Propeller Shaft and Axle

GENERAL AXLE AND KNUCKLE
WHEEL ALIGNMENT
PROPELLER SHAFT
FRONT PROPELLER SHAFT REAR AXLE
REAR PROPELLER SHAFT WHEEL HUB
AXLE HOUSING
FRONT AXLE
WHEEL HUB DIFFERENTIAL CARRIER ASSEMBLY
PA -2 PROPELLER SHAFT AND AXLE
GENERAL
SPECIFICATION EBA6B61B
PROPELLER SHAFT
Item Specification
Type P3
Pipe Outer Diameter × Thickness Ø76.2×2.6
Universal Joint Spider Outer Diameter Ø22.7
Bearing Cap Outer Diameter Ø35
Needle roller Bearing Outer Diameter Ø2.65
Length 19.4
Amount 30
Slip Joint Spline Diameter Ø38.7
Inner Diameter × Outer
Center Bearing 40×80
Diameter
Unit : mm
FRONT AXLE
Model
Item
HD65 HD72 HD78
Tread (mm) 1665 1650 1667
Camber 1 ±30′ ← ←
Caster 2 30′ ±30′ ← ←
King Pin Tilting Angle 8 ±10′ ← ←

Toe In (mm) 0~6 0~6 ←
King Pin Offset (mm) 26.87 17.10 17.10
King Pin Span (mm) 1508 1508 ←
Steering Angle( ) Inside 42.3~44.3 42.5~44.5 ←
Outside 31.5~33.5 30~32 ←
Wheel Offset(mm) 115 115 127
GENERAL PA -3
REAR AXLE
Item Specification
Reduction Type Single Reduction Speed Type
Gear Shape Hypoid Gear
Reduction Ratio R5.0/R5.714/R6.166/R6.666/R5.428
Differential Gear Shape Straight Bevel Gear
Gear Oil Type API GL-5, SAE 80W/90
API GL-5, SAE 140W(for tropical region)
Injection Amount 4.5±0.25ℓ
Hub Grease Type Hub Grease LIG-2
(Left/Right)
Injection Amount 330g at each
SERVICE STANDARD
PROPELLER SHAFT
Reference Remedy and

Item Limit Value
Value Remark
Propeller Shaft Run-out 0.4
0.1 or less Repair or replace
0.6
Clearance of Spline Rotational Direction 0.01~0.09 0.3 Replace
Front 5g/3000rpm - Adjust Balance
Unbalance of Propeller Shaft Weight
Rear 10g/3000rpm -
Replace with
Clearance between Spider and Needle Bearing 0.02~0.05 0.1
spider kit
Clearance of Snap Ring to axis 0.06 or less - Adjust Snap Ring
Unit : mm
FRONT AXLE
Reference Value
Item Limit Value Remedy and Remark
(STD Diameter is in [])
A=122.9±1 A=126 Repair or replace
King Pin Outer Diameter 29.947~29.98 - Replace
Bushing Inner Diameter
30~30.033 -
(After pressed-in)
Clearance between King
0.020~0.086 0.15 Replace the bushing
pin and Bushing
Vertical clearance of 0.02~0.1 0.2 Adjust with Shim
knuckle Shim thickness: 0.10, 0.15, 0.20, 0.30
Front Wheel Hub Starting 0.98~3.45 Nm (10~35kgf·cm,
Adjust
Torque (kgf·cm) 0.73~2.55 Ib-ft)
REAR AXLE
Item Reference Value Limit Value Remedy and Remark

Rear Axle Shaft Bending of shaft Replace
2 4
center
Bending of flange
0.03 0.05
surface
Clearance between differential gear Replace
0.05~0.15 0.5
and rear axle shaft spline portion
Backlash between the differential Adjust by differential gear spacer
gear and pinion (when the tooth of differential
0.18 ~0.23 0.5
gear is damaged, replace the
differential gear).
Backlash between the final drive gear
0.2 ~ 0.28 - Adjust
and the final drive pinion
Run-out of the back surface the
0.05 or less 0.05 Replace the carrier assembly
final drive gear
Final drive pinion D2H,D3H 0.1 ~ 0.2 - Adjust (do not install the
Starting outer oil seal)
torque(kgf·m) D033H 0.2 ~ 0.3
Starting torque of Rear wheel 0.2 ~ 0.4 Adjust (do not install the outer
-
hub(kgf.m) oil seal and axle shaft)
A 0.5 or less 1 Repair or replace
B1 - B2 1.0 or less 5 Replace
TIGHTENING TORQUE
PROPELLER SHAFT
Install Position Tightening Torque

Nm kgf·m Ib.f-ft
Nut for tightening the flange yoke to
59~69 6~7 43.3~50.6
the propeller shaft flange
Lock nut for tightening the
294~392 30~40 216.9~289.3
companion flange
Center bearing bolt tightening 20~29.4 2~3 14.4~21.6
GENERAL PA -5
FRONT AXLE
Tightening Torque
Install Position
Nm Kgf·m Ib.f-ft
Tightening Nut for Knuckle Arm 196~294 20~30 144.6~216.9
Tightening Nut for King pin Lock pin 28~38 2.9~3.9 20.9~28.2
Tightening Nut for Shock Absorber 13~17 1.3~1.7 9.4~12.2
Tightening Bolt for Brake Backing Plate 98~137 10~14 72.3~101.2
Tightening Nut for Hub bolt 539~588 55~60 397.8~433.9
Tightening the wheel hub lock nut 1st tightening torque 98~127 10~13 72.3~94.0
2nd tightening torque
58 6 43.3
after full loosening
Loosening angle after
Approximately 45 <1/8 turns>
tightening
REAR AXLE
Install Position Tightening Torque

Nm Kgf·m Ib.f-ft
Bolt (for install the final drive gear and the
226~265 23~27 166.3~195.2
differential case)
Tightening bolt for bearing cap 69~78 7~8 50.6~57.8
Bolt (for install the side bearing lock plate) 20~26 2.0~2.7 14.4~19.5
Tightening Nut for differential carrier assembly 34~44 3.5~4.5 25.3~32.5
Tightening Bolt for rear brake assembly 98~137 10~14 72.3~101.2
Nut (for install the wheel hub and the rear
drum brake):After tightening, lock using a 304~382 31~39 224.2~282.0
triangular or pyramid punch
Tighten the wheel bearing 1st tightening 98~127 10~13 72.3~94
lock nut
2nd tightening torque
29~39 3~4 21.6~28.9
after full loosening
Tightening Bolt for rear axle shaft 98~117 10~12 72.3~86.7
Filler plug 59~78 6~8 43.3~57.8
Drain plug 59~78 6~8 43.3~57.8
TROUBLESHOOTING ECCF9E4D
PROPELLER SHAFT
Symptom Causes Remedy

Vibration at High Speed The yoke direction is wrong. Rearrange the align mark.
Propeller Shaft
The universal joint needle roller
Replace with the spider kit.
bearing is defective.
The propeller shaft is bent Replace the propeller shaft.
The dynamic balance of the propeller
Adjust the dynamic balance.
shaft is incorrect.
The flange linking bolt is loosened. Tighten with specified torque.
The ball bearing is worn out
Replace the ball bearing.
or adhered.
Low Speed Move the shift bar of the transmission
The transmission is too fast.
to proper position.
The axial clearance of the universal
Adjust the clearance by Shim.
joint spider is too large.
The clearance of the slip joint
Replace the yoke sleeve or propeller shaft.
spline is too large.
Abnormal At start The flange linking blot is loosened. Tighten with specified torque.
Noise at
The tightening bolt for center
Propeller Shaft Tighten with specified torque.
bearing is loosened.
The center bearing is weakened
Replace the rubber
or deformed.
bearing is worn.
The clearance of the slip joint
Replace the yoke sleeve or propeller shaft.
spline is too large.
Running with The axial clearance of the universal
Adjust the clearance by Shim.
Regular speed joint spider is too large.
bearing is worn.
The ball bearing is worn out
Replace the ball bearing.
or adhered.
The lubricant between the bearing
Lubricate.
and the spline is defective.
GENERAL PA -7
FRONT AXLE
Symptom Causes Remedy

Vibration at Steering Wheel Kingpin wear. Replace.
The clearance of kingpin and bushing
Replace the kingpin bushing.
is too large.
The front wheel hub bearing is adhered,
Replace.
worn or defective in rotation.
The wheel alignment is defective. Adjust
The tie rod end ball stud is too worn out. Replace the tie rod end assembly.
The air pressures of the tires are uneven. Adjust.
The tightening castle nuts for the knuckle
Tighten with the specified torque.
arm and the tie rod arm are loosened.
The tightening nut for tie rod ball
stud is loosened.
The tightening nut for suspension
U-bolt is loosened.
The vertical clearance between the knuckle
Adjust the kingpin thrust washer.
and the front axle is too large.
Hard to control the The clearance between the kingpin and
Replace the kingpin bushing.
steering wheel the kingpin bushing is too large.
The strut ball bearing is adhered, worn
Replace the thrust ball bearing.
or defective in rotation.
The tire air pressure is too low. Adjust the air pressure.
The wheel alignment is defective. Adjust.
The grease is deficiency in kingpin. Oil the grease.
Steering wheel does not The front axle parts are too tightened. Tighten with the specified torque.
return properly.
The wheel alignment is defective. Adjust.
Steering wheel can not The rotating angle adjustment is defective. Adjust the rotating angle.
be turned.
The tie rod is bent. Replace.
Vehicle is drawn to The sizes of the left and right tires
Replace with the same size.
one side. are different.
The outer diameters of the left and
Replace with the same size.
right tires are different.
The air pressures of the tires are different. Apply the same air pressure.
The front axle is bent. Replace.
The front spring is damaged or its
Replace.
tension is defective.
Front tire is worn irregularly The wheel alignment is defective. Adjust.
or too early.
The sizes or types of the left and
Replace with the same size and type.
right tires are different.
The tire is not managed properly. Replace the tire position.
REAR AXLE
Moving force is not transmitted properly.
Oil leakage at differential carrier and

Trouble
Oil leakage at companion flange
Noise at start or changing shift bar.

Propeller shaft is rotating but the
During running, irregular noise
During curving, noise is made.

Symptom
During running, noise is made
During running, tire is drawn.

Oil leakage at rear axle shaft
vehicle does not move

vrear axle housing
continually.
Adhesion
is made.
Damage
Causes
Wheel Hub The tightening bolt for rear axle shaft is loosened.
and Axle
The rear axle housing is bent.
Housing
The rear axle shaft is bent.
The rear axle shaft is broken.
The rear axle shaft is slept out.
The oil seal is defective.
The air breather is cracked, damaged or clogged.
The wheel hub bearing is adhered.
The wheel hub bearing is worn out.
The wheel hub bearing is defective in rotation.
The wheel hub bearing is damaged.
The gear oil is too much.

Reduction
and The gear oil is deficiency.
Differential
The oil seal is defective.
The sealant is improper.
The side bearing is adhered.
The side bearing is worn out.
The side bearing is defective in rotation.
The side bearing is damaged.
The operating torque of the side bearing is too high.
The operating torque of the side bearing is too low.

The tightening bolt for reduction and differential assy
is loosened.
The tightening nut for differential carrier assembly
is loosened.
EMTPA5001AA
GENERAL PA -9
GENERAL INFORMATION
Trouble Moving force is not transmitted properly.
Oil leakage at companion flange

Symptom
Oil leakage at differential carrier
During curving, noise is made.

During running, noise is made
During running, irregular noise
During running, tire is drawn.

Oil leakage at rear axle shaft
Propeller shaft is rotating but
the vehicle does not move
Noise at start or changing
and rear axle housing
continually.
Adhesion
shift bar.
Damage
is made.
Causes
Reduction The differential carrier is cracked or damaged.

and
The tightening bolts for reduction gear and the
Differential
differential case are loosened.
The reduction gear or the reduction pinion is damaged.
The reduction gear or the reduction pinion is worn.
The reduction gear or the reduction pinion is defective.
The backlash of the reduction gear is too large.
The backlash of the reduction gear is too small.
The adjustment of teeth contacting surface of the
reduction gear is defective.
The operating torque of the reduction pinion is too large.
The operating torque of the reduction pinion assy is too small.
The castle nut of the reduction pinion is loosened.
The inner bearing and outer bearing of the
reduction pinion are adhered.
The inner bearing and outer bearing of the reduction
pinion are worn out.
The inner bearing and outer bearing of the reduction
pinion are damaged.
The reduction pinion plot bearing is worn.
The reduction pinion plot bearing is adhered or damaged.
The pinion spider is broken.
The differential gear or differential pinion is damaged.
The differential gear or differential pinion is adhered.
The differential gear or differential pinion is worn.
The washer of differential gear is worn or damaged.
The backlash of the differential gear is too large.
The backlash of the differential gear is too small.
The clearance between the differential gear and
the rear axle shaft spline is too large.
EMTPA5002AA
GENERALS E3DCA32E
2
1
1. Front Propeller Shaft

2. Rear Propeller Shaft
3
3. Rear Axle
EMTPA5003A
The propeller shaft installing between the transmission The relative position of the transmission to the rear axle is
and the rear axle transmits the engine force changed by varying in accordance with the condition of the road sur-
the transmission to the final gear of the rear axle. The pro- face, the vibration during running of the vehicle and the
peller shaft comprises of the front and the rear propeller amount of the load. To compensate the varying of the po-
shafts. Two or more parts are linked and supported by sition, the propeller shaft includes the universal joint and
wheel base. The propeller shaft having two or more parts the slip joint.
includes a center bearing at the center portion supported
by the frame. Moving Direction of the Universal Joint
Horizontal Movement
Moving Direction of the Slip Joint
Vertical Movement
Movement along
with the axis
EMTPA5005A
EMTPA5004A
GENERAL PA -11
ADJUSTMENT E26E49E2
UNIVERSAL JOINT AND BOOT
1. Set the transmission to the neutral position or the N.
2. Lift up the vehicle.
3. Check that the center bearing moves excessively or

makes an abnormal noise. If there is any problem,
replace the propeller shaft.
KMTPA101A
3. If the run-out of the propeller shaft excesses the spec-

ifications, replace the propeller shaft.
A
KMTPA5003A
4. Check that the universal joint boot is torn or shocked.

If there is any problem, replace the propeller shaft.
5. Check that the universal joint moves excessively or

makes an abnormal noise. If there is any problem,
replace the propeller shaft.
PROPELLER SHAFT RUN-OUT
1. Install a dial gauge at the body of the center portion

of the front propeller shaft.
2. With rotating the front shaft slowly, check the run-out.

And then, check the other side propeller shaft also.
Item Run-out Spec.(mm)

Front Propeller Shaft 0.4 or less
Center Propeller Shaft
0.4 or less
(Long wheel base)
Rear Propeller Shaft 0.4 or less
PROPELLER SHAFT
COMPONENTS EAC10FB7
540~608
(55~62, 398~448)
98~117 : P3 (10~12, 72.3~86.7)

59~69 : P2 59~69 : P2 (6~7, 43.3~50.6)
(6~7, 43.3~50.6)
98~117 : P3
(10~12, 72.3~86.7)
69~93
(7~9.5, 50.6~61.5)
1. Transmission
2. Front Axle
3. Rear Propeller Shaft Support
5. Rear Axle
Tightening Torque : Nm (kgf.m, Ib-ft)
EMTPA5006A
PROPELLER SHAFT PA -13
REMOVAL EEFAB8EE 3. Making an align mark (C) to the rear axle companion
flange (A) and the flange yoke (B) of the rear propeller
1. Making an align mark (C) to the flange yoke (A) of the shaft, remove the tightening bolt (D) of the propeller
front propeller shaft and the parking brake drum (B), shaft.
remove the tightening nut (D) of the propeller shaft.
B
A
B A
D C
D
KMTPA113A
KMTPA111A
INSPECTION EE607F95
2. Remove the tightening bolt (A) of the center bearing
bracket.
1. After checking the clearance between the spider and
the needle roller bearing, if it excesses the specifica-
NOTE tions, replace the spider kit.
For the short wheel base, the center bearing is one,
while for the long wheel base, the center bearings are Clearance between the Spider and the Needle
two. Roller: 0.01~0.06mm
Needle Roller
Bearing
Spider Dial Gauge
EMTPA5007A
A
KMTPA112A
2. Measuring the bending at the 50mm around the weld-

ing center portion of the propeller shaft, if it excesses
the specification, replace the propeller shaft.
Limit value : 0.4mm or less
[ Measure at center portion ]
EMTPA5008A
FRONT PROPELLER SHAFT
DISASSEMBLY EAA08AEC
10 6
Gap to the Axis Wear

Reference: 0.06 or less
Gap
Reference : 0.02~0.05 9 Deterioration or Deformation
Limit : 0.1
12
2 Rotating State 1
11 Rotating State
Crack or Damage 4
13
Disassembling Sequence
1 . Snap Ring 8. Hanger
2 . Needle Roller Bearing 9. Cushion
3. Flange Yoke 10. Oil Seal Kit
4. Universal Joint Spider (Housing and Oil Seal)
5. Self Locking Nut 11. Packing
6. Companion Package 12. Ball Bearing
7. Holder 13. Front Propeller Shaft
* For disassembly for the number, refer to the corresponding contents.
EMTPA5009A
1. Remove the snap ring INSPECTION E5821BD6
CAUTION 1. Check the clearance between the spider and the nee-
dle roller bearing.
• Replace the snap ring with new ones after re-
moval.
CAUTION
• When replace the spider or needle roller bear-
ing, replace them with the spider kit.
Needle Roller
Bearing
Screw Driver
Spider Dial Gauge
EMTPA5010A
2. Remove the needle roller bearing.

EMTPA5007A
Universal Tool Set
Yoke Assembly 2. Check the clearance of snap ring along to the axis
direction
Push Rod 1. Measure the clearance
2. Adjust the clearance
CAUTION
Guide
• Replace the snap ring with new ones after re-
moval.
• Use the snap rings having the same thickness
Guide
at the both sides.
EMTPA5011A
3. Remove the ball bearing
Gear Puller
KMTAX5009A
EMTPA5012A
Snap Ring
Thickness Color Code

1.5 No Color
1.55 Yellow
1.6 Blue
1.66 Cyan
Adjust with Snap Ring
Insert the snap ring
EMTPA5013A
3. Measure the bending at the bent center portion of the

propeller shaft.
EMTPA5008A
REASSEMBLY E7F77928
20~29
(2~3, 14~22)
6 5
Apply an adhesive to the upper split 7
Align the arrows of housing
P2 : 201~250
(20.5~25.5, 148~184)
P3 : 294~392
(30~40, 217~289)
2 12
11
1
* 10
3
Apply grease to the center bearing
13
Fill with the wheel bearing grease

4 25~30g
54~64 (5.5~6.5, 40~47)
Reassembly Sequence
4 2
13 3 1 6 5 7
12 11 10 9 8
For assembly for the number, refer to the corresponding contents.
[Caution] 1. Fill the grease enough between the bearing inner side
The center bearing should be check at every 50,000km and the outer race.
running. If the grease is leaked out, fill the grease. 2. Fill the grease between the main of the oil seal and the
When assembling the center bearing, align the aligning dust rip.
mark (arrow) and then fill the center bearing grease with 3. Fill the grease into the cylindrical container of the housing.
specification amount. 4. The total amount of the grease is 25~30g.
EMTPA5014A
1. Insert the needle roller bearing by pressing-in.

Housing Installer Housing
Universal Joint Tool Set Installer A
Align Arrow
Yoke Assembly of Housing
Push Rod
Housing
Installer B
Guide
Bolt Gap
Guide
EMTPA5015A
Front Side
2. Install the snap ring.
EMTPA5017A
Axis 4. Using a thickness gauge, measure the gap between

the snap ring and the groove of the snap ring.
Reference : 0~0.15mm
A Limit : 0.3mm or less
CAUTION
• If the gap excesses the limit value, replace the
snap ring.
EMTPA5016A
3. Assemble the center bearing. A C

Setting the arrow mark to upward, insert the center
bearing into cushion, and apply adhesion into the gap.
Install the housing tightening bolt with setting it’s head
to upward.
EMTPA5030A
5. Apply the grease enough to the grease nipple of the

universal joint.
Recommended Grease: SELL ALVANIA EP #2

REAR PROPELLER SHAFT
DISASSEMBLY E4C8BBCA
Clearance along to the axis

Reference : 0.06mm or less
Unit: mm 5
Clearance 6
7
Reference: 0.02~0.05 8
Limit: 0.1 Rotating
State 1 Bending Value
2
Crack, 3 Item Normal Value Limit
Damage 4 At Center
0.1 0.4
At Slip joint
Plug
Clearance of Spline Value
Item Normal Value Limit

Rotational Direction
Diameter Direction
Disassembly Sequence For disassembly for the ¡ number, refer to the corresponding contents.
1. Snap Ring
2. Needle Roller Bearing Service Kit
3. Front Yoke Spider Kit
4. Universal Joint Spider
5. Packing Retainer
6. Shield Packing
8. Sleeve Yoke
Unit: mm
EMTPA5018A
1. Remove the snap ring.
CAUTION
• Do not reuse the snap ring. Needle Roller
Bearing
Spider Dial Gauge
EMTPA5007A
Screw Driver
2. Check the clearance of snap ring along to the axis.
1. Measure the clearance.
2. Adjust the clearance.
EMTPA5010A
CAUTION
2. Remove the needle roller bearing. • Replace the snap ring with new ones after re-
moval.
Universal Tool Set • Use the snap rings having the same thickness
Yoke Assembly at the both sides.
Push Rod
Guide
Guide
EMTPA5011A
INSPECTION E8CBD7AF
KMTAX5009A
1. Check the clearance between the spider needle roller Snap Ring
bearings.
Thickness Color Code
CAUTION 1.5 No Color
• When replace the spider or needle roller bear- 1.55 Yellow
ing, replace them with the spider kit.
1.6 Blue
1.65 Cyan
4. Check the clearance of spline

Adjust with Snap Ring
[ Measure at rotational direction ]
Insert the snap ring
Clearance
EMTPA5013A
3. Check the bending of the propeller shaft.
EMTPA5020A
[ Measure at diameter direction ]
EMTPA5008A
EMTPA5021A
[ Measure at slip joint ]
EMTPA5019A
REASSEMBLY EA07E7DA
5 54~64 (5.5~6.5, 40~47)

6
7
8
1
2
3
4
Snap Ring For assembly for the number, refer to the corresponding contents.
2. Needle Roller Bearing
3. Flange Yoke
4. Universal Joint Spider Reassembly Sequence
5. Packing Retainer
6. Sheild Packing 4→
7. Rear Propeller Shaft 7→5→6→8→3→
8. Sleeve Yoke
EMTPA5022A
1. Insert the needle roller bearing by pressing-in.
Universal Tool Set B

A
Yoke Assembly
Push Rod
D C
Guide
Guide
EMTPA5011A
2. Install the snap ring.

KMTPA113A
2. Install the tightening bolt (A) of the center bearing

bracket.
Axis
Tightening Torque :
69~93 Nm (7~9.5 kgf.m, 50.6~68.7 lb-ft)
EMTPA5016A
INSTALLATION E39DE2B2
1. Setting the aligning mark (C) of the rear axle com-

panion flange (A) to that of the flange yoke (B) of the
rear propeller shaft, tighten the bolt (D) of the propeller
shaft.
A
Tightening Torque :
98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft) : P3
59~69 Nm (6~7 kgf.m, 43.3~50.6 lb-ft) : P2 KMTPA112A
NOTE
For narrow version, the center bearing is one, while
for the wide version, the center bearings are two.
3. Setting the aligning mark (C) of the flange yoke (A) of

the front propeller shaft to that of the parking brake
drum (B), tighten the bolt (D) of the propeller shaft.
Tightening Torque :
98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft)
B A
KMTPA111A
4. After filling up the recommended grease to the grease

nipple (A) until it leaks out from the oil seal, wipe out
the leaked grease completely.
Recommended Grease: ALVANIA EP #2
KMTPA114A
FRONT AXLE
WHEEL HUB
DISASSEMBLY EDDCCC3A
Wear, Rotation, Scratch
Wear, Corrosion
Wear
Check the Rotation State

Disassembly Sequence
1. Hub Cap 9. Outer Bearing Inner Race
2. Split Pin 10. Spacer
3. Lock Nut 11. Oil Seal
4. Washer 12. Inner Bearing Inner Race
5. Wheel Hub and Brake Drum 13. Inner Bearing Outer Race
6. Hub Bolt 14. Outer Bearing Outer Race
7. Front Brake Drum 15. Dust Cover
8. Front Wheel Hub 16. Front Brake Assembly
EMTPA5023A
FRONT AXLE PA -27
1. Place the wooden block (A) at the front and rear side 3. After removing the wheel nut (A), remove the wheel
of the rear wheel. and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (D) is not damaged.
A
A
C
KMTPA201A D
2. Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (C).
KMTPA203A
4. After removing the wheel cap(A), remove the split pin

(B) and the lock nut (C).
CAUTION
When removing the lock nut (C), be careful that
the washer and the outer bearing does not fall
down to the ground.
B
C
C
KMTPA202A B
A
KMTPA204A
5. Remove the washer (A), the outer bearing (B) and the 7. Tapping evenly the three notch parts on the other side
hub assembly (C) from the knuckle (D). hub inner surface with a brass bar, removing the outer
bearing race (A).
C
D
B
A
KMTPA205A
KMTPA207A
6. Tapping evenly the three notch parts on the hub inner
surface with a brass bar, removing the oil seal (A), the 8. After removing the hub nut (A), remove the drum (C)
inner bearing (B) and the inner bearing race (C). from the wheel hub (B).
NOTE
When using the brass bar, do not tap except the notch
A
parts (A) located inside of the hub.
B C
B
KMTPA208A
A
KMTPA206A
FRONT AXLE PA -29
[DISK BRAKE]
Wear, 6
Rotation,
Scratch
8
9
Wear, Corrosion
10
5
17
16 4
3
2
1
Wear 12
13
14
15 11

Disassembling Sequence
1. Hub Cap 10. Hub Bolt
2. Split Pin 11. Outer Bearing Inner Race
3. Lock Nut 12. Oil Seal
4. Washer 13. Inner Bearing Inner Race
5. Disk Brake Assembly 14. Inner Bearing Outer Race
6. Wheel Hub and Rotor 15. Outer Bearing Outer Race
7. Bolt 16. Adaptor
8. Rotor 17. Dust Cover
9. Front Wheel Hub
EMTPA5024A
1. Place the wooden block (A) at the front and rear sides 3. After removing the wheel nut (A), remove the wheel
of the rear wheel. and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire, be careful that
the hub bolt is not damaged.
A
A
C
KMTPA201A D
2. Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (C).
KMTPA203A
4. After removing the grease cap (A), remove the split

pin (B) and the lock nut (C).
B
C C
KMTPS5990A
KMTPA202A
5. Remove the washer (D), the outer bearing (E) and the
hub assembly (F) from the knuckle (G).
6. After taking off the disk tightening bolt, remove the

disk assembly from the wheel hub (B).
7. Remove the hub from the knuckle.

FRONT AXLE PA -31
INSPECTION E6636081
1. Check the cracks and wear on the hub.

B
2. Check the scratch and damage on the brake disk.
3. Check for the cracks.
4. Check the assembling state of the bearing.

A
REASSEMBLY E7AB2C7E
[DRUM BRAKE]
1. Installing the drum (C) at the wheel hub (B), tighten C

the hub nut (A).
Tightening Torque:
304~382 Nm (31~39 kgf·m, 224~282 lb-ft) KMTPA209A
3. Install the inner bearing (B) and the oil seal (C) at the
CAUTION wheel hub (A).
After tightening the hub nut (A), at least 4 portions

of the groove parts of the stud should be calked. CAUTION
• The bearing should be a set with the bearing
race.
• Use a new oil seal (C) always.
A
B C
C
KMTPA208A
2. By tapping evenly, install the inner bearing race (B)

and the outer bearing race (C) at the wheel hub (A). KMTPA210A
4. Fill the recommended grease in the wheel hub (A)

with specified amount.
Recommended Grease:
RETINAX 0434 of Hankook Shell Co., Ltd.
KO-GW02 of Cheonmi Mineral Oil Co., Ltd b
a
5. Install the washer (A), the outer bearing (B) and the
hub assembly (C) at the knuckle (D).
CAUTION
• The bearing should be a set with the bearing B
race.
A
KMTPA211A
7. Just before the wheel hub (A) is moving, measure the

C
D tangential force using a spring gauge (B). Calculate
the moving torque by multiplying the tangential force
to the radius.
B
Moving Torque:
A 0.98~3.4 Nm (0.10~0.35 kgf·m, 0.72~2.51 lb-ft)
KMTPA205A
6. Install the lock nut (A).

A
1) With rotating the hub assembly (B), tighten
the lock nut (A) fully with the force of 98~117
Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,
loosen the nut fully.
2) Again with rotating the hub assembly (B), tighten

the lock nut (A) with the force of 5~9 Nm (6
kgf·m, 43.3 lb-ft) and then loosen the nut at
45 (1/8 turns). KMTPA212A
FRONT AXLE PA -33
8. After installing the split pin (B), install the wheel cap 10. After removing the garage jack (B) supporting the axle
(A). and the safety stand (C) supporting the frame, tighten
the wheel nut (A) with the specified torque.
Tightening Torque :
539~588 Nm (55~60 kgf·m, 397.8~433.9 lb-ft)
B
A
KMTPA213A
B
C
9. After installing the wheel and tire (B) to the hub (C),
tighten the wheel nut (A).
KMTPA202A
11. Remove the wooden block (A) from the front and rear
sides of the rear wheel.
C
D
KMTPA203A A
KMTPA201A
[DISK BRAKE] 5. Fill the recommended grease in the wheel hub (A)
1. Installing the disk assembly (A) to the wheel hub (B),
tighten the disk tightening bolt (C). Recommended Grease:
Tightening Torque: RETINAX 0419 of Hankook Shell Co., Ltd.
57~60 Nm (5.8~6.1 kgf·m, 42~44 lb-ft) KO-GW02 of Cheonmi Mineral Oil Co., Ltd
A B 6. Install the washer, the outer bearing and the hub as-
sembly at the knuckle.
C
CAUTION
race.

1. With rotating the hub assembly (B), tighten
the lock nut (A) fully with the force of 98~117
Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,
KISE220E
loosen the nut fully.
2. Tighten the hub nut to the hub assembly. 2. Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 59 Nm (6 kgf·m,
3.31 lb-ft) and then loosen the nut at 45 (1/8
CAUTION turns).
After tightening the hub nut, at least 4 portions of
the groove parts of the stud should be calked.
3. By tapping evenly, install the inner bearing race (C)

and the outer bearing race (E) at the wheel hub (D).
4. Install the inner bearing (B) and the oil seal (A) at the
wheel hub (D).
CAUTION
race.
• Replace the oil seal(C) with new one after re-
B
moval.
A
E
KMTPA5002A
A
KISE210E
FRONT AXLE PA -35
8. Just before the wheel hub (A) is moving, measure the 10. After installing the wheel and tire (B) to the hub (C),
tangential force using a spring gauge (B). Calculate tighten the wheel nut (A).
the moving torque by multiplying the tangential force
to the radius.
Starting Torque :
0.98~3.4 Nm (0.10~0.35 kgf·m, 0.72~2.5 lb-ft) B
B
A
KMTPA5508A
A
11. After removing the garage jack (B) supporting the axle
and the safety stand (C) supporting the frame, tighten
the wheel nut (A) with the specified torque.
Tightening Torque :
539~588 Nm (55~60 kgf·m, 397.8~433.9 lb-ft)
KMTPA212A
9. After installing the split pin (A), install the wheel cap.
B
C
KMTPS5991A KMTPA202A
sides of the rear wheel.
KMTPA201A
FRONT AXLE PA -37
AXLE AND KNUCKLE
COMPONENTS EF86AEA2
196~294
(20~30, 145~217) 11
147~186 (15~19, 108~137)

7
9
3 69~118
(7.0~12, 51~87)
1 2 10
1. Hub Cap 7. Thrust Bearing

2. Front Wheel Hub 8. Drag Link
3. Knuckle 9. Knuckle Arm
4. Dust Cap 10. Tie Rod
5. Kingpin Shim 11. Front Axle
6. Kingpin
EMTPA5025A
DISASSEMBLY E3DCBCD2 4. After taking off the split pin (A) of the tie rod tightening
bolt and the lock nut (B), remove the tie rod (C).
[DRUM TYPE]
1. Remove the wheel hub. (Refer to the “ Wheel Hub

Disassembly” )
2. After taking off the tightening bolt (A) for brake assem-
bly, remove the brake assembly (B) from the knuckle
(C).
NOTE
Tie the brake assembly (B) around the relating parts
A
with a wire.
B
C B
KMTPA303A
5. After taking off the lock pin nut (A) and the washer (B),
A remove the lock pin (C).
B
KMTPA301A
3. After taking off the split pin (A) of the drag link tight-
ening bolt and lock nut (B), remove the drag link (C).
KMTPA304A
B
A
KMTPA302A
FRONT AXLE PA -39
6. After taking off the dust cap (A), remove the king pin [DISK TYPE]
(B).
1. Remove the wheel hub. (Refer to the “ Wheel Hub
Disassembly” )
2. After holding the brake hose with a vise pliers, loosen

A the brake hose tightening bolt (A). Remove the brake
hose.
KMTPA305A
KMTBR5536A
7. Remove the king pin shim (A) and the dust seal (B).
3. After taking off the tightening bolt(A) of the brake
caliper, remove the caliper(B).
A
A
B
KMTPA306A
KMTBR5538A
4. After taking off the tightening bolt of the dust cover,

remove the dust cover from the knuckle.
5. After taking off the split pin (A) of the drag link tighten- 7. After taking off the lock pin nut (A) and the washer (B),
ing bolt and the lock nut (B), remove the drag link (C). remove the lock pin (C).
B
A
A
KMTPA302A KMTPA304A
6. After taking off the split pin (A) of the tie rod tightening 8. After removing the dust cap (A), remove the king pin
bolt and the lock nut (B), remove the tie rod (C). (B).
A
B
KMTPA303A KMTPA305A
FRONT AXLE PA -41
9. Remove the king pin bushing (A) and the dust seal 2. Install the king pin (B) and then, install the dust cap
(B). (A).
CAUTION
The groove portion of the king pin (B) should face
to inside.
A
B
B
KMTPA306A
REASSEMBLY EF5CE09A
[DRUM TYPE] KMTPA305A
1. Install the king pin bushing (A) and the dust seal (B). 3. After installing the lock pin (C), install the lock pin
washer (B) and nut (A).
Tightening Torque :
28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)
A
B
B
KMTPA306A
KMTPA304A
4. After installing the tie rod (C), install the lock nut (B) 6. After install the brake assembly (B) to the knuckle (C),
and split pin (A). install the tightening bolt (A) for the brake assembly.
Tightening Torque : Tightening Torque :

69~118 Nm (7~12 kgf·m, 51~87 lb-ft) 98~137 Nm (10~14 kgf·m, 72~101 lb-ft)
C B
A A
KMTPA303A KMTPA301A
5. After installing the drag link (C), install the lock nut (B) 7. Install the wheel hub. (Refer to the “ Wheel Hub As-
and split pin (A). sembly” )
Tightening Torque : [DISK TYPE]

147~186 Nm (15~19 kgf·m, 108~137 lb-ft)
1. Install the king pin bushing (A) and the dust seal (B).
B
A
KMTPA302A KMTPA306A
FRONT AXLE PA -43
2. Install the king pin (B) and then, install the dust cap 4. After installing the tie rod (C), install the lock nut (B)
(A). and split pin (A).
CAUTION Tightening Torque :

69~118 Nm (7~12 kgf·m, 51~87 lb-ft)
The groove portion of the king pin (B) should face
to inside.
A
B
KMTPA303A
KMTPA305A
5. After installing the drag link (C), install the lock nut (B)
3. After installing the lock pin (C), install the lock pin
and split pin (A).
washer (B) and nut (A).
Tightening Torque :
Tightening Torque :
147~186 Nm (15~19 kgf·m, 108~137 lb-ft)
28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)
B
A
A
KMTPA304A KMTPA302A
6. After install the brake caliper (B), install the caliper

tightening bolt (A).
Tightening Torque :
98~127 Nm (10~13 kgf·m, 72~94 lb-ft)
KMTBR5538A
7. After installing the dust cover (B) to the knuckle (C),

install the tightening bolt (A) of the dust cover.
Tightening Torque :
98~137 Nm (10~14 kgf·m, 72~101 lb-ft)
8. After installing the brake assembly (B) to the knuckle

(C), install the tightening bolt (A) of the brake assem-
bly.
Tightening Torque :
125~139 Nm (12.7~14.2 kgf·m, 92~103 lb-ft)
9. Install the wheel hub. (Refer to the “ Wheel Hub As-

sembly” )
FRONT AXLE PA -45
WHEEL ALIGNMENT 4. Moving the vehicle to forward so that the marking

point moves backward. Setting the marking point to
the height of the toe-in gauge (i.e. turn 180 ), at the
DESCRIPTION E01B14C7
rear side, measure the distance (B) between the two
wheels.
When wheel alignment and steering angle are measured,
check that the vehicle has no load or every parts of the
front axle are properly assembled. B
CAUTION
Before the adjustment, check again followings.
1. The front wheel is loosened.
2. The knuckle is loosened.
3. The linkage between the knuckle flange and
knuckle arm is loosened.
4. The bolts, the screws or the nuts are loos-
ened.
5. The leaf spring is damaged or weakened.
6. The tire air pressure is too high or low.
7. The adjusted backlash of the steering gear is
KMTAX5020A
proper.
5. The difference between the measured value of rear
INSPECTION E811CE0D
side (B) and the measured value of front side (A) is
the toe-in value.
TOE-IN
Specified Value (B-A): 0~6mm
1. Set the front wheel along with the straight direction.
2. Make a mark at the front end of the front wheel. (The A

marking point is the middle position of the width and
height of the wheel)
α β
3. Setting the needle height of the toe-in gauge to the
marking point of the left and right tire, measure the Forward
toe-in value. Measure the distance (A) between the
two wheels.
B
KHHA850A
A
KMTAX5019A
6. If the measured toe-in value excesses the specified 3. Wipe out the grease at the end of the spindle. Install
value, adjust it by loosening the clamp bolts (B) of the the self centering plunger of the camber, the caster
left and right tie rods (A) and turning the tie rod (A) and the king pin gauge (A) to the wheel hub by setting
with a pipe wrench (C). them to the center hole of the spindle.
Tightening Torque of the Clamp Bolt (B):

20~29 Nm (2~3 kgf·m, 14~22 lb-ft)
Tie Rod End

2.0~3.0 kgf.m
B
A
C
EMTPA5026A
CAMBER KMTPA362A
1. Set the front wheel along with the straight direction. 4. Set the gauge (A) in horizontal plane. To do that, set
the bubble (in longitudinal direction) of the level gauge
2. Remove the wheel hub cap (A). to the zero point.
5. Measure the camber value(B) of the gauge (A). The

center line of the bubble is the camber value.
Specified Value : 1 ±30′
KMTPA361A
KMTPA363A
6. By the same method, measure the camber value of

the opposite wheel.
FRONT AXLE PA -47
KINGPIN INCLINATION ANGLE AND CASTER 4. Turn the tire to be measured to the outward until the
scale of the turn table is positioned 20 (A).
1. To maintain the vehicle in horizontal position, place a
plate (B) having the same height with the turn table
(A) under the rear tire (C).
A
B
C
A
KMTPA363A
5. Remove the wheel hub cap (A).

KMTPA371A
2. Positioning the two front tires of the vehicle to the cen-

ter of the turn table, pull (set up) the parking brake.
CAUTION
If it is hard to move the vehicle, lift up the vehicle
with a jack and place the turn table and the plate
under the front and rear tire.
3. Set the scales of the both turn table to zero point.
KMTPA373A
6. Wipe out the grease at the end of the spindle. Install

the self centering plunger of the camber, the caster
and the king pin gauge (A) to the wheel hub by setting
them to the center hole of the spindle.
7. Set the gauge (A) in horizontal plane. To do that, set

the bubble (in longitudinal direction) of the level gauge
to the zero point.
8. By turning the zero setting screws of the caster (A) STEERING ANGLE
under the gauge and the kingpin tilting angle, set the
bubble to 0. Before inspecting the steering angle, complete the inspec-
tion of the wheel alignment.
CAUTION
1. To maintain the vehicle in horizontal position, place a
For left side wheel, use the left scale as the king- plate (B) having the same height with the turn table
pin tilting angle scale. For right side wheel, use (A) under the rear tire (C).
the right scale as the kingpin tilting angle scale.
9. Turn the wheel 20 again so as to set the scale of the

turn table to 0 . Then the center line of the bubble
indicates the kingpin tilting angle value. Measure the
center line value of the bubble.
Specified Value : 8 ±10′
10. By turning the tire to inward, set the scale of the turn
table to 20 .
11. Set the gauge (A) in horizontal plane. To do that, set B

the bubble (in longitudinal direction) of the level gauge C
to the zero point.
12. From the caster scale, read the each pointing scale of A
the casters.
Specified Value: 1 ±30′

KMTPA371A
13. By the same method, measure the caster and the 2. Positioning the two front tires of the vehicle to the cen-
kingpin tilting angle values of the opposite wheel. ter of the turn table, pull (set up) the parking brake.
CAUTION
If it is hard to move the vehicle, lift up the vehicle
with a jack and place the turn table and the plate
under the front and rear tire.
3. Set the scales of the both turn table to 0 .
4. Turn the tire to inward. Measure the scale of the turn

table.
Specified Value( ) : 40.8~42.8
5. Turn the tire to outward. Measure the scale of the turn

table.
Specified Value( ) : 30.8~32.8

FRONT AXLE PA -49
6. If the measured value excesses the specified value, SIDE SLIP

tighten or loosen the knuckle stopper bolt (A) at both
sides (LH/RH) to adjust the steering angle. Before checking the side slip, complete the inspection of
the wheel alignment.
1. Set the front wheel along with the straight direction.

A
2. Maintaining the position of the front wheel to the
straight direction, drive the vehicle on the slip tester
slowly.
CAUTION
With maintaining the position of the front wheel to
the straight direction, pass through the side slip
tester thoroughly. Do not turn the wheel or do not
fall off from the tester.
3. The value indicated on the tester is the side slip. If

the side slip excesses the specified value, the wheel
alignment should be adjusted.
Specified Value: 3mm/(when going straight per 1m)
KMTPA382A
7. After adjusting the steering angle, tighten the nut (A)

of the stopper bolt with specified torque.
Tightening Torque :
39.2~53.9 Nm (4.0~5.5 Kgf·m, 28.9~39.8 lb-ft)
KMTPA383A
REAR AXLE
WHEEL HUB
COMPONENTS EE06A970
19
18
9
8
304~082 14 7
(31~39, 224~282) 4
10
3
11 98~117
13 (10~12, 72~87)
2
6
15 7~11 (0.7~1.1, 5~8)
17
16
12
1. Brake Pipe 11. Inner Oil Seal

2. Bolt 12. Wheel Hub Outer Bearing Outer Race
3. Rear Axle Shaft 13. Wheel Hub Inner Bearing Outer Race
4. Outer Oil Seal 14. Nut
5. Rear Brake Assembly 15. Hub Bolt
6. Bolt 16. Rear Wheel Hub
7. Lock Plate 17. Rear Brake Drum
8. Lock Nut 18. Wheel Hub Inner Bearing Inner Race
9. Wheel Hub Outer Bearing Inner Race 19. Nut
10. Wheel Hub and Drum Assembly
[Caution]
Be careful that the brake lining and the brake drum inner surface are not contaminated by the oil or grease.
EMTPA5027A
REAR AXLE PA -51
REMOVAL EC5EFA3E 3. After taking off the wheel nut (A), remove the wheel
and tire (B) from the hub (C).
1. Place the wooden block (A) at the front and rear sides
of the front wheel. CAUTION
C
A
A
KMTPA401A B
2. Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand (B). KMTPA403A
4. After taking off the hub bolt (A), remove the axle shaft
(B).
NOTE
When it is hard to remove the axle shaft (B), insert hub
bolts (A) into the removing screw holes (C) evenly.
B
B
KMTPA402A
B
C
A
KMTPA404A
5. Remove the oil seal (A). 7. Using the special tool (09527-47000), remove the lock
nut (A).
KMTPA405A
KMTPA407A
6. Loosening the tightening bolt (A) for the lock nut, re-
move the lock washer (B). 8. Remove the rear wheel hub (B) with the outer bearing
(C) from the axle housing (A).
CAUTION
Be careful that the outer hub bearing (C) do not
drop down to the ground.
A
B
A
B C
KMTPA406A
KMTPA408A
REAR AXLE PA -53
DISASSEMBLY E2B6EA98 2. Tapping evenly the three notch parts on the other side
hub inner surface with a brass bar, removing the outer
1. Tapping evenly the three notch parts on the hub inner bearing race (A).
surface with a brass bar, removing the oil seal (A), the
inner bearing (B) and the inner bearing race (C).
C
A
B
KMTPA410A
KMTPA409A 3. After taking off the hub nut (A), remove the drum (C)
from the wheel hub (B).
NOTE
When using a brass bar, do not tap except the notch
parts (A) located inside of the hub.
A
C
B
KMTPA411A
KMTPA420A
INSPECTION E62B4648
1. Check that the rotation state is proper after installing A

the bearing (B) to the bearing race (C). If it has been
adhered, worn or defective in rotation, replace the
bearing and the bearing race (C) in a set.
C
B
C
KMTPA411A
B
2. By tapping evenly, install the inner bearing race (B)
A and the outer bearing race (C) at the wheel hub (A).
KMTPA409A
B
2. If the hub bolt is worn or corroded, remove the hub
bolt from the wheel hub and replace it.
REASSEMBLY E7DFFF55
1. Installing the drum (C) to the wheel hub (B), tighten A

the hub nut (A).
CAUTION
After tightening the hub nut (A), at least 4 portions C
of the groove parts of the stud should be calked.
Tightening Torque :
304~382 Nm (31~39 Kgf·m, 224~282 lb-ft)
KMTPA412A
REAR AXLE PA -55
3. Install the inner bearing (B) and the oil seal (C) at the
wheel hub (A).
CAUTION
A
race.
• Replace the oil seal (C) with new ones after B
removal.
KMTPA408A

a. With rotating the hub assembly (B), tighten the
B
lock nut (A) fully with the force of 98~127 Nm
(10~13 kgf·m, 72~94 lb-ft). After that, loosen the
C nut fully.
b. Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 29~39 Nm (3~4
kgf·m, 22~29 lb-ft).
KMTPA413A
4. Fill the recommended grease in the wheel hub (A)

Recommended Grease:
RETINAX 0419 of Hankook Shell Co., Ltd. b
KO-GW02 of Cheonmi Mineral Oil Co., Ltd
a
5. Install the rear wheel hub (B) and the outer bearing
(C) to the axle housing (A).
CAUTION
The bearing should be a set with the bearing race. B
KMTPA211A
7. Setting the lock washer (A) to the spindle groove (B) 9. Install the oil seal (A).
of the housing, tighten the lock nut tightening bolt (C).
CAUTION
Tightening Torque : 7~11 Nm (0.7~1.1 Kgf.m, 5~8 lb-ft)
Use a new oil seal (C) always.
B
A
KMTPA415A
KMTPA405A
8. Just before the wheel hub (A) is moving, measure the

tangential force using a spring gauge (B). Calculate 10. After installing the axle shaft (B), tighten the hub bolt
the starting torque by multiplying the tangential force (A) with specified torque.
to the radius.
Tightening Torque :
Starting Torque : 2~4 Nm (0.2~0.4 Kgf.m, 1~3 lb-ft) 98~117 Nm (10~12 Kgf.m, 72~87 lb-ft)
KMTPA212A KMTPA416A
REAR AXLE PA -57
11. After installing the wheel and tire (B) to the hub (C), 13. Remove the wooden block (A) from the front and rear
tighten the wheel nut (A). sides of the front wheel.
A
A
B
KMTPA403A KMTPA401A
12. After removing the garage jack (A) supporting the axle
and the safety stand (B) supporting the frame, tighten
the wheel nut with the specified torque.
Tightening Torque :
539~588 Nm (55~60 Kgf.m, 398~434 lb-ft)
B
B
KMTPA402A
AXLE HOUSING
COMPONENTS E0BCD7AB
59~78 (6~8, 43~58)
49~59 (5~6, 36~43)
59~78 (6~8, 43~58)
245~255 (25~26, 181~188)
59~69 (6~7, 43~51)
1. Drain Plug 5. Reduction and Differential Assembly

2. Oiling Plug 6. Nut
3. Nut 7. Rear Axle Housing
4. Bolt
EMTPA5028A
REAR AXLE PA -59
DISASSEMBLY EDEA5C63 3. After taking off the wheel nut (A), remove the wheel
and tire (B) from the hub (C).
1. Place the wooden block (A) at the front and rear sides
of the front wheel. CAUTION
C
A
A
KMTPA401A B
2. Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand (B). KMTPA403A
4. As the same method with the 2~3 steps, remove the

opposite side wheel and tire.
5. Support the both hub with a jack (A).
B
B
KMTPA402A
KMTPA501A
6. Making an align mark (C) to the rear axle companion 8. After taking off the tightening nut (A) of the shock ab-
flange (A) and the flange yoke (B) of the rear propeller sorber, remove the shock absorber (B).
shaft, remove the tightening bolt (D) of the propeller
shaft.
B
B
A
D C
KMTPA503A
KMTPA113A 9. After taking off the tightening nut (A) of the U-bolt,
remove the U-bolt (B).
7. After removing the brake line (A), remove the brake
hose clip (B).
NOTE B
• If the brake line is rubber hose, remove it after

biting it with vise pliers.
• If the brake line is steel pipe, remove the line with
pressing the brake pedal.
B
A
KMTPA504A
KMTPA502A
REAR AXLE PA -61
10. After getting down the jack (A) supporting the both 2. Setting the center bolt (A) of the leaf spring to the
hub, remove the axle housing (B). center hole (B) of the axle housing, lift up the axle
housing (C) completely.
A
B
KMTPA505A
KMTPA510A
REASSEMBLY E769B06E
3. After installing the U-bolt (B), tighten the U-bolt tight-
ening nut (A) with the specified torque.
1. After positioning the axle housing (B) at the rear side
of the vehicle, lift up the jack (A) supporting the both Tightening Torque :
hubs slowly. 226~255 Nm (23~26 kgf·m, 166~188 lb-ft)
B
B
KMTPA505A
KMTPA504A
4. After installing the shock absorber (A), tighten the

shock absorber tightening bolt (A) with the specified
torque. A
Tightening Torque :
26~33 Nm (2.7~3.4 kgf·m, 20~25 lb-ft)
B
KMTPA502A
6. Setting the align marks (C) of the rear axle companion

A flange (A) to the flange yoke (B) of the rear propeller
shaft, install the tightening bolt (D) of the propeller
shaft.
Tightening Torque : 59~69 Nm (6~7 kgf·m, 43~51 lb-ft)

KMTPA503A
5. After installing the brake hose clip (B), install the brake
line (A).
B
A
NOTE
• If the brake line is rubber hose, remove the vise
pliers after installing the line.
• If the brake line is steel pipe, release the brake
pedal after installing the line.
D C
Tightening Torque :
25~29 Nm (2.5~3.0 kgf·m, 18~22 lb-ft)
KMTPA113A
REAR AXLE PA -63
7. Remove the jack (A) supporting the both hub. 9. After removing the garage jack (A) supporting the axle
and the safety stand (B) supporting the frame, tighten
the wheel nut with the specified torque.
Tightening Torque :
539~588 Nm (55~60 kgf·m, 398~434 lb-ft)
A
B
B
KMTPA501A
A
8. Install the wheel and tire (B) to the hub (C). Tighten
the wheel nut (A).
KMTPA402A
sides of the front wheel.
D
A
B
KMTPA403A
KMTPA401A
11. Bleed the brake system. (Refer to the "Air Bleeding

of BR Group")
DIFFERENTIAL CARRIER
ASSEMBLY
COMPONENTS EE429FB6
32
25
29
30
33
36
69~78
26 35
(7~8, 51~58)
31 27 34
28 20~26.4 (2~2.7, 14~20)
24
16
23
21
20
15
14
19
13 18
5 11 12 17
3 4 10
2
9 22
8
7
1 6
373~471
(38~48, 275~347)
1. Self Locking Nut 13. A/B Shim 25. Differential Case RH

2. O-Ring 14. Bolt 26. Differential Case Bolt
3. Companion Flange 15. Spring Washer 27. Differential Gear
4. Dust Cover 16. Pin 28. Differential Gear Washer
5. Oil Seal 17. Bolt 29. Differential Pinion Washer
6. Pinion Bearing 18. Spring Washer 30. Differential Pinion
7. Pinion Bearing Collar 19. Differential Collar 31. Differential Spider
8. Pinion Inner Bearing 20. Adjust Screw 32. Side Bearing Cap
9. Bearing Retainer 21. Side Bearing 33. Lock Plate
10. Pinion Driver 22. Bolt 34. Bolt
11. Pinion Pilot Bearing (ONLY D033H) 23. Differential Case, LH 35. Spring Washer
12. Lock Ring (ONLY D033H) 24. Drive Gear 36. Bearing Cap Bolt
[Caution]
The bearing cap and the differential carrier should be replaced as a set.
EMTPA5029A
DIFFERENTIAL CARRIER ASSEMBLY PA -65
REMOVAL EAA2625E 4. Making an align mark (C) to the rear axle companion
flange (A) and the flange yoke (B) of the rear propeller
1. After removing the drain plug(A), drain out the gear shaft, remove the tightening bolt (D) of the propeller
oil. shaft.
B
A
D C
KMTPA610A KMTPA113A
2. After taking off the hub bolt (A), remove the axle shaft 5. Disassemble the contacting surface between the rear
(B). axle companion flange (A) and the flange yoke (B) of
the rear propeller shaft.
NOTE
When it is hard to remove the axle shaft (B), insert CAUTION
hub bolts (A) into the removing screw holes evenly. As this part is very heavy, be careful the precau-
tions. Before the working, be sure that it is sup-
ported by jack.
A
B
A
KMTPA611A
3. Remove the axle shaft at the opposite side also. KMTPA613A

6. After taking off the differential carrier tightening bolt 2. Setting the aligning mark (C) of the rear axle com-
and nut (A), remove the differential carrier assembly panion flange (A) to that of the flange yoke (B) of the
(B) from the axle housing (C). rear propeller shaft, tighten the bolt (D) of the propeller
shaft.

B
A
B
A
D C
KMTPA614A
INSTALLATION E71B62CA
KMTPA113A
1. After installing the differential carrier assembly (B) to

the axle housing (C), tighten the differential carrier 3. After installing the axle shaft (B), tighten the hub bolt
tightening bolt (A) with the specified torque. (A) with the specified torque.
Tightening Torque : Tightening Torque :

34.3~44.1 Nm (3.5~4.5 kgf·m, 25.3~32.5 lb-ft) 98~118 Nm (10~12 kgf·m, 72~87 lb-ft)
B
A
A
B
KMTPA611A
KMTPA614A
4. Install the rear axle shaft of the opposite side.

5. Fill in the recommended oil. 2. Remove the differential carrier bearing cap bolt (A).
Recommended Oil:
API GL-5, SAE 80W/90 A
API GL-5, SAE 140W / For tropical region
Oil Amount : 4.5±0.25ℓ
KMTPA702A
3. After removing the bearing cap(A), remove the side

bearing nut (B).
KMTPA661A
A
DISASSEMBLY EBFC9735
1. Fix the differential carrier (A) at the vise or the working

base. B
KMTPA703A
4. Remove the differential carrier assembly (A) and the

side bearing race (B) from the differential carrier collar
(C).
A
KMTPA701A
KMTPA704A
5. After removing the side bearing (A), remove the dif- 9. Remove the pinion drive (A), the inner bearing (B), the
ferential case bolts (B). space (C) and the shim (D).
B
D
C
B
KMTPA705A KMTPA709A
6. After removing the differential case, remove the differ- 10. Remove the oil seal (A) and the outer bearing (B).
ential pinion, the differential pinion washer, the differ-
ential gear, the differential gear washer and the differ-
ential spider, sequentially.
7. After taking off the tightening bolt of the drive gear,

disassemble the differential case and the driver gear.
8. Remove the self locking nut (A) and the companion

flange (B). B
KMTPA710A
11. Remove the bearing race (A), the oil stopper (B) and
the outer bearing race (C) from the differential collar.
B
B
A
A
KMTPA708A
KMTPA711A
REASSEMBLY EBDDE802 4. Install the companion flange and the self locking nut
(A).
1. Install the outer bearing race (C), the oil stopper (B)
and the bearing race (A) into the differential collar. Tightening Torque : 373~471 Nm (38~48
kgf·m, 275~347 lb-ft)
B
KMTPA711A A
KMTPA708A
2. Install the outer bearing (B) and a new oil seal (A).
5. After assembling the differential case and the drive
gear, install the drive gear tightening bolt.
Tightening Torque : 226~265 Nm (23~27

kgf·m, 166~195 lb-ft)
6. After installing the differential pinion, the differential

B pinion washer, the differential gear, the differential
gear washer and the differential spider, install the dif-
A
ferential case.
7. After installing the differential case bolt (A), install the

side bearing.
KMTPA710A A
3. Install the shim (D), the space (C), the inner bearing B
(B) and the pinion drive (A).
D
C
B
KMTPA705A
KMTPA709A
8. Install the differential carrier assembly (A) and the

side bearing race (B) at the differential carrier collar
(C).
KMTPA704A
9. After installing the side bearing nuts (B), install the

bearing cap (A).
KMTPA703A

Propeller Shaft and Axle

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Propeller Shaft and Axle

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GENERAL AXLE AND KNUCKLE

Caster 2 30′ ±30′ ← ←

King Pin Tilting Angle 8 ±10′ ← ←

Reference Remedy and

Item Reference Value Limit Value Remedy and Remark

Install Position Tightening Torque

Install Position Tightening Torque

Symptom Causes Remedy

Symptom Causes Remedy

Moving force is not transmitted properly.

Oil leakage at differential carrier and

Oil leakage at companion flange

Noise at start or changing shift bar.

During running, irregular noise

During curving, noise is made.

During running, noise is made

During running, tire is drawn.

vehicle does not move

The rear axle shaft is broken.

The rear axle shaft is slept out.

The oil seal is defective.

The air breather is cracked, damaged or clogged.

The wheel hub bearing is adhered.

The wheel hub bearing is worn out.

The wheel hub bearing is defective in rotation.

The wheel hub bearing is damaged.

The gear oil is too much.

The sealant is improper.

The side bearing is adhered.

The side bearing is worn out.

The side bearing is defective in rotation.

The side bearing is damaged.

The operating torque of the side bearing is too high.

The operating torque of the side bearing is too low.

Trouble Moving force is not transmitted properly.

Oil leakage at companion flange

Oil leakage at differential carrier

During curving, noise is made.

During running, irregular noise

During running, tire is drawn.

Reduction The differential carrier is cracked or damaged.

1. Front Propeller Shaft

UNIVERSAL JOINT AND BOOT

1. Set the transmission to the neutral position or the N.

2. Lift up the vehicle.

3. Check that the center bearing moves excessively or

3. If the run-out of the propeller shaft excesses the spec-

4. Check that the universal joint boot is torn or shocked.

5. Check that the universal joint moves excessively or

PROPELLER SHAFT RUN-OUT

1. Install a dial gauge at the body of the center portion

2. With rotating the front shaft slowly, check the run-out.

Item Run-out Spec.(mm)

98~117 : P3 (10~12, 72.3~86.7)

Tightening Torque : Nm (kgf.m, Ib-ft)

Spider Dial Gauge

2. Measuring the bending at the 50mm around the weld-

Limit value : 0.4mm or less

[ Measure at center portion ]

FRONT PROPELLER SHAFT

Gap to the Axis Wear

* For disassembly for the number, refer to the corresponding contents.

1. Remove the snap ring INSPECTION E5821BD6

2. Remove the needle roller bearing.