SECTION 4B - FRONT AXLE & PROPELLER SHAFT

MAIN DATA AND SPECIFICATIONS

SPECIAL PARTS FIXING NUTS AND BOLTS

RECOMMENDED LIQUID GASKET

RECOMMENDED THREAD LOCKING AGENTS

SERVICING

GENERAL DESCRIPTION

FRONT DRIVE AXLE ASSEMBLY

REMOVAL AND INSTALLATION

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

DIFFERENTIAL

DISASSEMBLY

MAJOR COMP ONENTS

MINOR COMPONENTS

INSPECTION AND REPAIR

REASSEMBLY

MINOR COMPONENTS

MAJOR COMP ONENTS

FRONT HUB AND DISC (4×

××

×2 MODEL)

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

Techline

FRONT HUB AND DISC (4×

××

×4 MODEL)

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

FRONT HUB AND DISC (MANUAL LOCKING HUB)

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

FRONT PROPELLER SHAFT

REMOVAL AND INSTALLATION

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

MAIN DATA AND SPECIFICATIONS

FRONT AXLE AND DI FFERENTIAL

Type one piece cast iron housing and steel axle tubes.

Gear type Hypoid

Gear ratio

6VD1 Manual 4x2 4.300 : 1

6VD1 Automatic 4x2 4.555 : 1

6VD1 Manual 4x4 4.555 : 1

6VD1 Automatic 4x4 4.555 : 1

4JB1T Manual 4x2 4.300 : 1

4JB1T Manual 4x4 4.555 : 1

C22NE Manual 4x2 4.555 : 1

Differential type Two pinion

Oil capacity 1.4 litres

Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).

Hub locking type Manual locking & SOF free wheel hubs.

FRONT PROPELLER SHAFT mm(in)

Engine Model 4JA1 4JB1 4JG2

Transmission Type 5M/T ←←←4A/T 5M/T 4A/T

(MSG) ←(MUA) ←(MUA)

Rear Axle 167mm 194mm ←←←←←

Type Type-A Type-B Type-B Type-B Type-B Type-B Type-B

Outside Diameter mm 40.0 40.0 40.0 40.0 40.0 40.0 40.0

(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)

Inside Diameter mm 33 32 32 32 32 32 32

(in) (1.30) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)

Length mm 545 517 421 421 627 421 627

(in) (21.46) (20.35) (16.57) (16.57) (24.69) (16.57) (24.69)

Spline Outside mm 31.67 36.67 36.67 36.67 36.67 36.67 36.67

Diameter (in) (1.25) (1.44) (1.44) (1.44) (1.44) (1.44) (1.44)

Fix Bolt Size M8 M8 M10 M10 M10 M10 M10

Engine Model X22SE 6VD1

Transmission Type 5M/T ←←←4A/T

(MSG) ←(MUA) ←

Rear Axle 194mm 167mm 194mm ←←

Type Type-B Type-A Type-B Type-B Type-B

Outside Diameter mm 40.0 40.0 40.0 40.0 40.0

(in) (1.57) (1.57) (1.57) (1.57) (1.57)

Inside Diameter mm 32 33 32 32 32

(in) (1.26) (1.30) (1.26) (1.26) (1.26)

Length mm 471 505 376 393 559

(in) (18.54) (19.88) (14.80) (15.47) (22.01)

Spline Outside mm 36.67 31.67 36.67 36.67 36.67

Diameter (in) (1.44) (1.25) (1.44) (1.44) (1.44)

Fix Bolt Size M8 M8 M10 M10 M10

SPECIAL PARTS FI XING NUTS AND BOLTS

FRONT DRIVE AXLE AND PROPELLER SHAFT N⋅m (kgf⋅m/lb⋅ft)

FRONT DIFFERENTIAL N⋅m (kgf⋅m/lb⋅ft)

FREE WHEELING HUB N⋅m (kgf⋅m/lb⋅ft)

11.8±2.0 (1.2±0.2/8.7±1.4)

58.9±5 (6±0.5/43.4±3.6)

103±5 (10.5±1/75.9±7.2)

58.9±5 (6±0.5/43.4±3.6)

RECOMMENDED LI QUI D GASKET

Type Brand Name Manufacture Remarks

RTV*

Silicon Base

ThreeBond 1207B

ThreeBond 1207C

ThreeBond 1215

Three Bond

For Engine Repairs

For Axle Case

Repairs, T/M

Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent

ThreeBond 1104

BelcoBond 4

BelcoBond 401

BelcoBond 402

Three bond

Isuzu

For Engine Repairs

Anerobic LOCTITE 515

LOCTITE 518 Loctite

Loctite All

* RTV : Room Temperature Vulcanizer

Note :

1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.

2. Be careful to use the specified amount of liquid gasket.

Follow the manufacture's instructions at all times.

3. Be absolutely sure to remo ve all lubricants and mo isture from the conn ecting surfaces before ap plying the

liquid gasket.

The connecting surfaces must be perfectly dry.

4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.

Do not apply LOCTITE 515 or LOCTIT E 518 between tw o metal surfaces having a clearance of greater than

0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242 Blue 1. Completely remove all lubricant and moisture from the bolts and

the female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

LOCTITE 262 Red 2. Apply LOCTITE to the bolts.

LOCTITE 270 Green

LOCTITE 271 Red 3. Tighten the bolts to the specified torque.

4. Wait at least on hour before continuing the installation procedure.

SERVICING

HUB BEARING PRELOAD AT THE WHEEL PIN

4×4 Model kg(lb

)

New bearing and New oil seal 2 - 2.5 (4.4 - 5.5)

Reuse bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)

4×2 Model kg(lb)

New bearing and New oil seal 0.8 - 1.0 (1.8 - 2.2)

Reuse bearing and New oil seal 0.8 - 1.0 (1.8 - 2.2)

GENERAL DESCRIPTI O N

FRONT DRIVE AXLE

FRONT HUB AND DISC (4×

××

×2 MODEL)

FRONT HUB AND DISC (4×

××

×4 MODEL)

LOCKING HUB

MANUAL TYPE

FRONT PROPELLER SHAFT

FRONT DRIVE AXLE ASSEMBLY

REMOVAL AND INSTALLATION

1. Refer to SECTION 10 “WHEEL AND TIRES” for road wheel Disassembly and Reassembly procedure.

2. Refer to SECTION 5 “BRAKES” for disc brake caliper removal and installation procedure.

3. Refer to SECTION 9 “STEERING” for Steering linkage removal and installation procedure.

REMOVAL STEPS

▲1. Assembly of hub and disc, back plate,

knuckle, knuckle arm, and lower end.

▲2. Propeller shaft

3. Nut and bolt

4. Washer

▲5. Front drive axle assembly

6. Washer

INSTALLATION STEPS

6. Washer

▲5. Front drive axle assembly

4. Washer

▲3. Nut and bolt

▲2. Propeller shaft

1. Assembly of hub and disc, back plate,

knuckle, knuckle arm, and lower end.

IMPO RTANT OPERATIONS - REMOVAL

1. Assembly of hub and disc, back plate, knuckle, knuckle

arm, and lower end.

Before removal, jack up the front of vehicle and support the

frame with jack stands.

2. Propeller Shaft

Apply the setting marks.

5. Front Drive Axle Assembly

(1)Put the lifting jack under the center part of the front.

(2)Remove four bolts fixing axle case mounting brackets to the

frame.

Note :

Be careful not to damage birfield joints or double off-set

joints when supporting axle shaft assembly.

(3)Lower the f r ont axle assembly and roll it out toward the front

of the vehicle.

Take care not to damage the birfield joints or the double off-

set joints.

IMPORTANT OPERATIONS - INSTALLATION

5. Front Drive Axle Assembly

Place the front axle assembly in position under the vehicle

using a lifting jack.

3. Nut

Front Axle Mounting Nut Torque N⋅m (kgf⋅m/lb⋅ft)

152.1 ± 14.7 (15.5 ± 1.5/112.1 ± 10.8)

2. Propeller Shaft

Align the setting marks applied the removal.

Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

167 mm 35.3 ± 2.9 (3.6 ± 0.3/26.0 ± 2.2)

194 mm 62.8 ± 3.9 (6.4 ± 0.4/46.3 ± 2.9)

DISASSEM BLY

DISASSEM BLY STEPS

▲1. Band

2. Bellows

▲3. Circlip

4. BJ shaft assembly

▲5. Ball

▲6. Snap ring

7. Ball retainer

8. Ball guide

▲9. Band

10. Bellows

11. Dust seal

12. BJ shaft

13. Bolt

14. DOJ case assembly

15. Snap ring

16. Bearing

17. Snap ring

18. O-ring

19. Oil seal

20. Bracket

21. DOJ case

22. Axle case and differential

IMPORTANT OPERATIONS

1. Band

Raise the hooked end of the band with a screwdriver or

equivalent.

3. Circlip

Pry off with a screwdriver or equivalent.

5. Ball

Remove the six balls with a screwdriver or equivalent.

Rotate the case half a pitch to align the ball guide on the case

with the projected portion of the ball retainer, then slide the

case toward the bellows. The case can not be removed in the

reverse direction.

6. Snap Ring

Remove the snap ring fastening the ball retainer to the center

shaft.

8. Band

Raise the hooked end of the band with a screwdriver or

equivalent.

INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered

during inspection.

• BJ assembly

• DOJ case, ball, ball guide, ball retainer

• Bellows

• Bearing

• Dust seal, oil seal

VISUAL CHECK

Inspect the following parts for wear, damage, or other

abnormal conditions.

REASSEMBLY

REASSEMBLY STEPS

1. Axle case and differential

2. DOJ case

3. Bracket

4. Oil seal

5. O-ring

6. Snap ring

7. Bearing

8. Snap ring

9. DOJ case assembly

▲10. Bolt

11. BJ shaft

12. Dust seal

▲13. Bellows

▲14. Band

▲15. Ball guide

▲16. Ball retainer

▲17. Snap ring

▲18. Ball

▲19. BJ shaft assembly

▲20. Circlip

▲21. Bellows

▲22. Band

IMPORTANT OPERATIONS

10.Bolt

Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

115.7 +8.8

−9.8 (11.8 +0.9

−1.0 /85.3 +6.5

−7.2 )

13.Bellows

(1)Apply a thin coat of grease to the shaft for smooth

installation.

(2)Apply specified grease to the ½ space of the bellows.

14.Band

Note the setting direction.

After installation, check that the bellows is free from distortion.

15.Ball Guide

16.Ball Retainer

Install the ball guide with the smaller diameter side ahead onto

the shaft.

17.Snap Ring

Install the snap ring securing the ball retainer to the shaft.

18.Ball

Bring the ball guide of the cage into alignment with the

projected portion of the ring on the ball retainer, then turn the

cage ½ pitch. Align the track on the ball retainer with the

window in the cage and install the six balls into position.

19.BJ Shaft Assembly

Apply specified grease to the half of the space of the DOJ case

(Approx. 50g (1.8 oz)).

20.Circlip

Install the circlip so that open ends are positioned away from

the ball groove.

21.Bellows

(1)Before installation, insert the appropriate amount o

specified grease into the DOJ case.

(2)Adjust the air pressure within the bellows by inserting a

screwdriver or equivalent, so that it equals atmospheric

pressure.

22.Band

After installation, check that the bellows is free from distortion.

DIFFERENTIAL

DISASSEM BLY

MAJO R COMPONENTS

DISASSEM BLY STEPS

1. Bolt

2. Differential assembly

3. Axle case

4. Bolt

▲5. Bearing cap

6. Diff. cage assembly

▲7. Side bearing outer race

▲8. Side bearing

▲9. A djust shims

▲10. Flange nut

11. Flange

12. Dust cover

▲13. Pinion gear

▲14. Inner bearing

15. Adjust shim

16. Collapsible spacer

▲17. Inner bearing outer race

18. Oil seal

19. Outer bearing

▲20. Outer bearing outer race

21. Diff. carrier

IMPORTANT OPERATIONS

5. Bearing Cap

Apply a setting mark to the side bearing cap and the differential

carrier.

7. Side Bearing Outer Race

After removal, keep the right and left-hand side bearing

assemblies separate to maintain inner and outer race

combinations.

8. Side Bearing

Remover : 5-8840-0013-0

(J-22888)

Adapter : 5-8521-0019-0 167 mm)

9-8521-1743-0 (194 mm)

(J-8107-2)

9. Adjust Shims

Note the thickness and position of the shims removed.

10.Flange Nut

Holding wrench : 5-8840-0133-0 (167 mm and 194 mm)

(J-8614-01)

13.Pinion Gear

Remove the drive pinion assembly using a soft metal rod and a

hammer.

Spindle : 9-8521-5032-0

14.Inner Bearing

Remove the inner bearing using a separator and a press.

Separator : 5-8840-0015-0

(J-22912-01)

17.Inner Bearing Outer Race

20.Outer Bearing Outer Race

Remove the inner bearing outer race and the outer bearing

outer race by using a brass bar and a hammer.

MINOR COMPONENTS

DISASSEM BLY STEPS

1. Bolt

2. Ring gear

▲3. Lock pin

▲4. Cross pin

5. Pinion gear

6. Side gear

7. Thrust washer

8. Differential cage

IMPORTANT OPERATIONS

3. Lock Pin

Break staking on the lock pin using a 5 mm (0.20 in.) diameter

drill.

4. Cross Pin

Remove the cross pin using a soft metal rod and a hammer.

INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered

during inspection.

• Ring gear, pinion gear

• Bearing

• Side gear, pinion gear, cross pin

• Differential cage, carrier

• Thrust washer

• Oil seal

VISUAL CHECK

Inspect the following parts for wear, damage, or other

abnormal conditions.

RING G EAR REPLACEMENT

(1)The ring gear should always be replaced with the drive

pinion as a set.

(2)When installing the ring gear, apply LOCTITE 271 o

equivalent to the threaded hole and bolt.

(3)Tighten the fixing bolts in a diagonal sequence as

illustrated.

(4)Discard used bolts and install new ones.

Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

167 mm 78.5 ± 9.8 (8 ± 1/57.9 ± 7.2)

194 mm 107.9 ± 9.8 (11 ± 1/79.6 ± 7.2)

FOR 167 mm

Note that all bolts have a left hand thread.

CLEARANCE BETWEEN THE DIFFERENTIAL PINION

AND THE CROSS PIN mm(in)

Standard Limit

167 mm 0.06 - 0.12 (0.002 - 0.005) 0.2 (0.008)

194 mm 0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)

CLEARANCE BETWEEN THE SIDE G EAR AND THE

DIFFERENTIAL BO X mm(in)

Standard Limit

167 mm 0.03 - 0.11 (0.001 - 0.004) 0.15 (0.006)

194 mm 0.03 - 0.10 (0.001 - 0.004) 0.15 (0.006)

PLAY IN SPLI NES BETWEEN THE SIDE G EAR AND

THE AXLE SHAFT mm(in)

Standard Limit

167 mm 0.11 - 0.38 (0.004 - 0.015) 0.30 (0.012)

194 mm 0.07 - 0.36 (0.003 - 0.014) 0.25 (0.010)

REASSEMBLY

MINOR COMPONENTS

REASSEMBLY STEPS

1. Differential cage

2. Thrust washer

3. Side gear

▲4. Pinion gear

▲5. Cross pin

▲6. Lock pin

▲7. Ring gear

▲8. Bolt

IMPORTANT OPERATIONS

4. Pinion Gear

Install the pinion gear by engaging it with the side gears while

turning both pinion gears simultaneously in the same direction.

5. Cross Pin

(1)Be sure to ins tall the cross pin so that it is in alignm ent with

the lock pin hole in the differential cage.

(2)Adjust the backlash between the side gear and the pinion

gear. mm(in)

Backlash 0.10 - 0.20 (0.004 - 0.008)

Thickness of thrust washers available mm(in)

167 mm 1.05, 1.15, 1.25 (0.041, 0.043, 0.049)

194 mm 1.00, 1.05, 1.10 (0.039, 0.041, 0.043)

6. Lock Pin

After lock pin installation, stake the cage to prevent discharge

of the lock pin.

7. Ring Gear

When installing the ring gear, apply LOCTITE 271 or

equivalent to the threaded hole and bolt.

8. Bolt

Tighten the bolts in diagonal sequence as illustrated.

Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

167 mm 78.5 ± 9.8 (8 ± 1/57. 9 ± 7.2)

194 mm 107.9 ± 9.8 (11 ± 1/79.6 ± 7.2)

Note :

Discard used bolts and install new ones.

For 167 mm

Note that all bolts have a left hand thread.

MAJO R COMPONENTS

REASSEMBLY STEPS

1. Diff. carrier

▲2. Outer bearing outer race

▲3. Inner bearing outer race

▲4. A djust shim

▲5. Inner bearing

▲6. Collapsible spacer

7. Pinion gear

8. Outer bearing

▲9. Oil seal

10. Dust cover

11. Flange

▲12. Flange nut and washer

▲13. Adjust shim

▲14. Side bearing

15. Bearing outer race

16. Diff. cage assembly

▲17. Bearing cap

▲18. Bolt

19. Axle case

▲20. Differential assembly

21. Bolt

IMPORTANT OPERATIONS

2. Outer Bearing Outer Race

Installer : 5-8522-0048-0 (167 mm)

(J-29038)

9-8522-1141-0 (194 mm)

(J-24256)

Grip : 5-8840-0007-0

(J-8092)

3. Inner Bearing Outer Race

Installer : 5-8522-0049-0 (167 mm)

(J-29039)

9-8522-1274-0 (194 mm)

Grip : 5-8840-0007-0

(J-8092)

4. Adjust Shim

Adjustment of drive pinion mounting distance

(1)Apply gear oil to the inner and outer drive pinion bearing.

Clean the pinion setting gage set.

Then install the gage set together with the inner and oute

bearings.

For 167 mm

1Pilot : 5-8840-2092-0

(J-23597-28)

2Nut and bolt : 5-8840-0127-0

(J-21777-43)

3Rear pilot : 5-8840-02091-0

(J-23597-27)

4Gage plate : 5-8840-2090-0

(J-23597-26)

For 194 mm

1Pilot : 5-8840-2085-0

(J-21777-42)

2Nut and bolt : 5-8840-2089-0

(J-23597-9)

4Gage plate : 5-8840-2087-0

(J-23597-7)

Tighten the nut to the specified torque. N⋅m (kgf⋅m/lb⋅ft)

New bearing 2.26 (23/20)

Used bearing 0.98 - 1.18

(10 - 12/8.7 - 10.4)

(2)Clean the side bearing bores. Install the dial indicator with

the discs and Arbor. Install and tighten the bearing caps to

the specified torque.

Torque N⋅m (kgf⋅m/lb⋅ft)

167 mm 68.7 ± 9.8 (7.0 ± 1.0/50.6 ± 7.2)

194 mm 98.1 ± 9.8 (10.0 ± 1.0/72.3 ± 7.2)

For 167 mm

1Dial indicator: 5-8840-0126-0

(J-8001)

2Disc (2 pcs.) : 5-8840-2086-0

(J-23597-4)

3Arbor : 5-8840-0128-0

(J-23597-1)

4Gage plate : 5-8840-2090-0

(J-23597-26)

For 194 mm

1Dial indicator: 5-8840-0126-0

(J-8001)

2Disc (2 pcs.) : 5-8840-2088-0

(J-23597-8)

3Arbor : 5-8840-0128-0

(J-23597-1)

4Gage plate : 5-8840-2087-0

(J-23597-7)

(3)Set the dial indicator to “0”. Place it on the mounting post o

the gauging arbor with the contact button touching the

indicator pad. Force the dial indicator downward until the

needle has made a half turn clockwise. Tighten down the

dial indicator in this position.

(4)Position the plunger on the gage plate. Move the gauging

arbor slowly back and for th and locate the position at which

the dial indicator shows the greatest deflection. At this

point, once again set the dial indicator to “0”.

Repeat the procedure to verify the “0” setting.

(5)

fter the ZERO setting is obtained, rotate the gauging arbo

until the dial indicator rod does not touch the gauging plate.

Record the number the dial indicator needle points to.

(6) Record the pinion depth code on the head of the drive

pinion.

The number indicates a necessary change in the pinion

mounting distanc e. A plus number indic ates the need for a

greater mounting distance (which can be achieved by

decreasing the s him thick ness). A m inus num ber indicates

the need for a smaller mounting distance (which can be

achieved by increasing the shim thickness). If examination

reveals pinion depth code “0”, the pinion is “nominal”.

(7)Select the shim using the chart:

For 167 mm mm(in)

Pinion

marking +6 +4 +2 +0 -2 -4 -6

Dial indicator

reading (inches)

0.052 1.39 (0.0547)

0.053 1.39 (0.0547) 1.41 (0.0555)

0.054 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563)

0.055 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571)

0.056 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587)

0.057 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594)

0.058 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602)

0.059 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610)

0.060 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626)

0.061 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634)

0.062 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642)

0.063 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657)

0.064 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665)

0.065 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673)

0.066 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681)

0.067 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)

0.068 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)

0.069 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)

0.070 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)

0.071 1.75 (0.0689) 1.77 (0.0697)

0.072 1.77 (0.0697)

For 194 mm mm (in)

Pinion

marking +10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10

Dial indicator

reading (inches)

0.081 2.18 (0.0858)

0.082 2.18 (0.0858) 2.20 (0.0866)

0.083 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)

0.084 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)

0.085 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)

0.086 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914)

0.087 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921)

0.088 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929)

0.089 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937)

0.090 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953)

0.091 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961)

0.092 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969)

0.093 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977)

0.094 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992)

0.095 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000)

0.096 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.097 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.098 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.099 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.002 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.003 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

0.005 2.54 (0.1000) 2.56 (0.1008)

0.006 2.56 (0.1008)

Note:

When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed in

the above table.

5. Inner Bearing

Place the shim on the drive pinion, with the chamfered side

turned towards the pinion head then install the inner bearing on

to the pinion using an installer and a press.

Installer : 9-8522-1165-0 (J-6133-01)

Note:

Do not apply pressure to the roller cage.

Apply pressure only to the inner race.

6. Collapsible Spacer

Discard the used collapsible spacer and install a new one.

9. Oil Seal

Use oil seal installer to install a new oil seal that has been

soaked in rear axle lubricant.

Installer : 5-8522-0046-0 (J-26234) (For 167 mm)

9-8522-1275-0 (J-24250) (For 194 mm)

Note :

Take care not to use a rear differential oil seal instead of

the front differential oil seal.

12.Flange Nut and Washer

For 194 mm

(1)Apply lubricant to the pinion threads.

(2)Tighten the nut to the specified torque using the pinion

flange holder.

Pinion flange holder : 5-8840-0133-0

(J-8614-01)

Torque N⋅m (kgf⋅m/lb⋅ft

)

176.6 - 274.7 (18 - 28/130 - 202)

Discard used flange nut and install new one.

(3)Pinion bearing preload

(a)Measure the bearing preload by using a torque meter . Note

the scale reading required to rotate the flange.

(b)Continue tightening until the specified starting torque is

obtained.

Starting Torque N⋅m (kgf⋅cm/lb⋅in

)

0.63 - 1.13 (6.5 - 11.5/5.7 - 9.9)

For 167 mm

(1)Apply lubricant to the pinion threads.

(2)Tighten the nut to the specified torque using the pinion

flange holder.

Pinion flange holder : 5-8840-0133-0 (J-8614-01)

Torque N⋅m (kgf⋅m/lb⋅ft)

117 - 127 (12 - 13/87 - 94)

Discard used flange nut and install new one.

(3)Continue tightening until the specified starting torque is

obtained.

Starting Torque N⋅m (kgf⋅cm/lb⋅in)

0.59 - 1.0 (6 - 11/5.2 - 9.5)

13.Adjust Shim

(1)Attach the side bearing to the differential assembly without

shims. Support the opposite side using a pilot to prevent

bearing damage.

For 167 mm

1Installer : 5-8840-0138-0

(J-29036)

2Drive handle : 5-8840-0007-0

(J-8092)

3Pilot : 5-8521-0019-0

For 194 mm

1Installer : 9-8521-1164-0

(J-24244)

2Drive handle : 5-8840-0007-0

(J-8092)

3Pilot : 9-8521-1743-0

(J-8107-2)

(2)Insert the differential cage assembly with bearing oute

races into the side bearing bores of the carrier.

(3) Using two sets of feeler gauges, insert a feeler stock o

sufficient thickness between each bearing outer race and

the carrier to remove all end plat. Make certain the feele

stock is pushed to the bottom of the bearing bores.

Mount the dial indicator on the carrier so that the indicato

stem is at right angles to a tooth on the ring gear.

Dial indicator : 5884-0126-0

(J-8001)

(4) Adjust feeler gauge thickness from side to side until ring

gear backlash is in the specified range.

Backlash mm(in)

0.13 - 0.18 (0.005 - 0.007)

With zero end play and correct backlash established,

remove the feeler gauge packs, determine the thickness o

the shims required and add 0.05 mm (0.002 in) to each

shim pack to provide side bearing preload. Always use ne

shims.

(5)Remove side bearing

Remover : 5-8840-0013-0

(J-22888)

Pilot : 5-8521-0019-0 (167 mm)

9-8521-1743-0 (194 mm)

(J-8107-2)

14.Side Bearing

Install the side bearings together with the selected shims.

For 167 mm

1Installer : 5-8840-0138-0 (J-29036)

2Drive handle : 5-8840-0007-0 (J-8092)

3Pilot : 5-8521-0019-0

For 194 mm

1Installer : 9-8521-1164-0 (J-24244)

2Drive handle : 5-8840-0007-0 (J-8092)

3Pilot : 9-8521-1743-0 (J-8107-2)

17.Bearing Cap

Align the setting marks applied at disassembly.

18.Bolt

Bolt Torque N⋅m (kgf⋅m/lb⋅ft

)

167 mm 68.7 ± 9.8 (7.0 ± 1.0/50.6 ± 7.2)

194 mm 98.1 ± 9.8 (10.0 ± 1.0/72.3 ± 7.2)

Measure the amount of run-out of the ring gear at its rear face.

mm(in)

Standard Limit

0.02 (0.001) 0.05 (0.002)

Gear Tooth Contact Pattern Check and Adjustment

Apply a thin coat of Prussian blue or equivalent to the faces of

the 7 - 8 teeth of the ring gear. Check the impression of

contact on the ring gear teeth and make necessary adjustment

as described below if the contact is abnormal.

20.Differential Assembly

(1)Clean the faces of the front axle case and differential

carrier.

Apply the recommended liquid gasket or its equivalent to

the sealing side of the axle case and the carrier.

(2)Attach the differential case and the carrier assembly to the

front axle case and tighten the nuts and bolts. The axle

case bolt is used for drainage.

Torque N⋅m (kgf⋅m/lb⋅ft)

25.5 ± 5 (2.6 ± 0.5/18.8 ± 3.6)

(3)Install the axle shaft assem blies as instructed earlier in this

section under “Axle Shaft Replacement”.

(4)Fill the axle case with hypoid gear lubricant, to just belo

the filler hole.

Lubricant capacity liter (US/UK gal)

167 mm 1.0 (0.26/0.22)

194 mm 1.4 (0.37/0.31)

FRONT HUB AND DISC (4×

××

×2 MODEL)

DISASSEM BLY

Refer to SECTION 10 “WHEEL AND TIRE” for wheel removal procedure.

DISASSEM BLY STEPS

1. Bolt

▲2. Brake caliper

▲3. Hub cap

4. Split pin

5. Nut retainer

6. Hub nut

7. Lock washer

8. Outer bearing

▲9. Hub and disc assembly

10. Oil seal

11. Inner bearing and outer race

▲12. Bolt

▲13. Wheel pin

IMPORTANT OPERATIONS

Before removal, jack up the front of vehicle and support frame

with jack stands.

2. Brake Caliper

(1)Remove the two bolts from the rear side of the knuckle arm,

and then remove the brake caliper, with the brake hose

attached.

(2)Use a wire etc., for attaching the brake caliper to the uppe

link.

3. Hub Cap

When removing hub cap, exercise care so as not to scratch or

distort hub fitting face.

9. Hub and Disc Assembly

Using a brass bar to remove the outer bearing outer race (1),

oil seal, inner bearing and inner bearing outer race (2) from the

hug.

If necessary, replace the wheel pin in the following manner.

12.Bolt

13.Wheel Pin ; Front Hub

(1)Scribe mark on hub to disc before disassembly to insure

proper assembly.

(2)Clam p hub and disc ass embly in vise using protective pads

and remove six (6) disc to hub retaining bolts.

(3) Place hub on a suitable work surface and remove wheel

studs, as required, using a hammer.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

• Hub

• Hub bearing

• Bearing outer race

• Disc

• Oil seal

VISUAL CHECK

Check the following parts for wear, damage or other abnormal

conditions.

REASSEMBLY

Refer to SECTION 10 “WHEEL AND TIRE” for wheel removal procedure.

REASSEMBLY STEPS

▲1. Wheel pin

▲2. Bolt

▲3. Inner bearing and outer race

▲4. Oil seal

▲5. Hub and disc assembly

6. Outer bearing

7. Lock washer

▲8. Hub nut

9. Nut retainer

10. Split pin

▲11. Hub cap

12. Brake caliper

▲13. Bolt

IMPORTANT OPERATIONS

1. Wheel Pin

(1)Place hub on a wood workbench or a block of wood,

approx. 6” by 6” to protect the wheel stud ends and threads.

(2)Install wheel stud using a hammer.

Be sure wheel stud is started squarely and seats

completely.

(3)Align index marks and install hub to disc.

2. Bolt

Torque N⋅m (kgf⋅m/lb⋅ft)

103 ± 5 (10.5 ± 1/75.9 ± 7.2)

3. Inner Be aring and Outer Race

4. Oil Seal

▲Outer Bearing Outer Race

(1)Install the bearing outer race by driving into the hub.

Installer (Outer) : 5-8822-0053-0 (J-29016)

Installer (Inner) : 5-8822-0054-0 (J-29015)

Drive handle : 5-8840-0007-0 (J-8092)

(2)Install the outer and inner bearing into the hub with fingers.

(3)Install oil seal using special tools.

Installer : 5-8522-0051-0

(J-33161)

Grip : 5-8840-0007-0

(J-8092)

5. Hub and Disc Assembly

11. Hub Cap

Apply grease in the hub and hub cap.

Description Amount g(oz)

Hub 50 (1.76)

Hub cap 20 (0.70)

Outer bearing 6.5 (0.23)

Inner bearing 12 (0.42)

8. Hub nut

Adjustment of front wheel hub bearing preload

1. Tighten spindle nut to 3.0 kg⋅m (21.7 lb.ft/29.4 N⋅m) torque.

2. Turn the hub 2-3 turns and loosen the nut just enough so

that it can be turned with the fingers.

3. Turn the nut all the way in with the fingers and check to be

sure the hub has no free play.

4. Measure the bearing preload by pulling one of the wheel hub

studs with a spring scale.

5. Tighten the spindle nut until specified bearing preload Is

obtained.

After reassembling, install the disc brake caliper assembly.

Bearing Preload kg(lb)

New bearing and New oil seal 0.8 - 1.0(1.8 - 2.2)

Reuse bearing and New oil seal 0.8 - 1.0 (1.8 - 2.2)

13.Bolt

Torque N⋅m (kgf⋅m/lb⋅ft)

155 ± 15.7 (15.8 ± 1.6/114.3 ± 11.6)

FRONT HUB AND DISC (4×

××

×4 MODEL)

DISASSEM BLY

Refer to SECTION 10 “WHEEL AND TIRE” for wheel removal procedure

DISASSEM BLY STEPS

1. Bolt

2. Hub cap

3. Snap ring and shim

4. Flange

5. Lock washer

▲6. Hub nut

▲7. Hub and disc assembly

8. Outer bearing

9. Oil seal

10. Inner bearing

IMPORTANT OPERATIONS

6. Hub nut

Wrench : 5-8840-2117-0

(J-36827)

Refer to Section 5 “Brake” for disc brake

caliper removal procedure.

7. Hub and disc assembly

Before disassembly, remove the disc brake caliper assembly

and hang it on the frame with wires.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

For inspection and servicing of disc caliper, and relative parts, refer to Section 5 “Brakes”.

• Hub

• Hub bearing, oil seal

• Knuckle spindle

• Disc

• Caliper

• Free wheeling hub parts

(Option)

• Clutch, knob, follower, inner, ring and

spring

VISUAL CHECK

Check the following parts for wear, damage or other abnormal

conditions.

REASSEMBLY

Refer to SECTION 10 “WHEEL AND TYRE” for wheel removal procedure.

REASSEMBLY STEPS

▲1. Inner bearing

▲2. Oil seal

▲3. Outer bearing

▲4. Hub and disc assembly

▲5. Hub nut

▲6. Lock washer

7. Flange

▲8. Snap ring and shim

9. Hub cap

▲10. Bolt

IMPORTANT OPERATIONS

1. Inner Bearing

Outer race ; outer bearing

Install the outer race by driving it into the hub.

Installer : 5-8840-2119-0

(J-36829)

Grip : 5-8840-0007-0

(J-8092)

2. Oil Seal

Installer : 5-8840-2120-0

(J-36830)

Grip : 5-8840-0007-0

(J-8092)

Apply grease (Besco L-2 or equivalent) to the lip portion.

3. Outer bearing

Outer race ; outer bearing

Install the outer race by driving it into the hub.

Installer : 5-8840-0054-0

(J-29015)

Grip : 5-8840-0007-0

(J-8092)

4. Hub and Disc Assembly

(1)Apply grease in the hub.

(2) Apply grease (Besco L-2 or equivalent) to the outer and

inner bearing. g(oz)

Hub 35 (1.23)

Outer bearing 10 (0.35)

Inner bearing 15 (0.53)

5. Hub Nut

(1)Turn the place where there is a cham fer in the tapped hole

to the outer side, and attach the nut.

Wrench : 5-8840-2117-0

(J-36827)

PRELOAD ADJUSTM ENT

Tighten the hub nut at 29.4 N⋅m (3 kgf⋅m / 21.716 lb.ft), then

loosen the nut to the full.

Tighten the hub nut at the value given below, using a spring

scale on the wheel pin.

Bearing Preload kg(lb)

New bearing and New oil seal 2 -2.5 (4.4 - 5.5)

Used bearing and New oil seal 1.2 - 1.8 (2.68 - 4.0)

If the measured bearing preload is outside the specifications,

adjust it by loosening or tightening the bearing nut.

6. Lock Washer

Turn the side with larger diameter of the tapered bore to the

vehicle outer side, and attach the washer.

If the bolt holes in the lock plate are not aligned with the

corresponding holes in the nut, reverse the lock plate.

If the bolt holes are still out of alignment, turn in the nut just

enough to obtain alignment,. Screw is to be fastened tightly so

its head may come lower than the surface of the washer.

8. Snap ring, shims

Adjust the clearance between the collar and the snap ring.

Clearance mm(in)

0 - 0.3 (0 - 0.01)

Adjust shims available mm(in)

0.2, 0.3, 0.5, 1.0

(0.008, 0.011, 0.020, 0.039)

10.bolt

Torque N⋅m (kgf⋅m/lb⋅ft

)

10 - 14 (1.0 - 1.4 / 7 - 10)

FRONT HUB AND DISC (MANUAL LOCKING HUB)

DISASSEM BLY

DISASSEM BLY STEPS

▲1. Bolt

2. Housing assembly

3. Snap ring and shim

4. Body assembly

5. Lock washer

▲6. Hub nut

▲7. Hub and disc assembly

8. Outer bearing

9. Oil seal

10. Inner bearing

▲11. Clutch assembly

12. Snap ring

13. Knob

14. Compression spring

15. Follower

▲16. Retaining spring

17. Detent ball and spring

18. X-ring

19. Snap ring

20. Inner assembly

21. Snap ring

22. Ring

23. Spacer

IMPORTANT OPERATIONS

1. Bolt

Before removal, shift transfer lever into “2H” position and set

free wheeling hub knob into “FREE” position.

6. Hub Nut

Wrench : 5-8840-2117-0

(J-36827)

Refer to Section 5 “Brake” for disc brake

caliper removal procedure.

7. Hub and Disc Assembly

Before disassembly, remove the disc brake caliper assembly

and hang it on the frame with wires.

11.Clutch Assembly

While pushing follower knob, turn clutch assembly clockwise

and then remove clutch assembly from knob.

16.Retaining Spring

Remove retaining spring from clutch assembly by turning it

counterclockwise.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

For inspection and servicing of disc caliper, and relative parts, refer to Section 5 “Brakes”.

• Hub

• Hub bearing, oil seal

• Knuckle spindle

• Disc

• Caliper

• Free wheeling hub parts

(Option)

• Clutch, knob, follower, inner, ring and

spring

VISUAL CHECK

Check the following parts for wear, damage or other abnormal

conditions.

REASSEMBLY

REASSEMBLY STEPS

▲1. Spacer

2. Ring

3. Snap ring

▲4. Inner assembly

5. Snap ring

6. X-ring

7. Detent ball and spring

▲8. Knob

▲9. Snap ring

▲10. Retaining spring

▲11. Follower

▲12. Compression spring

▲13. Clutch assembly

▲14. Outer bearing

▲15. Inner bearing

▲16. Oil seal

▲17. Hub and disc assembly

▲18. Hub nut

▲19. Lock washer

▲20. Body assembly

▲21. Snap ring and shims

▲22. Cover assembly

▲23. Bolt

IMPORTANT OPERATIONS

1. Spacer

Apply grease to both faces of spacer.

4. Inner Assembly

Apply grease wheel bearing to inside face of ring. g(oz)

Amount of grease 3 (0.10)

8. Knob

(1)Apply greas e Wheel bear ing to outer c irc umf er ence of k nob

and inner circumference of cover.

(2)Align detent ball to either groove of cover.

9.Snap Ring

Turn the smoother face to knob side.

10.Retaining Spring

Align the end of spring to the end of cut portion of clutch spring

groove.

11.Follower

Install follower to clutch so that follower nail will come closer to

the bent portion of retaining spring by aligning follower stopper

nail to outer teeth of clutch. Then, hook retaining spring onto

upper portion of hanger nails of follower.

12.Compression Spring

Turn the smaller diameter side to follower.

13.Clutch Assembly

Align follower nail to handle groove, and then assemble clutch

with knob by pushing and turning clutch counterclockwise to

knob.

14.Outer Bearing

Outer race ; outer bearing

Install the outer race by driving it into the hub.

Installer : 5-8840-0054-0

(J-29015)

Grip : 5-8840-0007-0

(J-8092)

15.Inner Bearing

Outer race ; inner bearing

Install the outer race by driving it into the hub.

Installer : 5-880-2119-0

(J-36829)

Grip : 5-8840-0007-0

(J-8092)

16.Oil Seal

Installer : 5-8840-2120-0

(J-36830)

Grip : 5-8840-0007-0

(J-8092)

17.Hub and Disc Assembly

(1)Apply grease in the hub.

(2) Apply grease (Besco L-2 or equivalent) to the outer and

inner bearing. g(oz)

Hub 35 (1.23)

Outer bearing 10 (0.35)

Inner bearing 15 (0.53)

18.Hub Nut

(1)Turn the place where there is a cham fer in the tapped hole

to the outer side, and attach the nut.

Wrench : 5-8840-2117-0

(J-36827)

PRELOAD ADJUSTM ENT

Tighten the hub nut at 29.4 N⋅m (3 kgf⋅m / 21.716 lb⋅ft), then

loosen the nut to the full.

Tighten the hub nut at the value given below, using a spring

scale on the wheel pin.

Bearing Preload kg(lb)

New bearing and New oil seal 2 -2.5 (4.4 - 5.5)

Used bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)

If the measured bearing preload is outside the specifications,

adjust it by loosening or tightening the bearing nut.

19.Lock Washer

Turn the side with larger diameter of the tapered bore to the

vehicle outer side, and attach the washer.

If the bolt holes in the lock plate are not aligned with the

corresponding holes in the nut, reverse the lock plate.

If the bolt holes are still out of alignment, turn in the nut just

enough to obtain alignment,. Screw is to be fastened tightly so

its head may come lower than the surface of the washer.

20.Body Assembly

Apply adhesive (Loctite 15 or equivalent) to the both joining

faces.

21.Snap Ring and Shims

Adjust the clearance between the free wheeling hub body and

the snap ring.

Clearance mm(in)

0 - 0.3 (0 - 0.01)

Adjust Shims Available mm(in)

0.2, 0.3, 0.5, 1.0

(0.008, 0.011, 0.020, 0.039)

22.Cover Assembly

Align stopper nails to grooves of body.

23.Bolt

Torque N⋅m (kgf⋅m/lb⋅ft)

11.8 ± 2.0 (1.2 ± 0.2 / 8.7 ± 1.4)

FRONT PROPELLER SHAFT

REMOVAL AND INSTALLATION

Since the propeller shaft assembly is carefully

balanced, a setting mark should be applied to

the flange before removal to indicate correct

position.

Install the parts by aligning the setting marks

made at removal.

REMOVAL STEPS

1. Nut ; differential side

2. Bolt ; transfer side

3. Propeller shaft assembly ; rear side

4. Propeller shaft assembly ; front side

INSTALLATION STEPS

4. Propeller shaft assembly ; front side

▲3. Propeller shaft assembly ; rear side

▲2. Bolt ; transfer side

▲1. Nut ; differential side

IMPORTANT OPERATION - INSTALLATION

3. Propeller Shaft Assembly ; Rear Side

Align the indexing marks (about 3 mm dia. punched mark) on

the propeller shaft end and the splined yoke.

2. Bolt ; Transfer Side

Torque N⋅m (kgf⋅m/lb⋅ft)

Bolt size M10 62.8 ± 3.9 (6.4 ± 0.4/46.3 ± 2.9)

1. Bolt ; Differential Side

Torque N⋅m (kgf⋅m/lb⋅ft)

Bolt size M8 35.3 ± 2.9 (3.6 ± 0.3 / 26 ± 2.2)

DISASSEM BLY

DISASSEM BLY STEPS

1. Snap Ring

▲2. Needle Roller Bearing

3. Spider

4. Flange Yoke

5. Grease Fitting

IMPORTANT OPERATION

2. Needle Roller Bearing

(1) Apply alignment marks (1) on the yokes of the universal

joint, then remove snap ring.

(2)Tap out the needle roller bearing by gently striking the

shoulder of the yoke, using a mallet or a copper hammer.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

Spider

Needle roller bearing

Yoke

Flange

Center bearing

Cushioning rubber

Bracket

VISUAL CHECK

Check the following parts for wear, damage or other abnormal

conditions.

OUTSIDE DIAMETER OF SPIDER PINS

TF Side for Type - A and B mm(in)

Standard Limit

17.000 (0.669) 16.90 (0.665)

Axle Side for Type - A mm(in)

Standard Limit

14.724 (0.580) 14.624 (0.576)

PLAY IN SPLINES IN NORMAL DIRECTION OF

ROTATION

Check the amount of play in the sleeve yoke and propeller

shaft splines in the direction of rotation, using a pointed feeler

gauge. mm(in)

Standard Limit

0.074 - 0.156

(0.003 - 0.006) 0.3 (0.012)

REASSEMBLY

REASSEMBLY STEPS

1. Flange yoke

2. Spider

▲3. Needle roller bearing

4. Snap ring

5. Grease Fitting

IMPORTANT OPERATIONS

3. Needle roller bearing

(1)Install spider to flange yok e. Be sure to install the spider by

aligning the setting marks made during disassembly.

(2) Apply molybdenum-disulfide grease or multi-purpose type

grease NLGI No.2 to inside of the bearing cap.

Grease Amount: Approx. 1.2g (0.042 oz)

(3)Using either mallet (or copper hammer) or a press, install

the needle roller bearing into the yoke so that the snap ring

can be installed in its groove.

CAUTION:

The needle roller bearing cannot be installed smoothly if it

is set at an incorrect angle with the flange and excessive

hammering will damage the needle roller bearing.

(4)Align setting marks (1) and join the yokes.

(5)Install snap ring.

NOTE:

Discard used snap rings and install new ones.

When the bearing cap is in position, select and attach a snap

ring of suitable thickness so that the end play of the spider pin

is held within 0.1mm (0.004 in).

T/F side for Type - A and B

Snap ring thickness and Identification color

1.5mm (0.059 in); Blue

1.53mm (0.060 in); White

1.59mm (0.063 in); Yellow

1.62mm (0.064 in); Green

1.68mm (0.066 in); Not colored

Axle side for Type - A

1.44mm (0.057 in); Not colored

1.49mm (0.059 in); Not colored

1.54mm (0.061 in); Not colored

NOTE:

Be sure to use snap rings of the same thickness on both sides.