33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . .
SERVICE SPECIFICATIONS. . . . . . .
SPECIAL TOOL(S) . . . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . . .
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT <2WD (except High rider)>
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT <2WD (High rider), 4WD> .
LOWER ARM BALL JOINT AXIAL PLAY CHECK
...................................... 33-8
LOWER ARM BALL JOINT DUST COVER CHECK
...................................... 33-8
UPPER ARM ASSEMBLY . . . . . . . . .
UPPER ARM ASSEMBLY REMOVAL AND
INSTALLATION <2WD (except High rider)>
UPPER ARM ASSEMBLY REMOVAL AND
INSTALLATION <2WD (High rider), 4WD>
UPPER ARM ASSEMBLY INSPECTION . .
SHOCK ABSORBER AND COIL SPRING
<2WD (except High rider)>. . . . . . . . 33-13
SHOCK ABSORBER AND COIL SPRING REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . 33-13
SHOCK ABSORBER AND COIL SPRING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
SHOCK ABSORBER ASSEMBLY <2WD (High
33-2 rider), 4WD> . . . . . . . . . . . . . . . . . . . . 33-15
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SHOCK ABSORBER ASSEMBLY REMOVAL AND
33-3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 33-15
SHOCK ABSORBER ASSEMBLY INSPECTION
33-4 ...................................... 33-15
SHOCK ABSORBER ASSEMBLY DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 33-16
33-5
SHOCK ABSORBER ASSEMBLY INSPECTION
(DISASSEMBLY AND REASSEMBLY) . . . . 33-18
33-5
33-6 LOWER ARM . . . . . . . . . . . . . . . . . . . 33-19
LOWER ARM REMOVAL AND INSTALLATION <2WD
(except High rider)> . . . . . . . . . . . . . . . . . . . 33-19
LOWER ARM REMOVAL AND INSTALLATION <2WD
(High rider), 4WD>. . . . . . . . . . . . . . . . . . . . 33-20
LOWER ARM INSPECTION . . . . . . . . . . . . 33-21
33-9 LOWER ARM BUSHING REPLACEMENT <2WD
(except High rider)> . . . . . . . . . . . . . . . . . . . 33-22
33-9 LOWER ARM BUSHING REPLACEMENT <2WD (High
rider), 4WD> . . . . . . . . . . . . . . . . . . . . . . . . 33-22
33-11
33-12 STRUT BAR <2WD (except High rider)>
................................. 33-24
STRUT BAR REMOVAL AND INSTALLATION
...................................... 33-24
STABILIZER BAR <2WD (High rider), 4WD>
................................. 33-25
33-14 STABILIZER BAR REMOVAL AND INSTALLATION
...................................... 33-25
STABILIZER BAR INSPECTION. . . . . . . . . 33-26
33-2 FRONT SUSPENSION
GENERAL INFORMATION

GENERAL INFORMATION
M1332000102168
The Independent-wishbone, coil springs has been
adopted.

CONSTRUCTION DIAGRAM
<2WD (except High rider)>

Upper arm
Shock absorber

Strut bar

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Coil spring

Lower arm
AC501759 AB

<2WD (High rider)>

Coil spring

Shock absorber Upper arm

Stabilizer bar

Lower arm
AC608652 AC
 FRONT SUSPENSION
SERVICE SPECIFICATIONS
33-3
<4WD>

Coil spring

Shock absorber Upper arm

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Stabilizer bar

Lower arm
AC501760 AB

SERVICE SPECIFICATIONS
M1332000301954

Item Standard value

Toe-in At the centre of tyre tread mm 0−5
Toe-angle (per wheel) 0°00' − 0°12'
Camber 0°00' ± 0°30'*
Caster 2WD (except High rider) 3°48' ± 1°00'*
2WD (High rider), 4WD 3°48' ± 1°00'*
Kingpin inclination 2WD (except High rider) 15°24'
2WD (High rider), 4WD 12°45'
Upper arm ball joint starting torque N⋅m 1.0 − 5.6
Protruding length of shock absorber thread part mm 2−3
Lower arm ball joint starting torque N⋅m 2.9 − 6.9
Strut bar installation dimension mm 99.5
Stabilizer link ball joint turning torque N⋅m 0.2 − 3.5
NOTE: *: Difference between right and left wheels must be 0°30' or less.
33-4 FRONT SUSPENSION
SPECIAL TOOLS

SPECIAL TOOLS
M1332000601063

Tool Number Name Use

MB992058 Coil spring compressor Compression of front
suspension coil spring
<2WD (except High
rider)>
MB991783

A: MB991237 A: Spring compressor Compression of front

B: MB991238 body suspension coil spring
A B: Arm set, large <2WD (High rider), 4WD>

B MB991237

MB990326 Preload socket Ball joint starting torque

check

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MB990326

A MB991680 Wrench and socket set Shock absorber assembly

B A: MB991681 A: Wrench disassembly and
reassembly
MB991680

MB992047 Socket

MB992047

MB992011 Ball joint remover Upper arm and lower arm

ball joint disconnection

MB992011
 FRONT SUSPENSION
ON-VEHICLE SERVICE
33-5
Tool Number Name Use
MB991172 Inner shaft installer base Lower arm bushing
removal and press-fitting
<2WD (except High
rider)>

MD998911 Bearing installer

MD998911

MB990645 Installer and remover Lower arm bushing

A: MB990647 control arm bushing removal and press-fitting
A A: Bar <2WD (High rider), 4WD>

MB990645

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MB991015 Knuckle oil seal installer

MB991015

ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT <2WD (except High rider)>
M1331000901715
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to nor-
mal condition before measuring wheel alignment.
TOE-IN
Standard value:
At the centre of tyre tread: 0 − 5 mm
Toe angle (per wheel): 0°00' − 0°12'
NOTE: The toe will move out as the left turnbuckle
is turned toward the front of the vehicle and the
right turnbuckle is turned toward the rear of the
vehicle.
2. Install the clip and tighten the lock nut to the
specified torque.
Tightening torque: 93 ± 15 N⋅m
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the
steering angle is at the standard value (Refer to
GROUP 37 − On-vehicle Service, Steering Angle
Check ).

Clip CAMBER, CASTER AND KINGPIN INCLINATION

Compensator
Lock nut

AC502610 AB

1. Adjust the toe-in by undoing the clip and lock nut,

and turning the left and right tie rod turnbuckles by ACX00712AC
the same amount (in opposite directions).
33-6 FRONT SUSPENSION
ON-VEHICLE SERVICE

Standard value:
Camber 0°00' ± 0°30'* A
Caster 3°48' ± 1°00'*
Kingpin inclination 15°24' Nut
NOTE: *: Difference between right and left wheels Nuts
Washer
must be 0°30' or less.
Strut bar
Washer
AC502815 AB

–Direction +Direction
3. If the caster is not within the standard value,
adjust by turning the nut on the strut bar bushing.
Relation of variation:
Dimension (A) +1.0 mm
Caster angle −0°13'
AC504041AC
NOTE: Turning the nut on the strut bar one turn
1. Adjust the camber and caster until they meets the

standard value by turning the lower arm camber
adjusting bolt according to the camber and caster
reference table (Refer to ).
2. After adjusting the camber, the toe should be
adjusted.
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clockwise will increase the dimension by 1.5 mm (A).
4. Measure the camber again to confirm that its
value is within the standard value. If the value is
not within the standard value, repeat the
adjustment.

CAMBER AND CASTER REFERENCE TABLE

RELATION OF VARIATION
Bolt scale −4 −3 −2 −1 0 +1 +2 +3 +4
Camber +0°56' +0°41' +0°28' +0°15' 0° −0°15' −0°28' −0°40' −0°54'
angle
Caster +1°11' +0°53' +0°36' +0°20' 0° −0°20' −0°36' −0°53' −1°11'
angle

FRONT WHEEL ALIGNMENT CHECK AND

ADJUSTMENT <2WD (High rider), 4WD>
M1331000901867 Clip
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to nor-
mal condition before measuring wheel alignment. Lock nut

TOE-IN
Standard value:
At the centre of tyre tread: 0 − 5 mm AC502611AB
Toe-angle (per wheel): 0°00' − 0°12'
1. Adjust the toe-in by undoing the clip and lock nut,
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions).
NOTE: The toe will move out as the left turnbuckle
is turned toward the front of the vehicle and the
right turnbuckle is turned toward the rear of the
vehicle.
 FRONT SUSPENSION
ON-VEHICLE SERVICE
33-7
2. Install the clip and tighten the lock nut to the NOTE: *: Difference between right and left wheels
specified torque. must be 0°30' or less.
Tightening torque: 93 ± 15 N⋅m
CAMBER AND CASTER REFERENCE
3. Confirm that the toe-in is at the standard value.
TABLE
4. Use a turning radius gauge to check that the
steering angle is at the standard value (Refer to HOW TO READ THIS TABLE (EXAMPLE)
GROUP 37 − On-vehicle Service, Steering Angle
Check ).
B A
CAMBER, CASTER AND KINGPIN INCLINATION

Compensator
Lower arm
mounting bolt
AC407369AD

If the camber difference −0°35' and the caster differ-

ence is 0°17' by comparing the measurement value

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with the standard value, rotate the front adjusting
ACX00712AC cam by 1.5 graduations to the "B" direction and the
rear adjusting cam by 2.5 graduations to the "A"
Standard value: direction.
Camber 0°00' ± 0°30'*
Caster 3°48' ± 1°00'*
Kingpin inclination 12°45'
Front side
adjust bolt scale
Direction A
6'
'

2'

7'
˚2

˚4

˚3

˚1
–1

–1

–0

–0

0˚

7'
˚1

+4
+0
2'
˚3

+3
+0
6'
˚4

+2
+0
'
˚2

+1
+1

Rear side
adjust bolt scale
Direction A Direction B
+4 +3 +2 +1 0 –1 –2 –3 –4
–0
˚3
5'

–1
–0
˚2
6'

–2
–0
˚1
8'

–3
–0
˚1
0'

–4
–0
+0

+0

+0

+0

: Caster angle
˚3

˚1

˚1

: Camber angle
26
5'

8'

0'
'

Direction B AC407327 AC

NOTE: Solid lines show caster, broken lines show

camber.
33-8 FRONT SUSPENSION
ON-VEHICLE SERVICE

LOWER ARM BALL JOINT AXIAL PLAY
CHECK
M1332011300416
1. Raise the vehicle.
2. Remove the stabilizer link from the lower arm.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly (Refer to
P.33-19 <2WD (except High rider)> or P.33-20
<2WD (High rider), 4WD>).
LOWER ARM BALL JOINT COVER
CHECK
M1332008601056
1. Press the lower arm ball joint cover with your
finger to check that there are no cracks or
damage in the lower arm ball joint cover.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly (Refer
to P.33-19 <2WD (except High rider)> or P.33-20
<2WD (High rider), 4WD>).
NOTE: If the lower arm ball joint cover is cracked
or damaged, it is possible that there may also be
damage to the ball joint.

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 FRONT SUSPENSION
UPPER ARM ASSEMBLY
33-9
UPPER ARM ASSEMBLY
REMOVAL AND INSTALLATION <2WD
(except High rider)>
M1332004300373

CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.
Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with your finger.
• Wheel Alignment Check and Adjustment (Refer to P.33-
5).

105 ± 10 N·m*

105 ± 10 N·m*

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13 ± 2 N·m

2
74 ± 14 N·m

N 1

AC502846AB

Removal steps Removal steps (Continued)

1. Split pin 3. Upper arm assembly
<<A>> 2. Upper arm ball joint and 4. Rebound stopper
knuckle connection
33-10 FRONT SUSPENSION
UPPER ARM ASSEMBLY

REMOVAL SERVICE POINT 1. Install special tool ball joint remover (MB992011)
<<A>> UPPER ARM BALL JOINT AND KNUCKLE as shown in the figure.
CONNECTION REMOVAL
CAUTION Bolt
• Do not remove the nut from ball joint. Loosen
it and use special tool to avoid possible dam- Parallel
age to ball joint threads.
• Hang special tool with a cord to prevent it Good
Knob
from falling.
• Because it is very dangerous when the ball
joint comes off, raise the lower arm using a
Bad
jack or similar device, making sure that the AC106821AB

rebound stopper is free from any reaction 2. Turn the bolt and knob as necessary to make the
force. jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
Cord NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the fig-
ure.

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Ball joint
Bolt 3. Tighten the bolt with a wrench to disconnect the
ball joint.

MB992011
Nut
AC106820 AF
 FRONT SUSPENSION
UPPER ARM ASSEMBLY
33-11
REMOVAL AND INSTALLATION <2WD
(High rider), 4WD>
M1332004300362

CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in an unladen condition.
• When the suspension is adjusted or replaced, the calibration of steering wheel sensor must be
performed. (Refer to GROUP 35C, On-vehicle Service ). <Vehicles with ASTC>
Post-installation Operation
• Check the Dust Cover for Cracks or Damage by pushing it
with your finger.
• Wheel Alignment Check and Adjustment (Refer to P.33-
6).

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105 ± 10 N·m*
105 ± 10 N·m*

35 ± 5 N·m

6 7
3
13 ± 2 N·m

2
4
74 ± 14 N·m
N 1 AC501886AC

Removal steps Removal steps (Continued)

1. Split pin <<B>> 5. Upper arm assembly and front
2. Front wheel speed sensor frame connection
bracket mounting bolt 6. Upper arm assembly
<Vehicles with ABS or ASTC> >>A<< 7. Rebound stopper
3. Brake hose 8. Upper arm ball joint assembly
<<A>> 4. Upper arm ball joint and
knuckle connection
33-12 FRONT SUSPENSION
UPPER ARM ASSEMBLY

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT

<<A>> UPPER ARM BALL JOINT AND KNUCKLE >>A<< REBOUND STOPPER INSTALLATION
DISCONNECTION
CAUTION Inside of vehicle
• Do not remove the nut from ball joint. Loosen
it and use special tool to avoid possible dam-
age to ball joint threads.
• Hang special tool with a cord to prevent it
from falling.
• Because it is very dangerous when the ball
Rebound stopper
joint comes off, raise the lower arm using a
jack or similar device, making sure that the AC502383AB

rebound stopper is free from any reaction Install the rebound stopper with its arrow mark point-
force. ing toward inside the vehicle.

Cord INSPECTION
M1332004400176
• Check the bushing for wear and deterioration.
• Check the upper arm for bend or breakage.

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Ball joint
Bolt • Check all bolts for condition and straightness.
UPPER ARM BALL JOINT STARTING TORQUE
CHECK
MB992011
Nut
AC106820 AF

1. Install special tool ball joint remover (MB992011) MB990326

as shown in the figure.

Bolt

Parallel

AC504006AB

Knob Good
Bad AC106821AB
2. Turn the bolt and knob as necessary to make the
jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the fig-
ure.
3. Tighten the bolt with a wrench to disconnect the
ball joint.
<<B>> UPPER ARM ASSEMBLY AND FRONT
FRAME CONNECTION REMOVAL
Remove the mounting bolts and nuts from the shock
absorber assembly, and secure a working space.
1. After shaking the ball joint stud several times,
install the nut to the stud and use special tool
preload socket (MB990326) to measure the
starting torque of the ball joint.
NOTE: Rotation starting torque measurement
should be carried out with parts temperature
above 0°C.
Standard value: 1.0 − 5.6 N⋅m
2. If the measured value exceeds the standard
value, replace the upper arm ball joint assembly
(Refer to P.33-9 <2WD (except High rider)> or
P.33-11 <2WD (High rider), 4WD>).
3. If the measured value is lower than the standard
value, check that the upper arm ball joint turns
smoothly without excessive play. If so, it is
possible to use that ball joint.
 FRONT SUSPENSION
SHOCK ABSORBER AND COIL SPRING <2WD (except High rider)>
33-13
UPPER ARM BALL JOINT DUST COVER CHECK NOTE: If the dust cover is cracked or damaged, it
1. Press the dust cover with your finger to check that is possible that there may also be damage to the
there are no cracks or damage in the dust cover. ball joint.
2. If the dust cover is cracked or damaged, replace
the upper arm ball joint assembly (Refer to P.33-9
<2WD (except High rider)> or P.33-11 <2WD
(High rider), 4WD>).

SHOCK ABSORBER AND COIL SPRING <2WD (except

High rider)>
REMOVAL AND INSTALLATION
M1332012200036

CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.

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Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with finger.
• Front wheel alignment check and adjustment (Refer to
P.33-5).

15 ± 2 N·m

1 2

98 ± 12 N·m*

19 ± 3 N·m
AC501937AE
33-14 FRONT SUSPENSION
SHOCK ABSORBER AND COIL SPRING <2WD (except High rider)>

Removal steps INSTALLATION SERVICE POINTS

1. Washer >>A<< COIL SPRING INSTALLATION
2. Shock absorber bushing
>>B<< 3. Shock absorber
4. Hub and knuckle assembly (Refer to
GROUP 26, Hub and knuckle
assembly ).
5. Front wheel speed sensor bracket
<Vehicles with ABS>
6. Bump stopper Piece of
7. Strut bar wood MB992058
<<A>> >>A<< 8. Coil spring
9. Spring pad Jack
AC502094 AB

REMOVAL SERVICE POINT Support the lower arm by the special tool Coil spring
<<A>> COIL SPRING REMOVAL compressor (MB992058), and install the coil spring
by compressing it using a jack.
Wrench
>>B<< SHOCK ABSORBER INSTALLATION

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A

MB992058

AC502093AB

Install as shown in the figure. Then, use a wrench to

hold the special tool Coil spring compressor
(MB992058), and remove the coil spring. AC407426 AB

Tighten the nuts until its protruding length meets the

standard value (A).
Standard value (A): 2 − 3 mm

INSPECTION
M1332012300011
• Check for oil leaks from the shock absorber
assembly.
• Check the shock absorber assembly for damage
or deformation.
 FRONT SUSPENSION
SHOCK ABSORBER ASSEMBLY <2WD (High rider), 4WD>
33-15
SHOCK ABSORBER ASSEMBLY <2WD (High rider), 4WD>
REMOVAL AND INSTALLATION
M1332004600233

CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in an unladen condition.
• When the suspension is adjusted or replaced, the calibration of steering wheel sensor must be
performed. (Refer to GROUP 35C, On-vehicle Service ). <Vehicles with ASTC>
Pre-removal Operation Post-installation Operation
• Upper arm assembly (Refer to P.33-11). • Upper arm assembly (Refer to P.33-11).
• Front wheel alignment check and adjustment (Refer to
P.33-6).

1
44 ± 5 N·m

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2 3

105 ± 10 N·m*

AC502982 AB

Removal steps INSPECTION

1. Cap M1332004700025

2. Front wheel speed sensor harness • Check for oil leaks from the shock absorber
clamp <Vehicles with ABS or ASTC> assembly.
3. Shock absorber assembly • Check the shock absorber assembly for damage
or deformation.
33-16 FRONT SUSPENSION
SHOCK ABSORBER ASSEMBLY <2WD (High rider), 4WD>

DISASSEMBLY AND REASSEMBLY

M1332004800204

22 ± 2 N·m
1N

9 2
3

11 10 5

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8
AC502848AB

Disassembly steps DISASSEMBLY SERVICE POINT

<<A>>>>C<<1. Self-locking nut <<A>> SELF-LOCKING NUT REMOVAL
2. Seat
3. Upper bushing CAUTION
>>B<<4. Spring bracket assembly • Install special tool arm set (MB991238) evenly,
5. Spring upper pad and so that the maximum length will be
6. Collar attained within the installation range.
7. Upper bushing • Do not use an impact wrench to tighten the
8. Cup bolt of special tool spring compressor body
9. Dust cover (MB991237), otherwise the special tool will
>>A<<10. Coil spring
break.
11. Shock absorber

MB991237

MB991238
AC503997 AB

1. Use following special tools to compress the coil

spring.
• Spring compressor body (MB991237)
• Arm set (MB991238)
 FRONT SUSPENSION
SHOCK ABSORBER ASSEMBLY <2WD (High rider), 4WD>
33-17
WARNING
Do not use an impact wrench to remove the
self-locking nut. Vibration of the impact
wrench will cause special tools (MB991237
and MB991238) to slip and cause personal
injury. Spring seat
MB992047
Coil
spring end
MB991681 AC503832AB
Self-locking nut
2. Align the coil spring lower end with the shock
absorber spring seat stepped part.

>>B<< SPRING BRACKET ASSEMBLY

INSTALLATION
AC503833 AB

2. Use following special tools to secure the strut, and

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then remove the self-locking nut. A
• Wrench (MB991681)
• Socket (MB992047) Shock
absorber
REASSEMBLY SERVICE POINTS
>>A<< COIL SPRING INSTALLATION Spring upper
bracket assembly
CAUTION View A AC503831AB
• Do not tighten the special tool bolt too tight.
install the spring bracket assembly which faces the
The tool will be broken if the bolt is tightened
shock absorber as shown in the illustration.
over the allowable torque 74 N⋅m.
• Install the special tools evenly, and so that the
>>C<< SELF-LOCKING NUT INSTALLATION
maximum length will be attained within the
installation range. 1. Tighten the self-locking nut loosely.
• Do not use an impact wrench, as it will cause CAUTION
the bolt of the special tool to be seized. Do not use an impact wrench, as it will cause the
bolt of the special tool to be seized.
MB991237
MB991237

MB991238
AC503997 AB MB991238
AC503997 AB
1. Install the special tools same as its removal and
compress the coil spring to install to the shock 2. Install the special tools same as its removal and
absorber. compress the coil spring to install to the shock
• Spring compressor body (MB991237) absorber.
• Arm set (MB991238) • Spring compressor body (MB991237)
• Arm set (MB991238)
33-18 FRONT SUSPENSION
SHOCK ABSORBER ASSEMBLY <2WD (High rider), 4WD>

• Wrench (MB991681)
MB992047
• Socket (MB992047)
Tightening torque: 22 ± 2N⋅m
MB991681
Self-locking nut
INSPECTION
M1332004900029
• Check the rubber parts for damage or deteriora-
tion.
• Check the coil spring for deformation, deteriora-
tion or damage.
AC503833 AB • Check the shock absorber assembly for deforma-
tion.
3. Using following special tools tighten the self-
locking nut 22 ± 2 N⋅m.

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 FRONT SUSPENSION
LOWER ARM
33-19
LOWER ARM
REMOVAL AND INSTALLATION
<2WD (except High rider)>
M1332001601668

CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.
Post-installation Operation
• Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-5).

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3
129 ± 15 N·m*

111 ± 14 N·m
AC502908AC

Removal steps <<A>> LOWER ARM ADJUSTING BOLT

• Coil spring (Refer to P.33-13). REMOVAL
1. Lower arm ball joint
<<A>> 2. Lower arm adjusting bolt
3. Plate Mating mark
4. Lower arm assembly

REMOVAL SERVICE POINT

AC503237AE
33-20 FRONT SUSPENSION
LOWER ARM

After making a mating mark on the lower arm adjust- REMOVAL AND INSTALLATION
ing bolt, remove the lower arm adjusting bolt. <2WD (High rider), 4WD>
M1332001601657

CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in an unladen condition.
• When the suspension is adjusted or replaced, the calibration of steering wheel sensor must be
performed. (Refer to GROUP 35C − On-vehicle Service ). <Vehicles with ASTC>
Post-installation Operation
• Check the Dust Cover for Cracks or Damage by pushing it
with finger.
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-6).

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11

10
129 ± 15 N·m*
11
10
7 4

8
105 ± 10 N·m*

N 1

40 ± 4 N·m
12
3
26 ± 4 N·m 5

9
108 ± 10 N·m 6
2
111 ± 14 N·m 147 ± 29 N·m

N 1
AC600978AD

Removal steps Removal steps (Continued)

1. Split pin <<A>> 3. Tie rod end and knuckle assembly
<<A>> 2. Lower arm ball joint and knuckle connection
assembly connection
 FRONT SUSPENSION
LOWER ARM
33-21
Removal steps (Continued) NOTE: When adjusting the special tool wedge
4. Upper arm and upper arm ball joint horizontally, position the knob as shown.
connection 3. Turn the bolt to disengage the lower arm ball joint
5. Knuckle (Refer to GROUP 26 − Front
from the knuckle.
axle hub assembly <2WD>,
<4WD>).
6. Lower arm ball joint <<B>> LOWER ARM MOUNTING BOLT REMOVAL
7. Shock absorber and lower arm
assembly connection
8. Bump stopper Mating mark
9. Lower arm assembly and stabilizer
link connection
<<B>> 10. Lower arm mounting bolt
11. Plate
12. Lower arm assembly

REMOVAL SERVICE POINTS

AC503237AE
<<A>> LOWER ARM BALL JOINT AND KNUCKLE
ASSEMBLY/ TIE ROD END AND KNUCKLE After making a mating mark on the adjusting bolt,
ASSEMBLY DISCONNECTION remove the lower arm mounting bolt.

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CAUTION INSPECTION
• The self-locking nut must be only loosened M1332001701096
but not removed from the ball joint. Be sure to • Check the lower arm bushing for wear and deteri-
use the special tool. oration.
• To prevent the special tool from dropping off, • Check the lower arm assembly for bend or break-
suspend it with a cord. age.
• Check all bolts for condition and straightness.
Cord LOWER ARM BALL JOINT STARTING TORQUE
CHECK
Self-locking nut

MB990326

MB992011

Ball joint AC208247AK

1. Install special tool ball joint remover (MB992011)

as shown in the figure. AC504006AB

Bolt 1. After shaking the ball joint stud several times, use
special tool preload socket (MB990326) to
measure the starting torque of the ball joint.
Parallel
NOTE: Rotation starting torque measurement
should be carried out with parts temperature
Knob Correct above 0°C.
Standard value: 2.9 − 6.9 N⋅m
2. If the measured value is not within the standard
Wrong AC104739AB
value, or if the ball joint is difficult to turn or does
2. Turn the bolt and knob to make the special tool not turn smoothly, replace the lower arm
insert horizontal, then hand-tighten the bolt. After assembly (Refer to P.33-19 <2WD (except High
tightening, verify that the insert is still horizontal. rider)> or P.33-20 <2WD (High rider), 4WD>).
33-22 FRONT SUSPENSION
LOWER ARM

LOWER ARM BALL JOINT DUST COVER CHECK 1. Use the special tool inner shaft installer base
1. Check the lower arm ball joint dust cover for (MB991172) to drive out the bushing.
cracks or damage by pushing it with your finger.
2. If the lower arm ball joint dust cover is cracked or
MD998911
damaged, replace the lower arm assembly (Refer
to P.33-19 <2WD (except High rider)> or P.33-20
<2WD (High rider), 4WD>).
NOTE: If the dust cover is cracked or damaged, it
is possible that there may also be damage to the
ball joint.

LOWER ARM BUSHING REPLACEMENT

<2WD (except High rider)> Lower arm
M1332008100995
assembly

Bushing

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AC503616 AB
AC503605 AB

Replace the bushing as follows: 2. Use the special tool bearing installer (MD998911)
to press in the bushing.

LOWER ARM BUSHING REPLACEMENT

<2WD (High rider), 4WD>
M1332008101006

MB991172 Bushing

Lower arm
assembly

AC503607 AB

Replace the bushing as follows:

AC503615 AB
 FRONT SUSPENSION
LOWER ARM
33-23

MB991015

MB990647 Lower arm

assembly

Lower arm
assembly

AC503618 AB

2. Use the special tool knuckle oil seal installer

(MB991015) to press in the bushing.

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AC503617AB

1. Use the special tool bar (MB990647) to drive out

the bushing.
33-24 FRONT SUSPENSION
STRUT BAR <2WD (except High rider)>

STRUT BAR <2WD (except High rider)>

REMOVAL AND INSTALLATION
M1332011900043

CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.
Post-installation Operation
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-5).

162 ± 24 N·m

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3
5
2

162 ± 24 N·m

98 ± 12 N·m*
AC501901AB

Removal steps INSTALLATION SERVICE POINT

>>A<< 1. Washer >>A<< WASHER/STRUT BAR BUSHING INSTAL-
>>A<< 2. Strut bar bushing LATION
3. Collar
>>A<< 4. Washer
5. Bump stopper A
6. Strut bar

Nut
Washer
Nuts

Strut bar
Washer
AC502815 AB

1. Install the washer and strut bar bushing to the

direction as shown in the figure.
 FRONT SUSPENSION
STABILIZER BAR <2WD (High rider), 4WD>
33-25
2. Install so that the dimension (A) shown in the Standard value (A): 99.5 mm
figure will meet the standard value.

STABILIZER BAR <2WD (High rider), 4WD>

REMOVAL AND INSTALLATION
M1332004000703

CAUTION
When the suspension is adjusted or replaced, the calibration of steering wheel sensor must be per-
formed. (Refer to GROUP 35C, On-vehicle Service ). <Vehicles with ASTC>
Pre-removal Operation Post-installation Operation
• Engine Room Under Cover (Refer to GROUP 51, Under • Check the Dust Cover for Cracks or Damage by Pushing
Cover ). it with Finger.
• Engine Room Under Cover (Refer to GROUP 51, Under
Cover ).

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4

108 ± 10 N·m

3
44 ± 10 N·m

2 1
AC502730 AB

Removal steps INSTALLATION SERVICE POINT

1. Stabilizer link assembly >>A<< STABILIZER BUSHING INSTALLATION
2. Stabilizer clamp
>>A<< 3. Stabilizer bushing Vehicle front
4. Stabilizer bar

Stabilizer bar

Stabilizer bushing
AC501977AB
33-26 FRONT SUSPENSION
STABILIZER BAR <2WD (High rider), 4WD>

Install the bushing with its cut line located as shown 1. After shaking the ball joint stud several times,
in the figure. install the nut to the stud and use special tool
preload socket (MB990326) to measure the
INSPECTION turning torque of the ball joint.
M1332002000901
• Check the stabilizer rubbers and stabilizer bush- Standard value: 0.2 − 3.5 N⋅m
ings for wear and deterioration. 2. When the measured value exceeds the standard
• Check the stabilizer bar for deterioration or dam- value, replace the stabilizer link (Refer to P.33-
age. 25).
• Check all bolts for condition and straightness. 3. When the measured value is lower than the
STABILIZER LINK BALL JOINT TURNING standard value, check that the ball joint turns
TORQUE CHECK smoothly without excessive play. If so, it is
possible to re-use that ball joint.
MB990326
STABILIZER LINK BALL JOINT DUST COVER
CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
2. If the dust cover is cracked or damaged, replace

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the stabilizer link (Refer to P.33-25).
NOTE: Cracks or damage of the dust cover may
AC404845 AD cause damage to the ball joint.