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    48 views122 pages

    Section FS - Front Axle and Suspension PDF

    Uploaded by

    Lucy Lu Lu Simba

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 122
    DAIHATSU F300 FRONT AXLE & SUSPENSION OUTLINE OF FRONT AXLE & ‘SUSPENSION .. DISC WHEELS WHEEL CAPS WHEELS & TIRES FRONT WHEEL ALIGNMENT FRONT SUSPENSION FRONT AXLE HUB ... ‘STABILIZER BAR ‘STEERING KNUCKLES DRIVE SHAFTS... LOWER ARMS UPPER & LOWE! '85Ts (Special Service Tools) SERVICE SPECIFICATION TIGHTENING TORQUE Fea FRONT AXLE & SUSPENSION OUTLINE OF FRONT AXLE & SUSPENSION FRONT AXLE ‘+The ckiving force trom the engine is trarsmitted to the dive shafts at the right and left sides via the rranemeson, Vanetar, ant proper shaft and tran. alfetewta, ily esching the tort uo meshec wih the spine provided at the forward end ol each dive shaft Consequently, te res are avon. ‘+ The crve shalt empioys a ful floating ‘ype in wricn the vehicle weight le eusained by moans of two ‘tapered rer bearings located beaween ihe ont axle hub snd the steering kauckle, Hence, ro vehicla \Weight is applied tthe ave shah. +The fowa'e section o the rant axle hub adopls two types, depending upon the vehicle type the rigid ype and te focking hub ype Furthmore, the lacking hu comes in wo Kinde: the marual locking hub mechanism andthe eutomatle locking nub mechanism ‘This mechaniem mares it possbe to resuce a mechanicalloss which wit be generated when the power trom te front wheel srves te front aiferental anc traneter curing he 2WD operation, lb iP " Fron ante outer sat Mange one =) site F52 FRONT AXLE & SUSPENSION Front as rs / Frog une nub assent Fone nes covet sisccenely LL, ‘Manu ocknghub-eseiped vile 7 aaorate ki rb cove saasserety J ‘Automate lecing ubequppes vehicle Feo FRONT AXLE & SUSPENSION 1. MANUAL LOCKING HUB Te manual lockng hub Is @ mechanism whaceby the suitching of power flow is made so tat the driving foroe "fom tho front ave shaft can 9 tranamied tothe front wheel or the oraue tom the ont wheel can rote tansinated to te front cive shall le. ane this Swiching is pecormed trough the operation of he hance provides atthe ont wheal hao. How to operate ‘+ Whon th transfer shit lever is shited to the [24] positon, 91 the lacking hub handle to the [FREE] postion at both the right ana lot wheal. + When the vaneter shit lover is shifted :o the aH] or [4U) position. set he lcking nub handle to the [LOCK] positon [st bot he right and let wheels SAUTION 1. Do not move the veticle ifthe hana (A mark) i not algned exactly with the mark at the “Free” or “Look” Postion on te cover 2. Do nt operate the vehicle inthe AL or 4H postion when the hub handle is set o the "Free" poston {3 Mako cur to sat the handle (2 mark) on both the right ‘ard leh wheels at te same postion, Construction +The manval locking hb (manual Ieee wheel hub assembly) consis ofthe tee whee hub body, fee ‘whee! hub inner. ree wheel hb ring sub assembly, ree whee’ nub clutch. fee wneel hub handle, flower andso torr, + The fae whee! hub inner ie enline-connectad tothe eve shat On the other hand, the free wheel nu body is mounted on the Hn wheel nus. Furthermove, is inside © splne-connected 1 the lee whoe! hub lute, 4+ The fe wheel nub eluten i at springs hed to the fee whes! hub handle by means ofthe folower and two recwmine pte \ /[cmminact wee S, aan % St \ Fee sror ine ae Free westruo rng subassoriy FRONT AXLE & SUSPENSION Operation LOCKING HUB HANOLE (FREE WHEEL HUB HANDLE) WHEN SET TO [FREE] POSITION ‘Wien the free whes! hub handle is set to the [FREE] postion, the trae whee! hub clutch comes al the ‘uiermost postion on He spline ofthe free whael hub body (al the extremely right postion the Figura below). where no civng free from the cive shat ie wanemited 0 he ot whee! hue, + LOCKING HUB HANDLE (FREE WHEEL HUB HANDLE) WHEN SET TO [LOCK] POSITION ‘When te ree whesthub hand is tuned irom the [FREE] postion tate [LOCK] poston the flower moves {warcitne insige (toward! the let sid inthis figure) along the Gagonel groove provided insice te ree whos hub handie. AS @ reut, te fee whes! nub cluich whichis alacned:0 the foomot by means o sprigs wil move toward the nside slong the spline ofthe roa wnesl hub body, This operaton causes the fee whet hhub etch to mesh withthe spine ofthe ree wheel hud inner Consequently, the crking fee cane ‘ve shat is transmits to he front whet hub Fotoner FRONT AXLE & SUSPENSION 2. AUTOMATIC LOCKING HUB. ‘The eutomatis locking hub & & mechaniem whereby the switching of power flow is mace autematcaly 60 thatthe diving fores trom the font cive shal can be transmitted to ne ont wheel or no cing lorce can hot be transmitted to te fant wheel whan the Wanslr lever i shit From the [2H] peetion fo te [al] pion or the [4] postion and the venice is run How to operate 1. [FREE] STATE TO (LOOK] STATE (4) With the vehicle in a stationary stat, sit the vansier Shit lever from the [2H] postion tothe [4H] postion or the [4L] poston (2) Win he Steering wheel cat toa straight ahead postion. stony move olf the vehicle and un ft approxenataly ‘more than 2 mies, Then, he vehicle Is put automat teal under the [LOCK] conation Nore: ‘When the vehicle rune In a diction opposite to the former drection belore stopping (forwarc movement <> backward moverient aftr te vehicle has been run wh ‘the vansler shut lever placed inthe [4H] or] position ‘and with the automatic locking hub set to the [LOCK] State and the vehicle has been stoped, the aula ‘poking hub wile switned tom the [LOCK] state tthe [FREE] state and wil become the [LOCK] stato again. 2, [LOCK] STATE TO [FREE) STATE (1) Wet he vehicle ba Stationary state, shit the vanstor shit lever fom the [4H} or [41] positon :0 tha (2) poston. (2) Wit the steering whe! set 0a straight ahead postion, slowly move ofthe vaicia ina dracon opposte to the former dieeton betore the swtching to (24) positon and un the vehicle aparoximaiely more than 8 mars Then, te vehicle is put eviomsticelly uncer the [FREE] ccondiven note: ‘If she vehicle Is moved off inthe same direction asthe farmer directon botore the suetching tothe [2H] postion inthe operaton descrived in Step (2) above, the vehicle will tun under the [LOCK] lock sete conta. Fs8 Fun yore arora 3 mets Esl tha © | erating eetwctine on Automatie Looking Hub FRONT AXLE & SUSPENSION ‘Avoidance of Ratcheting Phenomenon 7 eae ent ‘The atzheing phenerenon meane a gear lashing oo hich occurs when the aulmatc exng mio caren | > meshes wih iw automatic lckng hub body Here existe | Auomat” usmase Ziference nrewlufona speed between hese wocors | SS ate ponents ‘esssenoly ee ‘nen such pharemenon ooo, fret sto se vehicle ‘gan plzce te verter inthe AND postion, Sow tone ca vile sight Then, proceed to eve te varie noxmaly a Prohiotion of shitng operation of transfer dung cunting I the trarsler shoud be shifted ‘tom the 2D tothe rotor @ 2% Mecowet cures stone ne motor at the speciied postion, simutanecusly lacking te retr the rotor rotates tothe speciied poston. ator in he folowing eaeuence, motor > Foe FRONT AXLE & SUSPENSION TIRES Radial tres are mounted on all venicie models. These tes come ether in tubeless or withtube, depending upon destinations. Deteaion ‘ECE A EEC Genera’ Awetralian ec. ne 15 FOS Tae) 3 o 3 = em WE) = = = = “PRR RTS wD = = = o STORIE WS awe) o S 3 = eT RTE eS) = = = o Tie Sea © Desinsion) ere a gEc Generel ‘Auatreven coe ama] oe] Toten | venga = venga Few | engfor | tigtew | a0ice = Teas [re | ite? Tangier] tice = ree [ 2a) aaigier | aioe = Gee eke = = ‘seprsacs ra Fitter = = omen!” Lew be ehoten = -— Ie few [= Fagin = = ower = = Teste nanos me = = Biker ew bron = = erator a = = Banater? Guomg POR [Teiatia? | veteran | aeonse | aan? arom ex | atte erngien | tise Patio Tee [row | hater? | erator [ice [at fer | 2araiee? | aaagiow’ | ~ awice a ae EeErer sews lips aimawenrs —|iaiegne | inane FRONT AXLE & SUSPENSION WHEEL CAPS e ‘whee! oape are Insalod on EL and ELI grades. The wheel cap forthe front wheel comes in two kinds; & standard wheel cap and a wheel cap for the front wheel with free whee’ nub. ‘On the rear wnesle tho same wheel caps are iretaled on EL and EL grades. Aste wheel cap is provided forthe aluminum wheel ‘net op for ron wheats wt fee whee! hon suminum whoa OU FRONT AXLE & SUSPENSION om Denson | #40 ee ‘Aumioum aie whan F525 WHEELS & TIRES Note: 1+ The tres should exhibit no damage, such as oxcossive Wear, uneven wear and scratches. ++ Any foreign matter, such as gt caught inthe groove of {he tire, shoul be removed in aovance. ++ The tres should nat be 80 worn that sip signs appear on thi read surfaces. 1. Check of tre size Contin the folowing poins, (7) Ensure tat retires having ne designated tre size are mounted. Dosignated Tre Size: 195 RIS 195180 R15, 22570 RIS (2) Ereuro thatthe fou tros have the same size and they are ones mace by te same marwlacture, (3) There is no eignieans dfferenes in wer Between the ont and it tres. 2, Teo ivtation pressure Ensure that th tres are nflates tothe specitied ar pres Specie Value otent = a TES we [te] a | a8 waronisos | we | 16 | an | 2a vosgonteos | ve [ie pan ee Nore: ‘+The te inflation pressure should be acfusted when the tio temporature Isat the ambient temperature (por to the runsing) ‘+ Tho te Infaion pressure should be adjusted under the unloaded sste 8, Chock o dae whee! and te (1) Ensure thatthe cise wheel exhibits no damage, such as ormation and orks, Itany damage is presen, replace he diac whe (2) Jack up the vehicie and aupper it with salty stands, (See the GI section) FRONT AXLE & SUSPENSION FRONT AXLE & SUSPENSION (@) Chock ne whee! and tre for unout, using a dal aug. Ensure tha he runout is within he allowable Em Whe! tasimum Runt: ‘Mean valve of runouts at ont and rer sides not te exceed 1.0 mm (0.04 inch} Tre Maximum Fusout ‘Vorical Runovt: Not to Exeo0d 1.6 mm (Not fo Exceed 6.0551 inch) Lateral Runout: Not fo Exc90d 2,0 mm (Not to Exceed 0.0787 inch) (4) Jack down the vehicle. 4, Removal and instalation of re (3) Peyote canter cap by inserting an type handle into between the whael and the center cap, NOTE: + Be vory careful nat to damage the wheel. 12) Sight loosen the wheel hue nuts in the sequence Indleated in te ight haute (3) Jack up the vehicle anc support it wih stety stands (See Gl section (42 Remove the whoo! hub nuts. Remove the wheel from thevehice (6) Ensure mat no forsign mater, such a8 dr, get to the whee! attaching surface at he vehicle i. (€) Ensure that no foreign mater gets tothe wheel atach Ing surtece, (7) Ensure that the hub bats and hao nuts axniot ro camage. Itany hub bot cr hub put exhibis damage, replace the ‘damaged hub bot anajor hub nut (@) Attach the whee! to the vehicle. Temporarily Bhan the hub nut, unl te wheel can be eecured (9) Jack cown te vetics (10) Eveniy tighten the whos! hub nuts to the specifed torque over tao oF thee stages in the sequence Ind ‘cated in the right figure Tightening Torque: 89.2 - 118 Nem (0-120 kgm, 65.1 - 67.0 Mb) (11) Attach te vehicle toot indicate inthe right figure tothe Wheel cep. Press the wheel cap to tre wheel FRONT AXLE & SUSPENSION FRONT AXLE & SUSPENSION 5. Check of each retated part for excessive play (1) Front whee! beating for excessive play {2) Suspension ball ort ox excessive play {@) Stoering inkage for excessive play and deformation (4 Sueporsion elated pars lor excessive play and detor- ration ‘Check the tems above by rocking te tre n afore rat ‘rection as wol asin a ight-Biattdecton, Fs-20 FRONT AXLE & SUSPENSION FRONT WHEEL ALIGNMENT ‘TROUBLE SHOOTING Sete Pon cae rosie pars Tae ueeny worn atener ace | Town out ora Seana Canter amet to reckeartr Tes uneven wor aoaar ce | Tavsn sou ge roar Check worn | aroovins ne aaah Turing wins o gem open | Car age woe Grearcasor en hcl sta nn ‘Ceo te arinition sss, Wave pus wanoace | Caner ange ton erat cartraay we nae Seanad aves sco erence nconber angle beneen ight rain cee Crecccam ceca Vance pas oe side Ging Kngpn gle pope sel bate ‘Gres uppe: gm bah Chace ape arr (Chescuooe a ba ct rece Ceaklower am bats Shack wet pon aca sy, Kevste Somes Sapna usp arto a PRELIMINARY CHECK ITEMS 1. Chock of ire size and te wear Ensure that the tres having the designated size are ‘mounted and tat there ie no signticantaiference n wear Between the right anc left res, Dosignated Tie Size: TOS RIS 19580 R15, 22570 RIS 2. Check ote inaton pressure Sat he tre inflation pressure tothe speotied value in ac cordance win the designated tres mounted Species Value ten Fo few (Usoadea] Uoasea [uneasea] Cece iaeRESS ve | te | an | aa zanonsies | 16 | ie | a1 | as waeonsos | te | se [a1_[ 28 Fea FRONT AXLE & SUSPENSION 3. Cheek of dae wheel and the for runout (1) Chock the se whee! fer uncut using a dial gauge. ‘Nlowable Unt: Mean value of runouts at ent and rear cides nat to excsed 1.0 me. (2) Check the tie for runout, using a dial gauge. Fadl Runout: Not to Exooed 1.4 mm. Lteral Runout: Not to Exceed 2.0 mn. 4, Check the suspensionselsted sections for bot and nut tightness 5. Check thatthe front chock absorber operates correctly while rocking the vehicle body. TToein check 11" Move te vetice forward 80 thet he tront wheels becomes sxaigtt. 2. Apply a toe-n gauge tothe center point ofthe height atthe tear de of each front whe of the vehicle, 3, Mark te toad center atthe rear side of each front tre. Measure to dstance betwoon the marks, 4. Move the vehicle slowly unt the font wheals turn 180, ogrees. 5. Measure the cistance between the marks atthe ont side ‘of each tront wheel, Determine the toen amount by ea culating the iterence, ‘Specified Value: 43am Fe-32 the oe.in amount fast conform tothe specication, adit ‘he te od length by turing the be rod aching tube ina same mount athe right and let ses, unt he efetence in length between tne right and lt te rods @ an @ shown inthe ght figure becomes wihin 3mm, ‘Tie od Tightening Procedure> Tighton the te fod by tering the nut @, with a wrench pled io the section ® shown in ho right haut. 2, Tighten the te fod by urring the mit ©, with wrench ‘apple to tho section ® crown in he right Four. ‘Tigttoning Torque: 118-167 Nm (12-17 kgm, 87.0 - 125 8) ‘Camber check and caster check 1 Place the whoo! on a turning racius gauge 2 Remove te free wheel nub cover. 3. Align the forward end of the center rod of the camber, caster and kingoin gauge withthe control the erve shat Proceed 10 make the forward ond o! the cantar rect coeely ntact with tre hub body, 4. Camber measurement ‘Spectied Camber Amount: 1° NOTE: ‘+ Tho measurement shouldbe petormedin the same way atthe right and ie wheels 5. Castor measurement ‘Specited Caster amount: 2°30" ‘Speciied Kingpin Angi: 9°20" NOTE: + For the alignmant checks, tun the steering wheel unt the reading of the turing radius gauge becomes 20 degrees al he cght wheel or the lt wheel, respectively. FRONT AXLE & SUSPENSION FRONT AXLE & SUSPENSION [Adjusting procedure for camber and caster Tha camber and castor vary by ineroacinglec-easing the numberof tho adusting shims provided at the rare instalation sulace ofthe upper a shaft ‘Selecting method of adjusting shim 11 Secct a sultable adjusting shim, using the diagram below. terre me costion an wasbr an the abc: trod 8. Remove the stabilizer bracket cover 1. Remove the stables bush FRONT AXLE & SUSPENSION INSPECTION © TATE eE Te ae alc a el Fee FRONT AXLE & SUSPENSION INSTALLATION 2 Inotall he Gun tothe stabilizer ba. instal the stabizer Enk fod tthe cushion, Temporary intl the tabiizer bracket cover Install the washer and cusrion t the stablizer nk ro, Insta the cushion tothe lower arm, Connect the sablizer tote loner arm ataching bok, Install the stabilize” fink to the Tame. Tighten the out with the cushion and washer interposed Nore: ‘+ Tighten the nut so thatthe threaded porton ofthe sta- bilzer ink provudes 2 to 6 mm tom the nut end surlace. Fe68 FRONT AXLE & SUSPENSION @ « esr even and waorto the ner rm Tighten the sesh nt Nore 1 Tatton the nut so hatte treed porton of th ower a protudes #10 @ ram fem then nd srtace 7. Tighten the stabitzor Bracket cover ataching bot Tightering Terque: 29.4 = 44.1 Nim (0-45 kgtm, 21.7-90.5 fb) 8. Insta the engine front undercover. FRONT AXLE & SUSPENSION TORSION BAR SPRINGS COMPONENTS, meee Bier) Ee, oe gecesoame ist § Toon be ae a sere gas 8 eoewmen BEE Ean 8 TROUBLE SHOOT a aa aa ae {amerieanonnans —frameane Fs-70 REMOVAL 1. Jack up the vehicle and suport with sfoty stands {See Gi secon) 2 Measure tie provuding dimension of the anchor batt Fevord the messured value 3 Remove the rubber boot, Put mating matks at @ pont be- ‘ween the tteion Dar spring ana the anchor arm an also at point between the torsion bar spring and the torque fim.’ For tis ideritication marks, use white part r fe Note: 1+ Since the shape ofthe torsion bar sping differs between the right side and te let sie, be sure to put mating ‘marks, so thatthe torsion bar springs may Be inetallod Correciy in tele orginal position. 4 Loosen the Ioek nut ofthe anchoe bol, unt the ration force of the tarion bar sing i ust eine, 5. Measure she provuding dimension of the anchor bol Record the measured value ren FRONT AXLE & SUSPENSION FRONT AXLE & SUSPENSION 6, Remove the torque arm ram the lower arm by removing the torque arm attaching bot, 7. Remove the adjusting seat fom the ancher aim Theo, Temove the anchor air evivel together wth ths anchor bots, nuts and anchor arm adjusting sat rom the fame, 8. Femove the anchor arm stopper trom the frame. Pull out the torsion bar spring ftom the anchor arm. Remove the anchor arm trom the frame Fore FRONT AXLE & SUSPENSION 41. Remove the forcue arm and cust covers from the torsion bar spring, INSPECTION Check he folowing parts Replace ery defective parts. Dus coves ee = seneae Sina er erage ad deterrason > ting eat ‘oraanage NOTE Care must be exercised as to tho following identification marks *+ Torsion bar springs for the right and forthe left are the designated parte exclusively for each side -ldontiication Marks> cc Yalow Pure peor We oh ak @ Co For Be unoa Kose CAUTION: ' AS respects the tocsion bar springs, be sure to observe ‘he combination above, ee + IV this caution stould fal to be observed, the running perlormance may drop sgniicanly. _ Fe79 FRONT AXLE & SUSPENSION INSTALLATION 1 Install the cust covers and torque arm to the torsion bar, NOTE: + Mae sure that the font and roar dust covers ate in

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