Page 513 of 2248

G3M1050
19) Install rear cover and tighten bolts to specified torque.
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
F: INSTALLATION
To install, reverse the removal sequence.
1) Install the air breather cap tapping with a plastic ham-
mer.
CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
NOTE:
When installing rear differential front member, do not con-
fuse the installation sequence of the upper and lower stop-
pers.
G3M1026
3) Install DOJ of rear drive shaft into rear differential.
to 3-4 [W2A2].>
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1051
4) Installing procedure hereafter is in the reverse order of
removal.
5) After installation, fill differential carrier with gear oil to
the upper plug level.
CAUTION:
Apply fluid packing to plug.
Fluid packing:
THREE BOND 1205 or equivalent
Oil capacity:
0.8(0.8 US qt, 0.7 Imp qt)
Tightening torque:
44±4 N⋅m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
37
3-4SERVICE PROCEDURE
2. Rear Differential
Page 514 of 2248
3. Rear Differential Front Member
A: REMOVAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
4) Loosen wheel nuts.
5) Jack-up vehicle and support it with sturdy racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.
8) Remove rear differential front member.
NOTE:
When removing rear differential front member, work the
removal procedure as rear differential.
38
3-4SERVICE PROCEDURE
3. Rear Differential Front Member
Page 515 of 2248
G3M1029
B: INSTALLATION
To install, reverse the removal sequence.
1) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
G3M0101
NOTE:
When installing rear differential front member, do not con-
fuse the installation sequence of the stopper.
G3M1026
2) Insert DOJ of rear drive shaft into rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
CAUTION:
Before inserting, replace the differential side oil seal
and the circlip at the end of the spline shaft with a new
one.
3) Installing procedure hereafter is in the reverse order of
removal.
39
3-4SERVICE PROCEDURE
3. Rear Differential Front Member
Page 516 of 2248

1. Rear Differential
Symptom and possible cause Remedy
1. Oil leakage
1Worn, scratched, or incorrectly seated front or side oil seal.
Scored, battered, or excessively worn sliding surface of com-
panion flange.Repair or replace.
2Clogged or damaged air breather. Clean, repair or replace.
3Loose bolts on differential spindle or side retainer, or incor-
rectly fitted O-ring.Tighten bolts to specified torque. Replace O-ring.
4Loose rear cover attaching bolts or damaged gasket. Tighten bolts to specified torque. Replace gasket and apply liquid
packing.
5Loose oil filler or drain plug. Retighten and apply liquid packing.
6Wear, damage or incorrectly fitting for spindle, side retainer
and oil seal.Repair or replace.
2. Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be
repaired or replaced as required.
1Insufficient backlash for hypoid gear. Readjust or replace.
2Excessive preload for side, rear, or front bearing. Readjust or replace.
3Insufficient or improper oil used. Replace seized part and fill with specified oil to specified level.
3. Damage
Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or
replaced as required.
1Improper backlash for hypoid gear. Replace.
2Insufficient or excessive preload for side, rear, or front bear-
ing.Readjust or replace.
3Excessive backlash for differential gear. Replace gear or thrust washer.
4Loose bolts and nuts such as crown gear bolt. Retighten.
5Damage due to overloading. Replace.
4. Noises when starting or shifting gears
Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making noise before dis-
assembly.
1Excessive backlash for hypoid gear. Readjust.
2Excessive backlash for differential gear. Replace gear or thrust washer.
3Insufficient preload for front or rear bearing. Readjust.
4Loose drive pinion nut. Tighten to specified torque.
5Loose bolts and nuts such as side bearing retainer attaching
bolt.Tighten to specified torque.
40
3-4DIAGNOSTICS
1. Rear Differential
Page 517 of 2248

Symptom and possible cause Remedy
5. Noises when cornering
1Damaged differential gear. Replace.
2Excessive wear or damage of thrust washer. Replace.
3Broken pinion mate shaft. Replace.
4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.
1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
2Improper backlash for hypoid gear. Readjust.
3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.
4Seized hypoid gear. Replace hypoid gear set.
5Improper preload for front or rear bearings. Readjust.
6Seized, scored, or chipped front or rear bearing. Replace.
7Seized, scored, or chipped side bearing. Replace.
8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.
1Worn or damaged universal joint. Replace.
2Unbalanced propeller shaft due to bend or dent. Replace.
3Loose installation of propeller shaft. Retighten.
4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.
1Worn or damaged universal joint. Replace.
2Worn spline of sleeve yoke. Replace.
3Loose installation of propeller shaft. Retighten.
4Loose installation of joint. Replace.
5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft
Page 518 of 2248

Symptom and possible cause Remedy
5. Noises when cornering
1Damaged differential gear. Replace.
2Excessive wear or damage of thrust washer. Replace.
3Broken pinion mate shaft. Replace.
4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.
1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
2Improper backlash for hypoid gear. Readjust.
3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.
4Seized hypoid gear. Replace hypoid gear set.
5Improper preload for front or rear bearings. Readjust.
6Seized, scored, or chipped front or rear bearing. Replace.
7Seized, scored, or chipped side bearing. Replace.
8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.
1Worn or damaged universal joint. Replace.
2Unbalanced propeller shaft due to bend or dent. Replace.
3Loose installation of propeller shaft. Retighten.
4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.
1Worn or damaged universal joint. Replace.
2Worn spline of sleeve yoke. Replace.
3Loose installation of propeller shaft. Retighten.
4Loose installation of joint. Replace.
5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft
Page 519 of 2248

1. Suspension
A: SPECIFICATIONS
1. STABILIZER
Bar dia. mm (in)
Front Rear
Sedan 19 (0.75) 15 (0.59)
Wagon 19 (0.75) 15 (0.59)
B: WHEEL ALIGNMENT
Sedan Wagon
FWD AWD FWD AWD
FrontCamber
(tolerance: ±0°30′) 0°05′ 0°05′ 0°05′ 0°05′
Caster
(tolerance: ±1°)3°05′3°05′3°05′3°05′
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Kingpin angle (tolerance: ±1°) 14°15′14°15′14°15′14°15′
Wheel arch height
[tolerance:
+12
24mm (+0.47
0.94in)] mm (in)385 (15.16) 385 (15.16) 385 (15.16) 385 (15.16)
RearCamber
(tolerance: ±0°45′) 0°55′ 1° 0°45′ 0°55′
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Wheel arch height
[tolerance:
+12
24mm (+0.47
0.94in)] mm (in)369 (14.53) 369 (14.53) 379 (14.92) 379 (14.92)
Thrust angle 0°±20′
B4M0182A
NOTE:
Front and rear toe-ins and front camber can be adjusted.
If toe-in or front camber tolerance exceeds specifications,
adjust toe-in and camber to the specification.
The other items indicated in the specification table can-
not be adjusted. If the other items exceeds specifications,
check suspension parts and joint portions of body suspen-
sion parts for deformities; and replace with new ones as
required.
2
4-1SPECIFICATIONS AND SERVICE DATA
1. Suspension
Page 520 of 2248
1. Conventional Suspension
1. FRONT SUSPENSION
B4M0183B
1Crossmember
2Bolt ASSY
3Housing
4Washer
5Stop rubber (Rear)
6Rear bushing
7Stop rubber (Front)
8Ball joint
9Transverse link
10Cotter pin
11Front bushing
12Stabilizer link
13Clamp
14Bushing
15Stabilizer
16Jack-up plate
17Dust seal
18Strut mount
19Spacer
20Upper spring seat
21Rubber seat
22Dust cover
23Helper
24Coil spring
25Damper strut
26Adjusting bolt
27Castle nut
28Self-locking nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 18±5 (1.8±0.5, 13.0±3.6)
T2: 20±6 (2.0±0.6, 14.5±4.3)
T3: 25±4 (2.5±0.4, 18.1±2.9)
T4: 29±5 (3.0±0.5, 21.7±3.6)
T5: 39 (4, 29)
T6: 44±6 (4.5±0.6, 32.5±4.3)
T7: 49±10 (5.0±1.0, 36±7)
T8: 54±5 (5.5±0.5, 39.8±3.6)
T9: 98±15 (10.0±1.5, 72±11)
T10:152±20 (15.5±2.0, 112±14)
T11:186±10 (19.0±1.0, 137±7)
T12:245±49 (25.0±5.0, 181±36)
3
4-1COMPONENT PARTS
1. Conventional Suspension