I1 ± 1 (0.04 ± 0.04)

• FAOO16

(e) Make sure the steering gear is centered.

Front
(f) Loosen the nuts holding the clamps to the tie rod.
(g) Adjust toe-in to the correct value by turning the tie ro'"
(h) Torque the nuts holding the clamps.
Torque: 375 kg-em (27 ft-Ib, 37 N ·m)
NOTE: The steering damper side clamp opening must be
positioned at the front of the tie rod, and face within 45°
from straight down as shown in the figure.
FAOOS1 FAOOS2

6. ADJUST WHEEL ANGLE

Remove the caps of the knuckle stopper bolts and check
the steering angles.

Wheel angle
Inside wheel +1°
30°30' -2°
Max.
A: Inside Outside wheel 29°
B: Outside Inside wheel 20°30'
at 20°
FA001S Outside wheel 20°

Adjusting Bolt
NOTE: When the steering wheel is fully turned, make sure
that the wheel is not touching the body or brake flexible
hose.
If maximum steering angles differ from the standard value,
adjust the wheel angle with the knuckle stopper bolts.
Torque: 480 kg-cm (35 ft-Ib, 47 N·m)
If the wheel angle still cannot be adjusted within limits, in-
spect and replace damaged or worn steering parts.

FAOOS3
FRONT AXLE AND SUSPENSION - Front Wheel Alignment (4WD) FA-27

7. INSPECT SIDE SLIP WITH SIDE SLIP TESTER

Side slip limit:
Less than 3.0 mm/m (0.118 in./3.3 ft)
If the side slip exceeds the limit, the toe-in or other front
wheel alignment may not be correct.

81292
 SION - Free Wheeling Hu b (4WD)
:.....:.._ _)
FRONT AXLE AND SUSPEN HEELING HUB (4WD
FREE W
COMPONENTS

Snap Ring

.
Free Wheeling H u bRing

Snap Ring

~ - - --- - - - - - - __Free Wheeling

I . Hub Body
_
Inner Hub

~I
I _
I Clutch _

! I
~--OO() Snap Ring

Spring

Spring

Contro I Handle an d Seal

Mf
 FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD) FA-29

REMOVAL OF FREE WHEELING HUB

1. REMOVE FREE WHEELING HUB COVER
(a) Set the control handle to FREE.
(b) Remove the cover mounting bolts and pull off the
cover.

FAOO54

2. REMOVE SNAP RING

Using snap ring pliers, remove the snap ring.

3. REMOVE FREE WHEELING HUB BODY

(a) Remove the mounting nuts.
(b) Using a tapered punch, tap on the slits of the cone
washers and remove them.
(c) Pull off the free wheeling hub body.

FAOl18

DISASSEMBLY OF FREE WHEELING HUB

1. REMOVE CONTROL HANDLE FROM FREE WHEELING HUB
COVER
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the control handle.
(c) Remove the steel ball and spring from the control
handle.

FAOO57

2. REMOVE INNER HUB AND FREE WHEELING HUB RING

FROM FREE WHEELING HUB BODY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the inner hub and free wheeling hub ring.

/
FA-30 FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD)

3. REMOVE FREE WHEELING HUB RING FROM INNER HUB

(a) Using snap ring pliers, remove the snap ring.
(b) Remove the free wheeling hub ring and spacer.

FA0059

INSPECTION OF FREE WHEELING HUB

1. INSPECT COVER, HANDLE AND SEAL
(a) Temporarily install the handle in the cover and check
that the handle moves smoothly and freely.

2. INSPECT BODY AND CLUTCH

(a) Check that the clutch moves smoothly in the body.

FA0213

3. MEASURE THE OIL CLEARANCE BETWEEN THE INNER

HUB AND FREE WHEELING HUB RING
Oil clearance (A - B): 0.3 mm (0.012 in.)
FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD) FA-31

ASSEMBLY OF FREE WHEELING HUB

(See page FA-28)

1. APPLY MP GREASE TO SLIDING SURFACE OF PARTS

FA0210

2. INSTALL CONTROL HANDLE TO COVER

(a) Install the seal, spring and steel ball to the handle.
(b) Insert the handle in the cover and install the snap ring
with snap ring pliers.

FAOO57

3. INSTALL TENSION SPRING IN CLUTCH

Install the tension spring in the clutch with the spring end
aligned with the initial groove.

FA0063

4. INSTALL FOLLOWER PAWL TO CLUTCH

(a) Place the follower pawl on the tension spring with one
of the large tabs against the bent spring end.
(b) Place the top ring of the spring on the small tabs.

FAOO64

5. INSTALL CLUTCH AND SPRING INTO COVER

(a) Place the spring between the cover and clutch with
the large spring end toward the cover.
(b) Compress the spring and install the clutch with the
pawl tab fit to the handle cam.

FA0065
FA-32 FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD)

6. INSTALL SPACER AND FREE WHEELING HUB RING TO

INNER HUB
(a) Install the spacer and free wheeling hub ring to .,
inner hub.
(b) Using snap ring pliers, install the snap ring.

FAOO59

7. INSTALL INNER HUB AND FREE WHEELING HUB RING IN

FREE WHEELING HUB BODY
(a) Insert the inner hub and free wheeling hub ring in the
body.
(b) Using a screwdriver, install the snap ring.

8. TEMPORARILY INSTALL COVER TO BODY AND CHECK

FREE WHEELING HUB
(a) Set the control handle and clutch to the free position.

F AOO60 F A0066

(b) Insert the cover in the body and verify that the inner
hub turns smoothly.
(c) Remove the cover from the body.
FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD) FA-33

INSTALLATION OF FREE WHEELING HUB

(See page FA-28)

1. INSTALL FREE WHEELING HUB BODY

(a) Place the gasket in position on the front axle hub.
(b) Install the free wheeling hub body with six cone wash-
ers and nuts. Tighten the nuts.
Torque: 315 kg-em (23 ft-Ib, 31 N·m)

2. INSTALL SNAP RING

(a) Install a bolt in the axle shaft and pull it out.
(b) Using snap ring pliers, install the snap ring.
(c) Remove the bolt.

3. APPLY MP GREASE TO INNER HUB SPLINES

FAOO70

4. INSTALL FREE WHEELING HUB COVER WITH NEW

GASKET
(a) Set the control handle and clutch to the free position.
(b) Place a new gasket in position on the cover.

FAOO60 FA0066

(c) Install the cover to the body with the follower pawl
tabs aligned with the non-toothed portions of the
body.
(d) Tighten the cover mounting bolts.
Torque: 100 kg-em (7 ft-Ib, 10 N·m)

FAOO71
FA-34 FRONT AXLE AND SUSPENTION - Automatic Locking Hub (4WD)

AUTOMATIC LOCKING HUB (4WD)

TROUBLESHOOTING
Problem Possible cause Remedy Page
Will not lock Brake shoe worn or damaged Replace brake assembly FA-36
Will not unlock Brake spring weak Replace brake assembly FA-36
Bad rubbing between the inner hub and Replace hub assembly FA-36
clutch
Engage and disengage between the Replace hub assembly FA-36
clutch and hub body did not go smoothly
Abnormal noise Body and clutch looseness or damage Replace hub assembly FA-36
Looseness of set bolt for axle shaft Tighten or replace hub FA-36
and inner hub assembly
Looseness of brake assembly set screw Replace brake assembly FA-36
Needs grease Apply grease or replace FA-36
hub assembly
Brake drag Outer cam worn or damaged Replace hub assembly FA-36
(ALH) Front brake dragged Replace hub assembly FA-36
 Automa t ic Lac k "Ing Hub
-~- FRONTAXLE AN
D SUSPENSION
COMPONENTS

Bra k e A ssembly
A . 9 Nut

o
~-----------
~b'4lC.IW ------..., I

l--o i@~CamfOllower
II
I

Return Spring
Inner Hub

~-------
&OJ
-0 p:~e~ 5;,;:;;'g- - - - - - - -
I
I
I Preset Spring ---JI
l_ Joint Spring Clutch

r- _
- --,
I
II Hub Body I
I I
I I
I
I Th~sher
------------------------
Bearing Ring _
J
I
I

I
r - - _ _ _ ---JI
I
:I +Gasket Cover I
I
I
I

FA0216
FA-36 FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD)

REMOVAL OF AUTOMATIC LOCKING HUB

1. REMOVE HUB COVER

2. REMOVE AXLE BOLT WITH WASHER

FA0186

3. REMOVE HUB BODY

(See step 3 of page FA-29)

FAOllS

4. REMOVE BRAKE ASSEMBLY

(a) Using needle-nose pliers, compress and turn the brake
spring to the position of the screw.
NOTE: To prevent the spring tension from weakening,
not overly compress the spring. Also, do not remove the
shoe from the drum.
(b) Using a torx socket, remove the screw, and also the
other two screws in the same manner.
(c) Remove the brake assembly.

5. IF NECESSARY REMOVE ADJUSTING NUT

(a) Using SST, remove the adjusting nut.
SST 09607-60020

DISASSEMBLY OF AUTOMATIC LOCKING HUB

1. REMOVE INNER HUB SUBASSEMBLY FROM HUB BODY
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the inner hub subassembly from the hub.

FA0176
FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD) FA-37

2. REMOVE CLUTCH WITH JOINT SPRING. PRESET

SPRING AND SPRING RETAINER
(a) Using snap ring pliers, extend the joint spring and
release it from the cam follower claw.
NOTE: Be careful not to stretch the spring too much.
(b) Remove the clutch with the joint spring, preset spring
and spring retainer.

3. REMOVE OUTER CAM WITH INNER CAM. CAM

FOLLOWER AND RETURN SPRING
(a) Using SST, attach it to the cam follower claw and then
compress the return spring.
SST 09950-20015
(b) Using snap ring pliers, remove the snap ring.
(c) Remove the outer cam with the inner cam, cam fol-
lower and return spring.

INSPECTION OF AUTOMATIC LOCKING HUB

1. MEASURE BRAKE SHOE THICKNESS
(a) Using pliers, compress the brake spring and slightly
draw it out from the drum.
NOTE: To prevent the spring tension from weakening, do
not overly compress the spring. Also, do not remove the
shoe from the drum.

(b) Measure the shoe thickness.

Minimum thickness: 1.0 mm (0.039 in.)
If the shoe thickness is less than minimum. replace the
brake assembly.
(c) Using pliers, install the brake shoe all the way back.

FA0192

2. INSPECT HUB BODY AND CLUTCH

(a) Check to see that the hub body and clutch engage
and disengage smoothly.
(b) If engage or disengage are not smooth, replace the
hub assembly.

3. INSPECT OTHER PARTS

(a) Check for abnormal wear or scratches on each part.
(b) If there are abnormal wear or scratches, replace the
hub assembly.
FA-38 FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD)

ASSEMBLY OF AUTOMATIC LOCKING HUB

(See page FA-35)
NOTE: The automatic locking hub is maintenance frbv,
and requires no grease except when foreign matter be-
comes attached or cleaning becomes necessary.
When greasing, use the grease listed below:
BENTON TYPE GREASE "PLUSGUARD SG"
ARCO CALDRON EP2
CASTROL WB or Equivalent

1. ADJUST HEIGHT OF SST

(a) Position SST. Place the clutch hub above it and in-
sert the cam follower.
SST 09950-20015
(b) Adjust the height of SST so the cam follower mesh-
es with the inner hub spline and also so the cam fol-
lower claw aligns with the claw of SST.
(c) Remove the cam follower.

2. ASSEMBLE OUTER CAM, INNER CAM

(a) Align the inner cam notch with the outer cam claw
and insert it.
(b) Align the positions of the inner and outer cam.

3. ASSEMBLE RETURN SPRING, CAM FOLLOWER, OUTER

CAM WITH INNER CAM TO INNER HUB
(a) Install the return spring.
NOTE: Set the follower claw to the spring end of the
return spring.
(b) Align the cam follower with the outer cam with inner
cam and install it to the inner hub.
SST
(c) Compress the return spring and attach the cam fol-
lower claw to SST.
SST 09950-20015
(d) Using snap ring pliers, secure the snap ring.

SST
FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD) FA-39

4. INSTALL CLUTCH, JOINT SPRING, PRESET SPRING,

SPRING RETAINER TO INNER HUB
(a) Install the joint spring to the clutch.
(b) Install the spring retainer and preset spring to the
clutch.
(c) Install the joint spring with the clutch to the inner hub.
Using snap ring pliers, expand the spring and attach
it to the cam follower.

5. INSTALL INNER HUB ASSEMBLY TO HUB BODY

(a) Install the thrust washer to the inner hub.
(b) Install the hub body to the inner hub.
(c) Install the thrust washer.
(d) Using snap ring pliers, secure the snap ring.

FA0176
FA-40 FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD)

INSTALLATION OF AUTOMATIC LOCKING HUB

(See page FA-35)

1. IF NECESSARY, INSTALL ADJUSTING NUT

CAUTION: When converting to an automatic locking type
from a type without free wheeling hubs or a manual lock-
ing type, a thrust washer must not be installed.

2. ADJUST PRELOAD
(a) Using SST, torque the adjusting nut.
SST 09607-60020
Torque: 600 kg-cm (43 ft-Ib, 59 Nom)
(b) Turn the hub right and left two or three times.
(c) Loosen the nut until it can be turned by hand.

(d) Using a spring tension gauge, measure the frictional

force of the oil seal.
(e) Retighten the adjusting nut.
Torque: 250 kg-cm (18 ft-Ib, 25 Nom)

3. INSTALL BRAKE ASSEMBLY

(a) Tighten the adjusting nut by the smallest amount pos-
sible and align it in either position shown at left.
(b) Align the brake hub with the spindle groove and fully
insert it to where it is up against the adjusting nut.
Then confirm that the holes of the brake hub and ad-
justing nut coincide.

FA0179 FA0178

(c) Using a spring tension gauge, check the preload.

Preload (rotating):
Frictional force plus 1.0 - 3.9 kg
(2.2 - 8.6 Ib, 10 - 38 N)
If not within specification, adjust with the adjusting nut.
(d) Using needle-nose pliers, compress the brake spr
by the smallest amount possible and turn it to where
the holes of the brake assembly and adjusting nut are
aligned.
FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD) FA-41

(e) Using a torx socket, install the screw, and also the
other two screws in the same manner and equal dis-
tance apart. Torque the screw.
Torque: 70 kg-cm (61 in.-Ib, 6.9 Nom)
CAUTION:
1. Tighten as close to specifications possible.
2. Insure that the brake shoe is as far back into the drum
as it will go.

FA0187 FA0240

4. INSTALL AUTOMATIC LOCKING HUB

(a) Align the spring claw of the brake assembly with the
knock pin.
(b) Align the inner cam protrusion with the hub body
knock pin hole.
(c) Install the hub body. Confirm that the hub body fits
perfectly on the axle hub, and then install the six cone
washers and nuts.
Torque: 315 kg-cm (23 ft-Ib, 31 Nom)
FA0196 FA0197
NOTE: If the hub body and axle hub do not fit perfectly,
reinstall them.
Spline are not aligned, turn the propeller shaft to align them.

5. INSTALL PLATE WASHER WITH NUT

Torque the nut.
Torque: 185 kg-cm (13 ft-Ib, 18 Nom)

6. INSTALL COVER
Torque the bolt.
Torque: 100 kg-cm (7 ft-Ib, 10 Nom)

FA0198
FA-42 FRONT AXLE AND SUSPENTION - Automatic Locking Hub (4WD)

CAUTION: When assembling the automatic locking hub, the

locking of the left and right hubs may not be identical. So, in
the first run after assembly, shift to H4.
OPERATION CHECK
Perform this check with 2 persons.

CONFIRMATION OF FORWARD MOTION

1. CHECK LOCK OPERATION
(a) Shift to H4 and 1st position and slowly proceed for
several meters.
(b) Stop the vehicle.

FA0443

(c) For transfer, shift to H2 and proceed slowly.

During this, one person should check under the vehi-
cle to see that the propeller shaft is turning. If turn-
ing this means that the automatic locking hub '
locked.

FA0444

2. CHECK-FREE OPERATION
(a) Transfer is done in H2, shifting to reverse position and
backing up several meters.

. During this one person should check under the vehi-

cle to see that the propeller shaft is not turning .

FA0445

CONFIRMATION OF REVERSE r\llOTION

Reverse is checked in the same manner.
If the event that checking reveals abnormalities, re-confirm
the assembly and/or installation.
 FRONT AXLE AND SUSPENSION - Front Axle Hub (4WD) FA-43

FRONT AXLE HUB (4WD)

COMPONENTS

--15-5-(-11-,-15-)----~
t:@ c
~---- Brake Caliper
900 (65, 88) I

Inner Bearing

~.
Outer Bearing
Automatic Locking Hub

Oil Seal

Axle Hub with Disc

°f~
Adjustin~O~~'Shf
*Thrust Washer Lock Nut
I I
I
w/o Automatic
Locking Hub

Free Wheeling Hub

Flange and Gasket
Snap Ring

Automatic Locking Hub

* CAUTION: When converting to an auto-

matic locking hub from a hub without
free wheeling hubs or a free wheeling
hub, a thrust washer must not be in-
stalled.
I kg-cm (ft-Ib, Nom)\ : Tightening torque
FAOO85
FAOO86
• : Non-reusable part FA0215
FA-44 FRONT AXLE AND SUSPENSION - Front Axle Hub (4WD)

Front Axle Hub

DISASSEMBLY OF FRONT AXLE HUB
1. REMOVE DISC BRAKE CYLINDER
(a) Using SST, disconnect the brake tube.
SST 09751-36011
(b) Remove the disc brake cylinder.

2. REMOVE FLANGE, FREE WHEELING HUB OR

AUTOMATIC LOCKING HUB
NOTE: For the free wheeling hub. (See page FA-29)
For the automatic locking hub. (See page FA-36)
(a) Remove the cap from the flange.
(b) Using snap ring pliers, remove the snap ring.
(c) Remove the mounting nuts.

FAOO72

(d) Using a tapered punch, tap the slits of the cone wash-
ers and remove them.

(e) Install and tighten the two bolts, and remove the
flange.

FAOO73

3. REMOVE AXLE HUB WITH DISC

(a) Using a screwdriver, release the lock washer.
(b) Using SST, remove the lock nut.
SST 09607-60020
(c) Remove the lock washer and adjusting nut.
(d) Remove the axle hub with the disc.
FRONT AXLE AND SUSPENSION - Front Axle Hub (4WD) FA-45

4. REMOVE INNER BEARING AND OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
(b) Remove the inner bearing from the hub.

FAOO77

INSPECTION AND REPAIR OF FRONT AXLE HUB

1. INSPECT BEARING
Clean the bearings and outer races and inspect them for
wear or damage.

2. REPLACE BEARING OUTER RACE

(a) Using a brass bar and hammer, drive out the bearing
outer race.

(b) Using SST, carefully drive in the new bearing outer

race.
SST 09608-35013

FAOl80

ASSEMBLY OF FRONT AXLE HUB

1. PACK BEARINGS 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.

2. COAT INSIDE OF HUB AND CAP WITH MP GREASE

FA-46 FRONT AXLE AND SUSPENSION - Front Axle Hub (4WD)

3. INSTALL INNER BEARING AND OIL SEAL

Place inner bearing into the hub. Using SST, drive the ,,:1

seal into the hub. Coat the oil seal with MP grease.
SST 09608-35013

4. INSTALL AXLE HUB ON SPINDLE

(a) Place the axle hub on the spindle.
(b) Install the outer bearing and thrust washer.
CAUTION: When converting to an automatic locking hub
FAOO82 FAQ078
from a hub without free wheeling hubs or a free wheeling
hub, a thrust washer must not be installed.

5. ADJUST PRELOAD
(a) Using SST, install and torque the nut.
SST 09607-60020
Torque: 600 kg-em (43 ft-Ib, 59 Nom)
(b) Turn the hub right and left two or three times.
(c) Loosen the nut until it can be turned by hand.

(d) Using a spring tension gauge, measure the frictional

force of the oil seal.
(e) Retighten the adjusting nut.
Torque: 250 kg-em (18 ft-Ib, 25 Nom)

6. INSTALL LOCK WASHER AND LOCK NUT

(Ex. AUTOMATIC LOCKING HUB)
(a) Install the lock washer and lock nut.
(b) Using SST, torque the lock nut.
SST 09607-60020
Torque: 450 kg-em (33 ft-Ib, 44 Nom)
(c) Check that the bearing has no play.
(d) Using a spring tension gauge, check the preload.
Preload (rotating):
Frictional force plus 2.8 - 5.6 kg
(6.2 - 12.3 Ib, 27 - 55 Nom)
If not within specification, adjust with the adjusting nut.
(e) Secure the lock nut by bending one of the lock wash-
\ er teeth inward and another lock washer teeth
outward.

FAQ081
FRONT AXLE AND SUSPENSION - Front Axle Hub (4WD) FA-47

7. INSTALL FLANGE, FREE WHEELING HUB OR

AUTOMATIC LOCKING HUB
NOTE: In case of the free wheeling hub. (See page FA-33)
In case of the automatic locking hub. (See page FA-40)
(a) Place the gasket in position on the axle hub.
(b) Install the flange to the axle hub.
(c) Install six cone washers and nuts.
Torque the nuts.
Torque: 315 kg-em (23 ft-Ib, 31 N ·m)
FAOO83

(d) Install a bolt in the axle shaft and pull it out.

(e) Using snap ring pliers, install the snap ring.
(f) Remove the bolt.
(g) Install the cap to the flange.

FAOO84

8. INSTALL BRAKE CALIPER

(a) Install the brake caliper to the steering knuckle.
Torque the mounting bolts.
Torque: 900 kg-em (65 ft-Ib, 88 N·m)
(b) Using SST, connect the brake tube.
SST 09751-36011
Torque: 155 kg-em (11 ft-Ib, 15 N·m)

8R0157 BR0209

.~ .
FA-48 FRONT AXLE AND SUSPENSION - Steering knuckle and Axle shaft (4WD)

STEERING KNUCKLE AND AXLE

SHAFT (4WD)
COMPONENTS

Front Axle Shaft Steering Knuckle Arm

Oil Seal

1IIIiIIlI~----Bearing

Oil Seal Retainer

':~~
~
Oil Seal Set \
~ Knuckle Spindle

~BearingCap
~

I 530 (38, 521

;---l
250 (18, 251

Dust Cover Dust Seal

Front Axle Hub with Disc

Ikg-em (ft-Ib, N·m) I : Tightening torque

FA0087
• : Non-reusable part FA0231
FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD) FA-49

DISASSEMBLY OF STEERING KNUCKLE

AND AXLE SHAFT
1. REMOVE FRONT AXLE HUB
(See page FA-44)

FAOO88

2. REMOVE KNUCKLE SPINDLE MOUNTING BOLTS

3. REMOVE DUST SEAL AND DUST COVER

4. REMOVE KNUCKLE SPINDLE

Using a brass bar, tap the knuckle spindle off of the steer-
ing knuckle.

FAOO90

5. REMOVE AXLE SHAFT

Position one flat part of the outer shaft upward and pull
out the axle shaft.

6. REMOVE OIL SEAL SET RETAINER

7. DISCONNECT DRAG LINK FROM KNUCKLE ARM

(a) Remove the cotter pin from the drag link end.
(b) Using a screwdriver, remove the plug.
(c) Disconnect the drag link from the knuckle arm.

802215
FA-50 FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD)

8. DISCONNECT TIE ROD FROM KNUCKLE ARM

Using SST, disconnect the tie rod from the knuckle arr--
SST 09611-22012

9. REMOVE KNUCKLE ARM AND BEARING CAP

(a) Remove the knuckle arm and bearing cap mounting
nuts.
(b) Using a tapered punch, tap the slits of the cone wash-
ers and remove them from the knuckle arm.

(c) Using SST, push out the knuckle arm and shims from
the steering knuckle.
SST 09606-60020
NOTE: Use the SST without a collar..

(d) Using SST, push out the bearing cap and shims from
the steering knuckle.
SST 09606-60020

10. REMOVE STEERING KNUCKLE AND BEARINGS

LH NOTE: Mark the removed adjusting shims and bearings
Upper so as to enable reassembling them to their proper positions.

LH
Lower

FA0099

802216
FRONT AXLE AND SUSPENSION - Steering Knukcle and Axle Shaft (4WD) FA-51

INSPECTION AND REPAIR OF STEERING KNUCKLE

AND AXLE SHAFT
1. INSPECT KNUCKLE SPINDLE
Clean the knuckle spindle and inspect the bushing for wear
or damage.

2. REPLACE BUSHING
(a) Using SST, remove the bushing.
SST 09612-65013
(b) Using SST, press a new bushing into the spindle.
SST 09608-35013

3. INSPECT BEARING
Clean the bearings and outer races and inspect them for
wear or damage.

4. IF NECESSARY, REPLACE BEARING OUTER RACE

(a) Using a brass bar, drive out the bearing outer race.
(b) Using SST, carefully drive in a new bearing outer race.
SST 09605-60010

FA0205 FA010l

: ;;5. INSPECT BIRFIELD JOINT INNER PARTS

(a) Hold the inner shaft in a vise.
(b) Place a brass bar against the joint inner race and drive
out the outer shaft.

". , ..
. '~-

802217
FA-52 FRONT AXLE AND SUSPENSION - Steering Knukcle and Axle Shaft (4WD)

(c) Tilt the inner race and cage and take out the bearing
balls one by one.

FA0102

(d) Fit the two large openings in the cage against the pro-
truding parts of the outer shaft, and pull out the cage
and inner race.

FA0103

(e) Take out the inner race from the cage through the large
Large Opening
opening.
(f) Clean and inspect the joint inner parts for wear or
damage.

FAQ10S

(g) Coat the joint inner parts and outer shaft inside with
Large Opening molybdenum disulplaide lithium base grease.
(h) Insert the inner race in the cage through the large
opening.
(i) Position the protruding end the inner race toward the
wide side of the cage.

Protruding End
Narrow Wide FA01Q4

(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.

L---
F
A0--Jl03 802218
FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD) FA-53

(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 bear-
ing balls in the outer shaft. (See step (C))
(m) Pack molybdenum disulphide lithium base grease in
the outer shaft.

M9795

(n) Install the new snap rings on the inner shaft.

(0) Hold the outer shaft in a vise and, while compressing

the snap inner ring, install the inner shaft to the outer
shaft.
(p) Verify that the inner shaft cannot be pulled out.

FA0107

802219
FA-54 FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD)

ADJUSTMENT OF STEERING KNUCKLE

ALIGNMENT AND BEARING PRELOAD
NOTE: Whenever the axle housing or the steering knuck..",
is replaced, the steering knuckle alignment and knuckle
bearing preload are to be adjusted with the SST.
SST 09634-60013

1. ADJUST BEARING PRELOAD

(a) Using SST, remove the oil seal.
FA0108
SST 09308-00010
(b) Coat the knuckle bearings lightly with MP grease.
(c) Mount the SST on the housing with the bearings.
SST 09634-60013

(d) Add preload to the bearings by tightening nut F.

Using a spring tension gauge, measure the preload.
Preload (rotating): 3.0 - 6.0 kg
(6.6 - 13.2 Ib, 29 - 59 N)

(e) Measure distance /I A".

SST

FA0110

(f) Measure distance /18/1.

The difference between A" and "8" is the total ad-
/I

justing shim thickness that is required to maintain the

correct bearing preload.
"B"
TOTAL SHIM THICKNESS "c"

FA0111
802220
 FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD) FA-55

2. ADJUST STEERING KNUCKLE ALIGNMENT

(a) Apply a light coat of red lead on the center part of
rod D.
(b) Press adapters A and B against the housing, press plug
SST C against the rod D, and turn lever G so that a line
will be scribed on rod D.

M9797

(c) Temporarily install the spindle to the knuckle.

Tighten the bolt with two washers.

FAOl12

(d) Dismount the SST from the housing, and mount it

on the knuckle.
SST 09634-60013
NOTE: Use care not to erase the scribed line when dis-
mounting and remounting the SST.
SST '-_....l....lII",-,
Make sure that rod D is in the same vertical direction that
it was when mounted on the housing.

M9798

(e) Turn rod D and scribe another line on it.

Measure distance "D" between the two scribed lines.
The thickness of the steering knuckle lower bearing
shim "E" will be the distance "D" less 3 mm (0.12
in.).

LOWER SHIM THICKNESS "E"

liE" = "0" - 3 mm

M9799
The thickness of the steering knuckle upper bearing shim
"F" will be the difference between the total adjusting shim
thickness "e" and shim thickness "E".

Adjusting shim thickness mm (in.) UPPER SHIM THICKNESS "F"

I Thickness
0.1 (0.004)
0.2 (0.008) . . ' ....
NOTE: Compare "E" and "F" with the thicknesses of the
0.5 (0.020) shims removed at disassembly. If there is considerable
I 1.0 (0.039) difference, remeasure "E" and "F".

802221
FA-56 FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD)

ASSEMBLY OF STEERING KNUCKLE

AND AXLE SHAFT
(See page FA-48)
1. INSTALL OIL SEAL TO AXLE HOUSING
Using SST, drive the oil seal into the axle housing.
SST 09618-60010

2. INSTALL OIL SEAL SET

Install the parts in the following order:
(a) Felt dust seal
(b) Rubber seal
(c) Steel ring

FA0114

3. PACK BEARINGS WITH MP GREASE

(a) Place Molybdenum disulphide lithium base grease in
the palm of your hand.
(b) Pack grease into the bearing, continuing until tl
grease oozes out from the other side.
(c) Do the same around the bearing circumference.

4. INSTALL STEERING KNUCKLE AND BEARINGS

(a) Place the bearings in positions on the knuckle and axle
housing.
(b) Insert the knuckle on the axle housing.

FA0115

5. INSTALL KNUCKLE ARM AND BEARING CAP

(a) Using SST, support the upper bearing inner race.
SST 09606-60020
NOTE: Use SST with a collar.
(b) Install the knuckle arm over the shims that were orit
nally used or were selected as described in adjustmel .
operations.
(c) Using a hammer, tap the knuckle arm into the bear-
ing inner race.
802222
FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD) FA-57

(d) Using SST, support the lower bearing inner race.

SST 09606-60020
NOTE: Use SST with a collar.
(e) Install the bearing cap over the shims that were origi-
nally used or were selected as described in adjustment
operations.
(f) Using a hammer, tap the bearing cap into the bearing
inner race.
(g) Remove SST from the knuckle.

(h) Install the cone washers to the knuckle arm and tor-
que the nuts.
Torque: 975 kg-em (71 ft-Ib, 96 N am)
(i) Install and torque the bearing cap mounting nuts.
Torque: 975 kg-em (71 ft-Ib, 96 N am)

6. MEASURE BEARING PRELOAD

Using a spring tension gauge, measure the preload.
Preload (rotating): 3.0 - 6.0 kg
(6.6 - 13.2 Ib, 29 - 59N)

7. CONNECT TIE ROD TO KNUCKLE ARM

Torque the castle nut and secure it with a cotter pin.
Torque: 930 kg-em (67 ft-Ib, 91 N am)

8. CONNECT DRAG LINK TO KNUCKLE ARM

(a) Insert the drag link on the knuckle arm.
(b) Install the ball stud seat, spring, spring seat and plug
in the drag link end.
(c) Torque the plug completely and then loosen 1-1/3
turns.
(d) Secure the plug with a cotter pin.

FAOO92
FA0146
802223
FA-58 FRONT AXLE AND SUSPENSION - Steering Knuckle and Axle Shaft (4WD)

9. INSTALL OIL SEAL SET RETAINER TO KNUCKLE

10. INSTALL AXLE SHAFT

Position one flat part of the outer shaft upward, and in-
stall the shaft.

11. PACK MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE IN KNUCKLE
Pack Molybdenum disulphide lithium base grease into the
knuckle to about three fourths of the knuckle volume.

FA0147

12. INSTALL KNUCKLE SPINDLE, DUST COVER AND DUST

SEAL WITH NEW GASKETS
(a) Place the gasket in position on the knuckle and install
the spindle.
(b) Place the dust cover, gasket and dust seal on the
spindle.

FA0148

(c) Torque the spindle mounting bolts.

Torque: 530 kg-em (38 ft-Ib, 52 Nom)

13. INSTALL AXLE HUB (See page FA-45)

FAOO88
802224
 FRONT AXLE AND SUSPENSION - Front Differential (4WD) FA-59

FRONT DIFFERENTIAL (4WD)

REMOVAL OF DIFFERENTIAL
(See page RA-7)

1. REMOVE DRAIN PLUG AND DRAIN DIFFERENTIAL OIL

2. REMOVE FRONT AXLE SHAFT (See page FA-49)

3. DISCONNECT PROPELLER SHAFT FROM DIFFERENTIAL

L- ~::.:..J
84055 (See page RA-6)

4. REMOVE DIFFERENTIAL CARRIER ASSEMBLY

DISASSEMBLY OF DIFFERENTIAL
(See page RA-8)

INSTALLATION OF DIFFERENTIAL
(See page RA-19)

1. INSTALL A NEW GASKET

2. INSTALL DIFFERENTIAL CARRIER ASSEMBLY

Install the differential carrier assembly in the axle and in-
stall the ten nuts.

3. CONNECT PROPELLER SHAFT FLANGE TO COMPANION

FLANGE
(a) Align the marks on the flanges and connect the flanges
with four bolts and nuts.
(b) Torque the bolts and nuts.
Torque: 750 Kg-cm (54 ft-Ib, 74 Nom)

4. INSTALL FRONT AXLE SHAFT (See page FA-56)

84055

5. INSTALL DRAIN PLUG AND FILL DIFFERENTIAL WITH

GEAR OIL
Differential oil:
API GL-5 hypoid gear oil
SAE 90 above - 18°C (OOF)
SAE 80W or 80W-90 below - 18°C (OOF)
Capacity: 2.3 liters (2.4 US qts, 2.0 Imp. qts)
Install a filler plug.
Less than 5 mm (0.20 in.)
84060
FA-GO FRONT AXLE AND SUSPENSION - Front Suspension (4WD)

FRONT SUSPENTION (4WD)

COMPONENTS

~e-~••
e
I 260 (19, 25)
~
B
~ 930 (67, 91)
CS
Stabilizer Bar Q Shackle Pin

130 (9, 13)

Hanger Pin

FA0211

Leaf Spring and Shock Absorber

REMOVAL OF LEAF SPRING AND SHOCK
ABSORBER
1. JACK UP AND SUPPORT BODY
(a) Jack up and support the body on the stands.
(b) Lower the axle housing until the leaf spring tension
is free, and keep it at this position.

2. REMOVE SHOCK ABSORBER

FA0151 FA0206
FRONT AXLE AND SUSPENSION - Front Suspension (4WD) FA-61

3. DISCONNECT STABILIZER BAR FROM AXLE HOUSING

FA0152

4. DISCONNECT DRAG LINK FROM KNUCKLE ARM

(a) Remove the cotter pin.
(b) Using a screwdriver, remove the plug.
(c) Disconnect the drag link from the knuckle arm.

5. REMOVE U-BOLTS
(a) Remove the U-bolt mounting nuts.
(b) Remove the spring lower seat.
(c) Remove the U-bolt.
(d) Remove the spring bumper.

6. REMOVE LEAF SPRING

(a) Remove the hanger pin mounting nut.
(b) Remove the shackle pin mounting nut.
(c) Remove the hanger pin.
(d) Remove the shackle pin.
(e) Remove the leaf spring.

REPLACEMENT OF LEAF SPRING

1. BEND OPEN SPRING CLIP
Using a chisel, pry up the spring clip.
FA-62 FRONT AXLE AND SUSPENSION - Front Suspension (4WD)

2. REMOVE CENTER BOLT

~~,
Hold the spring near the center bolt in a vise and remc
the center bolt.

~r FA0157

3. IF NECESSARY, REPLACE SPRING CLIP

(a) Drill off the head of the rivet, and drive it out.
(b) Install a new rivet into the holes of the spring leaf and
clip. Then rivet with a press.

FA0158 FA0159

4. INSTALL SPRING CENTER BOLT

(a) Attach the spring silencer.
(b) Align the leaf holes and secure the leaves with a vi~'
(c) Install and tighten the spring center bolt.
Torque: 450 kg-em (33 ft-Ib, 44 N·m)

5. BEND SPRING CLIP

Using a hammer, bend the spring clip into position.

INSTALLATION OF LEAF SPRING

(See page FA-GO)
1. INSTALL LEAF SPRING
(a) Insert the bushings into the frame and into both ends
of the leaf spring.
(b) Place the leaf spring in position.
(c) Install the hanger pin and tighten the bolt.

FA0209
Torque: 130 kg-em (9 ft-Ib, 13 N ·m)
 FRONT AXLE AND SUSPENSION - Front Susponsion (4WD) FA-63

(d) Finger tighten the hanger pin nut.

(e) Install the shackle pin.
(f) Install the plate and finger tighten the nuts.

FA0162 FA0163

2. INSTALL U-BOLTS
(a) Install the spring bumper and U-bolts onto the leaf
spring.
(b) Install the spring seat and nuts.
NOTE: Be careful of the installation direction of the LH
spring seat.
(c) Tighten the U-bolt mounting nuts.
Torque: 1,250 kg-em (90 ft-Ib, 123 N ·m)

NOTE: Tighten the U-bolts, so that the length of all the

U-bolts under the spring seat are the same.

All same length

FA0208

3. CONNECT DRAG LINK TO KNUCKLE ARM

(See page SR-78)

FAOO92
FA0146

4. CONNECT STABILIZER BAR TO AXLE HOUSING

Tighten the mounting nuts.
Torque: 260 kg-em (19 ft-Ib, 25 N·m)

FA0152 FA0167
FA-64 FRONT AXLE AND SUSPENSION - Front Suspension (4WD)

5. INSTALL SHOCK ABSORBER

(a) Position the shock absorber and install the bushin('lC::
retainers and nut.
Torque: 260 kg-em (19 ft-Ib, 25 N·m)
(b) Install the lower mounting bolt.
Torque: 970 kg-em (70 ft-Ib, 95 N ·m)

FA0151 FA0206

6. STABILIZE SUSPENSION
Remove the stands and bounce the car to stabilize the sus-
pension.

FA0123

7. TIGHTEN HANGER PIN AND SHACKLE PIN

Tighten the hanger pin nut.
Torque: 930 kg-em (67 ft-Ib, 91 Nom)
Tighten the shackle pin nut.
Torque: 930 kg-em (67 ft-Ib, 91 Nom)

/ FA0165 FA0166
FRONT AXLE AND SUSPENSION - Front Suspension (4WD) FA-55

Stabilizer Bar
REMOVAL OF STABILIZER BAR
(See page FA-60)
1. DISCONNECT STABILIZER BAR FROM FRONT AXLE
HOUSING
Remove the nuts, cushions and bolts holding both sides
of the stabilizer bar to the axle housing.

2. DISCONNECT STABILIZER BAR FROM FRAME

Remove both stabilizer bar brackets from the frame, and
remove the stabilizer bar.

INSTALLATION OF STABILIZER BAR

1. PLACE STABILIZER BAR
Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
Finger tighten the bolts.

FA0167 FA0152

U 2. CONNECT STABILIZER BAR TO AXLE HOUSING

Connect the stabilizer bar on both sides to the axle hous-
ing with bolts.
Cushions and nuts as shown.
Torque: 260 kg-em (19 ft-Ib, 25 N·m)

3. TORQUE BRACKET SET BOLTS

Torque: 130 kg-em (9 ft-Ib, 13 N ·m)
FA-66 FRONT AXLE AND SUSPENSION - Front Suspnsion (4WD)

Torque Rod
REMOVAL OF TORQUE ROD
(See page FA-60)

1. DISCONNECT TORQUE ROD FROM AXLE HOUSING

2. DISCONNECT TORQUE ROD FROM FRAME

FA0168 FA0169

REPLACEMENT OF TORQUE ROD BUSHING

1. REMOVE BUSHING
Using SST, press out the bushing
SST 09726-35010 and 09527-10010
NOTE: When inserting and removing the bushing, press
or pull from the chamfered side as shown in the figure.

FA0170 M4256

2. INSTALL BUSHING
Using SST, press in the new bushing
NOTE: Do not use a lubricant when pressing in the
bushing.

INSTALLATION OF TORQUE ROD

(See page FA-60)

1. INSTALL TORQUE ROD

Finger tighten the mounting bolts.

2. STABILIZE SUSPENSION
Bounce the car to stabilize the suspension.

3. TIGHTEN TORQUE ROD MOUNTING BOLTS

Torque: 1,450 kg-em (105 ft-Ib, 142 N·m)

FA0173 FA0174