Modul lengkap

PR-1
PROPELLERSHAFT
(for4WDl
PRECAUTIONS
TROUBLESHOOTING
PROPELLERSHAFT
Page
PR.2
PR-2
PR.2
ril:t'
ry*';'"'"s, 'f,'
$gu

PR-z PROPELLERSHAFT - Precautions,Troubleshooting,PropellerShaft
PRECAUTIONS
1. As the universalioint is a non-disassemblytype' the
propeller shaft or intermediate shaft must be replaced
as an assemblyin the event of universalioint trouble.
2. Be careful not to grip the propellershaft tube too tight-
ly in the vise as this will causedeformation.
TROUBLESHOOTING
Problem Possiblecause Remedy Page
Noise Sleeveyokesplineworn
Centerbearingworn
Spiderbearingworn or stuck
Replaceintermediateshaft
Replacecenterbearing
Replaceintermediateshaft or
propellershaft
PR-3
PR-3
PR-3
Vibration Propellershaft runout
Propellershaftunbalance
Transmissionextensionhousingrear
bushingworn
Sleeveyokesplinestuck
CenterbearingheightimProPer
Replacepropellershaft
Balancepropellershaft
Replacebushing
Replaceintermediateshaft
Adjustbearingheight
PR-3
PR-3
TA.4O
PR-3
PROPELLERSHAFT
COMPONENTS
lntermediate Shaft
----
9-Height Washer [ 430(3il42t
a ProPellershaft
w- --@
I
I
I
Ffiffiiib-ntnl : Tighteningtorque
O : Non-reasable part
CenterSuPPortBering- -

PROPELLERSHAFT- PropellerShaft PR.3
REMOVALAND DISASSEMBLYOF
PROPELLERSHAFT
(SeepagePR-21
1. DISCONNECTPROPELLERSHAFTFLANGEFROM
COMPANIONFLANGEON DIFFERENTIAL
(a) Placematchmarkson the flanges.
(b) Removethe four bolts and nuts.
2. REMOVETWO BOLTSHOLDINGCENTERSUPPORT
BEARINGTO BODY
3. REMOVEPROPELLERSHAFT WITH INTERMEDIATE
SHAFT
h) Pullout the yokefrom the transmission.
(b) InsertSSTin the transmissionto preventoil leakage.
ssT 09325-120rO
4. SEPARATEPROPELLERSHAFTAND INTERMEDIATE
SHAFT
(a) Placematchmarkson the flanges.
(b) Removethe four bolts and nuts.
5. REMOVECENTERSUPPORTBEARINGFROM
INTERMEDIATESHAFT
(a) Usinga hammerandchisel,loosenthestakedpartof
the nut.
(b) UsingSSTto holdthe flange,removethe nut.
ssT 09330-00020

PR-4 PROPELLERSHAFT- PropellerShaft
(c) Placematchmarkson the flangeandshaft.
(d) Clampthe flangeyokein a viseandtapoff the shaft.
(e) Removethe centersupportbearing.
INSPECTIONOF PROPELLERSHAFT
COMPONENTS
1. INSPECTPROPELLERAND INTERMEDIATESHAFTS
FORDAMAGEORRUNOUT
Maximumrunout: 0.8 mm (0.031in.l
lf shaft runoutis exceedsmaximum,replacethe shaft.
2. INSPECTSPIDERBEARINGS
(a) Inspectthe spiderbearingsfor wearor damage.
(b) Checkthe spiderbearingaxialplay by turningthe
yokewhileholdingthe shafttightly.
Bearingaxial play: O mm (0 in.l
lf necessary,replacethe intermediateshaft orland pro-
pellershaft.
3. INSPECTCENTERSUPPORTBEARINGFORWEAROR
DAMAGE
Checkthat the bearingturns freely.
lf the bearingis damaged,worn, or does not turn freely,
replaceit.

PROPELLERSHAFT- PropellerShaft PR.5
ASSEMBLYAND INSTALLATIONOF
PROPELLERSHAFT
(Seepage PR-21
NOTE: When replacing parts, install them facing as
shown in the illustration.
f l
rthffihP
tuldi€?ih
1. INSTALLCENTERSUPPORTBEARINGON
INTERMEDIATESHAFT
lnstallthe centersupportbearingwith the cutout on the
rearside.
2. INSTALLFTANGEYOKEON INTERMEDIATESHAFT
ta) Apply MP greaseto the splinesof the intermediate
shaft.
(b) Align the matchmarkson the yoke and shaft and
installthem.
(c) UsingSST to hold the flange,tightendown a
nut to pressthe bearinginto position.
ssT09330-ooo20
Torque: 1,850 kg-cm (134 ft-lb, 181 N.ml
(d) Loosenthe nut.
(e) Torquethe nut again.
Torque: 300 kg-cm (22 ft-b,29 N.ml
(f) Usinga hammerand punch,stakethe nut.

PR-6 PROPELLERSHAFT - PropeilerShaft
SST
3. ASSEMBTEPROPELLERSHAFTAND
INTERMEDIATESHAFT
(a) Align the matchmarkson the flangesand connect
them with the four bolts and nuts.
Torque: 430 kg-cm (31 ft-|b,42 N.ml
4, INSERTSLEEVEYOKEIN TRANSMISSION
{a) Apply MP greaseto the outsadediameterandsplines
of the yoke.
(b) RemoveSST.
ssT09325-12010
(c) Pushthe yoke into the transmission.
5. CONNECTPROPELLERSHAFT FLANGETO
COMPANIONFLANGEON DIFFERENTIAL
(a) Alignthe matchmarkson theflangesandconnectthe
them with the four bolts and nuts.
(b) Torguethe nuts.
Torque: 43Okg-cm (31 ft-tb,42 N.m)
6. CONNECTCENTERSUPPORTBEARINGTO BODY
ta) Placethe height washer betweenthe body and
centersupport bearing,and installthe two mount
boltsfingertight.
NOTE: Somevehiclesdo not havea heightwasher..
In this case,it is not necessaryto insertone.
(b) Checkthat the bearingbracketis at right anglesto
the propellershaft Adjust the bracketif necessary.
(c) Checkthat the centerlineof the centerbearingis set
to the centerlineof the bracketwhenthe vehicleis in
a no-loadcondition.
Adjust the bracketif necessary.
(d) Torquethe mountbolts.
Torque: 375 kg-cm Q7 tt-ab,37N.m)
Front1-
Centerof Center
Bearing

FA.1
FRONTAXLEAND
SUSPENSION
TROUBLESHOOTING
FRONTWHEELALIGNMENT
AXLE HUB
FRONTDRIVESHAFT
FRONTSHOCKABSORBER
FRONTSUSPENSION
Ball Joints
Lower Arm
Stabilizer Bar
Page
FA-2
FA.3
FA.23
FA-24
FA-7
FA.13
F4.19
FA-23
F4.27

FA.2 FRONTAXLE AND SUSPENSION- Troubleshooting
TROUBLESHOOTING
Problem Possiblecauss Remedy Page
Wanders/pulls Tiresworn or improperlyinflated
Alignmentincorrect
Wheel bearingworn
Front or rearsuspensionparts looseor
broken
Steeringlinkageloosenor worn
Steeringgear out of adjustmentor broken
Replacetire or inflatetiresto
properpressure
Checkfront end alignment
Replacewheelbearing
Tightenor replacesuspension
part
Tightenor replacesteering
linkage
Adjust or repairsteeringgear
FA-3
FA-3
FA.8
sR-9
Bottoming Vehicleoverloaded
Shock absorberworn out
Springsweak
Checkloading
Replaceshockabsorber
Replacespring
FA.19
FA.l9
Sways/pitches Tires improperlyinflated
Stabilizerbar bentor broken
lnflate tires to proper pressure
Replacestabilizerbar
FA-3
FA-27
FA-19
Frontwheelshimmy Tires worn or improperlyinflated
Wheelout of balance
Shockabsorberworn out
Alignmentincorrect
Wheel bearingworn
Balljointsor bushingworn
Steeringlinkageloosenor worn
Steeringgear out of adjustmentor broken
Replacetire or inflatetires
to properpressure
Balancewheel
Checkfront end alignment
Replacewheelbearing
Inspectballjoint and bushing
Tightenor replacesteering
linkage
Adjustor repairsteeringgear
FA-3
FA-19
FA.3
FA-8
FA.23
sR-9
Abnormaltirewear Tires improperlyinflated
Alignmentincorrect
Suspensionpartsworn
Inflatetires to proper pressure
Checktoe-in
Replacesuspensionpart
FA.3
FA-19
FA.3

FRONTAXLEAND SUSPENSION- FrontWheelAlignment FA-3
FRONTWHEELALIGNMENT
1. MAKE FOLLOWINGCHECKSAND CORRECTANY
PROBLEMS
(d Checkthe tiresfor wearand properinflation.
Coldtire inflationpressure kg/cm2(psi,kPa)
Tire size FrontandRear
FWD
1 4 5S R1 3
3A-C 4-speedM/T
Others
2.2(32.220l.
2.OQ8,2001
1 5 5S R1 3 1 . 8(26.180)
1 6 5S R1 3 1.8 (26,180)
4WD
1 5 5S R1 3 2.OQ8,2001
1 7 5S R1 3 1.8 (26.180)
(b) Checkthe front wheelbearingsfor looseness.
(d Checkthe wheelrunout.
Lateralrunout: 1.2 mm (0.047 in.) or less
(d) Checkthe front suspensionfor looseness.
(e) Checkthe steeringlinkagefor looseness.
(f) Check that the front absorberswork properly by
usingthe standardbouncetest.
ADJUSTTOE.IN
Adjust toe-in with a toe-ingaugeby the followingpro-
cedure.
(d Checkto seethat both rightandleft tie rodsmeasure
the samein length.
Left-right error: 1.5 mm (0.059 in.l or less
Movethe vehicleforwarda few meterswith the front
wheelsinthestraight-aheadpositionon a levelplace.
Mark the centerof eachreartreadand measurethe
distancebetweenmarksof the right and left tires.
(d) Advancethe vehicletill the markson the rearof the
tirescometo the measuringheightsof the gaugeon
the front.
(e) Measurethe distancebetweenthe marksonthe front
of the tires.
Toe-in: lnspectionSTD -1 {- 1 mm
(-0.O4 + O.O4in.)
A A
+=ruf,ffiWry@=S--A-- F--B--i
A = B
2.
(b)
(c)
! , . - !
'ru,

FA.4 FRONTAXLE AND SUSPENSION- FrontWheelAlignment
(f) lf the toe-in is not within inspectionSTD,adjustthe
toe-in.
(1) Loosenthe clamp.
el Removethe boot clip.
(3) Turn the left and right rack ends an equal
amountto adjust.
Wl Checkthat the length of the left and right tie
rods arethe same.
(5) Torquethe tie rod endclamp.
Torque: 195 kg-cm (14 ft-lb, 19 N'ml
(6) Placethe boot on the sealandclampit.
NOTE: Checkthat the boot is not twisted.
3. INSTALTWHEELALIGNMENTEOUIPMENT
Follow the specific instructionsof the equipmentmanu-
facturer.
fuwry'$A = B

FRONTAXLEAND SUSPENSION- FrontWheelAlignment FA-5
Front Rear (FWDI
Rear (4WD)
MoreCamber
4, INSPECTVEHICLEHEIGHT
Vehicleheight mm (in.)
lf heightof the vehicleis not within specification,try to
levelit by shakingit down.lf the heightis stillnotcorrect,
checkfor badspringsandwornor loosesuspensionparts.
5. ADJUSTCAMBER camber:
Vehicle Inspectionstandard Left-right error
FWD
Sedan 1 0 ' + 3 0 '
30' or lessWagon s' + 30'
4WD 40' -t- 30'
lf camberisout of tolerance,adjustbyturningthecamber
adjustingcam.
(a) Loosenthe shockabsorbermountnut.
(b) Turnthe camto adjust.
NOTE: Camberchangesabout20'with eachgraduation
of the cam.
(c) Tightento the specifiedtorque.
Torque: 1,45Okg-cm {105ft-lb, 142 N'm)
6. ADJUSTSTEERINGAXIS INCLINATION
Vehicle Inspectionstandard Left-righterror
FWD
Sedan 12'30' * 30'
30' or lessWagon 12035' + 30'
4WD 11'50' -t- 30'
lf the steeringaxisinclinationis out of tolerance,inspect
andreplaceanydamagedor wornfronts$rplnsionparts.
s[
Tiresize Front Rear
o
3
Sedan
1 4 5S R1 3
1 5 5S R1 3
165/70SR13
203.017.9921
208.0(8.189)
204.0(8.O31)
287.O
292.O
288.0
11.299)
11.496)
11.339)
Wagor 1 5 5SR 1 3 207 (8.150) 308.5 12.146l.
4WD
1 5 5S R1 3
t75/70SR13
234.419.2281
235.4(9.268)
273.O
274.O
10.748)
10.787)

FA.6 FRONTAXLE AND SUSPENSION- FrontWheelAlignment
Front a-
Spacer
(o
7. ADJUSTCASTER
Caster
w/o PS w/ PS
o
3lt-
Inspection
Standard
Sedan 1 ' 1 0 ' + 3 0 ' 2"40' + 30'
Wagon 0045' + 30' 2"15' + 30'
Left-righterror 30' or less
o
3<f
Inspectionstandard 2"25' -+-30'
Left-righterror 30' or less
1'
lf the casteris not within specification,adjustby increas-
ing or decreasingthe numberof spacers.Do not install
morethantwo spacers.
Torque: 1,O75kg-cm (78 ft-lb, 105 N.ml
NOTE: The casterwill change13' with eachspacer.
ADJUSTWHEELANGLE
Wheelangle
Insidewheel Outsidewheel
o
=|'l-
Sedan
w/o PS
Max. 36020' + 10 32040' + 1"
at 2Oo 21"30' 200
w/ PS
Max. 35050' ! 10 3 2 ' 5 5 ' f 1 0
at 20o 21"05' 20"
Wagon
w/o PS
Max. 3 6 0 1 3 ' + 1 0 3 2 0 5 8 ' + 1 0
at 2Oo 21'25' 20"
wi PS
Max. 35047' 1 1' 3 2 0 5 0 ' = 1 "
at 20" 21"O9' 20"
4WD
w/o PS
Max. 36030' + 10 3 3 0 1 s ' +1 0
at 200 2' 1"15' 20"
w/ PS
Max. 3 6 0 2 0 ' + 1 0 33020' + 1'
at 2Oo 21005' 200
lf the steeringanglesdiffer from the standardspecifica-
,'4o* tion, checkto seethat the lengthof the left and right tie
t:ry rods arethe same.
NOTE: lf the tie rod lengthsare not equal,the steering
anglecannotbe adjustedpropedy.
lf the rie rod lengthswere changedto adjustthe steering
anble,reinspectthe toe-in.
9. INSPECTSIDESLIPWITH SIDESLIPTESTER
Side slip: 3.Omm/m (O.118in./3.3ft) or less
lf the side slip is not within specification,the toe-in or
front wheelalignmentmaynot be correct.
8.

- - , - , - j : * - a t-

FRONTAXLEAND SUSPENSION- AxleHub FA.7
AXLEHUB
COMPONENTS
1,450 (105, 142)
DiscBrakeCaliper
shocknusoruer-----'1 I I i I wheetBearins
n t d l i f f *>> q$J d^%J- |
*@r
rieRodr"o E
h^
t.''"'lo:'t cam
:-^'
*9@n^6g1'
i:T:":it:iY9J'A-
ffi31?yrnnerRacell*ryDiseBrakeDustcover t"'" *1":iHJ"r,""l
Lt^:::l1l"ner
Race (NSKrype)
-l
a?6,
I
iOuterOitSeal
LockNut Cap
i r
/1"i"
Y&r-A
l S U
Ikg-cm (ft-lb, N.m)l : Tighteningtorque
O : Non-reusablepart

n
I
FA.8 FRONTAXLE AND SUSPENSION- AxleHub
REMOVALOF FRONTAXLE HUB
1. REMOVECOTTERPIN.BEARINGLOCKNUTCAPAND
LOCKNUT
(a) Removethe cotter pin and lock nut cap.
(b) Before removingthe brakecaliper,loosenthe lock
nut while depressingthe brakepedal.
2. REMOVEBRAKECALIPER
Removethe brakecaliperfrom the steeringknuckleand
suspendit with wire.
REMOVEDISC
*fi*frcr BEARTNGpLAyrNAxtALDtREcnoN
'' Maximum:0.05mm(O.OO2Oin.l
5. DISCONNECTTIE RODEND FROMSTEERING
KNUCKLE
(d Removethe cotter pin and nut.
(b) UsingSST,disconnectthe tie rod end.
ssT09610-20012
(Lernorrn*fucr6. DISCONNECTSTEERINGKNUCI
nC
t
r YI
It
I
I
li
,
)t-
5 f '
ABSORBER
(d Place matchmarks on the shock absorber lower
bracketand camberadjustcam.
(b) Removethe two boltsend nuts,anddisconnectthe
steeringknuckle.
DISCONNECTLOWERARM FiOM STEERING
KNUCKLE
Removethe two bolts holdingthe balljointto the steering
knuckle.
7.
.. ...t
3.
4.
".-*ffi,i.,.* f.isEl;-*r: .

FRONTAXLEAND SUSPENSION- AxleHub
8. REMOVEAXLE HUB FROM
UsingSST,removethe axlehub.
ssT 09950-20015
,. CAUTION: Cover the drive shaftrhl
( protect it from damage. (r':q
t;; , +in f,rlvetl""ffii
!,ocr* d i t{" cIo*h to " .rr:'r,
gra*ec* it €ro*r ata^4 1e.
REPLACEMENTOF FRONTAXLEHUBAND
WHEELBEARING
(Seepage FA-7)
1. REMOVEDUSTDEFLECTOR
Usinga screwdriver,removethe dustdeflector.
REMOVEINNEROIL SEALFROMSTEERING
KNUCKLE
UsingSST,pullou.tthe oil seal.
ssr 09308-00010
REMOVEHOLESNAPRING
Usingsnapringpliers,removethe holesnapring.
REMOVETHREEBOLTS
Removethe threeboltsholdingthe discbrakedust
to the steeringknuckle.
,..F. REMOVEAXLEHUQFROMSTEERINGKNUCKLE
€r:
UsingSST,pushoff the axlehub.
ssT 09950-20015
6. REMOVEDISCBRAKEDUSTCOVER
7. REMOVEBEARINGINNERRACE'(INSIDE)
2.
a
,{
n.1
n
t
3.
4.
fr
,f+
8. REMOVE.BEARTNGrlruen.qAbe(OUrSlOe)
Using9ST,pulloff the beaiing'innerrace.
ssT 09950;20015 t r

FA.1O
' -'v7:'
FRONTAXLEAND SUSPENSION- AxleHub
9. REMOVEOUTEROIL SEAL
UsingSST,pullout oil seal.
ssT 09308-00010
1O. REPLACEWHEELBEARING
h) Firstplacethe innerrace(outside)of the bearingin
the bearing
(b) UsingSST,pressout the bearing.
SST09228-22O2Oand09950-20015
(c) U$ilfiSST,prestffi a newbearing.
ssT 09309-35010
NOTE: Therearetwotypesof bearings;KOYOandNSK.
INSTALLOUTEROIL SEAL
h) Installthe bearinginnerrace(outside)beforeinstall-
ing a pew oil seal.
(b) UsingSST,drivetheoilsealintothesteeringknuckle.
ssT 09515-35010
(c) ApplyMP greaseto the oit seallip.
INSTALLDISCBRAKEDUSTCOVERONTOSTEERING
KNUCKLEWITH THREEBOLTS,
Applyliquidsealerto the dustcoverandsteeringknuckle
connectionbeforeassembly.
INSTALLAXLE HUB
(a) Installnew innerracesinto the innerbearing.
(b) UsingSST, ggss in the innerraceuntil it is tightty
againstthe sftlulderof the hub.
SST09228-22O2OandO9310-35010
NOTE: Do not interchangethe inner and outer races
wheninstalling.
'.tfi

H
r
FE
1 1 .
12.
1 3 .
i
f r _ , .,,iW;ffiqa- * L - L _ _

_ l + l i ' - : r ' : : '
FRONTAXLEAND SUSPENSION- AxleHub FA-l1
3.3 -+
INSTALLHOLESNAPRING
Usingsnapring pliers,installthe holesnapring into the
steeringknuckle.
INSTALLINNEROILSEAL
UsingSST,drivein a newbil seal.
ssT 09309-35010
NOTE: Tapintheoilseal3.3-t-0.1 mm(O.130+ 0.004
in.)from the end surface.
16. INSTALLDUSTDEFLECTOR
UsingSST, drive a new dust deflector into the steering
knuckle.
ssTo9316-60010
INSTALLATIONOF FRONTAXLEHUB
(SeepageFA-7)
1. INSTALLAXLEHUBTO DRIVESHAFT
lnstallthe axlehubwith the washerandlock nut.Do not
torquethe nut yet.
CAUTION: Be careful not to damagethe drive shaft
boot and oil seal lip.
14.
1 5 .
2. INSTALLAXLE HUB TO LOWERARM
Torquethe*holdingtwo bolts the steering'knuckleto the
ilxb rowerarm.
Torque: 82Okg-cm (59 ft-lb, 80 Nrml
3. INSTALLDISCTO
INSTALLSTEERINGKNUCKLETO SHOCKABSORBER
(a) Lowerthe stabilizerbar and assemblethe steerirfi"
knuckleto the shockabsorberlowerbracket. :l;;
'' .!
jG;','
T6i'
4sft

'l
FA..12 FRONTAXLE AND SUSPENSION- AxleHub
(b) lnsertthe bolts from the front side and align the
matchmarksof the camberadjustcam.
(c) Torquethe bolts.
Torque: 1,450 kg-cm (105 ft-lb, 142 N'ml
5. INSTALLBRAKECALIPERTO STEERINGKNUCKLE
Torquethe bolts.
Torque: 970 kg-cm (70 ft-lb, 95 N.ml
#
6. CONNECTTIE RODENDTO STEERINGKNUCKLE
Torquethe nut and secureit with a new cotter pin.
Torque: 6O0kg:cm (43 ft-lb, 59 N.m)
' i .
i
tr,
b
W
Vii
i
TOROUEBEAfriG LOCKNUT AND INSTALLLOCK
NUT CAP AND;COTTER?IN
(a) Torqrlethe locknutwtriledepiUs.s.lngthe brakepedal.
Torque: 1,900 kg-cm (137ft-lb, f86 N.m)
(b) Installthe locknutcapaffittsing plieib,.installa new
7.
cott*. pin.
8.
+
CHECKFRONTWHEELALIGNMENTf$6e pageFA-3)
'-*+***n,. it'
. , . . i . : ) " . 4 . . , ,'i".:"
I
l .I
f,'l .

FRONTAXLE AND SUSPENSION- FrontDriveShaft FA.13
FRONTDRIVESHAFT
REMOVALOF FRONTDRIVESHAFT
ShockAbsorber
StiffenerPlate
(LeftSideOnly)
ffi- :
R---x+.
Tie RodEnd---€
lRgrcmITi-|b,T.mi]: Tishteningtorque
DiscBrakeCaliper
1.900 {137, 186}
LowerArm
. t .
1. REMOVESTEERINGKNUCKEAND
AXLEHUBWITHOUTDISCONNECTING
LOWERARM
(Seestep 1 to 6 and8 on pageFA-81
2. REMOVEFRONTDRIVESHAFT
(a) Removethe stiffenerplatefrom the transaxleas-
semblyand"engine(leftsideonly).
(b) UsingSST.anda hammer,tap out the front drive
shaft.
ssr 09648-16010
k

1 FA.l4 FRONTAXLE AND SUSPENSION- FrontDriveShaft
(d After pullingout the shaft, leavethe SST inserted.
ssT 09563-16010
DISASSEMBLY OF FRONT DRIVE SHAFT
1. REMOVESNAPR|NGFROMTNBOARD'OITI
2. CHECKDRIVESHAFT
,-
(a) Check to see that therejS.po play in the outboard
joint. ' :*
(b) Checkto seethat inboardjoint slidessmoothlyin the
thrust direction.
(c) Checkto seethat there is no remarkableplay in the
radialdirectionof the inboardjoint.
(d Checkfor damageto the boot.
3. DISASSEMBLEBOOTCLAMPS
COMPONENTS
DynamicDamper(LHShaft Only)
L*lt,. t f .
{ft
DriveShaft(withOutboardJoint)
O Non-reusablepart
InboardJoint Shaft
Tripod
Boot
,,h

FRONTAXLE AND SUSPENSION- FrontDriveShaft FA-l5
4. DISASSEMBLEINBOARDJOINTSHAFT
(d Place matchmarkson the inboard joint shaft and
driveshaft.
CAUTION: Do not use a punch.
(b) Removethe inboardjoint from the driveshaft.
5. DISASSEMBLETRIPODJOINT
{a) Usingsnapring pliers,removethe snapring.
(d Usinga punchandhammerplacematchmarksonthe
shaft and tripod.
(d Uniformilytap to removethe tripod joint from the
driveshaft.
CAUTION: Do not tap on the roller.
6. REMOVEFOLLOWINGPARTS:
(a) Removethe boot from the driveshaft
(b) Removethe clamp and dynamicdamper (LH shaft
only.)
i,l_
n r n
(c) Removethe two boot clampsfrom the boot of the
outboardjoint.
(d) Removethe boot from the outboardjoint.
CAUTION: Do not remove the outboard joint.
(e) Checkthe insideandoutsideof the bootfor damage.
Do not remove.
-ffi,,.@,

FA-l6 FRONTAXLEAND SUSPENSION- FrontDriveShaft
TVinylTape
406 mm r
(15.98in.) |
ASSEMBLYOF FRONTDRIVESHAFT
(Seepage FA-l41
1. PROVISIONALLYINSTALLBOOTAND BOOTCLAMP
TO OUTBOARDJOINT
NOTE: Beforeinstallingthe boot wrapvinyltape around
the splineof the shaft to preventdamagingthe boot.
INSTALLDYNAMIC DAMPERAND CLAMP
(LH SHAFTonlyl
PROVISIONALLYINSTALLBOOTAND CLAMP
(ForINBOARDJOINTITO DRIVESHAFT
ASSEMBLEBOOTCLAMPSONTODRIVESHAFT
ASSEMBLETRIPODJOINT
(a) Place the beveledside of the tripod axial spline
toward the outboardjoint.
(b) Align the matchmarksplacedbeforedisassembly.
When replacingthe inboardjoint, first align the
centerof the inboardjoint and outboardjoint.
Usinga brassbar and hammer,tap the tripod onto
the driveshaft.
2.
3.
4.
5.
(c)
i
I . {
-^'ret , - /
(d)

FRONTAXLE AND SUSPENSION- FrontDriveShaft FA-l7
6. INSTALLNEW SNAPRING
Usingsnapringpliers,installa new snapring.
7. ASSEMBLEBOOTTO OUTBOARDJOINT SHAFT
Before assemblingthe boot pack in 24O g (0.5 lb) of
grease.
NOTE: Usethe greasesuppliedin the boot kit.
8. ASSEMBLEINBOARDJOINT TO DRIVESHAFT
(a) Packin 140 g (0.3lb, 1.4 N) of grease.
Amount: Joint side 90 g {0.2 lOl
Boot side 50 g (0.1 lul
NOTE: Usethe greasesuppliedin the boot kit.
(b) Align the matchmarksplacedbeforedisassembly.
(c) lnstallthe inboardjoint shaft to the driveshaft.
(d) lnstall.lF Uoo,to the inboardjoint shaft.
9. ASSEMBLEBOOTSCLAMP TO BOTHBOOTS
(d Be surethe boot is on the shaft groove.
(b) Installa new 4amp on the inboardjoint sidearound
the hollow pffin of the cover.
' .
.-"
e_

I
FA-l8 FRONTAXLEAND SUSPENSION- FrontDriveShaft
Length
(c) Bendthe clampandlockit as is shownin the figure.
(d) Checkthat the boot is not stretchedor contracted
when the driveshaft is at specifiedlength.
Drive shaft length:
Right side Approx. 620 mm 124.41in.l
Left side Approx. 722 mm (28,43 in.)
10. INSTALLNEW SNAP RINGTO INBOARDJOINT
SHAFT
INSTALLATIONOF FRONTDRIVESHAFT
(Seepage FA-l3)
1. INSTALLDRIVESHAFTTO TRANSAXLEASSEMBLY
(a) Apply MP greaseto the oil seallip.
(b) lnstallthe driveshaft by tappingon the SST.
ssT 09648-16010
NOTE: Whether or not the drive shaft is contactingthe
pinionshaft can be know by its soundor feel when tap-
pingit in.
INSTALLSTIFFENERPLATE
lnstallthe three bolts holdingthe stiffener plate to the
engineandtransaxle.Torquethe bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N'm)
INSTALLSTEERINGKNUCKEAND AXLE HUB
(Seestep 2 to 7 on page FA-l1 and 12)
4. CHECKFOLLOWINGPARTS:
(d Checkthe bootsfor damage.
NOTE: Checkthe entirecircumferenceof the boots.
(b) Check the length betweenthe left and right shaft
after installinq,.thedriveshaft.i": '
-|*it
Length: Approjff{93 mm (7.60 in.)
5. CHECKFRONT"WHEELALIGNMENT(Seepage FA-31
2.
3.
"1.

FRONTAXLE AND SUSPENSION- FrontShockAbsorber FA-l9
FRONTSHOCKABSORBER
COMPONENTS
REMOVALDISASSEMBLYOF FRONTSHOCK
ABSORBERASSEMBLY
1. DISCONNECTSTEERINGKNUCKLEFROMSHOCK
ABSORBER(Seestep 6 on page FA-81
2. REMOVE SHOCK ABSORBERASSEMBLY FROM
BODY ii.
(d Removethedust coverfrom the suspqnsionsupport.
(b) Loosenthe nut.Do not removethe nut yH"
$-Dust Cover
o@
g--
ZA
- r - a
/:A-F SuspensionSupport
Ef
@-Dust Seat
@-sprinsseat
W
: Tighteningtorque
| : Non-reusablepart
CoilSpring
(ft-lb.N.m)

FA-20 FRONT AXLE AND SUSPENSION - FrontShockAbsorber
w/o PS
w/ PS and 4WD
(c) Removethe threenutsholdingthe shockabsorberto
the body.
(d Removethe shockabsorberassembly.
CAUTION: Cover the drive shaft boot with cloth to
avoid damage.
3. CLAMPSHOCKABSORBERIN VISE
Installa bolt andnutsto the bracketat the lowerportionof
the shockabsorbershelland secureit in a vise.
4, REMOVECOILSPRING
(d UsingSST,compressthe coil spring.
ssr 09727-22032
(b) Hold the suspensionwith a screwdriveror such so
that it will not turn,andthenremovethe supportnut.
(c) Removethe suspensionsupport,springseat,spring
and dust cover.
tr-;
W

FRONTAXLE AND SUSPENSION- FrontShockAbsorber FA.21
INSPECTIONOF FRONTSHOCKABSORBER
INSPECTOPERATIONOF SHOCK
(d Pullout the shockabsorberpistonrod at a constant
speed and check to see that the pull feeling
throughoutthe strokeis the same.
b) Checkto seethatthereis nochangeinthe pullwhen
the pistonrod is rapidlymovedup anddown with a
strokeof 5 - 1Omm (0.20- 0.39 in.).
ASSEMBLYAND INSTALLATIONOF FRONT
SHOCKABSORBERASSEMBLY
(Seepage FA-l91
1. INSTALLBUMPER,COILSPRINGINSULATOR,
SPRINGSEATAND DUSTSEAL
(d Mountthe shockabsorberin a vise.
(b) lnstallthe bumberto the pistonrod.
(c) UsingSST,compressthe coil spring.
ssT 09727-22032
(d) Alignthe coil springendwith the lowerseathollow
andinstall.
(d Alignthe springseatwith the pistonrod andinstall.
(fl lnstallthe dustsealon the springseat.
(g) Installthesuspensionsupportwith a newnut.Do not
torquethe nut yet.
2. INSTALLSHOCKABSORBERTO BODY
Connectthree bolts holdingthe shock absorberto the
body.Torquethe nuts.
Torque: 24Okg-cm {17 ft-lb, 24 N.ml

I
FA-22 FRONTAXLE AND SUSPENSION- FrontShockAbsorber
w/ PS and 4WD
3. INSTALLSTEERINGKNUCKTETOSHOCKABSORBER
(Seestep4 on pageFA-l1)
4. TOROUESUSPENSIOTSUPPORTNUT
Torque: 500 kg-cm(36ft-|b,49 N.ml
5. INSTALLDUSTCOVER
Pack the bearingin the suspensionsupport with MP
grease.Installthe dust cover.
4 r y . 6 .
c H E c KC A M B E R( S e ep a g eF A . s l
l..:t
b
!r

FRONTAXLE AND SUSPENSION- FrontSuspension FA-23
COMPONENTS
I 1,075(78,los) |
a{Balljoint
*-<-ry"
Bushing7 S--t sro(5r,sot I
h
YooT.€l l - @
| | t (
I
cottar
| |
I t BooCr,so-|l
l - lSpacer O
Fs-AmTliET'fri| : Tishteninstorque
l: Non-reugablepart
StabilizerBar
FRONTSUSPENSION
BallJoints
INSPECTIONOF BALLJOINTS
1. INSPECTBALLJOINTSFOREXCESSIVELOOSENESS
(d Jack up the tront of the vehicleandplacea wooden
blockwith a heightof 18O- 2OOmm (7.09- 7.87
in.)underonefront tire.
(d Lowerthe jack untilthereis abouthalf a loadon the
front coil springs.Placestandsunderthe vehiclefor
safety.
(c) Makesurethe front wheelsare in a straightforward
positionand blockthem with chocks.
(d) Movethe lowerarm up anddown andcheckthat the
balljoint hasno excessiveplay.
Maximum balljoint vertical play: 0 mm (0 in.l
2. INSPECTBALL JOINT DUSTCOVERSFORDAMAGE
OR DETERIORATION
lf a problemis found,replacethe balljointassembly.

'l
FA.24 FRONTAXLE AND SUSPENSION- FrontSuspension
7
3. INSPECTBALL JOINT FORROTATIONCONDITION
(d Removethe balljoint. (SeepageFA-29)
(b) As shown in the figure,flip the balljoint stud back
andforth 5 times beforeinstallingthe nut
(d Usinga torquegauge,turn the nut continuouslyone
turn each 2-4 secondsand take the torque reading
on the 5th turn.
Torque{turning}:
I - 25 kg-cm 17- 21 in.-lb,0.8 - 2'4 N'ml
lf the torque is not within specification,replacethe ball
ioint.
LowerArm
(Seepage FA-23)
REMOVALOFLOWERARM
1. DISCONNECTLOWERARM TO STEERINGKNUCKLE
Removethe two boltsholdingthe balljointto the steering
knuckle.
2. DISCONNECTSTABILIZERBAR ENDTO LOWER
ARM
Removethe stabilizerbar nut, retainerandcushion.
3. REMOVELOWERARM
(a) Jack up the oppositewheel until the vehiclebody
lifts off the stands.
(b) Loosenthe lowerarmbolt,prythe lowerarmandpull
out the bolt.
(d Disconnectthe lower arm from the stabilizerbar.
CAUTTON: Be careful not to lose the caster adiust
spacer.
(d) UsingSST,disconnectthe balljoint from the lower
arm.
ssT 09950-20015
NOTE: Temporarilyinstallthe nutto preventtheballjoint
from fallingout.

FRONTAXLE AND SUSPENSION- FrontSuspension FA.28
REPLACEMENTOF LOWERARM BUSHING
1. REMOVELOWERARM BUSHING
(a) Cut off the flangetip of the bushingas is shownin
the figure.
(b) Bend the remainingportions inward with a cold
chisel.
CAUTION: Be careful not to damagethe flange.
(c) Bendin the flangetips andpulloff the flangewith a
pair of pliers.
(d) UsingSSTanda press,pressout the bushing.
ssT 09726-32010
INSTALLLOWERARM BUSHING
UsingSST and a press,pressthe bushinginto the arm.
ssr 09726-32010
CAUTION: Do not allow greaseor oil to get on the
bushing.
2.

4
FA.26 FRONTAXLE AND SUSPENSTON- FrontSuspension
INSTALLATIONOF LOWERARM
1. CONNECTLOWERARM TO BALL JOINT
lnstallthe lowerarm to the balljoint with a nut.
Torquethe nut and installa new cotter pin.
2. INSTALLSPACER,RETAINER,CUSHIONAND
COLLAR
3. CONNECTLOWERARM TO BODY
(d Passthe lowerarm throughthe stabilizerbar.
(b) Connectthe lower arm with the bolt. Do not torque
the bolt yet.
(c) lnstallthe stabilizerbarwith the cushion,washerand
a new nut.Do not torquethe nut Yet.
4. CONNECTLOWERARM TO STEERINGKNUCKLE
(a) Lowerthe stabalizerbarandconnectthe balljointto
steeringknucklewith the two nuts.

FRONTAXLE AND SUSPENSION- FrontSuspension FA-27
(b) Torquethe nuts.
Torque: 820 kg-cm (59 ft-lb, 8O N.ml
5. INSTALLTIREAND LOWERVEHICLE
Bouncethe vehicleto stabilizethe suspension.
6. TOROUENUT HOLDINGSTABILIZERBARTO
LOWERARM
,#i{:
Torque: 1,O75kg-cm (78 ft-lb, lOb N.m)
! : r t ! '
7. TOROUEBOLTHOLDINGLOWERARM TO BODY
Torque: 1,150kg-cm (83 ft-tb, 113 N.ml
8. CHECKFRONTWHEELALIGNMENT(Seepase FA-31
o
' . ' * '
t
StabifizerBar
(Seepage FA-231
REMOVALOFSTABILIZERBAR
1. REMOVEENGINEUNDERCOVER
2. REMOVEBOTHSTABILIZERBAR BRACKETS
FROMCROSSMEMBER
;;.".r:,!""
- .ti'" .
.q

a
FA.28 FRONTAXLE AND SUSPENSION- FrontSuspension
3. DISCONNECTBOTHSTABILIZERBAR ENDS
TO LOWERARM
4. REMOVESTABILIZERBAR
CAUTION: Be careful not to lose the spacer.
INSTALLATIONOFSTABILIZERBAR
1. INSTALLSTABILIZERBAR END TO LOWERARM
(d lnstall the spacer, retainer, rubber and collar as
shown in the figure.
(b) Fingertighten a new stabilizerbar nut.
2. INSTALL BRACKETTOGETHERWITH STABILIZER
BAR
Pry the barforward and installthe brackets.
Torquethe bolts.
Torque: rt4o kg-cm (32 ft-lb,43 N.ml
3. TOROUENUT HOLDINGSTABILIZERBARTO LOWER
ARM
Torque: 1,O75kg-cm (78 ft-lb, 105 N.ml
NOTE: Bouncethe vehicleto stabilizethe suspension
beforetorquingthe stabilizerbar nut.
4. INSTALLENGINEUNDERCOVER
5. CHECKFRONTWHEELALIGNMENT(Seepage FA-3)

RA.1
REARAXLE AND
SUSPENSION
(FWD}
TROUBLESHOOTING
REARWHEELALIGNMENT
REARAXLE HUB AND CARRIER
Sedan
Wagon
REARSUSPENSION
RearShock Absorber
SuspensionArm
Strut Rod
(4wD)
TROUBLESHOOTING
REARAXLE SHAFT
DIFFERENTIAL
FOURLINK TYPEREARSUSPENSION
Coil Springand RearShockAbsorber
Lateral Control Rod
Upper and Lower Control Arm
RearStabilizerBar
Page
RA-2
RA-3
RA.5
RA-5
RA-l2
RA.l6
RA.l7
RA.20
RA.23
RA.24
RA-25
RA.28
RA'42
RA.43
RA.46
RA-48
RA.s1

'l
RA-2 REARAXLEANDsusPENstoN - Troubteshootinq(FWD)
TROUBLESHOOTING(FWD}
Wanders/pulls Tiresworn or improperlyinflated
Alignmentincorrect
Wheel bearingadjustedtoo tight (Sedan)
Wheel bearingworn {Wagon)
Rearsuspensionparts looseor broken
Replacetire or inflatetiresto
proper pressure
Checkalignment
Adjustwheelbearing
Replacewheelbearing
Tightenor replacesuspension
parts
RA-3
RA.3
RA-5
RA-12
RA-s.17
Springweak
Checkloading
Replacespring
RA-17
RA.17
Sways/pitches Tires improperlyinflated
RA.3
RA.17
Abnormal tire wear Tiresimproperlyinflated
Alignmentincorrect
Suspensionpartsworn
Inflate tires to proper pressure
Checktoe-in
Replacesuspensionparts
RA-3
RA.17
RA.4
RA-s,17

REARAXLE AND SUSPENSION- RearWheelAlignment(FwD) RA.3
REARWHEELALIGNMENT(FWD}
1. MAKE FOLLOWINGCHECKSAND CORRECTANY
PROBLEM
(d Checkthe tiresfor wearand properinflation.
(SeepageFA-3)
(b) Checkthe rearwheelbearingsfor looseness.
(c) Checkthe wheelrunout.
Lateral runout: 1.2 mm {0.047 in.l or less
(d) Checkthe rearsuspensionfor looseness.
(e) Use the standardbouncetest to check if the rear
absorberswork properly.
2. INSPECTVEHICLEHETGHT(Seepase FA-51
INSTALLWHEELALIGNMENTEOUIPMENT
Follow the specific instructionsof the equipment
manufacturer.
INSPECTCAMBER
Inspection standard: -5' t 3O' (Sedanl
-10' t 3O'(Wagonl
Left-right error: 30'
lf not within specification, inspect and replace any
damagedor worn rearsuspensionparts.
ADJUSTTOE-IN
(a) Measurethe distancebetweeneachwheeldisc and
cam bolt centerof the suspensionarm and check
that both arethe same.
Left-right error: 3 mm (0.12 in.)or less
(b) Movethe vehicleforwarda few meterswith the rear
wheelsinthestraight-aheadpositionon a levelplace.
(c) Mark the centerof eachreartreadand measurethe
distancebetweenthe marksof the rightandleft tires.
(d) Advancethevehicleuntilthe markson the rearof the
tirescometo the front.
NOTE: Thetoe-inshouldbe measuredat the samepoint
on the tire andat the samelevel.
3.
5.

4
RA.4 REARAXLE AND SUSPENSION- RearWheelAlignment(FWD)
- A -
t
Front
B - A = T o e - i n
B
(e) Measurethe distancebetweenthe markson thefront
of the tires.
Toe-in:
Inspection STD 0 + 1 mm (0 + O.O4in.)
(f) lf not within specification,turn the left andrighttoe-
in adjustingcamsan equalamountto adjust.
NOTE: Thetoe-inwillchangeabout2 mm (0.08in.)with
eachgraduationof the'cam(oneside).
6. CHECKSIDESIIP WITH SIDESLIPTESTER
Side slip: 3.0 mm/m (0.118in./3.3ftl or less
lf the sideslip is not withinspecification,the toe-inmay
not be correct.

REARAXLE AND SUSPENSION- RearAxle Huband Carrier(FWD) RA-s
REARAXLEHUBAND CARRIER(FWDI
Sedan
COMPONENTS
REMOVALOFREARAXLEHUBAND CARRIER
1. JACK UP VEHICLE
Jack up the vehicleand supportthe body with stands.
2. REMOVEAXLE HUB
(a) Removethe cap,cotter pin, nut lock and nut.
(b) Removethe axlehubtogetherwith the outerbearing
andthrust washer.
No. 1 SuspensionArm
No.2 SuspensionArm
BrakeTube
Axle Hub (withDrum)
,outer
Bearins
a | *u..o"*
W^I | ',,
Y Y*q@ll
outernalet
*ld
(OuterBearing)| a CoiterPin
ThruitWasher
OuterRace
(lnnerBearing)
lkg-cm(ft-lb.N.m)l : Tighteningtorque

-
RA-6 REARAXLE AND SUSPENSION- RearAxle Huband Carrier(FWD)
3. DISCONNECTBRAKETUBEFROMWHEELCYLINDER
UsingSST,disconnectthe braketube.
ssT 09751-36011
4. REMOVEAXLE SHAFT
Removethe bolts holdingthe axleshaftto the carrier,and
removethe axleshaft and rearbrakeassembly.
5. REMOVEAXLE CARRIER
(d Removethe bolt and nut holdingthe axle carrierto
the strut rod.
(b) Removethe bolt and nut holdingthe axle carrierto
the No.1 suspensionarm.
(d Removethe bolt and nut holdingthe axle carrierto
the No.2 suspensionarm.

REARAXLE AND SUSPENSION- RearAxle Huband Carrier(FWD) RA-7
RAO233
(d) Removethe boltsandnuts holdingthe axle'carrierto
the shockabsorber,and removethe axlecarrier.
REPLACEMENTOFWHEELBEARINGS
1. REMOVEINNERBEARINGAND OILSEAL
(a) Usinga screwdriver,pry out the oil seal.
(b) Removethe innerbearingfrom the disc.
2, REMOVEBEARINGOUTERRACES
UsingSST,pressout the bearingraces.
SST09608-16010 and09608-20011
3. INSTALLBEARINGOUTERRACES
UsingSST,carefullypressin new bearingraces.
SST09608-16010and09608-20011
4. FILLINSIDEOFAXLEHUB AND CAPWITH MP
GREASE
L:

-
RA-8 REARAXLE AND SUSPENSION- RearAxte Huband Carrier(FWD)
5. PACKBEARINGSWITH MP GREASE
(a) PlaceMP greasein the palmof your hand.
(b) Pack grease into the bearing,continuinguntil the
greaseoozesout from the other side.
(c) Do the samearoundthe bearingcircumference.
6. INSTALLINNERBEARINGAND NEW OIL SEAL
(a) Placethe innerbearinginto the axlehub.
(b) UsingSST,drivea new oil sealin the axle hub.
ssT 09608-20011
(c) Apply MP greaseto the oil seal.
INSTALLATIONOF REARAXLE HUBAND
CARRIER
(Seepage RA-51
1. INSTALLAXLE CARRIER
(a) Placethe axlecarrierin position.
(b) Installthe two boltsandnuts holdingthe axlecarrier
to the shock absorber.Torquethe nuts.
Torque: 1,450 kg-cm (105 ft-lb, 142 N.m)
(c) Provisionallyinstallthe bolt andnut holdingthe axle
carrierto the No.2suspensionarm.
NOTE: Besurethe lip of the nut is restingon the flange
of the suspensionarm-notoverit.
(d) Provisionallyinstallthe bolt and nut holdingthe axle
carrierto the No.l suspensionarm.
NOTE: When installing,insertthe lip of the nut into the
holeon the suspensionarm.
I

REARAXLE AND SUSPENSION- RearAxle Huband Carrier(FWD) RA-g
RA0238
(e) Provisionallyinstallthe bolt and nut holdingthe axle
carrierto the strut rod.
NOTE: When installing,insertthe lip of the nut into the
grooveon the bracket.
2. INSTALL AXLE SHAFT
lnstallthe axle shaft and rear brakeassemblywith four
bolts.Torquethe bolts.
3. CONNECTBRAKETUBETO WHEELCYLINDER
ssr 09751-36011
Torque: 155 kg-cm (11 ft-lb. 15 N.m)
4. INSTALLAXLE HUB ON SPINDLE
(a) Placethe axle hub and outer bearingon the axle
shaft.
(b) Fill in MP grease between the outer bearingand
thrust washer.
(d lnstallthe thrustwasher.
5. ADJUST PRELOAD
(a) Installandtorquethe nut.
Torque: 300 kg-cm {22 tt-b,29 N'ml

r.1
E4-10 REARAXLE AND SUSPENSION- RearAxle Huband Canier(FWD)
(b) Snug down the bearingby turning the hub several
times.
(c) Loosenthe nut untilit can be turnedby hand.
NOTE: Makesurethat thereis absolutelyno brakedrag.
(d) Measureand make a note of the rotationfrictional
force of the oil seal.
Oil sealfrictionalforce: Approx.rtoog (0.9 lb, 3.9 Nl
(e) Tightenthe nut untilthe preloadis withinspecifica-
tion.
Bearingpreload(while turning):
In addition to oil seal frictional force
400 - 1,000g (0.9- 2.2 tb,3.9 - 9.8 Nl
(fl Insurethat the drum rotatessmoothly.
6. INSTALL NUT LOCK,COTTERPIN AND CAP
NOTE: lf the cotter pin holedoesnot lineup, correctby
tighteningthe nut the smallestamountpossible.
7. FILL BRAKERESERVOIRWITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM(Seepage BR-ZI

REARAXLE AND SUSPENSION- RearAxle HubandCarrier(FWD) RA-l1
8. TOROUEAXLE CARRIERMOUNT BOLTS
(a) Removethe standsandbouncethe vehicleto stabil-
izethe suspension.
(b) Torquethe mount bolts with the vehicleweight on
the suspension.
Torque: 89O kg-cm (64 ft-lb, 87 N.ml
9. CHECKREARWHEELALIGNMENT
(Seepage RA-3)

r.1
RA-12 REARAXLE AND.SUSPENSION- RearAxleHubandCarrier(FWD)
Wagon
COMPONENTS
RearBrakeAssembly
er+/
->--:
| 0l
/ --<_:+,--/
No. 1 Suspension I
Arm
II
BearingInner I
Race(lnside) StrutRod
RearAxle Carrier
I
fr@
,0,1rol I
I
AxleHub
Bearing
t-lb.N'm)l : Tighteningtorque
BrakeDrum
MeasuringPoint
REMOVALOFREARAXLEHUBANDCARRIER
1. REMOVEBRAKEDRUM
2. CHECKBEARINGPLAY IN AXIAL DIRECTION
Limit: O.O5mm (O.OO2Oin.l

REARAXLEANDsusPENstoN- RearAxleHubandcarrier(FwD) RA-13
3. DISCONNECTBRAKETUBEFROMWHEEL
CYLINDER
UsingSST,disconnectthe braketube.
ssT 09751-36011
4. REMOVEREARAXLE HUB
(a) Removethe four bolts holdingthe axle hub to the
axle carrier,and remove the axle hub and brake
assembly.
(b) Removethe O-ring.
5. REMOVEREARAXLE CARRIER
(Seepages RA-6 and 7l
REPLACEMENTOF REARAXLE HUBAND
WHEELBEARING
(Seepage RA-121
1. REMOVENUT
(d Usinga chiseland hammer,unstakethe nut.
(b) Removethe nut.
2. REMOVEAXLESHAFTFROMAXLEHUB
UsingSST,pushthe axleshaftoff the axlehub.
ssT 09950-20015
3. REMOVEBEARINGINNERRACE(INSIDEI
4. REMOVEBEARINGINNERRACE(OUTSIDE)
UsingSST,pulloff the bearinginnerrace(outside)from
the axleshaft.
ssT 09950-20015

a
RA.14 REARAXLE AND SUSPENSION- RearAxIe HubAndCarrier(FWD)
5. REMOVEOIL SEAL
6. REMOVEBEARING
(a) First installtheinnerrace(innerside)of the removed
bearing.
(b) UsingSST,pressout the bearing.
SST09228-22O2Oand09636-20010
7. INSTALLBEARING
NOTE: Alwaysreplacethe bearingasan assembly.
(a) ApplyMP greasearoundthe bearingouterrace.
(b) UsingSST, press a new bearinginto the bearing
case.
ssr 09316-60010
8. INSTALLOIL SEAL
(a) UsingSST,drivean oil sealintothe axlehub.
ssT o9310-35010
(b) ApplyMP greasebetweenthe oil seallip'
9. INSTALL AXLE SHAFT
(d Installthe bearingboth side innerrace.
(b) UsingSST,pressthe innerraceinto the axleshaft.
SST09228-22O2Oand09636-2001O

REARAXLEANDsusPENstoN- RearAxleHubandcarrier(FWD) RA-ls
81104
(c) Installandtorquea new nut.
Torque: 1,25,Okg-cm (90 ft-tb, 123 N.ml
(d) Stakethe nut.
INSTALLATIONOF REARAXLE HUBAND
CARRIER
(SeepageRA-l2)
1. INSTALLREARAXLE CARRIER
(Seepages RA-8 and 9l
2. INSTATLREARAXLE HUB
(a) Installa newO-ringto the axlecarrier.
(b) lnstallthe axlehubandrearbrakeassemblywith the
four bolts.Torquethe bolts.
Torque: 820 kg-cm (59 ft-tb, 80 N.ml
ssT 09751-36011
Torque: 155 kg-cm (t 1 ft-lb, 15 N.m)
4. INSTALLBRAKEDRUM
5. FILLBRAKERESERVOIRWITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM(Seepage BR-7)
6. TOROUEAXLE CARRIERMOUNT BOLTS
(SeepageRA-111
7. CHECKREARWHEELALTGNMENT{Seepage RA-3}
'
, " 4 '
'
r 4 " '

a
RA-16 REARAXLE AND SUSPENSION- RearSuspension(FWD)
REARSUSPENSION(FWD}
COMPONENTS
g- DustCover
a@supportNut
@-suspension
support
s
V-upper
Insurator
CoilSpring
2& 117,241
F-spring Bumper
v
@-Lowerrnsurator
Shock Absorber
Assembly
1,45,01105 ,1421
BrakeDrum
andAxle
Carrier
Assembly
No.2 SuspensionArm
No. 1 Bashing No. 1 SuspensionArm
N.ml : Tighteningtorque

REARAXLE AND SUSPENSTON- RearSuspension(FWD) RA,l7
RearShockAbsorber
(Seepage RA-l61
REMOVALOF REARSHOCKABSORBER
1. REMOVESHOCKABSORBERCOVERAND PACKAGE
TRAY BRACKET
2. REMOVEBRAKETUBE
(a) UsingSST,disconnectthebraketubefrom thewheel
cylinder.
ssT 09751-36011
(b) UsingSST,removethe braketubefrom the flexible
hose.
ssT 09751-36011
3. DISCONNECTFLEXIBLEHOSEFROMSHOCK
ABSORBER
4. LOOSENNUT HOLDINGSUSPENSIONSUPPORTTO
SHOCKABSORBER
h) Removethedustcoverfromthe suspensionsupport.
(b) Loosenthe nut.Do not removethe nut yet.
5. DISCONNECTSHOCKABSORBERFROMAXLE
CARRIER
Removethe boltsandnuts holdingthe shockabsorberto
the axlecarrierand disconnectthe absorber.
6. REMOVESHOCKABSORBERFROMBODY
Removethe nuts holdingthe shockabsorberto the body
and removethe shockabsorber.

-
RA.l8 REARAXLE AND SUSPENSION- RearSuspension(FWD)
e FI
ry
7. REMOVECOILSPRING
(d Installa bolt and nut to the bracketat the lowerend
of the shock absorberand secureit in a vise.
(d UsingSST,compressthe coil spring.
ssr 09727-22032
(c) Removethe nut.
(d) Removethe suspensionsupport,upperinsulatorcoil
spring,lower insulatorand bumper.
8. HANDLINGOFSHOCKABSORBER
(a) Do not disassemblethe shockabsorberbecausethe
cylinderis filledwith gas.
(b) lf you replacea shockabsorber,drilla 2.0 - 3.0 mm
(0.079- 0.118 in.)holein the bottomof the rep-
lacedshockabsorber'scylinderto completelyrelease
the highpressuregas.ffhe gasis colorless,odorless
and not poisonous.However,when drilling,chips
mayfly out so work carefully.)
(c) Handlethe shockabsorbercarefully.Neverscoreor
scratchtheexposedpartof the pistonrod,andnever
allowpaintor oil to get on it.
(d) Do not turn the piston rod and cylinderwith the
shockabsorberextendedcompletely.
1Omm (0.39in.)

REARAXLE AND SUSPENSION- RearSuspension(FWD) RA.l9
LowerBracket
Suspension
Support
INSTALLATIONOF REARSHOCKABSORBER
1. INSTALLSPRINGBUMPER,COILSPRING,
INSULATORAND SUSPENSIONSUPPORT
(a) Mountthe shockabsorberin a vise.
(b) Installthe lower insulatorto the lower seatof the
shockabsorber.
(c) UsingSST,compressthe coil spring.
ssT 09727-22032
(d) Align the coil spring end with the lower insulator
hollowandinstallthe coil spring.
(e) lnstallthe springbumperand insulator.
(f) Alignthe suspensionsupportlowerseathollowand
lowerinsulaterhollow.
(g) Alignthesuspensionsupportwith the pistonrodand
install.
(h) Alignthe suspensionsupportwith the shockabsor-
ber lower bracketas shown.
(i) Provisionallyinstalla new nut.
2. CONNECTSHOCKABSORBERTO BODY
Connectthe shockabsorberwith threenuts.Torquethe
nuts.
Torque: 240 kg-cm {17 ft-lb, 24 N.m}
3. INSTALLSHOCKABSORBERTO AXLECARRIER
Installthe shock absorberwith two bolts and two nuts.
Torquethe nuts.
Torque: 1,450 kg-cm (105ft-tb, 142 N.m)

RA.20 REARAXLE AND SUSPENSION- RearSuspension(FWD)
4. TOROUENUT HOLDINGSUSPENSIONSUPPORTTO
SHOCKABSORBER
(a) Torquethe nut.
(b) Installthe dust coveron the suspensionsupport'
5. INSTALL FLEXIBLE HOSE TO SHOCK ABSORBER
BRACKET
6. INSTALLBRAKETUBE
7. FILLBRAKERESERVOIRWITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM(SeepageBR-7)
8. CHECKREARWHEELALIGNMENT(SeepageRA-3)
9. INSTALL PACKAGE TRAY BRACKET AND SHOCK
ABSORBER
SuspensionArm
(Seepage RA-l6)
REMOVALOF SUSPENSIONARM
1. JACK UPVEHICLE
2. REMOVENO.2SUSPENSIONARM
(a) Removethe bolt andnut holdingthe suspensionarm
to the axlecarrier.
(b) Removethe cam and bolt holding the suspension
arm to the body and removethe suspensionarm.
NOTE: (1) Rememberwhere the cam plate mark is
when removingthe suspensionarm.
Ql When removing,loosenthe bolt.Do notturn
the cam.

REARAXLE AND SUSPENSION- RearSuspension(FWD) RA.21
3. REMOVENO.l SUSPENSIONARM
(d Removethe bolt andnut holdingthe suspensionarm
to the axlecarrier.
(b) Removethe bolt andnut holdingthe suspensionarm
to the body and removethe suspensionarm.
REPLACEMENTOF NO.l BUSHING
1. REMOVEBUSHING
UsingSST,pressout the bushing.
ssT 09726-32010
2. INSTALLBUSHING
UsingSST,pressin a new bushing.
ssr 09726-32010
CAUTION: Do not use a lubricantwhen pressingin
the bushing.
INSTALLATIONOF SUSPENSIONARM
1. INSTALLNO.l SUSPENSIONARM
(a) Connectthe suspensionarm to the body with the
bolt and nut.Do not torquethe bolt yet.
of the bracket,not over it.
-----7
=/
"'wb

a
REARAXLE AND SUSPENSION
(d Connectthe suspensionarm to the axlecarrierwith
the bolt and nut.Do not torquethe bolt yet.
NOTE: When connectingthe suspensionarm,insertthe
lip of the nut intothe holeon the suspension.
2. INSTALLNO.2SUSPENSIONARM
(a) Placethe suspensionarm in position.
(b) lnstallthe cam and bolt holdingthe suspensionarm
to the body.Do not torquethe bolt yet.
(c) Align the cam platemarkat the samepositionit was
beforeremoval.
(d) Installtheboltandnutholdingthesuspensionarmto
the axlecarrier.Do not torquethe bolt yet.
of the suspensionarm, not over it.
3. TOROUESUSPENSIONARM SETTINGBOLTS
(a) Removethe standsand bouncethe vehicleto stabi-
lizethe suspension.
(d Torquethe setting bolts with the vehicleweight on
the suspension.
Torque: 89O kg-cm (64 ft-lb, 87 N.ml
4. CHECKREARWHEELALTGNMENT(Seepage RA-31

REARAXLE AND SUSPENSION- RearSuspension(FWD) RA-23
Strut Rod
(Seepage RA-l61
REMOVALOF STRUTROD
1. JACK UP VEHICLE(Seepage RA-2OI
2. REMOVESTRUTROD
(a) Removethe bolt andnut holdingthe strutrod to the
axlecarrier.
b) Removethe bolt andnut holdingthe strut rod to the
body and removethe strut rod.
INSTALLATIONOF STRUTROD
1. INSTALLSTRUTROD
(a) Connectthe strut rod to the body with the bolt and
nut Do not torquethe bolt yet.
of the bracket.
(b) Connectthestrutrodto the axlecarrierwith the bolt
andnut.Do not torquethe bolt yet.
NOTE: When connectingthe strut rod, alignthe lip of
the nut with the grooveon the bracket.
2. TOROUESTRUTRODSETTINGBOLTS
(a) Removethe standsandbouncethe vehicleto stabil-
izethe suspension.
(b) Torquethe settingbolts with the vehicleweight on
the suspension.
3. CHECKREARWHEELALIGNMENT(SeepageRA-31

RA.24 REARAXLE AND SUSPENSION- Troubleshooting(4WD)
TROUBLESHOOTING(4WD}
Oil leakat rearaxle Oil sealsworn or damaged
Bearingretainerloose
Rearaxlehousingcracked
Replaceoil seal
Replaceretainer
Repairas necessary
RA-25
RA-25
Oil leakat pinionshaft Oil leveltoo highor wrong grade
Oilsealwornor damaged
Companionflangelooseor damaged
Drainand replaceoil
Replaceoil seal
Tightenor replaceflange
RA-28
RA-28
Noisein rearaxle Oil levellow or wrong grade
Excessivebacklashbetweendrivepinion
and ringor sidegear
Ring,drivepinionor sidegearsworn or
chipped
Drivepinionbearingworn
Axle shaft bearingworn
Side bearinglooseor worn
Drainand replaceoil
Checkbacklash
Checkgears
Replacebearing
Replacebearing
Tightenor replacebearings
RA-28
RA-28
RA-28
RA.25
RA-36
Springsweak
Checkloading
Replacespring
RA.43
RA.43

REARAXLE AND SUSPENSION- RearAxle Shaft (4WD) RA-25
Wheel
BrakeDrum
RearAxleShaft
Bearing
[g-cm (tt-tu,trl'm)l : Tighteningtorque
<): Non-reusablepart
YV?@ dmi
-r-/
oEnd Gasket
| | | WBearins outerRetainer
ORetainerCasret| |
I
lnnerRetainerl
REARAXLE SHAFT (4WD)
COMPONENTS
REMOVALOF REARAXLE SHAFT
1. REMOVEWHEELANDBRAKEDRUM
2. REMOVEFOURBACKINGPLATEMOUNTINGNUTS
REMOVEREARAXLE
UsingSST, pullout the rearaxle.
ssr 09520-ooo31
CAUTION: When pulling out the rearaxle, be careful
not to damagethe oil seal.

RA-26 REARAXLE AND SUSPENSION- RearAxteShaft (4WD)
INSPECTIONAND REPAIROF REARAXLE
SHAFTCOMPONENTS
1. INSPECTREAR AXLE SHAFT AND FLANGE FOR
WEAR,DAMAGEORRUNOUT
Maximum shaft runout: 1.5 mm {0.059 in.}
Maximum flangerunout: 0.1 mm (0.0O4in.)
lf the rearaxleshaft or flangeis damagedor worn, or if
theirrunoutisgreaterthanmaximum,replacetherearaxle
shaft.
INSPECT REAR AXLE BEARING FOR WEAR OR
DAMAGE
lf the bearingis damagedor worn, replaceit.
REMOVEBEARINGINNERRETAINER
(a) Usinga grinder,grinddown the innerretainer.
(b) Usinga chiseland hammet cut off the retainerand
removeit from the shaft.
REMOVEBEARINGFROMSHAFT
UsingSST,pressthe bearingoff the shaft.
ssT 09527-20011
INSTALL BEARING OUTER RETAINERAND NEW
BEARINGON SHAFT
UsingSST,presson the bearingouterretainerand new
bearing.
ssT 09515-20010
6. INSTALLBEARINGINNERRETAINERON SHAFT
(d Graduallyheat the bearinginnerretainerto about
150'C (302'F)in an oil bath.
2.
3.
150'c
lnnerRetainer

REARAXLE AND SUSPENSION- RearAxleShaft (4WD) RA..27
(b) While the innerretaineris still hot, pressthe retainer
on the shaft with SST.
ssT 09515-20010
NOTE: Besurethat thereis no oil or greaseon the rear
axleshaft or retainer.
Facethe non-beveledsideof the innerretainertowardthe
bearing.
7. INSPECTOIL SEALFORWEAR ORDAMAGE
lf the sealis damagedor worn, replaceit.
8. REMOVEOIL SEALFROMAXLE HOUSING
UsingSST,removethe oil seal.
ssT09308-00010
9. INSTALLNEW OIL SEALIN AXLE HOUSING
(d Apply MP greaseto the oil seal.
(b) UsingSST,driveinthe oil sealto a depthof 5.6 mm
(0.220ini.
ssr 09517-12010
INSTALLATIONOF REARAXLE SHAFT
{Seepage RA-25}
1. APPIY LIOUIDSEALEARTO BOTHSIDESOF
ENDAND RETAINERGASKETS
2. PLACENEW ENDAND RETAINERGASKETSIN
POSTTtON
Facethe notch of the gasketdownward.
3. INSTALLREARAXLE SHAFTIN HOUSING
(a) Facethe notch of the retainerdownward.
(b) Installthe rearaxleshaft with four new self-locking
nuts.
Torque: 670 kg-cm (48 ft-tb, 66 N'm)
NOTE:
o Be carefulnot to damagethe oil seal.
o When insertingthe axleshaft, be carefulnot to hit or
dentthe oil deflectorinsidethe axlehousing.
4. INSTALLBRAKEDRUMAND WHEEL
Drivein

RA.28 REARAXLE AND SUSPENSTON- Differentiat(4WD)
DIFFERENTIAL(4WD)
COMPONENTS
PinionShaft
I
*:#ffi#6--PinionGear
DifferentialCase
Oil Slinger
-rb,N.m)l : Tighteningtorque
DifferentialCarrier

REARAXLE AND SUSPENSION- Differential(4WD) RA.29
SST
ON.VEHICLEREPLACEMENTOF OILSEAL
1. DISCONNECTPROPELLERSHAFTFROM
DIFFERENTIAL(Seepage PR-3)
2. REMOVECOMPANIONFLANGE
(Seestep 7 on pageRA-31)
3. REMOVEOILSEALAND OILSLINGER
(d UsingSST,removethe oil sealfrom the housing.
ssT 09308-10010
(b) Removethe oil slinger.
4. REMOVEFRONTBEARINGAND BEARINGSPACER
(Seestep 9 on pageRA-311
5. INSTALLNEW BEARINGSPACERAND FRONT
BEARING(Seestep 9 on page RA-391
6. INSTALLOILSLINGERAND NEW OIL SEAL
(a) lnstallthe oil singerfacingas shown.
(b) UsingSST,drivein a new oil sealas shown.
ssr 09554-30011
Oil seal drive in depth: 1.0 mm (0.039in.l
(c) ApplyMP greaseto the oil seallip.
7, INSTALLCOMPANIONFLANGE
8. ADJUSTDRIVEPINION
(Seestep 12 on pageRA-4OI
9. STAKEDRIVEPINIONNUT
10. CONNECTPROPELLERSHAFTFLANGETO
COMPANIONFLANGE(Seepage PR-6)
11. CHECKDIFFERENTIALOIL LEVEL
Fillwith hypoidgearpil if necessary.
Oil grade: API GL-s hypoidgear oil
Viscosity: Above - 18'C (O"F) SAE 90
Below - 18'C (O"Fl SAE 8OW
or 8OW-90
Capacity: 1.Oliters (1.1 US qts, 0.9 lmp. qts)
Torquethe fillerplug.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)5 mm (O.20in.)

RA.30 REARAXLE AND SUSPENSION- Differential{4WD)
REMOVALOF DIFFERENTIAL
(Seepage RA-28)
1. DRAINDIFFERENTIALOIL
2. REMOVEREARAXLE SHAFT(Seepage RA-25)
3. DISCONNECTPROPELLERSHAFTFROM
DIFFERENTIAL(Seepage RA-28)
4. REMOVEDIFFERENTIALCARRIERASSEMBLY
DISASSEMBLYOF DIFFERENTIAL
(Seepage RA-281
NOTE: lf the differentialis noisy,performthe following
pre-inspectionbeforedisassemblyto determinethecause.
lf the differentialhas severeproblems,disassembleand
repairas necessary.
1. CHECKRINGGEARRUNOUT
Maximumrunout: 0.07 mm (O.OO28in.l
lf the runoutis exceedsmaximum,replacethe ringgear.
2. CHECKRINGGEARBACKLASH
Backlash: 0.10 - 0.15 mm (O.OO39- O.OO59in.)
lf the backlashis not withinspecification,adjustthe side
bearingpreloador repairas necessary.(Seestep 5 on
pageRA-36)
3, INSPECTTOOTH CONTACTBETWEENRING GEAR
AND DRIVEPINION(Seestep 6 on pageRA-38)
Notethe tooth contactingposition.
4. CHECKSIDEGEARBACKLASH
Measurethe sidegearbacklashwhile holdingone pinion
geartoward the case.
Standardbacklash:
O.OZ- 0.15 mm (0.0008- 0.0059 in.)
lf the backlashis not withinspecification,installthe cor-
rect thrust washers.
5. CHECKDRIVEPINIONPRELOAD
Usinga torquewrench,measurethe preloadof the back-
lashbetweenthe drivepinionand ringgear.
Preload: 4-7 kg-cm
{3.5- 6.1 in.-lb,0.4 - O.7N'm}
6. CHECKTOTALPRELOAD
Usinga torquewrench,measurethe total preload.
Total preload:
In additionto drive pinionpreload
2 - 4 kg-cm $.7 ' 3.5 in.-lb,O.2- O.4N'm)

REARAXLE AND SUSPENSTON- Differentiat(4WD) RA-31
7. REMOVECOMPANIONFLANGE
(a) Usinga chiselandhammer,loosenthe stakedpartof
the nut.
(b) UsingSST to hold the flange,removethe nut and
washer.
ssT 09330-00020
b) UsingSST,removethe companionflange.
ssT 09557-22022
8. REMOVEOILSEALAND OILSLTNGER
h) UsingSST,removethe oil sealfrom the housing.
ssr 09308-10010
(b) Removethe oil slinger.
9. REMOVEFRONTBEARINGAND BEARINGSPACER
(a) UsingSST,removethe front bearingfrom the drive
pinion.
ssT 09556-12010
(b) Removethe bearingspacer.
lf the front bearingis damagedor worn,replacethe bear-
ing.
10. REMOVEDIFFERENTIALCASEFROMCARRIER
(d Put matchmarkson the bearingcap and differential
carrier.
(b) Removethe two adjustingnut locks.
(c) Removethetwo bearingcapsandtwo adjustingnuts.
(d) Removethe two bearingouter races.
(d Removethe differentialcase.

RA.32 REARAXLE AND SUSPENSION- Differential(4WD)
NOTE: Tagthe disassembledpartsto showthe location
for reassembly.
11. REMOVEDRIVEPINIONFROMDIFFERENTIAL
CARRIER
INSPECTIONAND REPLACEMENTOF
DIFFERENTIAL
(Seepage RA-281
1. REPLACEDRIVEPINIONREARBEARINGRACE
(a) UsingSSTanda press,pullout the rearbearingfrom
the drivepinion.
ssT09950-00020
(b) Installthe resuedthrustwasheron the drivepinion
with the chamferedendfacingthe piniongear.
(c) UsingSSTanda press,pressa new rearbearingon
the drivepinion.
ssT 09608-12010
REPLACEDRIVEPINIONFRONTAND REARBEARING
OUTERRACES
(a) Usinga brassbar and hammer,tap out the outer
race.
(b) UsingSSTanda press,drivein a new outerrace.
ssT 09608-12010
RA0062
2.

REAR AXLE AND SUSPENSION - Differential(4WD) RA-33
3. IF NECESSARY,REPLACESIDE BEARINGS
(a) Using SST, remove the side bearing from the
differentialcase.
ssT 09502-10012
NOTE: On the differential case there are indentations
into which the ssT fits.
(b) UsingSSTanda press,pressin a new bearing.
ssr 09608-20011
4. INSPECTSIDEGEARBACKLASH
Measurethe sidegearbacklashwhileholdingthe other
sidegeartowardthe case.
Standardbacklash: 0.02 - 0.15 mm
(0.0008- 0.0059in.)
5. IF NECESSARY,REPLACERINGGEAR,SIDEGEARS
AND PINIONGEARS
NOTE:
o lf the ringgearis to be usedagain,placematchmarks
beforeseparatingit.
o lf the ring gear or drive pinionare damaged,replace
them as a set.
(a) Lift the lock platesandremovethe mountbolts.
(b) Usinga plastic-facedhammer,tapontheringgearto
separateit from the differentialcase.

RA.34 REARAXLEAND SUSPENSION- Differential(4WD)
(c) Usinga pinpunchandhammer,driveoutthe straight
pinfowardthe ringgearinstallationsurface.
(d) Removethe pinionshaft, piniongerars,side gears
andthrustwashers.
te) Installthe side gears,thrust washers,piniongears
andshaft.
(f) Checkthe sidegearbacklash.(SeepageRA-33)
Standardbacklash: O.O2- 0.15 mm
(0.0008- O.OO59in.)
(g) lf the backlashis not withinspecification,usethrust
washerof a differentthickness.
Thrustwasherthickness mm (in.)
1.50(0.0591) | r.65(0.0650)
1.s5 (0.0610) | t .70(0.0669)
1.60(0.0630) | r.75(0.0689)
(h) Usinga pin punchand hammer,tap a new straight
pinthroughthe caseandholein the pinionshaft.
(i) Stakethe pin anddifferentialcase.
(j) Cleanthe contactsurfaceof the differentialcase.
(0 Graduallyheatthe ringgearto about1OO'C(212"F1
in an oil bath.
CAUTION: Do not heat the ring gear above 1lO'C
(230"F).
RingGear
=-_-
&

REARAXIE AND SUSPENSION- Differential(4WD) RA-35
(l) Cleanthecontactsurfaceof the ringgearwith clean-
ing solvent.
(m) Thenquicklyinstallthe ring gearon the differential
case.
(n) Coatthe ringgearmountboltswith gearoil.
(o) Installnew lock platesandthe mountbolts.Tighten
the mountboltsuniformlyanda littleat a time.Tor-
quethe bolts.
Torque: 985 kg-cm (71 ft-lb, 97 N.m)
(p) Checkthe ringgearrunout.
Maximumrunout: 0.07 mm (0.028in.)
(q) Stakethe lockplate.
NOTE: Stakeoneclawflushwith the flat surfaceof the
nut.Forthe clawcontactingthe protrudingportionof the
nut, stake(bend)only the half on the tighteningside.
ASSEMBLYOFDIFFERENTIAL
(Seepage RA-28)
1. TEMPORARILYADJUSTDRIVEPINIONPRELOAD
(a) lnstallthe followingparts:
o Drivepinion
o Frontbearing
NOTE: Assemblethe spacer,oil slingerandoil sealafter
adjustingthe gearcontactpattern.
(b) UsingSST,installthe companionflange.
ssT 09557-22022
(c) Adjust the drive pinion preloadby tighteningthe
companionflangenut.
UsingSSTto holdthe flange,tightenthe nut.
ssT 09330-00020
CAUTION: As there is no spacer,taghtena little at a
time, being carefulnot to overtighten.

a
RA-36 REARAXLE AND SUSPENSION- Differential(4WD)
(d) Usinga torquewrench,measurethe preload.
Preload: New bearing 6.5 - 12.5 kg-cm
(5.6- 1O.9in.-lb)
(0.6- 1.2 N.ml
Reusedbearing 4 - 7 kg-cm
(3.5- 6.1 in.-lb)
(0.4 - 0.7 N.ml
2. INSTALLDIFFERENTIALCASEIN CARRIER
(d Place the bearingouter races on their respective
bearings.Makesurethe left andrightouterracesare
not interchanged.
(b) Installthe casein the carrier.
3. INSTALLADJUSTINGNUTS
Installthe adjustingnutson their respectivecarrier,mak-
ing surethey arethreadedproperly.
NOTE: Makesurethat thereis backlashbetweenthe ring
gearanddrivepinion.
4, INSTALLBEARINGCAPS
Alignthe matcfimarkson the capandcarrier.Screwin the
two bearingcap boltstwo or threeturnsand pressdown
the bearingcap by hand.
NOTE: lf the bearingcapdoesnot fit tightlyon the car-
rier,the adjustingnut threadsare not threadedproperly.
Reinstalladjustingnuts if necessary.
5. ADJUSTSIDEBEARINGPRELOAD
(a) Tighten the bearing cap bolts until the spring
washersareslightlycompressed.
(b) UsingSST,tightenthe adjustingnut on the ringgear
sideuntilthe ringgearhasa backlashof about0.2
mm (0.0O8in.).
ssr 09504-oool1

REARAXLEAND SUSPENSION- Differential(4WD) RA.37
(c) UsingSST,firmly tightenthe adjustingnut on the
drivepinionside.
ssr o9504-ooo11
(d) Checkthe ringgearbacklash.
lf tighteningthe adjustingnut createsringgearbacklash,
loosenthe nut so that backlashis eliminated.
(e) Placea dialindicatoron the top of the bearingcapon
the ring gearside.
(f) Adjustthe sidebearingfor zeropreloadby tightening
the otheradjustingnutuntilthe pointeron the indica-
tor beginsto move.
(g) Tightenthe adjustingnut 1 - 1llznotchesfrom the
zeropreloadposition.
(h) Usinga dialindicator,adjustthe ringgearbacklash
untilit is withinspecification.
Backlash: 0.10 - 0,15 mm (O.OO39- O.OO59in.l
NOTE: The backlashis adjustedby turningthe left and
right adjustingnutsequalamounts.For example,loosen
the nut on the left sideonenotchandtightenthe nut on
the rightsideonenotch.
(i) Torquethe bearingcap bolts.
Torque: 6OOkg-cm (43 ft-lb, 59 N.ml

RA.38 REARAXLE AND SUSPENSION- Differentiat(4WD)
(j) Recheckthe ring gearbacklash.
(0 Usinga torque meter,measurethe total preload.
Total preload:
ln addition to drive pinion preload
2 - 4 kg-cm 11.7- 3.5 in.-lb,O.2- 0.4 N.m)
Backlash: O.1O- O.15mm (0.0039- 0.O059in.)
6. INSPECTTOOTH CONTACT BETWEEN RING GEAR
AND DRIVEPINION
(a) Coatred leadon 3 or 4 teethat threedifferentposi-
tions of the ring gear.
(b) Holdthe companionflangefirmly androtatethe ring
gearin both directions.
(d lnspectthe tooth pattern.
HeelContact FaceContact
Selecta thrustwasherthat wiltbrinqthe
drivepinioncloserto the ring gear.
-
,rfl
Selecta thrustwasherthat will shiftthe
drivepinionawayfrom the ringgear.

NOTE: lf adjustingthe meshingof the teeth of the drive
pinionandringgearbychangingtheextensionof thedrive
pinion,selecta thrustwasherof the appropriatethickness
from the tablebelow.
REMOVECOMPANIONFLANGE
(Seestep 7 on page RA-31)
REMOVEFRONTBEARING
INSTALLNEW BEARINGSPACERAND FRONT
BEARING
(d lnstalla new bearingspaceron the shaft.
(b) lnstallthe front bearingon the shaft.
10. INSTALLOILSLINGERAND NEW OILSEAL
(d Installthe oil slingerfacingas shown.
(b) UsingSST,drivein a new oil sealas shown.
ssT 09517-12010
Oil seal drive in depth: 1.0 mm (0.039 in.)
(d Apply MP greaseto the oil seallip.
11. INSTALLCOMPANIONFLANGE
(a) UsingSST,installthe companionflange.
ssr 09557-22022
7.
8.
9.
Drive in depth
Drivepinionthrustwasherthickness mm (in.)
2.24(O.O882) | Z.+8(0.0976)
2.27l}.O8e4l I Z.S1(0.0988)
2.30(0.0906) I Z.S4(0.1000)
2.33(0.0917) | 2.57(0.1012)
2.36(O.Os29) | Z.A0{0.1024)
2.39(0.0941) I 2.63(0.103s)
2.42(0.0953) | Z.A6(0.1047)
2.45(0.096s)

RA-/[() REARAXLE AND SUSPENSION- Differential(4WD)
RAOO3
(b) Coat the threadsof a new nut with MP grease.
(c) UsingSSTto hold the flange,tightenthe nut.
Torquethe nut.
ssr 09330-ooo20
Torque: 1,425 kg-cm (103 ft-lb, 140 N'ml
12. ADJUST DRIVEPINIONPRELOAD
Usinga torquewrench,measurethe preloadof the back-
lashbetweenthe drivepinionandringgear.
Preload: New bearing 6.5 - 12.5 kg-cm
(5.6- 10.9in.-lbl
(0.6- 1.2 N'ml
Reusedbearing 4 - 7 kg-cm
(3.5 - 6.1 in.-lbl
(0.4 - 0.7 N'ml
lf preloadis exceedsspecification,replacethe bear-
ing spacer.
lf preloadis lessthan specification,retightenthe nut
130 kg-cm (9 ft-lb, 13 N.m) at a time until the
specifiedpreloadis reached.
lf the maximumtorqueis exceededwhile retighteningthe
nut,replacethebearingspacerandrepeatthepreloadpro-
cedure.Do not back off the pinion nut to reduce the
preload.
Maximum torque: 2,4OOkg-cm
(174ft-lb, 235 N'm)
CHECKDEVIATIONOFCOMPANIONFLANGE
Maximumtateralrunout: 0.10 mm (0.0039in.l
Maximumradialrunout: 0.10 mm (0.0039in.l
14. STAKEDRIVEPINIONNUT
(a)
(b)
1 3 .

15. INSTALLADJUSTINGNUT LOCKS
(a) Selecteithera lock plateNo. 1 or No. 2 whichever
will fit the adjustingnuts.
(b) lnstallthe lockplateon the bearingcaps.
Torque: 55 kg-cm (48 in.-lb,5.4 N'ml
INSTALLATIONOF DIFFERENTIAL
(Seepage RA-281
1. INSTALLDIFFERENTIALCARRIERASSEMBLY
Installa newgasketandthedifferentialcarrierassemblyin
the axleand installthe twelvenuts.Torquethe nuts.
2. CONNECTPROPELLERSHAFTFLANGETO
COMPANIONFLANGE(Seepage PR-61
3. INSTALLREARPLUGAND FILLDIFFERENTIALWITH
GEAROIL
Torquethe drainplug.
Torque: 500 kg-cm (36 ft-|b,49 N'm)
Oil grade: API GL-s hypoidgear oil
Viscosity: Above - 18"C (O'Fl SAE 90
Below - 18'C (0"F) SAE 8OW
or 80W-90
Capacity: 1.0 liters (1.1 US qts, 0.9 lmp. qts)
Torquethe fillerplug.
Torque: 500 kg-cm (36 ft-|b,49 N'ml
5 mm (0.2Oin.)

RA-42 REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD)
FOURLINKTYPEREARSUSPENSION(4WDI
COMPONENTS
fl,rooEz lrol
.ffi |
Upperlnsutator-{sH9 I
€ d @ (
g - LateralControl Rod
l l- 650t+?,54l_l
€ ^T-l l n o o o @
A/----_-9 a,r
f f I r,zooraz,nat]. I a
g
I
uooe,ControlArm ', @
o t r 1 1 " @
a",,,0.,"n@
Lowertnrut.tor-@
D aia I i @v @
i o'wr=:i
b | .g
e € t , 6
E i*u
, W t eq ShockAbsorber
a n v
%=
e @
e
Fv
? u.,
r€
@.,a
i,' a^ @a
LowerControlArm
-lb, N'm)l : Tighteningtorque
Rear StabilizerBar

REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD) RA-43
CoilSpringandRearShockAbsorber
(Seepage RA-421
REMOVALOFCOILSPRINGAND SHOCK
ABSORBER
1. JACK UP VEHICLE
Jack up the rearaxlehousingand supportthe bodywith
stands.Leavethe jack underthe rearaxle.
2. REMOVEREARSHOCKABSORBER
(a) Removethe bolt holdingthe shock absorberto the
rearaxlehousinganddisconnectthe shockabsorber.
(d Removethe nuts holdingthe shockabsorberto the
body,and removethe shockabsorber.
3. REMOVESTABILIZERBAR BUSHINGBRACKETS
Removethe boltsholdingthe stabilizerbarbushingto the
rearaxlehousing.
4. DISCONNECTLATERALCONTROLROD FROM REAR
AXLE HOUSING
Removethe nut holdingthe lateralcontrolrod to the rear
axle housingand disconnectthe lateralcontrolrod.

RA-/14 REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD)
5. REMOVECOILSPRING
(a) Beginto lowerthe rearaxlehousing.
NOTE: Becarefulnot to pullthe brakelineand parking
brakecable.
(b) Whileloweringthe rearaxlehousing,removethe coil
springandthe upperandlowerinsulators.
INSTALLATIONOFCOILSPRINGAND
SHOCKABSORBER
1. PUTLOWERINSULATORON AXLE HOUSING
2, PUTUPPERINSULATORON COILSPRING
3. INSTALLCOILSPRING
4. CHECKPOSITIONOF LOWERINSULATOR
(a) Jackup the rearaxlehousing.
(b) Checkthat the lowerinsulatoris installedcorrectly.
lf the insulatoris not in correctposition,reinstallthe
coilspring.

REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD) Rl-+S
5. INSTALLLATERALCONTROLROD
In order,installa washer,bushing,spacer,lateralcontrol
rod,bushing,washerandnut on the rearaxlehousing.
Do not tightenthe nut yet.
6. INSTALLSHOCKABSORBER
b) Connecttheshockabsorberto thebodywiththenut.
Holdtheshaftwith anadjustablewrench.Torquethe
nut.
(b) Connectthe shockabsorberto the rearaxlehousing
with the nut Torquethe bolt.
Torque: 375 kg-cm (27 ft-b,37 N.ml
7. INSTALLSTABILIZERBAR BUSHINGBRACKETSTO
REARAXLE
8. STABILIZESUSPENSION
Removethe standsand bouncethe car to stabilizethe
suspension.

RA-/t6 REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD)
9. TIGHTENLATERALCONTROLRODNUT
h) Raisethe axlehousinguntilthe body is freefrom the
stands.
(b) Torquethe lateralcontrolrod nut.
LateralControlRod
(Seepage RA-421
REMOVALOF LATERALCONTROLROD
1. SUPPORTREARAXLE HOUSING
Jack up the rearaxlehousingand supportit with stands.
2. DISCONNECTLATERALCONTROLRODFROM REAR
AXLE HOUSING
Removethe nut holdingthe lateralcontrolrod to the rear
axle housing,and disconnectthe lateralcontrolrod.
3. DISCONNECTLATERALCONTROLRODFROM BODY
Removethe nut holdingthe lateralcontrolrodto the body
and removethe lateralcontrolrod.
REPLACEMENTOF LATERALCONTROLROD
BUSHING
1. REMOVEBUSHING
UsingSST,pressout the bushingfrom the lateralcontrol
rod.
ssT 09710-14012
NOTE: When insertingand removingthe bushing,press
or pullfrom the chamferedsideas shown in the figure.tRemove

REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD) RA.47
Chamfer
RAO343
2. INSTALLBUSHING
UsingSST and a press,pressa new bushinginto the
lateralcontrolrod.
ssT 09710-14012
NOTE: Donot usea lubricantwhenpressinginthebush-
ing.
INSTALLATIONOF LATERALCONTROLROD
1. INSTALL LATERALCONTROLRODTO BODY
(a) Raisethe axlehousinguntilthe housingis free from
the stands.
(b) Installthelateralcontrolrodto the bodywith the nut.
INSTALL LATERAL CONTROLROD TO REAR AXLE
HOUSING
(d Consecutivelyinstallthe washer,bushing,spacer,
lateralcontrolarm, bushing,washerand nut on the
rearaxlehousing.
(b) Removethe standsand bouncethe car to stabilize
the suspension.
2.

RA-48 REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD)
(d Jack up the axlehousing.
(d) Torquethe nut.
Torque:
Body side
1,2OOkg-cm (87 ft-lb, 118 N.m)
Axle housingside
650 kg-cm {47 ft-lb, 64 N.ml
Upperand LowerGontrolArm
(SeepageRA-421
REMOVALOFUPPERANDLOWERCONTROL
ARM
1. JACK UP VEHICLE
Holdthe rearaxle housingwith a jack.
2. REMOVEUPPERCONTROLARM
(a) Removethe bolt holdingthe uppercontrolarmto the
body.
(b) Removethebolt holdingthe uppercontrolarmto the
rearaxlehousing,thenremovethe uppercontrolarm.
3. REMOVELOWERCONTROLARM
(a) Removethe bolt holdingthe lower control armto the
body.

REARAXLE AND SUSPENSION- FourLinkTypeRearSuspension(4WD) nA-+g
(b) Removethe boltholdingthe lowercontrolarmto the
rearaxlehousing,andthenremovethe lowercontrol
arm.
INSTALLATIONOF UPPERAND LOWER
CONTROLARM
1. INSTALLUPPERCONTROLARM
(a) lnstallthe uppercontrol arm on the body with the
bolt andnut.Do not tightenthe nut yet.
(b) Installthe uppercontrolarmon the rearaxlehousing
with the bolt and nut.Do not tightenthe nut yet.
2. INSTALLLOWERCONTROLARM
(a) lnstallthe Iowercontrolarm on the body with the
bolt and nut.Do not tightenthe nut yet.
(b) lnstallthe lowercontrolarmon the rearaxlehousing
with the bolt andnut.Do not tightenthe nutyet.

RA-50 REARAXLE AND SUSPENSION- FourLinkTypeRearSuspension(4WD)
3. STABILIZESUSPENSION
Removethe stands and bouncethe car to stabilizethe
suspension.
4. JACK UP VEHICLE
Raisethe axle housinguntil the body is free from the
stands.
5. TIGHTENBOIT HOLDINGUPPERCONTROLARM TO
BODY
Torquethe bolt.
Torque: 1,2OOkg-cm (87 ft-lb, 118 N.ml
6. TIGHTENBOLTHOLDINGUPPERCONTROTARM TO
REARAXLE HOUSING
Torquethe bolt.
7, TIGHTENBOLTHOLDINGLOWERCONTROLARM TO
BODY
Torquethe bolt.
8. TIGHTENBOLTHOLDINGLOWERCONTROLARM TO
REARAXIE HOUSING
Torquethe bolt.

REARAXLE AND SUSPENSION- FourLinkType RearSuspension(4WD) ne-St
RearStabilizer Bar
(Seepage RA-421
REMOVALOF REARSTABILIZERBAR
1. REMOVESTABILIZERBAR BUSHINGBRACKETS
2. REMOVEREARSTABILIZERBAR FROMBODY
3. DISCONNECTSTABILIZERBAR END FROMLINK
INSTALLATIONOF REARSTABILIZERBAR
1. INSTATLSTABILIZERLINK TO BODY
Installthe linkonto the bodyas shown.
2. INSTALLSTABILIZERBARTO LINK
Connectthe stabilizerbaron both sidesto the linkswith
bolts,collars,cushions,nut and new cotter pins.
Torque: 310 kg-cm (22 ft-b,30 N'ml
3. INSTALLBRACKETSTO REARAXLE HOUSING
Torque: 375 kg-cm 127ft-1b,37 N'm)

BR.1
BRAKESYSTEM
PRECAUTIONS
TROUBLESHOOTING
CHECKSAND ADJUSTMENTS
MASTERCYLINDER
BRAKEBOOSTER
FRONTBRAKE
REARBRAKE
Sedan
Wagon FWD
Wagon 4WD
BRAKEHOSESAND TUBES
Page
BR.2
BR-2
BR-6
BR.9
8R.14
8R.16
B,R.22
BR-22
8R.29
8R.36
8R.43

BR-2 BRAKESYSTEM - Precautions,Troubleshooting
PRECAUTIONS
1. Care must be taken to replaceeach part properly as it
could affect the performance of the brake system and
result in a driving hazard.Replacethe parts with parts
of the same part number or equivalent.
2, ltnis very important to keep parts and the area clean
wltsn repairingthe brake system.
TROUBLESHOOTING
Low or spongy pedal Liningsworn
Leakin brakesystem
Mastercylinderfaulty
Air in brakesystem
Wheelcylinderfaulty
Pistonsealsworn or damaged
Rearbrakeautomaticadiusterfaulty
Replacebrakeshoesor pads
Repairleak
Repairor replacemastercylinder
Bleedbrakesystem
Repairwheelcylinder
Repairbrakecalipers
Repairor replaceadjuster
BR-16,22
BR-43
BR-9
BR-7
8R.22
BR-16
B,R.22
Brakesdrag Parkingbrakeout of adjustment
Parkingbrakewire binding
Boosterpushrod out of adjustment
Returnspringfaulty
Brakeline restricted
Liningcrackedor distorted
Wheelcylinderor caliperpistonsticking
Automatic adjusterbroken
Mastercylinderfaulty
Adjust parkingbrake
Repairas necessary
Adjustpushrod
Replacespring
Repairas necessary
Replacebrakeshoe
Repairas necessary
Replaceadjuster
Repairor replacemastercylinder
BR.8
BR.15
BR-22
BR-22
BR-18,22
BR-22
BR-9
Brakespull Tires improperlyinflated
Oil or greaseon linings
Brakeshoesdistorted,liningsworn or
glazed
Drumor discout of round
Returnspringfaulty
Wheelcylinderfaulty
Pistonfrozenin caliper
Disc brakepad sticking
Checkfor cause,replacelining
Replacebrakeshoes
Replacedrum or disc
Replacespring
Repairwheelcylinder
Repaircaliper
Replacepads
FA-3
BR-16,22
BR-16,22
BR-l8,22
BR-22
BR-18,22
BR.18
BR-16
Hard pedalbut
brakesinefficient
Oil or grbaseon linings
Brakeshoesdistorted,liningsworn
or glazed,drumsworn
Discbrakepadsworn
Pistonfrozenin caliper
Brakeboosterfaulty
Brakeline restricted
Checkfor cause,replacelining
Replacebrakeshoes
Replacepads
Repaircaliper
Repairbooster
Repairas necessary
BR-I6,22
BR-16,22
BR-16
BR-16
BR.14

BRAKESYSTEM - Troubleshooting BR.3
TROUBLESHOOTING(Cont'd)
r+i
:?*
a
?"t
Snappingor clicking
noisewhen brakes
are applied
Drumbrakes- brakeshoesbinding
at backingplateledges
Drumbrakes- backingplateledges
worn
Drumbrakes- looseor missing
hold down spring
Drumbrakes- looseset bolt
at backingplate
Discbrakes- rust on front edgeof
inboardshoes
Discbrakes- looseor missingpad
supportplate
Discbrakes- looseinstallation
bolt
Discbrakes- wearon slidebushing
Lubricate
Replaceand lubricateledges
Replace
E ,
Tisnteffit'
Inspect lubricate,replaceif
necessary
Replace
Tighten
Replace
BR-22
BR-22
BR-22
BR-22
BR.16
BR-16
BR-16
BR-16
Scrapingor grinding
noisewhen brakes
areapplied
Worn brakelinings
Caliperto wheel or rotor interference
Dust coverto rotor or drum
interference
other brakesystemcomponents:
Warpedor bentbrakebacking
plateor splashshield,cracked
drumsor rotors
Tiresrubbingagainstchassisand
body
Replace,refinishdrumsor
rotors if heavilyscored
Replaceas required
Corrector replace
lnspector service
Inspector service
BR-16,22
BR.18
BR-l8,22
BR-h1N,22
%

BR-4 BRAKESYSTEM - Troubleshooting
TROUBLESHOOTING (Cont'd)
Squeaking,squealing
groaningor chatter-
ing noisewhen brakes
areapplied
Note: Brakefriction
materialsinherently
generatenoiseand
heat in order to
dissipateenergy.
As a result
occasionalsqueal
is normalandis
aggravatedby severe
environmetalcondi-
tionssuch as cold,
heat,wetness,snow,
salt mud, etc.
This occasional
squealis not a func-
tional problemand
does not indicate
any loss of brake
effectiveness
Brakedrumsand liningsrotorsand
padsworn or scored
Disc brakes- missingor damaged
brakepad anti-squealshim
Disc brakes- burredor rustedcalipers
Dirty, greased,contaminatedor
glazedlinings
lmproperliningparts
Maladjustmentof brakepedalor
booster push-rod
Drumbrakes- weak damagedor
incorrectshoe hold down springs,loose
or damagedshoeholddown springpins
springsand groovedbackingplate
ledges
Inspect,serviceor repalce
Replace
Cleanor deburr
Cleanor replace
Inspectfor conect usage
replace
lnspectand adjust
Inspect serviceor replace
BR-16,22
BR.l6
BR-18
BR-16,22
BR-'t6,22
BR-6,15
8R.22
Squealingand
squeakingnoise
when brakesare
not applied
Bentor warpedbackingplatecausing
interferencewith drum
lmpropermachiningof drum causing
interferencewith backingplateor shoe
booster push-rod
Poor returnof brakeboosteror master
cylinderor wheelcylinder
Disc brakes- rusted,stuck
Otherbrakesystem,components:
Looseor extra parts in brakes
Reardrum adjustmenttoo tight
causingliningto glaze
Worn, damagedor insufficiently
lubricatedwheelbearings
Serviceor replace
Replacedrum
Inspectand adjust
Inspect,serviceor replace
Inspect lubricateas necessary
Inspect,service,replaceas
required
BR-22
8R.22
BR-6,15
BR-g,15,22
BR.16
BR-16,22

BRAKESYSTEM - Troubleshooting BR-5
TROUBLESHOOTING(Cont'dl
Squealingand
squeakingnoise
when brakesare
not applied(cont'd)
Drumbrakes- weak,damagedor
incorrectshoeholddown springs
Drumbrakes- groovedbackingplate
ledges
lmproperpositioningof pad in caliper
Outsidediameterof rotor rubbing
caliperhousing
Housinginstallationof disc brake
pad support plate
Inspectand service
Correct
BR-22
BR-22
BR-l6
BR-l6
BR-16
Groaning,clicking
or rattling noise
when brakesare
not applied
Stonesor foreignmaterialtrapped
insidewheelcovers
Loosewheel hub nuts
Discbrakes- failureof shim
Discbrakes- wearon slidebushing
Discbrakes- looseinstallation
bolt
boosterpush-rod
Disc brakes- poor return of piston
Drumbrakes- looseor extraparts
Worn, damagedor dry wheelbearings
Removestones,etc.
Tightento correcttorqueand re-
placeif stud holesareelongated
lnspect,replaceif necessary
Inspect,replaceif necessary
Inspect,tightenif necessary
lnspectandadjust
Inspect removeor service
lnspect lubricateor replace
BR-18,22
BR.16
BR.16
BR-16
BR-6,15
BR.18
B,R.22

Stop LightSwitch
PedalPushRod
PedalFreeplay
AsphaltSheet PedatHeight
BRAKESYSTEM - Checksand
CHECKSAND ADJUSTMENTS
CHECKANDADJUSTMENTOFBRAKEPEDAL
1. CHECKTHAT PEDALHEIGHTIS CORRECT'AS
SHOWN
Pedatheishtfromasphaltslreet:
i#;:?ifil.,
IF NECESSARY.ADJUSTPEDALHEIGHT
(a) Sufficientlyloosenthe stop light switch.
(b) Adjust the pedal height by turning the pedal push
rod.
(c) Returnthe stop light switch until it lightly contacts
the pedalstopper.
(d) After adjustingthe pedalheight,checkandadiustthe
pedalfreePlay.
CHECKTHAT PEDALFREEPLAYIS CORRECT,AS
SHOWN
(a) Stop the engineand depressthe brakepedalseveral
times until there is no more vacuum left in the
booster.
(b) Pushin the pedaluntil the beginningof resistanceis
felt. Measurethe distance,as shown'
Pedaffreepfay: 3 - 6 mm (0.12 - O,24in.l
NOTE: The pedalfreeplayis the amountof the stroke
untilthe boosterairvalveis movedby the pedalpushrod.
IF NECESSARY,ADJUST PEDALFREEPLAY
(a) lf incorrect adiustthe pedalfreeplayby turningthe
pedalPushrod.
(b) Startthe engineandcheckthat pedalfreeplayexists.
(c) After adjustingthe pedalfreeplay,check the pedal
height.
CHECKTHAT PEDALRESERVEDISTANCEIS
CORRECT,AS SHOWN
(a) Releasethe parkingbrake.
(b) With enginerunning,depressthe pedalandmeasure
the pedalreservedistance,as shown.
Pedafreservedistanceat 50 kg (11O-21b,490 Nl:
More than 90 mm (3.54 in.l
lf incorrect,troubleshootthe brakesystem.

BRAKESYSTEM - Checksand Adjustments BR-7
@ @
V V
1st
2nd
OPERATIONALTESTOF BRAKEBOOSTER
NOTE: lf available,use a brakeboostertesterto check
the boosteroperatingcondition.
1. OPERATINGCHECK
(a) Depress the brake pedal several times with the
engineoff, and checkthat thereis no changein the
pedalreservedistance.
(b) Depressthe brakepedaland start the engine.lf the
pedalgoesdown slightly,operationis normal.
2. AIR TIGHTNESS
(d Startthe engineandstop it afteroneor two minutes.
Thendepressthe brakepedalseveraltimesslowly.lf
the pedal goes down fartherestthe first time, and
less the second and third time, the boo$teris air
tight.
(b) Depressthe brakepedalwhilethe engineis running,
and stop it with the pedaldepressed.lf there is no
changein pedalreservetravelafter holdingthe pedal
for thirty seconds,the boosteris air tight.
BLEEDINGOFBRAKESYSTEM
NOTE: lf anywork isdoneon the brakesystemor if airis
suspectedin the brakelines,bleedthe systemof air.
CAUTION: Do not let brake fluid remain on a painted
surface. Wash it off immediataly.
1. FILL BRAKERESERVOIRSWITH BRAKEFLUID
Checkthe reservoirafterbleedingeachwheel.Add fluid,if
necessary.
2, CONNECTVINYL TUBETO WHEELCYLINDER
BLEEDERPLUG
lnsertthe other endof the tube in a half-fullcontainerof
brakefluid.
3. BLEEDBRAKELINE
(a) Slowly pump the brakepedalseveraltimes.
(b) While an assistantdepressesthe pedal,loosenthe
bleederplug until fluid starts to runout.Then close
the bleederplug.
(c) Repeatthis procedureuntilthereareno moreairbub-
blesin the fluid.
Bleeder plug tightening torque:
85 kg-cm (74 in.-lb,8.3N.m)
4. REPEATPROCEDUREFOREACHWHEEL

BR.8 BRAKESYSTEM - ChecksandAdjustments
CHECKANDADJUSTMENTOFPARKING
BRAKE
1. CHECKTHAT PARKINGBRAKELEVERTRAVEL
IS CORRECT
Pullthe parkingbrakeleverall the way up, and count the
numberof clicks.
Parking brake lever travel at 2O kg (44.1 lb, 196 Nl:
Sedan 5-Sclicks
Wagon 6-Sclicks
2. IF NECESSARY,ADJUST PARKINGBRAKE
NOTE: Before adjustingthe parking brake,make sure
that the rearbrakeshoeclearancehas beenadjusted.
Forshoeclearanceadjustment,seepagesBR-28,35 and
42.
(a) Removetheconsolebox.
(d Loosenthelocknutandturnthe adjustingnutuntil
thetravelis correct.
(d Tightenthelocknutandinstalltheconsolebox.
*r .;"

BRAKESYSTEM- MasterCylinder BR-9
MASTERCYLINDER
REMOVALOF MASTERCYLINDER
Master Cylinder
BrakeFluidLevelWarningSwitchConnector t) Gasket
II
s
BrakeTube
-cm (ft-lb,
O: Non-reusablepart
1 s5 (11 , 1 5 )
Tighteningtorque
GAUTION: Do not let brakefluid remainon a painted
surface. Wash it off immediatoly.
1. TAKEOUTFLUIDWITH SYRINGE
2. DISCONNECTBRAKETUBES j ,.
Usin! SST, disconnectthe braketubesfrom tfie master
cylinderand3-wayunion.
ssT 09751-36011
3. REMOVEMASTERCYLINDER
(d Disconnectthe brakefluid levelwarningswitch con-
nector.
(b) Removethe two nuts.
(c) Removethemastercylinder,3-wayunionandgasket
from the brakebooster.

a BR.lO BRAKESYSTEM - MasterCylinder
COMPONENTS
ReservorSet Screw
I
F (I r
I rzt{rtaz-l
%-Reservoir
I
9-.o
RNry'jbTry^?
SnapRing
}N ryofltort""* | |- + ) r l l l s c i o t
| |
*" 1 Piston(withSPring)
p - l ^ l N o . 2 p i s t o n R i n s
I I uprrng
-^ I I rootz,rot Ie r l
(ft-rb,N
PistonStopperBolt
: Tighteningtorque
O Gasket
DISASSEMBLYOF MASTERCYLINDER
1. REMOVERESERVOIRFROMCYLINDERHOUSING
(a) Removethe cap and strainer.
(d Removethe set screw.
(c) Pullout the reservoir.
2. MOUNTCYLINDERHOUSINGIN VISE
3. REMOVETWO GROMMETSFROMCYLINDER
HOUSING
4. REMOVEPISTONSTOPPERBOLT
Usinga screwdriver,push the pistonsin all the way and
removethe pistonstopper'bolt.

BRAKESYSTEM- MasterCylinder BR-11
5. REMOVETWO PISTONSAND SPRINGS
(d Usinga screwdriverand snapringpliers,removethe
snapring.
(b) Placea ragon two woodenblocksandlightlytap the
cylinderflangebetweenthe blocksuntilthe pistontip
protrudes.
(c) Removethe pistonby hand,pullingstraightout, not
at an angle.
NOTE: lf pulledout at an angle,thereis a possibilityof
damagingthe cylinderbore.
ASSEMBLYOF MASTERCYLINDER
(Seepage BR-10)
1. APPLYLITHIUMSOAPBASEGLYCOLGREASE
TO RUBBERPARTSINDICATEDBY ARROWS
2. INSTALLTWO SPRINGSAND PISTONS
CAUTION: Be careful not to damagethe rubber lips
on the pistons.
(d lnsertthe springand pistonsstraightin, not at an
angle.
(b) Pushin the pistonand,usingsnapring pliers,install
the snapring.
INSTALLPISTONSTOPPERBOLT
Usinga screwdriver,pushthe pistonsin all the way and
installthe pistonstopperbolt with the gasket.Torquethe
bolt.
Torque: 100 kg-cm (7 ft-lb, 1ON.m)
.g
G@D
t r
.g
OnmmU=$
r t
3.

BR-l2 BRAKESYSTEM - MasterCylinder
INSTALLTv/OGROMMETSTO CYLINDERHOUSING
INSTALLCAPAND STRAINERTO RESERVOIR
6. INSTALLRESERVOIRTO CYLINDERHOUSING
Pushthe reservoirontothe cylinderandinstallthe screw.
Torque: 10 - 25 kg-cm
19- 21 in.-lb,1.0 - 2.4 N.ml
CAUTION: Becausethe master cylinder and reser-
voir tank union is a grommet type, the set screw is
designednot to separatefrom the reservoiror cylinder
and will not tighten down the reservoir. Therefore,
there is a clearanceat point A. Do not insert washers
or such when tightening.
4.
5.
'*i,.

BRAKESYSTEM - MasterCylinder BR-l3
INSTALLATIONOF MASTERCYLINDER
(See page BR-91
1. CLEANOUT GROOVEON LOWERINSTALLATION
SURFACEOF MASTERCYLINDER
2. CHECKTHAT ''VP" MARK ON MASTERCYLINDER
BOOTIS IN CORRECTPOSITION
3. ADJUST LENGTHOF BRAKEBOOSTERPUSHROD
BEFOREINSTALLINGMASTERCYLINDER
(Seepage BR-151
4. INSTALLMASTERCYLINDER
Installa newgasket,the mastercylinderand3-way union
with the two nuts.Torquethe nuts.
*
5. CONNECTBRAKETUBES
UsingSST,connectthe braketubesto the mastercyliner
and 3-way union.Torquethe nuts.
ssr 09751-36011 ;
Torque: 155 kg-cm(11ft-lb, 15 N'ml
1?
6. FILLBRAKERESERVOIRWITH BRAKEFLUID
AND BLEEDBRAKESYSTEM{Seepage BR-71
7. CHECKAND ADJUSTBRAKEPEDAL(SeepageBR-61

8R.14 BRAKESYSTEM - BrakeBooster
REMOVALOF BRAKEBOOSTER
levis
II
dCI
130(9,131
f=s(lr=' I
5llJ
3-WayUnionl
(ft-lb,N.m) :Tighteningtorque
0 : Non-reusablepart
Brake Fluid Level Warning
Switch Connector
BrakeBooster
BRAKEBOOSTER
1. REMOVEMASTERCYLINDER(SeepageBn-gl
2. DISCONNECTVACUUM HOSEFROM BRAKE
BOOSTER
3. REMOVEDISTRIBUTORCAP
4. REPEATPROCEDUREFOREACHWHEEL
5. REMOVEHEATERAIR DUCT
6. DISCONNECTPEDALRETURNSPRINGFROM
BRAKEPEDAL
7. DISCONNECT PUSH ROD CLEVIS FROM BRAKE
PEDAL
Removethe clip and clevispin.
8. REMOVEBRAKEBOOSTER
Removethe four nuts,and pullout the brakebooster.

BRAKESYSTEM - BrakeBooster 8R.15
INSTALLATIONOF BRAKEBOOSTER
(SeepageBR-l41
1. ADJUSTLENGTHOFBOOSTERPUSHROD
(a) SetSSTonthe mastercylinderwiththegasketand
lowerthe pinuntilitstip slightlytouchesthe piston.
ssr 09737-00010
(d Tum SST upsidedown, and set it on the booster.
ssT 09737-OOO10
(c) Checkthat thereis no clearancebetweenthe booster
pushrod and pin headof SST.
Clearance: O mm (0 in.l
(d) Adjustthe boosterpushrod lengthuntilthe pushrod
lightlytouchesthe pin head.
2. INSTALL BRAKEBOOSTER
3. INSTALL MASTERCYLINDER(Seepage BR-131
4. CONNECTVACUUM HOSETO BRAKEBOOSTER
5. CONNECTPUSHRODCLEVISTO BRAKEPEDAL
Installthe clevispin andclip.
6. CONNECTPEDALRETURNSPRINGTO PEDAL
SPRING
INSTALL HEATERAIR DUCT
INSTALLLOWERFINISHPANEL
INSTALLIIA CAP
FILL BRAKERESERVOIRWITH BRAKEFLUID
AND BLEEDBRAKESYSTEM (Seepage BR-71
CHECKBRAKEPEDAL(Seepage BR-61
PERFORMOPERATIONALCHECK(Seepage BR-71
7.
8.
9.
10.
1 1 .
12.

BR-l6 BRAKESYSTEM - Front Brake
FRONTBRAKE
COMPONENTS
I
I
REPLACEMENTOFBRAKEPADS
. lf a squeakingnoise occurs while braking,inspect the
. brake pads. Brakesqueakwill occur when the gap be-
tweenthe padwearindicatorplateandrotordisc reaches
about2.5 mm (0.098in.).
1. REMOVEFRONTWHEET
Rqmovethe wheel and temporarilyfasten the rotdfudisc
with the wheelnuts. ;:E"'
2. INSPECTPAD LININGTHICKNESS
Checkthe pad thicknessthrough the cylinderinspection
' holeand replacepadsif not within specification.
Standard
Minimum
1O.0mm (0.394-in.l
1.0 mm (0.039 in.)

_ [-5s ntzst IFlexibleHose--
> . ; l c o
Ja-- |I 'r fa-l
235 117,231
900 165,88) j Torque Plate
Leh
AH)
RotorDisc
Anti-squealshim
t__Anti-squeal
I Spring
-cm (ft-lb,N.m)
8ao?36

l'-
BRAKESYSTEM - FrontBrake
,ritl t'i'.
ihffi:ir '
' $ ,
8R.17
3. REMOVECYLINDERFROMTOROUEPLATE
(a) Removethe two installationbolts from the torque
plate.
(b) Removethe brake cylinderand suspendit so the
hoseis not stretched.
NOTE: Do not disconnectthe brakehose.
' t ' l
'|
I
, t'r
REMOVEFOLLOWINGPARTS:
(a) Two anti-squealsprings
(b) Two brakepads
(d ."Twoanti-squealshims
(d) 'Two pad wear indicatorplates
(e) .'FoUrsupportplates
CHECKROTORDISCTHICKNESS
(See*step2 on page BR-l91
CHECKROTORDISCRUNOUT
(Seestep 3 on page BR-2OI
INSTALL NEW PAD SUPPORTPLATES
4.
5.
6.
7.
$
INSTALL NEW PADS
(a) Installnew pad wear indicatorplatesto eachpad.
NOTE: Besurethe arrowon the padwe*fiQicator plate
is pointingin the rotatingdirectionof thd diiHt_
(b) Installnew anti-squealshimsto eachpad.
iffi
8.
@
n @ r
ilPnn- )tPllli{1qr4J
w
# BRo281
l ' l

BR-l8 BRAKESYSTEM - FrontBrake
' - t . t
d[
(c! Installthe padsonto eachsupportplate'
9. INSTALLNEW ANTI-SOUEALSPRINGS
10. INSTALLCYLINDER
(d Draw out a small amount of brake fluid from the
reservoir.
(b) Pressin pistonwith a hammerhandleor such.
NOTE: Alwayschangethe padon onewheelat a timeas
there is possibilityof the oppositepistonflying out
(c) Insertthe brakecylindercarefullyso the dust boot is
not wedged.
t1.,
(d) lrfiiprrandtorquethetwo instatlationbolts.
Torque: 255 kg-cm(18ft-lb, 25 N'ml
tt. tNsrArLFRoNrItr#
*12. CHECKTHATFLUIDTEVELISAT "MAX" LINE
I ,iw,i
REMOVALOFCYUTNDER
'
(Seepage BR-l61
1. REMOVECYLINDER
(a) UsingSST,disconnectthe brakeline.
Usea containerto catch the brakefluid.
ssT 09751-36011
(b) Rembvethe two installationbolts and cylinder.
2. REMOVEPADS(Seestep 4 on.pageBR-l71
DISASSEMBLYOFCYLINDER
(Seepage BR-l61
1. REMOVEFOLLOWINGPARTS:
(a) Two slidebushings
(b) Fourdust boots
(d Two collars
I'id
r
SST
"'L i-

BRAKESVSTEM - FrontBrake 8R.19
2. REMOVECYLINDERBOOTSETRINGANDCYLINDER
BOOT
Usinga screwdriver,removethesetringandboot.
3. REMOVEPISTONFROMCYLINDER
(a) Put a pieceof cloth or such betweenthe pistonand
cylinder.
(d Use compressedair to removethe piston from the
cylinder.
WARNING: Do not place your fingers in front of the
piston when using compressedair.
- REMOVEPISTONSEAL FROMBRAKECYLINDER
Usinga screwdriver,removethe pistonseal.
INSPECTIONAND REPAIROF FRONTBRAKE
COMPONENTS
1. TNSPECTPAD LININGTHICKNESS
Standardthickness: 10.Omm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.l
Replacethe pad if the thicknessis lessthanminimum(the
1.0 mm slit is no longervisible)or if it shows signsof
unevenwear.
INSPECTROTORDISCTHICKNESS
Standardthickness: 11.0 mm (0.433 in.l
Minimum thickness: 10.0 mm {0r39ain.}
lf the disc is scoredor worn, or if thicknessis lessthan
minimum,repairor replacethe disc.
4.
:t-$ixt
:r- ,
.-rr,
*i,

BR-2O BRAKESYSTEM - FrontBrake
3. INSPECTROTORDISCRUNOUT
Measuretherotordiscrunoutat 1Omm (0.39in.)from the
outer edgeof the rotor disc.
Maximum disc runout: 0.15 mm (0.0059in.l
lf the runoutis greaterthan maximum,replacethe disc.
NorE: Beforemeasuringthe runout checkthat the front
bearingplay is within specification.
4. IF NECESSARY,REPLACEROTORDISC
(d Removethe torqueplatefrom the knuckle.
(b) Removethe wheel nuts of the temporarilyinstalled
disc and pull off the rotor disc from the axlehub.
(c) Temporarilyinstalla new rotor disc with the wheel
nuts.
(d) Installthe torqueplateonto the knuckle.
ASSEMBLYOF CYLINDER
(SeepageBR-161
1. APPLYLITHUMSOAPBASEGLYCOLGREASE
TO PARTSINDICATEDBY ARROWS
2. INSTALLPISTONSEALAND PISTONIN CYLINDER
INSTALLCYLINDERBOOTAND SETRINGIN
CYLINDER

ti
3.
Q++, i,

BRAKESYSTEM - FrontBrake BR-2;1,,,":l-
4. INSTALLCOLLAR,DUSTBOOTAND CYLINDER
SLIDEBUSHING
(a) Installthecollaranddustboot intothe brake"VlinOer.'"'f,.
(b) Checkthat the boot is securedfirmly to the brlkp
cylindergroove.
';1"t,
(c) Installthe bushinginto the boot.
(d) Checkthat the boot is securedfirmly to the bushing
groove.
t:' t;
INSTALLATIONOFCYLINDER JS.t
(SeepageBR-l61
1. INSTALLPADS ,,,$,
(Seesteps 7 to 9 on pag6sBR-17and 18)-i
2. INSTALLCYLINDER
(Seestep 11 on page BR-271
3. INSTALLFLEXIBLEHOSETO BRAKECYLINDER
4. CONNECTFLEXIBLEHOSETO BRAKETUBE
UsingSST,connectthe flexiblehose.
ssT 09751-36011
SST

BR-22 BRAKESYSTEM - RearBrake(Sedan)
REARBRAKE
Sedan
COMPONENTS
BackingPlate
Shoe
AdjustingShim
O C-Washer
AdjustingLever
Spring
ReturnSpring
o b @
lGc.l?t-lb' Nrdl : Tishtenins
O: Non-reusablepart
REMOVALOFREARBRAKE
1. INSPECTSHOELININGTHICKNESS
Removethe inspectionholeplug,and checkthe shoelin-
ing thicknessthroughthe hole.
lf lessthan minimum,replacethe shoes.
Minimum thickness: 1.0 mm (O.039in.l
2. REMOVEREARWHEEL
3. REMOVEBRAKEDRUM
(Seestep 2 on page RA-51
lf the brakedrumcannotbeeasilyremoved,do the follow-
ing procedure:
(d Inserta screwdriverthrough the holein the backing
plate, and hold the automaticadjustingleveraway
from the adjustingbolt
(b) Using another screwdriver, reduce the brake shoe
adjustmentby turningthe adiustingbolt.

BRAKESYSTEM - RearBrake(Sedan) BR-23
REMOVESHOERETURNSPRING
Usinga screwdriver,removethe returnspring.
REMOVESHOERETURNSPRINGCLAMP
Usinga screwdriver,removethe clamp.
REMOVEFRONTSHOE
(a) Removethe hold-downspring,retainersand pin.
(b) Disconnectthe anchor spring from the front shoe
and removeit.
REMOVEANCHORSPRING
8. REMOVEREARSHOE
(d Removethe hold-downspring,retainersand pin.
(b) Usingpliers,disconnectthe parkingbrakecablefrom
the leverandremovethe rearshoetogetherwith the
strut.
9. REMOVESTRUTFROMREARSHOE
(a) Removethe adjustingleverspring.
(b) Removethe strut.
10. REMOVEPARKINGBRAKELEVERAND AUTOMATIC
ADJUSTINGLEVERFROMREARSHOE
Usinga screwdriver,pryout the C-washerandremovethe
shim and levers.
4.
5.
6.
7.

.,ea-24 BRAKESYSTEM - RearBrake(Sedan)
11. DISCONNECTBRAKETUBEFROMWHEELCYLINDER
UsingSST,disconnectthe line.Use a containerto catch
the brakefluid.
ssr 09751-36011
12. REMOVEWHEETCYLINDER
Removethe two bolts and wheel cylinder.
REMOVEFOLLOWING
CYLINDER:
(d Two boots
(b) Two pistons
(c) Two pistoncups
(d Spring
PARTSFROMWHEEL
INSPECTIONOF REARBRAKECOMPONENTS
1. INSPECTBRAKEDRUMINSIDEDIAMETER
Standardinsidediameter: 180.0 mm (7.087 in.)
Maximuminsidediameter: 181.0mm (7.126in.)
lf the drum is scored or worn, the brake drum may be
lathedto the maximuminsidediameter.
NOTE: Perform operations with the following parts
removed:
(d Oil seal
(b) lnnerandouterbearing
2. INSPECTBRAKESHOELININGTHICKNESS
Minimum thickness: 1.0 mm (0.039 in.)
lf the shoeliningis lessthanminimumor showssignsof
unevenwear,replacethe brakeshoes.
NOTE: lf the thicknessof any brakeshoeis not within
specification,replaceall of the brakeshoes.
. r S
Ao@(
fl@oTu"/ I
v / l l
| | Piston
I
sorins

BRAKESYSTEM - RearBrake(Sedan) 8R.25
Apply Grease
3. INSPECTBRAKE LINING AND DRUM FOR PROPER
CONTACT
Replacethe brakeshoeor lathethe brakedrumasnecess-
4ry.
4. INSPECTWHEEL CYLINDERFOR CORROSIONOR
DAMAGE
5. INSPECTBACKINGPLATEFORWEAR OR DAMAGE
INSTALLATIONOF REARBRAKE
(See page BR-221
1. APPLYLITHIUMSOAPBASEGILYCOLGREASE
TO FOTLOWINGPARTS:
(d Two pistoncups
(b) Two pistons ,, ,
. .
' t
2. ASSEMBLEWHEELCYLINDER
(a) Installtwo new pistoncupsto the pistons.
(b) Installthe two pistonsand spring into the wheet
cylinder.Checkthat the flangeof the pistonsare
pointedinward.
(c) Installtwo new boots.
3. INSTALLWHEELCYLINDER
Installthewheelcylinderon the backingplatewith thetwo
bolts.
Torque: lOO kg-cm (7 ft-lb, 1ON.ml
UsingSST, connectthe braketube.
ssT 09751-36011
Torque: 155 kg-cm(11ft-lb, 15 N.ml
Ao@O
o@rT*1,,i""l l c u pt t
I Spring
Boot

a
BR-26 BRAKESYSTEM - RearBrake{Sedan)
5. APPLY HIGHTEMPERATUREGREASETO
FOLLOWINGPARTS:
(a) Backingplateand brakeshoecontactpoints
(b) Anchor plateand brakeshoecontactpoints
(c) Strut and adjustingbolt contact points
(d) Strut and brakeshoecontact points
6. INSTALL PARKINGBRAKELEVERAND AUTOMATIC
ADJUSTINGLEVERTO REARSHOE
(d Temporarilyinstallthe leverswith the shim and a
new C-washer.
(d Usinga feelergauge,measurethe clearancebetween
the shoeand lever.
Standardclearance: O - 0.35 mm (O- 0.0138 in.l
lf not within specification,adjustwith a shim.
Shimthicknesses mm (in.)
0.2 (0.008) | 0.5 (0.020)
0.3 (0.012) | 0.6(0.024)
0.4(0.016) | 0.s(0.035)
(cl Usingpliers,stakethe C-washer.
INSTALLSTRUTONTO REARSHOE
Set the strut in placeand intallthe adjustingleverspring.
7.
wl

BRAKESYSTEM - RearBrake(Sedan) B,R.27
Left-handThreads
oa)"
o V o
Right-handThreads
Right Wheel
Front
+
Front
r+
Left Wheel
8. INSTALLREARSHOE
CAUTION: Do not allow greaseto get on the rubbing
face
(a) Usingpliers,connectthe parkingbrakecableto the
lever.
(b) Set the rearshoe in placewith the end of the shoe
insertedinthewheelcylinderandthe otherendinthe
anchorplate.
(c) Installthe pin andthe shoe hold-downspring.
9. INSTALLFRONTSHOE
GAUTION: Do not allow greaseto get on the rubbing
face
(a) Installthe anchorspringbetweenthe front and rear
shoes.
(b) Set the front shoein placewith the end of the shoe
insertedin the wheelcylinderandthe strut in place.
(c) Installthe shoehold-downspring,retainersand pin.
INSTALLSHOERETURNSPRINGCLAMP
INSTALLSHOERETURNSPRING
Usinga screwdriver,installthe returnspring.
10.
1 1 .

8R.28 BRAKESYSTEM - RearBrake(Sedan)
12. CHECK OPERATIONOF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parkingbrakeleverof the rearshoe back
and forth, as shown.Check that the adjustingbolt
turns.
lf the bolt doesnot turn,checkfor incorrectinstallationof
the rear brakes.
(b) Adjust the strut length to the shortest possible
amount.
(d lnstallthe drum.
(d) Pullthe parkingbrakeleverall the way up.
13. CHECKCLEARANCEBETWEENBRAKESHOESAND
DRUM
h) Removethe drum.
(b) Measure the brake drum inside diameter and
diameter of the brake shoes. Check that the
differencebetweenthe diametersis the correctshoe
clearance.
Shoe clearance: 0.6 mm (0.O24in.l
lf incorrect checkthe parkingbrakesystem.
14. INSTALLBRAKEDRUM AND ADJUST PRELOAD
(Seepage RA-61
15. INSTALLREARWHEEL
AND BLEEDBRAKESYSTEM(Seepage BR-71
17. CHECKFORFLUIDLEAKAGE
ffi6VFsz'

WagonFWD
COMPONENTS
/a 7-AutomaticAdjusti
uu A Lever
gqJ#*i' J( N b
.-fl 4il)Parkirfse,"x"/ ///cc-
Lever 4//ReturnSpring
WheelCylinder
RearShoe
-*__-a
tr&9)Anchorsprins I LZ/
J.^h' I
- @ @
FrontShoe
AdjustingLeverSpring
-.-Retainer
-
@ ^ ShoeHold-DownSpring
@
kg-cm (ft-lb,N'm) :Tighteningtorque
| : Non-reusablepart
Drum
100(7,r0l
BackingPlate
REMOVALOF REARBRAKE
Removethe inspectionholeplug,andcheckthe shoelin-
Minimum thickness: 1.0 mm (0.039 in.l
2. REMOVEREARWHEEL
3. REMOVEBRAKEDRUM
lf the brakedrumcannotbeeasilyremoved,do thefollow-
ing procedure:
(d Inserta screwdriverthroughthe hole in the backing
plate, and hold the automaticadiustingleveraway
from the adjustingbolt.
(b) Using anotherscrewdriver,reduce the brake shoe
adjustmentby turningthe adjustingbolt.

4. REMOVEFRONTSHOE
(d UsingSST,disconnectthe returnspring.
ssr 09703-30010
(d Removethe hold-downspring,retainersand pin.
(c) Disconnectthe anchor spring from the front shoe
and removeit
REMOVEANCHORSPRING
6. REMOVEREARSHOE
(a) Removethe hold-downspring,retainersand pin.
b) Using a screwdriver,disconnect the parking brake
cablefrom the anchorPlate.
(d Usingpliers,disconnectthe parkingbrakecablefrom
strut.
(a) Removetheadiustingleverspring.
(d Removethestruttogetherwith thereturnspring.
8. REMOVEPARKINGBRAKELEVERAND
AUTOMATICADJUSTINGLEVERFROMREARSHOE
Usingascrewdriver,pryouttheC-washerandremovethe
shimandlevers.
5.
BRO337 BR0286

BRAKESYSTEM - RearBrake(WagonFWD) 8R.31
9. DISCONNECTBRAKETUBEFROMWHEEL
CYLINDER
UsingSST,disconnectthe line.Usea containerto catch
the brakefluid.
10. REMOVEWHEELCYLINDER
Removethe two bolts andwheelcylinder.
11. REMOVEFOLLOWINGPARTSFROMWHEEL
CYLINDER:
(a) Two boots
(b) Two pistons
(c) Two pistoncups
(d) Spring
1. INSPECTBRAKEDRUMINSIDEDIAMETER
Standardinsidediameter: 200.0 mm (7.874in.l
Maximuminsidediameter: 201.0 mm (7.913in.)
lf the drum is scoredor worn, the brake drum may be
Standardthickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.Omm {0.039 in.l
specification,replacethe allof the brakeshoes.
6)o9o
IPiston
Boot
o O "

o / '
;zo /
INSPECTBRAKELININGAND DRUM FORPROPER
CONTACT
Replacethe brakeshoeor lathethe brakedrumasnecess-
4ry.
INSPECTWHEETCYLINDERFORCORROSIONOR
DAMAGE
INSPECTBACKINGPLATEFORWEAR OR DAMAGE
(Seepage BR-291
1. APPLYLITHIUMSOAPBASEGLYCOLGREASE
TO FOLLOWINGPABTS:
(d Two pistoncups
(b) Two pistons
(a) lnstall two new piston cups to each piston, check
that the flangesof the cups arepointedinward.
(b) Install the two pistons and spring into the wheel
cylinder.
Installthewheelcylinderonthe backingplatewiththetwo
bolts.
Torque: 1OOkg-cm (7 ft-lb, 1ON.ml
UsingSST,connectthe braketube
ssT 09751-36011
4.
5.
Pistoncu'
^cloqO
fl@6alA"
Y r lI I Piston
I SPring
Boot

BRAKESYSTEM - RearBrake{WagonFWD) 8R.33
5. APPLY HIGH-TEMPERATUREGREASETO
FOLLOWINGPARTS:
H Backingplateand brakeshoecontactpoints
(c) Strut and adjustingbolt contact points
(d) Strut and brakeshoecontactpoints
6. INSTALL PARKINGBRAKELEVERAND
AUTOMATIC ADJUSTINGTEVERTO REARSHOE
(a) Temporarilyinstallthe leversandshimwith a newC-
washer.
(d Usinga feelergauge,measuretheclearancebetween
the shoeand lever.
Standardclearance: O - 0.35 mm (0 - 0.0138 in.l
Shim thicknesses mm (in.)
o.2 (0.008) | 0.5 (0.020)
0.3 (0.012) | 0.6 (0.024)
o.4 (0.016) | o.g (0.035)
(c) Usingpliers,stakethe C-washer.
7. INSTALLSTRUTONTO REARSHOE
Set the strut and return spring in place
adjustingleverspring.
Shim
and install the

BR-34 BRAKESYSTEM - RearBrake(WagonFWD)
Left-handThreads
Left Wheel
Right-handThreads
Right Wheel
o / o
)"(r"(
Front
.|
80939 8R0253
INSTALT REARSHOE
CAUTION: Do not allow oil or groase to get on the
rubbing face.
(a) Usingpliers,connectthe parkingbrakecableto the
lever.
(b) Passthe parkingbrakecablethroughthe notchin the
anchorplate.
(c) Set the rearshoe in placewith the end of the shoe
insertedinthe wheelcylinderandthe otherendin the
anchorplate.
(d) Installthe hold-downspring,retainersand pin.
INSTALLFRONTSHOE
CAUTION: Do not allow oil or grease to get on the
rubbing face.
(d lnstallthe anchorspringbetweenthe front and rear
shoes.
(b) Set the front shoe in placewith the end of the shoe
insertedin the wheelcylinderandthe strut in place.
(c) Installthe hold-downspring,retainersand pin.
(d) UsingSST,connectthe returnspring.
ssr 09703-30010
8.
9.

BRAKESYSTEM - RearBrake(WasonFWD) BR-35
1O. CHECKOPERATIONOF AUTOMATICADJUSTER
MECHANISM
(d Move the parkingbrakeleverof the rearshoe back
and forth, as shown.Checkthat the adjustingbolt
turns.
the rearbrakes.
Adjust the strut length to the shortest possible
amount.
Installthe drum.
Pullthe parkingbrakeleverall the way up.
CHECKCLEARANCEBETWEENBRAKESHOESAND
DRUM
(a) Removethedrum.
(b) Measurethe brake drum inside diameterand
diameterof the brake shoes.Check that the
differencebetweenthediametersistheconectshoe
clearance.
Shoeclearance: 0.6 mm (0.024in.l
lf inconectchecktheparkingbrakesystem.
INSTALLBRAKEDRUM
INSTALLREARWHEEL
FILI BRAKERESERVOIRWITHBRAKEFLUIDAND
BLEEDBRAKESYSTEM
(SeepageBR-71
CHECKFORFLUIDLEAKAGE
(b)
(c)
(d)
1 1 .
12.
13.
14.
15.

BR-36 BRAKESYSTEM - RearBrake(Wagon4WD)
Wagon4WD
COMPONENTS
StrutandReturnSpring
O C-Washer
$ry"<'i
shoelotAnchorSpring
AutomaticAdjustingLever
arkingBrakeLever
6f,Aai""tins
Shim
RearShoe
Hold-down Spring
clip | ,u
| | / / / ,
{ATK
Front
BackingPtate
O: Non-reusablepart
Wheel Cylinder

6
q Y((^WF -/
// //
*
//l
w
REMOVALOFREARBRAKE
Removethe inspectionholeplug,andcheckthe shoelin-
Standardthickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVEREARWHEEL
3. REMOVEBRAKEDRUM
lf the brakedrumcannotbeeasilyremoved,do thefollow-
ing procedure:
(a) Inserta screwdriverthroughthe hole in the backing
plate, and hold the automaticadjustingleveraway
from the adjustingbolt.
(d Using another screwdriver,reduce the brake shoe
adjustmentby turningthe adjustingbolt.

a
BRAKESYSTEM - RearBrake(Wagon4WD) 8R.37
4. REMOVEFRONTSHOE
(d UsingSST,removethe returnspring.
ssT09703-30010
(b) Removethe hold-downspring.
(c) Removethe front shoeand the anchorspring.
5. REMOVEREARSHOE
(a) Removethe hold-downspring.
(b) Usingpliers,disconnectthe parkingbrakecablefrom
strut.
(a) Removethe adjustingleverspring.
(b) Removethe strut.
7. REMOVEPARKINGBRAKELEVERAND AUTOMATIC
ADJUSTINGLEVERFROMREARSHOE
Usinga screwdriver,pry out the C-washerandremovethe
shim and levers.
DISCONNECTBRAKETUBEFROMWHEELCYLINDER
UsingSST, disconnectthe line.Usea containerto catch
the brakefluid.
ssr 09751-36011
REMOVEWHEELCYLINDER
Removethe two bolts andwheelcylinder.
8.
9.

8R.38 BRAKESYSTEM - RearBrake(Wagon4WD)
Pistoncup
t'"fon
^,I
i *^m.GSDW)'"i.
lK3r)Y*
Am'Q)gr---..-IJ/ SPring
10. REMOVEFOLLOWINGPARTSFROMWHEEL
CYLINDER:
(a) Two boots
b) Two pistons
(c) Spring
1. INSPECTBRAKEDRUM INSIDEDIAMETER
Standard inside diameter: 200.0 mm (7.874 in.l
Maximum insidediameter: 2O1.Omm (7.913in.)
lf the drum is scoredor worn, the brakedrum may be
Minimum thickness: 1.0 mm {0.039 in.l
specification,replaceall of the brakeshoes.
3. INSPECTBRAKE LINING AND DRUM FOR PROPER
CONTACT
Replacethe brakeshoeor lathethe brakedrumas neces-
sary.
4. INSPECTWHEEL CYLINDERFOR CORROSIONOR
DAMAGE
5. INSPECTBACKINGPLATEFORWEAR OR DAMAGE
,- a-Z"
( )
< ) ( )

Apply Grease
(Seepage BR-361
1. APPLY LITHIUM SOAPBASEGLYCOLGREASE
TO FOLLOWINGPARTS:
H Two pistoncups
(d Two pistons
(d Installtwo new pistoncups to the pistons.
(d Install the two pistons and spring into the wheel
cylinder.Check that the flanges of the piston are
pointedinward.
Installthewheelcylinderonthebackingplatewiththetwo
bolts.
Torque: lOO kg-cm (7 ft-lb, 1ON.ml
UsingSST,connectthe braketube.
ssT 09751-36011
5. APPTYHIGHTEMPERATUREGREASETO
FOLLOWINGPARTS:
(a) Backingplateand brakeshoecontactpoints
(d Strut and adjustingbolt contactpoints
(d) Strut and brakeshoecontactpoints
Pistoncup
Piston
'"i'
lKs^*@#@
d@*''*,J."n

BR.4O BRAKE SYSTEM - RearBrake(Wagon4WD)
6. INSTALL PARKINGBRAKELEVERAND AUTOMATIC
ADJUSTINGLEVERTO REARSHOE
(a) Temporarilyinstalltheleversandthe shimanda new
C-washer.
(d Usinga feelergauge,measurethe clearancebetween
the shoeand lever.
Standard clearance: O - 0.35 mm (O- 0.0138 in.)
Shimthicknesses mm (in.)
0.2(o.oo8) | 0.5 (0.020)
o.3 (0.012) I 0.6 (0.024)
o.4(0.016) I o.s (0.035)
(c) Usingpliers,stakethe C-washer.
7. INSTALLSTRUTONTOREARSHOE
Set the strut and return spring in place
adjustingleverspring.
and installthe
Left-handThreads Right-handThreads
pVe
Front
f
Front
+
Left Wheel RightWheel
8RO256 8R0257

8. INSTALLREARSHOE
rubbing face.
H Usingpliers,connectthe parkingbrakecableto the
lever.
(b) Set the rearshoein placewith the end of the shoe
insertedin thewheelcylinderandthe otherendinthe
anchorplate.
(c) lnstallthe pin and the shoe hold-downspring.
9. INSTALLFRONTSHOE
rubbing face.
(a) Installthe anchorspringbetweenthe front and rear
shoes.
(b) Set the front shoein placewith the end of the shoe
insertedin the wheelcylinderand the strut in place.
(c) Installthe shoehold-downspringandpin.
(d) UsingSST,connectthe returnspring.
ssr 09703-30010
10. CHECK OPERATIONOF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parkingbrakeleverof the rearshoe back
and forth, as shown.Checkthat the adjustingbolt
turns.
the rearbrakes.

BRAKESYSTEM - RearBrake(W
(b) Adjust the strut length to the shortest possible
amount.
(c) Installthe drum.
(d) Pullthe parkingbrakeleverall the way up.
CHECKCLEARANCEBETWEENBRAKESHOESAND
DRUM
(a) Removethe drum.
(b) Measure the brake drum inside diameter and
diameter of the brake shoes. Check that the
differencebetweenthe diametersis the correctshoe
clearance.
Shoe clearance: 0.6 mm (0.024 in.l
lf incorrect checkthe parkingbrakesystem.
INSTALLBRAKEDRUM AND REARWHEEL
FILLBRAKERESERVOIRWITH BRAKEFLUID
CHECKFORFLUIDLEAKAGE
1 1 .
12.
13.
14.

BRAKESYSTEM - BrakeHosesandTubes
$-crio
BRAKEHOSESAND TUBES
DISCONNECTAND CONNECTHOSEAND
TUBE
1. DISCONNECTHOSEAND TUBE
(a) Diconnectthe clip.
(b) Usingawrenchto holdthe hose,andSSTto holdthe
tube,disconnectthe tube and hose.
ssT 09751-36011
2. CONNECTHOSEAND TUBE
(a) Connectthe hoseand tube by hand.
(b) Usingawrenchto holdthe hose,andSSTto holdthe
tube, torquethe connection.
ssT09751-36011
(c) Installa new hoseclip.
INSPECTIONOF BRAKEHOSESAND TUBES
1. INSPECTBRAKEHOSES
(a) Inspectthe hosefor damage,cracksor swelling.
(b) Inspectthe threadsfor damage.
2. INSPECTBRAKETUBES
(d Inspectthe tubefor damage,cracks,dentsor corro-
sion.
(b) Inspectthe threadsfor damage.

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