Page 3537 of 4264

FRONT SUSPENSION 3C-45
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 tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-8840-
2123-0.
Front
901RW154
Front
901RW155
19. Remove rear bushing by using remover 5-8840-
2124-0.
Front
901RW051
Front
901RW052
Page 3538 of 4264

3C-46 FRONT SUSPENSION
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:
Lower control arm
Bushing
Installation
1. Install rear bushing by using installer 5-8840-2124-
0.
Front
901RW053
2. Install front bushing by using installer 5-8840-
2123-0.
Front
901RW156
3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install cam bolt the hole and projection are
upward.
8. Install lower ball joint and tighten it to the specified
torque (12).
Torque: 127 N
m (12.9kg
m/94 lb ft)
9. Install shock absorber and tighten it to the
specified torque (13).
Torque: 93 N
m (9.5kg
m/69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque (14).
Torque: 50 N
m (5.1kg
m/37 lb ft)
11. Install torsion bar arm bracket and tighten it to the
specified torque.
Torque: 116 N
m (11.8kg
m/85 lb ft)
12. Install Torsion bar, refer to Torsion Bar in this
section.
13. Install rear nut and tighten lower link nut finger-
tight (4).
NOTE: Apply oil to the thread.
NOTE: Tighten the nut or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 235 N
m (24.0kg
m/174 lb ft)
450R100002
Page 3539 of 4264
FRONT SUSPENSION 3C-47
14. Install cam plate and nut then tighten lower link nut
finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (3) or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 186 N
m (19.0kg
m/137 lb ft)
NOTE: Adjust the trim height. Refer to Front En
d
Alignment Inspection and Adjustment in Steering
section.
450R100002
Page 3540 of 4264
3C-48 FRONT SUSPENSION
Upper Ball Joint
Upper Ball Joint and Associated Parts
RTW440LF001401
Legend
(1)
Bolt and Nut
(2)
Upper Ball Joint
(3) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2121-0 to remove the uppe
r
ball joint from the knuckle.
Page 3541 of 4264

FRONT SUSPENSION 3C-49
CAUTION: Be careful not to damage the ball joint
boot.
RTW340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450RS023
After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3–3.2 N
m (0.13-0.33kg
m/0.9-
2.4 lb ft)
450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut (1), then tighten them to the
specified torque.
Torque: 57 N
m (5.8kg
m/42 lb ft)
3. 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 (3).
Torque: 98 N
m (10.0kg
m/72 lb ft)
Page 3542 of 4264
3C-50 FRONT SUSPENSION
Lower Ball Joint
Lower Ball Joint and Associated Parts
RTW340LF001601
Legend
(1)
Bolt
(2)
Lower Ball Joint
(3) Nut
(4)
Nut and Cotter Pin
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 tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then
use remover 5-8840-2005-0 to remove the lowe
r
ball joint from the knuckle.
Page 3543 of 4264

FRONT SUSPENSION 3C-51
CAUTION: Be careful not to damage the ball joint
boot.
901RW271
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement .
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450RS026
After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N
m (0.25-0.65kg
m/1.8-
4.7 lb ft)
450RS024
If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut (3) and tighten it to the specified torque.
Torque: 127 N
m (12.9kg
m/94 lb ft)
4. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (4).
Torque: 147 N
m (15.0kg
m/108 lb ft)
Page 3544 of 4264
3C-52 FRONT SUSPENSION
Bump Rubber
Bump Rubber and Associated Parts
RTW340MF001001
Legend
(1)
Bolt
(2)
Bump Rubber
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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 :
Bump Rubber
Installation
1. Install bump rubber.
NOTE: Arrow points to be vehicle outer side of afte
r
assembly to vehicle.
2. Install bolt (1), then tighten it to the specified
torque.
Torque: 42 N
m (4.3kg
m/31 lb ft)