WHEELS/TIRES 11-1

Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications .....................................,....................... 11-4
Special Tools ......................................................................................................................,... 11-5
Wheel Alignment .................................................................................................................... 11-6
Toe-in Inspection............................................................................................................... 11-6
Toe-in Adjustment ............................................................................................................. 11-6
Wheels (Rims)........................................................................................................................ 11-8
Wheel Removal...................................,............................................................................. 11-8
Wheel Installation.................................,............................................................................ 11-8
Wheel (Rim) Inspection..................................................................................................... 11-8
Wheel (Rim) Replacement........,........................................... 11-8
Tires.......................................................,.........................................,...................................... 11-10
Tire Removal.................................................................................,................................... 11-10
Tire Installation.................................................................................................................. 11-10
Tire Inspection ...... .............. 11-12
Front Hub ..... 11-13
Front Hub Removal...................................................................................,....................... 11-13
Front Hub Installation..........................................................................................,............. 11-14
Rear Hub .. . .......................... .............. .. ......................................................... 11-16
Rear Hub Removal .............. . 11-16
Rear Hub Installation ....................................... 11-17
11
11-2 WHEELS/TIRES
Exploded View

R U

a S

Lh
 WHEELSIIRES 11-3
Exploded View

Torque
No. Fastener Remarks
N•m kgf•m ft•lb
1 Front Axle Nuts 144 14.7 106 R
Beadlock Wheel Bolts, First 18 1.8 13 s
2 55 5.6 41 S
Beadlock Wheel Bolts, Final 55 5.6 41 S
3 Wheel Nuts 120 12.2 88.5 S
4 Tie-Rod End Locknuts 106 10.8 78.2
Rear Axle Nut (Left, Black Colored) 220 22.4 162 R, Lh
Rear Axle Nut (Right) 220 22.4 162 R
Lh“: Left-hand Threads (Left side only)
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
U: Apply “ARP Ultra-Torque Fastener Assembly Lubricant."
WL: Apply soap and water solution or rubber lubricant.
11-4 WHEELSIIRES
Specifications
Standard
Front Wheel Alignment
Caster (Rake Angle) 10°
Trail 65 mm (2.6 in.)
Camber —1.9•
Toe-in (at 1G) 10 mm (0.39 in.)
(Usable Range: 0 - 20 mm (0 - 0.79 in.))
King Pin Angle 14•
Rear Wheel Alignment
Camber —0.8•
Wheels (Rims)
Rim Size:
Front 15 « 8.0AT
Rear 15 • 8.0AT
Tires
Air Pressure (when cold):
Front 82.8 kPa (0.84 kgf/cm*, 12 psi)
Rear 117 kPa (1.20 kgf/cm°, 1T psi)
Maximum Air Pressure (when cold):
Front 250 kPa (2.5 kgf/cm*. 36 psi)
Rear 250 kPa (2.5 kgf/cm*. 36 psi)
Tread Depth:
Front 18 mm (0.71 in.)
(Servioe Limit: 4.1 mm (0.16 in.))
Rear 18 mm (0.71 in.)
(Service Limit: 4.1 mm (0.16 in.))
Standard Tires:
Front:
Make MAXXIS
Type MU Carnivore, Tubeless
Size 31 » 10.00R15
Rear:
Make MAXXIS
Type MU Carnivore, Tubeless
Size *1 • 10.00R15
 WHEELSIIRES 11-5
Special Tools
Rotor Puller, M16/M18/M20/M22 • 1.5: Brake Drum Remover:
57001-1216 5700t -1813

Brake Drum Remover Nuts: Brake Drum Holder:

57001-1326 57001-1814

Brake Drum Pusher & Washer: Hub Puaher & Washer:

57001-1709
11-6 WHEELSIIRES
Wheel Alignment
Toe-in is the difference between the distance of front and
the one of rear at the axle height position in the front wheels.
When there is toe-in, the distance [A] (Rear) is the greater
than [B] (Front) as shown.
The purpose of toe-in is to prevent the front wheels from
getting out of parallel at any time, and to prevent any slip-
ping or scuffing action between the tires and the ground. If
toe-in is incorrect, the front wheels will be dragged along
the ground, scuffing and wearing the tread knobs.
Caster and camber are build-in and require no adjust-
ment.
(A) (Rear) — [B] (Front) = Amount of Toe-in
(distance [A] and [B] are measured at axle height with
the vehicle sitting on the ground, or at 1G.)
Joe-in Inspection
• Lift the front wheels off the ground.
• Apply a heavy coat of chalk near the center of the front
tires.
• Using a needle nose scribes, make a thin mark near the
center of the chalk coating while turning the wheel.
• Set the wheels so that the marks on the tires are at the
front side and at the level of the axle height.
• Ground the front wheels.

• Set the steering wheel straight ahead.

• At the level of the axle height, measure the distanoe be-
tween the scribed lines with a measure.
• Move the vehicle rearward until the marks on the front
tires are at the rear side and at the same level as the axle.
e Measure the distance between the scribed lines.
• Subtract the measurement of the front from the measure-
ment of the rear to get the toe-in.
Toe-in of Front Wheelc
Standard: 10 mm (0.39 in.) at 1G
Usable Rang•: 0 - 20 mm (0 - 0.7e in.)
a If the toe-in is not the specified range, go on to the Toe-in
Adjustment procedure.
Toe-in All/osfmerit
• Loosen the locknuts [A] on each tie-rod and turn the ad-
justing rods [B] the same number of turns and the same
direction on both sides to achieve the specified toe-in.
 WHEELSfTlRES 11-7
Wheel Alignment
NOTE
0 The toe-in will be near the specified range, if the lenglh
as shown is 16 mm (0.63 in.) (A) (both sides of tie-rod
ends).
• Tighten:
Torque - Tie-rod End Locknuts [B}: 106 Num (10.8 kgf-m,

• Check the toe-in again.

• Test drive the vehicle.
11-8 WHEELS/TIRES
Wheels (Rims)
Wfzee/ Remova/
• Loosen the wheel nuts (A].
• Lift the wheels off the ground.
• Remove:
Wheel Nuts
Washers
Wheel

Wheel /nsfa/iaffon
NOTE
0 There is no tire rotation mark on the standard tire.

• Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
Bolt Threads Portion [A]
Wheel Nut Threads Poi1ion [B]

• Position the wheel so that the air valve [A] is toward the
outside of the vehicle.
• Install:
Wheel
Washers [B]
• Tighten the wheel nuts [C] in a criss-cross pattern.
Torque - Wheel Nuts: 120 N•m (12.2 kgf•m, 88.5 ft•Ib)

W'fiee/ (Rim) inspection

e Refer to the Wheel (Rim) Inspection (see Wheel (Rim_}
Inspection(2-37)).
Wheel (Rim) Replacement
• Remove the wheel (see Wheel Rempval(11-8_}}.
e Disassemble the tire from the rim (see Tire Removal(11
1- }j0.
ORemove the air valve and discard it.

Replace the air valve whenever the tire is replaced.

Do not reuae the air valve.
Plastic Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [Dj
Valve Seat [E]
Valve Opened (F]
 WHEELSfTlRES 11-9
Wheels (Rims)
• Install a new air valve in the new rim.
ORemove the valve cap, lubricate the stem with a soap and
water solution or rubber lubricant, and pull [A] the stem
through the rim from the inside out until it snaps into place.

Do not use engine oil or petroleum distillates to lu-

bricate the stem because they will deteriorate the
rubber.
• Mount the tire on the new rim (see Tire Installation(11
10 .
• Install the wheel (see Wheel Installation(11-8)).
• Install the air valve cap.
11-10 WHEELSfTIRES
Tires
7"/re Remova/
• Remove the wheel {see Wheel Removal(11-8)).
• Unscrew the valve core to deflate the tire.
OUse a proper valve core tool [A].

e Lubricate the tire beads and rim flanges on inside of the

wheel with soap and water solution or rubber lubricant [Aj.
This helps the tire beads slip off the rim flanges.

Do not lubricate the tire beads and rim flanges with

engine oil or petroleum distillates because they will
deteriorate the tire.

e Loosen the beadlock wheel bolts as shown sequence [1

16], and remove them.
• Remove the tire from the rim using a suitable commer-
cially available tire changer.
NOTE
OThe tires cannot be removed with hand tools because
they fit the rims tightly. 13

Tire Installation
e Inspect the rim lsee Wheel (Rim) Inspection(2-37)).
• Replace the air valve with a new one.
NOTlC.E
Replace the air valve with whenever the tire is re-
placed. Do not reuse the air valve.
• Check the tire for wear and damage (see Tire Inspection(2
36 .
e Lubricate soap and water solution or rubber lubricant to
the rim flanges.
e Lubricate soap and water solution or rubber lubricant to
the outside and inside of the tire beads.
WARNING
Lubricants other than soap and water solution or
rubber lubricant can cause the bead to separate
from the rim and cause an accident resulting in se-
rious injury or death. Use only soap and water solu-
tion or rubber lubricant to lubricate the bead when
installing the tire.
 WHEELS/TIRES 11-11
Tires
• Install the tire on the rim.
NOTE
OThere is no tire rotation mark on the standard tire.
• Install the inside bead on the rim using a suitable com-
mercially available tire changer.
• Lubricate the tire beads again.
• Align the mark [A] of the beadlock wheel to the air valve
[B] to install the beadlock wheel.

• Tighten the beadlock wheel bolts following the tightening

sequence [1 - 16].
Torque - Beadlock Wheel Bolts First: 18 N•m (1.8 kgf•m, 13 11
ft•lb)
Beadlock Wheel Bolts S•cond: 55 N•m (5.6 kgf•m,

• After tightening in the above sequence, retighten the

specified tightening sequence [1 16].
Torqu• - Beadlock Wheel Bolts Final: 55 N•m (5.6 kgf•m, 41
ft-lb)

• Support the wheel rim [A] on a suitable stand [B] to pre-

vent the tire from slipping off.
• Inflate the tire until the tire beads seat on the rim.
Maximum Tira Air Pressure (to seat beads when cold)
Front and Rear 250 kPa (2.5 kgf/cm’, 36 psi)

WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than maximum pressure.
11-12 WHEELSfTIRES
Tires
• Check to see that rim lines [A] on both sides of the tire are
parallel with the beadlock wheel [B] or rim flanges.
all the rim lines and the rim fIar›pes are not parallel, deflate
the tlre, lubricate the sealing surfaces again, and reinflate
the tire.
• After the beads are properly seated, check for air leaks.
• Apply a soap and water solution or rubber lubricant
around the tire bead and check for bubblas.
• Deflate the tire to the specified pressure.
• Check the tire preaeuze using an alr pressure gauge.
Tire Air Pæesuæ (wh•n cold)
Front 82.8 kPa (0.84 kgscm°, 12 psl)
Rear 117 kPa (II kgf/cm^, 17 psi)
• Install the alr valve cap.
• InstaII the wheel (see Wheel Installation(11-8)).
• Npe off the soap and water solution or rubber lubriœnt
on the tire and dry the tire before operation.
D WARNING
Saap and water soluaon or rubber lubricant on the
tlre bead can cause tire aaparation and an accident
resulting In serious injury or death. Do not oper-
ate the vehicle untll any eoap and wator solution or
rubber lubricant applied to th•bead has completely'
dded.
Tire Inspection
• Refer to the Tire Inspection fsee Tiæ Inspection(2-36)).
 WHEELSfTIRES 11-13
Front Hub
Front Hub Remova/
• Remove:
Front Wheel (see Wheel Removal(11-8))
Cotter Pin [A1
• Remove the caliper [B] from the knuckle (see Front Brake
Caliber Removal(13-17)).

• Using the brake drum holder [A], hold the front hub [Bj.
Special Tool - Brake Drum Holder: 57001•1814
Wheel Nuts [C]
• Remove:
Axle Nut [D] and Washer [E]
Front Hub with Brake Disc

elf the front hub seems too difficult to remove, follow the
below steps.
• Mount the brake drum remover [Aj on the hub bolt with
the remover nuts [B] and suitable washers [Cl (" ls ide di-
ameter: 17 mm (0.67 in.)).
Special Tools - Brake Drum Remover Nuts: 57001-1326
Brake Drum Remover: 57001-1813
• Tighten the rotor puller [D1, and remove the front hub.
Special Tool - Rotor Puller, M16/M18/M20/M22 • 1.5: 57001
-1216

• Separate the brake disc from the front hub (see Brake
Disc Removal(13-26)).

• Do not remove the hub bolts [Al *‹°m the hub [B1-
11-14 WHEELS/TIRES
rront Hub
Prom Hub Installation
6 If any hub bolt [A] is damaged, replace the hub [B] and
bolts as a unit.
• When installing the hub bolt, press in it using a press.

• Replace the following parts with new ones.

Cotter Pin
Front Axle Nut
Washer
• Install:
Brake Disc (see Brake Disc Installation(13-26))
• Apply molybdenum disulfide grease to the spline [A] of
the front axle.
• Install:
Washer [B]
Front Hub [C1
elf the front hub seems too difficult to install, use the fol-
lowing steps.
• Using the brake drum holder [A], hold the front hub (B].
Special Tool - Brake Drum Holder: 57001-1814
Wheel Nuts [C]
• Using the brake drum pusher [D] only, tighten it until the
pusher stops.
Special Tool - Brake Drum Pusher & Washer: 57001-1709
• Remove the brake drum pusher, and install one washer
[E] to the pusher.
• Tighten the brake drum pusher until the pusher stops.
• Remove the brake drum pusher, and install two washers
to the pusher.
• Tighten the brake drum pusher until the pusher stops.
• Remove the brake drum pusher and washers.
• Install:
Washer [A]
• Apply a fastener assembly lubricant (ARP Ultra-Torque)
to the front axle threads and washer [B].
 WHEELSIIRES 11-15
Front Hub
• Using the brake drum holder [A], hold the front hub [B].
Special Tool - Brake Drum Holder: 57001•1814
Wheel Nuts [C]
• Install:
Front Axle Nut [D)
• Tighten:
Torque - Front Axle Nut: 144 N-m (14.7 kgf•m, 106 ft-lb)

& WARNING
A loose axle nut can cause an accident resulting in
serious injury or death. Apply “ARP Ultra-Torque
Fastener Assembly Lubricant," and tighten the axle
nut to the proper torque.
• Insert a new cotter pin [A].
• Bend the cotter pin along the axle shaft end [B].
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
• Install the removed parts.
11-16 WHEELSfTIRES
Rear Hub

• Remove:
Rear Wheel (see Wheel Removalf11-8))
Cotter Pin [A]
• Remove the caliper (B] from the knuckle (see Rear Brake
Caliper Removal(13-17)).

• Using the brake drum holder [A], hold the rear hub [B]
Special Tool - Brcke Drum Holder: 57001-1814
Wheel Nuts tC]
NOTE
O7f/e ie/IYear ax/a nut (black) has a ie/I-Gianr/ threads.
Left Side [D]
Right Side [E]
• Remove:
Axle Nut [F] and Washer [G]
Rear Hub

a If the rear hub seems too difficult to remove, follow the

below steps.
• Mount the brake drum remover [A] on the hub bolt with
the remover nuts [B] and suitable washers [C] (inside di-
ameter: 17 mm (0.67 in.)).
Special Toole - Brnk• Drum Remover Nuts: 57001-1326
Brake Drum Remover: 57001-1813
• Tighten the rotor puller [D], and remove the rear hub.
Special Tool - Rotor Puller, M16/M18/M2O/M22• 1.5: 57001
-1216
• Separate the brake disc from the rear hub (see Brake Disc
Removal(13-26)).
 WHEELSfTIRES 11-17
Rear Hub
• Do not remove the nub bolts [A] from the hub [B].

Rear Hub Installation

elf any hub bolt [Aj is damaged, replaoe the hub [B] and
bolts as a unit.
• When installing the hub bolt, press in it using a press.

• Replace the following parts with new ones.

Cotter Pin
Rear Axle Nut
Washer
• Install:
Brake Disc (see Brake Disc Installation(13-26))
• Apply molybdenum disulfide grease to the spline [A] of
the rear axle.
• Install:
Washer [B]
Rear Hub [C]
elf the rear hub seems too difficult to install, use the follow-
ing steps.
• Using the brake drum holder [Al. hold the rear hub [B].
Special Yool - Brake Drum Holder: 57001-t814
Wheel Nuts [C]
• Using the brake drum pusher only, and tighten it until the
pusher stops.
Special Tool - Hub Pusher & Washer: 57001-1931
NOTE
0 The left rear axle has a left-fianc/ threads.
Left Side [D]
Right Side [E]
Hub Pusher for Left-hand Threads [F]
Hub Pusher for Right-hand Threads [G]
• Remove the hub pusher, install one washer [H] to the
pusher.
• Tighten the hub pusher until the pusher stops.
• Remove the hub pusher, and Install two washers to the
pusher.
• Tighten the hub pusher until the pusher stops.
• Remove the hub pusher and washers.
11-18 WHEELSfT!RES
Rear Hub
• Install:
Washer [A]
• Apply a fastener assembly lubricant (ARP Ultra-Torque)
to the rear axle threads and washer [B].

NOTE
OThe left rear axle nut (black) has a laft-hand threads.
Left Side [A]
Right Side [B]
• Install:
Rear Axle Nut (Black) [C]
Rear Axle Nut [D]
• Using the brake drum holder [E], hold the rear hub [F].
Special Tool - Brake Drum Hold•r: 57001-1814 ma» r
Wheel Nuts [G]
• Tighten:
Torque - Rear AxI• Nut: 220 N•m (22.4 hgf-m, 162 ft lb)

& WARNING
A loose axle nut can cause an accident resulting in
serious injury or death. Apply "ARP Ultra-Torque
Fastener Assembly Lubricant," and tighten the axle
nut to the proper torque.

• Insert a new cotter pin l A].

• Bend the coxer pin along the axle shaft end [B].
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
• Install the removed parts.
 FINAL DRIVE 12-1

Fical Drive
Table of Contents
Exploded View..................................................... ............,.................................................... 12-2
Specifications ........ 12-6
Special Tools and Sealant.............. 12-7
Front Final Gear Case ....................................................................... ................................. 12-8
Front F! nal Gear Case Oil Level Inspection 12-8
Front F!nal Gear Case Oil Change ................................................................................... 12-8
Front F!nal Gear Case Removal ................................ 12-8
Front Final Gear Case Installation ................................................................................ ,. 12-9
Front F!nal Gear Case Disassembly ............. .................................................................. 12-9
Front Final Gear Case Assembly ...................................................................................... 12-10
2WD/4WD/DIFF-LOCK Actuator Removal ..... ....... 12-14
12-15
2 D/4 /DIFF"LOCK Aviator Ins e ” n “ “ ” ””’" "” 12-16
2WD/4WD/DIFF-LOCK Shift Mechanism Inspect on .:..I...............I.................I..I.I........... 12-18
Right Axle Rotation Sensor Removal..... 12-20
Right Axle Rotation Sensor Installation................................ 12-20
Right Axle Rota n Sensor Inspection .. .. ..... 12-21
' !°
Right Axle Rota‹ !° n Sensor Circuit...........................................................................,........ 12-22
R!ng Gear Rotat on Sensor Removal................................................................................ 12-22
!
R ng Gear Rotation Sensor Installation......................,......................................... 12-22
!
Ring Gear Rotation Sensor Inspection . ......... 12-22
Output Bevel Gears................................................................................................................ 12-23
Output Bevel Gear Removal ............................................................................................. 12-23
Output Bevel Gear Installation ........................................... 12-23
Output Bevel Gear Adjustment ......................................................................................... 12-23
Bevel Gears Inspection..................................................................................................... 12-26
Propeller Shafts .. ...... ............... 12-27
Front Propeller Shaft Removal......................................,....... 12-27
Front Propeller Shaft Installation....................................................................................... 12-27
Rear Propeller Shaft Removal .................,...........,......................................................,..... 12-28
Rear Propeller Shaft Installation ....................................................................................... 12-28
Rear Propeller Shaft Disassembly .................................................................................... 12-29
Rear Propeller Shaft Assembly......................................................................................... 12-29
Axles....................................................................................................................................... 12-32
Front Axle Removal 12-32
Front Axle Installation ................................................... 12-32
Rear Axle Removal........................................................................................................... 12-33
Rear Axeie Installation ..t..................................................................................................... 12-33
Axle Joint Boot Inspection................................................................................................. 12-33
Axle Inspection......................................................................................... ....................... 12-33
Axle Joint Boot Replacement......t..................................................................................... 12-54
Ball Bearing, Needle Beaming, and Oil Seal.......... ............,..................... ............................. 12-41
Ball and Needle Bea’!ng Replacements............................................................................. 12-41
Ball and Needles Bearing Wear Inspection ..... 12-41
Oil Seal Inspection ............................................................................................................ 12-41
12-2 FINAL DRIVE
Exploded View

R G S
 FINAL DRIVE 12-3
Exploded View

Torque
No. Fastener Remarks
N f lb
1 2WD/4WD/DIFF-LOCK Actuator Bolts 9.0 | 0.92 | 80 in-lb
2 Front Final Gear Case Cover Bolts (M6) 9.0 | 0.92 | 80 in lb S
3 Differential Shift Cam Bolt 9.8 | 1.0 | 87 in-lb
4 Front Final Gear Case Shift Lever Pivot Bolt 9.0 | 0.92 | 80 in lb L
5 Front Final Gear Case Oil Filler Plug 17.5 | 1.78 12.9
6 Right Axle Rotation Sensor Bolt 9.0 | 0.92 80 in lb
7 Ring Gear Rotation Sensor Bolt 9.0 I 0.92 80 in lb
8 Sensor Lead Clamp Mounting Bolts 9.0 | 0.92 80 in lb
9 Front Final Gear Case Cover Bolts (M8) 24 | 2.4 18 s
10 Front Final Gear Case Cover Bolts (M10) 49 | s.o [ as s
11 Front Final Gear Case Oil Drain Bolt 16.5 | 1.68 12.2
12 Front Final Gear Case Mounting Bolts 50 ) 5.1 t 37
13 Front Pinion Gear Cover Bolts 9.0 | 0.92 1 80 in lb
G: Apply grease.
GO: Apply gear case oil (API "GL-5" Hypoid gear oil).
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
12-4 FINAL DRIVE
Exploded View

GR

GR
R
R 4 LH
5 L
3

ßO
RG

Ch
 FINAL DRIVE 12-5
Exploded View
Torque
No. Fastener Remarks
N•m kgf•m ft•Ib
1 Rear Universal Joint Holder Bolts 25 2.5 18
2 Propeller Shaft Bearing Case Bolts 25 2.5 18
3 Propeller Shaft Bearing Case Bracket Bolts 25 2.5 18
4 Output Driven Bevel Gear Housing Bolts 25 2.5 18
5 Output Drive Bevel Gear Housing Bolts 25 2.5 18 L
6 Output Shaft Driven Gear Nut 200 20.4 148 LN“*
7. Yellow Green Colored Band (Left side only)
G: Apply grease.
GO: Apply gear case oil (API "GL-5" Hypoid gear oil).
L: Apply a non-permanent locking agent.
Lh”: Left-hand Threads (The outer end threads of the rear axle is left-hand threads. One of the boot
band is colored to yellow green for identification.)
LN**: Apply a non-permanent locking agent (High Strength: LOCTITE 609 or equivalent).
M: Apply molybdenum disulfide grease.
R: Replacement Parts
12-6 FINAL DRIVE
Specifications
Item Standard Service Limit
Front Final Gear Caee
Gear Case Oil:
Type API “GL-5“ Hypoid gear oil
Viscosity above 5•C (41°F): SAE 90
below 5•C (41°F): SAE 80
Capacity 0.80 L (0.85 US qt)
Oil Level Bottom thread of filler opening
2WD/4WD/DIFF-LOCK Actuator:
Resistanoe in the text
Shift Mechanism:
Shift Fork Ear Thickness:
2WD/4WD 5.9 - 6.0 mm (0.232 - 0.236 in.) 5.8 mm (0.228 in.)
Differential 5.9 - 6.0 mm (0.232 - 0.236 in.) 5.8 mm (0.228 in.)
Shifter Groove Width:
2WD/4WD 6.00 - 6.10 mm (0.236 - 0.240 in.) 6.2 mm (0.24 in.)
Differential 6.00 - 6.10 mm (0.236 0.240 in.) 6.2 mm (0.24 in.)
Shift Fork Guide Pin Diameter:
2WD/4WD 5.9 - 6.0 mm (0.232 - 0.236 in.) 5.8 mm (0.228 in.)
Differential 5.9 - 6.0 mm (0.232 - 0.236 in.) 5.8 mm (0.228 in.)
Shift Lever Groove Width:
2WD/4WD 6.00 - 6.15 mm (0.236 - 0.242 in.) 6.3 mm (0.25 in.)
Differential 6.00 - 6.15 mm (0.236 - 0.242 in.) 6.3 mm (0.25 in.)
Output Bevel Gears
Backlash 0.020 - 0.046 mm (0.0008 0.0018 in.)
 FINAL DRIVE 12-7
Special Tools and Sealant
Inside Circlip Pliers: Oil Seal Driver:
57001-143 57001•1926

6T6 71996€ T 6

Outside Circllp Pliers: Oil Seal Driver, $70:

57001-144 57001-1928

Bearing Driver Set: Oil Seal Driver, @60:

57001-1129 57001-1930

alszlesosT s

Knuckle Joint Remover: Liquid Gasket, TB1216:

57001-1619 92104-1063
12-8 FINAL DRIVE
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
• Park the vehicle so that it is level, both side-to-side and
front-to-rear.
• Remove:
Oil Filler Cap [A]
O-ring

Be careful not to allow any dirt or foreign materials

to enter the gear case.
• Check the oil level. The oil level should come to the bot-
tom of the filler opening [A].
a If it is insufficient, first check the front final gear case for
oil leakage, remedy it if necessary, and add oil through
the filler opening. Use the same type and brand of oil that
is already in the final gear case.
e Replace the O-ring with a new one, and apply grease to
it.
• Tighten:
Torque • Front Final Gear Case Oil Filler Plug: 17.5 N•m
(1.78 kgf•m, 12.9 ft•lb)
Front Final Gear Gase Oil Change
• Refer to the Front Final Gear Case Oil Change (see Front
Final Gear Case Oil Chanoe(2-38)).
Front Final Gear Case Remova/
• Drain the gear case oil (see Front Final Gear Case Oil
Chanoef2-38)).
• Remove:
Radiator fsee Radiator Removal(4-17))
Front Axles (see Front Axle Removal(12-32))
2WD/4WD/DIFF-LOCK Actuator (see 2WD/4WD/DIFF
-LOCK Actuator Removal(12-14))
• Disconnect:
Breather Hose [A]
Ring Gear Rotation Sensor Connector [B]
Right Axle Rotation Sensor Connector [C]
• Open the clamps [D].
 FINAL DRIVE 12-9
Front Final Gear Case
• Remove:
Bolts [A] (Both Sides)
Radiator Bracket [B] (Both Sides)

• Slide the front final gear case forward to disconnect the

front propeller shaft [A].
• Remove the front final gear case upward.

Front Final Gear Case Installation

• Installation is the reverse of removal.
• Apply grease to the oil seal lips [A] and the dust cover [B].
• Apply molybdenum disulfide grease to the inside splines
(C] of the front univemal joint.
• Tighten:
Torque - rr t rinal Genr Case Mounting Bolts: 50 N•m (5.1
kgf-m, 37 ft•Ib)
• Fill the front final gear case with the specified oil see
Front Final Gear Case Oil Change(2-38)).
Front Final Ceac Case Oisassem6/y
NOTE
OOo not open the left cover unless necessary. the inner
parts of the gear case are not supplied.
• Remove:
Front Final Gear Case (see Front Final Gear Case Re-
moval(12-8))
Ring Gear Rotation Sensor (see Ring Gear Rotation
Sensor Removal(3-74))
Right Axle Rotation Sensor (see Riqht Axle Rotation
Sensor Removal(12-20))
12-10 FINAL DRIVE
Front Final Gear Case
• Remove:
Front Pinion Gear Cover Bolts [A]
Front Pinion Gear Cover Assembly [B]
O-rings
Needle Bearing

• Remove:
Front Final Gear Case Cover Bolts (M6) [A]
Front Final Gear Case Cover [B]
Dowel Pins
OUse the pry points [C].

• Remove:
Front Final Gear Case Shift Lever Pivot Bolt [A]
Front Final Gear Case Shift Lever [B]
Pivot Pin [C]
Differential Shift Fork [D]
Differential Shifter [E]

• Remove:
Pivot Pin [A]
2WD/4WD Shift Fork [B]
2WD/4WD Shifter [C]
NOTE
ODo the disassem6/a the 2WD/4WD shifter. The inner
parts of the shifter are not supplied.

Front Final Gear Case Assemb/y

• When assembling the left cover, press the oll seal [A] so
that its surface is flush with the cover end [B] using the
special tool.
Special Tool - Oil Seal Driver: 57001-1926
 FINAL DRhfE 12-11
Front Final Gear Case
• When installing the left cover, be sure to Install the shim
[A].
• Replace the O-ring (B] wlth a new one and apply grease
to iL

• lghton the front final gaar case bolts following the spec-
Ifled sequence [1 - 8). O*
Yorqua - Front Final Gear Cses Cover Bow (MB): 34 No
(2.4 kgf•m, 18 ft•Ib)
Front Final Qear Caas Cover Bofta (M10): Jg N•m
(5.0 kgf•m, 36 'ft•Ib)

• When assembllng the right cover. precs the ball bearing

[A] until it is bottomed uslng the spedal tool.
Special Tool - Bearing Driver Set: 57001-1129
• Press the oil seal [B] so that its surface is flush with the
cover end [C] using the special tool.
spe«ul Tool - Oh 6eal Drive. S7001-1928
12-12 FINAL DRIVE
Front Final Gear Case
• When assembling the front pinion gear cover [A], apply
grease to the oil seal lips [B].
e Press the oil seal so that its surface is flush with the cover
end [C] using the special tool.
Special Tools - Bearing Driver Set [D]: 5700-1129
Knuckle Joint Remover [Ej: 5700-1619
Oil Seal Driver, $70 [F]: 57001-1928

• Install:
2WD/4WD Shifter [A]
ONote the direction.

• Install.
2WD/4WD Shift Fork (A]
Pivot Pin [B]
OEngage the shifter groove and the shift fork ears.
• Replace the O-ring [C] with a new one and apply grease
to it.

• Replace the O-ring [A] with a new one and apply grease

• Apply front final gear case oil (API “GL-5" Hypoid gear oil)
to the needle bearing [B].
• Install:
Needle Bearing
Front Pinion Gear Assembly [C]
• Tighten:
Torque - Front Pinion Gear Cover Bolts [D]: 9.0 N-m (0.92
kgf•m, 80 in-lb)
 FINAL DRIVE 12•13
Front Final Cear Case
• When installing the differential shift cam [A], press the
pins [B].
3 - 4 mm (0.1 - 0.2 in.) [C]
O•
• Tighten:
Torque - Differenoal Shift Cam Bolt [D]: 9.8 N•m (1.0 kgf•m,
87 in-lb)

• Engage the differential shifter [A] and the differentlal shift

fork (Bj as shown.

• Install:
Pin [A]
Front Final Gear Case Shift Lever [B]
• Apply a non-permanent locking agent to the front final
gear case shift lever pivot bolt [C].
• Tighten:
Torqu• - Front Flnal Gear Case Shift Lever Pivot Bolt: 9.0
N•m (0.92 kgfsn, 80 in•lb)

• Using a high flash-point solvent, clean off any oil or dirt

on the mating surface of the front final gear case cover.
• Apply liquid gasket to the mating surface {A1 of the front
final gear case cover as shown.
SesMnt • Liquid Oesket. TB1216: 92104-100d
NOTE
OMake the installation ftnish wlmin 20 minutes w'fien tfie
liquid gasket (TB1216) to the mating surface is applied.
12-14 FINAL DRIVE
Front Final Gear Case
• Position the shift lever [A] to the “2WD" position as shown.
e Install:
Dowel Pins [B]
Right Cover [C]
• Tighten the front final gear case bolts following the spec-
ified sequence [1 - 81-
Torque - Front Final Gear Case Cover Bolts (M6): 9.0 N•m
(0.92 kgfm, 80 in-lb)

2WD/4WD/DlFF-LOCK Actuator Remova/

• Remove:
Screws [A]
Cover [B]

• Disconnect the 2WD/4WD/DIFF-LOCK actuator connec-

tor (A].
• Remove:
2WD/4WD/DIFF-LOCK Actuator Bolts [B]
2WD/4WD/DIFF-LOCK Actuator [C]

Do not tap the actuator with a hammer while remov-

ing it. Tapping could damage the internal parts of
the actuator.
 FINAL DRIVE 12-15
Front Final Gear Case
2WD/4WD/DIFF-L.OCK Actuator Installation
• Check the groove angle [A] of the 2WD/4WDIDIFF-LOCK
actuator output shaft.
• Position the front final gear case shift lever [B] according
to the shaft angle.
2WD Position [C]
4WD Position (2WD —+ 4WD) [D1
4WD Position (DIFF-LOCK —• 4WD) {E]
DIFF-LOCK Position [F]

O ” O

• Replace the O-ring {A) with a new one, and apply grease
to it.
• Apply gear case oil (API “GL-5“ Hypoid gear oil) to the
actuator output shaft.
• install the 2WD/4WD/DIFF-LOCK actuator [B].
OTake care not to move the front final gear case shift lever.
xoricz
Do not tap the actuator with a hammer while in-
stalling it. Tapping could damage the internal parts
of the actuator.
• Tighten:
Torque - 2WD/4WD/DIFF-LOCK Actuator Bolts [C}: 9.0 N•m
(0.92 kgf•m, 80 in•lb)
12-16 FINAL DRIVE
Front Final Gear Case
• Connect the 2WD/4WD/DIFF-LOCK actuator connector.
• Install:
Cover [A]
Screws [B]

2WD/4WD/DIFF-LOCK Actuator Inspection

NOTICE
To prevent the actuator damage, observe the follow-
ing instructions while inspecting.
• Do not apply voltage to the actuator terminals di-
rectly from the battery.
• Do not disassemble the actuator. If foreign parti-
cles are allowed to pass through into the actuator,
it may become stuck.
• Never drop the actuator, especially on a hard sur-
face. Such a shock to the part can damage it.

NOTE
OBe sure the battery is fully chaiped.
• Remove:
2WD/4WD/DIFF-LOCK Actuator (see 2WD/4WD/DIFF
-LOCK Actuator Removal(12-14))
• Inspect the groove angle [A] of the 2WD/4WD/DIFF
-LOCK actuator output shaft.
a If the output shaft angle is not within the range as shown,
replace the actuator with a new one
a If the output shaft angle is within the above range, check
the actuator whether it operates properly.
23
 FINAL DRIVE 12-17
Front Final Gear Case
• Connect the 2WD/4WD/DIFF-LOCK actuator to the main
harness.
• Turn the ignition switch on.
• Inspect the groove angle of the 2WD/4WD/DIFF-LOCK
actuator output shaft.
OTurn the 2WD/4WD/DIFF-LOCK shift switch to check it
with each position.
alf the output shaft angle ie not within the range as shown
in the below table. replaoe the actuator with a new one.
Shift Switch Output ShaR Angle
2WD Position Range [A] (-30• - 0•) )
4WD Position Range [B] (99° - 130•) )
23
DIFF-LOCK Position Range [C] (200• - 230°) )
elf the actuator does not operates, check the electrical sys-
tem.
12-18 FINAL DRIVE
Front Final Gear Case
• Disconnect the 2WD/4WD/DIFF-LOCK actuator connec-
tor.
e Measure the 2WD/4WD/DIFF-LOCK actuator resistance
using a tester.

2WD/4WD/DIFF-LOCK Actuator Resistance Inspection

Tester Output Shaft Groove Angle
Connection 2wD Position [A] 4WD Position [B] DIFF-LOCK Position [C]
[1] — [5] = CI 0 CI = CI
[2] — [5] 0 CI = CI = CI
[3] — [5] 0 CI = CI = CI
[4] — [5] = CI 0 D = CI
[6] — [5] = CI = CI 0 CI
[7] — [8] 3.5 5.5 D 3.5 5.5 CI 3.5 5.5 CI

23

elf the tester reading is not within the specified, replace the
2WD/4WD/DIFF-LOCK actuator with a new one.
a If the tester reading is within the specified, the actuator is
normal.
2WD/4WD/Dl •E-LOCK shin Mechanism Inspection
• Remove the 2WD/4WD/DIFF-LOCK shift mechanism
(see Front Final Gear Case Disassembly(12-9)).
• Visually inspect the splines [A].
6 If the splines are damaged or excessively worn, replace
the front final gear case assembly.
 FINAL DRIVE 12-19
Front Final Gear Case
• Visually inspect the dogs [A].
elf the dogs are damaged or excessively worn, replace the
front pinion gear cover assembly and the shiner.

• Visually inspect the dogs [A] and dog holes [B].

6 If the dogs and the dog holes are damaged or excessively
worn, replace the front final gear case assembly.

• Measure the shift fork ear thickness and shifter groove

width.
Shlft Fork Ear Thickness [A]
Standard:
2WD/4WD 5.9 - 6.0 mm (0.232 - 0.236 in.)
Differential 5.9 - 6.0 mm (0.232 - 0.236 in.)
Service Limit:
2WD/4WD 5.8 mm (0.228 In.)
Differential 5.8 mm (0.228 in.)

Shifter Groove Wldth [B]

Standard:
2WD/4WO 6.00 - 6.10 mm (0.236 - 0.240 in.)
Differential
Service Limit:
2WD/4WD 6.2 mm (0.24 In.)
Differential 6.2 mm (0.24 in.)
all the shift fork is worn over the service limit, replace the
shift fork.
elf the shifter is worn over the service limit, replace the
shifter.
12-20 FINAL DRIVE
Front Final Gear Case
• Measure the shift fork guide pin diameter and shift lever
groove width.
Shift Fork Guide Pin Diameter [A]
Standard:
2WD/4WD 5.9 - 6.0 mm (0.232 - 0.236 in.)
Differential 5.9 - 6.0 mm (0.232 - 0.236 in.)
Service Limit:
2WD/4WD 5.8 mm (0.228 in.)
Differential 5.8 mm (0.228 in.)

Shift Lever Groove Width [B]

Standard:
2WD/4WD 6.00 - 6.15 mm (0.236 - 0.242 in.)
Differential 6.00 - 6.15 mm (0.236 - 0.242 In.)
Service Limit:
ZWD/4WD 8.3 mm (0.25 in.)
Differential 6.3 mm (0.25 in.)
elf the shift fork is worn over the service limit, replace the
shift fork.
elf the shift lever is worn over the service limit, replace the
shift lever.
Right Axle Rotation Sensor Removal
» Disconnect the speed sensor connector [A].
• Remove:
Right Axle Rotation Sensor Bolt (B]
Right Axle Rotation Sensor [C]

Right Ax/e Rotation Sensor Installation

» Installation is the reverse of removal.
• Replace the O-ring (A) with a new one. and apply grease
to it.
• Tighten:
Torqu• - Right Axle Rotation Sensor Bolt: 9.0 N•m (0.92
kgf•m, 80 in•Ib)
OWhen installing the sensor which is fastened by bolt,
tighten the bolt after placing the sensor on the bottom
surface completely.
 FINAL DRIVE 12-21
Front Final Gear Case
/tight Axle Rotation Sensor Inspection
NOTE
O//ffie right axle rotation sensor failure is suspected, fol-
low t/ie procedt/ze be/ow.
1. Turn the Ignition switch on, and shift the 2WD/4WD/DIFF
-LOCK shift switch to 4WD position.
2. Run the vehicle at a speed of 24 km/h (15 mph).
3. Turn the steering wheel to the right or lef't (No need to
fully).
4. Shift the 2WD/4WD/DIFF-LOCK shift switch to
DIFF-LOCK position.
a If the shifter moves to the DIFF-LOCK position, the right
axle rotation sensor is no problem. Inspect other shift
mechanism parts.
elf the shifter does not move to the DIFF-LOCK position,
inspect the right ade rotation sensor.
• Remove the right axle rotation sensor (see Riaht Axle Ro-
tation Sensor Removal(12-20)).
• Connect the right axle rotation sensor connector [A] with
the battery [B], 1.8 kO resistor[C] and tester [D] as shown.

• Trace [A] each side of the speed sensor surface with the
screwdriver.
OThen the tester Indicator should flick [B].
a If the tester indicator does not flick, replace the speed
sensor.

elf the reading is within the standard, check the wiring

for continuity [see Right Axle Rotation Sensor Circuit(12
22 .
a If the wiring is good, check the ECU for its ground
and power supply (see ECU Power Supnlv Inspec-
tion(3-1091).
a If the ground and power supply are good, replace the
ECU.
12-22 FINAL DRIVE
Front Final Gear Case
Rioht Ax/e Rotation Sensor Circuit

1. Right Axle Rotation Sensor

2. Joint Connector
3. ECU
Ring Cear Rotation Sensor Remova/
• Disconnect the ring gear rotation sensor connector [A].
• Remove:
Ring Gear Rotation Sensor Bolt [B]
Ring Gear Rotation Sensor [C]

Ring Gear Rotation Sensor /nsfa/lation

• Installation is the reverse of removal.
• Replace the 0-ring [A] with a new one, and apply grease
to it.
• Tightén:
Torque - Ring Gear Rotation Sensor Bolt: 9.0 N•m (0.92
kgf•m, 80 in•Ib)
OWhen installing the sensor which is fastened by bolt,
tighten the bolt after placing the sensor on the bottom
surface completely.
Ring Gear Rotation Sensor inspection
• Refer to the Ring Gear Rotation Sensor Input Voltage In-
spection (see Rinq Gear Rotation Sensor Input Voltage
Inspection(3-74)).
 FINAL DRIVE 12-23
Output Bevel Gears
Output Beve/ Gear Remova/
• Refer to the Transmission Case Disassembly (see Trans-
mission Case Disassembly(10-11)).
NOTE
Othe output bevel gears cannot be disassembled.

Oofpot Bev'e/ Gear Installation

• Refer to the Transmission Case Assembly (see Transmis-
sion Case AssembI\/(10-14)).
• When installing the oil seal [A] to the output driven bevel
gear housing [Bj, apply grease to the oil seal lips.
• Press the oil seal so that its surface is flush with the hous-
ing end [Cj using the special tool.
Special Tools - Bearing Driver Set [D]: 57001-1129
Knuckle Joint Remover [E]: 57001-1619
Oil Seal Driver, $70 [F]: 57001-1928

Output Bevel Gear Azfosfment

The backlash and tooth contact pattern of the bevel
gears must be correct to prevent the gears from making
noise and being damaged.
When replacing any one of the backlash-related parts, be
sure to check and adjust the backlash and tooth contact.
First adjust the backlash, and then tooth contact by replac-
ing shims.
These two adjustments are of critical importance and
must be carried out in the correct sequence, using the
procedures shown.
12-24 FINAL DRIVE
Output Bevel Gears
Output Bevel Gears (Backlash-related Parts)

1. Output Shaft 4. Output Drive Bevel Gear

2. Driven Bevel Gear Shim(s) 5. Drive Bevel Gear Shim(s)
3. Output Driven Bevel Gear

Drive Bevel Gear Shims for Tooth Contact Adjustment

Thickness Part Number
0.15 mm (0.006 in.) 92180-1543
0.20 mm (0.008 in.) 92180-1544
0.50 mm (0.020 in.) 92180-1545
0.80 mm (0.031 in.) 92180-1546
1.00 mm (0.039 in.) 92180-1547
1.20 mm (0.047 in.) 92180-1548

Driven Bevel Gear Shims for Backlash Adjustment

Thickness Part Number
0.15 mm (0.006 in.) 92180-1549
0.20 mm (0.008 in.) 92180-1550
0.50 mm (0.020 in.) 92180-1551
0.80 mm (0.031 in.) 92180-1552
1.00 mm (0.039 in.) 92180-1553
1.20 mm (0.047 in.) 92180-1554
 FINAL DRIVE 12-25
Output Bevel Gears
Bevel Gear Backlash Adjustment
OThe amount of backlash is influenced by driven bevel gear
position more than by drive bevel gear position.
• Remove the output shaft driven gear (see Transmission
Case Disassembly(10-11)).
• Set up a dial gauge [A) against the output shaft spline [B].
• Check the gear backlash at the four positions of the shaft.
OTo measure the backlash, turn the drive bevel gear shaft
clockwise and counterclockwise slightly so as not to move
the mate gear. The difference between the highest and
lowest gauge reading is the amount of backlash.
6 If the backlash is not within the standard, replace the
driven bevel gear shim(s).
a Change the thickness a little at a time.
• Recheck the backlash, and readjust as necessary.
Output Bevel Gear Backlash
Standard: 0.020 - 0.046 mm (0.0008 - 0.0018 in.)
(at output shaft spline)

Tooth Contact Pattern Adjustment

OTooth contact pattern is influenced by drive gear position
more than by driven gear position.
• Clean any dirt and oil off the bevel gear teeth with a high
flash-point solvent.
• Apply checking compound to 4 or 5 teeth on the output
driven bevel gear.
NOTE
OApply checking compound to the /ee/h in a thin, even
coat with a fairly stiff paint brush. If painted too thickly,
the exact tooth pattern may not appear.
OThe checking compound must be smooth and firm with
the consistency of tooth paste.
OSpecial compounds are available at aotomofive supply
stores for the purpose of checking differential gear tooth
contact patterns. Use this for checking the bevel gears.
• Turn the output drive shaft for 3 or 4 turns in the drive and
reverse (coast) directions, while creating a drag on the
driven bevel gear shaft.
• Check the drive pattern and coast pattern of the bevel
gear teeth. The tooth contact pstterns of both drive and
coast sides should be centrally located between the top
and bottom of the tooth, and a little closer to the toe of the
tooth as shown.
elf the tooth contact pattern is incorrect, replace the shim(s)
at the drive bevel gear and shim(s) at the driven bevel
gear, following the examples shown. Then erase the tooth
contact patterns, and check them again. Also check the
backlash every time the shims are replaced. Repeat the
shim change procedure as necessary.
NOTE
Olf the backlash is out of the standard range after chang-
ing shfms, correct the backlash before checking the
tooth contact pattern.
12-26 FINAL DRIVE
Output Bevel Gears
Example 1: Decrease the thickness of the drive bevel gear
shim(s) by 0.3 mm (0.01 in.), and/or increase the thickness
of the driven bevel gear shim(s) by 0.3 mm (0.01 in.) to
correct the pattern shown below. Repeat the changing in
the minimum difference of the thickness if necessary.

Example 2: Increase the thickness of the drive bevel gear

shim(s) by 0.3 mm (0.01 in.), and/or decrease the thickness
of the driven bevel gear shim(s) by 0.3 mm (0.01 in.) to
correct the pattern shown bdlow. Repeat the changing in
the minimum difference of the thickness if neoessary.

Beve/ Years inspection

• Visually check the bevel gears [A] for scoring, chipping,
or other damage.
a Replace the bevel gear assemblies as a set if either gear
is damaged.
 FINAL DRIVE 12-27
Propeller Shafts
Front Propeller Shaft Remova/
• Remove:
Center Bottom Guard (see Bottom Guard Removal(16
51
Front Final Gear Case (see Front Final Gear Case Re-
moval(12-8))
Rear Universal Joint Holder Nut [A] and Bolt

• Remove:
Front Universal Joint [A]

• Remove:
Front Propeller Shaft [A]
Spring [B]
Washer [C]
Circlip [D]
Dust Boot [E]
Special Tool - Ou%ide Circlip Pliers: 57001-144

Front Propeller Shaft /nsfaffaf/on

• Replace the circlip [A] with a new one.
• Apply grease to the spring [B].
• Install:
Dust Boot [C]
Circlip
Washer [D]
Spring
Special Tool - Outside Circlip Plieze: 57001-144

• Apply molybdenum disulfide grease to the inside splines

[A] of the rear universal joint.
• Install:
Front Propeller Shaft [B]
• Replace the rear universal joint holder nut with a new one.
• Tighten.
Torque • Rear Universal Joint Holder Bolt: 25 N-m (2.5
kgf•m, 18 ft•Ib)
12-28 FINAL DRIVE
Propeller Shafts
• Apply molybdenum disulfide grease to the inside splines
[A] of the universal joint.
• Install:
Front Universal Joint [B]

• Remove the center access cover (see Center Access

Cover RemovaIf16-28)).
• Check that the dust boot [A] is installed securely.
• Install the removed parts.

Rear Propeller Shaft /temovaI

• Remove:
Front Propeller Shaft (see Front Propeller Shaft Re-
moval(12-27))
Rear Universal Joint Holder Nut [A] and Bolt
Rear Universal Joint [B]

• Remove:
Propeller Shaft Bearing Case Bolts [A]
Rear Propeller Shaft Assembly [B]

/tear Propeller Shaft Installation

• Apply molybdenum disulfide grease to the inside splines
[A] of the rear joint shaft.
• Replace the 0-ring [B) with a new one and apply grease
to It.
• Install:
Rear Propeller Shaft Assembly [C]
• Tighten:
Torqu• - Propeller 6haft Bearing Caae Bolts: 25 N•m (2.5
kgf•m, 18 ft•Ib)
 FINAL DRIVE 12-29
Propeller Shafts
• Apply grease to the oil seal lips [A] and the dust cover [B].
• Apply molybdenum disulfide grease to the inside splines
[C] of the rear universal joint.
• Install:
Rear Universal Joint
• Replace the rear universal joint holder nut with a new one.
• Tighten:
Torque - Rear Universal joint Holder Bolt: 25 N•m (2.5
kgf•m, 18 ft•lb)
e Install the removed parts.
Rear Propeller Shaft OisassemD/y
• Disassemble:
Circlip [A]
Oil Seal [B]
Circlip [C]
Shaft [D]
O-ring [E]
Oil Seal [F]
Circlip [G]
Ball Bearing [H]
Special Tools •Inside Circlip Pliers: 57001•143
Outside Circlip Pliers: 57001•144

Rear Propeller Shan A«semai;/

• Replace the O-ring, the cimlips, the oil seals and the ball @
bearing with new ones.
• Press the ball bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set: 57001•1129
• Install:
Circlip [B]
Special Tool - Inside Circlip Pliers: 57001•143
• Apply grease about 12 cm° (0.41 oz.) onto the ball bear-
ing.
12-30 FINAL DRIVE
Propeller Shafts
e Press the oil seal [A] so that its surface is flush with the
housing end.
OUse the large inside diameter side of the oil seal driver.
Special Tools - Bearing Driver Set: 57001-1129
Oil Seal Driver, @60 [B]: 57001-1930
• Apply grease to the oil seal lips of the oil seal.

• Apply grease to the oil seal lips [A] and the dust cover [B].
• Install the shaft [C] to the housing [D1.

• Install:
Circlip [A]
Special Tool - Outside Circlip Pliers: 57001-144
• Apply grease about 12 cm° (0.41 oz.) onto the ball bear-
ing.
 FINAL DRIVE 12-31
Propeller Shafts
• Apply grease to the lips of the oil seal [A].
• Press the oil seal so that its surface is flush with the hous-
ing end.
ODo not apply load to the dust cover [B].
OTake care not to damage the oil seal lips by the grooves
of the shafL
OUse the small inside diameter side of the oil seal driver.
SpecialTools - Bearing Driver Set: 57001-112d
Oil Soal Driver, §›60 [C]: 57001-1930

• Replace the O-ring [A] and the circlip [B] with new ones
and install them to the grooves [C].
Special Tool - Outside Circlip Pliers: 57001-144
B
12-32 FINAL DRIVE
Axles
Front Axle Removal
• Remove:
Steering Knuckle fsgq Front Stjspension Arm Re-
moval(14-16))
Front Shock Absorber (see Front Shock Absorber Re-
movaIf14-9))
• Remove:
Stabilizer Joint Nut [A] and Washer

• Raise the front suspension arm [A] and hold it.

• Remove the front axle [A] straight.

OThe front axle is caught by the snap ring. Pull it rather
strong.

Front Axle /nsts1/affon

• Replace the oil seal for the axle with a new one.
• Install the oil seal so that its surface is flush with the front
final gear case.
Special Tool - Oll Seal Driver [A]: 57001-1926

• Be sure to install the snap ring [A] onto the axle end.
OTo avoid the damaging of the oil seal lips, the snap ring
opening must be upward as shown.
Correct [B]
Incorrect [C]
• Apply molybdenum disulfide grease to the axle splines
[D], spline hole and the oil seal lips [E].
• In9ert the front axle end so that it does not touch the oil
seal lips.
OSupport the inboard side by hand, and insert the front axle
straight.
• Check that the front axle is caught by the snap ring and it
does not come off easily.
 FINAL DRIVE 12-33

Rear Axle Remova/

• Remove:
Rear Knuckle fsee Rear Knuckle Removal(14-221)
• Remove the rear axle [A] BDaight.
OThe rear axle is caught by the snap ring. Pull It rather

NOTE
OThe lefl and right rear ax/es heve different. When in-
availing tfie iaar ax/e, refer fa tfie lâllowing table.
Outer End Threads Identification
One of the boot band is
LeRAxb LoN-h*ndTh
F#gMAide Riga-hendTlhnmmdm

• Bs sure to insall the snap ring [A] onto the axle end.
OThe snap ring opening must be upward as shown.
Correct [B]
Incorrect [C]
• Apply molybdenum disulfide grease to the ade 9plines
[D], splines hole and the oil seal lips [E].
• Insert the rear axle end so that It does not touch the oil

osupport the inboard side by hand, and insert the rear axle
straight.
• Check that the rear axle is caught by the snap ring and it
does not come all easily.
Axle to/nt Boot fnspeczfon
« Visually lnspect the axle joint boots [A].
alfthejointbootis tom, worn, deteriorated, or leaks grease,
replace the joint boot or axle assembly (see Axle Joint
Boot Replacement(12-34)).

• Remove:
Front Axle (see Front Axle Removal(12-32))
Rear Axle (see Rear Axle Removal(12-33))
• Visually inspect the axis splines [A].
elf they are twisted, badly wom, or chipped, mplace the
axle with a new one.
• Check that the constant velocity joints [B] work smoothly
without rattling or sticking.
elf it does not, replaoe the axle with a new one.
12-34 FINAL DRIVE
Axles
Ax/e Joint Boot Rep/acemenf
Outboard Joint Boot Removal
• Remove:
Front Axle (see Front Axle Removal(12-32))
Rear Axle (see Rear Axle Removal(12-33))
• Remove the boot bands [A].
NOTE
ODo not reuse the boot bands. Always replace the boot
bands with new ones.
• Slide the joint boot [B] toward the inboard joint.
• Separate the constant velocity joint from the axle shaft.
OTap the inner race [A] or the outer race [B] with a copper
hammer.
NOTIC•E
Do not tap on the cage [C]. Be careful not get hurt
when the housing comes out. If the splined portion
of shaft cracked or damaged during disassembling
of outboard joint, do not reuse the shaft.

• Remove:
Snap Ring [A]
Outboard Joint Boot [B]
Boot Band [C]

Outboard Joint Boot Installation

• Clean the axle shaft by wiping off the used grease on it.
• Wind a tape on the splines to protect the joint boot.
• Install:
New Small Band [A]
New Outboard Joint Boot (B]
New Snap Ring (C]
OApply the special grease slightly on the inside of the new
boot small diameter, and install the boot on the axle shaft.

Only the special grease that is included with the

boot kit can be applied to the boots.
 FINAL DRIVE 12-35
Axles
• Fill the bearing housing [A]with the special grease [B] until
the grease comes out from the joint bearine-

• Install the axle shaft to the bearing housing.

• Tap the shaft end [A] straight with a plastic or copper ham-
mer until it is stopped by the snap ring.

• Make sure the circular rib [A] inside the small end of the
boot has baen fitted into the groove on the axle shaft.
• Position the small boot band [B] into the groove on the
boot.
• Fasten the band and fold the tabs to secure the end of the

• Be sure the outside diameter [A] of the band is less than

the specified value shown below.
Maximum Outside Diameter of Small End Band:
Front ar.a mm (1.49 in.)
Rear 39.3 mm (1.55 in.) @

• Squeeze all of the special grease [A] into the new boot
[B], and slide the boot onto the outboard joint [C].
12-36 FINAL DRIVE
Axles
• Compress the axle assembly to the specified length [A]
while relieving the air pressure inside the inboard boot.
• Hold the axle at this setting.
Standard Length of Ana«mbling:
Front 275.0 mm (10.83 in.)
Rear 256.8 mm (10.11 in.)

• Open the boot end [A] to equalize the air pressures.

• Make sure the circular rib [A] inside the large end of the
boot has been fitted into the groove on the outboard joint.
• Position the large boot band [B] into the groove on the

• Fasten the band and fold the tabs to secure the end of the
band.

• Be sure the outside diameter of the band (A] is less than

the maximum diameter.
Maximum Outside Diameter of Big End Band:
Front 103.2 mm (J.06 in.)
Rear 9M.9 mm (3.78 in.)

lnbaard Joint Boot Removal

NOTE
OThe left and right rear axles have different. W’fien re-
p/acir›g /he inboard/oint boots, re/'er to the following ta-
6Ie.
Outer End Threads Identification
One of the inboard boot
Left Axle Left-hand Threads band is colored to yellow
green.
Right Axle Right-hand Threads
 FINAL DRIVE 12-37
Axles
• Remove:
Front Axle (see Front Axle Removal(12-32))
Rear Axle (see Rear Axle Removal(12-33))
• Remove the boot bands [A].
NOTE
ODo not reuae the boot bands. A/ways replace the boot
bands wf/ñ new ones.
• Gllde the joint boot [B) toward the outboard joint.

• Remove the retaining ring [A].

• Separate the bearing cup [B] from the axle shafL

• Remove the steel balls [A].

• Sllde the cage [B] toward the outboard joint.

• Remove:
Clrclip [A]
9peclal Tool - Outelde Circlip Pliers: 57001-144

• Remove:
Inner Race [A]
Cage [B]
Inboard Joint Boot [C]
12-38 FINAL DRIVE

Inboard Joint Boot Installation

e Install:
New Small Band [A]
New Inboard Joint Boot [B]
Cege{C]

• Install the inner raoe [A] to the shaft.

OFace the stepped side [B] toward the outboard joint

• Install:
New Circlip [A]
Special Tool - Outside Circlip Pliers: 57001-IM
• Slide the cage [B] on the inner race and install the steel
balls (C].
• Apply the special grease [D] to the steel balls and cage.

Only the special grease that is Included with the

boot kit can be applied to the boots.
• Squeeze aI>xit haC a tube of the special grease into the
bearing cup [A].

• Install the bearing cup [A] onto the balls and cage assem-
bly.
• Install the new retaining ring [B].
 FINAL DRIVE 12-39

• Align the retaining ring opening [A] with one of the projec-
tions [B] on the bearing cup.

• Squeeze the remaining special grease into the bearing

cup [A] and inboard joint boot [B].

• Make sure the circular rib [A] inside the small end of the
boot has been fitted into the groove on the axle shaft.
• Pasition the small boot band [B] into the groove on the
boot.
• (Front Axle) Pinch the small boot band with a suitable tool
[C] to secure it.
Recommendad Tool: OETIKER 192
• (Rear Axle) Fasten the band and fold the tabs to secure
the end of the band.
• Be sure the outside diameter of the band [A] is less than
the speciFzed value shown below.
B0aximum Outside Diameter of Small End Band:
Front 39.4 mm (1.551 in.)
Resr 39.3 mm (1.M7 in.)

• Compress the axle assembly to the specified length [A]

while relieving the air pressure inside the inboard boot.
• Hold the axle at this setting.
Standard Length of Assembling
Front:
188.J - 188.9 mm (7.417 - 7A37 in.)
Right 217.J -217.9 mm (8.559 - 5.579 in.)

LeRand RfgN 2ZZ.6 mm (8.76d in.)

12-40 FINAL DRIVE
Axles
• Open the boot end [A] to equalize the air pressures.

• Make sure the circular rib [A] inside the large end of the
boot has been fitted into the groove on the inboard joint.
• Position the large boot band [B] into the groove on the

• (Front Axle) Pinch the boot band with a suitable tool (Cj
to secure it.
Recommended Tool: OETIKER 192
• (Rear Axle) Fasten the band and fold the tabs to secure
the end of the band.
• Be sure the outside diameter of the band [A] is less than
maximum diameter.
Maximum Outside Diameter of Big End Band:
Front 92.3 mm (3.63 In.)
Rear 107.6 mm (4.23 in.)
 FINAL DRIVE 12-41
Ball Bearing, Needle Bearing, and Oil Seal

Do not remove the ball or needle bearings unless It

Is necessary. Removal may damage them.
• Using a press or puller, remove the ball bearing and/or
three needle bearings.
NOTE
Oln the absence of the above mentioned fi‹›ots, aefisfeo-
toryzesuits may 0s o6fained dy heating /ñe case /o ap-
pn›xlmateiy93•C(200•F) max., endfapptng tfiebearing
in or out

Do not heat the case with a torch. Thia will warp the
caee. 8oak the case In oil and heat the oil.
• Ueing a pr66s and the bearing driver set [A], install the
new ball bearing until it stops at the bottom of"m housing.
OThree new needle bearings must be pressed into the
crankcase so that the end Is flush with the end of the
hole.
Gpeclal Tool - Bearlng Drtver Setz 07001-112s
Ball and J\/eed/e Beazfng W'ear Inspeofion
doTlce
Do not remove the bearings for lncpectlon. Re-
moval may damage them.
• Check the ball beadngs.
OSince the ball beai1ngs are made to extremely cloee toler-
ances, the wear must be judged by feel rather than mea-
surement Clean each bearing In a high flash-point sok
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
OSpln [A] the bearing by hand to check its condition.
Elf the bearing is noisy, does not spin smoothly, or has any
rough spots, rsplaoe it.
• Check the needle beadngs.
OThe rollers in a needle bearing normally wear very little,
and wear is diñicult to measure. Instead of measuring,
inspect the bearing for abraeion, color change, or other
damaga.
elf there is any doubt as to the condition of a needle bear-
ing, replace it
Oi/ Seal Inapeotfon
• Inspect the oil seals.
a Replace it If the lips are misshapen, discolored (indicating
that the rubber has detorioratad), hardened or otherwise
damaged.
 BRAKES 13-1

Brakes
Table of Contents
Exploded View................................... 13-2 Brake Caliper Piston and Cylinder
Specifications ...................... 13-6 Damage Inspection ................... 13-22
Brake Fluid ................................. 13-7 Brake Caliper Holder Shaft Wear
13-7 Inspection..............................,... 13-22
Brake Flud Rebel I ” .t't't 13-7 Brake Pads........................................ 13-23
13-7 Front Brake Pad Removal............ 13-23
Br:ke Fi:dAhBneeding .............:. 13-8 Front Brake Pad Installation......... 13-23
Brake Pedal and Master Cylinder...... 13-10 Rear Brake Pad Removal ............ 13-24
Brake Pedal Free Play Inspection 13-10 Rear Brake Pad Installation ......... 13-24
Brake Pedal Removal .. 13-10 Brake Pad Wear Inspection ......... 13-25
Brake Pedal Installation ............... 13-11 Brake Discs ....................................... 13-26
Master Cylinder Removal............. 13-12 Brake Disc Cleaning ..... .. . ... . . 13-26
Master Cylinder Installation.......... 13-13 Brake Disc Removal ..... .... . .... .. 13-26
Master Cylinder Disassembly/As- Brake Disc Installation ................. 13-26
sembly................... 13-15 Brake Disc Wear Inspection...,.,... 13-26
Master Cylinder Inspection .......... 13-16 Brake Disc Warp Inspection......... 13-26
Calipers ............................... ............. 13-17 Brake Hoses and Pipes..................... 13-27
Front Brake Caliper Removal....... 13-17 Brake Hose and Pipe Inspection.. 13-27
Front Brake Caliper Installation.... 13-17 Brake Hose Replacement............ 13-27
Rear Brake Caliper Removal ....... 13-17 Parking Brake Pedal and Cables....... 13-28
Rear Brake Caliper Installation .... 13-18 Parking Brake Lever Inspection... 13-28
Front Brake Caliper Disassembly 13-19 Parking Brake Lever Removal ..... 13-28
Front Brake Caliper Assembly ..... 13-19 Parking Brake Lever Installation .. 13-28
Rear Bra e a er assbmbly . 13-19 Parking Brake Cable Removal..... 13-30
|!
k 13-19 Parking Brake Cable Installation.. 13-30
Cancer Pieton Seal Damage "' Parking Brake Cable Lubrication 13-31
Inspection.................................. 13-20
Dust Seal and Friction Boot
Damage Inspection ................... 13-21
13-2 BRAKES
Exploded View

si '9

10

11 LN
 BRAKES 13•3
Exploded View
Torque
No. Fastened Remarks
Nul
1 Brake Hose Banjo Bolts (Front) 23.5 ) 2.40 17.3
2 Front Brake Hose Clamp Bolts 8.8 | 0.90 ( 78 in-lb
3 Brake Hose Banjo Bolt (Master Cylinder) 23.5 | 2.40 ) 17.3
4 Brake Fluid Reservoir Bolt 8.8 0.90 | 78 in-lb
5 Brake Master Cylinder Bolt 23.5 | 2.40 17.3
6 Master Cylinder Push Rod Locknut 13.2 1.35 9.7
7 Brake Pedal Bracket Bolts 26 ) 2.7 ) 19
8 Front Caliper Holder Pins 40 ) 4.1 30 Si
9 Caliper Bleed Valves 5.4 | 0.55 | 48 in lb
10 Caliper Mounting Bolts 45 ( 4.6 33 L
11 Brake Disc Bolts 56.5 ) 5.76 41.7 LN”’
AG: Apply lithium grease (NLGI Grade No. 2).
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
LN”1: Apply a non-permanent locking agent (High Strength: TB 2478 or equivalent).
R: Replacement Parts
Si: Apply silicone grease.
13-4 BRAËES
Exploded View

12
10’

t° 11 “

IMO20g6BW5 4
 BRAKES 13-5
Exploded View
Torque
No. Fastener Remarks
N f I
1 Parking Brake Cable Locknuts 7.8 |0.80 )
89 in-lb
2 Parking Brake Lever Bolts 26 2.7 19
3 Master Cylinder Brake Pipe Joint 23.5 )2.40 (17.3
4 Brake Pipe Joint Nuts 17.5 I1.78 (12.9
5 Brake Pipe Joint Mounting Bolt 8.8 |0.90 |
78 in-lb
6 Brake Hose Banjo Bolts (Rear, TORX) 23.5 |2.40 )17.3
7 Caliper Mounting Bolts 45 ) 4.6 1 33 L
8 Rear Caliper Holder Shafts 22 ) 2.2 ( 16 Si
9 Caliper Bleed Valves 5.4 I0.55 )
48 in lb
10 Rear Caliper Holder Pins 40 | 4.1 30 Si
11 Brake Disc Bolts 56.5 )
5.76 )41.7 LN“1
12 Swaper Bolts - I 0.90 1 78 in-lb
13. Scraper
AG: Apply lithium grease (NLGI Grade No. 2).
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
LN°1: Apply a non-permanent locking agent (High Strength: TB 2478 or equivalent).
R: Replacement Parts
Si: Apply silioone grease.
13-6 BRAKES
Specifications
Item Standard Service Limit
Brake Fluid
Grade DOT4
Fluid Level Between upper and lower level lines
Brake Pedal
Brake Pedal Free Play 2 15 mm (0.08 0.59 in.)
Brake Pads
Lining Thickness:
Front 5 mm (0.20 in.) 1 mm (0.04 in.)
Rear S mm (0.20 in.) 1 mm (0.04 in.)
Brake Discs
Thickness:
Front 5.6 - 6.0 mm (0.22 0.24 in.) 5.3 mm (0.21 in.)
Rear 5.6 - 6.0 mm (0.22 0.24 in.) 5.3 mm (0.21 in.)
Parking Brake Lever and Cables
Parking Brake Travel Less than 10 notches (clicks)
 BRAXES 13-7
Brake Fluid
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
• Never reuse old brake fluid.
• Do not use fluid from a container that has been left
unseated or that has been open for a long time.
• Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to dete-
riorate.
• Do not leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
• Do not change the fluid in the rain or when a
strong wind is blowing.
• Except for the disc pads and disc, use only disc
brake nuid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
nuid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.
• When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.
• Brake nuid quickly damages painted surfaces;
any spilled nuid BhotJld be completely wiped up
immediately.
• If any of the brake line fittings or the bleed valve is
opened at any time, the AIRMUST BE BLED FROM
THE BRAKE LINE.

Brake Fluid Recommenz/at/on

Use extra heavy-duty brake fluid only from a container
marked DOT4.
Recomm•nd•d Disc Brake rluid
Grade DOT4

Brake Fluid Leve/ inspection

• Refer to the Brake Fluid Level Inspection (see Brake Fluid
Level Inspection(2-39)).
BraAe Fluid Change
• Refer to the Brake Fluid Change (see Brake Fluid
Chanoe(2-40}).
13-8 BRAKES
Brake Fluid
BraAe Line Afr B/eez/ing
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake pedal is transmit-
ted directly to the caliper for braking action. Air, however, is
easily compressed. When air enters the brake lines, brake
pedal movement will be partially used in compressing the
air. This will make the pedal feel spongy, and there will be
a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake pedal has a soft or "spongy" feel-
ing mushy when It is applied, there might be air in
the brake lines or the brake may be defective. Do
not operate the vehicle and service the brake sys-
tem immediately.

• Remove:
Front Access Cover (see Front Access Cover Re-
moval(16-40))
Reservoir Cap [A]
Diaphragm Plate
Diaphragm
• Fill the reservoir [B] with fresh brake fluid to the upper
level line [C].
• Slowly pump the brake pedal several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
OBleed the air completely from the master cylinder by this
operation.

NOTE
OThe airbleeding procedures should be done in the order
from farthest caliper to nearest ca/iper in rfisfance mom
the master cylinder.

• Remove the wheels (see Wheel Removal(11-8)).

• Remove the rubber cap from the bleed valve (A] on the
rear brake calipers.
• Connect a clear plastic hose [B] to the bleed valve on the
rear brake caliper, and run the other end of the hose into
a container.
 BRAKES 136
Brake Fluid
• Bleed the brake line and the rear brake caliper as follows:
ORepeat thls operation until no more air can be seen com-
Ing out into the plastic hose.
1. Pump the brake pedal until it becomes hard, and apply
the brake pedal and hold it [Aj.
2. Quickly open and close (ej me»eea valve while holding
the brake pedal applied.
3. Release the brake pedal [C].
NOTE
0 The /fUid/eve/moatdechecyed'seve/a/t/ones dt/zfngfhe
bleedizzg operationandreplenlshedasneoessary. dms
ftuld in the /ese/voir runs comp/e/ely out any time dur-
ing bleeding, the bleeding opera6on must be done over
again from the beginning since air will have entered the

• Disoonnect tha clear plastic hose from the bleed valve.

Torqu• - Caliper Bleed Valvea: 5.4 N•m(0.55 kgf•m, 46 In•lb)

• Install the rubber cap.
• Re/zeat the previous atep for front callpers [A].
• Tighten the caliper bleed valves after oomplete tha air
bleeding.
Torque - Callpsr Bkad V¥lves: 5.4 N•m(0.55 kgf•m, 48 ln•lb)

• When air bleeding is finished, add fluid up to the upper

level [A] in the recervolr.
• Install the reservoir cap, diaphragm plate and diaphragm.
• Apply the brake foroefully for a few seconds, and check
for fluid leakage around the fittings.
13-10 BRAKES
Brake Pedal and Master Cylinder
BzaAe Pezfa/ Free P/ay inspector
• Refer to the Brake Pedal Free Play inspection (see Brake
Pedal Free Plav Inspection(2-42)).
BraAe Pedal Remova/
• Remove:
Snap Pin [A] and Joint Pin [B]
Brake Light Switch Spring [C]
Brake Light Switch [D]
OPush the lock tabs on the adjusting nut to pull off the brake
light switch.

• Remove:
Brake Pedal Bracket Bolts [A]
Brake Pedal Assembly [B]

• Remove:
Cotter Pin [A]
Washer [B]
Brake Pedal Shaft [C]
Return Spring [D]
Brake Pedal [E]

e Remove the bushings [A] from the pedal if necessary.

NOTE
ODo not fern tfie d/ake peda/ stopper bolt unless make
these adjustment.