Page 3529 of 4264
FRONT SUSPENSION 3C-37
Knuckle
Knuckle and Associated Parts
RTW340LF001301
Legend
(1) Torsion Bar
(2 )Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle
(6) Needle Bearing (44 Model Only)
(7) Thrust Washer (44 Model Only)
(8) Oil Seal (4
4 Model Only)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Speed Sensor harness
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
Page 3530 of 4264
3C-38 FRONT SUSPENSION
4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.
901RW271
11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.
901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)
(4
4 Model Only)
RTW340SH00401
Page 3531 of 4264

FRONT SUSPENSION 3C-39
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts:
Knuckle
Knuckle arm
Thrust washer (44 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and
install needle bearing by using installer 5-8840-
2128-0 and grip 5-8840-0007-0. (4
4 Model Only)
(44 Model Only)
901RW275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (44 Model Only)
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5-8840-2127-0 and grip 5-
8840-0007-0 to install oil seal. After fitting the oil
seal to the installer, drive it to the knuckle using a
hammer or bench press until the tool front face
contacts with the thrust washer. (4
4 Model Only)
(44 Model Only)
901RW274
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (9).
Torque: 98 N
m (10.0kg
m/72 lb ft)
6. Install lower ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (2).
Torque: 147 N
m (15.0kg
m/108 lb ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar, refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.
Page 3532 of 4264
3C-40 FRONT SUSPENSION
Upper Control Arm
Upper Control Arm and Associated Parts
RTW440LF001301
Legend
(1)Bolt and Plate
(2)Camber Shims
(3)Caster Shims
(4)Nut Assembly
(5)Upper Control Arm Assembly
(6)Fulcrum Pin
(7)Bushing
(8)Plate
(9)Nut
(10)Speed Sensor harness
(11)Nut and Cotter Pin
(12)Upper Ball Joint, Bolt and Nut
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the brake caliper and disconnect brake
pipe. Refer to Disc Brakes in Brake section.
Page 3533 of 4264
FRONT SUSPENSION 3C-41
4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle
using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.
RTW340SH000401
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut (9).
14. Remove plate (8).
15. Remove bushing (7) by using remover 5-8840-
0256-0.
RTW340SH000501
RTW340SH000601
16. Remove fulcrum pin (6).
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
Upper control arm
Bushing
Fulcrum pin
Page 3534 of 4264
3C-42 FRONT SUSPENSION
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0
and 5-8840-2307-0.
RTW340SH000701
RTW340SH000801
3. Install upper ball joint and tighten it to the specified
torque (12).
Torque: 57 N
m (5.8kg
m/42 lb ft)
4. Install nut and cotter pin then tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (11).
Torque: 98 N
m (10.0kg
m/72 lb ft)
5. Install plate (8).
6. Install nut (9) and tighten fulcrum pin nut finger-
tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N
m (11.0kg
m/80 lb ft)
450R100002
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.
RTW340SH000901
Legend
(1) Projection
(2) Outward
8. Install the caster shims (2) between the chassis
Page 3535 of 4264
FRONT SUSPENSION 3C-43
frame and fulcrum pin.
9. Install the camber shims (1) between the chassis
frame and fulcrum pin.
450R100004
10. Install nut assembly.
11. Install bolt and plate (1), then tighten the bolt to the
specified torque.
Torque: 152 N
m (15.5kg
m/112 lb ft)
NOTE: Apply oil to the thread.
12. Install speed sensor harness.
Page 3536 of 4264
3C-44 FRONT SUSPENSION
Lower Control Arm
Lower Control Arm and Associated Parts
RTW33CLF000201
Legend
(1) Cam Bolt
(2)Bush, Front
(3) Cam Plate and Nut
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint
(8) Bolt, Torsion Bar Arm
(9) Torsion Bar Arm Bracket and Nut
(10) Torsion Bar
(11) Lower Control Arm
(12) Lower Ball Joint and Nut
(13) Shock Absorber, Bolt and Nut
(14) Stabilizer Link and Nut