Page 89 of 513
FRONT
AXLE
FRONT
SUSPENSION
FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
Removal
1
Jack
up
the
vehicle
and
support
the
vehicle
with
stands
See
the
Section
GL
2
Remove
the
hub
nuts
and
remOve
the
wheel
3
Remove
the
splash
board
4
Loosen
the
brake
tube
connecting
nut
remove
the
brake
hose
locking
spring
withdraw
the
plate
and
remOve
the
brake
hose
from
the
strul
assembly
bracket
Fig
FA
3
Detaching
brake
hose
Note
Be
careful
not
to
allow
dust
entering
the
brake
hose
5
Remove
the
stabilizer
from
the
body
Fig
FA
4
Removing
stabilizer
6
Remove
cotter
pin
from
the
side
rod
socket
ball
joint
of
the
steering
remove
the
castle
nut
and
separate
the
side
rod
socket
from
the
knuckle
arm
Fig
F
A
5
Removing
side
socket
from
knuckle
arm
7
Loosen
the
tension
rod
securing
bolts
and
nuts
and
remove
the
tension
rod
Fig
F
A
6
RemotJing
tension
rod
FA
3
Page 90 of 513
CHASSIS
8
Support
the
engine
remove
the
engine
mounting
bolts
indicated
by
arrow
mark
and
separate
the
sus
pension
cross
member
from
the
engine
assembly
Ij
i
1
C
w
ii
lJ
c
l
I
N
r
1
a
n
h
JI
Fig
FA
7
Supporting
engine
I
IV
U
II
G
11J
r
j
F
l
I
IV
I
iL
I
0
I
l
tt
I
i
L
I
It
v
i
1
0
b
c
Ii
irti
J
I
I
1
1
Zi
J
l
ll
c
h
f
J
f
C
Fig
FA
8
Removing
engine
mounting
bolts
9
Apply
a
jack
to
the
patch
unit
in
the
center
of
the
suspension
cross
member
to
support
the
member
loosen
the
bolts
indicated
by
arrow
marks
and
separate
the
suspension
cross
member
from
the
body
Fig
FA
9
Jack
up
point
of
suspension
cross
member
Fig
FA
10
Removing
suspension
cross
member
10
Loosen
the
self
locking
nut
on
the
strut
assembly
and
holding
the
strut
assembly
dismount
the
front
suspension
assembly
Fig
F
1
11
Removing
s
flocking
nut
Fig
F
A
12
Removing
front
axle
and
suspension
assembly
FAA
Page 91 of 513

FRONT
AXLE
FRONT
SUSPENSION
Reinstalla
tion
First
check
rubber
parts
such
as
tension
rod
mount
ing
bushing
stabilizer
bar
bushing
etc
for
deterioration
crack
and
other
defective
conditions
and
replace
as
required
2
Reinstall
the
front
axle
and
suspension
assembly
in
reverse
sequence
of
removal
noting
the
following
matters
1
Tighten
the
transverse
link
mounting
bolts
and
stabilizer
bar
body
side
installation
bolt
to
the
raled
tightening
torque
under
the
unladen
vehicle
2
Install
the
stabilizer
bar
so
that
the
white
paint
identification
mark
on
the
stabilizer
bar
is
faced
to
the
left
side
of
the
vehicle
Tighten
the
stabilizer
connecting
rod
with
tightening
torque
from
0
9
to
1
2
kg
m
6
5
to
8
7
ft
lb
through
bushings
The
same
tightening
torque
0
9
to
1
2
kg
m
6
5
to
8
7
ft
Ib
also
applies
the
frame
side
installation
bolt
Two
types
of
transverse
link
side
installation
bolts
length
below
neck
35
mm
1
378
in
and
25
mm
0
984
in
are
used
and
for
both
types
the
tightening
torque
is
2
2
to
3
0
kg
m
15
9
to
217
ft
lb
WH
ITFPAI
Nli
F
OR
IDENjIFICATION
H
Fig
FA
13
Identification
mark
on
stabilizer
I
J
1
Rubber
hush
2
Washer
3
Stabilizer
con
necting
rod
4
Transverse
link
5
Washer
6
Stabilizer
bar
Fig
FA
14
Stabilizer
connecting
rod
bushing
layout
3
Install
the
tension
rod
so
that
LH
mark
on
the
tension
rod
is
faced
to
left
side
of
the
vehicle
and
R
H
mark
is
to
right
as
shown
in
Figure
FA
IS
Make
sure
that
the
body
side
bushing
is
in
the
correct
position
and
tighten
the
tension
rod
securely
with
tightening
torque
from
5
5
to
6
5
kg
m
39
7
to
47
0
ft
lb
ii
j
iY
l
fj
i
f
i
Of
1
0
Fig
FA
15
Mark
on
the
end
of
tension
rod
il
1
Washer
2
Rubber
bush
3
Frame
4
Collar
5
Tension
rod
Fig
FA
16
Tension
rod
body
side
bushing
layout
FA
5
Page 92 of 513

CHASSIS
Tightening
torque
of
front
suspension
cross
member
and
body
is
3
2
to
4
0
kg
m
23
1
to
28
9
ft
Ib
5
Tightening
torque
of
bolt
used
to
secure
the
upper
portion
of
the
strut
assembly
on
the
body
is
1
6
to
2
1
kg
m
11
6
to
15
2ft
lb
FRONT
AXLE
Removal
I
Jack
up
the
vehicle
remove
the
wheel
and
discon
nect
the
brake
hose
at
the
strut
outer
casing
bracket
unit
For
details
see
Removal
of
front
axle
and
suspension
assembly
2
Remove
the
brake
caliper
installation
bolts
and
remove
the
caliper
assembly
Disc
type
brake
3
Remove
the
brake
druOL
Drum
type
brake
4
Remove
the
hub
cap
with
a
flal
headed
screwdriver
or
other
proper
tool
and
hammer
Be
sure
to
tap
lightly
5
Remove
cotter
pin
from
the
wheel
bearing
lock
nut
and
remove
the
lock
nut
6
With
the
wheel
bearing
washer
and
wheel
bearing
installed
on
the
wheel
hub
remove
the
wheel
hub
from
the
spindle
In
the
case
of
a
disc
type
brake
the
wheel
hub
may
be
removed
with
the
disc
rotor
installed
on
the
wheel
hub
Fig
FA
17
Removing
wheel
hub
7
Remove
the
return
spring
and
brake
shoes
remove
brake
disc
assembly
installation
bolts
and
remove
the
brake
disc
assembly
from
the
spindle
Drum
type
brake
Fig
FA
IS
Removing
brake
disc
a
ssembly
8
Remove
baffle
plate
set
screws
and
remove
the
baffle
plate
Disc
type
brake
Fig
FA
19
Removingbaffleplate
9
Utilizing
two
grooves
inside
the
wheel
hub
tap
and
remove
the
wheel
bearing
outer
race
from
the
hub
Fig
FA
20
Removing
wheel
bearing
outer
race
FA
6
Page 93 of 513
FRONT
AXLE
FRONT
SUSPENSION
10
Remove
four
brake
disc
fitting
bolts
and
remove
the
brake
disc
rotor
from
the
wheel
hub
assembly
Disc
type
b
rake
Inspection
1
Grease
seal
I
ycQ
r
A
1
r
j
t
I
I
i
I
When
grease
leakage
is
delected
during
disassembly
replace
2
Replace
the
grease
seal
with
a
new
one
if
worn
or
cracked
Fig
FA
21
Removing
brake
disc
rotor
2
Wheel
bearing
Remove
used
grease
from
the
wheel
bearing
with
solvent
and
inspect
the
bearing
for
operating
condition
from
the
rotation
operating
sound
and
appearance
The
outer
race
may
be
checked
for
the
condition
of
rolling
surface
with
the
race
installed
on
the
wheel
hub
Visual
serviceability
judgement
standard
for
the
wheel
bearing
is
indicated
in
the
following
table
Visual
Serviceability
Judg
ment
Standard
for
Wheel
Bearing
INNER
RACE
SURFACE
OUTER
RACE
FITTED
SURFACE
COLLAR
SURFACE
OUTER
RACE
SURFACE
INNER
RACE
FITTED
ROLLER
ROLLING
SURFACE
SURFACE
SMALL
COLLAR
INNER
RACE
LARGE
COLLAR
ROLLER
SUPPORTER
OUTER
RACE
FA
7
Page 94 of 513

Judgemenr
Flaking
Fig
a
b
Crack
Fig
c
d
Seizure
Scratch
Recess
or
wear
made
by
pressing
or
striking
Fig
e
f
g
Wear
Biting
Fretting
CHASSIS
Unserviceable
May
be
used
when
minor
Rust
should
be
removed
with
1
0
emery
paper
X
6
Race
and
roller
oo
c
u
o
C
U
x
x
x
6
6
6
6
6
x
x
6
6
6
6
6
o
0
0
Cause
Shortened
service
life
due
to
rolling
fatigue
However
this
symptom
occurs
before
the
service
life
The
following
causes
are
considered
Abnormal
load
overload
Improper
handling
or
installing
x
Excessive
tighrening
Excessive
gap
and
a
considerable
shock
received
from
the
outside
Rapid
hear
generation
on
the
race
due
to
creep
Bitten
supporter
with
seizing
rollers
Abnormal
thrust
load
Tapped
with
a
hammer
while
removing
x
In
the
most
cases
seizure
occurs
as
result
of
grown
discoloring
or
flaking
6
Shock
is
given
carelessly
during
installation
Bit
foreign
matter
6
Careless
installation
removal
or
other
rough
handling
scar
due
to
striking
Recess
made
by
foreign
matter
6
Poor
lubricant
quality
or
deteriorated
lubricant
Intrusion
of
dust
Fitted
surface
is
worn
remarkably
Wear
due
to
excessive
preliminary
pressure
6
Excessive
preliminary
pressure
or
faulty
lubrication
6
The
fitted
part
is
discolored
to
brown
ur
black
The
fitted
part
is
discolored
to
brown
or
black
Fretting
corrosion
rust
on
fitted
part
means
fine
relative
slip
on
metal
contact
surface
FA
8
Page 95 of 513

Judgement
Components
Rust
Fig
h
Discoloring
FRONT
AXLE
AND
FRONT
SUSPENSION
x
f
Unserviceable
May
be
used
when
minor
Rust
should
be
removed
with
0
emery
paper
Race
and
roller
00
u
o
o
Ou
u
The
wheel
bearing
is
serviceable
if
discolor
ing
can
be
removed
with
solvent
or
by
polishing
r
c
1
1
Ie
r
r
iJ
a
Inner
race
flaking
d
Cracked
roller
J
I
11
Ji
l
L
i
I
11
J
g
Recess
on
roller
o
0
0
CIl
Cause
Temperature
increase
during
operation
lowers
when
the
bearing
stops
moisture
inside
the
bearing
is
condensed
becoming
fine
drips
and
the
grease
is
moistened
The
bearing
has
been
placed
in
a
highly
moistened
place
for
a
long
period
of
time
Intrusion
of
moisture
chemicals
etc
or
the
bearing
is
touched
with
bare
hand
and
no
rustproof
action
has
been
taken
Slight
discoloring
may
look
like
oxidized
oil
stain
due
to
grease
In
the
most
cases
this
occurs
when
preliminary
pressure
is
too
high
b
Roller
flaking
c
Cracked
inner
race
I
lJ
f
t
j
e
Recess
on
inner
race
f
Recess
on
outer
race
cc
h
Rust
on
outer
race
FADD7
FA
9
Page 96 of 513

CHASSIS
Reinstallation
Reinstall
the
wheel
bearing
in
reverse
sequence
of
removal
2
Install
the
bearing
outer
race
by
the
use
of
a
froot
wheel
bearing
drift
special
tool
ST353
10000
Fig
FA
22
Installing
bearing
outer
race
3
Fill
the
wheel
hub
and
hub
cap
with
multi
purpose
grease
MIL
G2108
or
10924
up
to
the
portion
indicated
by
asterisk
in
Figure
F
A
23
l
I
L
I
I
P
p
r
Fig
FA
23
Greasing
points
of
hub
assembly
4
Fill
the
spaces
between
wheel
bearing
rollers
and
grease
seal
lip
pocket
with
multi
purpose
grease
suf
ficiently
FA
10
Fig
FA
24
Filling
spaces
betweetJ
wheel
bearing
rollers
with
grease
5
Apply
multi
purpose
grease
to
the
spindle
shaft
and
threaded
portions
wheel
bearing
washer
and
wheel
bearing
lock
nut
surfaces
slightly
6
Install
the
wheei
bearing
and
grease
seal
on
the
wheel
hub
and
install
them
on
the
spindle
Note
In
order
to
provide
the
bearing
with
a
proper
prepressure
and
to
extend
the
bearing
service
life
install
the
wheel
bearing
grease
seal
washer
and
lock
nut
carefully
so
that
no
dust
and
foreign
matters
stick
on
grease
applied
to
them
Wheel
bearing
adjustment
I
Tighten
the
wheel
bearing
lock
nut
to
2
2
to
2
4
kg
m
15
9
to
174
ft
lb
tightening
torque
Fig
FA
25
Tightening
wheel
bearing
lock
nut
2
Turn
the
wheel
hub
a
few
turns
both
clockwise
and
counterclockwise
to
settle
down
the
bearing
and
retighten
the
wheel
bearing
lock
nut
to
the
same
tightening
torque
3
Return
the
wheel
bearing
lock
nut
in
range
from
400
to
700
and
coincide
it
with
cotter
pin
hole
on
the
spindle