1977 DATSUN PICK-UP wheel torque

Adjustment
of
front
end

play

Sele
t
front
dutch
thrust
washer

by

calculating
the

following
formula

T

F
C
D

0
2
mm

where

T

F
Required
thickness
of
front

clutch
thrust
washer
mm
in

C
Measured
distance
C
mm
in

D
Measured
distance
D
mm
in

Available
front
clutch
thrust

washer

Thickness
mm
in

1
5
0
059

I
7
0
067

1
9
0
075

2
1
0
083

2
3
0
091

2
5
0
098

27
0
106

Specified
front
end

play

0
5
to
0

8
mm

0
020
to
0

031
in

Notes

a
Correct
thickness
of

bearing
race

and
thrust
washer
is
always
the
one

which
is
nearest
the
calculated
one

b
Installed
thickness
of
oil

pump
gas

ket
is
0
4

mm
0
016
in

10
Check
to
be
sure
that
brake

servo

piston
moves
freely
For
detailed

ptocedure
refer
to

page
AT
42
for

Servo
Piston
Use
care
to

prevent

piston
from

coming
out
of

place
dUI

ing
testing
since
servo
retainer
is
not

tightened
at
this

point
of

assembly

II
Make
sure
that
brake
band
strut

is

correctly
installcd

Torque
piston

stem
to
1
2
to
1
5

kg
m
9
to
11

f1
lb
Back
off
two
full
lurns
and

secure
with
lock
nut
Lock
nut

tight

ening
torque
is
1
5
to
4

0

kg
m

II
to

9

f1
lb
Automatic
Transmission

12
After
inhibitor
switch
is
in

stalled
check
to
be
sure
that
it

op

erates

properly
in

each
range
For

detailed

procedure
refer
to

page
AT

49
for
Checl
ing
and

Adjusting
Inhibi

tor
Switch

13
Check
the

length
L
between

case
end
to
rod
end
ofvacuum
throllle

valve
fully

pushed
in
Then
select

adequate
diaphragm
rod
of
corre

sponding
measured
length
See
Figure

AT
77

Available

diaphragm
rod

Distanl
e

measured
L
ITIm
in

Under25
55

l
OO59

25
65

to
26
05
1

0098
to
1
0256

26
15
to
26
55
1

0295
to
1

0453

26

65
to
27
05
1
0492
to
1

0650

Over
27
15
1
0689

COMPONENT
PARTS

The
transmission
cons
sts
of

many

small

parts
that
are

quite
alike
in

construction
yet
machined
to

very

close
tolerances
When
disassembling

parts
be
sure
to

place
them
in

order
in

part
rack
so

they
can

be
restored
in

the

unit
in
their

proper
positions
It
is

also

very
important
to

perform
func

tianal
test
whenever
it
is

designated

FRONT
CLUTCH

Disassembly

Front

clutch
drum

I

Pinon

lcz

t

AT146

1

Snap
ring

2

Retaining
plate

3
Drive

plate

4

Driven

plate

Fit
AT
78
S
Dished

plate

6

Snap

ring

7

Spring
retainer

8
Coil

spring

Sectional
view

of

front
clu
tch

AT
40
i

i
n
H

I
I

ni
c
A
i

iif

L

1

AT145

Fig
AT
77

Measuring
the
distance

L

Diaphragm
rod

length
mm
in

29
00
142
u

29

5
1161

30
0
1
81

30
5
1201

31
0
I
O

I

Pry
off

snap
ring
D
with

a

suitable
screwdriver
or

a

pair
of

pliers

Remove
a

retaining
plate
@
drive

plate
CID
driven

plate
@
and
dished

plate
@
in

the
order
listed
as
shown

in

Figure
AT
78

I

2

Compress
clutch

springs
using

Clutch

Spring
Compressor

ST25420001
or

51
25420000
Re

move

snap
ring
@
from

spring
re

tainer

using
Snap
Ring
Remover

ST2532000
I

See

Figure
AT
79

AT147

Fig
AT
79

Removing
snap
ring

Note
When
Clutch

Spring
Compres

sor
ST25420000
is
to
be
used
cut

the

toe

tips
of
three

legs
by
a

grinding
wheel
See

Figure
AT
80

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
both

directions

from

each
lever
set

position
and
check

each

continuity

range
It

is
normal
if

the

electricity
is

on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of
the
switch

body
and
then
remove

the
machine
screw
under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of
the

selector
lever

When
the

slot
of
the

shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with
a

clicking
sound

MSlVe
the

switch

slightly
asj
Je
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the
manual
shaft
and

check
their

alignment
by
inserting
a

1
5
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

PROPELLER
SHAFT

8l

DIFFERENTIALCAAR
ER

CHECKING
AND

CQRRECTING

UNBALANCED

PROPELLER
SHAFT
anced

propeller
shaft

proceed
as

follows

I
Remove

undercoating
and
other

foreign
materials
which
could

upset

shaft
balance
and

check
shaft

vibra

tion

by
road
test

2
If

shaft
vibration
is

noted

during
To
check

and
correct
an
unbal

SERVICE
DATA

Pe
issible

dynamic
unbalance

Axi

play
of

spider

journal

Journal

swinging

torque

Propeller
shaft
front

and
rear
out
of

round

Tightening
torque

Shaft
to

conipanion
flange
Gear
carrier
bolt

Self

locking
nut
front
shaft

Flange
yo
e
rear
shaft
to

companion
flange

front
shaft
bolt

Center

bearing
bracket
to
cross
member
bolt
road

test
disconnect

propeller
shaft
at

differential
carrier

companion

flange

rotate

companion

flange
180

degrees

and

reinstall

propeller
shaft

3

Again
check

shaft
vibration
If

vibration
still

persists
replace

pro

peller
shaft

assembly

gr
cm
in
oz

3S
0
49
at
S
800

rpm

mm
in

Less
than
0
02
0
0008

kg
em
in

Ib
Less
than
IS
O
13

mm
in

Less
than
0
6
0
024

kg
m

ft
lb

kg
m

ft
Ib

kg
m
ft
lb

kg
m
ft
lb
2

4
to
3
3
17

to
24

20
0
to
24
0

l4S
to
174

2
4
to

3
3
17
to
24

1

6
to
2
2

12
to
16

TROUBLE

DIAGNOSES
AND

CQRRECTIONS

Condition

Probable

cause

Vibration

during
at

medium

or

high
speed
Worn

or

damaged
universal

joint
needle

bearing

Unbalance

due
to
bent
or

dented

propeller

shaft

Loose

propeller
shaft

installation

Worn
transmission
rear

extension

bushing

Damaged
center

bearing
or
insulator

Tight
universal

joints

Undercoating
or
mud
on
the
shaft

causing

unbalance

Tire
unbalance

Balance

weights
missing

PD
4
Corrective

action

Replace

I
l
eplace

Retighten

Replace

Replace

Impact
yokes
with
hammer
to
free

up

Replace
joint
if
unable
to
free

up
or
if

joint

feels

rough
when

rotated

by
hand

Clean

up
shaft

Balance
wheel
and
tire

assembly
or

replace

from
known

good
vehicle

Replace

PROPELLER

SHAFT

DIFFERENTIAl

CARRIER

TROUBLE
DIAGNOSES

AND

CORRECTIONS

When
a
differential
carrier
is

sus

pected
of

being

noisy
it
is

advisable
to

make
a

thorough
lest

to
determine

whether
the

noise

originates
in
the

Condition

Noise

on
drive

coast

and
float

Noise
on
turn

Knocking
sound

during

starting
or

gear

shifting
tires

road
surface

exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission

or
differential

carrier

Noise
which

originates
in

other

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

Loose
bolts
or
nuts

fIXing
ring
gear
bearing

cap
etc

Seized

up
damaged
or
broken
side
and

pinion
mate

Seized

up
damaged
or
broken

side

gear
and

pinion
thrust
washer

Pinion

mates
too

tight
on

their
shaft

Excessive
backlash

Incorrect

backlash

ring
ar

to
drive

pinion
or
side

gear
to

pinionmate

Worn

gears
or
case

Worn
rear

axle
shaft
and

side

gear
spline

Drjve
pinion

bearing
under

p
reload

Loose
drive

pinion
nut

Loose
bolts

or
nuts

ftxing
ring
gear

bearing

cap
etc

PD

14
places
cannot
be
corrected

by

adjust

ment
or

replacement
of

parts
in
dif

ferential
carrier

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

faulty

parts

Replace
the

side

bearing
and

faulty
parts

Clamp
them

to

specified

torque
and

replace

faulty
parts

Replace

faulty
parts

Replace

faulty
parts

Replace
faulty
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
them
or

replace
if

necessary

The

design
of
the
front

suspension

adopts
the

independent
double

wishbone

type
suspension
used
the

torsion
bar

spring
Both
the

upper
and

lower
links

are
installed
on
the
bracket

which
is
welded
on
the
frame

A
1d
the

above
links

swing
to
allow
the
knuckle

spindle
to
move

freely
in
a
vertical

dimension

The

top
and
bottom

of
the
knuckle

spindle

support
are
connected
to
the

upper
link

through
rubber

bushing
and

to
the
lower
lick

through
screw

bushing

The
tension

rod
held

by
the
brack

ets
on
the
chassis
frame
and
lower
lick

wiih
rubber

bushings
bears
the
force

of
fore
and
aft
direction

The
front
end

of
the
torsion

bar

spring
is

installed
to
the

torque
arm

which

attaches
to
the
lower
link
The

opposite
end
is

installed
to
the

spring

anchor
that

secures
to
chassis
frame

firmly
The
both
ends
of

the
torsion

bar

spring
are
serrated

The

shock
absorber
is

double

action

telescopic

hydraulic
type

The

upper
stem
is
attached
to
the

bracket
of
the
chassis
frame
The

lower
insulated
bracket
is

bolted
to

the
lower
lick

The

bumper
rubber
secured
to
the

bracket
Of
the
frame
limits
the
verti

cal
motion
of
the

suspension
lick

The
knuckle

spindle
is

connecied
to

the
k

ufkle
spindle
arm

by
the

king

pin
The

king

pin
bushings
are
fitted

to

the

upper
and
lower
arm

portIOns
of

the
knuckle

spindle
and

seals
are

provided
at
the

portions
mentioned
to

keep
water
and

dirt
from
enteri

g

The
knuckle
arm
is

connected
to

the
lower
end
of
the
knuckle

spindle

to
transmit

ttLe
movement
of
the

steering
wheel
to
the
knuckle

spindle

The
wheel
hub
is

supported
by
two

taper
roller

bearings
on
the

knuckle

spindle
Tlie
brake
drum
and
wheel
are

secured
to
ihe
hub

by
the

hub
bolts
Front
Axle
Front

Suspension

FRONT
AXLE

REMOVAL
AND

INSTALLATION

Removal

I
Jack

up
and

support
vehicle
on

the
stands

at
the
frame
in

a
safe

manner

2
Remove

front
wheel

3
Re

ove
brake
hose

together
with

connector
from
wheel

cylinder

4
Remove

brake
drum

S

Remove
hub

cap
and
then

remove

cotter

pin
adjusting
cap
and

spindle

nut
from
knuckle

spindle

6
Remove
wheel
hub
outer
and

inner

wheel

bearings
bearing
washer

and

grease
seal
from
knuckle

spindle

7
Remove
brake
disc

assembly
from

the

flange
of
knuckle

spindle

8

Remove
knuckle
arm
from

knuckle

spindle

9
Remove

king
pin
lock
bolt

FA225

Fig
FA
R

mol1ing
king
pin
loch
nut

10
After

removing
air
breather
re

move

plug
from
the

top
of

king
pin

with
the

following
method
Drill
a

10
5
mm
0
413
in

diameter
hole
on

the

plug
thread
hole
with
a

tap

M
12
1
2S
screw
a
bolt
into
threaded

hole
and

pull
out
the

plug

II

Apply
drift
to
the

top
of

king

pin
and
drive
out

king
pin
along
with

lower

plug

12

Tap
spindle
with
a
soft
haJnmer

and

detach
it
from
knuckle

spindle

support
Take

care
not
io

drop
thrust

bearing

FA
3
FA226

Fig
FA
3
R

moving
knuckle

piridle

Installation

Install
front
axle
in
reverse
se

quence
to
removal

by

noting
the
fol

lowing
matters
Furthermore

when

installing
front
axle

lightly
coat

grease

to

sliding
parts

I
Insert

O

ring
on
the
lower
end
of

knuckle

spindle
support
Install
thrust

bearing
and

spindle
shim

together
with

knuckle

spindle
to
knuckle

spindle

support

In

this

operation
select

spindle

shims
to
obtain
the

specified
clearance

between
knuckle

spindle
and
knuckle

spindle
support
To

measure
the
Clear

ance
with

a
filler

gauge
jack
up
the

bottom
of

spindle
slightly

Standard
clearance

0
1

mOl
0
004
in
or
less

Note
Be

sure
to
iristsll
thrust

bearing

to
face
coverea
side

upward

2
Line

up
locking
bolt
hole
of

knuckle

spindle
support
with
the

notch
in

king
pin
and

secure
lock
bolt

Be
sure
to
check
killJckle

spindle
for

smooth
movement
Be

certain
to
move

knuckie

spindle
smoothly
and

reailjust

shim
if

necessary
In
addition
check

bushings
and

king
pin
as

required

3
Press
fit

plug
to
the

upper
of

knuckle

spindle
Then
install
lower

plug
to
the
lower
knuckle

spindle

Note
Make
sure
to

place
lower

plug

conectly

4

Secure
knuckle

arm
to
knuckle

spindle
and

torque
bolt
to
10
3

to

12
1

kg
m
75
to

88
ft

lb
Bend

lock

plate
to

engaged
flats
on
boll
head

Note

When
disassembled
discard

used
lock

plate

5

Pack

grea
to
the

upP
r

and

lower

bushings
on

knuckle

spindle

until

grease
c
omes
out

from

gr
ease

seal

6
Fill
wheel
hub
and

cap
with

grease

up
to
the

described
level
See

Figure
F
A
4

FA141

Fig
FA
4

Gre
ing
wheel
hub

7
Pack

roller
and
cone

assembly

and
the

cavity
of

grease
seal

lip
with

grease

8
Coat

grease
to

the
thread
of

knuckle

spindle

bearing
washer
and

bearing
lock
nul

9
Secure
wheel
hub

bearings
bear

ing
washer
and

spindle
nut
on
knuckle

spindle
and

adju
t

bearing

preload

referring
to

the

paragraph
Wheel

bearing
adjustment

Note
Be

sure
to
obtain

correct

pre

load

on
wheel

bearings
for
the

pu
rpose
of

ving
their

long
life

taking
care
to

keep
wheel

be8rlngs

grease
seal

bearing
washer
and

spin

dle
nut
clean
when

installing
them

WHEEL

BEARING

D

TM
NT

Wrong

adjustment
of
wheel
bear

ing
causes
abnonnal
wear
and
score

on
the

bearings
and
knuckle

spindle
Front
Axle
Front

Suspension

To
attain

proper
preload
on
wheel

bearings

proceed
the

following

opera

tions

I

Torque
spindle
nut

to
3

0
to
3
S

kg
m
22
to

25
ft
lb

using

torque

wrench

FA227

Fig
FA
5

Tightening
apindle
nut

2

Rotate
wheel

hub
a
few
turns

clockwise
and

counterclockwise
to

seat

bearings
Then

retighten
spindle

nut
to
the
same

tightening

torque
Be

certain

to
rotate
hub

smoothly

3

Back
off

spindle
nut
in

range

from
40
to
70

degrees
Locate

adjust

ing
cap
on

spindle
nut

so
as
to

align

the
castellation
on

the

cap
with

the

cotter

pin
hole
in

the

spindle

4

Check
the
hub
rotation

If
hub

rotates

properly
measure

bearing
rota

tion

starting
torque
If
measured

torque
is
deviated
from

the

specified

value
r

place
beari

gs
r
re

dju
st

The

starting

torque
can

be
mea

sured

by
a

spring
balance
as
shown
in

Figure
F

A
6

Spring
balance

indication
at
hub
bolt

New

bearing

2
1

kg
4

Ib
o

ess

Used

bearing

1
0

kg
2
2
lb
or

less

Notes

a

When

measuring
the

starting
force

pull
the

spring
balance
toward
tan

gential
direction

against
normal
line

connected
between
hub
boll
and

spindle
center

b

Axial

play
is

permissible
to
exist

in

0
1
mm
0
004
in
or
less

FA
4
fA22S

Fig
FA
6
Mea

uring
bearing
rotation

atarting
torque

S

Install

a
new
cotter

pin
Bend

the

ends
of
coller

pin
around
the

castel

lated

flange
of

adjusting
cap
Then

install
hub

cap

DISASSEMBLY
AND

ASSEMBLY

Knuckle

spindle

I
Drive

spindle
bushing
and

grease

seal
out
of
knuckle

spindle
with

KiTlg

Pin
Bush
Drift

ST3S380000
Discard

bushing
and

grease
seal
when

disas

sembled

2

After

cleaning
king
pin
bores

thoroughly
install

bushing
carefully

by
using
the
above

special

tpol
Posi

tion

bushing
in

accordance
With
the

instructions
fIlled
in

Figure
F
A

7
and

FA
8

34
mm

1
34
in
Upper
side
in

lower
boss

I

I

1

II

I
Pla
ce
this

position
in
line
with

grease
nipple
hole

Upper
side
in
upper
boss

FA229

Fig
FA
7

King
pin
bu

hing

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