FRONT SUSPENSION

CONTENTS
TOOLS....................................................................................................... FSU-1
LEAF SUSPENSION ................................................................................. FSU-2
CONSTRUCTION ................................................................................. FSU-2
DISASSEMBLY AND REASSEMBLY.................................................... FSU-4
INSPECTION ........................................................................................ FSU-6
STABILIZER .............................................................................................. FSU-8
CONSTRUCTION ................................................................................. FSU-8
DISASSEMBLY AND REASSEMBLY.................................................... FSU-9 FSU
SERVICE DATA ....................................................................................... FSU-10
SPECIFICATIONS............................................................................... FSU-10
SPRING STRUCTURE ....................................................................... FSU-10
SERVICE DATA.................................................................................... FSU-11
TIGHTENING TORQUE ....................................................................... FSU-11
 TOOLS
Tool name and number Description Shape

T-type socket
Used when installing and removing the spring clip bolt.
99535 Z0005

Bushing replacer
Used when replacing the spring (shackle) pin bushing.
99888 Z0003 (30 mm)

FSU-1
 LEAF SUSPENSION
CONSTRUCTION
GKB series

FSU-2
CWB and GWB series

FSU-3
DISASSEMBLY AND REASSEMBLY
CWB and GKB series

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Nut 2 Lock washer 3 Plain washer
4 Washer (outer) 5 Rubber bushing 6 Washer (inner)
7 Nut 8 Washer 9 Cushion rubber
10 Washer 11 Washer 12 Cushion rubber
13 Washer 14 Shock absorber assembly 15 Nut
16 Lock washer 17 Shock absorber pin 18 Nut
19 U-bolt 20 Pad 21 Bumper rubber
22 Grease nipple 23 Nut 24 Bolt
25 Spring (shackle) pin 26 Shim 27 Grease nipple
28 Nut 29 Bolt 30 Spring (shackle) pin
31 Shim 32 Shackle 33 Grease nipple
34 Nut 35 Bolt 36 Spring (shackle) pin
37 Spring assembly 38 Bracket (shock absorber) 39 Grease harness assembly
40 Grease nipple 41 Nut 42 Connector
43 Elbow

FSU-4
Key point of disassembly
1. Pushing down the center portion of the spring by using the
press machine, remove the clip bolt by using the T-type socket
(99535 Z0005).
2. Removing the center bolt, return the press machine slowly and
then disassemble the leaf spring.

3. When removing the bushings of the spring and shackle, use

the bushing replacer (99888 Z0003).

Key point of reassembly

1. As in the case of disassembly, install the center bolt by press-
ing securely using the press machine.

Center bolt
Tightening torque [N•m {kgf•m}]: 108 - 127 {11 - 13}

2. Tighten the clip bolt with the specified torque using T-type
socket (99535 Z0005).

Clip bolt
Tightening torque [N•m {kgf•m}]: 49 - 59 {5 - 6}

3. When pressing the bushings of the spring and shackle, use

the bushing replacer (99888 Z0003).

FSU-5
4. When installing the spring to the spring bracket, set the shims
on both sides of the shackle. Select and adjust the shims so
that specified clearance value is obtained.
Unit: mm
Maintenance standard Service limit Thickness of shims
0.05 - 0.70 – 1.8, 2.0, 2.3

INSPECTION
Clean all disassembled parts in cleaning solvent. Check carefully
for scratches, cracks, etc. Replace faulty parts with new ones.

Leaf spring
When wear of the leaf has reached to 15% or more of the original
thickness (while new), replace with a new one.

Outside diameter of spring (shackle) pin

Unit: mm
Maintenance standard Service limit
29.98 - 30.00 29.5

Inside diameter of spring (shackle) pin bushing

Unit: mm
Maintenance standard Service limit
30.02 - 30.12 31.0

FSU-6
Clearance between spring (shackle) pin and bushing
Unit: mm
Maintenance standard Service limit
0.02 - 0.14 1.0

Clearance between shackle and spring bracket (L1)

Unit: mm
Maintenance standard Service limit Remarks
0.05 - 0.70 – Adjust using shims

Clearance between shackle and spring (L2)

Unit: mm
Maintenance standard Service limit Remarks
0.05 - 0.70 – Adjust using shims

FSU-7
 STABILIZER
CONSTRUCTION

FSU-8
DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Nut 2. Lock washer 3. Pin
4. Bushing 5. Nut 6. Bolt
7. Nut 8. Bolt 9. Bushing
10. Stabilizer clamp 11. Stabilizer clamp 12. Stabilizer bar
13. Self lock nut 14. Washer 15. Cushion rubber
16. Washer 17. Washer 18. Cushion rubber
19. Washer 20. Link rod 21. Nut
22. Wave washer 23. Bolt 24. Bolt
25. Stabilizer bracket

FSU-9
 SERVICE DATA
SPECIFICATIONS
Vehicle series CWB, GWB GKB
Suspension type Axle type
Spring type Semi-elliptic leaf spring type (shackle type)
Spring structure
See the item spring structure
(Length Width Thickness Number of leaves)
Shock absorber type Telescopic twin tube type
Stabilizer type Torsion bar type

SPRING STRUCTURE
Unit: mm
Vehicle series Model Description Spring structure (Length Width Thickness - Number of leaves)
R.H.D. Cargo 14 - 2
14 - 1
Mixer 16 - 3
CWB 1550 90  15 - 4 1550 90  
L.H.D. Dump 15 - 1
13 - 1
Full trailer 13 - 1
R.H.D. 14 - 2
14 - 1
16 - 3
GWB 1550 90  15 - 4 1550 90  
L.H.D. 15 - 1
13 - 1
Tractor 13 - 1
R.H.D. 22 - 1
21 - 1 21 - 1
GKB 1800 90  1800 90  1800 90  24 - 2
L.H.D. 25 - 2 25 - 2
14 - 1

FSU-10
SERVICE DATA
Unit: mm
Item Maintenance standard Service limit Remarks
Leaf wear – 15% of thickness Against new part
Outside diameter of spring (shackle) pin 29.98 - 30.00 29.5
Inside diameter of spring (shackle) pin bush-
30.02 - 30.12 31.0
ing
Clearance between spring (shackle) pin and
0.02 - 0.14 1.0
bushing
Clearance between shackle and spring
0.05 - 0.70 – Adjust using shims
bracket
Clearance between shackle and spring 0.05 - 0.70 – Adjust using shims

STABILIZER
Unit: mm
Item Maintenance standard Service limit Remarks
Stabilizer bushing outside diameter 37.5 - 38.0 –

TIGHTENING TORQUE
Tightening torque
Item Remarks
N•m kgf•m
Apply oil to bolt threads and the
Nut of U-bolt 491 - 539 50 - 55
seat of the nut
spring (shackle) pin lock bolt 39 - 49 4-5
Center bolt 108 - 127 11 - 13
Clip bolt 49 - 59 5-6
Stabilizer bracket mounting bolt/nut 137 14

FSU-11