REAR AXLE sem RA. CONTENTS SERVICE DATA AND SPECIFICATIONS....... 2 Rear Axle Assembly on 5 ‘TROUBLE DIAGNOSES AND CORRECTIONS. 3 Component Patt .nrnnnnnin 8 PRECAUTIONS AND PREPARATION. 4 Removal 7 Precautions. eal Inspection 9 ‘Special Service Tools 4 Installation. 0 REAR AXLE...... 5 Adjustment 3SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS TIGHTENING TORQUE aa aeeml ar aee |e rss Bae eae Seite treed ae eee Swing YP P02 series. NT-M7 13-158 94-108 Cree en ieee Sagpin inclination, Tiered tock nut 447-196 15-20 108-145 angie ‘Stopper plato securing bolt M453 45-60 33-43 nner whee ‘Outer whee! INSPECTION AND ADJUSTMENT Adjustment specifications (Rotation starting force) (9 1) ‘Spindle axial clearance mm tm) ‘aria coer foreat clearence rn (i) ‘Standard ue-red length ‘Adjusimont speci a-z4 (10-30,22-66) 0-02 (0- 0.008) 0-07 (@- 0028) {al std contero-ball su center cistance) sm (in) Por sens 4175 (1644) Paz sens a2 (889) “Tire steor angie ae ‘ase swing anole (Stopper platet-swing stopper sistance) mm cin 95-15 fo seree (0374-0459 39-73 coe ozw-026n Adjusting shim ‘Spindle axial erection play acusting shim ‘Axe conter adjusting shim (at bearing location) “Aalo canir aajusting shim (lore girection) ‘Axle awing angle adivstng shir “Thcaneas mm i) (0.70 (0.088) (0.254 (0.0100) (0.750 (0.0295) 12 @.0«7 16 (0.05) 10 (0039) 23 (0.080) 12 (0087) 23 (0001) 60 (0238) REVISED 11/02 RA-2 AS caumon: 2 8.000 bunts requie using a poly ster tre only, The use ‘of any other tie matenal(e.,ruober) could cause premature ‘wear or damage fo steer inkage, steering gear, and steer motor.CAUTION: The following table | occur. TROUBLE DIAGNOSES AND CORRECTIONS is only typical examples. To perform an accurate diagnosis, carefully listen to the user's complaints and check the actual vehicle to fully understand under what conditions the symptoms Probable cause Corrective action = Low tre air pressure Je improper e-toc movement > imoropery siding kingpin Insutclent lubrication J¢ Mattunctioning steering system fo Asst Je Chock bal studs and replace ity bal stage. J+ Chock thrust bearing and needle bearing and roplacefaully pars. Apply grease to kingpin, J+ Apply grease. J Reler to ST section ‘Unstable driving and vehicle vibration [> Loose wheel nite J¢ Unequal right and let tie pressure | Ditlerent type tire oF whoo! on right and lat J Improperly adjusted whee! alignment (Teen) 1 Dilerently worn right and lt tres + improperly adjusted spindie stopper J+ Excessive whee! beating backlash Je Loose kingpin Je Loose axle mounting © Impropery inclines vehicle on a slope Tighten. Adjust Replace, 6 Cheek and adjust, © Cheek and replace © Adjust ‘Adjust bearing preload. Replace worn whee! bearings as a set. J+ Chock kingpin-elated pats (especially bearings) necessary, replace. ‘Adjust by replacing adjusting shims. Je Check rubber mount. necessary, replace, ‘Adjust by replacing adjusting shims. # Acjust ate swing angle. ‘Omer © Dragging wheels Je Loote nuts and bolts fe Check wheel Bearing fr rust formation. Adjust whee! bearing preload /¢ Tighten. RA-3PRECAUTIONS AND PREPARATION Precautions CAUTION: ‘© When raising or lowering the vehicle using a Jack, reter to GI section for safe operation and follow all safety precau- tions. © Be careful not to drop heavy components or parts. Always use a Iifting device. NOTE: © Axle center assembly can be removed or installed after removing tires. This RA section deals primarily with the disassembly and reassembly of the axle center assembly. ‘© For removal and installation of tie-rod and bell-crank, refer to ST section. © For information concerning wheels and tires, refer to MA section, ‘© Only toe-in adjustment is possible for performing wheel alignment. (Camber and caster cannot be adjusted.) © Removal and installation of some rear axle parts require the use of special service tools. Be sure to use designated special service tools for proper servicing. Special Service Tools Too! number Tool name em 11772520000 ‘Separating ball joints Ball joint remover roan v40703500 Removing or installing wheel bearing nuts Wheel bearing nut wrench Parooot RA-4REAR AXLE Rear Axle Assembly [ por ‘SERIES P02 SERIES areon|REAR AXLE Component Parts Mounting seer [EJ 80 45-6039 - somes Shims ° Shims Front sige r Dle-ee-728-59 wa Pug e8 - (yrs s2 75-04, 54-60) 8p OQ | — —- S NSB - DP ® om Mounting ap . 3 a on ene oe seat eos - Foi rt [hpor 70-96-10, 58-72) P02 127-147 G2 15, 8-108)Power cylinder ball joint Beit crank REAR AXLE Removal AXLE CENTER 4. Loosen whee! nuts until possible to turn by hand. Raise rear end of vehicle using a jack. Refer to GI section. 2. Remove tires together with rims. CAUTION: When removing wheel nuts (large), do not confuse them with rim bolts (small). Rim bolts are fixed by welding. @ Before removing pneumatic tires, bleed a slight amount of air from tires. Disengage bell-crank and power cylinder at ball joint © Use balll joint remover (special service tool; HT72520000) to disengage. 4. Support axle center assembly with a jack CAUTION: Properly place jack to prevent axle center assembly from tilt- ing or slipping during removal. 5. Remove mounting cap bolts, then remove axle center assembly. CAUTION: After removing axle center, place it on a worktable. 6. Remove rubber mount together with adjusting shim(s). HUB NOTE: Removal of axle center assembly is not necessary when only the hub is to be removed. 1. Remove hub cap. RA-7Kvdoreas00 ‘set screw REAR AXLE Removal (Cont'd) 2. Remove two screws, then remove wheel bearing nut lock washers. 3. Using wheel bearing nut wrench (special service tool; 40103500), remove wheel bearing nuts. NOTE: It a wheel bearing nut wrench (special service tool) is not available, install and tighten a M6 x 20 mm (0.79 in) screw in lock washer securing hole until 3 or 4 threads are engaged. Using a suitable bar, remove whee! bearing nuts. 4, Remove outer bearing, then remove hub assembly. 5. Remove bearing outer race as necessary. © Drive bearing outer race out of the inner rim of hub. 6. Remove inner bearing, CAUTION: Be careful not to damage grease seal while removing inner bearing. 7. Remove grease seal as necessary. © If grease seal is removed, replace with a new one. STEERING SPINDLE AND KINGPIN 4. Loosen lock nut, then remove spindle setscrew. 2. Using a chisel or similar tool, remove plug from kingpin. CAUTION: © Be careful not to damage kingpin. © Always replace plug with a new one. 3, Place a pad on the upper side of kingpin, then drive kingpin out. CAUTION: Be careful not to drop kingpin on floor when removing. RA-8Owe sees roaring ‘Thrust bearing o_. Shims crease see! EES Kingpin (B—neosie bearing Ore REAR AXLE Removal (Cont'd) 4. Remove spindle together with thrust bearing and shim(s). 5. Remove grease seal from axle center assembly as neces: sary. |f grease seal is removed, replace with a new one. 6. Drive needie bearing out of inner side of kingpin as neces- sary. Inspection Clean all removed parts in cleaning solvent. Carefully check for cracks or damage. If necessary, repair or replace faulty parts. AXLE CENTER © Check axle center for bending, twisting or cracks. If necessary, replace with a new one. © Check kingpin for smooth insertion into upper and lower needle bearings. If necessary, repair or replace with a new one. BEARINGS Check bearing for damage, seizure, flaking, improper rotation ‘or abnormal noise. If necessary, replace with a new one. WHEEL HUBS Check whee! hub using a dye penetration method. If it is cracked, replace with a new one. STEERING SPINDLE Using a dye penetration method, check steering spindle for cracks. If necessary, replace with a new one. THRUST BEARINGS AND NEEDLE BEARINGS © Check both the thrust bearing and needle bearing for damage, seizure, flaking, improper rotation or abnormal noise. If necessary, replace with a new one. © Check thrust bearing seal and O-ring for abnormal wear or damage. If necessary, replace with a new one. RA-SGrease seal Lock nut setscrow Pus PB Neodte nearing omits Spindie Shims ~ cease son ES Kingpin BN nrg —rvsee aroot| yy —f REAR AXLE Installation STEERING SPINDLE AND KINGPIN NOTE: Before installation, remove burr from inner wall of plug press- fitting hole on axle center using file or a suitable tool 1. Press-fit needle bearing into place from the inner side of the kingpin (if previously removed). 2. Install grease seal with concave side facing upward. 3. Install spindle together with thrust bearing and shim(s). © Be careful not to install spindle upside down. ‘e Install thrust bearing, with cover side facing upward, on upper side of spindle, © Select and install shims with proper thickness into lower side of spindle so that clearance in the axial direction is within standard. Standard clearance 20 0.10 (0.0038) Available shim thickness 0.254 (0.0100) 0.750 (0.0295) 4, Insert kingpin from lower side. CAUTION: Do not insert kingpin from upper side. Shims may be damaged. 5. Install spindle setscrews, then secure with lock nuts. (O): 31 - 42 Nem (3.2 - 4.3 kg-m, 23 - 31 ft-lb) CAUTION: Make sure setscrew Is properly seated In groove on kingpin. 6. Press-fit upper and lower plugs into place. Using a punch, clinch them at three places, avoiding the previously clinched points. Press-fit depth: 11-2 mm (0.04 - 0.08 in) RA-10ev40109500 REAR AXLE Installation (Cont'd) 7. Apply multi-purpose grease (or equivalent) through grease nipple until the seal-fitting area brims over with grease. 8. Press-fit grease seal into spindle. © Apply multi-purpose grease (or equivalent) to grease seal lip, also filling the pocket area with the grease. 9. Install inner bearing, © Apply a coat of multi-purpose grease (or equivalent) to stid- ing surtaces of bearing race and rollers. CAUTION: Do not apply grease to bearing inner wall (which mates with spindle). HUB 1. Install hub assembly to spindle. ‘© Press-fit bearing outer race in hub (if previously removed). 2. Install inner bearing into bore on the outer side of hub. Apply a coat of multi-purpose grease to whee! bearing nut threads and mating surface of wheel bearing, then install wheel bearing nut to hub using special service tool (KV40103500). 3. Adjust hub bearing preload. © While rotating hub, tighten whee! bearing nut until hub is, hard to rotate. © Loosen wheel bearing nut by turning approximately 60 degrees. © Rotate hub two or three turns to seat wheel bearing. © While rotating hub again, tighten wheel bearing nut until hub is hard to rotate. From that position, loosen wheel bearing nut by turning approximately 60 degrees. © ‘Tap hub with a copper hammer to properly seat wheel bea ing. @ Attach one end of the string to hub bolt and hang it halfway around circumference of hub. Suspend a spring scale on the other end of the string. Pull spring scale horizontally and measure bearing preload. If measured preload is outside specifications, adjust by tightening or loosening wheel bearing nut. Hub rotation starting torque: 9.8 - 29.4 N (1.0 - 3.0 kg, 2.2 - 6.6 Ib) © After adjusting bearing preload, rotate hub 2 or 3 turns to make sure there is no backlash in wheel bearing. RA-11a ne] (edge inward to ist TT Mounting robber REAR AXLE Installation (Cont'd) 4. Install lock washer while mating protrusion of lock washer and groove in spindle. Set wheel bearing nut on lock washer and tighten with two lock screws. CAUTION: i lock washer hole does not match bearing-nut hole property, turn over lock washer or turn spindle nut, within preload spec: fication range, to adjust. When turning spindle nut, turn It in tightening direction if lighter preload, within specification, is set. Turn spindle nut In loosening direction if a higher preload is set. 5. Install hub cap. AXLE CENTER CAUTION: Be sure to prevent axle center from tilting or slipping off of Jack during installation. 1. When installing rubber mount on axle center assembly, select and install shim(s) with proper thickness into lower side of axle center to eliminate any clearance, Available shim thickness: 1.2 mm (0.047 in) 1.6 mm (0.063 in) CAUTION: Install rubber mount, paying attention to its installation direc- tions. 2. Install axle center on mounting bracket. © Select and install adjusting shim(s) with proper thickness on rear side of axle center mounting bracket so that total fore- and-att mount clearance is within standard, Unit: mm Cin) ‘Standard clearance 0-07 (0- 0028) 1.0 (0.038), Available shim thickness 23 (0.091) 3. Install mount cap bott. (Dy: 49 - 69 Nem (5-7 kg-m, 36 - 51 ft-lb) RA-12REAR AXLE Installation (Cont'd) 4. Attach bell-crank and power cylinder at ball joints. (Dy: 98 - 147 Nem (10 - 15 kg-m, 72 - 108 ft-b) CAUTION: Install cotter pin affer tightening nut to specitication. 5._Install tires together with rims. NOTE: @ Tighten wheel nuts to a lesser value than specification, making sure it is enough to keep component installation stable when the vehicle is lowered to the ground 6. Carefully lower vehicle to ground. Tighten wheel nuts to specified torque. POt series: (): 78 - 98 Nem (8 - 10 kg-m, 58 - 72 f-1b) P02 series: [D127 - 147 Nem (13 - 15 kg-m, 94 - 108 ft-Ib) © Inflate pneumatic tires to specified air pressure (if so equipped). Adjustment NOTE: Only toe-in adjustment is possible for performing wheel align- ment. (Camber and caster cannot be adjusted.) TOE-IN 1. Raise rear end of vehicle using a jack. Refer to Gl section. 2. Align the center hole of axle center assembly with the cen- ter hole of bell-crank, then insert a pin [230 mm long x 16 mm diameter (9.06 in long x 0.63 in diameter)] through these holes. Ensure that bell-crank is properly centered, 3. Equally adjust left and right tie-rod lengths unti! toe-in is “0 ‘© Tie-rod adjustment length is determined by measuring dis- tance between the centers of ball studs. Standard tie-rod length: PO! series 417.5 mm (16.44 In) P02 series 402 mm (15.83 in) 4. After adjusting tie-rod length, tighten lock nut. (Oy: 147 - 196 Nem (15 - 20 kg-m, 108 - 145 ft-b) RA-13REAR AXLE Adjustment (Cont'd) CAUTION: Set ball joint stud and socket so that runout does not occur. 5. Lower rear end of vehicle to the floor. TIRE STEERING ANGLE 1. Steering angle is adjusted following toe-in adjustment. 2. Place right and left rear wheels in the center of turntables or turning radius gauges (with scale graduations) making sure wheels are facing the straight-ahead position. 3. Turn steering whee! fully to left until right spindle arm con- tacts stopper bolt. This is the steering angle end point. If necessary, adjust stopper bolt so the steering angle end point is within specifications. NOTE: When adjusting wheel steer angle, turn key switch to ON posi- tion. Maximum steering angle: Unit: degree Inner whee! Pot series Poe series 8a ‘Outer wheel Pot series Pao 54 56 4. Similarly, turn steering wheel fully to right until left spindle arm contacts stopper bolt. If necessary, adjust tire steer angle using stopper bolt. 5. After adjusting tire steer angle, lock stopper bolt by tighten- ing lock nut. (0): 74 - 94 Nem (7.5 - 9.6 kg-m, 54 - 69 ft-lb) 6. Turn steering wheel from tock to lock two or three times to make sure that tires are free from interference with adjacent Parts and abnormal noise. AXLE SWING ANGLE 1. Locate vehicle on a solid and level surface. 2. Turn key switch to ON position. Turn steering wheel fully in either direction so stopper is visible. RA-14REAR AXLE ‘Adjustment (Cont'd) 3. Select and install shim(s) with proper thickness between stopper plate and axle center so that stopper plate upper surface-to-swing stopper clearance “H” is within standard. Unit: ram (in) ‘Standard clearance “H” Pot series 9.5 - 11.5 (0.374 - 0.453) Poe series 59-7.3 (0.282 - 0.287) 4.2 (0.047) Available adjusting shims 23 (0.091) 6.0 (0.236) 4, After adjusting axle swing angle, tighten stopper plate securing bolts to specified torque. (Dy: 44 - 59 Nem (4.5 - 6.0 kg-m, 33 - 43 ft-lb) RA-15