FRONTAND REARAXLES

I N D E X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . .M
. .-. . 2. . . . . . . ,
O U T L I N.E. . . . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . .M . .-. .3. . . . . . .
SPECIF|CAT|ONS.................................... M_ 3
TROUBLESHOOTTNG GUtDE...................... M- 3
FRONTAX1E............................,............ M_ 3
REARAX1E..............................,............ M- 3
FRONTAXLE........................................... M_ 4

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PREPAFATION....................................... M_ 4
H U B8 O 1 T . . . . . , . . . . . . . . . . . . , . . . . . . . . . . . . . .M . .-. .5. . . . . . .
WHEELHUB,STEERING KNUCKLE.......... M- 6
REARAXLE...............................,............. M_l3
PREPARAT|ON..................................,.... M_i3
DRUMBRAKETypE.............................., M-l3
DRTVE SHAFT.....,............................,....,.. M-l7
PREPARAI|oN.........-............................. M-i7
DRTVE SHAFTORtpODJOTNT)................. M-l7
 INDEX
INDEX

SEFIVICE, J, K
SECTION,
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1- Frontaxle 2. Rearaxle
pageM- 5
Replacement.............................. ... pageM-13
Preinspection.......................
pageM- 6
Preinspection............................. Removal/Inspection /
Removal/ page
.................
Installation M- 6 Instal|ation . .... page[r-l4
.................
pageM- 8
/ Inspection...........
Disassembly Disassembly pageM-16
/ Assembly............
pageM-10
Assemb1y................................... 3. Driveshaft
pageM-17
Preinspection.............................
Removal / pageM-l 7
Installation.................
overhaul ... .. .... . " " pagelvl-20

M-2
 OUTLINE.TROUBLESHOOTING
GUIDE
OUTLINE
SPECIFICATIONS
TEnsaxle lilTX ATX
llem
Faontaxle
Beaangplay. ax,aldtreclol mm (r) 0 (0)

Bearingplay, axlaldireclion mm (in) o.o5(0.002)

Drlve 3hatt
Lengthof jolnl Rightsde 659.7(25.97) 6580 (259r)
(betweencenle's of joinis) mm (n) L€tt side 3857 05.1s) 386.0(1s20)
Shatldiameter mm (in) 20.0(0.79) 21.0(0.83)

TROUBLESHOOTING
GUIDE
FBONTAXLE

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Problem PosslbleCaus€ Page
Steerlng wheel Wornor damagedwheelbearng t\,{- 6
vlblallon Excessivewheelbeaing play l\4- 6
Sleerlngwhe€l pulla Wornor damagedwheelbearlng l\,1- 6
or on6€lded braklng Excessivewhe€lbearingplay M-6
Exc$slvo steedng Excessiv€wh€€lb€arng play M-6
whe€l play
Bentor worn drive shalt M17
Wornor damagedwheelbearing M-6
grcasen joinlor on spllnesot driveshalt
Insutficient M20
Worndriveshafilripodjoint M-22
Greas€ leakage trom Damagedor brokenboot M-20
boot M-20
M-20

REARAXLE

Problem Po3albleCau3e action Pag6

St6€rlng whe€l Wom or damagedwheel bearing I\,{-14
vlbration Excessive wheel bearins play l\,1 14
Sl€erlng urheel pulls Worn or damagedwheel beaing
or one.sided braking Excessive wheel trearlng play Tightenor €place [4 14
Excesslvesleering Ercessivesheel bearingplay
wheel play
Abnomal noi3e Wom of damagedwheel bearng M-14

M-3
 FRONTAXLE
FRONTAXLE
PREPARATION

49 0727 575 49 0118850C

49 FO26 143 49 8026140

Putier,wheelhub --_{ l]l

F

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49 G030727 49 G033102

49 8026 1A0) 49 8026 rAO)

49 DO172AO 49 F40t 3664

bearng bearlng
beanng
49 D0172A0)

49 BA92372 49 F 01 361

Remove,
bea,ins
#
F
Attachmenr ,6 beaang
(Parrof \V lll]l
49 Dor7 2AO)

49 0t 80 321A 49 G025001

49 G030 797

;:::::j::" \@ Handle
{Pari or
49 G030 795)

49 FO27041 49 F027005

49 F027 0A1)

M-4
 FRONTAXLE

49 BOO1727 49 01805108

49 8001 795 49 8001796

inslallation
ot oil
Body @
iParl ol
49 8001795)

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HUBBOLT
Replacement
'1. Removethe wheeland tire.
2. Bemovethe brakecaliperassembly and discplate.
3. Cutawaytheholeofthedustcoverto removethehubbolt.

4. Usethe SST to removethe hub bolt.

5. Pullin the newhub boltwitha nut(L412x1.5)anda flatwash-

er as shown in the fioure.

M-5
 FRONTAXLE
WHEELHUB. STEERING KNUCKLE
Pr€inspection
Wheel bearlngplay
'1.Removethe wheeland tire.
2. Removethe brakecaliperassembly and disc plate.
3. Positiona dialindicatoragainstthe wheelhub.Pushand
pullthewheelhubbyhandintheaxialditection andmeas-
ure the wheelbearingPlay.
4. ltthebearingplayexceedsspecification,checkandadjusi
the locknuttoroue, or replace the wheel bealing if
necessary.
Wheel bearingPlaY:omm (0 in) max.

Removal,/Installalion
1-Jackup the frontof the vehicleandsupportit withsaletystands-
2. Removethe wheelandtire.
3. Removein the ordershownin thetigure,reterringto RemovalNote
4. lnstallin the reverseorderol removal,referringto InstallationNole

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.2-57 (4.e-5.3, 31--{2)

REPLACE
157-235 (1C-2/r, 116-1?3)

1. Locknut 4. Tle rod end

Installation note........... -...-.......... pagel\r- 7 Removal note............................ pageM- 7
2. Brakecaliperassembly Installationnote.......................... pageM- 7
. . . - . .5.
S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . . .S. .e. c. .t.i.o.Pn . Nut, bolt
3. Discplate 6. Lowerarm
S e r v i c e . . . . . . . . . . . . . . . . . . . . . . - Section 7. Wheelhub,steeringknucle
Disassembly / lnspection ........... pageM- 8
A s s e m b 1 y . . . . . . . . . . . . . . . . . . .p. .a. g. .e.M
. .-. 1. .0. . . . .

M-6
 FRONTAXLE
Removalnote
Tie rod end
Caution
. Do not damagethe dust boot.

LoosenthenutandusetheSSTtodisconnect
thetierodend.

lnstallatlonnote
/' // Tie rod end
oll''--'--'- Caution
, - . Do not damageihe dust boot.
lr" I
Installthe nutand secureit withthe newcotterpin.

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Tighleningiorque:
42-57 N.m(4.3-5.8 m-kg, 3l-42 ft-lb)

Locknut
1.Installa newlocknutand stakeit, as shown.
Tightenlngtorque:
ls7-235 N|n (16-24 m-kg, 116-173 ft-lb)
2. Measure the wheelbearingaxialplay.
(Referto pageM-5.)

M-7
 FRONTAXLE
olaagsemblv/ Inspection
t. Disa""".6t" in the ordershownin the figure relerringto DisassemblyNote
2. Inspectall partsand repairor replaceas necessary

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1. Wheelhub assembly 5. Bearingrace(outer) 9. Dustcover
Disassembly note.....below Disassembly note Disassembly note
2. Spacer . . . . . . . . . . . .. . .P a g e M - 9 page lvl- I
3. Wheelbearing(outeo 6. Oil seal (inner) 10. Steering knuckle
Disassembly note Disassembly note Inspectfor wearand
p a g e
. . . . . . . . . . . . . . . . . . . . .l.v l - I Page M- I damage
Inspectfor wearand 7. Wheelbearing(inne0 1 1 .H u bb o l t
operation Disass€mbly note Disassembly note
4. Oil seal(oute4 . . . . . . . . . . . . . . .p. .a.g. .e.M. - 9 PageM- 9
Disassembly note Inspectfor wearand 12.Wheel hub
Page M- I operation Inspectfor wearand
8. Bearingrace (inne0 damage
Disassembly note
PageL4- I
Disassembly note
Wheel hub assembly
tjse the SST to removethewheelhub assembly

M-8
FBONTAXLE
Wheel bearlng (outer), oll seal (outer)
Caulion
. Hold ihe wheel hub to prevent lt lrom lalling.
'1.Removethewheelbearing(outer)wih theSlsTanda press.
2. Removethe oil seal(outer)witha screwdriver.
Caution
. Do not damagethe wheel hub when removingthe
oil seal.

Beadng race (outer)

Removethe bearingrace(outer)withthe SSTand a press.

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Oil seal (inner), wheel bearing (lnner), bearing raco
(inner)
1. Removethe oil sealfinner)witha screwdriver.
2. Removethe wheelbearing(nner).
3. Removethe bearingrace (inner)with the SST and a
hammer.
Cautlon
. Tap on the bea ng race 0nner) only.

Duat @ve.
Caution
. Do not remove the duat cover it not ngceasary.
. Do not reuae the duat covel lf removsd.

1. Marklhe dustcoverand knucklefor properreassembly.

2. Removethe dustcoverwitha chisel.

Hub bolt
Cautlon
. Do not remove the hub bolts if not necessary.
. Do not reuae lhe hub bolts It removed.

Removethe hub boltswith a oress.

M-9
 FRONTAXLE
Assembly
Assemblein the ordershownin the figure,referringto AssemblyNoie
REPIACE
E

.t
,
o/\ \Y'6"'l
\ @ E

\YIY6
| | (b
*REPLAoE

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l@E
6)E

1. Hubbott 6. Wheelbearing(oute4 9. Wheelbearing(innet

Assembly note.......... below Assembly note Assemblynote
2. Dust cover ...................... page M - 1 2 ......................pageM
Assemblynote.......... below 7. Oil seal (outer) 10.Wheelhub
3. Steeringknuckle Assemblynote Assemblynote
4. Bearingrace (outer) ''''''''''''''''''''''pageM-12 pageM-13
......... ........
Assemblynote 8. Spacer 11. Oilseal 0nneq
. . . . . . . . . . . . . . .p. .a. g
. .e.M
. -l 1 Assemblynote Assemblynote
5. Bearingrace(inner) . . . . . . . . . . . . . . .p. a
. .g. .e.M
. -12 ......................pageM
Assemblynote
...................... pageM-11
Assemblynote
Hub bolt
Pressin the newhubbolts.

Duatcover
1.Markthe newdustcoverastheonersmoved.

M-l0
 FRONTAXLE
2. Alignthe marksof the newdust coverand the steering
knuckle.
3. Taoon the newdustcoverwiththeSST anda hammer.

Bearlngrace(outer)
lnstallthebearingrace(outer)
withtheSSTanda hammer
untilit contacts
thesteerina
knuckle.

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Bearing race (inner)
Pressin the bearingrace(inner)withthe SST.
Note
. After replacing a beadng racs, adiust the wheel
bearlngpreload.

olEo|MX{122
Adluatment of whsel beadng preload
1. Insertthetwo wheelbearingsand removedspacerintothe
steeringknuckleand attachthe SST.
2. Securethe bottomol the SST.

3. Tightenthe nutof the SSTto the specified

torque.
Tlghtening torquer
ls7-23s Nm (16-24 m-kg, l 16-174 ftlb)
Caulion
. Urhentlghtening,torque in sleps ot 49 Nm (5 m-
k9, 36 ft-lb) to preve applylng excessive preload,

M-l I
 FRONTAXLE
4. Rotatethe steeringknuckleto seat the whoel bearings.
5. Measure thewheelbearingpreload withtheSSTanda pull
sca|e,
wheel bearlngpreload:
0.25-1.1? N.m(2.5-12 cm-kg, 2.17-10.41 ln'lb)
2.5-1 r.7 N (0.25-1.2 kg, 0.55-2.64 lb)
(pull scale re€ding)

selectthe proper
6. lt the preloadis notwithinspecilication'
spacerlrom the table to adjus{it.
1 6.245Q.2474) 12 6.725lO.4A)
2 6.325(0.2490) 6.765(0.2663) Note
3 6.365 (0.2506) 14 6.€05(0.2679) . lncrsaselhe spac€rthicknessto reducethe plsload
6.405 (02522) 15 6.845 (O2695) and dscGase it to increase the prgload.
5 6 445 (0.2538) 6-885(0,2711) . Whena spacerla changedby I rank, lhe preload
6 6.445 (0.2554) 17 6-925(0.272q

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7 6.525 (0.2570) l8 6.965 (0.2742) changesir.2 to 0.4 lsm (2.0 to 4.0 cm-kg, 1.7 to
I 6-s65 (0.2585) 19 7 oo5 (0.2754) 3.5 inlb)
9 6.605 (0.2600) m 7.U5 \O.2n4l . The ranli marklng is stamPedon the ouisr periph-
10 6.64s(0.2616) 21 7.OA5@.27ep)
6.6e5(0.2631) ery ol the apacer.
7. Removethe SST.

Wh€cl beadng(outer & inn€r), oll s€al (outer) and spacer

Note
. completelytlll the ahadedareashovtnin the llgure
with llthium glease.

1.Installthe wheelbearing(oute4.
2. Applygfeaseto the hpof the newoil seal(outer)
3.lnstallthe newoil seal(ouler)witha hammerand a plale
so thatit is flushwiththe steeringknuckle

Nv 01E0MX{23
4. lnstallthe spacerthatwasselectedat
''Adjuslmentof wheel
bearingpreload".
5. Installthe wheelbearing(inner).

M-12
 FBONTAXLE. REARAXLE
Wheelhub
PressthewheelhubintothesteeringknucklewiththeSST.
Plessure:24,500N (2,500kg, 5,500 lb) max.

Oll seal (inner)

1. Applygreaseto the lip of the new oil seal(inner).
2. Installthenewoilseal(inner)withthe SSTanda hammer
so thaiit is flushwiththe steeringknuckle.

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oIEOMX-O3I
REARAXLE
PREPARATION
ssT
49 0259 77OB I For
Wench, llare nLl 9r-€--€ I insiailalion
oj
I oraxeprpe

01E0MX-O53

DRUMBRAKETYPE
Prslmpscilon
Whod beadngplay
1. Removethe wheeland iire.
2. Position a dialindicator
againstthebrakedrum.Pushand
pulltherearbrakeassembly by handin theaxialdirection
and measurethe wheelbearingplay.
3. lf the bearingplayexceedsspecification,checkand adjust
the locknuttorque, or replacethe wh€el bearingif
necessary.
Whe€lbearingplay: 0.05mm(0.002in) mar.

M-l3
 REARAXLE
Removal/ Inspection / lnatallation
1. . tck uo theiear of the vehicleand supportit withsafetystands.
2. I ,:movethe wheeland tire.
3. Removein the ordershownin the figure,reterring to RemovalNote.
4. Insoectall partsand repairor replace
as necessary
5. Insiallin the reverseorderof removal,reterringto InstallationNote
6. Afterinstalling,bleed air from the brakesystem (Referto SectionP )

13-22f3-2.2, ro-iq Elfl

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e.a-1al Nf 000-150 d.t!, 8t-r30 |Flb)

,-,,5*"[g FEPLACE

1.Hubcap 5. Wheelhub assembly 7. Brakepipe

2. Locknut Disassembly / Removalnote..pageM-15
Installationnote pageM-16
Assembly....... lnstallation note
page M-l5 Inspecttor wearand ... .. .... . .. pagel\r-15
3. Screw operation 8. Nut
4. Brakedrum 6. Parkingbrakecable L Spindle
Section
Servic€................ P SeMce................ P
Section lnspectlor wearand
damage
10.Backingplate
service................
SeclionP

u-14
REARAXLE
Femoval note
Brake plpe
Cautlon
. Atter dlsconnecthg the b6ke plp€, plug lt to avoid
lluid leakage.
Disconnectthe brakeDipewith the SST.

lnstallation note
Brake plpe
Tightenthe brakepipewiththe SST.
Tigl enlng torque:
13-22 N{n 11.3-2.2 m-kg, 10-16 ftlb)

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Locknul
1. lnstalla newlocknutandstakeit, as snown.
Tightenlng torque:
167-215 N{n (17-22 m-kg, 123-159 ft-lb)
2. Measurethe wheelbearingaxialplay.
(Referto page l\,,|-13.)

M-l5
 REARAXLE
Dlsassembly/ Ass€mbly
i. b-e-".""rrjt. rn the ord;r shownin the figure,referringto DlsassemblyNote'
z.,q$"rOfl in ttt" reverseorderof disassehbly, reterringto A$embly Note'

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REPLACE

'L Hub bolt 2 Wheelhub

.. ...... . .. below
note................
Disassembly replaceas assembly)
(Notrepairable'
Assembly . be|ow
note..........................-......
Dlsassembly nole
Hub bolt
Caulion
. Do nol remove the hub bolG ll not n€cessary.
. Do not r€use the hub bolts lf removsd'

Removethe hub boltwitha Press

0lEoMx4a2
Assemblynote
Hubbolt
Pressin thenewhubbolt.

01EoMX063
M-l6
 DRIVESHAFT
DRIVESHAFT
PREPARATION
ssT

49 0118850C
Puller,balliont

DRTVE SHAFTORTPOD JOTNT)

Prelnapectlon
Drive shaft
1. Checklhe dustbooton thedriveshaftfor cracks,damage,
greaseleakage,and a loosebootband.
2. Checkthedriveshaftfor bending,cracks,andwearol joints

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or spltnes.
3. Repairor replacethe driveshaftif necessary.

Removal/ lnstallalion
1.Jackup the rearol the vehicleand supportit withsafetystands.
2. Removethe wheeland tire.
3. Removein the ordershownin the figure,referringto RemovalNote.
4.Instiall
in the reverseord€rol removal,reterringto InstallatlonNote.
5. Checkthe transaxleoil amount.(Refe.to Sections J, K.)
6. Checkthe trontwheelalignment. (Referto SectionR.)

/B-t2 (a,a-5.3, l2l4

1t-2?5 (13-24, 116-tta)

FEPLACE

1. Locknut 3. Tie rod end 5. Driveshaft

Installationnote Removalnote..pageM-18 Removalnote..pageM-18
. . . . . . .p. .a. g eM - 1 9 4. Lowerarm lnstaliationnote
2. Nut Removalnote..pageM-18 pagelV-18
......................
Overhaul..........pagel/'l-20

tt-17
 DRIVESHAFT
Removal note
Tie rod end
Cautlon
. Do not damaqEthe dust boot.
thetie rodend
Loosenthe nutandusetheSSTto disconnect

Lower arm
1. Removethe clinchboltand nut.
the ballioint.
2. Prydownon the lowerarmto disconnect
Cauilon
. Be caretul not to damagelhe ball ioint dust boot.

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Drlve shaft
Cautlon
. Do not damagelhe dustcoveror oil seal.
witha screwdriver.
Prylhe driveshaftkom thetransaxle

lnstallationnote
Drlve shatt
Caution
. Do nol damage the dust covet or oll seal.
'1.Inslallthedriveshaftwiththe gapof clip facingupward.

2. Pushthe driveshattintothetransaxle
Caution
. Do not damagethe oll seal.

Note
. Aftel instaltalion,pull the tront hub outwardto verily
that the drive shaft ls held.

M-l8
DRIVESHAFT
Locknut
lnslalla new locknutand slakeit, as shown.
Tlghi€nlng torque:
157-235 N.m(16-24 m.kg, l16-173 tt-lb)

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lt-l9
 DRIVESHAFT
Overhaul
Caution
. Secure tlre iolnt in a vise wlth plotectivs material (such as copper plales) on the vise Jaws'
. Be carefultfi6t dust or other fo;eign malerlaldoes not enler lhe ioint whlle lhe work is b€lng
p€rlormed.
. Do not dlaassemblethe wheel slde ball iolnt.
. Do not wash the ioint unless it is being disaaaembled.

1. Disassemble in the ordershownin the figure,relerringto DisassemblyNole.

2. lnsoectall oansand repairor replaceas necessary'
3. Asaemble in the reverseorderot disassembiy. referringto AssemblyNote.

DO NOT DISASSEMBLE

(ONLYRIGHTDRIVESHAFD

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FEPIACE

FEPTACE

FEPLACE

BEPLACE

'dtrl
frl'.","*".

'l1.Bootband
1.Clip 6. Tripodjoint
2. Bootband Disassembly note Assemblynote
Assemblynote . . . . . . . . . . . . . . .p. a
. .g. .e.M
. -21 pageM-23
......................
. . . . . . . . . . . . . . .P a g eM - 2 3 Inspectfor wearand 12.Bootband
3. Outerring damage Assemblynote
Disassemblynote Assemblynote . pageNr-23
....................
...................... PageM-21 ...................... p a g e M - 2 2 13.Boot (wheel side)
lnspectinsideborefor 7. Bootband Inspectfor wearand
wear,corroslon, and Assemblynote damage
scoring ...................... pageM-23 Assemblynote
Assemblynote 8. Boot(transaxleside) pageM-21
............ pageM-22 Inspecttor wearancl 14.Shattand balljointassembly
4. Retaining ring damage Inspectsplinesfor damage
5. Snapring 9. Bootband and wear
Assemblynote lnspectwheelsidejointfor
...................... M-23 page excessive PlaYand rough
10.Dynamicdamper rotataon
Assemblynote
...................... pageM-22

M-20
 DRIVESHAFT
Dlaasaemblynote
Outer rlng
1. Markthe outerringandthe shaftfor properreassembly.
2. Flemovethe oulerrino.

Trlpod lolnt
1. Markthe shaftandtripodlointfor properreassembly.
2. Removethe snapringwithsnatrringpliers.
Caution
. Do nol damagelhe bearing.

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3. Removethe uipodjointtromthe shafl.

Asaemblynole
Boot (wheel slde)
Caution
. The whegl side and transaxle side boots are
dlllerent.

MTX ATX
]BAN$O(E SIDE WHEELSIOE @ 82.0(3.23)
80.2(3.16) 85.3(3.36)
0rEoMx{45
caution
. Uselhe specifiedgreasethat lt is suppliedin the
boot klt and ioit kit.

1. Fillthe boot(wheelside)withthe speaifiedgrease.

Greaaeamount
MTX:60 + l0g (2.12 + 0.35 oz)
ATx: 80 + l0g (2.82 + 0.35 oz)
sideshaft,andinstallthe
2. Wraothesplinesol thetransaxle
wheelsideboot.

M-21
 DRIVESHAFT
Dynamlcdamper
the dvhamicdamperas shownin the figure.
1.-lnslall
2. lnstallthe nirwbootbandontothe dynamicdamper.
NEW BOOTBANO

{ 1 9 , 1 34 0 . 1 2 I n )

Tdpod iolnt
Cautlon
. Do nol damagethe bearlng.

1.Alignthe marksand installthetripodjointwitha bar and

a hammer.
2. Installa newsnapringwithsnaPringpliers.

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Ouler ring
Cauilon
. Uae the specified grsase that it ls supplled ln the
boot kit and lolnt klt.
1. Fillthe outerringandboot(transaxle
side)withthe speci-
fiedgrease.
Greaseamount:115 + 109 (4.06 + 0.35 oz)

2. Installthe newouterring.
3. Setthe driveshaftto the standardlength.
Standard length mm(n)
Tr.nsaxle Lelt 3lde Rlgm .lde
M]'X 63r.4 * 5 (24.98 + 0.20) 908.4 5 (35.76+ 0.20)
+
AfX 634.0+ 5 (24.96+ 0.20) 906.0+ s (35.67+ 0.20)

4. Release traopedairfrominsidetheboot(wheelside)
using
a screwdrivercovered with a rag.
5. Verilythe driveshaftlength.

M-22
DRIVESHAFT
Boot band
Caulion
. Always use ngn, band€.
. The bandaahouldbe mountedIn the direclionoF
posite lhe forward aevolvingdireclion of thg drive
shatt.
'|. Foldthe band backby pullingthe end of jt withpliers.
2. Lockthe end of the bandby bendinglhe lockingclips.

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M-23