Page 113 of 513

FRONT
AXLE
FRONT
SUSPENSION
Incorrectly
adjusted
steering
gear
Deformed
steering
linkage
Incorrect
wheel
alignment
Damaged
strut
upper
end
bearing
Damaged
or
stiff
piston
or
shock
absorber
rod
in
the
strut
Interference
of
steering
column
with
turn
signal
switch
Excessive
steering
wheel
play
Noises
Grating
tire
noise
Incorrectly
adjusted
steering
gear
housing
Worn
steering
linkage
Improperly
fitted
gear
box
Incorrectly
adjusted
wheel
bearing
Worn
transverse
link
and
tension
rod
fitting
bushings
Improper
air
pressure
of
tire
Insufficient
lubricating
oil
and
grease
for
suspension
ball
joint
and
steering
linkage
or
their
breakage
Loose
steering
gear
bolts
linkage
and
suspension
groups
Defective
shock
absorber
inside
the
strut
Defective
wheel
bearing
Worn
steering
linkage
Worn
transverse
link
and
tension
rod
fitting
bushings
Broken
collapsed
coil
spring
Loose
strut
mounting
insulator
tightening
nuts
Improper
air
pressure
of
tire
Incorrect
wheel
alignment
Deformed
knuckle
spindle
and
suspension
linkage
FA
27
Adjust
Replace
Adjust
Replace
Replace
Adjust
Adjust
Replace
Retighlen
Adjust
Replace
Adjust
Replenish
lubrication
oil
and
grease
or
re
place
Retighten
Replace
Replace
Replace
Replace
Replace
Retighten
Adjust
Adjust
Replace
Page 114 of 513
CHASSIS
Jumping
of
disc
wheel
Improper
air
pressure
of
tire
Adjust
Unbalanced
wheels
Adjust
Defective
shock
absorber
Replace
Defective
tire
Replace
Deformed
wheel
rim
Replace
Excessively
or
partially
worn
tire
Improper
air
pressure
of
tire
Adjust
Incorrect
wheel
alignment
Adjust
Defective
wheel
bearing
Replace
Incorrect
brake
adjustment
Adjust
Improper
tire
shifting
rotation
Adjust
Rough
and
improper
driving
manner
Drive
more
gently
SERVICE
JOURNAL
OR
BULLETIN
REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
FA
28
Page 119 of 513
CHASSIS
4
Tighten
he
brake
back
plate
to
housing
nunge
bults
and
nuts
with
a
torque
of
1
5
to
2
0
kg
m
10
8
to
145
ft
Ibl
Check
the
rear
axle
shaft
end
playas
shown
in
Figure
RA
9
The
end
plav
should
be
less
than
U
I
nun
0
0039
in
Fig
RA
9
Checking
axle
shaft
end
play
REAR
SUSPENSION
CONTENTS
DESCRIPTION
REAR
SPRING
Removal
I
nspection
and
repair
RA
5
RA
5
RA
5
RA
5
I
n5tallatlon
REAR
SHOCK
ABSORBER
Replacement
Inspection
RA
6
RA
6
RA
6
RA
6
0
tr
1
1
@
5
@
7
I
Leaf
spring
5
Axle
case
8
Hand
brake
wire
2
Front
mounting
6
Gear
carrier
9
Brake
hose
3
Shackle
7
Torque
arrester
10
Bound
bumper
4
Shock
absorber
Fig
RA
10
Rear
suspension
RA
4
Page 120 of 513

REAR
AXLE
REAR
SUSPENSION
DESCRIPTION
Rear
suspension
consists
of
semi
elliptic
leaf
springs
telescopic
hydraulic
shock
absorbers
and
rubber
bumpers
The
rear
spring
center
pin
is
off
set
110
mm
4
33
in
toward
the
front
from
the
center
of
the
spring
This
is
done
to
reduce
spring
wind
up
and
to
decrease
the
arc
while
the
rear
wheel
swings
through
Thereby
minimizing
the
possibility
of
the
rear
suspension
effecting
vehicle
stability
Iso
clamp
devices
are
used
for
attaching
the
axle
housing
to
the
spring
The
leaf
springs
shock
absorbers
and
rear
axle
housing
are
mounted
on
rubber
bushings
at
each
end
to
minimize
noise
and
vibration
of
the
transmission
to
the
car
body
and
passenger
compartment
REAR
SPRING
Removal
1
Jack
up
the
center
of
the
rear
axle
until
the
wheels
are
clear
from
the
ground
Support
the
rear
end
of
the
frame
on
stands
Fig
RA
l1
Rear
spring
U
bo
ts
2
Disconnect
the
shock
absorber
bottom
end
from
the
spring
lower
seat
3
Support
the
rear
axle
housing
with
a
jack
4
Loosen
the
lock
nuts
of
the
rear
spring
U
bolt
and
remove
the
bolts
spring
seat
location
plates
and
seat
pads
5
Loosen
the
three
fixing
nuts
securing
the
front
bracket
remove
the
front
bracket
from
the
leaf
spring
front
eye
and
car
body
and
lower
the
rear
spring
Fig
RA
12
Rear
spring
front
bracket
6
Remove
upper
and
lower
nuts
of
the
rear
shackle
Fig
RA
13
Shackle
Inspection
and
repair
1
Examine
the
spring
leaves
for
fractures
or
cracks
2
Test
spring
and
compare
with
the
specifications
given
in
Service
Data
and
Specifications
If
the
spring
is
found
defective
replace
with
a
new
assembly
3
Check
the
front
pin
shackle
U
bolts
and
spring
seat
RA
5
Page 121 of 513

CHASSIS
for
wear
cra
ks
straightness
and
damaged
thread
s
If
defective
parts
are
found
replace
with
new
ones
4
Inspect
all
rubber
pans
for
wear
damage
separation
and
deformation
Replace
them
if
necessary
Installation
Install
the
rear
spring
in
reverse
sequence
of
removal
noting
the
following
matters
Coat
the
front
bracket
pin
front
bracket
bushing
shackle
pin
and
shackle
bushing
with
a
soap
solution
prior
to
assembly
2
The
front
pin
securing
nut
and
shock
absorber
lower
end
securing
nut
should
be
tightened
with
the
vehicle
unladen
Note
Make
sure
that
the
flange
of
the
shackle
bushing
is
clamped
evenly
on
both
sides
REAR
SHOCK
ABSORBER
Replacement
lack
up
the
center
of
the
rear
axle
and
support
the
axle
housing
with
stands
Fig
RA
14
Removing
the
shock
absorber
ower
end
2
Remove
the
lower
end
of
the
rear
shock
absorber
from
the
spring
seat
See
Figure
RA
14
FiK
RA
15
Removing
shock
absorber
upper
bracket
3
Remove
the
rear
shock
absorber
installing
nut
located
under
the
rear
seat
back
4
Install
rear
shock
absorber
in
reverse
sequence
of
removal
Inspection
Test
the
shock
absorber
and
compare
with
the
specifications
given
in
Service
Data
and
Specifications
Replace
if
necessary
2
Check
for
leakage
cracks
and
the
shafl
for
straightness
3
Inspect
the
rubber
bushings
for
damage
cracks
and
excessive
deformation
Replace
the
defective
parts
jf
necessary
RA
6
Page 122 of 513

REAR
AXLE
REAR
SUSPENSION
SERVICE
DATA
AN
D
SPECIFICATIONS
Shock
absorber
Applied
model
Sedan
Coupe
Van
Stroke
x
max
length
mm
in
167x506
6
57xI9
9
180
x
440
7
09
x
17
3
180
x
468
7
09
x
18
4
Damping
force
at
0
3mjs
Rebound
Compression
kg
Ib
kg
lb
58
128
38
83
8
68
I
50
45
99
2
90
198
45
99
2
Rear
spring
Length
x
widlh
x
thickness
NO
ofleaves
mm
in
6
I
1
llOx50x72
O
6
1
I
ll
x50x7
2
6
3
1
110
x
50
x
13
1
0
24
1
43
7x
1
97x
0
28
2
0
24
2
43
7xI
97x
0
28
1
0
52
1
1
110x50x
6
2
43
7X
1
97
x
0
24
1
7
1
0
28
2
11
1
0
43
1
0
24
1
43
7x
1
97x
0
28
2
Heavy
duty
spring
Camber
Free
mm
in
109
t3
4
29
1
0
1181
11
0
433
109
1
3
4
29
1
0
1181
11
0
433
131
1
5
5
15
tO
1969
11
0
433
Loaded
wi
th
specified
load
mm
in
Specified
load
kg
Ib
In
423
In
423
295
650
Spring
eye
diameter
Front
mm
in
35
1
378
35
1
378
35
1
378
Rear
mm
in
23
0
906
23
0
906
23
0
906
Rear
axle
End
play
mm
in
Less
than
0
1
0
0039
Rear
axle
end
shim
mm
in
0
Q75
0
003
Wheel
bearing
coUar
pressing
force
ton
Ib
3
to
5
6
600
to
11
000
Tightening
torque
Axle
shaft
to
housing
flange
bolt
nuts
kg
m
ft
lb
1
5
to
2
0
10
9
to
14
5
L7
to
2
5
12
3
to
18
1
Differential
carrier
to
housing
bolts
Spring
V
bolts
3
2
to
4
0
23
1
to
28
9
RA
7
Page 123 of 513
CHASSIS
Wheel
nuts
8
0
to
9
0
7
8
to
65
1
Spring
front
bracket
to
body
bolt
nuts
Sedan
and
Coupe
Van
6
to
0
1
6
to
14
5
6
to
I
11
6
to
15
2
Spring
shackle
pin
nuts
1
6
to
0
11
6
to
14
5
Spring
front
pin
nut
Sedan
and
Coupe
Van
6
to
2
0
1
6
to
14
5
3
2
to
4
0
23
1
to
28
9
Shock
absorber
upper
nuts
Sedan
and
Van
Coupe
3
6
to
4
5
26
0
to
32
5
0
to
1
7
2
to
8
6
Shock
absorber
lower
nuts
Sedan
and
Van
Coupe
3
6
to
4
5
26
0
to
32
5
0
to
I
2
7
2
to
8
6
0
6
to
0
8
4
3
to
5
8
Torque
arrester
to
body
bolts
SERVICE
JOURNAL
OR
BULLETIN
REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
RA
8
Page 158 of 513

WHEEL
AND
TIRE
Note
In
replacing
tire
take
extra
care
not
to
damage
tire
bead
rim
flange
and
bead
seat
Do
not
use
tire
irons
to
force
beads
away
from
wheel
rim
flange
that
is
always
use
tire
replace
ment
device
whenever
tire
is
removed
WT005
2
Discard
when
any
of
the
following
trouble
occurs
I
Broken
or
damaged
bead
wire
2
Ply
or
tread
separation
3
Worn
febric
damage
on
tubeless
tire
4
Cracked
or
damaged
side
wall
etc
Fig
WT
4
Wheel
rim
run
out
heck
points
TROUBLE
DIAGNOSES
AND
CORRECTIONS
Condition
Probable
cause
Corrective
action
Wheel
wobbles
Improper
t
re
pressure
Measure
and
adjust
correctly
Damaged
tire
9f
distorted
wheel
rim
Repair
or
replace
UnbalanceiLwheel
Balance
correctly
Loose
wheel
nuts
Retighten
Worn
qr
damaged
wheel
bearing
or
excessive
play
of
wheel
bearing
Correct
play
or
replace
Improper
front
wheel
alignment
Adjust
Worn
or
damaged
ball
joint
and
link
bushing
Replace
Excessive
steering
linkage
play
or
worn
steering
lin
age
Adjust
or
replace
Loose
stcerin
linkage
connection
Retighten
the
nuts
with
the
rated
lightening
torque
or
replace
worn
parts
if
any
Broken
suspension
spring
Replace
Defective
shock
absorber
Replace
Unevenly
or
excessively
worn
tire
Improper
tire
rotation
Conduct
tire
rotation
periodically
Standard
every
10
000
km
6
000
miies
Improper
tire
pressure
Measure
and
adjust
correctly
Unbalanced
wheel
Balance
or
replace
Improperly
adjusled
brake
Readjust
correctly
WT5