Page 2140 of 4555

CL-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS008B8
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8CL-9CL-12
EM-81
(QR engine models), EM-222
(YD engine models)
CL-14
CL-16
EM-116
(QR engine models),EM-255
(YD engine models)
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 4 5 5 5 5 5 5 6 6 7
Page 2926 of 4555

FAX-2
PRECAUTIONS
PRECAUTIONSPFP:00001
CautionEDS0005P
When installing rubber parts, final tightening must be carried out under unladen condition* with tires on
ground.
Oil will shorten the life of rubber bushes. Be sure to wipe off any spilled oil.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
After installing removed suspension parts, check wheel alignment and adjust if necessary.
Observe the following precautions when disassembling and servicing drive shaft.
Perform work in a location which is as dust-free as possible.
Before disassembling and servicing, clean the outside of parts.
Prevention of the entry of foreign objects must be taken into account during disassembly of the service
location.
Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.
Page 2946 of 4555

RAX-2
PRECAUTIONS
PRECAUTIONSPFP:00001
CautionEDS00060
When installing rubber parts, final tightening must be carried out under unladen condition* with tires on
ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
After installing removed suspension parts, check wheel alignment and adjust if necessary.
Observe the following precautions when disassembling and servicing drive shaft.
Perform work in a location which is as dust-free and dirt-free as possible.
Before disassembling and servicing, clean the outside of parts.
The disassembly and service location must be clean. Care must be taken to prevent parts from becoming
dirty and to prevent the entry of foreign objects.
Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.
Page 2951 of 4555

WHEEL HUB (2WD)
RAX-7
C
E
F
G
H
I
J
K
L
MA
B
RAX
INSTALLATION
Install in the reverse order of removal. For tightening torque refer to RAX-6, "COMPONENT" .
Perform final tightening of nuts and bolts on each link mounting part (rubber bushing) under unladen con-
ditions with tires on level ground. Check wheel alignment. Refer to RSU-6, "
Wheel Alignment" .
Check wheel sensor harness for proper connection. Refer to BRC-46, "WHEEL SENSORS" .
Disassembly and AssemblyEDS0034I
DISASSEMBLY
CAUTION:
Do not disassemble if wheel bearing has no trouble.
1. Remove caulked of lock nut, and then remove lock nut from axle housing.
2. Remove sensor rotor from axle housing.
3. Set axle housing on vise at point where strut is attached. Using
a sliding hammer [SST] and attachment [SST] to remove wheel
hub from axle housing.
CAUTION:
When placing on vise, be careful not to damage strut
mounting surface of axle housing. Use an aluminum plate
or suitable tool.
4. Using a drift [SST] and a puller (suitable tool), press wheel bear-
ing outer side inner race from wheel hub.
5. Using a flat-bladed screwdriver or similar tool to remove snap
ring from axle housing.
6. Using a drift [SST] and a press wheel bearing from axle housing.
FAC0104D
SDIA2440E
SDIA0155E
Page 2959 of 4555

REAR DRIVE SHAFT
RAX-15
C
E
F
G
H
I
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K
L
MA
B
RAX
Disassembly and AssemblyEDS000FM
DISASSEMBLY
Final Drive Side
1. Remove boot bands.
2. Fix shaft to bench vise.
CAUTION:
When fixing shaft to bench vise, be sure to protect it with a copper or aluminum sheet.
3. Make alignment marks on shaft and spider assembly.
CAUTION:
Use paint or similar substance for alignment marks. Do not
scratch the surface.
4. Remove snap ring. Remove spider assembly from shaft.
5. Remove boot from shaft.
6. Remove old grease on slide joint assembly with paper towels.
7. Remove circular clip and dust shield from slide joint assembly.
Wheel Side
1. As shown in the figure, use a bearing replacer (suitable tool) and
puller (suitable tool) to remove sensor rotor from drive shaft.
2. Fix shaft to bench vise.
CAUTION:
When fixing shaft to bench vise, be sure to protect it with a
copper or aluminum sheet.
3. Remove boot bands. Remove boot from joint sub-assembly.
1. Sensor rotor 2. Joint sub assembly 3. Circular clip
4. Boot bands 5. Boot 6. Shaft
7. Boot 8. Boot bands 9. Spider assembly
10. Snap ring 11. Housing (Slide joint) 12. Circular clip
SDIA0605E
SDIA0594E
SDIA0595E
Page 2965 of 4555

FSU-1
FRONT SUSPENSION
E SUSPENSION
CONTENTS
C
D
F
G
H
I
J
K
L
M
SECTION FSU
A
B
FSU
FRONT SUSPENSION
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools (SST) ..................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
FRONT SUSPENSION ASSEMBLY ........................... 5
Components ............................................................. 5
On-Vehicle Inspection and Service .......................... 6
LOOSENESS, BACKLASH AND DAMAGE OF
MOUNTING PARTS AND CONNECTIONS .......... 6
Wheel Alignment ...................................................... 6
DESCRIPTION ...................................................... 6
PRELIMINARY INSPECTION ............................... 6
INSPECTION OF CAMBER, CASTER, AND
KINGPIN INCLINATION ANGLES ........................ 6
STEERING ANGLE INSPECTION ........................ 7
COIL SPRING AND SHOCK ABSORBER ................. 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8INSTALLATION ..................................................... 8
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
INSPECTION AFTER DISASSEMBLY .................. 8
ASSEMBLY ........................................................... 9
TRANSVERSE LINK ................................................. 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSPECTION AFTER REMOVAL ....................... 10
INSTALLATION ................................................... 10
STABILIZER BAR ..................................................... 11
Removal and Installation ........................................ 11
REMOVAL ........................................................... 11
INSPECTION AFTER REMOVAL ....................... 11
INSTALLATION ................................................... 11
FRONT SUSPENSION MEMBER ............................. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
General Specification ............................................. 13
Wheel Alignment (Unladen) .................................... 13
Ball Joint ................................................................. 13
Wheelarch Height (Unladen) .................................. 13
Page 2966 of 4555
FSU-2
PRECAUTIONS
PRECAUTIONSPFP:00001
CautionEES0006Z
When installing rubber bushings, final tightening must be carried out under unladen conditions with tires
on flat, level ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
“Unladen condition” means that fuel, coolant and lubricant are full and ready for drive. However, spare tire,
jack, and hand tools should be unloaded.
After installing the removed suspension parts, always check wheel alignment and adjust if necessary.
Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening.
Page 2967 of 4555
PREPARATION
FSU-3
C
D
F
G
H
I
J
K
L
MA
B
FSU
PREPARATIONPFP:00002
Special Service Tools (SST)EES00070
Commercial Service ToolsEES000JC
Tool number
Tool nameDescription
HT7252000
Ball joint removerRemoving tie-rod outer and lower ball
joint
ST3127S000
Preload gaugeMeasuring ball joint sliding torque
KV991040S1
CCK gauge attachment
1. KV99104020 Adapter A
2. KV99104030 Adapter B
3. KV99104040 Adapter C
4. KV99104050 Adapter D
5. KV99104060 Plate
6. KV99104070 Guide bolt
7. KV99104080 Spring
8. KV99104090 Center plateMeasuring wheel alignment
ST35652000
Strut attachmentDisassembling and assembling strut
S-NT146
ZZA0806D
ZZA1167D
ZZA0807D
Tool nameDescription
Attachment wheel alignment
a: screw M24 x 1.5 pitch
b: 35 mm (1.38 in) dia.
c: 65 mm (2.56 in) dia.
d: 56 mm (2.20 in) dia.
e: 12 mm (0.47 in) dia.Measure wheel alignment
S-NT148