Page 217 of 4264
REAR AXLE 4B-53
4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)
Checkpoint Trouble Cause Countermeasure
Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft
Page 218 of 4264
4B-54 REAR AXLE
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-0079-0
Wheel Pin Remover
9-8522-1269-0
Oil Seal Installer
5-8840-2202-0
Oil Seal Installer
9-8522-1271-0
Support Stand
5-8840-0275-0
Holding Fixture
5-8840-0003-0
Holding Fixture Base
5-8840-0013-0
Remover
5-8840-0014-0
Remover
5-8840-2196-0
Adapter
Page 219 of 4264
REAR AXLE 4B-55
ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-0133-0
Flange Holder
5-8840-2197-0
Separator
5-8840-2164-0
Installer
5-8840-0007-0
Grip
5-8840-2163-0
Installer
5-8840-2166-0
Gauge Plate
5-8840-0129-0
Inner Pilot
5-8840-0127-0
Stud and Nut
5-8840-2085-0
Outer Pilot
Page 220 of 4264
4B-56 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-0126-0
Dial Indicator
5-8840-2167-0
Disc
5-8840-0128-0
Arbor
9-8522-1165-0
Installer
5-8840-2165-0
Installer
5-8840-2293-0
Punch
5-8840-2162-0
Installer
5-8840-2682-0
Sid Gear Holder
Page 221 of 4264

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing............................................................................................................................. 4C1- 7
General Description........................................................................................................... 4C1- 8
Front Drive Axle Assembly ............................................................................................. 4C1- 14
Front Drive Axle Assembly and Associated Parts ................................................... 4C1- 14
Removal ....................................................................................................................... 4C1- 15
Installation ...................................................................................................................4C1- 16
Front Axle Drive Shaft ..................................................................................................... 4C1- 18
Front Axle Drive Shaft and Associated Parts ........................................................... 4C1- 18
Disassembly ................................................................................................................ 4C1- 19
Inspection and Repair................................................................................................. 4C1- 20
Bushing Replacement ............................................................................................... 4C1- 21
Reassembly ................................................................................................................. 4C1- 21
Standard caulk Measure ............................................................................................ 4C1- 22
Differential ...................................................................................................................4C1- 24
Disassembly ................................................................................................................ 4C1- 24
Major Components ................................................................................................ 4C1- 24
Minor Components................................................................................................ 4C1- 27
Inspection and Repair................................................................................................. 4C1- 29
Reassembly ................................................................................................................ 4C1- 31
Minor Components ................................................................................................. 4C1- 31
Major Components ................................................................................................. 4C1- 33
Page 222 of 4264

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4
2 Except High Ride Suspension Model) ................................. 4C1- 42
Disassembly ................................................................................................................ 4C1- 42
Inspection and Repair................................................................................................. 4C1- 45
Reassembly ................................................................................................................. 4C1- 46
Front Hub and Disc (4
4, 4
2 High Ride Suspension, 4
4 Rigid Hub,
4
4 Shift On The Fly Model) ........................................................................................... 4C1- 50
Disassembly ................................................................................................................ 4C1- 50
Inspection and Repair................................................................................................. 4C1- 52
Reassembly ................................................................................................................. 4C1- 53
Front Hub and Disc (4
4 Manual Locking Hub Model) ................................................. 4C1- 57
Disassembly ................................................................................................................ 4C1- 57
Inspection and Repair................................................................................................. 4C1- 60
Reassembly ................................................................................................................. 4C1- 61
Troubleshooting .............................................................................................................. 4C1-67
Special Service Tool ................................................................................................... 4C1-75
Page 223 of 4264
FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 4.100, 4.300, 4.555, 4.777, 5125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).
FRONT PROPELLER SHAFT mm(in)
4
4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Front Axle 194 mm
Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (23.90) (23.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10
Page 224 of 4264
4C1-4 FRONT WHEEL DRIVE
SPECIAL PARTS FIXING NUTS AND BOLTS
FRONT DRIVE AXLE AND PROPELLER SHAFT
N
m (kgf
m/lb
ft)
RTW440LF000101