CHASSIS
Strut
assembly
Strut
outer
diameter
Piston
rod
diameter
mmlin
nml
in
45
17
7
18
0
709
15
0
984
Piston
diameter
mmlin
Damping
force
at
piston
speed
0
3
m
sec
Expansion
kg
Ib
Compression
kg
lb
48
106
22
48
5
Piston
rod
Bend
limit
Wear
limit
mm
in
0
1
0
0039
mm
in
0
025
0
0010
Piston
cylinder
Bend
limit
Wear
limit
inside
mm
in
mm
in
0
2
0
0079
0
1
0
0039
17
0
669
Stabilizer
bar
diameter
mm
in
Front
wheel
bearing
rotation
starting
torque
kg
cm
in
lb
Ball
joint
shaking
torque
kg
cm
in
lb
Ball
joint
end
play
axial
direction
mm
in
9
0
7
8
35
to
60
30
4
to
52
1
0
3
to
1
0
0
0118
to
0
0394
TIGHTENING
TORQUE
Front
axle
Brake
disc
rotor
and
hub
assembly
tightening
torque
Wheel
bearing
lock
nut
Disc
brake
caliper
fixing
bolt
Buffle
plate
installation
screw
Brake
disc
assembly
installation
bolt
kg
m
ft
lb
4
4
to
5
9
31
8
to
42
7
2
2
to
2
4
15
9
to
174
4
6
to
6
1
33
3
to
44
1
0
3
to
0
4
2
1
to
2
9
2
7
to
3
7
19
5
to
26
8
Strut
assembly
Gland
packing
tightening
torque
Piston
rod
self
locking
nut
Upper
support
nut
8
0
to
11
0
57
8
to
79
5
3
6
to
4
5
26
0
to
32
5
1
6
to
2
1
I
1
6
to
15
2
Transverse
link
and
ball
joint
Bolts
used
to
install
the
knuckle
arm
to
strut
Ball
joint
castle
nut
Bolts
used
to
install
the
transverse
link
to
ball
4
6
to
6
1
33
3
to
44
1
5
5
to
7
4
39
8
to
53
5
FA
24
Vehicle
pulls
to
right
or
left
When
driving
with
hands
off
the
steering
wheel
over
a
flat
road
the
vehicle
gently
swerves
to
right
or
left
Note
A
defective
rear
suspension
may
also
be
the
cause
of
this
trouble
and
therefore
see
also
the
chapter
dealing
with
the
rear
suspension
Instability
of
vehicle
Stiff
steering
wheel
checking
up
procedure
Jack
up
front
wheels
detach
the
steering
gear
and
operate
the
steering
wheel
and
If
it
is
light
check
steering
linkage
and
suspension
groups
If
it
is
heavy
check
steering
gear
and
steering
colunm
groups
CHASSIS
Malfunction
of
shock
absorber
inside
the
strut
or
loose
installation
bolts
Unbalance
of
vehicle
level
Improper
air
pressure
of
tire
or
insuf
ficient
tightening
of
wheel
nuts
Difference
in
height
of
right
and
left
tire
treads
Incorrect
adjustment
or
abrasion
of
front
wheel
bearing
Collapsed
or
twisted
front
spring
Incorrect
wheel
alignment
Incorrect
brake
adjustment
binding
Worn
rubber
bushings
for
transverse
link
and
tension
rod
Deformed
steering
linkage
and
suspension
link
Unbalanced
vehicle
level
Improper
air
pressure
of
tire
Worn
rubber
bushings
for
transverse
link
and
tension
rod
Incorrect
wheel
alignment
Worn
or
deformed
steering
linkage
and
suspension
link
Incorrect
adjustment
of
steering
gear
Deformed
unbalanced
wheel
Improper
air
pressure
of
tire
Insufficient
lubricants
or
mixing
im
purities
in
steering
linkage
or
excessively
worn
steering
linkage
Stiff
or
damaged
suspension
ball
joint
or
lack
of
grease
Worn
or
incorrectly
adjusted
wheel
bearing
Worn
damaged
steering
gear
and
bearing
FA
26
Replace
or
retighten
Correct
the
unbalance
Adjust
or
tighten
Replace
tires
Adjust
or
replace
Replace
Adjust
Adjust
Replace
Replace
Correct
the
unbalance
Adjust
Adjust
Adjust
Replace
Adjust
Correct
or
replace
Adjust
Repl
nish
grease
or
re
place
the
part
Replace
Replace
or
adjust
Replace
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
CHASSIS
2
Remove
the
wheel
cover
and
nuts
Remove
the
road
wheel
and
b
rake
drum
If
brake
linings
should
hold
the
drum
slacken
off
the
brake
shoe
adjuster
a
few
notches
3
Disconnect
the
brake
pipe
CD
from
the
wheel
cylinder
Plug
up
the
open
end
of
the
brake
pipe
with
a
plastic
cover
or
wooden
peg
to
prevent
foreign
matters
from
entering
the
hydraulic
line
Fig
RA
2
Disconnecting
brake
Une
4
Straighten
the
cotler
pin
@
and
remove
it
Remove
clevis
pin
and
disconnect
the
hand
brake
cable
from
the
hand
brake
lever
Remove
the
hand
brake
return
spring
CID
5
Remove
the
four
bolts
securing
the
brake
back
plate
to
the
axle
housing
Draw
out
the
axle
shaft
assembly
together
with
the
brake
back
plate
using
sliding
hammer
ST36230000
and
rear
axle
stand
ST07640000
ST07640000
I
Fig
RA
3
Removing
axle
shaft
6
If
either
the
axle
shaft
or
rear
wheel
bearing
is
to
be
replaced
remove
the
bearing
locking
collar
by
nicking
it
deeply
with
a
cold
chisel
in
several
places
It
will
then
slide
easily
Be
careful
not
to
damage
the
axle
shaft
with
the
chiscl
Set
the
bearing
remover
ST37130000
and
remove
the
wheel
bearing
The
removed
bearing
collar
should
be
discarded
and
should
not
be
reused
Fig
RA
4
Removing
bearing
collar
Fig
RA
5
Removing
wheel
bearing
7
It
is
recommendable
that
the
oil
seal
be
replaced
whenever
the
rear
axle
shaft
is
replaced
To
remove
the
oil
seal
use
a
suitable
bar
such
as
a
screwdriver
RA
2
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
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
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
CHASSIS
FRONT
DRUM
BRAKE
14
I
l
Fig
BR
14
Front
drum
brake
components
Removal
and
disassembly
Jack
up
the
vehicle
support
with
a
stand
and
remove
the
wheel
cover
and
tire
2
Remove
the
brake
drum
and
remove
the
hub
cap
and
hub
assembly
from
the
spindle
3
Disconnect
the
brake
tube
at
the
bracket
unit
of
the
strut
assembly
For
the
details
refer
to
Section
FA
R
W
i
1
t
V
t
1
1
d
j
2
rl
s
J
J
i
Z
j
Fig
BR
15
Front
drum
brake
4
Unhook
the
return
spring
and
remove
the
brake
shoe
assembly
5
Disconnect
the
bridge
tube
from
lhe
fore
and
after
wheel
cylinders
I
I
After
wheel
cylinder
Bridge
tube
I
3
I
Fore
wheel
cylinder
Fig
BR
16
Fore
and
after
wheel
cylinders
and
bridge
tube
6
Remove
the
installation
bolts
and
remove
the
fore
and
after
wheel
cylinders
BR
B