Documente Academic
Documente Profesional
Documente Cultură
SECTION
AX
GI
MA
EM
LC
EC
CONTENTS
FRONT AXLE ..................................................................2
Precautions ..................................................................2
PRECAUTIONS .........................................................2
Preparation ..................................................................2
SPECIAL SERVICE TOOLS ........................................2
COMMERCIAL SERVICE TOOLS ................................3
Noise, Vibration and Harshness (NVH)
Troubleshooting ...........................................................4
NVH TROUBLESHOOTING CHART ............................4
On-vehicle Service.......................................................4
FRONT AXLE PARTS ................................................4
FRONT WHEEL BEARING .........................................5
DRIVE SHAFT ...........................................................7
Components.................................................................8
Auto-lock Free-running Hub ......................................10
DESCRIPTION ........................................................10
REMOVAL AND INSTALLATION ...............................10
INSPECTION ...........................................................11
TROUBLE DIAGNOSIS FOR NOISE .........................11
Wheel Hub and Rotor Disc........................................12
REMOVAL AND INSTALLATION ...............................12
DISASSEMBLY ........................................................13
INSPECTION ...........................................................13
ASSEMBLY .............................................................13
Knuckle Spindle .........................................................14
REMOVAL ...............................................................14
INSPECTION ...........................................................15
INSTALLATION........................................................16
Drive Shaft .................................................................16
COMPONENTS .......................................................16
REMOVAL ...............................................................17
DISASSEMBLY ........................................................18
INSPECTION ...........................................................19
ASSEMBLY .............................................................20
INSTALLATION........................................................22
FE
CL
MT
AT
TF
PD
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FRONT AXLE
Precautions
Precautions
PRECAUTIONS
NEAX0001
SBR686C
When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing and installing brake
tubes.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Always torque brake lines when installing.
CAUTION:
The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
Preparation
SPECIAL SERVICE TOOLS
NEAX0002
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
ST29020001
(J24319-01)
Gear arm puller
NT694
HT72520000
(J25730-B)
Ball joint remover
NT546
KV401021S0
(
)
Bearing race drift
NT153
AX-2
FRONT AXLE
Preparation (Contd)
Tool number
(Kent-Moore No.)
Tool name
Description
GI
KV40105400
(J36001)
Wheel bearing lock nut
wrench
MA
EM
NT154
NEAX0003
LC
Description
EC
FE
CL
NT360
MT
AT
TF
PD
SU
BR
ST
RS
BT
HA
SC
EL
AX-3
IDX
FRONT AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
=NEAX0004
NEAX0004S01
Symptom
AXLE
ROAD WHEEL
BRAKES
STEERING
Noise
Shake
Vibration
Shimmy
Judder
Refer to AXLE
in this chart.
TIRES
SUSPENSION
AXLE
AX-5, 28
Wheel bearing damage
Parts interference
Shake
AX-8, 29
DRIVE SHAFT
AX-19
Joint sliding resistance
Noise, Vibration
Reference page
Imbalance
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
: Applicable
On-vehicle Service
FRONT AXLE PARTS
SMA525A
NEAX0005
Check front axle parts for excessive play, cracks, wear and other
damage.
Shake each front wheel to check for excessive play.
If looseness is noted, adjust wheel bearing end play, then
check ball joint end play.
Make sure that the cotter pin is inserted.
Retighten all nuts and bolts to the specified torque.
: Refer to SU-20, FRONT SUSPENSION.
AX-4
FRONT AXLE
On-vehicle Service (Contd)
NEAX0006
GI
MA
EM
LC
SMA571A
SFA847BA
NEAX0006S01
EC
FE
CL
MT
AT
TF
PD
SFA890
6.
7.
SU
BR
ST
RS
SFA452B
8.
BT
HA
SC
EL
SMA574A
AX-5
IDX
FRONT AXLE
On-vehicle Service (Contd)
NEAX0006S02
2.
SFA891-C
3.
4.
5.
6.
AFA148
7.
8.
9.
SFA845B
SMA580A
AX-6
FRONT AXLE
On-vehicle Service (Contd)
SFA830
GI
MA
EM
LC
EC
FE
CL
MT
DRIVE SHAFT
NEAX0007
AT
TF
PD
SFA901
SU
BR
ST
RS
BT
HA
SC
EL
AX-7
IDX
FRONT AXLE
Components
Components
NEAX0008
WAX019
AX-8
FRONT AXLE
Components (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
SU
BR
ST
RS
BT
HA
SC
WAX018
EL
AX-9
IDX
FRONT AXLE
Auto-lock Free-running Hub
NEAX0041
NEAX0011
AAX008
1.
SFA828B
AX-10
FRONT AXLE
Auto-lock Free-running Hub (Contd)
2.
3.
4.
AFA143
INSPECTION
LC
EC
FE
CL
MT
AT
TF
PD
SU
BR
NEAX0043
Repair order
1. If the rear wheels slip during the 1. Reduce engine speed and drive forhub locking operation, noise can
ward slowly. The hubs will lock evenly
and the noise will stop.
occur in the hubs
AX-11
EM
ST
MA
NEAX0042
1.
2.
Symptom
GI
RS
BT
HA
SC
EL
IDX
FRONT AXLE
Auto-lock Free-running Hub (Contd)
Symptom
Possible cause
Repair order
1. Stop the vehicle, make sure the transfer case lever is fully in the 2H
position, then back up slowly in a
straight line at least 2-3 meters (7-10
feet).
Continual ratchet noise in one wheel when mov- 1. A hub may be mechanically
ing forward.
locked either by damage or
misinstallation
NEAX0012
CAUTION:
If equipped with ABS, disconnect the ABS wheel sensor from
the assembly before removing the front axle assembly. Then
move it away from the front axle assembly area. Failure to do
so may result in damage to the sensor wires and the sensor
becoming inoperative.
1.
SFA825B
3.
SFA364BB
AX-12
FRONT AXLE
Wheel Hub and Rotor Disc (Contd)
4.
GI
MA
EM
LC
AFA141
EC
FE
CL
MT
SFA827B
DISASSEMBLY
NEAX0013
Remove grease seal and bearing races with suitable brass bar.
AT
TF
PD
FA858
INSPECTION
NEAX0014
SU
NEAX0014S01
BR
Wheel Bearings
Make sure wheel bearings roll freely and are free from noise,
cracks, pitting and wear.
Wheel Hub
ASSEMBLY
1.
NEAX0014S02
NEAX0015
ST
RS
BT
HA
SC
EL
AFA156
AX-13
IDX
FRONT AXLE
Wheel Hub and Rotor Disc (Contd)
2.
3.
4.
5.
SBR400DA
AFA122
SFA459B
Knuckle Spindle
REMOVAL
1.
2.
NEAX0016
SFA828B
3.
SFA844-A
AX-14
FRONT AXLE
Knuckle Spindle (Contd)
GI
MA
EM
LC
AFA139
5.
a.
EC
FE
CL
MT
SFA829B
b.
Separate knuckle spindle from upper and lower ball joint studs
with Tool.
During above operation, never remove ball joint nuts
which are loosened in step (a) above.
Tool:
2WD
ST29020001 (J24319-01)
4WD
HT72520000 (J25730-B)
AT
TF
PD
SFA079
c.
d.
INSPECTION
Knuckle Spindle
SU
BR
NEAX0017
NEAX0017S01
Check knuckle spindle for deformation, cracks and other damage by using a magnetic exploration or dyeing test.
ST
RS
SFA830B
NEAX0017S02
BT
NEAX0017S03
HA
SC
EL
AX-15
IDX
FRONT AXLE
Knuckle Spindle (Contd)
INSTALLATION
NEAX0018
SFA962-C
2.
Install knuckle spindle to upper and lower ball joints with lower
link jacked up.
CAUTION:
Make sure that oil and grease do not come into contact with
tapered areas of ball joint, knuckle spindle and threads of ball
joint.
3. Connect tie-rod to knuckle spindle.
4. Install wheel hub and rotor disc. Refer to Wheel Hub and
Rotor Disc, AX-12.
SFA831B
5.
6.
7.
SFA369BC
Drive Shaft
COMPONENTS
NEAX0019
CAUTION:
The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
AX-16
FRONT AXLE
Drive Shaft (Contd)
GI
MA
EM
LC
EC
FE
SFA874-B
CL
MT
REMOVAL
NEAX0020
1.
AT
TF
PD
SFA832B
5.
SU
BR
ST
RS
SFA236
6.
BT
HA
SC
EL
SFA833B
AX-17
IDX
FRONT AXLE
Drive Shaft (Contd)
DISASSEMBLY
Final Drive Side (TS82F)
1.
2.
NEAX0021
NEAX0021S01
SFA880
3.
Move boot and slide joint housing toward wheel side, and
apply matching marks.
4.
5.
SFA963
SFA964
SFA392
SFA799
AX-18
FRONT AXLE
Drive Shaft (Contd)
GI
MA
EM
LC
Wheel Side (ZF100)
SFA455
NEAX0021S02
CAUTION:
The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
The procedures for the joint with the rubber boot are as follows:
Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
Separate joint assembly with suitable tool.
Be careful not to damage threads on drive shaft.
Remove boot bands.
EC
FE
CL
MT
AT
TF
PD
INSPECTION
NEAX0022
Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation and other
damage.
Drive Shaft
ST
NEAX0022S02
Check boot for fatigue, cracks and wear. Replace boot and boot
bands with new.
BR
NEAX0022S01
Boot
SU
NEAX0022S03
BT
HA
SC
NEAX0022S04
CAUTION:
The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
AX-19
RS
EL
IDX
FRONT AXLE
Drive Shaft (Contd)
ASSEMBLY
NEAX0023
NEAX0023S01
1.
Install new small boot band, boot and side joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damaging
boot during installation.
SFA800
2.
3.
Install spider assembly securely, making sure marks are properly aligned.
Press-fit with spider assembly serration chamfer facing
shaft.
Install new snap ring.
SFA397
4.
5.
SFA460BA
6.
Lock new large boot band securely with a suitable tool, then
lock new small boot band.
7. Install new plug seal to slide joint housing by lightly tapping it.
Apply suitable sealant to mating surface of plug seal.
SFA443B
AX-20
FRONT AXLE
Drive Shaft (Contd)
NEAX0023S02
CAUTION:
The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
The procedures for the joint with the rubber boot are as follows:
GI
MA
EM
LC
EC
FE
CL
MT
SFA800
2.
AT
TF
PD
SFA884
3.
4.
SU
BR
ST
RS
SFA473BA
5.
Lock new large boot band securely with a suitable tool, then
lock new small boot band.
BT
HA
SC
EL
SFA443B
AX-21
IDX
FRONT AXLE
Drive Shaft (Contd)
INSTALLATION
1.
NEAX0024
SFA887
SFA846
4.
a.
When installing drive shaft, adjust drive shaft axial end play by
selecting a suitable snap ring.
Temporarily install new snap ring on drive shaft in the same
thickness as the one that was removed.
SFA940
b.
c.
d.
mm
mm
mm
mm
(0.043
(0.051
(0.059
(0.067
in)
in)
in)
in)
SFA847
NEAX0025
NEAX0025S01
mm (in)
0 (0)
Tightening torque
Nm (kg-m, ft-lb)
degree
AX-22
45 - 60
FRONT AXLE
Service Data and Specifications (SDS) (Contd)
At wheel hub bolt
With new grease seal
N (kg, lb)
N (kg, lb)
GI
4WD Models
NEAX0025S02
Tightening torque
Nm (kg-m, ft-lb)
Retightening torque after loosening wheel bearing lock nut Nm (kg-m, ft-lb)
Axial end play
Turning angle
EM
N (kg, lb)
LC
degree
15 - 30
78 - 98 (8 - 10, 58 - 72)
mm (in)
N (kg, lb)
BA
EC
B
7.06 - 20.99 (0.72 - 2.14, 1.59 - 4.72)
NEAX0026
TS82F
Wheel side
ZF100*
mm (in)
AT
Grease
Boot length
CL
MT
29.0 (1.142)
Quality
Capacity
FE
1 (0.04)
mm (in)
MA
Wheel side
TF
g (oz)
95 - 97 (3.74 - 3.82)
96 - 98 (3.78 - 3.86)
PD
mm (in)
SU
BR
ST
RS
SFA877A
*: The ZF100 type (wheel side) joint assembly has two types of boot material; one is made of rubber and the other is made of plastic.
Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.
BT
HA
NEAX0026S01
mm (in)
SC
NEAX0026S02
Thickness mm (in)
Part No.*
AX-23
EL
IDX
FRONT AXLE
Service Data and Specifications (SDS) (Contd)
1.1
1.3
1.5
1.7
1.9
2.1
2.3
(0.043)
(0.051)
(0.059)
(0.067)
(0.075)
(0.083)
(0.091)
39253-88G10
39253-88G11
39253-88G12
39253-88G13
39253-88G14
39253-88G15
39253-88G16
*: Always check with the Parts Department for the latest parts information.
AX-24
REAR AXLE
Precautions
Precautions
PRECAUTIONS
SBR686C
NEAX0027
When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing and installing brake
tubes.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Always torque brake lines when installing.
GI
MA
EM
LC
Preparation
SPECIAL SERVICE TOOLS
NEAX0028
EC
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
FE
Description
CL
KV40101000
(J25604-01)
Axle stand
MT
NT159
AT
ST36230000
(J25840-A)
Sliding hammer
TF
NT126
PD
Removing wheel bearing, oil seal, wheel bearing
lock nut, and ABS sensor rotor
(J45073)
Rear axle bearing
removal kit
SU
BR
LAX034
ST
ST37840000
(
)
Rear axle shaft guide
RS
NT162
BT
NEAX0029
HA
Description
SC
EL
NT360
AX-25
IDX
REAR AXLE
Preparation (Contd)
Tool name
Description
NT115
NT115
AX-26
REAR AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
=NEAX0030
GI
MA
EM
LC
On-vehicle Service
REAR AXLE PARTS
Check rear axle parts for excessive play, wear and damage.
Shake each rear wheel to check for excessive play.
NEAX0031
EC
FE
CL
MT
SMA525A
AT
TF
PD
SRA839
SU
BR
ST
RS
BT
HA
SC
EL
AX-27
IDX
REAR AXLE
On-vehicle Service (Contd)
SRA734
SRA006-A
AX-28
NEAX0032
REAR AXLE
Components
Components
NEAX0033
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
SU
WAX021
BR
ST
RS
BT
HA
SC
EL
AX-29
IDX
REAR AXLE
Components (Contd)
WAX020
Removal
1.
2.
NEAX0034
SRA002
AX-30
REAR AXLE
Removal (Contd)
a.
GI
MA
EM
LC
LAX035
b.
Slide the extension tube with sleeve over the axle shaft.
EC
FE
CL
MT
LAX036
c.
Install the two halves of the collet around the ABS sensor rotor
making sure the lower lip of each collet is slid under the ABS
sensor rotor edge.
AT
TF
PD
LAX037
d.
SU
BR
ST
RS
LAX038
e.
Tighten the forcing screw in the extension tube until the ABS
sensor rotor is removed.
CAUTION:
Do not use an impact wrench to tighten the forcing screw.
f. Remove the Tool and ABS sensor rotor from the axle shaft.
BT
HA
SC
EL
LAX039
AX-31
IDX
REAR AXLE
Removal (Contd)
8.
SRA104
LAX040
a.
Slide the extension tube with sleeve over the axle shaft.
b.
Install the two halves of the bearing puller jaw over the baffle
plate studs.
c.
Slide the sleeve down over the bearing puller jaw halves.
LAX036
LAX041
LAX042
AX-32
REAR AXLE
Removal (Contd)
d.
GI
MA
EM
LC
LAX043
e.
Tighten the forcing screw in the extension tube until the baffle
plate, cage and bearing are pulled free.
11. Remove grease seal in bearing cage with suitable bar.
EC
FE
CL
MT
LAX044
12. Remove wheel bearing outer race with a brass drift (2WD
models).
AT
TF
PD
SRA106
SU
BR
ST
RS
ARA094
Inspection
AXLE SHAFT
NEAX0035S02
Make sure wheel bearing rolls freely and is free from noise,
cracks, pitting and wear.
AXLE CASE
NEAX0035S03
AX-33
BT
NEAX0035S01
WHEEL BEARING
NEAX0035
HA
SC
EL
IDX
REAR AXLE
Installation
Installation
2WD MODELS
NEAX0036
NEAX0036S03
SRA010
3.
4.
5.
6.
SRA510
SRA011
SRA730
7.
AX-34
REAR AXLE
Installation (Contd)
8.
GI
MA
EM
LC
SRA731
EC
FE
CL
MT
SRA652A
AT
TF
PD
SRA653A
b.
c.
ARA088
SU
BR
ST
RS
BT
HA
SC
EL
AX-35
IDX
REAR AXLE
Installation (Contd)
d.
If axial end play is not within the specified limit, reselect axle
case end shims.
While adjusting axial end play, be careful not to damage
oil seal.
SRA006-A
4WD MODELS
NEAX0036S04
1.
SRA288A
2.
SRA289A
3.
SRA761A
4.
SRA762A
AX-36
REAR AXLE
Installation (Contd)
5.
GI
MA
EM
LC
LAX045
6.
a.
b.
EC
FE
CL
MT
SRA763A
7. Install new oil seal to rear axle housing using a suitable tool.
After installing new oil seal, coat sealing lip with multi-purpose grease.
8. Install new O-ring to rear axle housing.
AT
TF
PD
SRA803A
9.
Press ABS sensor rotor onto axle shaft until it contacts wheel
bearing lock nut.
SU
BR
ST
RS
SRA802A
10. Position axle shafts in rear axle housing with Tool as a guide.
Be careful not to damage oil seal.
BT
HA
SC
EL
ARA088
AX-37
IDX
REAR AXLE
Installation (Contd)
SRA006-A
NEAX0037
NEAX0037S03
mm (in)
Part number*
(0.0020)
(0.0028)
(0.0039)
(0.0059)
(0.0079)
(0.0197)
(0.0394)
43086-P0110
43087-P0110
43088-P0110
43086-B9500
43089-P0110
43090-P0110
43036-01G00
*: Always check with the Parts Department for the latest parts information.
4WD Models
Total end play
NEAX0037S04
mm (in)
0 (0)
N (kg, lb)
AX-38