RSU-8
REAR SUSPENSION ASSEMBLY
Revision: 2006 January2006 M35/M45
Refer to GI section for symbol marks in the figure. Refer to GI-9, "HOW TO USE THIS MANUAL" .
Removal and InstallationNES000J9
REMOVAL
1. Remove tire with a power tool.
2. Remove brake caliper with a power tool. Hang it in a place where it will not interfere with work. Refer to
BR-29, "
REAR DISC BRAKE" .
CAUTION:
Do not depressing brake pedal while brake caliper is removed.
3. Put matching marks on both disc rotor and the wheel hub and
bearing assembly, then remove disc rotor.
4. Remove rear under cover.
5. Remove wheel sensor from rear final drive.
6. Remove harness from rear final drive and rear suspension
member.
7. Remove center muffler. Refer to EX-3, "
EXHAUST SYSTEM" .
8. Remove rear propeller shaft. Refer to PR-6, "
REAR PROPEL-
LER SHAFT" .
9. Remove stabilizer bar. Refer to RSU-17, "
STABILIZER BAR" .
10. Remove parking brake cable mounting bolt and separate park-
ing brake cable from vehicle and rear suspension member. Refer to PB-3, "
PARKING BRAKE CONTROL"
.
11. Remove rear lower link and coil spring. Refer to RSU-16, "
REAR LOWER LINK & COIL SPRING" .
12. Remove mounting bolt on lower side of shock absorber. Refer to RSU-10, "
SHOCK ABSORBER" .
13. Set jack under rear final drive.
14. Remove member stay from vehicle.
15. Remove rear pin stay mounting bolts and nuts.
16. Gradually lowering jack, remove rear pin stay and rear suspension assembly.
INSTALLATION
Installation is the reverse order of the removal. For tightening torque, refer to RSU-7, "Components" .
CAUTION:
Do not reuse non-reusable parts.
Assemble disc rotor and wheel hub and bearing assembly by
aligning each matching mark as shown in the figure when install-
ing disc rotor.
Perform the final tightening of each of parts under unladen con-
ditions, which were removed when removing rear suspension
assembly. Check the wheel alignment. Refer to RSU-5, "
Wheel
Alignment Inspection" .
Adjust neutral position of steering angle sensor after checking
the wheel alignment. Refer to BRC-6, "
Adjustment of Steering
Angle Sensor Neutral Position" .
Check for the following after finishing work.
1. Washer 2. Mounting seal 3. Bushing (upper side)
4. Distance tube 5. Mounting bracket 6. Bushing (lower side)
7. Bound bumper cover 8. Bound bumper 9. Shock absorber
10. Axle assembly 11. Upper seat 12. Coil spring
13. Ball seat 14. Rubber seat 15. Cotter pin
16. Suspension arm 17. Connecting rod mounting bracket 18. Connecting rod
19. Mount stopper 20. Rear lower link 21. Front lower link
22. Radius rod 23. Stabilizer Bushing 24. Stabilizer Clamp
25. Stabilizer bar 26. Rear suspension member 27. Member stay
28. Stopper rubber 29. Cap 30. Rear pin stay
SDIA2638E
SDIA2638E
RSU-10
SHOCK ABSORBER
Revision: 2006 January2006 M35/M45
SHOCK ABSORBERPFP:56210
Removal and InstallationNES000JA
REMOVAL
1. Remove tires from vehicle with a power tool.
2. Set a jack under rear lower link to relieve the coil spring tension.
3. Remove shock absorber lower end bolt with a power tool.
4. Gradually lower the jack to remove it from rear lower link.
5. Remove shock absorber assembly upper end nuts with a power
tool, and then remove shock absorber assembly from vehicle.
INSPECTION AFTER REMOVAL
Check shock absorber assembly for deformation, cracks, damage, and replace if there are.
Check welded and sealed areas for oil leakage, and replace if there are.
INSTALLATION
Installation is the reverse order of removal. For tightening torque. Refer to RSU-7, "Components" .
CAUTION:
Do not reuse non-reusable parts.
Perform final tightening of shock absorber assembly lower side (rubber bushing) under unladen condition
with tires on level ground. Check wheel alignment. Refer to RSU-5, "
Wheel Alignment Inspection" .
Adjust neutral position of steering angle sensor after checking the wheel alignment. Refer to BRC-6,
"Adjustment of Steering Angle Sensor Neutral Position" .
Disassembly and AssemblyNES000JB
DISASSEMBLY
CAUTION:
Make sure piston rod on shock absorber is not damaged when removing components from shock
absorber.
1. Remove mounting seal from mounting bracket.
2. Wrap a shop cloth around lower side of shock absorber and secure it in a vise.
CAUTION:
Do not set the cylindrical part of shock absorber in a vise.
3. Secure the piston rod tip so that piston rod does not turn, and
remove piston rod lock nut.
4. Remove washer, distance tube, bushing, bound bumper cover
and bound bumper from shock absorber.
INSPECTION AFTER DISASSEMBLY
Bound Bumper and Bushing
Check bound bumper cover and bushing for cracks and damage. Replace if there are.
FA-0274D
SEIA0218J
RSU-14
RADIUS ROD
Revision: 2006 January2006 M35/M45
RADIUS RODPFP:55110
Removal and InstallationNES000JD
REMOVAL
1. Remove tire with a power tool.
2. Remove brake caliper with a power tool. Hang it in a place where it will not interfere with work. Refer to
BR-29, "
REAR DISC BRAKE" .
CAUTION:
Do not depressing brake pedal while brake caliper is removed.
3. Put matching marks on both disc rotor and the wheel hub and
bearing assembly. then remove disc rotor.
4. Remove rear lower link and coil spring. Refer to RSU-16, "
REAR
LOWER LINK & COIL SPRING" .
5. Remove mounting bolt in lower side of shock absorber with a
power tool.
6. Remove mounting bolt and nut in axle side of front lower link
with a power tool.
7. Remove mounting bolt and nut in axle side of radius rod with a
power tool.
8. Remove mounting bolt in rear suspension member side of
radius rod with a power tool, then remove radius rod from vehicle.
INSPECTION AFTER REMOVAL
Check radius rod and bushing for any deformation, cracks, or damage. Replace if there are.
INSTALLATION
Installation is the reverse order of removal. For tightening torque. Refer to RSU-7, "Components" .
CAUTION:
Do not reuse non-reusable parts.
Assemble disc rotor and wheel hub and bering assembly by
aligning each matching mark as shown in the figure when install-
ing disc rotor.
Perform final tightening of rear suspension member and axle
installation position (rubber bushing) under unladen condition
with tires on level ground. Check wheel alignment. Refer to
RSU-5, "
Wheel Alignment Inspection" .
Adjust neutral position of steering angle sensor after checking
the wheel alignment. Refer to BRC-6, "
Adjustment of Steering
Angle Sensor Neutral Position" .
SDIA2638E
SDIA2638E
FRONT LOWER LINK
RSU-15
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RSU
Revision: 2006 January2006 M35/M45
FRONT LOWER LINKPFP:55110
Removal and InstallationNES000JE
REMOVAL
1. Remove tire with a power tool.
2. Set a jack under rear lower link to relieve the coil spring tension.
3. Remove mounting nut and bolt between front lower link and rear suspension member with a power tool.
4. Remove mounting nut and bolt between front lower link and axle with a power tool.
5. Remove front lower link from vehicle.
INSPECTION AFTER REMOVAL
Check front lower link and bushing for any deformation, cracks, or damage. Replace if there are.
INSTALLATION
Installation is the reverse order of removal. For tightening torque. Refer to RSU-7, "Components" .
CAUTION:
Do not reuse non-reusable parts.
Perform the final tightening of rear suspension member and axle installation position (rubber bushing)
under unladen condition with tires on level ground. Check wheel alignment. Refer to RSU-5, "
Wheel Align-
ment Inspection" .
Adjust neutral position of steering angle sensor after checking the wheel alignment. Refer to Refer to
BRC-6, "
Adjustment of Steering Angle Sensor Neutral Position" .
RSU-16
REAR LOWER LINK & COIL SPRING
Revision: 2006 January2006 M35/M45
REAR LOWER LINK & COIL SPRINGPFP:551B0
Removal and InstallationNES000JF
REMOVAL
1. Remove tire with a power tool.
2. Set a jack under rear lower link to relieve the coil spring tension.
3. Loosen mounting bolt and nut of rear lower link inside of suspension member, and then remove mounting
bolt and nut inside of axle with a power tool.
4. Slowly lower jack, then remove upper seat, coil spring and rubber sheet from rear lower link.
5. Remove mounting bolt and nut inside of suspension member to remove rear lower link with a power tool.
INSPECTION AFTER REMOVAL
Check rear lower link, bushing and coil spring for deformation, cracks, and damage. Replace rear lower link
and coil spring if there are.
INSTALLATION
Installation is the reverse order of removal. For tightening torque. Refer to RSU-7, "Components" .
CAUTION:
Do not reuse non-reusable parts.
Make sure that upper seat is attached as shown in the figure.
CAUTION:
Make sure that the projecting parts (3) on upper seat inside
is securely fitted on the bracket tabs(3).
Match up rubber seat indentions and rear lower link grooves and
attach.
CAUTION:
Make sure spring is not up side down. The top and bottom
are indicated by paint color.
Perform the final tightening of rear suspension member and axle
installation position (rubber bushing) under unladen condition
with tires on level ground. Check wheel alignment. Refer to
RSU-5, "
Wheel Alignment Inspection" .
Adjust neutral position of steering angle sensor after checking
the wheel alignment. Refer to BRC-6, "
Adjustment of Steering
Angle Sensor Neutral Position" .
SEIA0333E
SC-38
CHARGING SYSTEM
Revision: 2006 January2006 M35/M45
Removal (AWD Models)
1. Disconnect the battery cable from the negative terminal.
2. Remove power steering oil reservoir tank from the bracket.
3. Remove the clips (A) and the hose clamp (B) from the harness
bracket (1).
4. Remove engine front undercover, using power tools.
5. Remove alternator and power steering oil pump belt. Refer to
EM-15, "
DRIVE BELTS" .
6. Remove alternator mounting bolt (A) and alternator stay mount-
ing bolt (B) using power tools, then remove alternator stay (1).
7. Remove alternator mounting bolt (C), using power tools.
8. Pull and turn alternator, and then remove the harness bracket
bolts (A).
9. Disconnect alternator connector (1).
10. Remove “B” terminal nut (2).
11. Remove alternator assembly downward from the vehicle.
Alternator Pulley Inspection
Perform the following.
Make sure that alternator pulley does not rattle.
Make sure that alternator pulley nut is tight.
Installation
Installation is the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
Install alternator, and check tension of belt. Refer to EM-15, "Checking Drive Belts" .
For this model, the power generation voltage variable control system that controls the power generation
voltage of the alternator has been adopted. Therefore, the power generation voltage variable control sys-
tem operation inspection should be performed after replacing the alternator, and then make sure that the
system operates normally. Refer to SC-35, "
Power Generation Voltage Variable Control System Operation
Inspection" .
PKIB8818E
PKIB8819E
SKIB2608J
Alternator pulley nut:
: 118 Nꞏm (12.0 kg-m, 87 ft-lb)
TRANSFER FLUID
TF-9
C
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Revision: 2006 January2006 M35/M45
TRANSFER FLUIDPFP:31001
ReplacementNDS000D9
DRAINING
1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine, and remove the drain plug to drain the transfer
fluid.
CAUTION:
When draining fluid, protect exhaust tube flange with cover.
3. Apply sealant to drain plug. Install drain plug on transfer and
tighten to the specified torque. Refer to TF-45, "
COMPO-
NENTS" .
Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"Recommended Chemical Products and Sealants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
FILLING
1. Remove filler plug and add transfer fluid until fluid level reaches
the specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the fluid. (Fill up for approx. 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again.
3. Set a new gasket onto filler plug and install it on transfer and
tighten to the specified torque. Refer to TF-45, "
COMPO-
NENTS" .
CAUTION:
Do not reuse gasket.
InspectionNDS000DA
FLUID LEAKAGE AND FLUID LEVEL
1. Check if fluid is leaking from transfer or around it.
2. Check fluid level from filler plug mounting hole as shown in the
figure.
CAUTION:
Never start engine while checking fluid level.
3. Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to TF-45,
"COMPONENTS" .
CAUTION:
Do not reuse gasket.
SDIA2087E
Fluid capacity
: Approx. 1.25 (2-5/8 US pt, 2-1/4 lmp pt)
SDIA2028E
SDIA2028E