PR-1

P R O P E L L ES RH A F T (for 4WDl
Page PRECAUTIONS PR.2 PR-2 PR.2

TROUBLESHOOTING PROPELLER SHAFT

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PR-z

PropellerShaft Troubleshooting, SHAFT - Precautions, PROPELLER

PRECAUTIONS
1. As the universal ioint is a non-disassembly type' the propeller shaft or intermediate shaft must be replaced as an assembly in the event of universalioint trouble. Be careful not to grip the propeller shaft tube too tightly in the vise as this will cause deformation.

2.

TROUBLESHOOTING
Problem Noise Possiblecause Sleeveyoke splineworn Centerbearingworn Spiderbearingworn or stuck Propeller shaft runout Propeller shaft unbalance housingrear extension Transmission worn bushing Sleeveyoke splinestuck Centerbearingheight imProPer
Remedy Page

intermediate shaft Replace Replace center bearing intermediate shaft or Replace propeller shaft propellershaft Replace propellershaft Balance Replace bushing shaft intermediate Replace Adjust bearingheight

PR-3 PR-3 PR-3

Vibration

PR-3 PR-3 TA.4O PR-3

SHAFT PROPELLER
COMPONENTS

lntermediate Shaft

----

9-Height

Washer [ 430 (3il42t

Center SuPPortBering- -

ProPellershaft

w- -I- @
I I

Ffiffiiib-ntnl
O :

torque : Tightening

Non-reasable part

PROPELLER SHAFT - Propeller Shaft

PR.3

REMOVAL AND DISASSEMBLY OF PROPELLER SHAFT

(See page PR-21 1. DISCONNECT PROPELLER SHAFT FLANGEFROM FLANGE COMPANION ON DIFFERENTIAL (a) Placematchmarks on the flanges. (b) Removethe four bolts and nuts.

2.

REMOVETWO BOLTS HOLDINGCENTERSUPPORT BEARING TO BODY

3.

REMOVEPROPELLER SHAFT WITH INTERMEDIATE SHAFT h) Pullout the yoke from the transmission. (b) InsertSST in the transmission to prevent oil leakage. ssT 09325-1 20rO

4.

SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT (a) Placematchmarks on the flanges. (b) Removethe four bolts and nuts.

5.

REMOVECENTER SUPPORT BEARINGFROM INTERMEDIATE SHAFT (a) Usinga hammer and chisel, loosen the stakedpart of nut. the (b) UsingSST to hold the flange,removethe nut. ssT 09330-00020

PR-4

PROPELLER SHAFT - Propeller Shaft (c) Placematchmarks on the flangeand shaft.

(d) Clampthe flangeyoke in a viseand tap off the shaft. (e) Removethe center support bearing.

INSPECTION OF PROPELLER SHAFT COMPONENTS

1. INSPECT PROPELLER AND INTERMEDIATE SHAFTS FORDAMAGEOR RUNOUT Maximum runout: 0.8 mm (0.031 in.l lf shaft runout is exceedsmaximum,replacethe shaft.

2.

INSPECT SPIDERBEARINGS (a) Inspectthe spiderbearings for wear or damage. (b) Checkthe spider bearingaxial play by turning the yoke while holdingthe shaft tightly. Bearingaxial play: O mm (0 in.l lf necessary, replacethe intermediateshaft orland propellershaft.

3.

INSPECT CENTER SUPPORT BEARINGFORWEAR OR DAMAGE Checkthat the bearingturns freely. lf the bearingis damaged,worn, or does not turn freely, replace it.

PROPELLER SHAFT - Propeller Shaft

PR.5

ASSEMBLYAND INSTALLATION OF PROPELLER SHAFT

(See page PR-21 NOTE: When replacing parts, install them facing as shown in the illustration.

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1. INSTALLCENTER SUPPORT BEARING ON INTERMEDIATE SHAFT lnstall the center support bearingwith the cutout on the rear side.

2.

INSTALL FTANGEYOKE ON INTERMEDIATE SHAFT grease to the splinesof the intermediate ta) Apply MP shaft. (b) Align the matchmarkson the yoke and shaft and installthem.

(c) Using SST to hold the flange, tighten down a nut to pressthe bearinginto position.

ssT09330-ooo20
Torque: 1,850 kg-cm (134 ft-lb, 181 N.ml (d) Loosenthe nut. (e) Torque the nut again. Torque: 300 kg-cm (22 ft-\b,29 N.ml (f) Using a hammerand punch, stake the nut.

PR-6

PROPELLER SHAFT - PropeilerShaft 3. ASSEMBTEPROPELLER SHAFT AND INTERMEDIATE SHAFT (a) Align the matchmarkson the flanges and connect them with the four bolts and nuts. Torque: 430 kg-cm (31 ft-|b,42 N.ml

4,

INSERTSLEEVE YOKE IN TRANSMISSION grease {a) Apply MP to the outsade diameterand splines of the yoke. (b) RemoveSST.

ssT 09325-12010
(c) Push the yoke into the transmission.
SST

5.

CONNECTPROPELLER SHAFT FLANGETO COMPANIONFLANGEON DIFFERENTIAL (a) Align the matchmarks on the flangesand connectthe them with the four bolts and nuts. (b) Torguethe nuts. Torque: 43O kg-cm (31 ft-tb,42 N.m)

6.

CONNECT CENTER TO BODY SUPPORT BEARING

ta) Place the height washer between the body and center support bearing,and installthe two mount bolts fingertight. NOTE: Some vehiclesdo not have a height washer.. In this case, it is not necessary to insert one.

Front1Centerof Center Bearing

(b) Check that the bearingbracket is at right anglesto the propellershaft Adjust the bracket if necessary. (c) Checkthat the centerline of the centerbearingis set to the centerlineof the bracketwhen the vehicleis in a no-load condition. Adjust the bracketif necessary. (d) Torquethe mount bolts. Torque: 375 kg-cm Q7 tt-ab,37 N.m)

FA.1

AXLE AND FRONT SUSPENSION

TROUBLESHOOTING FRONTWHEEL ALIGNMENT AXLE HUB FRONTDRIVE SHAFT FRONTSHOCK ABSORBER FRONTSUSPENSION Ball Joints Lower Arm Stabilizer Bar Page FA-2 FA.3 FA-7 FA.13 F4.19 FA-23

FA.23 FA-24 F4.27

FA.2

- Troubleshooting FRONTAXLE AND SUSPENSION

TROUBLESHOOTING
Problem Wanders/pulls

Possible causs
Tires worn or improperlyinflated Alignmentincorrect Wheel bearingworn Front or rear suspensionparts loose or broken Steeringlinkageloosenor worn Steering gear out of adjustmentor broken

Remedy Replace tire or inflate tires to proper pressure Checkfront end alignment Replace wheel bearing Tightenor replacesuspension part Tightenor replacesteering linkage Adjust or repair steering gear Checkloading Replace shock absorber Replace spring lnflate tires to proper pressure Replace bar stabilizer Replace shock absorber Replace tire or inflate tires to proper pressure Balance wheel Replace shock absorber Checkfront end alignment Replace wheel bearing Inspectball joint and bushing Tightenor replacesteering linkage Adjust or repairsteeringgear Inflate tires to proper pressure Replace shock absorber Checktoe-in part Replace suspension

Page FA-3 FA-3 FA.8

sR-9
FA.19 FA.l9 FA-3 FA-27 FA-19 FA-3

Bottoming

Vehicle overloaded Shock absorberworn out Springsweak Tires improperly inflated Stabilizerbar bent or broken Shock absorberworn out Tires worn or improperly inflated Wheel out of balance Shock absorberworn out Alignmentincorrect Wheel bearingworn Balljoints or bushingworn Steeringlinkageloosenor worn Steering gear out of adjustment or broken

Sways/pitches

Front wheel shimmy

FA-19 FA.3 FA-8 FA.23

sR-9
FA.3 FA-19 FA.3

Abnormal tire wear

Tires improperly inflated Shock absorberworn out Alignmentincorrect parts worn Suspension

- FrontWheel Alignment FRONTAXLE AND SUSPENSION

FA-3

FRONT WHEELALIGNMENT
1. MAKE FOLLOWING CHECKS AND CORRECTANY PROBLEMS (d Check the tires for wear and proper inflation.
kPa) Cold tire inflationpressure kg/cm2(psi, Tire size 1 4 5S R 1 3 3A-C 4-speed M/T Others 1 5 5S R 1 3 1 6 5S R1 3 1 5 5S R1 3 1 7 5S R1 3 Frontand Rear

FWD

2.2 (32.220l. 2.OQ8,2001

1 . 8(26. 180) 1.8 (26, 180)

4WD

2.OQ8,2001
1.8 (26. 180)

(b) Checkthe front wheel bearings for looseness. (d Checkthe wheelrunout. Lateral runout: 1.2 mm (0.047 in.) or less (d) Checkthe front suspension for looseness. (e) Check the steeringlinkagefor looseness. (f) Check that the front absorbers work properly by using the standardbouncetest.

Wry@=S +=ruf,ffi
--A-F--B--i
A = B

A2.

ADJUST TOE.IN Adjust toe-in with a toe-in gauge by the following procedure. (d Checkto seethat both right and left tie rods measure the samein length. Left-right error: 1.5 mm (0.059 in.l or less (b) Move the vehicleforward a few meterswith the front positionon a levelplace. wheelsin the straight-ahead (c) Mark the center of each rear tread and measure the distancebetweenmarks of the right and left tires.

(d) Advancethe vehicletill the marks on the rear of the heightsof the gaugeon tires come to the measuring the front. (e) Measure the distancebetweenthe markson the front of the tires. Toe-in: lnspectionSTD -1 {- 1 mm (-0.O4 + O.O4in.)

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FA.4

- FrontWheel Alignment FRONTAXLE AND SUSPENSION (f) lf the toe-in is not within inspectionSTD, adjust the toe-in. (1) Loosen the clamp. the boot clip. el Remove

(3) Turn the left and right rack ends an equal amountto adjust.

Wl Check that the length of the left and right tie rods are the same.

fuwry'$
A = B (5) Torquethe tie rod end clamp. Torque: 195 kg-cm (14 ft-lb, 19 N'ml (6) Placethe boot on the sealand clamp it. NOTE: Checkthat the boot is not twisted. 3. INSTALTWHEEL ALIGNMENTEOUIPMENT Follow the specific instructionsof the equipmentmanufacturer.

- FrontWheelAlignment FRONT AXLE AND SUSPENSION

Front Rear (FWDI 4, INSPECTVEHICLE HEIGHT Vehicleheight Tire size Front

FA-5

mm (in.) Rear

203.017.9921 287.O 1 1 . 2 9 9 ) 1 4 5S R 1 3 208.0(8.189) 292.O 1 1 . 4 9 6 ) o Sedan 1 5 5 S R 1 3 1 6 5 / 7 0S R 1 3 204.0(8.O31) 288.0 1 1 . 3 3 9 ) 3 2 0 7 ( 8 . 1 5 0 ) 308.5 12.146l. Wagor 1 5 5SR 1 3
4WD

234.419.2281 273.O 10.748) 1 5 5S R 1 3 t 7 5 / 7 0 S R 1 3 235.4(9.268) 274.O 1 0 . 7 8 7 )

Rear (4WD)

try to lf height of the vehicleis not within specification, levelit by shaking it down.lf the heightis still not correct, parts. and worn or loosesuspension checkfor bad springs

5.

ADJUST CAMBER
Vehicle FWD Sedan Wagon

camber:
Inspection standard Left-right error 10'+ 30'

s' + 30'
40' -t- 30'

30' or less

4WD

More Camber

lf camberis out of tolerance, adjustby turningthe camber cam. adjusting (a) Loosenthe shock absorber mount nut. (b) Turn the cam to adjust. NOTE: Camber changes about20'with eachgraduation of the cam. (c) Tightento the specified torque. Torque: 1,45Okg-cm {105 ft-lb, 142 N'm)

6.

AXIS INCLINATION ADJUST STEERING

Vehicle

Inspection standard Left-righterror

Sedan

FWD 4WD

12'30' * 30'
12035' + 30'

Wagon

30' or less

1 1'50' -t- 30'

inspect lf the steering is out of tolerance, axis inclination front worn or s$rplnsionparts. and replace any damaged

s[

FA.6

- FrontWheel Alignment FRONTAXLE AND SUSPENSION 7.

Front a1'

ADJUSTCASTER
Caster w/o PS Inspection Standard Sedan Wagon 1'10'+ 30' 0045' + 30' w/ PS 2"40' + 30' 2"15' + 30'

o o

3 lt3 <f

Left-righterror Inspection standard Left-righterror

30' or less 2"25' -+-30' 30' or less

lf the casteris not within specification, adjust by increasing or decreasingthe number of spacers.Do not install more than two spacers. Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml NOTE: The casterwill change13' with each spacer. 8. ADJUSTWHEELANGLE Wheelangle
Insidewheel Max. w/o PS Sedan w/ PS
at 2Oo 36020' + 10

Spacer

Outsidewheel 32040' + 1"

200 32'55' f 10

21"30'
35050' ! 10

Max.
at 20o

(o

o = |'lw/o PS Wagon wi PS

21"05'
36013' + 10

20"
32058' + 10

Max.
at 2Oo

21'25'
35047' 1 1'

20"
32050' =1"

Max.

at 20"
Max. w/o PS

21"O9'
36030' + 10

20"
3 3 0 1 s ' +1 0

4WD
w/ PS

at 200

2' 1"15'
36020' + 10 21005'

20"
33020' + 1'
200

Max.
at 2Oo

,'4o* t:ry

lf the steeringanglesdiffer from the standardspecification, check to see that the length of the left and right tie rods are the same. NOTE: lf the tie rod lengthsare not equal,the steering anglecannot be adjustedpropedy. lf the rie rod lengthswere changedto adjust the steering anble,reinspectthe toe-in.

9.

INSPECT SIDE SLIP WITH SIDE SLIP TESTER Side slip: 3.O mm/m (O.118in./3.3 ft) or less lf the side slip is not within specification, the toe-in or front wheelalignment may not be correct.

--,-,-j:*-a

t-

- Axle Hub FRONTAXLE AND SUSPENSION

FA.7

AXLEHUB
COMPONENTS

1,450 (105, 142)

Disc BrakeCaliper

shocknusoruer-----'1 I
>>

n l i f f * q$J t d d^%J|
*@r
h^ *9@n^6g1' t.''"'lo:'t cam

wheet Bearins

r"o rieRod

\E

:-\^'
-

Dise Brake Dust cover

Y9J'A i:T:":it:i ffi31?yrnnerRacel l*ry

t"'" *1":iHJ"r,""l
-l Race (NSK rype)
Lock Nut Cap

Lt^:::l1l"ner

a?6,
Outer Oit Seal

Y&r-A

/1"i"

ir

lSU

Ikg-cm (ft-lb, N.m)l : Tighteningtorque part O : Non-reusable

n
I

FA.8

- Axle Hub FRONTAXLE AND SUSPENSION

REMOVALOF FRONTAXLE HUB

1. REMOVE COTTER PIN. BEARING LOCKNUT CAP AND LOCK NUT (a) Removethe cotter pin and lock nut cap. (b) Before removing the brake caliper,loosen the lock nut while depressing the brake pedal. REMOVEBRAKECALIPER Removethe brake caliperfrom the steeringknuckleand suspendit with wire.

2.

3.

REMOVE DISC

pLAy rN AxtAL DtREcnoN 4. *fi*frcr BEARTNG '' Maximum: 0.05mm (O.OO2O in.l
nC

t
r I

5.

I
t
I

DISCONNECT TIE ROD END FROM STEERING KNUCKLE (d Removethe cotter pin and nut. (b) Using SST, disconnectthe tie rod end.

ssT 09610-20012

li

6.

)t5f'

DISCONNECT STEERING KNUCI(Le rnorrn*fucr ABSORBER (d Place matchmarks on the shock absorber lower bracketand camberadjust cam. (b) Removethe two boltsend nuts, and disconnectthe steeringknuckle.

7.

DISCONNECT LOWERARM FiOM STEERING KNUCKLE Removethe two bolts holdingthe balljoint to the steering knuckle.

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f.isEl;-*r:

- Axle Hub AXLE AND SUSPENSION FRONT 8. REMOVE AXLE HUB FROM UsingSST, removethe axle hub. ssT 09950-2001 5 ,. CAUTION: Cover the drive shaftrhl (r':q ( protect it from damage.

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!,ocr* d i t{" cIo*h to " .rr:'r, g ra *e c* i t ro*r ata^4 1e.

REPLACEMEN TF F R O N T AXLEHUBAND O W H E E LB E A R I N G
(Seepage FA-7) 1. REMOVE DUSTDEFLECTOR removethe dust deflector. Usinga screwdriver,

, +in f,rlve tl""ff\ii

2.

REMOVE INNEROIL SEAL FROMSTEERING KNUCKLE UsingSST, pull ou.tthe oil seal. 0 ssr 09308-0001 REMOVE HOLESNAP RING Usingsnapring pliers,removethe hole snap ring. BOLTS REMOVE THREE Remove the three bolts holdingthe disc brakedust knuckle. to the steering KNUCKLE REMOVE AXLE HUQ FROMSTEERING UsingSST,pushoff the axlehub. ssT 09950-2001 5 REMOVE DISCBRAKEDUSTCOVER REMOVE BEARING INNERRACE'(INSIDE)
,{

3.
4.

n.1

fr
,..F.
r:

6. 7.
,f+

8.

REMOVE. rlruen.qAbe(OUrSlOe) BEARTNG

race. Using9ST, pull off the beaiing'inner r ssT 09950;20015 t

'

-'v7:'

FA.1O

- Axle Hub FRONTAXLE AND SUSPENSION 9. REMOVE OUTER OIL SEAL UsingSST, pull out oil seal. ssT 09308-0001 0

1O. REPLACE WHEELBEARING h) Firstplacethe inner race (outside) of the bearingin the bearing (b) UsingSST, pressout the bearing. SST 09228-22O2O and 09950-20015
'.tfi

H r F
E

(c) U$ilfi SST,prestffi a new bearing. ssT 09309-3501 0 NOTE: There aretwo types of bearings; KOYO andNSK.

1 1 . INSTALLOUTER OIL SEAL h) Install the bearinginnerrace (outside) beforeinstalling a pew oil seal. (b) UsingSST,drivethe oil sealintothe steering knuckle. ssT 09515-35010 (c) Apply MP greaseto the oit seallip.

12. INSTALLDISCBRAKEDUSTCOVER ONTOSTEERING

KNUCKLE WITH THREEBOLTS, Apply liquidsealer to the dust coverand steering knuckle connection beforeassembly. 1 3 . INSTALLAXLE HUB (a) Installnew innerracesinto the innerbearing. (b) Using SST, ggss in the innerrace until it is tightty against the sftlulder of the hub. SST 09228-22O2O and O9310-35010 NOTE: Do not interchange the inner and outer races when installing.

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'

- Axle Hub FRONT AXLE AND SUSPENSION

FA-l1

1 4 . INSTALLHOLESNAP RING Usingsnap ring pliers,installthe hole snap ring into the steering knuckle.
3.3 -+

1 5 . INSTALL INNER OILSEAL UsingSST,drive in a new bil seal. ssT 09309-35010 NOTE: Tap in the oilseal3.3-t-0.1 mm (O.130+ 0.004 in.)from the end surface. 16. INSTALLDUST DEFLECTOR Using SST, drive a new dust deflector into the steering knuckle.

ssT o9316-60010

INSTALLATION OF FRONT AXLE HUB

(See page FA-7) 1. INSTALLAXLE HUB TO DRIVESHAFT lnstallthe axle hub with the washerand lock nut. Do not torquethe nut yet. CAUTION: Be careful not to damagethe drive shaft boot and oil seal lip.

2. ilxb 3.

INSTALLAXLE HUB TO LOWERARM Torque the*holdingtwo bolts the steering'knuckleto the rowerarm. Torque: 82O kg-cm (59 ft-lb, 80 Nrml INSTALLDISC TO
'' .!

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T6i'

INSTALL STEERING KNUCKLE TO SHOCKABSORBER (a) Lower the stabilizer bar and assemble the steerirfi" knuckle to the shockabsorberlower bracket. :l;;

4sft

'l
FA..12 - Axle Hub FRONTAXLE AND SUSPENSION (b) lnsert the bolts from the front side and align the matchmarksof the camberadjust cam. (c) Torque the bolts. Torque: 1,450 kg-cm (105 ft-lb, 142 N'ml

5.

KNUCKLE INSTALL BRAKECALIPER TO STEERING Torque the bolts. Torque: 970 kg-cm (70 ft-lb, 95 N.ml

#
6.
tr,

W
Vi i
i

KNUCKLE CONNECT TIE ROD END TO STEERING Torque the nut and secureit with a new cotter pin. Torque: 6O0 kg:cm (43 ft-lb, 59 N.m)

'\i.

7.

TOROUEBEAfriG LOCK NUT AND INSTALL LOCK NUT CAP AND;COTTER?IN (a) Torqrlethe lock nut wtriledepiUs.s.lng the brakepedal. Torque: 1,900 kg-cm (137 ft-lb, f86 N.m) (b) Install a new the lock nut cap affittsing plieib,.install cott*. pin.

+
8.
' i " . :" I l . I

CHECKFRONTWHEEL ALIGNMENTf$6e page FA-3) '-*+***n,. it'

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f,' l .

FRONT AXLE AND SUSPENSION -

Front Drive Shaft

FA.13

FRONTDRIVESHAFT
SHAFT DRIVE OF FRONT REMOVAL

ShockAbsorber

DiscBrakeCaliper

Stiffener Plate (Left Side Only)

ffi - :

\R --\x+.
1.900 {137, 186}

Tie Rod End---

Lower Arm

torque ITi-|b,T.mi] : Tishtening lRgrcm part O : Non-reusable 1. KNUCKE AND REMOVE STEERING AXLE HUB WITHOUTDISCONNECTING LOWERARM (Seestep 1 to 6 and 8 on page FA-81 FRONTDRIVESHAFT REMOVE (a) Removethe stiffener plate from the transaxleas(left side only). semblyand"engine

2.

.t.

(b) UsingSST.anda hammer,tap out the front drive shaft. ssr 09648-16010

FA.l4

- FrontDriveShaft FRONTAXLE AND SUSPENSION After pulling out the shaft, leavethe SST inserted. ssT 09563-16010 (d

COMPONENTS

InboardJoint Shaft DynamicDamper(LHShaft Only)

Boot

Tripod

L*lt, .tf.

{ft
DriveShaft (with Outboard Joint) part O Non-reusable

DISASSEMBLY OF FRONT DRIVE SHAFT 1. REMOVE SNAP R|NG FROM TNBOARD'OITI ,2. CHECK DRIVE SHAFT
(a) Check to see that there jS.po play in the outboard ' :* joint. (b) Checkto seethat inboardjoint slidessmoothlyin the thrust direction. (c) Check to see that there is no remarkable play in the radial directionof the inboardjoint. (d Check for damageto the boot. 3. DISASSEMBLEBOOTCLAMPS

,,h

- FrontDriveShaft FRONTAXLE AND SUSPENSION 4.

FA-l5

INBOARDJOINT SHAFT DISASSEMBLE (d Place matchmarks on the inboard joint shaft and drive shaft. CAUTION: Do not use a punch. (b) Removethe inboardjoint from the drive shaft.

5.

TRIPODJOINT DISASSEMBLE {a) Using snap ring pliers,removethe snap ring. (d Usinga punchand hammerplacematchmarks on the shaft and tripod.

Uniformily tap to remove the tripod joint from the drive shaft. CAUTION: Do not tap on the roller. (d

6.

REMOVEFOLLOWINGPARTS: (a) Removethe boot from the drive shaft (b) Removethe clamp and dynamic damper (LH shaft only.)

i,l_

n r n

Do not remove.

(c) Removethe two boot clamps from the boot of the outboardjoint. (d) Removethe boot from the outboardjoint. CAUTION: Do not remove the outboard joint. (e) Checkthe insideand outsideof the boot for damage.

-ffi,,.@,

FA-l6

- FrontDriveShaft FRONTAXLE AND SUSPENSION

ASSEMBLYOF FRONTDRIVESHAFT
(See page FA-l41

1.

V inylTape

PROVISIONALLY INSTALLBOOTAND BOOTCLAMP TO OUTBOARD JOINT NOTE: Beforeinstalling the boot wrap vinyltape around the splineof the shaft to preventdamagingthe boot.

2. 3.
4. 406 mm (15.98 in.) r |

INSTALL DYNAMIC DAMPERAND CLAMP (LH SHAFT onlyl PROVISIONALLY INSTALLBOOTAND CLAMP (For INBOARDJOINTI TO DRIVESHAFT ASSEMBLEBOOTCLAMPS ONTO DRIVESHAFT

5.

-^'re
t,-/

ASSEMBLETRIPODJOINT (a) Place the beveled side of the tripod axial spline toward the outboardjoint.

(b) Align the matchmarksplacedbefore disassembly.

(c) When replacingthe inboard joint, first align the centerof the inboardjoint and outboardjoint. (d) Using a brass bar and hammer,tap the tripod onto the drive shaft.

I.{

- FrontDriveShaft FRONTAXLE AND SUSPENSION 6. INSTALL NEW SNAP RING Usingsnap ring pliers,installa new snapring.

FA-l7

7.

ASSEMBLEBOOTTO OUTBOARD JOINT SHAFT Before assemblingthe boot pack in 24O g (0.5 lb) of grease. NOTE: Use the greasesuppliedin the boot kit.

8.

ASSEMBLEINBOARDJOINT TO DRIVESHAFT (a) Packin 140 g (0.3 lb, 1.4 N) of grease. Amount: Joint side 90 g {0.2 lOl Boot side 50 g (0.1 lul NOTE: Use the greasesuppliedin the boot kit.

(b) Align the matchmarksplacedbefore disassembly. (c) lnstallthe inboardjoint shaft to the drive shaft. (d) lnstall.lF Uoo, to the inboardjoint shaft.

9.

ASSEMBLE BOOTSCLAMP TO BOTH BOOTS (d Be sure the boot is on the shaft groove. (b) Installa new 4amp on the inboardjoint side around the hollow pffin of the cover. '\.

.-"

e_

FA-l8

- FrontDriveShaft FRONTAXLE AND SUSPENSION (c) Bendthe clampand lock it as is shown in the figure.

(d) Check that the boot is not stretched or contracted when the drive shaft is at specifiedlength. Drive shaft length: Right side Approx. 620 mm 124.41in.l Left side Approx. 722 mm (28,43 in.)
Length

10. INSTALL NEW SNAP RINGTO INBOARDJOINT SHAFT

INSTALLATION OF FRONTDRIVESHAFT
(Seepage FA-l3) 1. INSTALL DRIVESHAFT TO TRANSAXLEASSEMBLY (a) Apply MP greaseto the oil seallip. (b) lnstallthe drive shaft by tapping on the SST. ssT 09648-16010 NOTE: Whether or not the drive shaft is contactingthe pinion shaft can be know by its sound or feel when tapping it in.

2.

PLATE INSTALLSTIFFENER lnstall the three bolts holding the stiffener plate to the Torquethe bolts. engineand transaxle. Torque: 400 kg-cm (29 ft-lb, 39 N'm) KNUCKEAND AXLE HUB INSTALLSTEERING (See step 2 to 7 on page FA-l1 and 12)

3.

4.

CHECKFOLLOWINGPARTS: (d Checkthe boots for damage. of the boots. NOTE: Check the entire circumference (b) Check the length between the left and right shaft drive shaft. after installinq,.the ' i": -|*it Length: Approjff{93 mm (7.60 in.) ALIGNMENT (See page FA-31 CHECKFRONT"WHEEL
"1.

5.

FRONTAXLE AND SUSPENSION- FrontShock Absorber

FA-l9

FRONT ABSORBER SHOCK

COMPONENTS

$-Dust

Cover

o@

g-ZA -r-a

/:A-F Ef @-Dust

Suspension Support Seat

@-sprinsseat

CoilSpring

(ft-lb. N.m) : Tighteningtorque part | : Non-reusable

REMOVALDISASSEMBLY OF FRONTSHOCK ABSORBER ASSEMBLY

1. 2. KNUCKLEFROM SHOCK DISCONNECT STEERING ABSORBER(See step 6 on page FA-81 REMOVE SHOCK ABSORBER ASSEMBLY FROM BODY ii. (d Removethe dust coverfrom the suspqnsion support. (b) Loosenthe nut. Do not removethe nut yH"

FA-20
w/o PS

FRONT AXLE AND SUSPENSION -

FrontShockAbsorber

(c) Remove the three nuts holdingthe shockabsorberto the body. (d Removethe shock absorberassembly. CAUTION: Cover the drive shaft boot with cloth to avoid damage.

w/ PS and 4WD

3.

tr-;

CLAMP SHOCKABSORBER IN VISE Installa bolt and nuts to the bracketat the lower portionof the shock absorber shelland secureit in a vise.

W
4,

-22032 ssr 09727

REMOVECOIL SPRING (d UsingSST, compress the coil spring.

(b) Hold the suspension with a screwdriveror such so that it will not turn, and then removethe support nut. (c) Removethe suspension support, spring seat, spring and dust cover.

- FrontShock Absorber FRONTAXLE AND SUSPENSION

FA.21

INSPECTION OF FRONTSHOCKABSORBER
INSPECTOPERATION OF SHOCK (d Pull out the shock absorberpiston rod at a constant speed and check to see that the pull feeling throughoutthe stroke is the same.

b)

Checkto seethat thereis no change in the pullwhen the piston rod is rapidlymoved up and down with a strokeof 5 - 1O mm (0.20 - 0.39 in.).

ASSEMBLYAND INSTALLATION OF FRONT SHOCKABSORBER ASSEMBLY

(Seepage FA-l91 1. INSTALLBUMPER, COILSPRING INSULATOR, SPRINGSEAT AND DUST SEAL (d Mount the shockabsorber in a vise. (b) lnstallthe bumberto the piston rod. (c) UsingSST, compress the coil spring.

-22032 ssT 09727

(d) Align the coil springend with the lower seat hollow and install. (d Align the springseatwith the pistonrod and install. (fl lnstallthe dust sealon the springseat. (g) Install the suspension supportwith a new nut.Do not torque the nut yet.

2.

INSTALLSHOCKABSORBER TO BODY Connectthree bolts holding the shock absorberto the body. Torquethe nuts. Torque: 24O kg-cm {17 ft-lb, 24 N.ml

FA-22
w/ PS and 4WD

- FrontShock Absorber FRONTAXLE AND SUSPENSION

3. 4.

ABSORBER INSTALL KNUCKTE TO SHOCK STEERING (Seestep 4 on pageFA-l1) NUT TOROUE SUPPORT SUSPENSIO\T Torque: 500 kg-cm(36 ft-|b,49 N.ml

5.

INSTALL DUST COVER support with MP Pack the bearing in the suspension grease.Installthe dust cover.

4 r y . 6 .

S pE e aR e c H E C c AK M( B Fg Ae . s l

l..:t

!r

FRONTAXLE AND SUSPENSION- Front Suspension

FA-23

FRONTSUSPENSION
COMPONENTS

*-< -ry"
I 1,075(78, los) |

a{Balljoint

Bushing 7 S--t

sro(5r,sot I

Stabilizer Bar

h
|
I I

YooT.\ l l - @
Spacer

l-l

cottar | | so-|l t BooCr,

t (
O

torque Fs-AmTliET'fri| : Tishtenins

l: part Non-reugable

Ball Joints
INSPECTION OF BALL JOINTS
1. INSPECT BALL JOINTS FOREXCESSIVE LOOSENESS (d Jack up the tront of the vehicleand place a wooden blockwith a heightof 18O - 2OOmm (7.09 - 7.87 in.) underone front tire. (d Lower the jack until there is about half a load on the front coil springs.Placestandsunderthe vehiclefor safety. (c) Make sure the front wheels are in a straightforward position and block them with chocks. (d) Move the lower arm up and down and checkthat the play. balljoint has no excessive Maximum balljoint vertical play: 0 mm (0 in.l INSPECTBALL JOINT DUST COVERSFOR DAMAGE OR DETERIORATION lf a problemis found,replace the balljoint assembly.

2.

'l
FA.24 - FrontSuspension FRONTAXLE AND SUSPENSION 3. CONDITION BALL JOINT FORROTATION INSPECT (d Removethe balljoint. (Seepage FA-29) (b) As shown in the figure, flip the ball joint stud back and forth 5 times before installingthe nut (d Using a torque gauge,turn the nut continuously one turn each 2-4 secondsand take the torque reading on the 5th turn. Torque {turning}: I - 25 kg-cm 17 - 21 in.-lb, 0.8 - 2'4 N'ml lf the torque is not within specification,replacethe ball ioint.

Lower Arm
(See page FA-23) 1.

ARM REMOVAL OF LOWER

\7
2. 3.

KNUCKLE LOWERARM TO STEERING DISCONNECT Removethe two bolts holdingthe balljoint to the steering knuckle.

BAR END TO LOWER DISCONNECT STABILIZER ARM Removethe stabilizerbar nut, retainerand cushion. REMOVELOWER ARM (a) Jack up the opposite wheel until the vehicle body lifts off the stands.

(b) Loosenthe lower arm bolt, pry the lowerarm and pull out the bolt. (d Disconnectthe lower arm from the stabilizerbar. CAUTTON: Be careful not to lose the caster adiust spacer.

(d) UsingSST, disconnect the ball joint from the lower arm. ssT 09950-20015 the balljoint NOTE: Temporarily install the nut to prevent from fallingout.

- FrontSuspension FRONTAXLE AND SUSPENSION

FA.28

REPLACEMENT OF LOWERARM BUSHING

1. REMOVELOWERARM BUSHING (a) Cut off the flangetip of the bushingas is shown in the figure.

(b) Bend the remaining portions inward with a cold chisel. CAUTION: Be careful not to damage the flange.

(c) Bendin the flangetips and pull off the flangewith a pair of pliers.

(d) UsingSST and a press,pressout the bushing. ssT 09726-32010

2.

INSTALL LOWERARM BUSHING Using SST and a press,pressthe bushinginto the arm.

ssr 09726-32010
CAUTION: Do not allow grease or oil to get on the bushing.

FA.26

- FrontSuspension FRONTAXLE AND SUSPENSTON

INSTALLATION OF LOWERARM
1. CONNECTLOWERARM TO BALL JOINT lnstallthe lower arm to the ball joint with a nut. Torque the nut and installa new cotter pin. Torque: 800 kg-cm (58 ft-lb, 78 N'm)

2.

CUSHIONAND RETAINER, INSTALLSPACER, COLLAR

3.

LOWERARM TO BODY CONNECT (d Passthe lower arm through the stabilizerbar.

(b) Connectthe lower arm with the bolt. Do not torque the bolt yet. (c) lnstallthe stabilizer washerand bar with the cushion, a new nut. Do not torque the nut Yet.

4.

KNUCKLE LOWERARM TO STEERING CONNECT (a) Lowerthe stabalizer bar and connectthe balljoint to steeringknucklewith the two nuts.

- FrontSuspension FRONTAXLE AND SUSPENSION (b) Torque the nuts. Torque: 820 kg-cm (59 ft-lb, 8O N.ml

FA-27

5.

INSTALLTIREAND LOWERVEHICLE Bouncethe vehicleto stabilize the suspension.

;;.".r:,!""

- .ti'" .

.q

6.

TOROUENUT HOLDINGSTABILIZER BAR TO LOWERARM ,#i{: Torque: 1,O75kg-cm (78 ft-lb, lOb N.m)

!:rt

!'

7.

TOROUEBOLT HOLDINGLOWERARM TO BODY Torque: 1,150 kg-cm (83 ft-tb, 113 N.ml CHECKFRONTWHEELALIGNMENT(See pase FA-31
o
t

8.

'.

'*'

StabifizerBar
(See page FA-231

REMOVALOF STABILIZER BAR

1. 2. REMOVE ENGINE UNDERCOVER REMOVEBOTH STABILIZER BAR BRACKETS FROM CROSSMEMBER

a
FA.28 - FrontSuspension FRONTAXLE AND SUSPENSION 3. 4. DISCONNECT BAR ENDS BOTH STABILIZER TO LOWERARM REMOVESTABILIZER BAR CAUTION: Be careful not to lose the spacer.

INSTALLATION BAR OF STABILIZER

1. INSTALLSTABILIZER BAR END TO LOWERARM (d lnstall the spacer, retainer, rubber and collar as shown in the figure. (b) Fingertighten a new stabilizerbar nut.

2.

INSTALL BRACKET TOGETHERWITH STABILIZER BAR Pry the bar forward and installthe brackets. Torque the bolts. Torque: rt4o kg-cm (32 ft-lb,43 N.ml

3.

TOROUENUT HOLDINGSTABILIZER BAR TO LOWER ARM Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml NOTE: Bouncethe vehicleto stabilizethe suspension before torquing the stabilizerbar nut.

4. 5.

INSTALLENGINEUNDERCOVER CHECKFRONTWHEEL ALIGNMENT (See page FA-3)

RA.1

REARAXLE AND SUSPENSION

(FWD} TROUBLESHOOTING
REARWHEEL ALIGNMENT REARAXLE HUB AND CARRIER Sedan Wagon REARSUSPENSION Rear Shock Absorber SuspensionArm Strut Rod Page RA-2 RA-3 RA.5 RA-5 RA-l2 RA.l6 RA.l7 RA.20 RA.23

(4wD)
TROUBLESHOOTING REARAXLE SHAFT DIFFERENTIAL FOURLINK TYPE REARSUSPENSION Coil Spring and Rear Shock Absorber Lateral Control Rod Upper and Lower Control Arm Rear Stabilizer Bar RA.24 RA-25 RA.28 RA'42 RA.43 RA.46 RA-48 RA.s1

'l
RA-2 (FWD) REAR AXLEAND susPENstoN - Troubteshootinq

(FWD} TROUBLESHOOTING
Problem Wanders/pulls Possible cause Tires worn or improperlyinflated Alignmentincorrect Remedy Replace tire or inflate tires to proper pressure Checkalignment Page RA-3 RA.3 RA-5 RA-12 R A - s .1 7

Wheel bearingadjusted too tight (Sedan) Adjust wheel bearing Wheel bearingworn {Wagon) Replace wheel bearing Rear suspensionparts loose or broken Bottoming Tightenor replacesuspension parts Check loading Replace shock absorber Replace spring Inflate tires to proper pressure Replace shock absorber Inflate tires to proper pressure Replace shock absorber Checktoe-in parts Replace suspension

Vehicle overloaded Shock absorber worn out Springweak

RA-17 RA.17 RA.3 RA.17 RA-3 RA.17 RA.4 R A - s ,1 7

Sways/pitches

Tires improperlyinflated Shock absorber worn out

Abnormal tire wear

Tires improperly inflated Shock absorberworn out Alignmentincorrect parts worn Suspension

- RearWheelAlignment(FwD) REARAXLE AND SUSPENSION

RA.3

REARWHEELALIGNMENT(FWD}
1. MAKE FOLLOWING CHECKS AND CORRECTANY PROBLEM (d Check the tires for wear and proper inflation. (Seepage FA-3)

(b) Check the rear wheel bearingsfor looseness. (c) Check the wheel runout. Lateral runout: 1.2 mm {0.047 in.l or less (d) Check the rear suspension for looseness. (e) Use the standard bounce test to check if the rear work properly. absorbers 2. (See pase FA-51 INSPECT VEHICLE HETGHT

3.

INSTALL WHEELALIGNMENTEOUIPMENT Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER Inspection standard: -5' t 3O' (Sedanl -10' t 3O'(Wagonl Left-right error: 30' lf not within specification, inspect and replace any parts. damagedor worn rear suspension

5.

ADJUST TOE-IN (a) Measurethe distancebetweeneach wheel disc and cam bolt center of the suspensionarm and check that both are the same. Left-right error: 3 mm (0.12 in.) or less

(b) Move the vehicleforward a few meterswith the rear positionon a levelplace. wheelsin the straight-ahead (c) Mark the centerof each rear tread and measure the distancebetweenthe marksof the right and left tires. (d) Advancethe vehicleuntil the markson the rearof the tires come to the front. NOTE: The toe-in shouldbe measured at the samepoint on the tire and at the same level.

RA.4

- RearWheelAlignment(FWD) REARAXLE AND SUSPENSION (e) Measure the distancebetweenthe markson the front of the tires. Toe-in: Inspection STD 0 + 1 mm (0 + O.O4in.)

-A-

Front B-A=Toe-in

B lf not within specification, turn the left and right toein adjustingcams an equalamount to adjust. NOTE: The toe-inwillchangeabout2 mm (0.08 in.)with each graduation of the'cam (oneside). (f)

6.

CHECKSIDESIIP WITH SIDESLIPTESTER Side slip: 3.0 mm/m (0.118 in./3.3 ftl or less lf the side slip is not within specification, the toe-in may not be correct.

REARAXLE AND SUSPENSION- RearAxle Hub and Carrier(FWD)

RA-s

(FWDI REAR AXLE HUB AND CARRIER Sedan

COMPONENTS

Arm No. 1 Suspension Arm No. 2 Suspension

BrakeTube

Axle Hub (with Drum)

Bearins \,outer

a\

',, W^I | Y l
OuterRace (lnnerBearing) torque lkg-cm (ft-lb.N.m)l : Tightening part O : Non-reusable

*u..o"*

outernale t (Outer Bearing) | a CoiterPin

Thruit Washer

Y*q@l *ld

REMOVALOF REARAXLE HUB AND CARRIER

1. JACK UP VEHICLE Jack up the vehicleand support the body with stands.

2.

REMOVEAXLE HUB (a) Removethe cap, cotter pin, nut lock and nut. (b) Removethe axle hub togetherwith the outer bearing and thrust washer.

RA-6

REARAXLE AND SUSPENSION- RearAxle Hub and Carrier(FWD) 3. DISCONNECT BRAKETUBE FROMWHEELCYLINDER Using SST, disconnectthe braketube. ssT 09751-36011

4.

REMOVEAXLE SHAFT Removethe bolts holdingthe axle shaft to the carrier,and removethe axle shaft and rear brakeassembly.

5.

REMOVEAXLE CARRIER (d Removethe bolt and nut holding the axle carrierto the strut rod.

(b) Removethe bolt and nut holding the axle carrier to the No.1 suspension arm.

(d

Removethe bolt and nut holding the axle carrierto the No.2 suspension arm.

REARAXLE AND SUSPENSION- RearAxle Hub and Carrier(FWD)

RA-7

(d) Removethe bolts and nuts holdingthe axle'carrier to the shock absorber,and removethe axle carrier.

RAO233

REPLACEMENT OF WHEEL BEARINGS

1. REMOVE INNERBEARING AND OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Remove the innerbearingfrom the disc.

2,

REMOVEBEARING OUTERRACES Using SST, pressout the bearingraces. SST 09608-16010 and 09608-20011

3.

INSTALLBEARING OUTERRACES pressin new bearingraces. UsingSST, carefully SST 09608-16010 and 09608-20011

4.

FILL INSIDEOF AXLE HUB AND CAP WITH MP GREASE

L:

RA-8

REARAXLE AND SUSPENSION- RearAxte Hub and Carrier(FWD) 5. PACK BEARINGS WITH MP GREASE (a) PlaceMP greasein the palm of your hand. (b) Pack grease into the bearing, continuing until the greaseoozes out from the other side. (c) Do the same aroundthe bearingcircumference.

6.

INSTALL INNER BEARING AND NEW OIL SEAL (a) Placethe inner bearinginto the axle hub. (b) Using SST, drive a new oil seal in the axle hub. ssT 09608-2001 1 (c) Apply MP greaseto the oil seal.

INSTALLATION OF REARAXLE HUB AND CARRIER

(See page RA-51 1. INSTALLAXLE CARRIER (a) Placethe axlecarrierin position. (b) Installthe two bolts and nuts holdingthe axle carrier to the shock absorber. Torque the nuts. (105 Torque: 1,450 kg-cm ft-lb, 142 N.m) (c) Provisionally installthe bolt and nut holdingthe axle carrierto the No.2 suspension arm. NOTE: Be surethe lip of the nut is restingon the flange of the suspension arm-notover it.

(d) Provisionally installthe bolt and nut holdingthe axle carrierto the No.l suspension arm. NOTE: When installing,insert the lip of the nut into the hole on the suspension arm.

REARAXLE AND SUSPENSION- RearAxle Hub and Carrier(FWD)

RA-g

(e) Provisionally installthe bolt and nut holdingthe axle carrierto the strut rod. NOTE: When installing,insert the lip of the nut into the groove on the bracket.

2.

INSTALL AXLE SHAFT lnstall the axle shaft and rear brake assemblywith four bolts. Torque the bolts. Torque: 820 kg-cm (59 ft-lb, 80 N'ml

RA0238

3.

CONNECTBRAKETUBE TO WHEEL CYLINDER

-3601 1 ssr 09751

Torque: 155 kg-cm (11 ft-lb. 15 N.m)

4.

INSTALLAXLE HUB ON SPINDLE (a) Place the axle hub and outer bearing on the axle shaft. (b) Fill in MP grease between the outer bearing and thrust washer. (d lnstallthe thrust washer.

5.

ADJUST PRELOAD (a) Installand torque the nut. Torque: 300 kg-cm {22 tt-\b,29 N'ml

r.1

E4-10

REARAXLE AND SUSPENSION- RearAxle Hub and Canier (FWD) (b) Snug down the bearingby turning the hub several times.

(c) Loosenthe nut until it can be turnedby hand. NOTE: Makesurethat thereis absolutely no brakedrag.

(d) Measureand make a note of the rotation frictional force of the oil seal. Oil sealfrictionalforce: Approx. rtoog (0.9 lb, 3.9 Nl

(e) Tightenthe nut until the preloadis within specification. Bearingpreload (while turning): In addition to oil seal frictional force 400 - 1,000 g (0.9 - 2.2 tb,3.9 - 9.8 Nl Insurethat the drum rotates smoothly.

(fl

6.

INSTALL NUT LOCK, COTTERPIN AND CAP NOTE: lf the cotter pin hole does not line up, correct by tighteningthe nut the smallestamount possible. FILL BRAKERESERVOIR WITH BRAKEFLUIDAND BLEEDBRAKESYSTEM (See page BR-ZI

7.

- RearAxle Hub and Carrier(FWD) REARAXLE AND SUSPENSION 8.

RA-l1

TOROUE AXLE CARRIER MOUNT BOLTS (a) Removethe standsand bouncethe vehicleto stabilize the suspension.

(b) Torque the mount bolts with the vehicleweight on the suspension. Torque: 89O kg-cm (64 ft-lb, 87 N.ml

9.

CHECKREARWHEELALIGNMENT (See page RA-3)

r.1

RA-12

- RearAxle Hub and Carrier(FWD) REARAXLE AND.SUSPENSION

Wagon
COMPONENTS

RearBrakeAssembly

Arm

No. 1 Suspension

->--:

er+\ --<_:+,--/
I
I

| 0l

I
Inner Bearing Race(lnside)

fr@
,0, 1rol I
Bearing

RearAxle Carrier I StrutRod Axle Hub BrakeDrum

t-lb. N'm)l : Tightening torque part O : Non-reusable

REMOVAL AXLE HUB AND CARRIER OF REAR

1. 2.
Measuring Point

REMOVE BRAKEDRUM CHECKBEARINGPLAY IN AXIAL DIRECTION Limit: O.O5mm (O.OO2O in.l

REAR AXLEAND susPENstoN- Rear AxleHubandcarrier(FwD)

3. DISCONNECT BRAKETUBE FROM WHEEL CYLINDER Using SST, disconnectthe braketube. s s T 0 9 7 5 1- 3 6 0 11

RA-13

4.

REMOVEREARAXLE HUB (a) Removethe four bolts holding the axle hub to the axle carrier, and remove the axle hub and brake assembly. (b) Removethe O-ring. REMOVEREARAXLE CARRIER (See pages RA-6 and 7l

5.

REPLACEMENT OF REARAXLE HUB AND WHEELBEARING

(See page RA-121 1. REMOVE NUT (d Usinga chiseland hammer, unstake the nut. (b) Removethe nut.

2.

REMOVE AXLE SHAFTFROMAXLE HUB UsingSST,pushthe axleshaft off the axlehub. ssT 09950-2001 5 REMOVEBEARINGINNERRACE(INSIDEI

3.

4.

REMOVE BEARING INNERRACE(OUTSIDE) UsingSST, pull off the bearinginnerrace (outside) from the axleshaft. ssT 09950-2001 5

a
RA.14 REARAXLE AND SUSPENSION- RearAxIe Hub And Carrier(FWD) 5. REMOVEOIL SEAL

6.

REMOVEBEARING (a) First installthe innerrace (innerside)of the removed bearing. (b) Using SST, press out the bearing. SST 09228-22O2Oand 09636-20010

7.

INSTALLBEARING the bearingas an assembly. NOTE: Alwaysreplace (a) Apply MP greasearoundthe bearing outer race. (b) Using SST, press a new bearinginto the bearing case. 0 s s r 0 9 3 16 - 6 0 0 1

8.

INSTALLOIL SEAL (a) UsingSST,drivean oil seal into the axle hub. 0 s s T o 9 3 10 - 3 5 0 1 (b) Apply MP greasebetweenthe oil seallip'

9.

INSTALL AXLE SHAFT (d Installthe bearingboth side inner race. (b) Using SST, pressthe inner race into the axle shaft. and 09636-2001O SST 09228-22O2O

REAR AXLEAND susPENstoN- Rear AxleHubandcarrier(FWD)

(c) Installand torque a new nut. Torque: 1,25,O kg-cm (90 ft-tb, 123 N.ml

RA-ls

81 104

(d) Stake the nut.

INSTALLATION OF REARAXLE HUB AND CARRIER

(See page RA-l2) 1. INSTALLREARAXLE CARRIER (See pages RA-8 and 9l INSTATLREARAXLE HUB (a) Installa new O-ringto the axle carrier. (b) lnstallthe axle hub and rear brakeassembly with the four bolts.Torquethe bolts. Torque: 820 kg-cm (59 ft-tb, 80 N.ml

'

,"4' r4 "'

'

2.

3.

CONNECT BRAKETUBE TO WHEEL CYLINDER s s T 0 9 7 5 1- 3 6 0 11 Torque: 155 kg-cm (t 1 ft-lb, 15 N.m) INSTALLBRAKEDRUM FILL BRAKERESERVOIR WITH BRAKEFLUID AND BLEEDBRAKESYSTEM (See page BR-7) TOROUE AXLE CARRIER MOUNT BOLTS (Seepage RA-111 CHECKREARWHEEL ALTGNMENT {See page RA-3}

4. 5. 6.

7.

a
RA-16 (FWD) REARAXLE AND SUSPENSION- RearSuspension

(FWD} REARSUSPENSION
COMPONENTS
ga@supportNut @-suspension support DustCover

Insurator

V-upper

CoilSpring

2& 117,241

F-spring

Bumper

@-Lowerrnsurator
Shock Absorber Assembly

1,45,01105 ,1421

Brake Drum andAxle

Carrier Assembly No. 2 Suspension Arm

No. 1 Bashing No. 1 Suspension Arm N.ml : Tighteningtorque part O : Non-reusable

- RearSuspension REARAXLE AND SUSPENSTON (FWD)

RA,l7

RearShock Absorber
(See page RA-l61

REMOVALOF REARSHOCKABSORBER
1. REMOVESHOCKABSORBER COVERAND PACKAGE TRAY BRACKET

2.

REMOVEBRAKETUBE (a) UsingSST,disconnect the braketube from the wheel cylinder. ssT 09751-36011 (b) Using SST, removethe braketube from the flexible hose. ssT 09751-36011 DISCONNECT FLEXIBLE HOSEFROM SHOCK ABSORBER LOOSENNUT HOLDINGSUSPENSION SUPPORT TO SHOCKABSORBER the dust coverfrom the suspension support. h) Remove (b) Loosen the nut. Do not removethe nut yet.

3. 4.

5.

DISCONNECT SHOCKABSORBER FROMAXLE CARRIER Removethe bolts and nuts holdingthe shock absorberto the axle carrierand disconnectthe absorber.

6.

REMOVESHOCKABSORBER FROM BODY Removethe nuts holdingthe shock absorberto the body and removethe shock absorber.

RA.l8

- RearSuspension (FWD) REARAXLE AND SUSPENSION 7. REMOVECOIL SPRING (d Installa bolt and nut to the bracketat the lower end of the shock absorberand secureit in a vise.

e FI

ry
(d the coil spring. UsingSST, compress

ssr 09727-22032

(c) Removethe nut. (d) Removethe suspension support, upper insulatorcoil spring,lower insulatorand bumper.

8.
1O mm (0.39in.)

HANDLINGOF SHOCKABSORBER (a) Do not disassemble because the the shock absorber cylinderis filled with gas. (b) lf you replace a shock absorber, drill a 2.0 - 3.0 mm (0.079- 0.118 in.) hole in the bottom of the reprelease lacedshockabsorber's to completely cylinder gas.ffhe gas is colorless, the high pressure odorless and not poisonous.However,when drilling,chips may fly out so work carefully.) (c) Handle Neverscoreor carefully. the shock absorber partof the pistonrod,and never scratchthe exposed allow paint or oil to get on it. (d) Do not turn the piston rod and cylinderwith the completely. shockabsorber extended

- RearSuspension (FWD) REARAXLE AND SUSPENSION

RA.l9

INSTALLATION OF REARSHOCKABSORBER
1. INSTALLSPRING BUMPER, COILSPRING, INSULATOR AND SUSPENSION SUPPORT (a) Mount the shock absorber in a vise. (b) Installthe lower insulatorto the lower seat of the shock absorber. (c) UsingSST, compress the coil spring.

-22032 ssT 09727

(d) Align the coil spring end with the lower insulator hollow and installthe coil spring. (e) lnstallthe springbumperand insulator. (f) Align the suspension supportlower seat hollow and lower insulater hollow. (g) Align the suspension supportwith the pistonrod and install. (h) Align the suspension supportwith the shock absorber lower bracketas shown.

Lower Bracket Suspension Support

(i)

Provisionally installa new nut.

2.

CONNECT SHOCKABSORBER TO BODY Connectthe shock absorber with three nuts.Torquethe nuts. Torque: 240 kg-cm {17 ft-lb, 24 N.m}

3.

INSTALLSHOCKABSORBER TO AXLE CARRIER Installthe shock absorberwith two bolts and two nuts. Torque the nuts. Torque: 1,450 kg-cm (105 ft-tb, 142 N.m)

RA.20

- RearSuspension (FWD) REARAXLE AND SUSPENSION 4. TO SUPPORT TOROUENUT HOLDINGSUSPENSION SHOCKABSORBER (a) Torque the nut. Torque: 500 kg-cm (36 ft-lb, 49 N'ml (b) Installthe dust cover on the suspension support' INSTALL FLEXIBLE HOSE TO SHOCK ABSORBER BRACKET INSTALL BRAKETUBE Torque: 155 kg-cm (11 ft-lb, 15 N'm) WITH BRAKEFLUIDAND FILL BRAKERESERVOIR BLEEDBRAKESYSTEM (See page BR-7) CHECKREARWHEEL ALIGNMENT (See page RA-3) INSTALL PACKAGE TRAY BRACKET AND SHOCK ABSORBER

5. 6.

7. 8. 9.

Arm Suspension
(See page RA-l6)

ARM REMOVALOF SUSPENSION

1. JACK UP VEHICLE Jack up the vehicleand support the body with stands.

2.

ARM REMOVENO.2 SUSPENSION (a) Removethe bolt and nut holdingthe suspension arm to the axle carrier.

(b) Removethe cam and bolt holding the suspension arm. arm to the body and removethe suspension (1) plate is mark Rememberwhere the cam NOTE: arm. when removingthe suspension loosenthe bolt.Do not turn Ql When removing, the cam.

(FWD) REARAXLE AND SUSPENSION- RearSuspension 3.

RA.21

ARM REMOVENO.l SUSPENSION (d Removethe bolt and nut holdingthe suspension arm to the axle carrier.

(b) Removethe bolt and nut holdingthe suspension arm arm. to the body and removethe suspension

REPLACEMENT OF NO.l BUSHING

"'wb
\-----7

1.

\=/

REMOVE BUSHING UsingSST, pressout the bushing. ssT 09726-32010

2.

INSTALL BUSHING Using SST, pressin a new bushing.

ssr 09726-32010
CAUTION: Do not use a lubricant when pressing in the bushing.

ARM INSTALLATION OF SUSPENSION

1. ARM INSTALLNO.l SUSPENSION (a) Connect the suspensionarm to the body with the bolt and nut. Do not torque the bolt yet. NOTE: Be sure the lip of the nut is restingon the flange of the bracket,not over it.

REARAXLE AND SUSPENSION Connectthe suspension arm to the axlecarrierwith the bolt and nut. Do not torque the bolt yet. NOTE: When connectingthe suspension arm, insert the lip of the nut into the hole on the suspension. (d

2.

INSTALL NO.2 SUSPENSION ARM (a) Placethe suspension arm in position. (b) lnstall the cam and bolt holdingthe suspension arm to the body. Do not torque the bolt yet. (c) Align the cam plate mark at the samepositionit was before removal.

(d) Install the bolt and nut holdingthe suspension arm to the axle carrier.Do not torque the bolt yet. NOTE: Be sure the lip of the nut is restingon the flange of the suspension arm, not over it.

3.

TOROUESUSPENSION ARM SETTINGBOLTS (a) Removethe stands and bouncethe vehicleto stabilize the suspension.

Torque the setting bolts with the vehicleweight on the suspension. Torque: 89O kg-cm (64 ft-lb, 87 N.ml 4. (See page RA-31 CHECKREARWHEEL ALTGNMENT

(d

(FWD) REARAXLE AND SUSPENSION- RearSuspension

RA-23

Strut Rod
(See page RA-l61

REMOVALOF STRUTROD
1. 2. JACK UP VEHICLE(Seepage RA-2OI REMOVESTRUTROD (a) Removethe bolt and nut holdingthe strut rod to the axle carrier. b) Removethe bolt and nut holdingthe strut rod to the body and remove the strut rod.

INSTALLATION OF STRUTROD
1. INSTALLSTRUTROD (a) Connectthe strut rod to the body with the bolt and nut Do not torque the bolt yet. NOTE: Be sure the lip of the nut is restingon the flange of the bracket.

(b) Connect with the bolt the strut rod to the axlecarrier and nut. Do not torquethe bolt yet. NOTE: When connecting the strut rod, align the lip of the nut with the grooveon the bracket.

2.

TOROUESTRUT ROD SETTINGBOLTS (a) Removethe standsand bouncethe vehicleto stabilize the suspension. (b) Torque the setting bolts with the vehicleweight on the suspension. Torque: 890 kg-cm (64 ft-lb, 87 N'ml CHECKREARWHEELALIGNMENT (See page RA-31

3.

RA.24

REARAXLE AND SUSPENSION- Troubleshooting(4WD)

(4WD} TROUBLESHOOTING
Problem Oil leak at rear axle Possible cause Oil sealsworn or damaged Bearingretainer loose Rearaxle housingcracked Oil leak at pinionshaft Oil leveltoo high or wrong grade Oil sealworn or damaged flange looseor damaged Companion Noisein rear axle Oil levellow or wrong grade Excessive backlashbetweendrive pinion and ring or side gear Ring,drive pinionor side gearsworn or chipped Drive pinionbearingworn Axle shaft bearingworn Side bearing loose or worn Bottoming Vehicleoverloaded Shock absorberworn out Springsweak Remedy Replace oil seal Replace retainer Repairas necessary Drainand replaceoil Replace oil seal Tighten or replaceflange Drainand replaceoil Checkbacklash Checkgears Replacebearing Replacebearing Tighten or replacebearings Check loading Replace shock absorber Replace spring RA.43 RA.43 RA-28 RA-28 RA-28 RA.25 RA-36 RA-28 RA-28 Page RA-25 RA-25

REARAXLE AND SUSPENSION- RearAxle Shaft (4WD)

RA-25

REARAXLE SHAFT (4WD)

COMPONENTS

Wheel BrakeDrum

RearAxle Shaft

oEnd Gasket

YV?@ dmi
WBearins

-r-/
outerRetainer

| | | Casret O Retainer | | I lnner Retainerl

Bearing torque [g-cm (tt-tu,trl'm)l : Tightening <): Non-reusable part

REMOVALOF REARAXLE SHAFT

1. 2. DRUM AND BRAKE REMOVE WHEEL NUTS MOUNTING PLATE BACKING FOUR REMOVE

REMOVEREARAXLE Using SST, pull out the rear axle.

ssr 09520-ooo31
CAUTION: When pulling out the rear axle, be careful not to damage the oil seal.

RA-26

- RearAxte Shaft (4WD) REARAXLE AND SUSPENSION

INSPECTION AND REPAIR OF REARAXLE SHAFTCOMPONENTS

1. INSPECTREAR AXLE SHAFT AND FLANGE FOR WEAR, DAMAGEOR RUNOUT Maximum shaft runout: 1.5 mm {0.059 in.} Maximum flange runout: 0.1 mm (0.0O4in.) lf the rear axle shaft or flange is damagedor worn, or if theirrunoutis greater replace than maximum, the rearaxle shaft. INSPECT REAR AXLE BEARING FOR WEAR OR DAMAGE lf the bearingis damagedor worn, replaceit. REMOVEBEARINGINNERRETAINER (a) Using a grinder,grind down the inner retainer. (b) Usinga chiseland hammet cut off the retainer and removeit from the shaft.

2.

3.

REMOVEBEARINGFROM SHAFT UsingSST, pressthe bearing off the shaft. ssT 09527-2001 1

INSTALL BEARING OUTER RETAINER AND NEW BEARING ON SHAFT Using SST, presson the bearingouter retainer and new bearing. s s T 0 9 5 15 - 2 0 0 1 0

150'c

6.
lnnerRetainer

INSTALLBEARINGINNERRETAINER ON SHAFT (d Graduallyheat the bearinginner retainerto about 150'C (302'F)in an oil bath.

- RearAxle Shaft (4WD) REARAXLE AND SUSPENSION

RA..27

(b) While the innerretaineris still hot, pressthe retainer on the shaft with SST. ssT 09515-20010 NOTE: Be sure that there is no oil or greaseon the rear axle shaft or retainer. Facethe non-beveled side of the innerretainertoward the bearing.

7.

INSPECT OIL SEAL FORWEAR OR DAMAGE lf the seal is damagedor worn, replaceit. REMOVEOIL SEAL FROMAXLE HOUSING Using SST, removethe oil seal.

8.

ssT 09308-00010

9.

INSTALLNEW OIL SEAL IN AXLE HOUSING (d Apply MP greaseto the oil seal. (b) UsingSST,drivein the oil sealto a depthof 5.6 mm (0.220ini.

7-12010 ssr 0951

Drivein

INSTALLATION OF REARAXLE SHAFT

{See page RA-25} 1. 2. APPIY LIOUIDSEALEAR TO BOTH SIDESOF END AND RETAINER GASKETS PLACENEW END AND RETAINER GASKETSIN POSTTtON Facethe notch of the gasketdownward.

3.

INSTALLREARAXLE SHAFT IN HOUSING (a) Facethe notch of the retainerdownward. (b) Installthe rear axle shaft with four new self-locking nuts. Torque: 670 kg-cm (48 ft-tb, 66 N'm) NOTE: o Be careful not to damagethe oil seal. o When insertingthe axle shaft, be careful not to hit or dent the oil deflector insidethe axle housing. INSTALLBRAKEDRUM AND WHEEL

4.

RA.28

- Differentiat REARAXLE AND SUSPENSTON (4WD)

(4WD) DIFFERENTIAL
COMPONENTS

Pinion Shaft I

*:#ffi#6-Pinion Gear Differential Case

Oil Slinger DifferentialCarrier

-rb, N.m)l : Tightening torque O : Non-reusable part

- Differential (4WD) REARAXLE AND SUSPENSION

RA.29

ON.VEHICLE REPLACEMENT OF OIL SEAL

1. 2. DISCONNECT PROPELLER SHAFTFROM (Seepage PR-3) DIFFERENTIAL REMOVECOMPANIONFLANGE (See step 7 on page RA-31)

3.

REMOVE OIL SEAL AND OIL SLINGER (d UsingSST, removethe oil sealfrom the housing. ssT 09308-10010 (b) Remove the oil slinger. REMOVEFRONTBEARING AND BEARINGSPACER (See step 9 on page RA-311 INSTALLNEW BEARING SPACER AND FRONT BEARING(See step 9 on page RA-391 INSTALLOIL SLINGER AND NEW OIL SEAL (a) lnstall facingas shown. the oil singer (b) UsingSST, drivein a new oil sealas shown.

4. 5.
SST

6.

1 ssr 09554-3001
Oil seal drive in depth: 1.0 mm (0.039 in.l (c) Apply MP greaseto the oil seallip. 7, 8. 9. INSTALLCOMPANION FLANGE (See step 11 on page RA-39) ADJUST DRIVEPINION (See step 12 on page RA-4OI STAKEDRIVEPINIONNUT

10. CONNECT PROPELLER SHAFTFLANGE TO COMPANIONFLANGE(See page PR-6)

5 mm (O.20in.)

1 1. CHECKDIFFERENTIAL OIL LEVEL Fillwith hypoidgearpil if necessary. Oil grade: API GL-s hypoid gear oil Viscosity: Above - 18'C (O"F) SAE 90 Below - 18'C (O"Fl SAE 8OW or 8OW-90 Capacity: 1.O liters (1.1 US qts, 0.9 lmp. qts) Torquethe filler plug. Torque: 500 kg-cm (36 ft-lb, 49 N.m)

RA.30

- Differential REARAXLE AND SUSPENSION {4WD)

REMOVALOF DIFFERENTIAL
(See page RA-28) 1. 2. 3. 4. DRAIN DIFFERENTIAL OIL REMOVEREARAXLE SHAFT (See page RA-25) DISCONNECT PROPELLER SHAFT FROM (Seepage RA-28) DIFFERENTIAL ASSEMBLY REMOVEDIFFERENTIAL CARRIER

DISASSEMBLY OF DIFFERENTIAL
(See page RA-281 NOTE: lf the differential is noisy,performthe following pre-inspection beforedisassembly to determine the cause. problems, lf the differential has severe disassemble and repairas necessary. 1. C H E C KR I N GG E A RR U N O U T in.l Maximum runout: 0.07 mm (O.OO28 the ring gear. maximum,replace lf the runoutis exceeds CHECKRINGGEARBACKLASH - O.OO59 in.) Backlash: 0.10 - 0.15 mm (O.OO39 lf the backlash is not within specification, adjustthe side (Seestep 5 on bearingpreloador repair as necessary. pageRA-36) INSPECTTOOTH CONTACT BETWEEN RING GEAR AND DRIVEPINION (See step 6 on page RA-38) Note the tooth contactingposition. CHECKSIDE GEARBACKLASH Measure the side gear backlash while holdingone pinion gear toward the case. Standardbacklash: - 0.15 mm (0.0008- 0.0059 in.) O.OZ lf the backlash installthe coris not within specification, rect thrust washers.

2.

3,

4.

5.

CHECKDRIVEPINIONPRELOAD the preloadof the backUsinga torquewrench,measure lash between the drive pinionand ring gear. Preload: 4-7 kg-cm {3.5 - 6.1 in.-lb,0.4 - O.7 N'm}

6.

CHECKTOTALPRELOAD the total preload. Usinga torquewrench,measure Total preload: In addition to drive pinion preload 2 - 4 kg-cm $.7 ' 3.5 in.-lb,O.2- O.4 N'm)

REARAXLE AND SUSPENSTON - Differentiat (4WD) 7.

RA-31

REMOVECOMPANIONFLANGE (a) Usinga chiseland hammer,loosenthe stakedpart of the nut. (b) Using SST to hold the flange, removethe nut and washer. ssT 09330-00020

b) UsingSST,removethe companion flange. ssT 09557-22022

8.

REMOVE OIL SEALAND OIL SLTNGER h) UsingSST,removethe oil sealfrom the housing.

ssr 09308-10010
(b) Remove the oil slinger.

9.

REMOVE FRONTBEARING AND BEARING SPACER (a) UsingSST, removethe front bearing from the drive pinion. ssT 09556-12010 (b) Remove the bearing spacer. lf the front bearing is damaged or worn, replace the bearing.

10. REMOVEDIFFERENTIAL CASE FROM CARRIER (d Put matchmarks on the bearingcap and differential carrier. (b) Removethe two adjustingnut locks. (c) Remove the two bearing caps and two adjustingnuts. (d) Removethe two bearingouter races. (d Removethe differentialcase.

RA.32

(4WD) - Differential REARAXLE AND SUSPENSION partsto show the location NOTE: Tag the disassembled for reassembly.

11. REMOVE DRIVEPINIONFROMDIFFERENTIAL CARRIER

OF AND REPLACEMENT INSPECTION DIFFERENTIAL

(See page RA-281 1. DRIVEPINIONREARBEARINGRACE REPLACE (a) UsingSST and a press,pull out the rear bearingfrom the drive pinion.

ssT 09950-00020

(b) Installthe resuedthrust washeron the drive pinion with the chamfered end facing the piniongear. (c) UsingSST and a press,pressa new rear bearingon the drivepinion. ssT 09608-12010

2.

AND REARBEARING REPLACE DRIVEPINIONFRONT OUTERRACES (a) Using a brass bar and hammer,tap out the outer race. (b) UsingSST and a press,drive in a new outer race. 2 0 10 ssT 09608-1

RA0062

REAR AXLE AND SUSPENSION 3.

Differential (4WD)

RA-33

IF NECESSARY,REPLACESIDE BEARINGS (a) Using SST, remove the side bearing from the differential case.

ssT 09502-10012
NOTE: On the differential case there are indentations into which the ssT fits.

(b) UsingSST and a press,pressin a new bearing.

1 ssr 09608-2001

4.

INSPECT SIDEGEARBACKLASH Measure while holdingthe other the side gear backlash side geartoward the case. Standardbacklash: 0.02 - 0.15 mm (0.0008 - 0.0059 in.)

5.

IF NECESSARY, REPLACE RINGGEAR,SIDEGEARS AND PINION GEARS NOTE: o lf the ring gear is to be used again,placematchmarks beforeseparating it. o lf the ring gear or drive pinion are damaged,replace them as a set.

(a) Lift the lock platesand removethe mount bolts. (b) Usinga plastic-faced tap on the ring gearto hammer, it from the differential separate case.

RA.34

- Differential (4WD) REARAXLE AND SUSPENSION (c) Usinga pin punchand hammer, driveout the straight pin foward the ring gear installation surface. (d) Removethe pinion shaft, pinion gerars,side gears and thrust washers.

te) Installthe side gears,thrust washers,pinion gears and shaft. (Seepage RA-33) (f) Checkthe sidegear backlash. - 0.15 mm Standardbacklash: O.O2 (0.0008 - O.OO59 in.)

(g) lf the backlash use thrust is not within specification, washerof a differentthickness.
Thrustwasherthickness mm (in.)

1 . 5 0( 0 . 0 5 9 1 ) 1.s5 (0.061 0) 1 . 6 0( 0 . 0 6 3 0 )

| | |

r.65(0.0650) t .70 (0.0669) r.75(0.0689)

(h) Usinga pin punch and hammer,tap a new straight pin throughthe caseand holein the pinionshaft. (i) Stakethe pin and differential case.

RingGear

=-_-

&

case. Cleanthe contactsurfaceof the differential Gradually heatthe ring gearto about 1OO'C(212"F1 in an oil bath. CAUTION: Do not heat the ring gear above 1lO'C (230"F).

(j) (0

- Differential (4WD) REARAXIE AND SUSPENSION (l)

RA-35

Clean the contactsurface of the ringgearwith cleaning solvent. (m) Then quicklyinstallthe ring gear on the differential case. (n) Coatthe ring gear mount bolts with gearoil. (o) Installnew lock platesand the mount bolts.Tighten the mountbolts uniformlyand a littleat a time. Torque the bolts. Torque: 985 kg-cm (71 ft-lb, 97 N.m) (p) Checkthe ring gear runout. Maximum runout: 0.07 mm (0.028 in.) (q) Stakethe lock plate. NOTE: Stakeone claw flush with the flat surfaceof the nut. For the claw contactingthe protrudingportion of the nut, stake (bend)only the half on the tighteningside.

ASSEMBLY OF DIFFERENTIAL
(Seepage RA-28) 1. TEMPORARILY ADJUST DRIVEPINIONPRELOAD (a) lnstallthe followingparts: o Drivepinion o Frontbearing NOTE: Assemble the spacer, oil slingerand oil sealafter adjusting the gearcontactpattern. (b) UsingSST,install the companion flange. ssT 09557-22022

(c) Adjust the drive pinion preload by tighteningthe companion flangenut. UsingSST to hold the flange, tightenthe nut. ssT 09330-00020 CAUTION: As there is no spacer,taghtena little at a time, being careful not to overtighten.

a
RA-36 - Differential (4WD) REARAXLE AND SUSPENSION (d) Usinga torquewrench,measure the preload. Preload: New bearing 6.5 - 12.5 kg-cm (5.6 - 1O.9in.-lb) (0.6 - 1.2 N.ml Reusedbearing 4 - 7 kg-cm (3.5 - 6.1 in.-lb) (0.4 - 0.7 N.ml

2.

INSTALL DIFFERENTIAL CASE IN CARRIER (d Place the bearing outer races on their respective bearings. Make surethe left and right outer racesare not interchanged. (b) Installthe casein the carrier.

3.

INSTALLADJUSTINGNUTS Installthe adjustingnuts on their respective carrier,making sure they are threadedproperly. NOTE: Makesurethat thereis backlash betweenthe ring gear and drive pinion.

4,

INSTALL BEARING CAPS Align the matcfimarks on the cap and carrier. Screw in the two bearingcap bolts two or three turns and pressdown the bearingcap by hand. NOTE: lf the bearing cap does not fit tightlyon the carrier, the adjustingnut threadsare not threadedproperly. Reinstall adjustingnuts if necessary.

5.

ADJUST SIDE BEARING PRELOAD (a) Tighten the bearing cap bolts until the spring washersare slightlycompressed. (b) UsingSST, tighten the adjustingnut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.0O8in.).

1 ssr 09504-oool

- Differential (4WD) REARAXLE AND SUSPENSION

RA.37

(c) Using SST, firmly tighten the adjustingnut on the drive pinionside.

1 ssr o9504-ooo1
(d) Checkthe ring gear backlash. ring gear backlash, lf tightening nut creates the adjusting is eliminated. loosenthe nut so that backlash

(e) Placea dial indicatoron the top of the bearingcap on the ring gear side. (f) Adjust the sidebearingfor zero preloadby tightening the other adjustingnut until the pointeron the indicator beginsto move.

(g) Tightenthe adjustingnut 1 - 1llznotchesfrom the zero preloadposition.

(h) Using a dial indicator, adjustthe ring gear backlash until it is within specification. - O.OO59 in.l Backlash: 0.10 - 0,15 mm (O.OO39 NOTE: The backlashis adjustedby turning the left and For example,loosen right adjustingnuts equal amounts. the nut on the left side one notch and tightenthe nut on the right side one notch.

Torque the bearingcap bolts. Torque: 6OOkg-cm (43 ft-lb, 59 N.ml

(i)

RA.38

REARAXLE AND SUSPENSION- Differentiat(4WD) Recheckthe ring gear backlash. Using a torque meter, measurethe total preload. Total preload: ln addition to drive pinion preload 2 - 4 kg-cm 11.7- 3.5 in.-lb, O.2 - 0.4 N.m) Backlash: O.1O- O.15 mm (0.0039 - 0.O059 in.) (j) (0

6.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEPINION (a) Coat red lead on 3 or 4 teeth at three different positions of the ring gear. (b) Hold the companionflange firmly and rotate the ring gear in both directions. (d lnspect the tooth pattern.

HeelContact

FaceContact

Selecta thrustwasherthat wilt brinq - the drive pinioncloserto the ring gear.

,rfl

Selecta thrustwasherthat will shift the drivepinionaway from the ring gear.

- Differential (4WD) REARAXLE AND SUSPENSION

RA.39

NOTE: lf adjustingthe meshingof the teeth of the drive pinionand ringgearby changing the extension of the drive pinion,selecta thrustwasherof the appropriate thickness from the table below.
Drive pinionthrust washerthickness mm (in.)

2.24 (O.O882) 2.27 l}.O8e4l 2.30(0.0906) 2 . 3 3( 0 . 0 9 1 7 ) 2.36(O.Os29) 2.39(0.0941) 2.42(0.0953) 2.45(0.096s) 7. 8.

| I I | | I |

Z.+8(0.0976) Z.S1(0.0988) Z.S4(0.1000) 2 . 5 7( 0 . 1 0 1 2 ) Z.A0{0.1024) 2.63 (0.103s) Z.A6(0.1047)

REMOVECOMPANIONFLANGE (See step 7 on page RA-31) REMOVEFRONTBEARING (See step 9 on page RA-31)

9.

INSTALL NEW BEARING AND FRONT SPACER BEARING (d lnstall a new bearingspaceron the shaft. (b) lnstallthe front bearing on the shaft.

10. INSTALLOIL SLINGER AND NEW OIL SEAL (d Installthe oil slingerfacing as shown. (b) UsingSST, drive in a new oil sealas shown. ssT 09517-12010 Oil seal drive in depth: 1.0 mm (0.039 in.) (d Apply MP greaseto the oil seallip.
Drive in depth

11. INSTALL FLANGE COMPANION (a) UsingSST, installthe companion flange. ssr 09557-22022

RA-/[()

REARAXLE AND SUSPENSION- Differential(4WD) (b) Coat the threadsof a new nut with MP grease. (c) Using SST to hold the flange,tighten the nut. Torque the nut.

ssr 09330-ooo20
Torque: 1,425 kg-cm (103 ft-lb, 140 N'ml

RAOO3

12. ADJUST DRIVEPINIONPRELOAD the preload of the backUsinga torquewrench,measure the drive pinionand ring gear. lash between Preload: New bearing 6.5 - 12.5 kg-cm (5.6 - 10.9 in.-lbl (0.6 - 1.2 N'ml Reused bearing 4 - 7 kg-cm (3.5 - 6.1 in.-lbl (0.4 - 0.7 N'ml

(a) lf preloadis exceeds replace the bearspecification,

ing spacer. (b) lf preloadis lessthan specification, retightenthe nut 130 kg-cm (9 ft-lb, 13 N.m) at a time until the specifiedpreloadis reached. the while retightening lf the maximumtorque is exceeded nut, replacethe bearingspacerand repeatthe preloadprocedure. Do not back off the pinion nut to reduce the preload. Maximum torque: 2,4OOkg-cm (174 ft-lb, 235 N'm) FLANGE 1 3 . CHECKDEVIATION OF COMPANION (0.0039 in.l Maximum tateralrunout: 0.10 mm Maximum radialrunout: 0.10 mm (0.0039in.l

14. STAKE DRIVEPINIONNUT

- Differential (4WD) REARAXLE AND SUSPENSION

RA.41

NUT LOCKS 15. INSTALLADJUSTING (a) Selecteithera lock plate No. 1 or No. 2 whichever nuts. will fit the adjusting (b) lnstallthe lock plateon the bearingcaps. Torque: 55 kg-cm (48 in.-lb, 5.4 N'ml

INSTALLATION OF DIFFERENTIAL
(See page RA-281 1. ASSEMBLY CARRIER INSTALL DIFFERENTIAL in assembly Install a new gasketandthe differentialcarrier the axle and installthe twelve nuts. Torque the nuts. Torque: 315 kg-cm (23 ft-lb, 31 N'm) PROPELLER SHAFT FLANGETO CONNECT COMPANIONFLANGE(See page PR-61 WITH INSTALLREARPLUGAND FILL DIFFERENTIAL GEAROIL Torquethe drainplug. Torque: 500 kg-cm (36 ft-|b,49 N'm) Oil grade: API GL-s hypoid gear oil Viscosity: Above - 18"C (O'Fl SAE 90 Below - 18'C (0"F) SAE 8OW or 80W-90 Capacity: 1.0 liters (1.1 US qts, 0.9 lmp. qts) Torquethe filler plug. Torque: 500 kg-cm (36 ft-|b,49 N'ml

2.

3.

5 mm (0.2Oin.)

RA-42

REARAXLE AND SUSPENSION- Four Link Type RearSuspension (4WD)

(4WDI FOURLINK TYPE REARSUSPENSION

COMPONENTS

fl,rooEz lrol
Upperlnsutator-{sH9
.ffi\ |

I
Lateral Control Rod

d@(
g

\-

a",, ,0.,"n@
Lower tnrut.tor-@

oD tr

f f

a, r A/----_-9 raz, nat]. I r,zoo I

I

\ ll

\l

^ T \nooo@
a

l- 650t+?,54l_l

Arm ', uooe, Control

'wr=:i

aia I 11 v @

" i
i

@ @
o

b |

.g

q
a

E i*u ,Wte
ShockAbsorber

et,6

%=
e
F v

@.,a
i ,'

? r

u.,
a^

@a

LowerControlArm
Rear StabilizerBar

-lb, N'm)l : Tightening torque

REARAXLE AND SUSPENSION- Four Link Type RearSuspension(4WD)

RA-43

Coil Springand RearShockAbsorber

(See page RA-421

REMOVALOF COILSPRING AND SHOCK ABSORBER

1. JACK UP VEHICLE Jack up the rear axle housingand support the body with stands.Leavethe jack under the rear axle.

2.

REMOVEREARSHOCKABSORBER (a) Removethe bolt holding the shock absorberto the rearaxle housingand disconnectthe shock absorber.

(d

Removethe nuts holding the shock absorberto the body, and removethe shock absorber.

3.

REMOVESTABILIZER BAR BUSHINGBRACKETS Removethe bolts holdingthe stabilizerbar bushingto the rear axle housing.

4.

DISCONNECTLATERALCONTROLROD FROM REAR AXLE HOUSING Removethe nut holdingthe lateralcontrol rod to the rear axle housingand disconnectthe lateralcontrol rod.

RA-/14

(4WD) REARAXLE AND SUSPENSION- Four Link Type RearSuspension 5. REMOVE COILSPRING (a) Beginto lower the rearaxle housing. NOTE: Be carefulnot to pull the brakeline and parking brakecable.

(b) While lowering the rearaxlehousing, removethe coil springand the upperand lower insulators.

INSTALLATION OF COILSPRING AND SHOCKABSORBER

1. PUT LOWERINSULATOR ON AXLE HOUSING

2,

PUT UPPER INSULATOR ON COILSPRING

3. 4.

INSTALLCOILSPRING CHECKPOSITION OF LOWERINSULATOR (a) Jack up the rearaxle housing. (b) Checkthat the lower insulator is installed correctly. lf the insulator is not in correctposition, reinstall the coil spring.

REARAXLE AND SUSPENSION- Four Link Type RearSuspension(4WD) 5.

Rl-+S

INSTALLLATERALCONTROL ROD In order, install a washer, bushing,spacer,lateralcontrol rod, bushing, washerand nut on the rear axle housing. Do not tighten the nut yet.

6.

INSTALLSHOCKABSORBER b) Connect the shockabsorber to the body with the nut. Holdthe shaftwith an adjustable wrench. Torquethe nut. Torque: 250 kg-cm (18 ft-lb, 25 N.m)

(b) Connectthe shock absorberto the rear axle housing with the nut Torque the bolt. Torque: 375 kg-cm (27 ft-\b,37 N.ml

7.

INSTALL STABILIZER BAR BUSHINGBRACKETS TO REARAXLE

8.

STABILIZESUSPENSION Removethe stands and bounce the car to stabilizethe suspension.

RA-/t6

REARAXLE AND SUSPENSION- Four Link Type RearSuspension(4WD) 9. TIGHTEN LATERALCONTROLROD NUT h) Raisethe axle housinguntil the body is free from the stands. (b) Torque the lateralcontrol rod nut. Torque: 650 kg-cm (47 ft-lb, 64 N'm)

LateralControl Rod
(See page RA-421

ROD REMOVALOF LATERALCONTROL

1. REARAXLE HOUSING SUPPORT Jack up the rear axle housingand support it with stands.

2.

DISCONNECTLATERAL CONTROLROD FROM REAR AXLE HOUSING Removethe nut holdingthe lateralcontrol rod to the rear axle housing,and disconnectthe lateralcontrol rod.

3.

DISCONNECT LATERALCONTROLROD FROM BODY Removethe nut holdingthe lateralcontrol rod to the body and removethe lateralcontrol rod.

ROD REPLACEMENT OF LATERALCONTROL BUSHING

1. REMOVE BUSHING Using SST, pressout the bushingfrom the lateralcontrol rod. ssT 09710-14012 NOTE: When insertingand removingthe bushing,press or pull from the chamferedside as shown in the figure.

Remove

(4WD) REARAXLE AND SUSPENSION- Four Link Type RearSuspension

Chamfer

RA.47

2.

INSTALLBUSHING Using SST and a press,press a new bushinginto the lateralcontrol rod. ssT 09710-14012 NOTE: Do not usea lubricant when pressing in the bushing.

INSTALLATIONOF LATERALCONTROLROD
1. INSTALL LATERALCONTROLROD TO BODY (a) Raisethe axle housinguntil the housingis free from the stands.

RAO343

(b) Installthelateralcontrol rod to the bodywith the nut.

2.

INSTALL LATERAL CONTROL ROD TO REAR AXLE HOUSING (d Consecutively install the washer, bushing,spacer, lateralcontrolarm, bushing, washerand nut on the rear axle housing.

(b) Removethe stands and bounce the car to stabilize the suspension.

RA-48

(4WD) REARAXLE AND SUSPENSION- Four Link Type RearSuspension (d Jack up the axle housing. (d) Torque the nut. Torque: Body side 1,2OOkg-cm (87 ft-lb, 1 18 N.m) Axle housingside 650 kg-cm {47 ft-lb, 64 N.ml

Upperand Lower GontrolArm

(Seepage RA-421

REMOVAL OF UPPER AND LOWER CONTROL ARM

1. JACK UP VEHICLE Jack up the vehicleand support the body with stands. Hold the rear axle housingwith a jack. REMOVEUPPERCONTROLARM (a) Removethe bolt holdingthe uppercontrolarm to the body.

2.

(b) Remove the bolt holdingthe uppercontrolarm to the rearaxlehousing, then remove the uppercontrolarm.

3.

REMOVELOWERCONTROLARM (a) Removethe bolt holding the lower control arm to the body.

- FourLink Type RearSuspension (4WD) REARAXLE AND SUSPENSION

nA-+g

(b) Remove the bolt holdingthe lowercontrolarmto the and then removethe lowercontrol rearaxlehousing, arm.

AND LOWER INSTALLATION OF UPPER ARM CONTROL

1. ARM INSTALLUPPER CONTROL (a) lnstall the upper control arm on the body with the bolt and nut. Do not tightenthe nut yet.

(b) Install the uppercontrolarm on the rearaxlehousing with the bolt and nut. Do not tighten the nut yet.

2.

ARM INSTALLLOWERCONTROL (a) lnstallthe Iower control arm on the body with the bolt and nut. Do not tightenthe nut yet.

(b) lnstallthe lowercontrolarm on the rearaxlehousing with the bolt and nut. Do not tightenthe nut yet.

RA-50

- FourLink Type RearSuspension (4WD) REARAXLE AND SUSPENSION 3. STABILIZESUSPENSION Removethe stands and bounce the car to stabilizethe suspension.

4.

JACK UP VEHICLE Raise the axle housing until the body is free from the stands. TIGHTENBOIT HOLDINGUPPER CONTROL ARM TO BODY Torque the bolt. Torque: 1,2OO kg-cm (87 ft-lb, 118 N.ml

5.

6.

TIGHTENBOLT HOLDINGUPPER CONTROT ARM TO REARAXLE HOUSING Torque the bolt. Torque: 1,2OO kg-cm (87 ft-lb, 1 18 N.ml

7,

TIGHTENBOLTHOLDINGLOWERCONTROL ARM TO BODY Torque the bolt. Torque: 1,2OOkg-cm (87 ft-lb, 118 N.ml

8.

TIGHTENBOLTHOLDINGLOWERCONTROL ARM TO REARAXIE HOUSING Torque the bolt. Torque: 1,2OOkg-cm (87 ft-lb, 1 18 N.ml

(4WD) REARAXLE AND SUSPENSION- Four Link Type RearSuspension

ne-St

Rear Stabilizer Bar

(See page RA-421

BAR REMOVALOF REARSTABILIZER

1. REMOVESTABILIZER BAR BUSHINGBRACKETS

2. 3.

REMOVEREARSTABILIZER BAR FROM BODY DISCONNECT STABILIZER BAR END FROM LINK

BAR INSTALLATION OF REARSTABILIZER

1. INSTATLSTABILIZER LINK TO BODY Installthe link onto the body as shown.

2.

INSTALLSTABILIZER BAR TO LINK Connectthe stabilizer bar on both sidesto the linkswith bolts, collars,cushions,nut and new cotter pins. Torque: 310 kg-cm (22 ft-\b,30 N'ml

3.

TO REARAXLE HOUSING INSTALL BRACKETS Torque: 375 kg-cm 127ft-1b,37 N'm)

BR.1

BRAKESYSTEM
PRECAUTIONS TROUBLESHOOTING CHECKSAND ADJUSTMENTS MASTERCYLINDER BRAKE BOOSTER FRONTBRAKE REARBRAKE Sedan Wagon FWD Wagon 4WD BRAKEHOSESAND TUBES

Page BR.2 BR-2

BR-6 BR.9 8R.14 8R.16 B,R.22 BR-22 8R.29 8R.36 8R.43

BR-2

Troubleshooting BRAKE SYSTEM - Precautions,

PRECAUTIONS
1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard.Replacethe parts with parts of the same part number or equivalent. ltnis very important to keep parts and the area clean wltsn repairing the brake system.

2,

TROUBLESHOOTING
Problem Low or spongy pedal Possible cause Liningsworn Leak in brake system Mastercylinderfaulty Air in brake system Wheel cylinderfaulty Pistonsealsworn or damaged Rearbrake automaticadiusterfaulty Parkingbrakeout of adjustment Parkingbrakewire binding Boosterpush rod out of adjustment Returnspringfaulty Brake line restricted Liningcrackedor distorted Wheel cylinderor caliperpiston sticking Automatic adjuster broken Mastercylinderfaulty Tires improperly inflated Oil or greaseon linings Brakeshoes distorted, linings worn or glazed Drum or disc out of round Return spring faulty Wheel cylinderfaulty Pistonfrozen in caliper Disc brake pad sticking Oil or grbaseon linings Brakeshoesdistorted,liningsworn or glazed,drums worn Disc brake pads worn Pistonfrozen in caliper Brakebooster faulty Brake line restricted Remedy Page

BR-16,22 Replace brakeshoesor pads BR-43 Repairleak BR-9 replace master cylinder Repairor BR-7 Bleed brake system 8R.22 Repairwheel cylinder BR-1 6 Repairbrakecalipers B,R.22 Repairor replaceadjuster
Adjust parking brake Repairas necessary Adjust push rod Replace spring Repairas necessary Replace brakeshoe Repairas necessary Replace adjuster Repairor replacemastercylinder Inflate tires to proper pressure Checkfor cause,replacelining Replace brakeshoes Replace drum or disc Replace spring Repairwheel cylinder Repaircaliper pads Replace Checkfor cause,replacelining Replace brakeshoes pads Replace Repaircaliper Repairbooster Repairas necessary

Brakesdrag

BR.8 BR.1 5 BR-22 BR-22 BR-18,22 BR-22 BR-9 FA-3 BR-16,22 BR-16,22 BR-l8,22 BR-22 BR-18,22 BR.1 8 BR-1 6
BR-I6,22 BR-16,22 BR-1 6 BR-1 6 4 BR.1

Brakespull

Hard pedal but brakes inefficient

BRAKE SYSTEM - Troubleshooting

BR.3

(Cont'd) BLESHOOTING TROU

Problem Snappingor clicking noisewhen brakes are applied Possible cause Drum brakes- brakeshoesbinding at backingplate ledges Drum brakes- backingplateledges worn Drum brakes- looseor missing hold down spring Drum brakes- loose set bolt at backingplate Disc brakes- rust on front edge of inboardshoes Disc brakes- looseor missingpad supportplate Disc brakes- loose installation bolt Disc brakes- wear on slide bushing Worn brakelinings Caliperto wheel or rotor interference Dust cover to rotor or drum interference other brakesystemcomponents: Warped or bent brake backing plate or splashshield,cracked drums or rotors Tires rubbingagainstchassisand body Lubricate Replace and lubricateledges Replace
E,

Remedy

Page

BR-22 BR-22 BR-22 BR-22 BR.1 6 BR-1 6 BR-1 6 BR-1 6 BR-16,22 BR.1 8 r+i BR-l8,22 BR-h1N,22
a

Tisnteffit'
replaceif Inspect lubricate, necessary Replace Tighten Replace Replace, refinishdrums or rotors if heavilyscored Replace as required Corrector replace lnspector service

Scrapingor grinding noise when brakes are applied

%
:?*

?"t

Inspector service

BR-4

BRAKE SYSTEM - Troubleshooting

TROU BLESHOOTI NG (Cont'd)

Problem Squeaking, squealing groaning or chattering noise when brakes are applied Note: Brake friction materialsinherently generatenoise and heat in order to dissipateenergy. As a result occasional squeal is normalandis aggravatedby severe environmetal conditions such as cold, heat, wetness, snow, salt mud, etc. This occasional squealis not a functional problem and does not indicate any loss of brake effectiveness Squealing and squeaking noise when brakes are not applied Possible cause Brakedrums and liningsrotors and pads worn or scored Disc brakes - missing or damaged brake pad anti-squeal shim Disc brakes - burred or rusted calipers Dirty, greased,contaminatedor glazedlinings lmproperliningparts Maladjustment of brakepedalor push-rod booster Drum brakes- weak damagedor incorrect shoe hold down springs, loose or damagedshoe hold down spring pins springsand groovedbackingplate ledges Remedy Inspect,serviceor repalce Replace Cleanor deburr Cleanor replace Inspectfor conect usage replace lnspectand adjust Inspect serviceor replace Page

BR-16,22 BR.l6 BR-1 8 BR-16,22 BR-'t6,22 BR-6,15 8R.22

Bent or warped backingplate causing interference with drum lmpropermachiningof drum causing interference with backingplate or shoe Maladjustment of brakepedalor booster push-rod Poor return of brake booster or master cylinderor wheel cylinder Disc brakes - rusted, stuck Other brakesystem, components: Loose or extra parts in brakes Reardrum adjustmenttoo tight causingliningto glaze Worn, damagedor insufficiently lubricated wheel bearings

Serviceor replace Replace drum Inspectand adjust Inspect,serviceor replace Inspect lubricateas necessary Inspect,service,replaceas required

BR-22 8R.22 BR-6,15

BR-g,15,22 B R . 16

BR-16,22

BRAKE SYSTEM - Troubleshooting

BR-5

(Cont'dl TROUBLESHOOTING
Problem Squealing and squeakingnoise when brakes are not applied(cont'd) Possible cause Drum brakes- weak, damagedor incorrectshoe hold down springs Drum brakes- groovedbackingplate ledges lmproperpositioningof pad in caliper Outsidediameterof rotor rubbing caliperhousing Housinginstallation of disc brake pad support plate Groaning, clicking or rattling noise when brakesare not applied Stonesor foreign materialtrapped insidewheel covers Loosewheel hub nuts Disc brakes- failureof shim Disc brakes- wear on slide bushing Disc brakes- looseinstallation bolt Maladjustment of brake pedalor boosterpush-rod Disc brakes - poor return of piston Drum brakes- looseor extra parts Worn, damagedor dry wheel bearings Remedy Inspect,serviceor replace Inspect,serviceor replace Inspect and service Inspect,serviceor replace Correct Removestones, etc. Tightento correct torque and replaceif stud holesare elongated lnspect,replaceif necessary Inspect,replaceif necessary Inspect,tighten if necessary lnspectand adjust Inspect,serviceor replace Inspect removeor service lnspect lubricateor replace BR.1 6 BR.1 6 BR-1 6 BR-6,15 BR.1 8 B,R.22 Page BR-22 BR-22 BR-l6 BR-l6 BR-16

BR-18,22

BRAKE SYSTEM - Checksand

Stop Light Switch PedalPushRod

AND ADJUSTMENTS CHECKS

PEDAL OFBRAKE AND ADJUSTMENT CHECK
1. AS CHECKTHAT PEDALHEIGHTIS CORRECT' SHOWN

slreet: fromasphalt Pedat heisht

i#;:?ifil.,

PedalFreeplay

AsphaltSheet

Height Pedat

ADJUST PEDALHEIGHT IF NECESSARY. (a) Sufficientlyloosenthe stop light switch. (b) Adjust the pedal height by turning the pedal push rod. (c) Returnthe stop light switch until it lightly contacts the pedal stopper. (d) After adjusting the pedalheight,checkand adiustthe pedal freePlay.

AS IS CORRECT, CHECKTHAT PEDAL FREEPLAY SHOWN (a) Stop the engineand depressthe brakepedal several times until there is no more vacuum left in the booster. is (b) Push in the pedaluntil the beginningof resistance felt. Measurethe distance,as shown' Pedaffreepfay: 3 - 6 mm (0.12 - O,24 in.l NOTE: The pedal freeplay is the amount of the stroke until the boosterair valveis moved by the pedalpush rod. ADJUST PEDALFREEPLAY IF NECESSARY, (a) lf incorrect adiust the pedal freeplayby turning the pedal Push rod. (b) Start the engineand check that pedalfreeplayexists. (c) After adjustingthe pedal freeplay,check the pedal height.

DISTANCEIS CHECKTHAT PEDAL RESERVE AS SHOWN CORRECT, (a) Release the parkingbrake. (b) With enginerunning,depressthe pedaland measure the pedal reservedistance,as shown. Pedafreserve distance at 50 kg (11 O-21b,490 Nl: More than 90 mm (3.54 in.l lf incorrect,troubleshootthe brake system.

BRAKE SYSTEM - Checksand Adjustments

BR-7

VV
1st 2nd

@ @

TEST OF BRAKE BOOSTER OPERATIONAL

NOTE: lf available, use a brake booster tester to check the booster operatingcondition. 1. OPERATING CHECK (a) Depress the brake pedal several times with the engineoff, and check that there is no changein the pedal reservedistance. (b) Depressthe brake pedal and start the engine.lf the pedal goes down slightly,operationis normal. AIR TIGHTNESS (d Start the engineand stop it after one or two minutes. Then depressthe brakepedalseveraltimes slowly.lf the pedal goes down fartherest the first time, and less the second and third time, the boo$ter is air tight. (b) Depress the brakepedalwhile the engineis running, lf there is no and stop it with the pedal depressed. changein pedalreserve travel after holdingthe pedal for thirty seconds,the booster is air tight.

2.

BLEEDING OF BRAKE SYSTEM

NOTE: lf any work is done on the brakesystemor if air is suspectedin the brake lines,bleed the system of air. CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediataly. 1. FILL BRAKERESERVOIRS WITH BRAKEFLUID Checkthe reservoir after bleeding eachwheel.Add fluid, if necessary. CONNECTVINYL TUBE TO WHEEL CYLINDER PLUG BLEEDER lnsert the other end of the tube in a half-full containerof brakefluid. BLEEDBRAKELINE (a) Slowly pump the brakepedal severaltimes. (b) While an assistantdepressesthe pedal, loosen the bleederplug until fluid starts to runout.Then close the bleederplug. (c) Repeatthis procedure until thereare no moreair bubbles in the fluid. Bleeder plug tightening torque: 85 kg-cm (74 in.-lb,8.3 N.m) FOREACH WHEEL REPEAT PROCEDURE

2,

3.

4.

BR.8

BRAKE SYSTEM - Checksand Adjustments

CHECK AND ADJUSTMENT OF PARKING BRAKE

1. CHECKTHAT PARKINGBRAKE LEVERTRAVEL IS CORRECT Pull the parkingbrakeleverall the way up, and count the numberof clicks. Parking brake lever travel at 2O kg (44.1 lb, 196 Nl: Sedan 5-Sclicks Wagon 6-Sclicks IF NECESSARY, ADJUST PARKING BRAKE NOTE: Before adjusting the parking brake, make sure that the rear brakeshoe clearance has been adjusted. For shoe clearance adjustment,see pagesBR-28,35 and

2.

42. (a) Remove the console box. (d Loosen nut until the lock nut and turn the adjusting the travelis correct. (d Tightenthe lock nut andinstallthe console box.

*r .;"

BRAKESYSTEM - MasterCylinder

BR-9

MASTERCYLINDER
REMOVALOF MASTERCYLINDER

Master Cylinder

BrakeFluidLevelWarning Switch Connector

t) Gasket

I I

1 s 5 ( 11 , 1 5 )

BrakeTube

-cm (ft-lb,

Tighteningtorque

O: Non-reusable part GAUTION: Do not let brake fluid remainon a painted surface. Wash it off immediatoly. 1. 2. TAKE OUT FLUIDWITH SYRINGE DISCONNECT BRAKETUBES j ,. Usin! SST, disconnectthe brake tubes from tfie master cylinderand 3-way union. ssT 09751-3601 1

3.

REMOVEMASTERCYLINDER (d Disconnect the brakefluid levelwarningswitch connector. (b) Removethe two nuts. (c) Remove the mastercylinder, 3-way unionand gasket from the brake booster.

BR.lO

BRAKE SYSTEM - Master Cylinder

COMPONENTS

Reservor Set Screw

I rzt{rtaz-l

F ( I r

SnapRing

%-Reservoir

9-.o

}N\ ryofltort""* | | RN ry'jbTry^?

- + ) r l l l s c i o t
*" \p-l I 1 Piston(with SPring) | | No.2pistonRins ^l uprrng I

-^ O Gasket e r Il

I rootz,rot I

PistonStopperBolt : Tighteningtorque part O : Non-reusable

(ft-rb,N

DISASSEMBLY OF MASTERCYLINDER
1. REMOVERESERVOIR FROM CYLINDERHOUSING (a) Removethe cap and strainer. (d Removethe set screw. (c) Pull out the reservoir. MOUNT CYLINDER HOUSING IN VISE REMOVETWO GROMMETSFROM CYLINDER HOUSING REMOVEPISTONSTOPPER BOLT Using a screwdriver,push the pistons in all the way and removethe piston stopper'bolt.

2. 3. 4.

BRAKESYSTEM - MasterCylinder 5.

BR-11

AND SPRINGS REMOVETWO PISTONS (d Using a screwdriver and snap ring pliers,removethe snap ring.

(b) Placea rag on two wooden blocksand lightly tap the cylinderflangebetweenthe blocksuntil the pistontip protrudes. (c) Removethe piston by hand,pulling straight out, not at an angle. NOTE: lf pulledout at an angle,there is a possibility of damaging the cylinderbore.

ASSEMBLYOF MASTERCYLINDER

.g
G@D

.g
OnmmU=$

(See page BR-10) 1. APPLY LITHIUM SOAP BASE GLYCOLGREASE TO RUBBER PARTSINDICATEDBY ARROWS

t r

2.

INSTALLTWO SPRINGS AND PISTONS CAUTION: Be careful not to damage the rubber lips on the pistons. (d lnsert the spring and pistons straight in, not at an angle. (b) Pushin the pistonand, usingsnapring pliers,install the snap ring.

3.

INSTALL PISTONSTOPPER BOLT push the pistonsin all the way and Using a screwdriver, installthe piston stopperbolt with the gasket.Torquethe bolt. Torque: 100 kg-cm (7 ft-lb, 1O N.m)

BR-l2

BRAKE SYSTEM - MasterCylinder 4. 5. INSTALLTv\/O GROMMETSTO CYLINDER HOUSING INSTALLCAP AND STRAINER TO RESERVOIR

6.

INSTALL RESERVOIR TO CYLINDERHOUSING Pushthe reservoir onto the cylinderand installthe screw. Torque: 10 25 kg-cm 19 - 21 in.-lb,1.0 - 2.4 N.ml

CAUTION: Because the master cylinder and reservoir tank union is a grommet type, the set screw is designed not to separate from the reservoir or cylinder and will not tighten down the reservoir. Therefore, there is a clearance at point A. Do not insert washers or such when tightening.

'*i,.

BRAKE SYSTEM - MasterCylinder

BR-l3

INSTALLATION OF MASTERCYLINDER
(See page BR-91 1. 2. CLEAN OUT GROOVE ON LOWERINSTALLATION OF MASTERCYLINDER SURFACE CHECKTHAT ''VP" MARK ON MASTERCYLINDER BOOT IS IN CORRECT POSITION

3.

PUSH ROD ADJUST LENGTHOF BRAKEBOOSTER BEFORE INSTALLINGMASTERCYLINDER (See page BR-151

4.

INSTALL MASTERCYLINDER and 3-way union Installa new gasket, the mastercylinder with the two nuts. Torquethe nuts. Torque: 130 kg-cm (9 ft-lb, 13 N.ml

* 5. CONNECTBRAKETUBES Using SST, connectthe braketubes to the mastercyliner and 3-way union.Torque the nuts.

1 ssr 09751-3601

Torque: 155 kg-cm(11ft-lb, 15 N'ml

1?

6. 7.

WITH BRAKEFLUID FILL BRAKERESERVOIR AND BLEEDBRAKESYSTEM {See page BR-71 CHECKAND ADJUST BRAKEPEDAL(Seepage BR-61

8R.14

BRAKE SYSTEM - BrakeBooster

BRAKEBOOSTER
REMOVAL OF BRAKE BOOSTER

Brake Fluid Level Warning Switch Connector

levis

I I

dCI

1 3 0( 9 , 1 3 1

f=s(lr='
3-WayUnionl

5ll

BrakeBooster

(ft-lb,N.m) :Tightening torque part 0 : Non-reusable

1. 2. 3. 4. 5. 6. 7.

REMOVEMASTERCYLINDER(See page Bn-gl DISCONNECT VACUUM HOSEFROM BRAKE BOOSTER REMOVEDISTRIBUTOR CAP REPEATPROCEDURE FOR EACH WHEEL REMOVEHEATERAIR DUCT DISCONNECT PEDAL RETURNSPRINGFROM BRAKE PEDAL DISCONNECT PUSH ROD CLEVIS FROM BRAKE PEDAL Removethe clip and clevis pin. REMOVEBRAKE BOOSTER Removethe four nuts, and pull out the brakebooster.

8.

BRAKE SYSTEM - BrakeBooster

8R.15

INSTALLATIONOF BRAKE BOOSTER

(Seepage BR-l41 1. PUSHROD ADJUSTLENGTH OF BOOSTER (a) Set SSTon the master with the gasket cylinder and the piston. lowerthe pin untilits tip slightlytouches ssr 09737-00010

(d

Tum SST upsidedown, and set it on the booster.

ssT 09737-OOO10
(c) Checkthat there is no clearancebetweenthe booster push rod and pin head of SST. Clearance: O mm (0 in.l

(d) Adjust the boosterpush rod lengthuntilthe push rod lightly touches the pin head.

2.

INSTALL BRAKE BOOSTER Torque: 130 kg-cm (9 ft-lb, 13 N'ml INSTALL MASTER CYLINDER(See page BR-131 CONNECTVACUUM HOSETO BRAKE BOOSTER CONNECTPUSH ROD CLEVISTO BRAKE PEDAL Installthe clevis pin and clip. CONNECTPEDAL RETURNSPRINGTO PEDAL SPRING INSTALL HEATERAIR DUCT INSTALL LOWERFINISHPANEL INSTALL IIA CAP

3. 4. 5.

6. 7. 8. 9.

WITH BRAKEFLUID 1 0 . FILL BRAKERESERVOIR AND BLEEDBRAKE SYSTEM (See page BR-71 1 1 . CHECK BRAKE PEDAL (See page BR-61 CHECK (See page BR-71 12. PERFORM OPERATIONAL

BR-l6

BRAKE SYSTEM - Front Brake

FRONT BRAKE
COMPONENTS
Flexible Hose--\\

\\

\\

[-5s ntzst I \ > . ; l c o

Ja-'r I

fa-l

235 117,231 900 165,88) j

Leh

Torque Plate

A\H)
RotorDisc

Anti-squeal shim

\t__Anti-squeal Spring I

-cm (ft-lb,N.m)
8ao?36

I
I

REPLACEMENT OF BRAKEPADS
. lf a squeaking noise occurs while braking, inspect the . brake pads. Brake squeak will occur when the gap between the pad wear indicatorplate and rotor disc reaches about 2.5 mm (0.098 in.). REMOVEFRONTWHEET Rqmove the wheel and temporarily fasten the rotdfu "' ;:Edisc with the wheel nuts. INSPECT PAD LININGTHICKNESS Check the pad thicknessthrough the cylinder inspection hole and replacepads if not within specification. Standard 1O.0mm (0.394-in.l Minimum 1.0 mm (0.039 in.)

1.

2. '

l'-

BRAKE SYSTEM - Front Brake 3.

ihffi:ir ' ' $ ,

,ritl

t'i'.

8R.17

REMOVECYLINDERFROM TOROUEPLATE (a) Removethe two installationbolts from the torque plate.
't'l

'|

t'r

(b) Remove the brake cylinder and suspend it so the hose is not stretched. NOTE: Do not disconnectthe brake hose.

4.

ilPnn )\ tPllli{1
q\r4J
# w
5.

@ \ r

REMOVEFOLLOWING PARTS: (a) Two anti-squeal springs (b) Two brake pads (d ."Twoanti-squeal shims 'Two (d) pad wear indicatorplates (e) .'FoUr support plates CHECK ROTORDISC THICKNESS (See*step2 on page BR-l91 CHECKROTOR DISC RUNOUT (See step 3 on page BR-2OI INSTALL NEW PAD SUPPORTPLATES

BRo281
6. 7.

8.

INSTALL NEW PADS (a) Installnew pad wear indicatorplatesto each pad. NOTE: Be surethe arrow on the pad we*fiQicator plate is pointing in the rotatingdirectionof thd diiHt_ (b) Installnew anti-squeal shims to each pad.

l ' l

iffi

BR-l8

BRAKE SYSTEM - Front Brake (c! Installthe pads onto each support plate' 9. SPRINGS INSTALL NEW ANTI-SOUEAL

d[

10. INSTALLCYLINDER (d Draw out a small amount of brake fluid from the reservoir. (b) Pressin piston with a hammer handleor such. NOTE: Alwayschangethe pad on one wheel at a time as there is possibilityof the opposite piston flying out (c) Insertthe brakecylindercarefullyso the dust boot is not wedged.
t1.,

(d) lrfiiprrandtorquethe two instatlation bolts. Torque: 255 kg-cm (18 ft-lb, 25 N'ml *12. CHECK IS AT "MAX" LINE TEVEL THATFLUID

FRoNr t t. tNsrArL Itr#

,iw
,i

SST
't.t

' OF CYUTNDER REMOVAL

(See page BR-l61 1. REMOVE CYLINDER (a) UsingSST, disconnect the brakeline. Use a containerto catch the brake fluid. ssT 09751-36011 (b) Rembvethe two installationbolts and cylinder. 2. REMOVEPADS (See step 4 on.page BR-l71

I'id

OF CYLINDER DISASSEMBLY
(Seepage BR-l61 1. PARTS: REMOVEFOLLOWING (a) Two slide bushings (b) Four dust boots (d Two collars

"'L

i-

BRAKE SVSTEM - Front Brake

8R.19

2.

REMOVE CYLINDER BOOT SETRINGAND CYLINDER BOOT Usinga screwdriver, removethe set ring and boot.

3.

REMOVEPISTONFROM CYLINDER (a) Put a piece of cloth or such betweenthe piston and cylinder. (d Use compressedair to remove the piston from the cylinder. WARNING: Do not place your fingers in front of the piston when using compressed air.

4. - REMOVEPISTONSEAL FROM BRAKE CYLINDER Using a screwdriver, removethe piston seal.

INSPECTION AND REPAIR OF FRONTBRAKE COMPONENTS

1. TNSPECT PAD LININGTHICKNESS Standard thickness: 10.O mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.l Replace the pad if the thicknessis lessthan minimum(the 1.0 mm slit is no longervisible)or if it shows signs of unevenwear.

INSPECTROTORDISC THICKNESS Standardthickness: 1 1.0 mm (0.433 in.l Minimum thickness: 10.0 mm {0r39a in.} lf the disc is scored or worn, or if thicknessis less than minimum,repairor replacethe disc.
:t-$ixt :r- , .-rr,

*i,

BR-2O

BRAKE SYSTEM - Front Brake 3. DISC RUNOUT INSPECTROTOR Measure the rotor disc runoutat 1O mm (0.39 in.)from the of the rotor disc. edge outer Maximum disc runout: 0.15 mm (0.0059 in.l lf the runout is greaterthan maximum,replacethe disc. the runout checkthat the front NorE: Beforemeasuring play within is specification. bearing

4.

REPLACE ROTORDISC IF NECESSARY, (d Removethe torque plate from the knuckle. (b) Removethe wheel nuts of the temporarilyinstalled disc and pull off the rotor disc from the axle hub. (c) Temporarilyinstall a new rotor disc with the wheel nuts. (d) Installthe torque plate onto the knuckle. Torque: 900 kg-cm (65 ft-lb, 88 N'm)

ASSEMBLYOF CYLINDER
(SeepageBR-161 1. GREASE APPLYLITHUMSOAPBASEGLYCOL ARROWS BY INDICATED TO PARTS

2.

INSTALL PISTONSEAL AND PISTONIN CYLINDER

\
ti

3.

BOOTAND SET RING IN INSTALL CYLINDER CYLINDER

Q++, i,

BRAKE SYSTEM - Front Brake 4.

BR-2;1,,,":l-

INSTALLCOLLAR,DUST BOOTAND CYLINDER SLIDEBUSHING (a) Installthecollarand dust boot into the brake"VlinOer.'"'f,. (b) Check that the boot is securedfirmly to the brlkp ';1"t, cylindergroove.

(c) Installthe bushinginto the boot. (d) Checkthat the boot is securedfirmly to the bushing groove.

INSTALLATION OF CYLINDER
(See page BR-l61 1. 2. INSTALL PADS (See steps 7 to 9 on pag6s BR-17 and 18)-i INSTALLCYLINDER (See step 11 on page BR-271

JS .t
,,,\$,

t:' t;

3.

INSTALLFLEXIBLE HOSETO BRAKECYLINDER Torque: 235 kg-cm (17 ft-lb, 23 N.m)

SST

4.

CONNECTFLEXIBLE HOSETO BRAKETUBE Using SST, connect the flexible hose. ssT 09751-36011 Torque: 155 kg-cm (11 ft-lb, 15 N.ml FILL BRAKE RESERVOIR WITH BRAKEFLUID AND BLEED BRAKE SYSTEM (See page BR-71

5.

BR-22

BRAKE SYSTEM - RearBrake(Sedan)

REARBRAKE
Sedan
COMPONENTS
BackingPlate

Shoe AdjustingShim O C-Washer Adjusting Lever Spring ReturnSpring

ob@

lGc.l?t-lb' Nrdl : Tishtenins

part O: Non-reusable

BRAKE REMOVAL OF REAR

1. INSPECT SHOELININGTHICKNESS Removethe inspectionhole plug, and check the shoe lining thicknessthrough the hole. lf less than minimum,replacethe shoes. Standardthickness: 4.0 mm (0.157 in.l Minimum thickness: 1.0 mm (O.039in.l REMOVEREARWHEEL REMOVEBRAKEDRUM (See step 2 on page RA-51 do the followlf the brakedrum cannot be easilyremoved, ing procedure: (d Insert a screwdriverthrough the hole in the backing plate, and hold the automatic adjusting lever away from the adjustingbolt (b) Using another screwdriver, reduce the brake shoe adjustmentby turning the adiustingbolt.

2. 3.

BRAKE SYSTEM - RearBrake(Sedan) 4. REMOVESHOERETURN SPRING Using a screwdriver, removethe return spring. REMOVESHOERETURN SPRINGCLAMP Using a screwdriver, removethe clamp.

BR-23

5.

6.

REMOVEFRONTSHOE (a) Removethe hold-down spring, retainersand pin. (b) Disconnectthe anchor spring from the front shoe and removeit. REMOVEANCHORSPRING

7.

8.

REMOVEREARSHOE (d Removethe hold-down spring, retainersand pin. (b) Usingpliers,disconnect the parkingbrakecablefrom the leverand removethe rear shoe togetherwith the strut.

9.

REMOVESTRUTFROM REARSHOE (a) Removethe adjustinglever spring. (b) Removethe strut.

10. REMOVEPARKINGBRAKELEVERAND AUTOMATIC ADJUSTINGLEVERFROM REARSHOE pry out the C-washerand removethe Usinga screwdriver, shim and levers.

.,ea-24

BRAKE SYSTEM - RearBrake(Sedan) BRAKETUBE FROMWHEELCYLINDER 1 1. DISCONNECT Using SST, disconnectthe line. Use a containerto catch the brakefluid.

1 ssr 09751-3601

12. REMOVEWHEETCYLINDER Removethe two bolts and wheel cylinder.

Ao@(
fl@oTu"/ v / l
|

I
l

sorins

Piston

PARTSFROM WHEEL FOLLOWING REMOVE CYLINDER: (d Two boots (b) Two pistons (c) Two pistoncups (d Spring

OF REARBRAKECOMPONENTS INSPECTION
1. BRAKEDRUM INSIDEDIAMETER INSPECT Standardinside diameter: 180.0 mm (7.087 in.) Maximum insidediameter: 181.0 mm (7.126in.) lf the drum is scored or worn, the brake drum may be lathedto the maximuminsidediameter. NOTE: Perform operations with the following parts removed: (d Oil seal (b) lnnerand outer bearing INSPECT BRAKESHOE LINING THICKNESS Standardthickness: 4.0 mm (0.157 in.l Minimum thickness: 1.0 mm (0.039 in.) lf the shoe liningis lessthan minimumor shows signsof unevenwear, replacethe brakeshoes. NOTE: lf the thicknessof any brakeshoe is not within replaceall of the brakeshoes. specification,

2.

BRAKE SYSTEM - RearBrake(Sedan) 3.

8R.25

INSPECTBRAKE LINING AND DRUM FOR PROPER CONTACT Replace the brakeshoeor lathethe brakedrum as necess4ry. INSPECT WHEEL CYLINDER FOR CORROSION OR DAMAGE INSPECTBACKING PLATE FORWEAR OR DAMAGE

4. 5.

INSTALLATION OF REARBRAKE
(See page BR-221 1. APPLY LITHIUM SOAP BASE GILYCOLGREASE TO FOTLOWING PARTS: (d Two piston cups (b) Two pistons ,, ,

Apply Grease
't ..

2.

Ao@O

o@rT*1,,i""
l t l
t

ASSEMBLEWHEELCYLINDER (a) Installtwo new piston cups to the pistons. (b) Install the two pistons and spring into the wheet cylinder.Check that the flange of the pistons are pointedinward. (c) Installtwo new boots.

I Boot

Spring

3.

INSTALL WHEELCYLINDER Installthe wheelcylinderon the backingplatewith the two bolts. Torque: lOO kg-cm (7 ft-lb, 1O N.ml

4.

CONNECTBRAKETUBE TO WHEEL CYLINDER Using SST, connectthe braketube. ssT 09751-36011 T o r q u e : 1 5 5 k g - c m( 1 1 f t - l b , 1 5 N . m l

a BR-26
BRAKE SYSTEM - RearBrake{Sedan) 5. APPLY HIGH TEMPERATURE GREASETO FOLLOWINGPARTS: (a) Backingplate and brake shoe contact points (b) Anchor plate and brake shoe contact points

(c) Strut and adjustingbolt contact points (d) Strut and brakeshoe contact points

6.

wl

INSTALL PARKING BRAKE LEVERAND AUTOMATIC ADJUSTINGLEVER TO REARSHOE (d Temporarilyinstall the levers with the shim and a new C-washer. (d Usinga feelergauge,measure the clearance between the shoe and lever. Standardclearance: O - 0.35 mm (O - 0.0138 in.l lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)

0.2 (0.008) 0.3 (0.012) 0.4 (0.016)

| | |

0.5 (0.020) 0.6 (0.024) 0.s (0.035)

(cl Using pliers,stake the C-washer.

7.

INSTALL STRUT ONTO REARSHOE Set the strut in placeand intall the adjustinglever spring.

BRAKE SYSTEM - RearBrake(Sedan)

B,R.27

Left-handThreads

Right-hand Threads

Front

oa)"
o V o

Front

r+

Left Wheel

Right Wheel

8.

INSTALL REARSHOE CAUTION: Do not allow grease to get on the rubbing face (a) Using pliers,connect the parking brake cable to the lever. (b) Set the rear shoe in place with the end of the shoe insertedin the wheelcylinderand the other end in the anchorplate. (c) Installthe pin and the shoe hold-down spring. INSTALL FRONTSHOE GAUTION: Do not allow grease to get on the rubbing face (a) Installthe anchor spring betweenthe front and rear shoes. (b) Set the front shoe in placewith the end of the shoe insertedin the wheel cylinderand the strut in place. (c) Installthe shoe hold-down spring, retainersand pin.

9.

1 0 . INSTALLSHOERETURN SPRINGCLAMP 1 1 . INSTALLSHOERETURN SPRING

Using a screwdriver, installthe return spring.

8R.28

BRAKE SYSTEM - RearBrake(Sedan) 12. CHECK OPERATIONOF AUTOMATIC ADJUSTER MECHANISM (a) Move the parking brake lever of the rear shoe back and forth, as shown. Check that the adjusting bolt turns. lf the bolt does not turn, checkfor incorrectinstallation of the rear brakes.

(b) Adjust the strut length to the shortest possible amount. (d lnstallthe drum. (d) Pull the parkingbrakeleverall the way up.

ffi6 V\Fsz'

13. CHECK CLEARANCE BETWEENBRAKE SHOESAND DRUM h) Removethe drum. (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the differencebetweenthe diametersis the correctshoe clearance. Shoe clearance: 0.6 mm (0.O24 in.l lf incorrect check the parkingbrake system. 14. INSTALL BRAKEDRUM AND ADJUST PRELOAD (See page RA-61 15. INSTALL REARWHEEL 16. FILL BRAKERESERVOIR WITH BRAKEFLUID AND BLEEDBRAKESYSTEM (See page BR-71 17. CHECKFORFLUID LEAKAGE

Wagon FWD
COMPONENTS
/a uu
1 0 0( 7 , r 0 l

Wheel Cylinder ReturnSpring RearShoe

Backing Plate

Front Shoe

Anchor sprins I LZ/

-.-Retainer @ ^ @

-*__-a tr&9)
-@@
Shoe Hold-Down Spring

Parkirfs e,"x" /
Lever

gqJ\#*i' \ J( \ \ N b .-fl 4il)

A

7-AutomaticAdjusti Lever

///cc-

4//

Drum

I J.^h' AdjustingLeverSpring

kg-cm (ft-lb, N'm) :Tighteningtorque part | : Non-reusable

REMOVALOF REARBRAKE
1. INSPECTSHOELININGTHICKNESS Removethe inspectionhole plug, and check the shoe lining thicknessthrough the hole. lf less than minimum,replacethe shoes. Standardthickness: 4.0 mm (0.157 in.l Minimum thickness: 1.0 mm (0.039 in.l REMOVEREARWHEEL REMOVEBRAKEDRUM lf the brakedrum cannotbe easilyremoved,do the following procedure: (d Insert a screwdriver through the hole in the backing plate, and hold the automatic adiusting lever away from the adjustingbolt. (b) Using another screwdriver,reduce the brake shoe adjustmentby turning the adjustingbolt.

2. 3.

4.

REMOVEFRONTSHOE (d Using SST, disconnectthe return spring.

ssr 09703-30010

(d Removethe hold-down spring, retainersand pin. (c) Disconnectthe anchor spring from the front shoe and removeit 5. REMOVEANCHORSPRING

6.

REMOVEREARSHOE (a) Removethe hold-down spring, retainersand pin. b) Using a screwdriver, disconnect the parking brake cable from the anchor Plate. (d Using pliers,disconnectthe parkingbrakecablefrom the lever and remove the rear shoe together with the strut.

7.

SHOE FROMREAR REMOVE STRUT (a) Remove leverspring. the adiusting (d Remove the strut togetherwith the returnspring.

BRO337 BR0286

8.

AND BRAKELEVER PARKING REMOVE SHOE FROMREAR LEVER ADJUSTING AUTOMATIC the pry out the C-washer andremove Usinga screwdriver, shimand levers.

BRAKE SYSTEM - RearBrake(WagonFWD) 9.

8R.31

BRAKETUBE FROM WHEEL DISCONNECT CYLINDER Using SST, disconnectthe line. Use a containerto catch the brakefluid.

WHEELCYLINDER 10. REMOVE Removethe two bolts and wheel cylinder.

6)o9o
Piston Boot

PARTSFROM WHEEL 11. REMOVEFOLLOWING CYLINDER: (a) Two boots (b) Two pistons (c) Two piston cups (d) Spring

INSPECTION OF REARBRAKECOMPONENTS
1. BRAKEDRUM INSIDEDIAMETER INSPECT Standardinside diameter: 200.0 mm (7.874 in.l Maximum insidediameter: 201.0 mm (7.913in.) lf the drum is scored or worn, the brake drum may be lathedto the maximuminsidediameter.

oO"
2.

INSPECT BRAKESHOELININGTHICKNESS Standardthickness: 4.0 mm (0.157 in.) Minimum thickness: 1.Omm {0.039 in.l lf the shoe liningis lessthan minimumor shows signsof unevenwear, replacethe brake shoes. NOTE: lf the thicknessof any brakeshoe is not within replace the all of the brakeshoes. specification,

INSPECT BRAKELININGAND DRUM FORPROPER CONTACT Replace the brakeshoeor lathethe brakedrum as necess4ry. o/' \
;z\o /

4. 5.

INSPECT WHEETCYLINDERFORCORROSION OR DAMAGE INSPECTBACKING PLATE FOR WEAR OR DAMAGE

INSTALLATIONOF REARBRAKE
(See page BR-291 1. APPLY LITHIUM SOAP BASE GLYCOLGREASE TO FOLLOWINGPABTS: (d Two piston cups (b) Two pistons

Pistoncu' ^cloqO

2.

fl@6alA"

Y
I I

I SPring

Piston

l
3.

ASSEMBLEWHEEL CYLINDER (a) lnstall two new piston cups to each piston, check that the flangesof the cups are pointed inward. (b) Install the two pistons and spring into the wheel cylinder. (c) Installtwo new boots.

Boot

INSTALLWHEEL CYLINDER Installthe wheelcylinder platewith the two on the backing bolts. Torque: 1OOkg-cm (7 ft-lb, 1O N.ml

4.

CONNECT BRAKETUBE TO WHEEL CYLINDER Using SST, connect the braketube ssT 09751-36011 Torque: 155 kg-cm (11 ft-lb, 15 N.ml

BRAKE SYSTEM - RearBrake{WagonFWD) 5. APPLY HIGH-TEMPERATURE GREASETO FOLLOWINGPARTS: H Backingplate and brakeshoe contact points (b) Anchor plate and brakeshoe contact points

8R.33

(c) Strut and adjusting bolt contact points (d) Strut and brakeshoe contact points

Shim

6.

INSTALL PARKINGBRAKE LEVERAND AUTOMATIC ADJUSTING TEVERTO REARSHOE (a) Temporarily installthe leversand shim with a new Cwasher. (d Usinga feelergauge,measure the clearance between the shoe and lever. Standard clearance: O - 0.35 mm (0 - 0.0138 in.l lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)

o.2 0.3 o.4

(0.008) (0.012) (0.016)

| | |

0.5 0.6 o.g

(0.020) (0.024) (0.035)

(c) Using pliers,stake the C-washer.

7.

INSTALL STRUTONTO REARSHOE Set the strut and return spring in place and install the adjustinglever spring.

BR-34

BRAKE SYSTEM - RearBrake(Wagon FWD)

Left-handThreads

Threads Right-hand

)"(r"(
Left Wheel 8. Right Wheel

o/\o

Front .|

80939 8R0253

INSTALT REARSHOE CAUTION: Do not allow oil or groase to get on the rubbing face. (a) Using pliers,connect the parkingbrake cable to the lever. (b) Passthe parkingbrakecablethrough the notch in the anchor plate. (c) Set the rear shoe in place with the end of the shoe insertedin the wheelcylinderand the other end in the anchor plate. (d) Installthe hold-down spring, retainers and pin. INSTALL FRONTSHOE CAUTION: Do not allow oil or grease to get on the rubbing face. (d lnstall the anchor spring betweenthe front and rear shoes. (b) Set the front shoe in placewith the end of the shoe insertedin the wheel cylinderand the strut in place. (c) Installthe hold-down spring,retainersand pin. (d) Using SST, connect the return spring.

9.

ssr 09703-30010

BRAKE SYSTEM - RearBrake(Wason FWD)

BR-35

1O. CHECKOPERATION OF AUTOMATICADJUSTER MECHANISM (d Move the parking brake lever of the rear shoe back and forth, as shown. Check that the adjustingbolt turns. lf the bolt does not turn, check for incorrectinstallation of the rear brakes.

(b) Adjust the strut length to the shortest possible amount. (c) Installthe drum. (d) Pull the parkingbrake lever all the way up.

1 1 . CHECK CLEARANCE BETWEEN AND BRAKE SHOES

DRUM (a) Remove the drum. (b) Measurethe brake drum inside diameterand diameter of the brake shoes. Check that the is the conectshoe difference between the diameters clearance. Shoeclearance: 0.6 mm (0.024in.l lf inconect checkthe parking brakesystem. 12. INSTALL BRAKE DRUM 1 3 . INSTALL REAR WHEEL 14. FILI BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (Seepage BR-71
1 5 . CHECK FORFLUIDLEAKAGE

BR-36

BRAKE SYSTEM - RearBrake(Wagon4WD)

Wagon 4WD
COMPONENTS

Strut and ReturnSpring O C-Washer Automatic AdjustingLever arkingBrakeLever

Hold-down Spring

Backing Ptate

{ATK $ry"<'i
| | ///, Front

clip |

,u

6f,Aai""tins

Shim

RearShoe

Wheel Cylinder

shoe lot

AnchorSpring

part O: Non-reusable

REMOVAL BRAKE OF REAR

\

F\\

q \\\ Y((^W
*
-/

6\

\\

//l

//

//

1.

INSPECT SHOELININGTHICKNESS Removethe inspectionhole plug, and check the shoe lining thickness throughthe hole. lf lessthan minimum,replace the shoes. Standardthickness: 4.0 mm (0.157 in.) Minimum thickness: 1.0 mm (0.039 in.) REMOVEREARWHEEL REMOVEBRAKEDRUM lf the brakedrum cannotbe easilyremoved,do the following procedure: (a) Inserta screwdriverthrough the hole in the backing plate, and hold the automatic adjusting lever away from the adjustingbolt. (d Using another screwdriver,reduce the brake shoe adjustmentby turning the adjustingbolt.

2. 3.

BRAKE SYSTEM - RearBrake(Wagon4WD) 4. REMOVEFRONTSHOE (d Using SST, removethe return spring.

8R.37

ssT 09703-30010
(b) Removethe hold-down spring. (c) Removethe front shoe and the anchor spring.

5.

REMOVEREARSHOE (a) Removethe hold-down spring. (b) Usingpliers,disconnectthe parkingbrakecablefrom the leverand removethe rear shoe togetherwith the strut.

6.

REMOVESTRUTFROM REARSHOE (a) Removethe adjustinglever spring. (b) Removethe strut.

7.

REMOVEPARKINGBRAKE LEVERAND AUTOMATIC ADJUSTINGLEVERFROM REARSHOE Using a screwdriver,pry out the C-washerand removethe shim and levers.

8.

DISCONNECT BRAKETUBE FROMWHEELCYLINDER Using SST, disconnectthe line. Use a containerto catch the brakefluid.

1 ssr 09751-3601
9. REMOVEWHEELCYLINDER Removethe two bolts and wheel cylinder.

8R.38

BRAKE SYSTEM - RearBrake(Wagon4WD)

t'"fon cup Piston

'"i.
\J/

I Am'Q)\gr---..SPring

lK3r)Y*

i
I

^,

*^m.GSDW)

PARTSFROM WHEEL 10. REMOVEFOLLOWING CYLINDER: (a) Two boots b) Two pistons (c) Spring

OF REARBRAKECOMPONENTS INSPECTION
1. INSPECTBRAKEDRUM INSIDEDIAMETER Standard inside diameter: 200.0 mm (7.874 in.l mm (7.913 in.) Maximum inside diameter: 2O1.O lf the drum is scored or worn, the brake drum may be lathed to the maximuminsidediameter.

,-\

-Z\" (

a\

< ) ( )

2.

INSPECTBRAKESHOELININGTHICKNESS Standardthickness: 4.0 mm (0.157 in.l Minimum thickness: 1.0 mm {0.039 in.l lf the shoe liningis lessthan minimumor shows signsof unevenwear, replacethe brakeshoes. NOTE: lf the thickness of any brakeshoe is not within replaceall of the brakeshoes. specification,

3.

INSPECTBRAKE LINING AND DRUM FOR PROPER CONTACT Replace the brakeshoe or lathe the brakedrum as neces-

sary.

4. 5.

OR INSPECT WHEEL CYLINDER FOR CORROSION DAMAGE INSPECTBACKING PLATE FORWEAR OR DAMAGE

BRAKE SYSTEM - RearBrake(Wagon4WD)

8R.39

INSTALLATIONOF REARBRAKE
(See page BR-361 1. APPLY LITHIUM SOAP BASE GLYCOLGREASE TO FOLLOWINGPARTS: H Two piston cups (d Two pistons

Apply Grease

'"i'

Pistoncup

Piston

2.

lKs^*@#@
3. 4.

d@*''*,J."n

ASSEMBLEWHEEL CYLINDER (d Installtwo new piston cups to the pistons. (d Install the two pistons and spring into the wheel cylinder. Check that the flanges of the piston are pointed inward. (c) Installtwo new boots. INSTALLWHEEL CYLINDER platewith the two Installthe wheelcylinder on the backing bolts. Torque: lOO kg-cm (7 ft-lb, 1O N.ml CONNECTBRAKETUBE TO WHEELCYLINDER Using SST, connectthe braketube. ssT 09751-36011 Torque: 155 kg-cm (11 ft-lb, 15 N.ml

5.

APPTYHIGH TEMPERATURE TO GREASE FOLLOWING PARTS: (a) Backingplate and brakeshoe contact points (b) Anchor plate and brakeshoe contact points

(d Strut and adjustingbolt contact points (d) Strut and brakeshoe contact points

BR.4O

BRAKE SYSTEM - Rear Brake (Wagon 4WD) 6. INSTALL PARKING BRAKE LEVERAND AUTOMATIC TO REARSHOE ADJUSTINGLEVER (a) Temporarilyinstallthe leversand the shim and a new C-washer. (d Usinga feelergauge,measure the clearance between the shoe and lever. Standard clearance: O - 0.35 mm (O - 0.0138 in.) lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)

0.2 (o.oo8) o.3 (0.012) o.4 (0.016)

| I I

0.5 (0.020) 0.6 (0.024) o.s (0.035)

(c) Using pliers,stake the C-washer.

7.

INSTALLSTRUTONTO REARSHOE Set the strut and return spring in place and installthe adjustinglever spring.

Left-handThreads

Right-handThreads

Front

Front

pVe

Left Wheel

RightWheel
8RO256 8R0257

BRAKE SYSTEM - RearBrake(Wagon4WD) 8.

8R.41

INSTALL REARSHOE CAUTION: Do not allow oil or grease to get on the rubbing face. H Using pliers,connect the parkingbrake cable to the lever.

(b) Set the rear shoe in place with the end of the shoe insertedin the wheelcylinderand the other end in the anchor plate. (c) lnstall the pin and the shoe hold-down spring.

9.

INSTALL FRONTSHOE CAUTION: Do not allow oil or grease to get on the rubbing face. (a) Installthe anchor spring betweenthe front and rear shoes. (b) Set the front shoe in placewith the end of the shoe insertedin the wheel cylinderand the strut in place.

(c) Installthe shoe hold-downspringand pin. (d) Using SST, connect the return spring.

ssr 09703-30010

10. CHECK OPERATIONOF AUTOMATIC ADJUSTER MECHANISM (a) Move the parking brake lever of the rear shoe back and forth, as shown. Check that the adjusting bolt turns. lf the bolt does not turn, check for incorrectinstallation of the rear brakes.

BRAKE SYSTEM - RearBrake (W (b) Adjust the strut length to the shortest possible amount. (c) Installthe drum. (d) Pull the parkingbrakeleverall the way up.

1 1 . CHECK CLEARANCEBETWEEN BRAKE SHOES AND DRUM (a) Removethe drum. (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference betweenthe diametersis the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 in.l lf incorrect check the parkingbrakesystem.

12. INSTALL BRAKEDRUM AND REARWHEEL 1 3 . FILL BRAKERESERVOIR WITH BRAKEFLUID

AND BLEEDBRAKE SYSTEM (See page BR-71 14. CHECKFORFLUID LEAKAGE

BRAKE SYSTEM - BrakeHosesand Tubes

BRAKEHOSES AND TUBES

DISCONNECT AND CONNECT HOSEAND TUBE
1. DISCONNECT HOSEAND TUBE (a) Diconnectthe clip. (b) Usinga wrenchto hold the hose,and SST to hold the tube, disconnectthe tube and hose. ssT 09751-36011 CONNECTHOSEAND TUBE (a) Connectthe hose and tube by hand. (b) Usinga wrenchto hold the hose,and SST to hold the tube, torque the connection.

\$-crio

2.

-3601 ssT 09751 1

Torque: 155 kg-cm (11 ft-lb, 15 N.ml (c) Installa new hoseclip.

INSPECTION OF BRAKEHOSESAND TUBES

1. INSPECT BRAKEHOSES (a) Inspectthe hose for damage,cracksor swelling. (b) Inspectthe threadsfor damage.

2.

INSPECTBRAKETUBES (d Inspectthe tube for damage,cracks,dents or corrosion. (b) Inspectthe threadsfor damage.