Front
Axle
Front
Suspension
X
Unserviceable
Judgement
6
May
be
used
when
minor
Rust
should
be
removed
with
0
emery
paper
Race
and
roller
C
Cause
Components
E
2
e
0
0
0
0
u
0
CIl
Flaking
X
Service
life
due
to
rolling
fatigue
However
this
symptom
occu
before
the
service
life
The
following
causes
are
considered
Abnormal
load
overload
Fig
a
b
Improper
handling
or
installing
Crack
X
X
X
Excessive
tightening
Excessive
gap
and
a
considerable
shock
received
from
the
outside
Rapid
heat
generation
on
the
race
due
to
creep
Bitten
supporter
with
seizing
rollers
Abnormal
thrust
load
Fig
c
d
Tapped
with
a
hammer
while
removing
Seizure
X
X
X
n
the
most
cases
seizure
occurs
as
the
result
of
grown
discoloring
or
flaking
Scratch
6
6
6
Shock
is
given
carelessly
during
installation
Bit
foreign
matter
Recess
or
wear
6
6
6
Careless
installation
removal
or
other
rough
handling
scar
due
to
made
by
pressing
striking
or
striking
Recess
made
by
foreign
matter
Fig
e
f
g
Wear
6
6
6
Poor
lubricant
quality
or
deteriorated
lubricant
Intrusion
of
dust
Fitted
surface
is
worn
remarkably
Wear
due
to
excessive
preliminary
pressure
Biting
6
6
6
Excessive
preliminary
pressure
or
faulty
lubrication
Fretting
6
6
6
The
fitted
part
is
discolored
to
brown
or
black
Fretting
corrosion
rust
on
fitted
part
means
fine
relative
slip
on
metal
contact
surface
FA
6
Components
Rust
Discoloring
Race
and
roller
u
u
e
2
2
0
3
0
t
c
6
6
6
Fig
h
The
wheel
bearing
is
serv
iceable
if
discoloring
can
be
removed
with
solvent
or
by
polishing
f
a
Inner
race
flaking
t
d
Cracked
roller
iT
t
j
t
11
1
1
t
t
I
l
1
t
F
1ll
JJ
J
t
I
1
ollf
oe
c
g
Recess
on
foDer
Front
Axle
Front
Suspension
Cause
Temperature
increased
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
become
like
oxidized
oil
stain
due
to
grease
In
the
most
cases
this
occurs
when
preliminary
pressure
is
too
high
I
I
I
1
v
i
n
dJ
b
RoUer
flaking
c
Cracked
inner
race
c
f
J
Jt
v
l
e
Recess
on
inner
race
f
Recess
on
outer
race
h
Rust
outer
race
F
A007
Fig
FA
12
Defective
conditions
of
bearing
FA
7
SHOCK
ABSORBER
REMOVAL
AND
INSTAUATION
1
Raise
vehicle
on
a
hoist
or
stands
2
Remove
wheel
3
Hold
the
upper
stem
of
shock
absorber
and
remove
outs
washer
and
rubber
bushing
4
Remove
bolt
from
the
lower
end
of
shock
absorber
FA232
Fig
FA
13
Shock
absorber
S
Retain
lower
rubber
bushing
in
position
install
the
lower
end
of
shock
absorber
to
the
bracket
of
lower
link
and
torque
the
bolt
to
3
1
to
4
1
kg
m
23
to
30
ft
lb
Note
Insert
the
bolt
from
the
front
side
of
vehicle
6
Install
the
upper
end
of
shock
absorber
to
body
bracket
and
tighten
lock
n
Jt
to
the
specifjcations
Tightening
torque
1
6
to
2
2
kg
m
121016
ft
lb
INSPECTION
I
Check
shock
absorber
for
visible
defects
and
oil
leaks
Place
shock
absorber
vertically
in
a
vise
and
hand
stroke
shock
absorber
as
outlined
be
low
Extend
and
compress
shock
ab
sorber
as
faI
as
possible
travelling
as
long
as
possible
If
smooth
hydraulic
resistance
is
not
present
in
bqth
Iirection
replace
absorber
2
Replace
rubber
bushing
if
crack
or
deterioration
is
detected
Front
Axle
Front
Suspension
Specifications
for
shock
absorber
Model
Item
Piston
stroke
mm
in
Damping
force
kg
lb
0
3
m
sec
0
98
ft
sec
j
Rebound
Compression
STABILIZER
REMOVAL
AND
INSTAUATION
I
Raise
vehicle
on
a
hoist
or
stands
2
Remove
wheel
3
Loosen
secUring
nut
at
the
lower
link
side
of
stabilizer
4
Remove
bolt
securing
stabilizer
mounting
bracket
to
chassis
frame
Install
stabilizer
in
the
reverse
se
quence
to
removal
noting
the
follow
ing
instructions
S
Attach
stabilizer
mounting
brack
et
to
chassis
frame
tightening
bolt
to
1
6
to
2
2
kg
m
12
to
16
ft
lb
torque
6
Install
stabilizer
lower
link
side
to
connecting
rod
and
tighten
nut
to
the
specifications
as
shown
in
Figure
FA
14
Then
torque
lock
nut
toJ
6
to
2
2
kg
m
12
to
16
ft
lb
F
A233
Fig
FA
14
Stabilizer
detail
INSPECTION
Check
stabilizer
for
deformation
FA
S
All
models
110
4
3
76
168
38
84
and
rubber
bushings
for
crack
wear
and
deterioration
Replace
if
ne
cessary
TENSION
POD
REMOVAL
AND
INSTALLATION
I
Raise
vehicle
on
a
hoist
or
stands
2
Remove
wheel
3
Remove
nuts
CD
from
both
ends
of
tension
rod
4
Remove
bracket
bolt
@
from
the
front
end
of
tension
rod
and
remove
tension
rod
with
bracket
CD
@
f
A234
Fig
FA
15
Ten
ion
rod
Install
tension
rod
in
reverse
00
qunce
to
removal
noting
the
following
instructions
s
Install
tension
rod
at
rear
end
tighten
nut
to
make
the
distance
of
rubber
bushing
to
be
33
4
mm
1
315
in
and
torque
lock
nut
to
1
6
to
2
2
kg
m
12
to
16
ft
lb
6
Install
tension
rod
bracket
to
chassis
frame
bracket
and
torque
nut
to
1
6
to
2
2
kg
m
12
to
16
ft
lb
When
two
rubber
bushings
are
dif
ferent
in
size
arrange
adjusting
nut
Standard
dimension
is
11
0
mOl
0
433
in
as
shown
in
Figure
FA
16
Torque
lock
nut
to
1
6
to
2
2
kg
m
12
to
16
ft
lb
Il
0
11
0
0
433
t
lP
33
4
1
315
I
11
0
0
433
1
0
11
0
0
433
Adjusting
nut
Y
i
w
36
6
l
441
Unit
mm
in
FA235
Fig
FA
16
Tension
rod
detail
INSPECTION
I
Check
tension
rod
for
bend
and
the
thread
for
faulty
condition
Repair
or
replace
as
required
2
Check
bushing
rubber
for
wear
and
deterioration
Replace
if
neces
sary
TORSION
BAR
SPRING
REMOVAL
AND
INSTALLATION
Removal
1
Raise
vehicle
on
a
hoist
or
stands
2
Remove
wheel
3
Loosen
nuts
at
spring
anchor
bolt
Front
Axle
Front
Suspension
4
Remove
dust
cover
at
the
rear
end
of
torsion
bar
spring
and
detach
snap
ring
S
Withdraw
torsion
bar
spring
rear
ward
after
pulling
ou
t
anchor
arm
realWard
I
nstallalation
Install
torsion
bar
spring
in
the
reverse
sequence
of
removal
noting
the
following
instructions
I
Coat
grease
on
the
serrations
of
torsion
bar
spring
and
install
it
to
torque
arm
Note
Be
sure
to
install
right
and
left
torsion
bar
springs
correctly
They
can
be
identified
with
R
Right
and
L
Left
marked
on
the
end
surface
2
Install
anchor
arm
and
tighten
adjusting
nut
to
obtain
A
dimen
sion
See
Figure
F
A
17
When
anchor
arm
is
properly
adjusted
to
A
specification
upper
link
should
be
in
contact
with
rebound
bumper
rubber
See
Figure
FA
18
Install
snap
ring
and
dust
cover
Temporarily
tighten
adjust
ing
nut
until
B
specification
is
reached
I
I
I
FA236
Fig
FA
17
Installing
anchor
arm
Specifications
for
torsion
bar
spring
Diameter
x
length
mOl
in
Torsional
rigidity
kg
m
deg
ft
lb
deg
FA
9
Anchor
arm
setting
post
ion
A
ISt02Smm
0
59
to
0
98
in
Temporary
tightening
distance
B
60
to
70
mOl
2
36
to
2
76
in
UjPPje
Rebound
bumper
rubber
j
4W
Fig
FA
18
Setting
procedure
Notes
3
A
and
8
specifications
are
only
the
preliminary
rough
settings
directions
for
performing
the
final
adjustment
that
determines
the
ride
height
are
found
on
page
F
A
II
under
Adjustment
b
Discard
old
snap
ring
after
re
moving
it
Replace
with
new
one
during
reinstallation
3
Install
wheel
and
lower
vehicle
Adjust
vehicle
posture
at
curb
weight
full
fuel
tank
no
passengers
refer
ring
to
Adjustment
4
Torque
lock
nut
to
3
1
to
4
1
kg
m
22
to
30
ft
lb
INSPECTION
Check
torsion
bar
spring
for
wear
twist
etc
When
adjusting
vehicle
posture
replace
torsion
bar
spring
with
a
new
one
if
the
specified
height
can
not
be
obtained
All
models
21
9
x
830
0
862
x
32
68
3
74
27
I
UPPER
AND
LOWER
LINKS
REMOVAL
AND
INSTALLATION
Removal
I
Raise
vehicle
on
a
hoist
or
stands
2
Remove
wheel
and
brake
drum
as
an
assembly
3
Remove
wheel
hub
Refer
to
see
tion
Front
Axle
4
Loosen
bolts
retaining
brake
disc
to
knuckle
spindle
and
remove
brake
disc
5
Remove
knuckle
arm
torsion
bar
spimgJ
stabilizer
shock
absorber
and
tension
rod
in
t
ili
order
referring
the
related
sections
6
Remove
upper
fulcrum
bolt
se
curing
knuckle
spindle
support
to
upper
link
assembly
and
disassemble
them
7
Remove
upper
link
bushings
from
knuckle
spindle
support
8
Remove
screw
bushings
from
both
ends
of
lower
link
fulcrum
pin
9
Loosen
nut
at
lower
portion
of
knuckle
spindle
support
from
inside
and
pull
out
cotter
pin
retaining
ful
crum
pin
10
Pull
out
fulcrum
pin
with
drift
and
remove
knuckle
spindle
support
with
knuckle
spindle
from
lower
link
Then
detach
dust
cover
FA237
Fig
FA
19
Removing
fulcrum
pin
II
Remove
bolts
retaining
upper
link
spindle
and
remove
upper
link
spindle
with
camber
adjusting
shims
from
body
bracket
FrClnt
Axle
Front
Suspension
FA238
Fig
FA
20
Removing
upper
link
spindle
12
Remove
nut
retaining
lower
link
spindle
and
remove
lower
link
spindle
Remove
lower
link
with
torque
arm
from
mounting
bracket
13
Using
Transverse
Unk
Bushing
Replacer
ST36070000
to
lower
link
bushing
tap
it
with
a
hammer
and
drive
out
lower
link
bushing
from
bracket
F
A239
Fig
FA
21
Removing
lower
link
bushing
InstallatIon
Install
upper
and
lower
links
in
the
reverse
sequence
to
removal
noting
the
following
instructions
I
When
the
collar
inside
of
lower
link
mounting
bracket
and
bushing
outside
are
rusted
remove
rust
with
emery
paper
2
Fit
lower
link
bushing
into
lower
link
mounting
bracket
using
Trans
verse
Link
Bushing
Replacer
ST36070000
When
tapping
the
frift
with
a
hammer
be
careful
to
hit
the
drift
squarely
3
Secure
lower
link
to
lower
link
bushing
with
lower
link
spindle
and
torque
nut
to
74
to
8
0
kg
m
54
to
S8
ft
Ib
1
4
1n
4
Install
upper
link
spindle
to
upper
link
mounting
bracket
with
used
camber
adjusting
shims
and
bolts
Torque
bolt
to
7
0
to
9
0
kg
m
SI
to
6S
ft
lb
S
Install
dust
seat
to
the
lower
end
of
j
nuckle
spindle
support
6
Coat
grease
on
the
thread
of
fulcrum
pin
and
line
up
the
notch
of
fulcrum
pin
with
knuckle
spindle
sup
port
for
inserting
cotter
pin
Fit
fulcrum
pin
to
spindle
support
with
a
soft
hammer
Secure
cotter
pin
and
torque
lock
nut
to
0
8
to
1
1
kg
m
S
8
to
8
0
ft
lb
7
Coat
grease
to
the
tIuead
portion
of
screw
bushing
inside
liberally
Posi
tion
knuckle
spindle
support
at
the
center
of
lower
link
and
secure
screw
bushings
temporarily
by
hand
Mter
ascertaining
the
dimensions
become
correct
as
shown
in
Figure
F
A
22
torque
screw
bushings
to
20
to
30
kg
m
I4S
to
217
ft
lb
3
9
05
to
11
05
36
5
9
05
to
11
05
0
3563
to
0
4350
1
431
0
3563
to
0
4350
FA240
Fig
FA
22
In
tailing
IICrew
bu
hing
8
Replace
filler
plug
with
grease
nipple
and
pack
grease
until
grease
comes
out
from
dust
cover
Reinstall
filler
plug
9
Upon
installation
make
sure
that
fulcrum
pin
operates
smoothly
with
the
following
torque
Operating
torque
Less
than
0
5
kg
m
3
6
ft
lb
10
Install
upper
link
bushing
to
knuckle
spindle
support
I
I
Install
knuckle
spindle
support
to
upper
link
insert
fulcrum
bolt
and
torque
nut
to
3
9
to
S
3
kg
m
28
to
38
ft
lb
Note
When
installing
fulcrum
pin
insert
it
from
rearward
of
vehicle
12
Install
tension
rod
shock
ab
sorber
I
stabilizer
torsion
bar
spring
and
knuckle
arm
referring
to
the
related
paragraphs
13
Install
brake
disc
to
knuckle
spindle
and
torque
securing
bolt
to
4
2
to
5
0
kg
m
30
to
36
ft
Ib
14
Install
wheel
and
brake
drum
as
an
assembly
and
torque
knuckle
spin
dle
nut
to
8
0
to
9
0
kg
m
58
to
65
ft
Ib
DISASSEMBLY
AND
ASSEMBLY
Upper
link
I
Detach
upper
link
spindle
from
upper
links
and
remove
clamp
dust
cover
and
dust
seal
Secure
upper
link
in
a
vise
and
loosen
screw
bushing
Assemble
link
spindle
in
reverse
sequence
to
disassembling
noting
the
following
instructions
2
Torque
screw
bushing
on
upper
link
to
3S
to
55
kg
m
253
to
398
ft
Ib
Install
new
dust
seal
and
dust
cover
and
secure
them
with
clamp
3
Coat
grease
to
screw
bushing
in
side
and
the
thread
portion
of
upper
link
spindle
liberally
Screw
front
and
rear
links
to
upper
link
spindle
in
the
same
length
so
as
to
obtain
the
speci
fied
figures
as
shown
in
Figure
FA
23
Unit
mm
in
I
44
6
1
156
FA2
Upper
link
and
upper
link
spindle
Fig
FA
23
Front
Axle
Front
Suspension
4
Make
sure
to
operate
upper
link
spindle
smoothly
after
installation
5
Replace
filler
plug
with
grease
nipple
and
pack
grease
until
grease
comes
out
from
dust
cover
Reinstall
f1ller
plug
Lower
link
When
installing
torque
arm
on
lower
link
tighten
it
to
the
following
specifications
Serration
boss
1
8
to
2
6
kg
m
13
to
19
ft
Ib
Arm
head
2
7
to
3
7
kg
m
20
to
27
ft
tb
INSPECTION
Upper
link
spindle
fulcrum
pin
and
screw
bushing
Apply
screw
bushing
to
upper
link
spindle
or
fulcrum
pin
and
measure
axial
end
play
between
them
When
the
end
play
exceeds
0
35
mm
0
0138
in
replace
upper
link
spindle
or
fulcrum
pin
together
with
screw
bushings
Condition
Vehicle
empty
no
payload
Vehicle
loaded
Notes
a
Vehicle
empty
no
payload
consists
of
the
following
conditions
I
Full
tank
of
gasoline
radiator
f1lled
and
engine
oil
level
full
2
Spare
tire
wheel
jack
and
jack
handle
in
design
position
b
Vehicle
loaded
consists
of
the
fol
lowing
conditions
For
all
models
2
persons
and
SIlO
leg
I
103lb
payload
FA
Check
the
screw
of
upper
link
spindle
fulcrum
pin
and
screw
bush
ing
and
repair
or
replace
if
necessary
Note
Discard
dust
cover
and
dust
seal
when
disassembled
ADJUSTMENT
VEHICLE
POSTURE
Vehicle
posture
may
be
incorrect
due
to
weakened
spring
or
other
faulty
condition
The
following
procedures
are
necessary
when
adjustment
is
Ie
quired
That
is
the
vehicle
posture
can
be
adjusted
by
obtaining
only
the
speci
fied
H
dimension
changing
the
length
of
anchor
bolt
I
Raise
front
of
vehicle
on
stands
2
Adjust
H
dimension
with
turn
ing
nut
adjusting
anchor
bolt
H
dimension
changes
approximately
3
5
mm
0
J38
in
vertically
when
adjust
nut
is
turned
one
complete
turn
3
To
make
the
best
vehicle
posture
H
dimension
must
be
in
the
follow
ing
range
H
dimension
mOl
in
All
models
79
to
84
3
11
to
3
31
54
5
2
15
o
i
Fig
FA
24
FA242
Dimension
for
standard
vehicle
postl4re
WHEEL
ALIGNMENT
Correct
front
wheel
alignment
attains
proper
vehicle
handling
charac
teristics
and
the
least
steering
effort
with
a
minimum
amount
of
tire
wear
Before
adjusting
front
wheel
align
ment
make
sure
to
carry
out
a
pre
liminary
inspection
of
the
front
end
parts
for
the
following
conditions
1
Tire
pressure
and
balance
2
Wheel
bearings
and
nuts
3
Steering
gear
play
4
Steering
gear
housing
at
frame
S
Steering
linkage
and
connections
6
Shock
absorber
action
When
using
the
equipment
for
front
wheel
alignment
inspection
follow
the
inst
c
tions
furnished
with
the
equip
ment
Furthennore
the
inspection
should
be
made
with
the
vehicle
level
and
at
curb
weight
Camber
and
caster
Measure
camber
and
caster
and
adjust
them
in
accordance
with
the
following
procedures
if
necessary
Both
camber
and
caster
are
ad
justed
by
increasing
and
decreasing
thickness
of
adjust
shim
inserted
be
tween
upper
link
spindle
and
upper
link
mounting
bracket
To
adjust
caster
make
a
difference
between
thickness
of
front
and
rear
shims
By
adding
a
shim
I
mm
0
039
in
at
front
side
caster
will
be
de
creased
by
33
At
the
same
time
camber
will
also
be
decreased
by
6
S
To
adjust
camber
add
or
remove
an
equal
amount
of
shims
to
front
and
rear
sides
By
adding
a
pack
of
shims
I
mOl
0
039
in
thick
at
both
sides
camber
will
be
decreased
by
13
Shims
are
available
in
I
mm
0
039
in
2
mOl
0
079
in
and
4
mOl
0
157
in
thickness
Front
Axle
Front
Suspension
FA243
Fig
FA
25
Adjustingcamberand
cCJ
ter
Notes
a
Do
not
make
difference
between
front
and
rear
shims
in
thickness
beyond
2
mm
0
079
in
on
a
upper
link
spindle
b
Umit
shim
thickness
for
anyone
stack
within
6
nun
0
236
in
c
Do
not
use
shims
for
anyone
stack
more
the
2
sheets
Toe
in
Measure
toe
in
and
adjust
if
neces
sary
For
adjustment
carry
out
the
follOWIng
procedures
Turn
steering
wheel
to
straight
ahead
position
with
front
wheels
in
the
same
position
Then
check
steer
ing
gear
straight
ahead
position
Loosen
lock
nuts
@
left
hand
thread
and
ID
right
hand
thread
and
turn
cross
rod
CD
to
adjust
toe
in
Turn
cross
rod
to
forward
direction
as
shown
by
arrow
and
toe
in
is
reduced
When
cross
rod
is
turned
to
opposite
side
toe
in
is
increased
After
correct
toe
in
is
obtained
tighten
lock
nut
to
8
0
to
10
0
kg
m
S8
to
72
ft
Ib
r
J
r
CD
0
HI
r
I
e
f
FA244
Fig
FA
26
Adju6ting
toe
in
STEERING
ANGLE
Check
steering
angle
and
use
the
follow
ng
procedures
if
necessary
Loosen
lock
nut
at
stopper
bolt
and
adjust
steering
angle
with
stopper
bolt
Mter
obtaining
correct
steering
angle
secure
lock
nut
firmly
FA245
Fig
FA
27
Adjusting
steering
angle
Model
Item
All
models
mOl
in
1
2
to
3
0
079
to
0
118
Toe
in
degree
2
10
to
16
Camber
lOIS
Io
Caster
10SO
4S
I
60IS
Kingpin
inc
inal10n
I
Inner
wheel
360
10
Steering
angle
I
Outer
wheel
310
10
1
The
extreme
front
and
rear
of
the
tire
center
Unladen
2
The
total
angle
of
the
both
tires
FA
12
Front
Axle
Front
Suspension
SERVICE
DATA
AND
SPECIFICATIONS
King
pin
Clearance
limit
between
the
king
pin
and
bushing
mm
in
0
15
0
0059
Bushing
inner
diameter
when
fitted
mm
in
20
010
to
20
035
0
7878
to
0
7888
Clearance
between
the
knuckle
spindle
support
and
spindle
mm
in
less
than
0
1
0
004
Wheel
bearing
Tightening
torque
kg
m
ft
Ib
3
0
to
3
S
22
to
2S
Spindle
nut
returning
angle
40
to
700
Wheel
bearing
rotation
starting
torque
When
both
bearing
and
seal
are
new
kg
em
in
Ib
less
than
IS
13
0
When
readjusted
kg
em
in
lb
less
than
7
6
1
At
the
hub
bolt
When
both
bearing
and
seal
are
new
kg
lb
less
than
2
1
4
6
When
readjusted
kg
lb
less
than
1
0
2
2
Suspension
link
Upper
link
sliding
resistance
kg
m
ft
Ib
less
than
O
S
3
6
Lower
link
sliding
resistance
kg
m
ft
lb
less
than
O
S
3
6
lightening
torque
kg
m
ft
Ib
Brake
hose
connecting
nut
1
9
to
2
S
14
to
18
Wheel
bearing
lock
nu
t
3
0
to
3
5
22
to
2S
Brake
disc
fIXing
bolt
4
2
to
S
O
30
to
36
Knuckle
arm
fixing
bolt
10
3
to
12
1
74
to
88
King
pin
lock
bolt
2
1
to
2
S
IS
to
18
Torque
arm
Arm
end
2
7
to
3
7
20
to
27
Serration
boss
1
8
to
2
6
13
to
19
Lower
link
spindle
nut
74
to
8
0
S4
to
58
Upper
link
screw
bushing
24
to
35
174
to
2S3
Upper
link
spindle
bolt
fIXing
to
bracket
7
to
9
51
to
6S
Cotter
pin
lock
nut
0
8
to
l
l
5
8
to
8
0
Lower
link
screw
bushing
25
to
32
181
to
231
Fulcrum
bolt
3
9
to
S
3
28
to
38
Tension
rod
Lock
nut
1
6
to
2
2
12
to
16
Bracket
bolt
1
6
to
2
2
12
to
16
Shock
absorber
Lock
nut
of
the
upper
end
1
6
to
2
2
12
to
16
Lower
end
3
1
to
4
1
22
to
30
Stabilizer
Bracket
bolt
1
6
to
2
2
12
to
16
Lock
nut
of
the
anchor
bolt
3
1
to
4
1
22
to
30
Bumper
rubber
bolt
0
8
to
l
l
5
8
to
8
0
FA
13