
CHASSIS
TROUBLE 
DIAGNOSES 
AND 
CORRECTIONS
When 
a
gear 
carrier
is
suspected 
of
being 
noisy 
it 
is
advisable 
to 
make 
a
thorough 
test 
to 
determine
whether
the 
noise
originates 
in
the 
tires 
road 
surface 
exhaust
universal
joint
propeller 
shaft 
wheel
bearing 
trans
Condition
Noise 
on 
drive
coast 
and
float
Noise
on 
turn
Knocking 
sound
during 
starting 
or
gear
shifting
Seizure 
or
breakage 
mission 
or
gear 
carrier 
Noise
which
originates 
in 
other
places 
cannot 
be 
corrected
by
adjustment 
or
replacement
of
parts 
in 
the
rear 
axle
assembly
Probable 
cause
Shortage 
of 
oil
Incorrect 
tooth 
contact
between
ring 
gear
and 
drive
pinion
Incorrect 
backlash 
between
ring 
gear 
and
drive
pinion
Seized
up 
or
damaged 
ring 
gear 
and 
drive
pinion
Seized
up 
damaged 
or
broken 
drive
pinion
bearing
Seized
up
damaged 
or 
broken 
side
bearing
Loosen
clamp 
bolts 
or
nuts
holding
ring
gear 
bearing
cap 
etc
Seized
up 
damaged 
or 
broken 
side 
and
pinion
gear
I 
Seized
up 
damaged 
or
broken 
side
gear 
and
pinion 
thrust 
washer
Pinion
gears 
too
tight 
on 
their 
shaft
Excessive 
backlash
Incorrect 
backlash
between
ring 
gear 
and
drive
pinion 
or
side 
and
pinion 
gear
Worn
gears 
or
case
Worn
rear 
axle 
shaft 
and 
side
gear 
spline
Pinion
bearing 
under
preload
Loosened
drive
pinion 
nut
Loosen
clamp 
bolts 
or
nuts
holding 
ring
gear 
bearing 
cap 
etc
Shortage 
of 
oil 
or
use 
of 
unsuitable 
oil
Excessively 
small 
backlash
PD 
16 
Corrective 
action
Supply 
gear 
oil 
Rebuild
gear 
carrier 
if
necessary
Adjust 
tooth
contact 
or
replace 
the
hypoid
gear 
set
Adjust 
backlash 
or
replace 
the
hypoid
gear
set 
if
necessary
Replace 
the
hypoid
gear 
set
Replace 
the
pinion 
bearing 
and
defective
parts
Replace 
the 
side
bearing 
and 
defective
parts
Clamp 
them 
to
specified 
torque 
and
replace
defective
parts
Replace 
defective
parts
Replace 
defective
parts
Replace 
defective
parts
Adjust 
backlash
Replace 
worn
parts
Replace 
worn
parts
Adjust 
preload
Repair 
or
replace
Clamp 
them 
or
replace 
if
necessary
Replace 
defective
parts
Adjust 
backlash 
and
replace 
as
required 

FRONT 
AXLE
FRONT 
SUSPENSION
ADJUSTMENT
CONTENTS
ADJUSTMENT 
DATA
ADJUSTMENT 
OF 
WHEEL 
ALIGNMENT
ADJUSTMENT 
OF 
VEHICLE 
LEVEL 
FA 
21
FA 
22
FA 
22
1
Carry 
out
wheel
alignment 
on 
a 
flat 
surface 
with 
tire
air
pressure 
adjusted 
to 
the 
normal
pressure
2
Thoroughly 
check 
all
component 
parts 
of 
the
steering 
and
suspension 
systems 
and
repair 
or
replace
AD
JUSTMENT 
DATA
I
Wheel
alignment 
unladen
Sedan
Coupe
Camber 
5 
to 
2005
Caster 
20 
to 
1050
Toe 
in 
mm 
in 
4 
to
6
0 
16 
to 
0 
24
King 
pin 
inclination 
7055
Steering 
angle 
In 
430
Out 
360
Tire 
Pressure 
Tobe
measured 
when 
tires 
are
cold
kgfcm2 
psi
6 
00 
12 
4PR 
Front 
Rear
For 
normal
speed
Under
100 
km 
h
or 
60 
MPH
For
high 
speed
Over 
100 
km 
h
or 
60 
MPH
15SSR 
12
Option 
Front 
Rear 
1
2 
1 
2
17
17
1
5 
1 
5 
21 
21
I
7
I 
7 
24 
24
Front 
Rear
5 
00 
12 
4 
6 
R 
ULT
Unloaded 
Option
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high 
speed
Over 
100 
km 
h 
or
60 
MPH
Loaded
For 
normal
speed
Under 
100 
km 
h
or 
60 
MPH
FA 
21 
ADJUSTMENT 
OF 
TOE 
IN
ADJUSTMENT 
OF
STEERING 
ANGLE 
FA 
22
FA 
22
defective
parts 
before
starting 
the 
wheel
alignment
3 
The 
camber
and 
caster
angles 
are
preset 
and 
cannot
be
adjusted 
Adjust 
the
toe 
in
and 
vehicle 
level
only
Van
Van
Heavy 
duty 
spring
45 
to 
1045 
45
to 
1045
1005 
to
2005 
40 
to 
1040
5 
to 
7 
5 
to 
7
0 
20 
to 
0
28 
0
20 
to 
0 
28
7045 
7045
430 
430
360 
360
1 
2
1
2 
I 
7
I 
7
1 
5 
1 
5 
21 
21
1
2 
1 
5
17 
21
1 
5 
1 
8 
21 
26
1 
2 
2 
5
17 
36 

FRONT 
AXLE 
FRONT 
SUSPENSION
SERVICE 
DATA 
AND
SPECIFICATIONS
Wheel
alignment 
unladen
Sedan
Van 
Van
Coupe 
Heavy 
duty 
spring
Camber 
50 
to 
2005 
45
to 
1 
45 
45 
to 
1045
Caster 
20 
to 
1050 
r005
to 
2005 
40 
to 
1040
Toe 
in
mm 
in 
4 
t06 
5
to 
7 
5 
to 
7
0 
08 
to 
032 
0 
20
to 
0 
28 
0 
20
to 
0 
28
King 
pin 
inclination 
7055 
7045 
7045
Steering 
angle 
In 
430 
430 
430
Out 
360 
360
360
Tire 
Pressure 
Tobe 
measured 
when 
tires 
are 
cold
kg 
cm2
psi
6 
00 
12
4PR 
Front 
Rear
For
normal
speed
Under 
100 
km 
h 
or 
60 
MPH 
1 
2 
1
2 
17
17 
1 
2 
1
2
17 
17
For
high 
speed
Over 
100 
km
h 
or 
60 
MPH
155SR 
12
Option 
Front 
Rear
5
00 
12 
4 
6
PR 
ULT
Unloaded 
1 
5 
1
5 
21 
21
1
7
1 
7
24 
24
Option 
Front 
Rear 
1 
5 
1 
5 
21 
21
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high 
speed
Over 
100 
km
h 
or 
60 
MPH
Loaded 
1
2
1
5 
17 
21
1
5 
1 
8 
21 
26
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high
speed
Over 
100
km 
h
or 
60 
MPH 
1 
2 
2 
5
17 
36
1
5 
2
8 
21 
40
Coil 
effective 
turns 
6
25
Free
length
Installed
height 
load 
mm 
in
mm 
in
kg 
338
i 
10
133 
0394
203i5 
7 
99 
iO 
1969
200 
441
Spring 
constan 
t
kgfmm 
lb 
in 
1 
6 
89 
6
FA
23 

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 

CHASSIS
1
I 
Front 
3
way 
connector
I 
2
I 
Brake
master
cylinder
I
Fig 
BR 
8 
Front 
3
way 
connector
2 
The 
brake
hose 
rubber 
hose 
is
used
at 
the 
front
strut
assembly 
unit 
and
fear 
axle
housing 
unit 
Remove
the
flare 
nut 
from 
the
brake 
tube 
and
remove 
the 
hose
I
r
I
I
l 
j
u 
l
I
J
II
V
r
1
0
l
I
l
I
I 
Brake 
hose
I 
3
I 
Rear 
axle
hOUSing
2 
Rear 
3
way 
connector
Fig 
BR
9 
Brake 
hose 
and 
3
way 
connector 
around
rear 
ax 
Ie 
housi
g
1 
1 
Brake 
hose
I 
2
I 
Strut
assembly
Fig 
BR 
J 
0 
Brake 
hose
around
front 
strut
assembly 
Inspection
L
Thoroughly 
clean 
the 
brake 
tube
and 
brake 
hose 
and
check 
them 
for
collapsing 
crack 
scar 
and 
rust 
brake
tube 
and 
for 
weakness
expansion 
wear 
etc 
brake
hose
Replace 
if 
defective
2 
Remove
mud 
and 
dust
from 
the
brake 
tube
clip 
unit
and 
check 
the
clip 
If 
the
clip 
covering 
vinyl 
coating 
is
torn
repair
Reinstallation
1 
Provide
a 
sufficient
space 
between 
the 
brake 
lines
and 
other
parts 
so 
that 
the 
brake 
lines
are 
not 
interfered
with 
other
parts 
due 
to 
vibration
during 
driving
SHORT 
NAIL
DOUBLECLI 
S
t
LONG 
NAI 
L
BRAKE 
TUBE
PANEL
CLIP
COATED
WITH
VINYL 
BRAKE
TUBE
Fig 
BR 
l1 
Brake
tube 
installation
clip
2 
When 
the 
brake 
hose
is 
disconnected 
from 
the 
3
way
connector 
on 
the 
rear 
axle
housing 
once 
be 
sure 
to
replace 
the
copper 
packing 
with 
a 
new 
one
3 
Be 
careful 
not 
to
warp 
or
twist 
the 
brake 
hose 
and
particularly 
be 
careful 
not 
to
interfere 
the 
brake 
hose 
with
tires
and
suspension 
components
4
Do 
not
tighten 
the 
brake 
line 
installation 
flare 
nut
forcedly 
or
excessively
BR 
6 

Pedal
yields 
under
slight
pressure
Excessive
pedal
travel
All
brakes
drag
One 
brake
drags
Unbalanced 
brakes 
BRAKE
Use 
of 
a 
brake 
fluid 
with
a
boiling 
point
which 
is 
too 
low
Reservoir
filler
cap 
ven 
t 
hole
clogged 
This
promotes 
a 
vacuum 
in 
master
cylinder 
that
sucks 
in 
air
through 
rear 
seal
Deteriorated 
check 
valve
External
leaks
Master
cylinder 
leaks
through 
primary 
cap
System 
has
not 
been 
bled
Improperly 
adjusted 
clearance
Fluid 
level 
in
master
cylinder 
is 
too 
low
Thermal
expansion 
of 
drums 
due 
to
over
heating
Insufficient 
shoe 
tlrdrum
clearance
Weak 
shoe
return
springs
Brake 
shoe
return 
no 
free
travel
Seized 
master
cylinder 
piston
Loose 
or
damaged 
wheel
bearings
Weak 
broken 
or
unhooked 
brake
shoe
return
springs
Insufficient 
clearance 
between 
brake 
shoe
and 
drum
Grease 
or 
oil 
on
linings
Seized
piston 
in 
wheel
cylinder
Tires
improperly 
inflated
Loose 
wheel
bearing
BR 
25 
Change 
with 
the
specified 
brake
fluid 
and
bleed
system
Clean 
reservoir 
filler
cap 
and 
bleed 
the
system
Fit 
a
new 
check
valve 
and 
bleed 
the
system
Check 
master
cylinder 
piping 
and
wheel
cylinder 
for 
leaks 
and 
make
necessary 
re
pairs
Overhaul 
master
cylinder
Bleed
the
system
Adjust 
shoe
to 
drum
clearance
Full
up 
with
specified 
brake
fluid
Bleed 
the
system 
if
required
Allow 
drums
to 
cool 
off 
Check 
brake
shoe
linings 
and 
drums
Replace 
damaged
parts
Adjust 
clearance
Replace 
the
springs
Adjust 
pedal 
height
Service 
the
master
cylinder 
replace 
the
piston 
and 
bleed
the
system
Adjust 
or
replace 
wheel
bearings
Replace 
spring
Adjust 
brakes
Clean 
brake 
mechanism
replace 
lining 
and
correct 
cause 
of
grease 
or
oil
getting 
on
lining
Service 
the 
wheel
cylinder 
and
bleed 
the
system
Inflate 
tires
to 
correct
pressure
Adjust 
wheel
bearing 

DESCRIPTION
MAINTENANCE
AND 
SERVICE
Tire 
inflation
Tubeless 
tire
repair
Wheel
repair
Wear
DESCRIPTION
TIRE
SIZE 
in
Standard
Optional 
WHEEL
AND 
TIRE
WHEEL 
AND 
TIRE
CONTENTS
WTl
WT2
WT2
WT2
WT2
WT2 
Radial 
tire
Tire 
rotation
INSPECTION
Wheel 
balance
Wheel 
and 
tire
6 
00
12
4PR
Tubeless
6 
00 
12
4PR
with 
tube
6 
00 
12
4PR
Snow 
tire
6
00S 
12
4PR
Sports 
Tubeless
155SR 
12 
Radial
with 
tube
except 
for 
Van
use
5 
00
12
4PRULT 
with
lube
front
for 
Van 
use
5 
00
12
jPRULT 
with 
tube 
rear
TIRE
INFLATION 
PRESSURE 
To 
be
measured 
when
tires 
are
cold
kg 
cm2
psi
6 
00 
I
2 
4PR
Front 
Rear
For 
normal
speed
Under 
100 
km 
h 
or 
60
mph
For
high 
speed
Over 
100
km 
h 
or 
60
mph
155SR 
12
Optional
Front
Rear
5 
00 
I 
2
4 
6PR 
ULT
Optional 
Front 
Rear 
Sedan
Coupe
1 
2 
1 
2
17
17
1 
5 
1
5
22
22
1
7
1 
7 
24 
24 
Van 
Van
Heavy
duty 
spring
1
2 
1
2
I 
7
17
1 
5 
1 
5
22
22
WTl 
WT 
3
WT 
4
WT 
4
WT 
4
WT 
4 

CHASSIS
Unloaded
For
normal
speed
U
nder 
100
km 
h 
or
60
mph
F 
or
high
speed
Over 
100
km 
h
or
60
mph
Loaded
For 
normal
speed
Under 
100
kmlh 
or
60
mph
For
high 
speed
Over 
100
kmlh 
or
60
mph
MAINTENANCE 
AND 
SERVICE
Tire 
inflation
Correct 
tire
pressure 
is
very 
importan 
t 
to
ease 
of
steering 
and
riding 
comfort 
This 
also 
reduces
driving
sound
to 
a 
minimum
resulting 
in
longer 
tire 
that
is
overinfla 
lion 
or
underinflation
promotes 
wear 
at 
center
tread 
or 
shoulder
of 
tire
If 
all 
tires 
are
inspected 
frequently 
and 
maintained
correct 
tire
pressure 
it 
is
possible 
to 
detect
sharp 
material
in 
the 
tread
Also 
the 
above
check 
avoids 
abnormal 
wear
which
invites 
serious 
trouble
If 
tires 
indicate 
abnormal 
or
uneven 
wear 
the
cause 
of 
trouble 
should 
be 
detected 
and
eliminated
After
inflating 
tices
leakage 
in 
valve
should 
be 
check
cd 
Without
valve
caps 
leakage 
will
occur 
due 
to
dirt 
and
water
resulting 
in
underinOation
Accordingly 
whenever
tire
pressure 
is
checked 
be 
sure 
to
secure 
valve
caps 
and
tighten 
firmly 
by 
hand
Tubeless 
tire
repair
In 
urder
to
inspect 
a 
leak
apply 
soapy 
solution 
to 
tire
or
submerge 
tire 
and 
wheel 
in 
the 
water 
after
inflating 
tire
to
specified 
pressure 
Special 
inspection 
for 
leaks 
should 
12
15 
17 
22
1 
5
1 
8
22
25
1
2 
2 
5
I 
7
36
1 
5 
2 
8 
22 
40
be
carried 
out 
around
the 
valve 
wheel 
rim 
and
along 
the
tread 
Exercise
care 
to 
bead 
and 
rim 
where
leakage 
occurs
Wipe 
out 
water
from 
area 
which 
leaks 
air 
bubbles 
and
then 
mark 
the
place 
with 
chalk
After
remuving 
the
materials 
caused
puncture 
seal 
the
point 
to 
avoid
damage 
to 
the
tire 
due 
to
entrance 
of
dirt
and
water 
When
repairing 
the
puncture 
use
the 
tire
repair
kits 
which 
are 
furnished
from 
tire
dealers
following 
the
instructions
provided 
with 
the 
kits 
In
case 
that 
a
puncture 
becomes
large 
or 
there
is
any 
other
damage 
on
the 
tire
fabric
repair 
must 
be
carried 
out
by 
authorized
tire
dealers
Wheel
repair
Inspect 
wheel 
rim
flange 
for 
bend 
or
dents 
If
any 
of
the 
above 
deterioration 
is 
detected
repair 
should 
be 
made
to
secure 
complete
sealing 
The
flange 
should
be 
cleaned
by 
a 
wire 
brush 
when 
rust 
is 
found 
on
the
flange
Furthermore 
if
excessive
pitting 
occurs 
on
the 
rim
eliminate 
it 
with 
a 
file
Wear
Misalignment
When 
the
front 
wheels
align 
in 
excessive 
toe
in 
or
WT 
2