eee MONTERO SERVICE awe y picked te 4Service Manual MONTERO 1998 Volume 2 FOREWORD This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnosis, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or restore the high levels of performance and reliability igned into these outstanding vehicles. % MITSUBISHI orOR SALES OF AMERICA. stich Motors Comporaton reserves the ight to make changes in| desi or omsne sao or emprovement nis pose witout S292 any obigatone upon tea to iatall tom on Ts produts dy manutoetures (© 1997 Mitsubishi Motors Corporation _—_—Printed in U.S.A, GROUP INDEX otosooiaas Propeller Shaft .. Front Axle Rear Axle Wheel and Tire <} Le BY DS bs Power Plant Mount .. Front Suspension ... Rear Suspension Service Brakes. Parking Brakes .... Steering ...... Body . Exterior Interior and Supplemental Restraint System (SRS) . Chassis Electrical . a Heater, Air Conditioning and Ventilation . Component Locations x ° Configuration Diagrams . Circuit Diagrams .. Alphabetical Index .... [ NoTE: For information on all service manual | ‘groups not listed above, please refer to | | Volume 4WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative), (2) If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in drying after painting, remove the SRS components (air bag module, SRS diagnosis unit, front impact sensors) beforehand. (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ~ Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring warnings TSB Revision z ]25-1 PROPELLER ™ SHAFT CONTENTS si0000%020 GENERAL SPECIFICATIONS ... SERVICE SPECIFICATIONS .. LUBRICANTS ... cecesesesseee2 SPECIAL TOOLS .....00eeeee PROPELLER SHAFT TROUBLESHOOTING ...CIRCUIT DIAGRAMS Accessory Socket Active Trac 4WD System Air Conditioning Antilock Braking System Back Door Window Defogger and Mirror Heater Back-up Light Brake Warning Light .... Central Door Locking System ‘ Central Door Locking System eVehicles with keyless entry system>. Centralized Junction Charging System Cigarette Lighter Clock Cruise onto! System Dome Light, Cargo Space Light, Reading Light, Door Light ELC 4-Speed Automatic Transmission Fog Light Fuel Waming Light Headlight Headlight Washer Heated Seat CONTENTS 111 Heater 116 Hor : 92 How to Reas Chrout Diagrams 120 Ignition Key Hole tlumination Light Ignition System + 98 Junction Block (VB) em Joint Connector (J/C) 71 Lighting MontoriKey Reminder/Seat Belt Wiamning Buzzer 2% \ainienance Requed Waring Lh ge ‘Meter and Gauge ...... te MFI System «Vehicles for Federal> po__MFI System to Muti Meter Vehicles without electronic compass> 109 Mut Meter 1126 Oil Pressure Warring Light St Power Distribution. 69 Power Seat 50 Power Windows 60 Radio and Tape Player 74 Nericles without ampliier.... 57 Radio and Tape Player too 1.25 G-B nee = ters indicates the basic color (color of the cable coating) and i 2 34 the second indicates the marking color. No. | Meaning 1 -: Flexible wire “: Twisted wire a Wire size (mmm) “ 3 Basic color (color ofthe cable coating) 4 Marking color NOTE *: No.code indicates 0.5 mm? (.0008 in?). Cable color code in parentheses indicates 0.9 mm? (.0008 in.) TSB Revision90-10 CIRCUIT DIAGRAMS - Junction Block JUNCTION BLOCK (J/B) ca ce cx cap ease =D A | Fusible inks TSB RevisionCIRCUIT DIAGRAMS - Centralized Junction 90-13 DEDICATED FUSE Power suplyereat | No. | Raledcapacity(A) | Housing coler Circuit = = wus ‘ : Battery 2 [10 Red ‘AIC compressor circuit ‘Battery 3 [25 Transparent ‘Condenser fan motor circuit e a |. = Si Tailight relay (battery) [8 _| 10 Red alight circuit Es ed a : Headlight relay (battery) [7 _ | 10 Red Upper beam indicator areut Battery a [10 Red Hazard ight circuit igntionswieh (ACO) [9 | 15 Blue Sunroof icuit Talight relay (battey) | 10 | 15 Blue | Fog ight circuit (Relay box in engine compartment) Dedicates tusee 20007148 ‘TSB Revision90-14 CIRCUIT DIAGRAMS - Centralized Junction MULTI-PURPOSE FUSES Pom erplycrcun [Ne [Fed capaciy (9) [Lowe area Batory 1 [zo = Ignition switch | (1G2) 2 10 | ELC-4 A/T control module, Auto-cruise control-ECU | [3 [io Blower motor relay, Headlight washer relay, Defogger relay (acc) | 4 | 10 | Radio, Clock, Accessory socket relay, Auto-cruise conitelECU, Datalink connector 5 [ts Remote controled minor, Cigarette lighter Battery 6 [ts Door lock relay, Door lock control unit H ignition swicn | (gay [7 [10 ‘Oversrive relay, Variable shock absorber control unt ‘AWD indicatoreontrl unt, ABS contrel unt, Combination meter 8 [10 Power window relay wacey [9 [as Wiper, Washer, Sunroof 10 | 40 Horn eee wey | 40 Combination meter, Multimeter, Antenna moto-ECU, Buzzer assembly | 2 10 “Turn-signal ight, Hazard ight, SRS dagnosis unit Battory 33 [10 : v4 [1s Accessory socket 15 [- - 16 [25 Biower motor faz [as Stop light Ignition wich [ (61) | 18 [15 ‘Back-up light, SRS air bag control unt Battery Ta9 [10 Engine control module, Dome light, Reading light, Cargo. space light, Vanity mirror light, Clock, Door lock relay, Radio, “Auto-cruise control-ECU, ELC-4A/T control module, Ignition key hole illumination light timer, (in junction block) Muti-purpose fuses! TSB RevisionCIRCUIT DIAGRAMS - Centralized CENTRALIZED RELAY Junction 90-15 | Classification Name Classitication Name Relay box in | A-09X | lODorstorage connector | Relay box in | C-70X | ~ engine passenger compartment | A-10X | Headlight relay fompariment | C-71X | = AMX 72x | Power window relay A12x | Generator relay c7sx |- ANBX | ©-142x | Defogger relay | Atax | Taillight relay C-74X | Rear intermittent wiper relay | a-t6x | Condenser fan motor relay ‘AA16X__ | A/G compressor clutch relay | ©-75X | Turn and hazard flasher unit (Relay box in engine compartment) oo fe) |. Le o Ee) (Relay box in passenger compartment) TSB Revision90-16 CIRCUIT DIAGRAMS - Joint Connector JOINT CONNECTOR (J/C) sororeznns 70K} C1 sci) e131 pea rr aE Eee ca supe sm al venicles. any or ene sarmingis connected in J/C are used. ‘TSB RevisionNOTES CIRCUIT DIAGRAMS90-18 CIRCUIT DIAGRAMS — POWER DISTRIBUTION Power Distribution earteR? x HEY ) i 2} 208-4 jen e a 303-L] a it |) 2 © =p ghee | (Relay box \) [Fe‘gnofe |i \comaar tment / far Ba ' 418 coNDIT TONING EI SYSTEM TSB RevisionCIRCUIT DIAGRAMS — Power Distribution 90-19 FUSIBLE LINK a g3 ah \| | | | | J kal sR 2o-u sore HEADLIGHT oR 2 ® =a a ap 0% on ay “4 2 | oof si cation vectan ractige e op. Seto" toie Fa Reo RRS" Blmee Gear buat mae 1: TSB Revision90-20 CIRCUIT DIAGRAMS — Power Distribution POWER DISTRIBUTION (CONTINUED) FUSIBLE LINK @ ie : : ae oD Sapper ager TBE FE aa msenco ae vee EE os Bile seme Gta | Be cero, ae Ee UU eae SARE Men ior marx oh [TsBRevisionCIRCUIT DIAGRAMS — Power Distribution 90-21 19p.08 athe ehiEion t <7 | \ i cugaserte LigiTER 1 apggssomy SocxeT | | egreuens | om re vy HERE Fe: ‘EAD /9, AND, TAPE PLAYER | coe ten cages eye SAE ERIE ay: eae Rea FT ae ately conree_svereu abid Alo THEE Seve pic al Wigs Oe us | Hebitls bien Geitrepe ke iBut Fina amy Hoe TSB Revision90-22 CIRCUIT DIAGRAMS - Power Distribution POWER DISTRIBUTION (CONTINUED) FUSIBLE_LINK @ 8 ew wa x onal i ® $ oF @ ® i" ae a i a Y Y Y SEW Mee EIR Rf pire | garees a | Bae cor ae es fe a | SEED. AUTOMATIC TRANSMISSION | | ae ae aD Gp Gp af 3) Se Ga Sy ee TSB RevisionCIRCUIT DIAGRAMS — Power Distribution 90-23 gain BU vw al a 2s | areca scm cme of 2 * a cggjoaren Peek 2) | free.) [2 1581 compar tment | | 154 | 0-63 | Te aE 0. 85R-W} 0. A5R-L, x aes . eae \ | er sao? rte : ions oven gegceen iar Fame YsHgE OBS oe TSB Revision90-24 CIRCUIT DIAGRAMS - Starting System STARTING SYSTEM soro00soere BATTERY IGMITION SWITCH (ST) a-o| “gyBcome Que Hbfhefee HEDGE miata gen, iBlue ¥ cWhite Y :Yetion SB:Sky c1ue . a Bint Y GRIeeCIRCUIT DIAGRAMS 90-25 NOTES90-26 CIRCUIT DIAGRAMS - Ignition System IGNITION SYSTEM ‘90t00050-—~ IGNITION swrTCH ren) BES BT RATT oy ‘OUCTI-PuREOBE FORE) ne IGNITION POWER TreanStsror THPUT SIGNAL, RSE VLE AE. PORPUSUEE sensor W Scho hooey FUGBUEATORE Encore “See ameren GEUSYEET PosiTion ‘PUEITTGK Eris ca a WISH seme i ENGINE OOWTROL NODULE Bee BE nen | ‘TSB RevisionCIRCUIT DIAGRAMS - Ignition System 90-27 cE) 38-W 38-0 rf some een i Tle | a] |e i i wala iG | ep =o afi HITE. S2.°" FREE sone aren G:Green f :Blue ¥ ii EO" Biron gegen fone 2anue Paige sese cue90-28 CIRCUIT DIAGRAMS NOTESCIRCUIT DIAGRAMS - Charging System 90-29 CHARGING SYSTEM soracarora, SE cn 36-4] | 38-W tension sesrew aR 2B-W lcowsinar ton eT \cenegaTor jeter = RELAY =| cs CD uok po0R,winooe He toi Ta CGH, Paediatr, Bibs wane Eger ang, Eeroscen AND vw] ieee fentes ELGENES PLATE Tia EFAKE whic 2 D | GENERATOR ae wae ee Y Voter paca i ome sonanoons TSB Revision90-30 CIRCUIT DIAGRAMS — MFI System MFI SYSTEM so10008¥="" FUSIBLE LINK © IGNITION SWITCH LGD oe 2B-¥ 2B-y| ee-y)1.258-¥| ENGINE Covteo. Re «0. 888-4) heise is) basses ils Ba,CIRCUIT DIAGRAMS — MFI System IGKITION SWITCH (IG) oa uv «F) 38-4] 90-31 i fasvstew F)1. 254-4 IGNITION POWER ‘TRANSISTOR ca Gs BeiBroen 6 Brenge ENGINE CONTROL ROSULE TSB Revision (ira) ap Fa a Ete ae] PRE] Ga See eis) fee bot eee ets) FBifront oven G.igreen PAYeL gy SBS tueCIRCUIT DIAGRAMS - MFI System 90-32 MFI SYSTEM (CONTINUED) BLE LINK @ IGNITION SWITCH (IG) uv ew RN IGHT se ey eu. a, || agen uD Be Bow C® jze Ge cw zenerwareeany (eres z ep a pees a ae ae ete aoasxeoesCIRCUIT DIAGRAMS ~ MFI System 90-33 Ign TION SUES 2-8 51 ' 6 i PARK ! ue i Sesiithn ! | rit 28 : ep is apels i ean aa} 10 28-1] Si 19 8 [ de 2) cm a 10 ag ae | ep =) aa an Ta aE Te EEace Lae y ee g ne ove8n een ynite ¥ :Yeliow | SB:Sey vive fase” elbias Brake HH if TSB Revision90-34 CIRCUIT DIAGRAMS ~ MFI System MFI SYSTEM (CONTINUED) Ebforrzourns cw ere) eee TSB RevisionCIRCUIT DIAGRAMS ~ MFI System | A 5H Ks Ca 73. “fl 90-35 cB = EEGs & ae aaa E Bmore debi kita Pane Paige ose one TSB Revision90-36 CIRCUIT DIAGRAMS ~ MFI System MFI SYSTEM (CONTINUED) 20. 86R-R (F)0. 888-8. 0. 888-R «P90. 888-8 age | «.gcsrge0 Tice on! 3] lp we HR peat = ‘TSB RevisionCIRCUIT DIAGRAMS - MFI System 90-37 650. 858-R, ‘pip ip ip iP “Pe ES Ge £2 2 am90-38 CIRCUIT DIAGRAMS - MFI System MFI SYSTEM (CONTINUED) ENGINE CONTROL MODULE I sai oo] eR ey 1 x| on cures. poor, = eee te 0,88 Hey" oy | g-R ad l ; (My (Es =e RES! 7 1 Ske Evoren y | G-R L__. RB yew 26 ‘Ia i 16 1 BBifctiBs BBN NE CD CWrrer swe Gl GSR Gl] eee g —S aera eS Fae sansscoea ‘TSB RevisionCIRCUIT DIAGRAMS - MFI System 90-39 vw of Rw L-0 1G ccm L-0 Heo RW 1.258} Lo vw 2D el: a a COMBINATION T Stee a a i: Bd 1 Hecayt Eatir AC wooute [osc Wy e i BaEeMnEa ay [aa eee = ROM Biimoe Gees a oke Banue PI See oe TSB Revision90-40 CIRCUIT DIAGRAMS ~ MFI System MFI SYSTEM soxo00es FUSIBLE LINK © 3+ 23-y | cusciNe S¥STEN 3B-W 2 : (CONTINUED) FUSIBLE LINK © IGNITION SWITCH (IG1) Pea Vv sw-r owi-a| 3B-W [gel at eae go | We eae BG 22 cs ca - fite] Gee TSB Revision90-43 CIRCUIT DIAGRAMS ~ MFI System T wee) a 10 aL-a| 28+ aD GD por iesleast uses TSB Revision90-44 CIRCUIT DIAGRAMS -— MFI System MFI SYSTEM (CONTINUED) ane. Ebiortronns =p ae WEEE GET [TSB RevisionCIRCUIT DIAGRAMS — MFI System 90-45 =e ED ED the, Eithe Beats Bio EMERGE! EMS ae ae eey 2/6 l\2] 6]I cS cs Mes) Gea faye] fre bea T panel eas a) Eee H ELEY Bbienarees gacgeere kur Balint Flier Sore [ise Revision —id90-46 CIRCUIT DIAGRAMS - MFI System MFI SYSTEM (CONTINUED) NE EORIREL. eenay (CONTINUED) CONTROL MODULE eps ong l BTR Bex | SEVERE, cB. ARTA Everew CB ror soe CMD _ CD TSB Revision En & ff S ume neem | Cee Ta Es g (oar) co ig =a F = 3 x | a esCIRCUIT DIAGRAMS — MFI System 90-49 a opis oo. [yeas age, ol] ew ae) 1.298 2E) = SES Tay) CEES — : 2) Sc Beididas GPibreRbe™ GeiGigg” be GRg? BBP Woet 8 gate eeecee ees ‘TSB Revision90-50 CIRCUIT DIAGRAMS - ELC 4-Speed Automatic Transmission ELC 4-SPEED AUTOMATIC TRANSMISSION IguiTioN 7 Seilen sine ait FUSIBLE_LINK © WR | oF 8 ® | sab son A i : 2 CHP Gays BW 1. 25R 10 OR STORAGE y CONNECTOR Page vasvane ee ERNE nel 2 Gage fyretl? ling 125R LG 1.25% Is 2 ER BAERY] BARROS) ELC-4R/7 CONTROL, MODULE = Ewes) Gees eer TSB RevisionTail Light, Parking Light, Side'Marker CIRCUIT DIAGRAMS — Light and License Plate Light ‘TSB Revision 90-59 PBL y cw &-R | ROE Soe, fs REESE cw ea, Oo @ ep ep [fname GRGe] Gees aa yee” BPibigns,orcer GeiGregn” biBuue BERNA Y AVeaige eee90-60 CIRCUIT DIAGRAMS — Fog Light FOG LIGHT ‘orooree——8 21-AER CONDITIONING RAB WPREn AARREAPEFOOSER Clganetre LisHTE® CRUISE CoWTROL SvSTEN a ues ‘Sere fest z DEDICATED, aM ew aR tae @ us oe 3 Ce 1nd G ie . § ‘on ont ek 5 cy 6 Cap HEATED SEAT wa ine Aloe Leet ’ Ga LE ine b.esc-nfo 0.886%, o gonna t T] Fog, ; Net SYSTEM OO Mousa | | eB SRL | fae Bree neaif 7! Eee = Hee 2B] o. a8 * 0.858] 3 ergs a SEbTRE Crear iStieren 0.088 5 a cD cz cm B@@ © ez Es B) EE | Bk" Plumes gitar be SEE Sey ove TSB RevisionDome Light, Ca e CIRCUIT DIAGRAMS — Light and Heecing Uisht 90-61 DOME LIGHT, CARGO SPACE LIGHT AND READING LIGHT sxtctscows REAR DOOR SvITCH aa [arate ve Tiiiced Gaseemene GD - EESIBIE — socencaaa LTSB Revision90-62 CIRCUIT DIAGRAMS - Vanity Mirror Light VANITY MIRROR LIGHT a ie 2 _BBHRECFor om SPCR vee os ow 1 : So) Loan ED Dp C2 Ce ta Se ne ee TSB RevisionCIRCUIT DIAGRAMS — Door Light 90-63 DOOR LIGHT ooo USIBLE LINK © 0 GED scp ss oops SR pas SEF 7 1 2 AEE t EATING, \TORy 7 Fn | CD 0 16 = 6-0 PRB RES" =p PraaSiraTe essere = Dag ice Bae eeeeeeeee TSB Revision90-64 CIRCUIT DIAGRAMS - Ignition Key Hole Illumination Light IGNITION KEY HOLE ILLUMINATION LIGHT FUSIBLE LINK @ cp os 4 ono igacIN HON TOR? Igursion xey Ce od ABRETION ey a] lee ‘Eebaaxanon| gy ane L i ed Sea ee Sens eal Siler 21 3-W Sea ea Pl. Gm 4 ou Wa = [ a = = 2a ad. = ook s¥iToH Oo «FRONT: LH) Gp_ cp ca cp I aaa Tin) GE) foamSacey babes E Seer ep Mase et BeSie” PEbranssrreem Gaigreyr bh eRoye Baghiee | Y AYplioy SBeGey ote TSB RevisionCIRCUIT DIAGRAMS 90-65 NOTES90-66 CIRCUIT DIAGRAMS — Turn-signal Light and Hazard TURN-SIGNAL LIGHT AND HAZARD LIGHT Sftiditlen sarreny au 5 DEDICATED 1 FUSE 0. 858-W] 0. a5y-5| wae Ir ros List <——_ Hae Heo, ieee ed 23510, ae, Better 2R 2 BERLEATED TS [ recy WETER AND Gace ‘@eEOSTATD HeAteR ee pgareer > ay =m = Ty GEE Ee ats Gee ae TSB RevisionCIRCUIT DIAGRAMS ~ Turn-signal Light and Hazard Light OLUMY SWITCH — v 4 CD | l a (om) 7 0.8sy| qroetiny Ly {0-886-L], 0. 856-¥], 8 aa : Buren ES 1&3 a : | TR Rt 2? ED =e Ye Sem) als 3 3 B| 2s] wes aa 8 a a a = CH oD cm cB ben) Gees f Eee) ES ES vicg color cope, a a TSS Hee pang goraer ay” ea oes) GS Pie BEA REP UGE. [Tse Revision Sd 90-6790-68 STOP LIGHT CIRCUIT DIAGRAMS -— Stop Light FUSIBLE LINK @ 5n-8| Hs. an we EWR 2 — a se 7 ae aT i | Gl 4 1 _0.85¢ 0. 856 - 0. 856] in tye fea eS eal uae, Ba 2 o.35c 4 0. 836} 0.856 Fob varron csror:tH «STOP:RiD =p Er 0.896 TSB Revision cD &® En Ge EeCIRCUIT DIAGRAMS - Stop Light 90-69 0.856 €=25) €4D Gm Gm i Bae Be B Eber 8 Geideey biBar Bae Rtulee Ow ove90-70 CIRCUIT DIAGRAMS — Back-up Light BACK-UP LIGHT rete Beye 0-851-8 0.8896 9 o.85L-R ossiee o. 880-3 2 peer [A] alo 3 |e eb 7 7 0.858 o.asa o.ase eee on | MUTE, | 4 a Sa Ea BE ia] ference] farasescae rsmea pS Ge Ee HE Bea eeeee| HEE 2 CD wig color ope, aa : GD ERErown BEEN ERiErSG A ify? GRNRS Healer pee ce TSB RevisionCIRCUIT DIAGRAMS - Horn 90-71 HORN sovons20560 IGNITION SWITCH (ACC) 68 1.256-8 1.2508 a Se 1 cae Lg a0 6-2! @zD seers (5 sit sq sad [Esa eR 1 ea 2) 5 CS GD £2 Ca Gm Co BE 8 6 & 6S 2S eg > BARE Pibimoces gataye kaye Ge Tater Soe one ‘TSB Revision90-72 CIRCUIT DIAGRAMS - Meter and Gage METER AND GAGE ora0se*--7 sie ten cov ‘CLOCK g eae ee ee BP yr soy] ie SSE ad See EM we sg ee LEE ee, 5H = eat? Cam ise NAA aR EEL SARIN Bocce ow o-¥ Foe Lice By] BY a 1 0. 888-4] REEOSTAT| : i aM 0. 858-1] A i 5 a Hi He 8) 2B) ee a a FIR SFGAaE Gat RAD haze 2 ce cD 32 | =e Ge Tae cD ee ce peaiaraee| (items ‘TSB RevisionCIRCUIT DIAGRAMS - Meter and Gage 90-73 cconrrat, a 7 Hap eleeege0iaL cams i Be 18 ew 0. 888-L I Bop yl ce fear aT #] ow | Bees ceive Z| | oa BUEN GD cm aan Gee] Eee a lore oreen guigreer b ipive Yams syelloy Sb:Sev o1ue 3 brShge (ise Ren Jcincurr il Pressure Warning Light, Fuel Warning Light, Maintenance Required 90-74 DIAGRAMS ~ Warning Light, Brake Warning Light, Seat Belt Warning Light OIL PRESSURE WARNING LIGHT, FUEL WARNING LIGHT, MAINTENANCE REQUIRED WARNING LIGHT, BRAKE WARNING LIGHT, SEAT BELT WARNING LIGHT sorost00458 IGNITION SWITCH (761) sew ccusmain sysTes FavitiaN STEN + giageun syereu SETHE Bren ae, a Bay eee = = — CHARGING SYSTEM = ED a to URES ca cD iia aT Ep eS ea O fy GEE GES ‘TSB RevisionCIRCUIT __ Oil Pressure Warning Light, Fuel Warning Light, Maintenance Required DIAGRAMS ~ Warning Light, Brake Warning Light, Seat Belt’ Warning Light 90-75 18 (BSE IgPUrPoSe) (HUBERSPURPOE) v wv ew 2 aw ED} Jace © see? peut BRAKE FLUID 4 ERIE BvitBe fs cm) 7 ae soa Sith em 2 28 aD cs» cm aa i ay i ee E BEBE” Branson geiseagy ke iRiat BaMNAEe Y ARylay Soret ote ‘TSB Revision90-76 CIRCUIT DIAGRAMS — Multi meter MULTI METER sotcouse-> saw cuocs Boo aosee 3 ETuedemeaen O°) cures sete co 2 bo wi oi i 9 2CaD (sca SIRTUPIS oe a RESIN cerseoee ‘ | Tce rey > UEree ine. poser eee TR Bie ell, 2 Elsen “oy J Aes BRE vio {BRA onan! METER gM Gace gL PRERITRE ORAS | Gee ep ca ca a" = Ey OD peste aye ieee 7 (a rr} [au a 7 ‘TSB Revision90-77 NOTES90-78 MULTI METER sov0pe—e7 IGNITION SWITCH IG? 3B-W CWO)“ PERFEISG SPST & o Suncor ion cD > Cee eD 5 Cm hh Aw ot Ss acer Ee] Enea TSB RevisionCIRCUIT DIAGRAMS - Multi meter 90-79 TAIL LIGHT RELAY Fic, washer ey ees Stelle ee janet ECA UENS cerosee Bete ees fe, ae sare FF 2b omy sgutmse, Ee Marrero Ty Eom Sa Tet en 1a | Fe pases core © te ee ee oH B en 4a “ye Ry =) BR-B] BR] Hiyjiame —_ te Hic. iG a8 al aa ||| GRD wrcty > Ue RAR QUEEERENTIAL BY feat DR | ee Beer weren aio sace Teeetoras cD cw ED cE EE] EEE Ee) GSS GR] GE Bless” EP elemaoreen Guigeaer k iBlue BaMgs YNtuley eee ove TSB Revision90-80 CIRCUIT DIAGRAMS — Power Windows POWER WINDOWS sor0048 | AUTO CIRCUIT 5 S : ig apr2r-W] 1er»26- F ar| co] 23] RAR" oev] 21-9 Ca, “Len : we j ] 1 aye ib t zea} au eal@ (a) 3 INT: LH} of power window uorcRL—— | gg ¥ Egan TSB RevisionCIRCUIT DIAGRAMS ~ Power Windows 90-81 “BOVER ear FARES FEES ERE ESEEIEIEEESRESE RENER Fae bet FUSIBLE LIK @ IGNITION SKI7CH (162) 2-3] 2c ai] at] 13 [FRO wel doors’ 2-8 Japs ® 2B-¢ ea-¢ * Ease Peony eS (FRONT: RE) POWER WINDOW NOTOR cH Toeen| oer) Go EE "Bbignareen guise b FBge [SSB Revision Rage § Yel low DeSIeE 5B:5ky bIve90-82 CIRCUIT DIAGRAMS - Power Windows POWER WINDOWS (CONTINUED) POWER WINDOW MAIN SWITCH ih RELAY eaR-y| |e, eB viagov Hee ar| 2 ri 1 de | cigs | giecut ] Be ery eam | EE ERR READ POWER WINDOW MOTOR Joy $B:Skv blueCIRCUIT DIAGRAMS 90-83 NOTES90-84 CIRCUIT DIAGRAMS - Central Door Locking System CENTRAL DOOR LOCKING SYSTEM 01008 iCIRCUIT DIAGRAMS ~ Central Door Locking System 90-85 128 Lac BRR but yy 30 «F)0. 85H-2 oR 1 1 je eat} (FRONT: RE) (BACK DOOR oR OB Crbaror (oA Ei EEE rr] PRA IneSseaC neni ane BEB SBLOT FREE sane i k iBiye Yithise ¥ iYetiow SB:Sky 0 Beifrons G'itranpe""°" Ge:Brgy"b iBes?B EBTnk® Y EVTOige SPISKY Dive ‘TSB Revision90-86 CIRCUIT DIAGRAMS — Central Door Locking System CENTRAL DOOR LOCKING SYSTEM ‘oro, HARE aOR Lock. CONTROL Ont aly Looe "Fis Phew & © ev Bla ee © a] > B VW. i £ ing SHLTOH ceyep| ” iapee Tag 8 : ‘i cep ce = TE TSB RevisionCIRCUIT DIAGRAMS - Central Door Locking System 90-87 sgt 0 CD =| LTT -wereR 7613) > Btaepe| KEY Less en CONTROL UNE i: FE reeCIRCUIT DIAGRAMS — Central Door Locking System CENTRAL DOOR LOCKING SYSTEM (CONTINUED) pooe Lack, ComTROL UNIT ce Snr nn ase) saneCIRCUIT DIAGRAMS - Central Door Locking System 90-89 J BBR EERE SD sii ben Gane. eAtat gro lel Syste esGegen Bly ings he era Best BTS PE sai iinees [TSB Rei90-90 CIRCUIT DIAGRAMS - Heater HEATER sortseene TALL LIGHT RELAY FUSIBLE LINK @ IGNITION SWITCH. al a 1 Buk aL-k 1€@ 2 eo ua su} 2 + o-uht BLOVER es SHgeREaE [iEeeerat =p ce [ED cesisrm em 22-12 ep *ETBR CARRIE goow ane cane Geren sii Fara 8 op Ai ee ae hae SiG" Rive TURN-SIGNAL, Lge BRE RRS a TSB Revision avtrth90-91 NOTESCIRCUIT DIAGRAMS - Air Conditi AIR CONDITIONING FUSIBLE LINK @ IGNITION swiTo: SW-R| 2L-R 1D 2 Cm JB ny eer ee ESSER cS @ | feet — |GiS resistor Gag 78~ Fi jerporpntea een ae 1255-8 eas ae eer “great ie i uri DSACIRCUIT DIAGRAMS - Air Conditioning 90-93 BLOWER SWITCH TONING at ie-R] G-L) 7... 13 CI TIONING. OL uy) i «| 3 t Poh Fe) [tea SIR TEERIO 4 SiRsde foo) a ci [B. su?” E80F ion: creen G :Green BeiBeéet D°ibrdhbe! Gaigrst ‘TSB Revision SB:5Ky ive90-94 CIRCUIT DIAGRAMS — Air Conditioning AIR CONDITIONING (CONTINUED) FUSIBLE LINK @ FUSIBLE LINK © SWeR Pub se SHTTER | | | ageeegyzer? 200800 (eo) een) a Al Pathe see ah C25 G25 CD cB 7] Lr apo [Hebretsta) (ewinseirreamed Eterrta| pits BiB" Stue =< a PBLsone oreen G.iGreen sBive neCIRCUIT DIAGRAMS - Windshield Wiper and Washer 90-95 WINDSHIELD WIPER AND WASHER so;oost0ssa ESF ion: oreen GeiGeee” Rive Wake y a Yellow SB:Sky vive Sen Bibrdnde BoPIn® y Hfaige TSB Revision90-96 CIRCUIT DIAGRAMS - Rear Wiper and Washer REAR WIPER AND WASHER 010067 = SWITCH (ACS) aD (=ii3} Pitts] [ices oisetoud Tahitelsraatetstsenat [| TSB RevisionCIRCUIT DIAGRAMS — Rear Wiper and Washer 90-97 SEfBeurare Eifevcrreye ee (£0. 85W-L

sor007e = Ta Talytioat TOW SwITGA TACO) 2 coo = ay 5-8 192,08 srace pepuoaren 2 Sina com ‘SUNROOF 26-WI ay 6 CD Ema 2 a} © 21S, won : : Te AIRY ie pe aR RERRIET A amu “ | Gy) | = | ey. wea) Cio } ig wera) je Ye { ek u cE i 1 C08) 2 “= T |) SOMBINATION fa 8 4 @ hie Ja 8 Be | RADIO WITH TAPE PLAYER 4 | RADIO WITH CD/TAPE PLAYER (=2D) | a c CH a cm @ ed 7 Tra ray a o@ TVET) EChEEn Tn MEP oe ane 3 i Taos aguas eal 7 - lactancona LTSB Revision JCIRCUIT DIAGRAMS — Radio and Tape Player 90-103 38 (wuLtt PURPOSE | FUS | “eS Igueton Sak Bililfcroe |? (GRafER } iz yorr wa EB 5 8) rena al 2 s fo 9 cD cS ce cm en Eee | ee ee EE E-42) TE Geen HES ee ee A. aaa ¥ ees TSB Revision90-104 CIRCUIT DIAGRAMS ~ Radio and Tape Player RADIO AND TAPE PLAYER 7 ruse SHEA Booy CYR ay ov pe, os grea SinBErER coe 1 zy yey -upo-d 0,25 ac-npe-4 0,85P- 85 3 She ll taoe Re "0 L-Gle=ap _ HME Bee Lg fee a ey w/e (3) Sa Bip 0.85 [ Fuen Lat (GW) =p ee a re i BY) Le 1 1 GRE, swrex—P | SBiforox fe (Bahe2R) ®| 20 lance =) we) {eRe Lets ra ao] L-we-cf aa 12 ba wo i RADIO WITH TAPE FLA RADIO WITH CO/TAPE PLAYER ED ce CD cH —=— GE [ cm fae B Be Goes 2 ssesemeebasd BF sosanotaa TSB Revisiongeaggye p——e Sit a CIRCUIT DIAGRAMS - Radio and Tape Player 90-107 BG 8 TSB Revision FBTR BF San “TSAR 2 x SBilEcror |? re cmp (EMR) we 2 : 4D 28 2 ] o c= ap R] GEEZER) Prerroal gre oreen90-108 CIRCUIT DIAGRAMS - Radio and Tape Player RADIO AND TAPE PLAYER (CONTINUED) Siler Saf" 2 Fea] eel aMeLIFIER =D 3 Pah axel 2, or Ly Pl SPEAKER CS > 5 =a TSB RevisionCIRCUIT DIAGRAMS - Clock 90-109 CLOCK sovo0770379 CATED FOG LIGHT suNROOF BH Ag Hise a ce ae] A Go Gees RE Bima Gia dur Soe Ytuige esty ove ‘TSB Revision90-110 CIRCUIT DIAGRAMS ~ Cigarette Lighter CIGARETTE LIGHTER ‘sor007e IGKLTION SMICH CACC) Oe icine FRSA i. gE “Ebmecw gutsy hie gangs $8 TSB RevisionCIRCUIT DIAGRAMS - Accessory Socket 90-111 ACCESSORY SOCKET sotcevseost 20-8 wom u| ult ce |i Cpls 1a Gapk...js Gia a ; | _ | | | cues oz 0.85P sg" sd ERONT | a : 8 8 | L eo : 4 7 0.885 | eee i aN, eee 23 Sir teegjer: a GD CGaCn cHa#caD ce cm REAR PROPELLER SHAFT/FRONT PROPELLE, SHAFT REMOVAL (1) Make mating marks on the flange yoke and the differential ‘companion flange. (2) Use the plug as a cover so that no foreign material gets into the transmission or transfer. INSTALLATION SERVICE POINT DA PA 3. Journal bearing BA 4. Joural 5. Flange yoke Rear propeller shaft 49 - 59 Nm 2 36 — 43 flbs. 8. Sleeve yoke 7. Sleeve flange NOTE Do not disassemble the Bu joint assembly. DISASSEMBLY SERVICE POINTS 44> SNAP RING REMOVAL Make mating marks on the yokes of the universal joint that is to be disassembled,25-6 113930840 Eront propeller shaft: MB980840 Rear propolir shaft: MBBST4TQ, 494, ‘ME990840, a Front propaler shat: MBog0840 Fear propeller shatt: MB93141Oxrecoroe Front propeller shatt| Rear propeller shaft Snap ring groove brap tng groove Front propeller shaft) Rear propeller shaft MB390840 ‘MB9a0e49| ‘TSB Revision PROPELLER SHAFT — Propeller Shaft “48> JOURNAL BEARING REMOVAL (1) Use the special tool to press in the joumal beariny one side, and take out the journal bearing on the opposie side. (2) Insert the special tool in the other side and press the journal to remove the first journal bearing that was pushed. Caution Do not tap the journal bearings to remove them, as this will upset the balance of the propeller shaft. REASSEMBLY SERVICE POINTS D>AqJOURNALJOURNAL BEARING INSTALLATION (1) Fit the journal onto the yoke. (2) Use the special tool to press the journal bearing the yoke until the snap ring groove is fully visible. (3) Use the special tool to press the opposite side journal bearing into the yoke. Caution Be careful when pressing the journal bearings, as if they are pressed at an angle, the inside of the journal bearings will be damaged by the journal.PROPELLER SHAFT — Propeller Shaft 25-7 Mating marke 2080004 Front propeller shaft) Rear propeller shaft wy, { Meseraio _ ewe Front propeller shaft Snap ring 7? Rear propeller shaft ae Shapring TSB Revision (4) Align the mating marks on the yoke and propeller shaft, and install the propeller shaft journal bearings in the method described in steps (2) and (3) above, D-B-4SNAP RING INSTALLATION (1) Install a snap ring to one side of the journal (2) Use the special tool at the opposite side of the installed snap ring to press in the journal bearing toward the snap ring. (3) Install the snap ring on the opposite side, and measure the clearance of the snap ring groove with a thickness gage. Standard valu Caution Always use snap rings of equal thicknesses on both sides. 0,06 mm (,0024 in.) or less25-8 PROPELLER SHAFT - Propeller Shaft (4) If the clearance exceeds the standard value, adjust by changing the thickness of the snap ring. ‘Snap ring thickness mm (in) Identification color Front propeller shaft | 1.28 (.050) ind 4231 (052) Yellow 7:34 (053) Blue 137 (054) Purple Rear propeller shaft | 1.50 (059) 7 155 (061) Yellow 7160 (063) Bus 5165 (065) Purple TSB Revision26-1 FRONT AXLE CONTENTS: 25109000058 AXLE HUB . sesee18 ON-VEHICLE SERVICE 9 ecards cannes eo Difterential Carrier Oil Soal Replacement ..... 10 Drive Shatt End Play Check ae a0 DIFFERENTIAL CARRIER AND Front Ayle Gear Oil Level Check : 8 FREE-WHEELING CLUTCH . 34 Front Axle Total Backlash Check .... 8 BRE Hace ESE ei Solenoid Valve Operation Check 2 FREE-WHEELING CLUTCH ....++ 3g SEALANTS AND ADHESIVES ............-.3 3ENERAL SPECIFICATIONS . ws1.2 SERVICE SPECIFICATIONS ..... ‘SOLENOID VALVE AND VACUUM INNER SHAFT . 90: OLENOD VALVE AND YA ae IOUCKLE eae “18 speciAL TOOLS. 3 LUBRICANTS us ‘TROUBLESHOOTING ..26-2 FRONT AXLE — Ger ral Specifications/Service Specifications GENERAL SPECIFICATIONS [items Specifications | Front axle hub bearing [ee ‘Taper roller bearing Drive shat | Joint type Outer Biricd joint Inner | Double-ofset joint Differential Final drive gear ype | Hypoid gear Reduction ratio 4272 | Pinion gear ype 2 pinion SERVICE SPECIFICATIONS asron0200ss items Standard value Limit Front axle total backlash mm (in.) ~ 11 (43) Drive shaft end play mm tn.) 04-07 (016-028) | — Solenoid vale resistance [at 20°O (68°F) (ae—a8 = Front hub play inthe axial direction mm (i.) 0.05 (.0020) or less = Front hub turning resistance Nm (in.bs.) ] 03-13 26-11.) - {Spring scale reading N (Ibs.)] | 180-14.) ‘Opening dimension ofthe special | When the B.J. boot | 2.9(.114) - too! (MB991561) mm (r.) band (small is crimped When the B.J. boot | 3.2 (.126) = band (big) is crimped | CGrimpes width of the BJ. Boot band mm (in) 24-28(094-.110) | — Clearance between the B J. boot (larger diameter side) and | 0.05~1.55 (.0020-.0610) | — the stepped phase of the BJ. housing mm (in.) Setting of D.O.5. boot length mm (in.) | 77-88 (3.08-3.27) = Clutch gear play (bearing end play) mm (in.) | 9.05-0.90 (.0020-.0120) | = Final drive gear backlash mm (in.) | 0.11-0.16 (,0043-.0063) | - Drive gear runout mm (in) - 0.05 (.0020) Differential gear backlash mm (in.) | 0-0.076 (0-.0030) 0.2 (.0078) Drive pinion | Withoutoi'sea! | With antixustagent | 0.30.5 (26~4.3) - rotation torque Nm (inlbs,) | with gear oi applies | 0.15-025(1.9-22) |- With oilseal | with antrrustagent | 0.5-0.7 (48-6.1) - | with gear oilapoties | 0.35-0.45 (31-39) | TSB RevisionFRONT AXLE — Lubricants/Sealants and Adhesives/Special Tools 26-3 LUBRICANTS. asso004eses | Hems Specified lubricants Quantity Front axle gearcil Frontifferential) | Hypoid gear oil API classification GL-S 1.18 dm$ (1.22 qts.) or higher SAE viscosity No. $0, 80W D.0.J. boot grease Repair kit grease | 1009 (3.5 oz.) Bu. boot grease Repair kit grease 1309 (4.6 02.) SEALANTS AND ADHESIVES ‘2st00050021 Items: Specified sealants and adhesives, Contact surface of drive flange and front axie hub Contact surface of hub cap and drive flange | Contact surface of differential cover and differential carrier Free-wheeling clutch assembly ‘3M ATD Part No. 8663 or equivalent Drive gear threaded hole ‘3M Stud Lacking Part No. 4170 or equivalent SPECIAL TOOLS [pot ‘Tool number and name | Supersession Application MB990247 7) iB980241-01 or Insertion of inner shaft assembly | YD General service tool (use with MB990211-01) Sliding hammer 980211 ] mB920211-01 Removal of housing tube oil seal | Insertion of inner shaft assembly {use with MB990241-01) Bearing and oil seal installer set | 18900025 T weae0e25-07 Pressing of front axle hub | bearing outer race MB930935-01 Prese-fiting of drive pinion bear- Ing outer race _MB990933-01, MB990934-01, MB990936-01 Press-fiting of differential carrier oil seal MB920934-01 Prese-fiting of fre wheel clutch oll seal MB990926.01 Press-fiting of free wheel clutch needle bearing MB990927-01 TSB Revision26-4 FRONT AXLE ~ Special Tools Too! ‘Too! number and name | Supersession MB920838 | mB990938-01 Application Presstfiting of front axle bearing outer race Handie | Pressviting of front axle hub oil seal | Pressing of knuckle needle bearing | Press-fiting of knuckle ol seal | Presscfitting of housing tube oil | seal | Prese-fitting of differential carrier oll seal | Press-iting of drive pinion bear- ing outer race Press-fittng of free wheel clutch oil seal Press-fitting of tree wheel clutch i needle bearing MB930954 11B990954-01 Removal and adjusiment of lock MB990955 MB990955-01 il seal installer Pressing of front axle hub of seal Pressdfting of housing tube oil seal [eae MB990811-01 | Side bearing cup | remover step plate Removal of side bearing inner | race | MB991119, MB990695, | MBO1113-01 Ma991408 Steering linkage puller Removal of knuckle Disconnecting the lower ball joint and upper ball joint Removal of knuckle Disconnecting the tie rod MB990956 iB90856-01 Needle bearing instar Presscfiing of knuckle needle bearing (use with MB¢30938-01) MB990985 | MB990985-01 il seal installer Press-fiting of knuckle oll seal (use with MB990938-01) KF | mB991587 = | Boot band crimping tot Installation of BW. boot band (resin boot band) ‘TSB RevisionFRONT AXLE — Special Tools 26-5 “ool "Tool number and name | Supersession ‘aplication M0898948 1MD998048-07 Removal and_presedting of inner shat bearing Bearing separator MBSOTSES 18990859-01 Removal of side bearing inner race (use with MB990817-01) Pinion cartier bearing Removal of deve pinion front puller bearing inner race wiTs0RT73 wiTa0aT73 Removal of side bearing Inner \ ‘ace (use with MB990811-01) Insert, Removal of ‘ve pinion front © beanng inser race waiTaaao; MiT#a801 Removal of side bearing Inner pA flee (ae wh aoa0" 04) iT {( Collet set Removal of drive pinion front WW bearing inner race 16900767 18990767-01 Holding of end yore S.., End yoke holder | ; 5980007 18990007-01 ‘Adjustment of prion height { De —— aa | Pinion height gage set ‘wass0a02 1mB990802-07 Press fiting of ive pinion front bearing inner ace © Bearing installor Press-fiting of side bearing inner 18990087 1mB990031-01 Pressing of drive pinion ol seal 5) Drive pinion oil seal S rotator ‘MIT304180 MIT304180 | Press-fitting of drive pinion oil seal Handle | al26-6 FRONT AXLE -— Special Tools aa [fester anda | Sopacasin lea = ~~ raBeea7e6 T weeeo72e-01 Prac ttrg ot es Wieal a. [oes Ball joint dust shield | ae ‘MIT310424 ~~ | wrrst0424 Press-fitting of free wheel clutch oa eS Dae pion ot seat | pogo TaD oy cesinha clase vesicle Eee Fat suspension oa ea TESS aie uaz ODA) ieee aan tse a eam iso [35095 Toes 310200 | MB990930-01 54.0 (2.13) ‘MB990831-01 97.0 (2.24) MB980992-01 61.0 (2.40) MB980933-01 63.5 (2.50) MB990934-01 67.5 (2.66) MB990935.01 71.5 (281) 'MB990996-01 755 (2.97) 1B990937-01 79.0 (3.11) TSB Revision JR eu lstO Me sree eee EyFRONT AXLE - Troubleshooting 26-7 TROUBLESHOOTING sevens ¢-REE-WHEELING CLUTCH Symptom Probable cause [Remedy oes not ock Negaive preseure leakage | Corrector replace vacuum nose | Vacuum tank damaged | Replace ‘Check valve damaged ‘Actuator assembly damaged Shift fork damaged Clutch gear damaged Main shaft damaged ‘Thrust bushing damaged ‘Actuator assembly attaching bolt loose Ratighten attaching bolts Locks but does not | Foreign substances on tooth surfaces of | Clean tooth surtaces or replace become free ‘main Shatt and clutch sleeve Foreign substances on tooth surfaces of | clutch sleeve and clutch gear DRIVE SHAFT, INNER SHAFT ‘Symptom Probable cause Remedy Noise during wheel | Housing tube bent Replace rotation Inner shaft bent | Inner shaft bearing worn, pounding | Replace Drive shaft assembly worn damaged, bent | Check or replace Noise due toexcessive | Inner shaft and side gear serration piay | Replace play of wheel in turning Girection Drive shaft and side gear serration play TSB Revision26-8 DIFFERENTIAL FRONT AXLE — Troubleshooting ‘Symptom Probable Cause | Remedy Constant noise | Incorrect adjustment of drive gear and drive | pinion (poor meshing) Correct or replace Loose, worn or damaged side bearing Correct or replace Loose, worn or damaged dive pinion bearing Correct or replace Wor dive gear or drive inion Correct or replace | Worn side gear thrust washer orpinion shait | Replace | Detormed drive gear or diferental case | Replace Damaged gear | Replace Foreign material Remove the forsign material and check, and replace if necessary Noo Fillor ange Gear noise while Poor gear engagement | Correct or replace arving Incorrect gear adjustment Correct or replace Incorrect drive pinion preload adjustment | Corrector replace Damaged gear Replace Foreign material Femave the foreign material and check, ana replace if necessary. insufficient of Fillor change Gear noise while Incorrect drive pinion rotation toraue | Correct or replace coasting | adjustment | ‘Damaged diferential gear Replace Bearing noise while | Cracked or damaged drive pion rear | Replace driving oreeastng | bearng Noise while turning | Loose side bearing place | Damaged side gear, pinion gear or pinion | Replace | shalt Heat Incortect differential goar backlash | Adust | Excessive preload Insufficient oi Fillor change Oilieakage Glogged vent plug | Olean or replace Cover is not tightened ‘Malfunction of seal Wom or damaged oil seal Re-tighten, apply sealant or replace the gasket, | Replace Excessive oll Adjust the cil level. ‘TSB RevisionFRONT AXLE - On-vehicle Service 26-9 —_— a ~ zvi1508 zisen007 ON-VEHICLE SERVICE aeroor2003s FRONT AXLE TOTAL BACKLASH CHECK 4. If the vehicle vibrates and produces a booming sound due to an imbalance in the drive system, measure the front axle total backlash by the following procedure to see ifthe difierential cartier assembly requires removal. (1) Place the transfer control lever in the "4H" position and drive the vehicle until the 4WD indicator changes from flashing to illuminated. (2) Hold the wheels and place the transfer control lever in the “2H” position. (8) Tur the companion’ flange clockwise until all play is eliminated, and then align the mating mark on the dust cover with the mating mark on the differential carter. (4) Tum the companion flange anti-clockwise until all play is eliminated and measure the distance through which the mating marks moved. Limit: 11 mm (.43 in.) 2. I the backlash exceeds the limit, remove the differential carrier assembly and final drive gear. Then check the differential gear meshing condition and the looseness of the drive shaft or inner shaft splines. FRONT AXLE GEAR OIL LEVEL CHECK 2x2000s0018 Remove the filer plug and check the gear oil level. Check that the gear oil level is not more than 8 mm (.31 in.) below the bottom of the filler piug hole. Specified gear oll: {gear oil API classification GL-5 or higher, SAE ity No. 90, 80W [1.15 dm? (1.22 ats.)] TSB RevisionFRONT AXLE ~ On-vehicle Service TSB Revision DRIVE SHAFT END PLAY CHECK etoorsome 1. Jack up the vehicle and remove the front wheels. 2. Remove the hub cap. 3. Manually push the drive shaft in the direction in which it will closely contact the knuckle. 4, Use a feeler gauge to measure the clearance between the drive flange and the snap ring as shown in the illustration, Standard value: 0.4-0.7 mm (.016-.028 in.) 5. If the play Is outside the standard value, adjust by adding or removing shims. DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT asano1003 1. Remove the under cover. 2. Remove the front hub and knuckle assembly. 3. Remove the left drive shatt Caution ‘When pulling the left drive shaft from the differential carrier assembly, be careful that the drive shaft spline does not damage the oil seal. 4. Remove the right drive shaft from the inner shaft assembly. 5. After removing the shock absorber (R.H.) lower mounting bolt, remove the inner shaft Caution When pulling the inner shaft out from the differential carrier, be careful that the spline of the inner shaft does not damage the oil seal. 6. Remove the actuator mounting bolt from the housing tube, and then remove the hamess from the clamp. 7. Remove the differential mounting bracket (F.H.) and housing tube. 8. Use the special tool to remove the oil seal.FRONT AXLE — On-vehicle Service 26-11 eriwest TSB Revision 9. Press-fit the oil seal firmly by using the special tools. 410. Apply multi-purpose grease to the lip of the oil seal and install it to the drive shaft (LH.) For the right side, apply multi-purpose grease to the lip of the oil seal and install to the housing tube and differential ‘mounting bracket (R.H.) 411. Install the inner shaft and drive shaft (R.H.). Caution 1. Do not damage the lip of the oil seal. 2. The circlip attached to the B.J. side spline of the drive shaft should be replaced with a new clip. 12, Install the actuator and secure the harness with the clamp, 13, Install the shock absorber. 14, Install the hub and knuckle assembly. 15, Install the under cover.FRONT AXLE ~ On-vehicle Service (Check vate ‘Vacuum tank J ul Solenoid Valve B ‘Check valve # Vacca tank Ry Solenoid valve A SOLENOID VALVE OPERATION CHECK astootso 1. Remove the vacuum hoses (blue stripe, yellow st. from the solenoid valves. 2. Disconnect the harness connectors. 3. Connect a hand vacuum pump to solenoid valve A. Apply negative pressure and carry out the following inspections. (1) Even if the hand pump is operated with no other operation, no negative pressure develops. (2) Even when battery positive voltage is applied to solenoid A, the condition is the same as in (1). But when the vacuum hose of solenoid B is blocked by bending at the * mark, negative pressure is maintained. (8) When battery positive voltage is applied to solenoids A and 8, negative pressure is maintained 4. Connect the hand vacuum pump to solenoid valve B. ‘Apply negative pressure and carry out the following inspections. (1) With no other operation, negative pressure is maintained, (2) When battery positive voltage is applied to solenoid B, the negative pressure equalizes. (3) When battery positive voltage is applied to solenoid A, the negative pressure equelizes. 5. Measure the resistance of the solenoid valves. Standard value: 36-46 © [at 20°C (68°F)] Replace the solenoid valve if not within the standard value.FRONT AXLE — Axle Hub 26-13 4XLE HUB an00170185 4EMOVAL AND INSTALLATION 88 Nm 15 fhibs, 9616 49-59 Nm Front hub shi Sealant: 3M ATD Pert No. 8663 or equivalent ] Caution | Make sure that there is no excess specified sealant on | the hub outside surface. Removal steps 1. Hub cap 6. Speed sensor Bd © Drive shaft end play adjustment {fei to GROUP 35C ~ Whee! 2. Snap ring speed Sensor.) Shim 7. Lock washer 4. Drive ftange DeAdd © Wheel bearing preload adjustment 5, Front brake assembly SNAP RING REMOVAL Use snap ring pliers to remove the snap ring from the drive shaft Caution The proper tool for removing and installing the snap ring is a pair of snap ring pliers. Using a screwdriver or other tool can deform or spread the snap ring beyond its yield Point. Be sure to use only snap ring pliers for removing and installing this snap ring. <4) FRONT BRAKE ASSEMBLY REMOVAL (1) Remove the front brake assembly with the brake hose connected. (2) Use wire to suspend the front brake assembly from the upper arm so that the front brake assembly won't fall, Caution Do not twist the brake hose. “40> LOCK NUT/FRONT HUB ASSEMBLY REMOVAL (1) After removing the lock washer, remove the lock nut with the special tool, (2) Remove the front hub assembly from the knuckle toge" with the inner and outer bearings. INSTALLATION SERVICE POINTS D-A<{WHEEL BEARING PRELOAD ADJUSTMENT (1) Use the special too! to tighten the lock nut by the following procedure. 1. Tighten to 162 Nm (119 ftibs.) 2. Loosen to 0 Nm (0 ftlbs.) 3. Re-tighten to 25 Nm (18 ftlbs.) and then loosen 30-40" (2) Install the lock washer. If the lock washer holes are not aligned with the lock nut holes, move the lock nut within a range of not more than 20° until the holes are aligned,FRONT AXLE — Axle Hub 26-15 (3) Loosen the lock nut approximately 30 to 40 degrees to adjust the front hub’s turning resistance and play in the axial direction so that they are at the standard values. Standard value: 0.3-1.3 Nm (26-113 in.lbs.) [Spring scale reading 5-18 'N (1.14.0 Ibs.)] Standard value: 0.05 mm (.0020 in.) or less NOTE If adjustment is not possible, the bearing may be incorrectly installed; check and repair if necessary. The lubrication condition should also be checked, (4) Install the lock washer. If the lock washer holes are not aligned with the lock nut holes, loosen the lock nut to align them. )>B-qDRIVE SHAFT END PLAY ADJUSTMENT Ater installing the shim and snap ring, check the drive shaft end play by the following procedure. i) Install the shim and snap ting to the drive shaft (2) Push the drive shaft in by hand toward the knuckle until they touch. (8) Measure the clearance between the drive flange and the shim with a feeler gage as shown in the illustration Standard value: 0.4-0.7 mm (.016-.028 in.) (4) If the amount of play is outside the standard value, adjust by selecting a shim that will bring the play to the standard value, INSPECTION asscornese ‘© Check the wheel bearing for seizure, discoloration and rough raceway surface. © Check the front hub for cracks. © Check the oil seals for cracks or damage.26-16 FRONT AXLE ~ Axle Hub DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Outer bearing DA 2 Oil seal 3. Inner bearing Mating marks| was 4. Rotor <> 5. Brake disco 8. Front hub DISASSEMBLY SERVICE POINT <4A> BRAKE DISC REMOVAL Make mating marks on the brake disc and front hub, and then separate the front hub and brake disc, if necessary. Caution Lock the disc in a vise and grip it with a copper or aluminum board. REASSEMBLY SERVICE POINT P-A{OIL SEAL INSTALLATION (1) Apply multipurpose grease to the lip of the oll seal and to the inside surface of the front hub. (2) Apply multi-purpose grease to the inner bearing inner race, and then install the inner race to the front hi (3) Use the special tools to press-fit the new oil seal tc front hub unti the oil seal is flush with the front hub end face.\ is i LW] nase aL] | eee FRONT AXLE — Axle Hub 26-17 J War aneo226 Pee TSB Revision BEARING REPLACEMENT 2stoosa0t7 (1) Wipe off any grease on the inside surface of the front hub. (2) Drive out the inner and outer bearing outer races by tapping them uniformly. (3) Apply multi-purpose grease to the outside surfaces of the new inner and outer bearing outer races. (4) Use the special tools to press-fit the inner and outer bearing outer races. NOTE The bearing inner race and bearing outer race should be replaced as an assembly.2 8 FRONT AXLE Knuckle KNUCKLE REMOVAL AND INSTALLATION Pre-removal and post-installation Operation 1” Prass the dust cover witha finger to check whether the dust cover is erackes of damaged ‘© Front Hub Removal and Installation (Rieter to P2613) Removal steps 1. Dust cover 2. Cotter pin MB90111S or MBOGO635 arswse0 147, im 408 fulbs. i m4 8. Cotter pin 7. Upper ball joint and knuckle ‘connection 8. Knuckle REMOVAL SERVICE POINTS 4A TIE ROD ASSEMBLY AND KNUCKLE: DISCONNECTION Use the special tool to disconnect the tie rod from the knuckle. Caution 1. Use a cord to bind the special tool closely so it will not become separated. 2. The nut should only be loosened, not removed.FRONT AXLE — Knuckle 26-19 [oss banjomrjl Upper ball ome) 48 LOWER BALL JOINT AND KNUCKLE/UPPER BALL et nf ee JOINT AND KNUCKLE DISCONNECTION Caution 1. Support the lower arm with a jack when removing the knuckle from the lower ball joint or the upper ball joint. After the knuckle has been removed, lower the jack slowly. Use a cord to bind the special tool closely so that it will not become separated. The nut should only be loosened, not removed. Insert the special tool securely. MBO91405 —veesoes cs se ep INSPECTION ero02s0025 © Check the needle bearing for wear or damage. © Check the knuckle for cracks or bends. © Check the knuckle spindle for wear or pounding. DISASSEMBLY AND REASSEMBLY WL Disassembly stops bCq 1 Oil seal PB 2 Spacer 4am PAS 5. Needle bearing 4. Knuckle ‘TSB RevisionFRONT AXLE ~ Knuckle DISASSEMBLY SERVICE POINT “4Ap NEEDLE BEARING REMOVAL (1) Remove the oil seal and take out the spacer. (2) Drive out the needle bearing by tapping the needles uniformly. Caution Once removed, the needle bearing must not be reused. REASSEMBLY SERVICE POINTS D-A< NEEDLE BEARING INSTALLATION (1) Apply multipurpose grease to the roller surface of the new needle bearing. (2) Use the special tools to press-fit the needle bearing until it is flush with the knuckle end face. Caution Use care to prevent driving the needle bearing too far in. D>B-4 SPACER INSTALLATION (1) Apply mutt-purpose grease to the knuckle attachment surface of the spacer. (2) Install the spacer to the knuckle with the chamfered toward the center of the vehicle. P>C-qOlL SEAL INSTALLATION (1) Use the special tools to press-fit the new oil seal until it is flush with the knuckle end face. (2) Apply multi-purpose grease to the inside and lip of the oil seal. ‘TSB RevisionFRONT AXLE — Drive Shaft 26-21 DRIVE SHAFT @EMOVAL AND INSTALLATION st003so269 Pre-removal and Post-installation Operation with 2 finger to check whether Under Cover Left drive shaft Right drive shaft ‘Sealar SM ATD Part No. 8663 or equivalent Removal steps 1. Hub cap 8. Cotter pin <<“ 2. Snap ring 8. Lower ball joint and knuckle 3. Shim ‘connection <> 4. Front brake assembly 10. Cotter pin 5. Speed sensor {D> 11. Upper ball joint knuckle connection (Refer to GROUP 850 — Wheel 42, Front hub and knuckle assembly Speed Sensor.) ED PA 13. Drive shalt 6 Cotter pin 14. Circlip <> 7. Tie rod assembly and knuckle connection TSB RevisionFRONT AXLE — Drive Shaft Mpe91113 or MB990695-a1sw590. Lower ball joint Upper ball joint REMOVAL SERVICE POINTS <4Ap SNAP RING REMOVAL Use snap ring pliers to remove the snap ring from the drive shatt. Caution ‘The proper tool for removing and installing the snap ring Is a pair of snap ring pliers. Using a screwdriver or other tool can deform or spread the snap ring beyond its yield point. Be sure to use only snap ring pliers for removing and installing this snap ring. 48> FRONT BRAKE ASSEMBLY REMOVAL (1) Remove the front brake assembly with the brake hose connected. (2) Use wire to suspend the front brake assembly from the upper arm so that the front brake assembly won't fall Caution Do not twist the brake hose. <4C> TIE ROD ASSEMBLY AND KNUCKLE. DISCONNECTION Use the special tool to disconnect the tie rod from the knuckle. Caution 1. Use a cord to bind the special tool closely so tha: it will not become separated. 2. The nut should only be loosened, not removed. <4D> LOWER BALL JOINT AND KNUCKLE/UPPER BALL JOINT AND KNUCKLE DISCONNECTION Caution 1. Support the lower arm with a jack when removing the knuckle from the lower ball joint or the upper ball joint. 2. After the knuckle has been removed, lower the jack slowly. 3. Use a cord to bind the special tool closely so that it will not become separated. 4. The nut should only be loosened, not removed. 5. Insert the special tool securely. TSB RevisionFRONT AXLE - Drive Shaft 26-23 <4ED DRIVE SHAFT REMOVAL FOR LEFT DRIVE SHAFT Pull the rive shaft out from the differential carrier. Caution When pulling the drive shaft out from the differential cartier, be careful that the spline part of the drive shaft does not damage the oil seal. INSTALLATION SERVICE POINT >A DRIVE SHAFT INSTALLATION FOR LEFT DRIVE SHAFT Drive the drive shaft into the differential carrier with 2 plastic hammer. Caution 4. Be careful not to damage the lip of the oil seal. 2. The circlip attached to the B.J. side spline of the drive shaft should be replaced with a new clip. INSPECTION seracasoas2 © Check the operation of the ball joint and check for excessive looseness. ‘© Check the boot for wear or damage. © Check the splines for wear or damage.26-24 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY asi00 Boot repair kit (B..) vre0208 8 SG IF Ps Pits ~ 5s yn. -_ 2 } i \\ 9 0 - / | 1 jn by 6 Ve $ a B.J. repair kit D.O.. repair kit Boot repair kit (D.0.J.) | Disassembly steps Reassembly steps 1. D.O.4. boot band (large) 16. BJ, assembly 2: D.0.J. boot band (small) Ad 15. B.. boot 3. Cireip DA 14. 8. boot band (large) 4. D.O.d. outer race DA 13. BJ. boot band (small) 5. Dust cover 2. D.O.J. boot band (small) 6 Circlip 12, D.O.J. boot <> 7. Ball PB 8 DOJ. cage

12. D.O. boot BC 4: D.O.s. outer race 18. Bu. Boot band (small) 5. Dust cover 14. B.J. boot band (large) 3. Circo 15. Bu. boot 1. D.0.J. boot band (large) 16. B.J. assembly 6 Circip TSB RevisionFRONT AXLE — Drive Shaft 26-25 ‘UBRICATION POINTS Grea Repair kit grease 130 g (4.6 oz.) NOTE ‘The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot |Grease: Repair kit ‘grease Grease: Repair kit grease 100 g (3.5 02.) NOTE ‘The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. DISASSEMBLY SERVICE POINTS 44> BALLS REMOVAL Remove the balls from the D.O.J. cage. TSB Revision |FRONT AXLE - je Shaft zutvos7 Is 11x0138 MB991561 48> D.0.J. CAGE REMOVAL Remove the 0.0.J. cage from the D.O.J. inner race ir direction shown in the illustration. < Screw in the adjusting bolt. Loosen the adjusting bolt. NOTE (1) The dimension (W) is adjusted by approx. 0.7 mm (.028 in.) per one tum. (2) Do not turn the adjusting bolt more than one tum, TSB RevisionFRONT AXLE - Drive Shaft 26-27 ~ a, boot band (srl) Prosruding portion (4) Place the boot band (small) along the protruding portion, and install it so that there Is some clearance (A) along the other side, (6) Use the special tool to crimp the BJ. boot band {small.) Caution (1) Hold the drive shaft perpendicularly, and use the special tool to crimp the B.J. boot band securely. (2) Crimp the BJ. boot band until the special tool touches the stopper. (6) Check that the crimped width (B) is within the standard value. Standard value (B): 2.4 - 2.8 mm (.094 ~ 11 When more than 2.8 mm (.110 in.)> Readjust the dimension (W) of step (3) to the value calculated by the following equation, and repeat step (5). W = 5.5 mm (217 in) ~ B Example: if (B) is 2.9 mm (114 In.), (W) Is 2.6 mm (102 in.) Remove the B.J. boot band, readjust the dimension (W) of step (3) ‘to the value calculated by the following equation, and use anew B.J. boot band to repeat steps (4) to ©). W = 55 mm (217 in) ~ B Example: if (B) is 23 mm (091 in.), (W) is 3.2 mm (126 in.) (7) Check that the BJ. boot band is secured correctly. If the band is secured incorrectly, repeat steps (4) to (6) to replace it (8) Fill the inside of the BJ. boot with specified grease, Specified grease: Repair kit grease 130 g (4.6 oz) Caution The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease. ) TSB RevisionFRONT AXLE - Drive Shaft BJ, boot Protruding portion BJ. boot band (large) iT annxors7 (Charter _ Ball (mall (Chamfer large) Shatt Snap fing - Inner race "HP (9) Install the BJ. boot to adjust the clearance (C) betwean the Bu. boot end and the stepped phase of the housing is within the standard value. Standard value (C): 0.05 ~ 1.55 mm (.0020 ~.061 in.) (10)Agjust the opening dimension (W) to the standard value ‘as mentioned at the step (3). Standard value (W): 3.2 mm (.126 in.) (11)Place the Bu. boot band (large) along the protruding portion, and install it so that there is some clearance (0) along the other side. (12)Use the special tool to crimp the B.J. boot band (large) in the same way as the step (5) (13)Check that the crimped width (E) is within the standard value. Standard value (E): 2.4 - 2.8 mm (094 ~ .110 in. Readjust the dimension (W) of step (10) to the value calculated by the following equation, and repeat step (12). W = 5.8 mm (228 Example: If (E) is 2.9 mm (.114 in. (W) is 2.9 mm (114 in). Remove the BJ. boot band, readjust the dimension (W) of step (10) to the value calculated by the following equation, and use new B.J. boot band to repeat steps (11) to (12). W = 5.8 mm (.228 in.) - E Example: If (E) is 2.3 mm (.091 in.), (W) is 3.5, mm (138 in.) (14)Check that the boot band is secured correctly. If the band is secured incorrectly, repeat steps (11) to (13) to replace it D-B-4D.0.. CAGE/D.O.J, INNER RACE/SNAP RING/BALLS INSTALLATION Install the cage, balls and inner race to the dive shaft, and fit the snap ring securely into the groove in the drive shaft Caution The inner race should be installed so that the Ir chamfer on the spline section is on the drive shaft s TSB RevisionFRONT AXLE - Drive Shaft 26-29 Boot band (mal) Direction of drive shaft rotation ‘when vehicle ie moving forward Bost bang, zsB007 }>C-4D.0.J. OUTER RACE INSTALLATION (1) Fill the inside of the D.OW. outer race and D.O.J. boot with specified grease. Specified grease: Repair kit grease 100 g (3.5 oz) Caution The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease. (2) Install the circlip onto the D.O.J. outer race. Place the D.O.J, boot over the D.O.J. outer race, and then use a boot band (small) to secure the boot. Caution Do not secure the boot band (large). (3) Secure the drive shaft, and then move the D.0.J. outer race until it is at the position where the D.O.J. boot assembly dimension is at the standard value. Standard value (A): 77-83 mm (3.03-3.27 in.) (4) Remove part of the D.0.J. boot from the 0.0.J. outer race to release the air within the boot. (5) Secure the boot band (large) on the D.O.J. boot. Caution Check that the installation directions of the boot bands are correct. INSPECTION ‘© Check the drive shaft for bending or wear. © Check the BJ. for entry of water, foreign’ materials or rust © Check the D.0.J. cage, D.O.4. inner race and balls for rust, wear or damage. © Check the circlip for damage or deformation, © Check the D.O.J. outer race for wear or damage. TSB Revision26-30 FRONT AXLE - Inner Shaft INNER SHAFT REMOVAL AND INSTALLATION ro-fomoval and Post-installation Operation ©” Press the dust cover with a finger to check whether the dust cover is cracked or damaged, ‘© Undor Cover Removal and instalation Sigs 10am Sel fin SS — Removal steps 1. Front hub and knuckle assembly (Refer to P26-18,) Drive shaft assembly (RLH.) (Refer to P26-21,) bolt and nut Inner shaft 2 3 A> pad 4 5. Cirelip So a pent Shock absorber lower mounting 12.Nm 9 fedbs. 12m ofibs. 8 'S 2s a nF tee © 36-45 fulbs. i eer io RY] X a & lbs. us St Ros. 6. Differential mounting bracket (F.H.) 7. Actuator mounting bolt 8. Breather pipe 8. Breather hose 10. Housing tube REMOVAL SERVICE POINT <4Ap INNER SHAFT REMOVAL Attach the special tools to the flange of the shaft, and pull the inner shaft out from the front differential carrier. Caution When pulling the inner shaft out from the front differe cartier, be careful that the spline part of the inner si... does not damage the TSB RevisionFRONT AXLE - Inner Shaft 26-31 INSTALLATION SERVICE POINT | D-A¢INNER SHAFT INSTALLATION Drive the inner shaft into the front differential carrier by using I the special tools (IMB990241 and MB990211). Caution Be careful not to damage the lip of the dust seal and oil seal. INSPECTION ‘26100810010 ‘© Check the inner shaft for bend. Check the bearing for wear or discoloration. Check the housing tube for cracks. © Check the dust seal for cracks or damage. DISASSEMBLY AND REASSEMBLY petoos20013 Disassembly steps 4. Inner shat PB 5. Dust cover 4am PC 2. Bearng 4. Housing tube DA 5. Dust seal DISASSEMBLY SERVICE POINT <4A> BEARING REMOVAL (1) Bend the outside edge of dust cover inward with a hammer. TSB Revision26-32 FRONT AXLE — Inner Shaft T | ‘15990938 MBea0ess { ‘Steel pine (2) After the special too! has been installed as shown, tighten the nut of the special tool until section “A” of the spr tool touches the bearing outer race. (3) Press out the inner shaft from the bearing Caution Do not allow the REASSEMBLY SERVICE POINTS D»A{DUST SEAL INSTALLATION Use the special tools to press-fit the new dust seal into **~ housing tube until it is flush with the housing tube end fe »B-4DUST COVER INSTALLATION Use a steel pipe to press-fit a new dust cover onto the inner shatt. iner shaft to drop. Steel pipe mm (in) [ Overall length 50(17) ‘Outer diameter 75 (3.0) Wall thickness 4(2) znwste >C-4BEARING INSTALLATION Use the special tool to press-fit the bearing onto the inner shatt TSB RevisionFRONT AXLE — Solenoid Valve and Vacuum Hose 26-33 SOLENOID VALVE AND VACUUM HOSE ez004s001s 4EMOVAL AND INSTALLATION 9Nm 7 fies. AS Ae 8 ‘9.Nm Tubs. 9 ee peae enc sco Removal steps 4. Check valve Bq 6. Vacuum hose 2, Vacuum hose 7. Vacuum pipe assembly 3 Solenoid valve connector 8 Vacuum tank 4. Vacuum pipe Aq 8 Vacuum hose PB 5. Solencia valve assembly INSTALLATION SERVICE POINTS DPA VACUUM HOSE INSTALLATION Install the vacuum hoses so that the identification colors match o those of the pipe assembly and the actuator. Furthermore, there are no identification colors on the vacuum hose at the ‘vacuum tank connection. XK Nipple > B-q VACUUM HOSE/SOLENOID VALVE ASSEMBLY Sf INSTALLATION nateafon 5 eniaton Install the vacuum hose and solonoid valve assembly so that coor ysion ‘sentation asco the colors of the identification marks are matched.26-34 FRONT AXLE - Differential Carrier and Free-wheeling Clutch DIFFERENTIAL CARRIER AND FREE-WHEELING CLUTCH cxzcors-s REMOVAL AND INSTALLATION Pre-removal and Postinstallation Operations fe" Press the dust cover with a finger to check whether the. dust cover Ig cracked oF damages. Under Cover Removal and instalation © Gear if Draining and Suppiying (Refer to P.26-9.) eet 36-43 fuibs. 88 Nm x 65 felbe. ye s-67 Nm 32m 48-51 ftbs. 9 ftlbs. sft UES Li an =< 18m 20 51 fulbs. 67 Nm 51 tubs, 98-118 Nm 72-87 flbs. 2 eee Sealant: 3M ATD Part No. 8563 or equivalent ‘20007088 Removal steps mC 1. Vacuum hose 12, Front differential carrier assembly, 2 Pin housing tube and differential 3. Actuator assembly ‘mounting bracket (F.H.) 4. Drive shaft (Refer to P26-21,) 418. Differential mounting bracket (F.H.) 5. Circlip 14, Breather pipe 6. Inner shaft (Refer to P.26-30.) 415: Breather hose 7. Circlip 18. Housing tube Ab hE 8 Front propeller shatt 17. Free-wheeling engage switch © Suport the front’ differential with 18. Gasket transmission jack. D-Add 19. Free-wheeling clutch assembly 9. Differential mounting bracket (LH.) 20. Front differential carrier assembly 410. Front suspension crossmember ‘V1. Free-wheeling engage switch connector TSB Revision ]FRONT AXLE - Differential Carrier and Free-wheeling Clutch 26-35 [————ietsgnarne >] REMOVAL SERVICE POINT <4Ap FRONT PROPELLER SHAFT REMOVAL Make mating marks on the flange yoke of the rear propeller shaft and on the companion flange of the differential case. Caution Suspend the propeller shaft from the body with wire, ete. to avoid spilling transmission fluid and to avoid injury from falling propeller shaft when not secured. 200505 INSTALLATION SERVICE POINTS DPA FREE-WHEELING CLUTCH ASSEMBLY INSTALLATION Alter installing the free-wheeling clutch assembly, select a spacer so that the clutch gear play (bearing looseness) is within the standard value Standard value: 0.05-0.30 mm (.0020-.0120 in.) D-B-4FRONT PROPELLER SHAFT INSTALLATION Install the front propeller shatt so that the mating marks on the flange yoke and differential carrier companion flange are ned. >C-4 VACUUM HOSE INSTALLATION Install the vacuum hoses so that the identification colors match those of the actuator assembly nipples. INSPECTION 25200180016 FREE-WHEEL ENGAGE SWITCH The switch Is normal if there is continuity when the shaft is pushed in and no continuity when the shaft is released, Continuity Contact Pole zrse00e7 ‘TSB Revision26-36 FREE-WHEELING CLUTCH DISASSEMBLY AND REASSEMBLY E0208 Removal steps ‘Main shaft ‘Spacer Bearing Clutch sleeve Spring pin Snap ring Shift fork FRONT AXLE — Free-wheeling Clutch sezoczennes 8. Shift rod 9. Oil seal {8b P84 10. Clutch gear BP PB 11. Bearing DA 12. Oil seal 18. Clutch housing DISASSEMBLY SERVICE POINTS <4Ap MAIN SHAFT/BEARING REMOVAL (1) After assembling the special tool as shown in the illustration, tighten the nut of the special tool so that A section of the special tool contacts the bearing outer race. (2) Use a press and pull the bearing off the main shaft. TSB RevisionFRONT AXLE — Free-wheeling Clutch 26-37 (4 stest plate 21160087 Ve Wi MrTa04160 Mrsto424 ‘s11E0082 a { a 18990799, pgaa890 TSB Re\ «48> CLUTCH GEAR/BEARING REMOVAL (1) Use a press and a steel plate to remove the clutch gear and bearing together. (2) Use a press to hold the supports against the bearing inner race, and then separate the clutch gear and bearing. REASSEMBLY SERVICE POINTS PA(OIL SEAL INSTALLATION Use the special tool to tap the oil seal until it is flush with the clutch housing. )>B-4BEARING/CLUTCH GEAR INSTALLATION (1) Use the special tool to press-fit the bearing onto the shoulder of the clutch gear. (2) Use the special tool to press-fit the bearing into the side of the clutch housing, Caution Place the special tool against the outer race of the bearing. ion26-38 FRONT AXLE - Free-wheeling Clutch ME990938, a ‘Mega0926 0088 Spring pin SK Gee ae ae ‘Chamter fant @) D-C-qOL SEAL INSTALLATION Use the special tool to tap the oil seal. D-D-4SPRING PIN INSTALLATION Tap the spring pin from the chamfered side of the shift rod until the projection length is 1-2 mm (.04~.08 in.) DE BEARING INSTALLATION Pressefit the bearing as far as the shoulder of the main shaft. D-F-4 SPACER INSTALLATION (1) After installing the free-wheeling clutch assembly, select @ spacer so that the clutch gear axial play (bearing looseness) is within the standard value. Standard value: 0.05 - 0.30 mm (.0020 ~ .0120 in.) (2) Ifitis outside the standard value, disassemble and select the appropriate again. NOTE The thickness of the spacer is different 0.25 mm (.10 in.) each, TSB RevisionFRONT AXLE - Differential Carrier 26-39 DIFFERENTIAL CARRIER 2sanoss0019 INSPECTION BEFORE DISASSEMBLY Remove the cover and gasket. Hold the working base in a vise, and install the differential cartier assembly to it. FINAL DRIVE GEAR BACKLASH ‘Check the final drive gear backlash by the following procedure. (1) With the drive pinion locked in place, use a dial indicator to measure the final drive gear backlash on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: 0.11-0.16 mm (,0043-.0063 in.) (2) If the backlash Is outside the standard value, adjust it by using the side bearing adjustment spacers. DRIVE GEAR RUNOUT Check the drive gear runout by the following procedure. (1) Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit: 0.05 mm (.0020 in.) (2) If the runout exceeds the limit, check for incorrect tightening of the drive gear and differential case. DIFFERENTIAL GEAR BACKLASH Weoge atachment Check the differential gear backlash by the following procedure. (i) While locking the side gear with a wedge, use a dial indicator to measure the differential gear backlash on the pinion gear. Side gear NOTE thrust spacer ‘The measurement should be made for both pinion gears Side gear 7 ingividually. thrust spacer 11 21ers Standard value: 0.076 mm (.0030 in.) or less Limit: 0.2 mm (.0079 in.) (2) If the backlash exceeds the limit, adjust by using the side gear thrust spacers. TSB Revision26-40 FRONT AXLE — Differential Carrier /| Awe 2110090 FINAL DRIVE GEAR TOOTH CONTACT Check the final drive gear tooth contact by the follo procedure. (1) Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth (2) Insert a brass tod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the forward direction, and then once in the reverse direction) while applying a load to the gear, so that the rotation torque [2.5-3.0 Nm (28-33 in.ibs.)] is applied to the drive pinion. Caution If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check. (3) Check the tooth contact of the drive gear and drive pinion, TSB RevisionFRONT AXLE — Differential Carrier 26-41 Standard toot contact pattern 1 Narrow toot side 2 Drive-side tooth surface (the side applying power during forward movement) 3 Wide tooth side 4 Coast-side tooth surface (the side applying power during reverse movement) Problem Solution Tooth contact pattern resulting from exces- sive pinion height RS The drive pinion is positioned too far from the center of the drive gear. Tooth contact pattern resulting from insutti- cient pinion height The drive pinion is positioned too far from the center of the drive gear. NOTE “onfirm that the pinion height and backlash adjust- ‘ents have been done properly by inspecting the tooth contact pattern, Continue to adjust the pinion height and backiash until the tooth contact pattern resembles the standard pattern Increase the thickness of the pinion height adjust- ing shim, and position the drive pinion closer to the center of the drive gear. Also, for backlash adjustment, position the drive gear farther from the drive pinion. IS Decrease the thickness of the pinion height ad- justing shim, and position the drive pinion farther from the center of the drive gear. Also, for backlash adjustment, position the drive gear closer to the drive pinion. If the correct tooth contact pattem cannot be ob- tained even after adjustments, the drive gear and the drive pinion must be worn beyond the allowable limit. Replace the gear set. TSB Revision26-42 FRONT AXLE - Differential Carrier DISASSEMBLY Inspection before Disassembly Final Drive Gear Backlash (Refer to P26-30.) Drive Gear Funout (Refer to 25-30.) Differential Gear Backlash (Refer to P26-32) Final Drve Gear Tooth Contact (Reter to P25-40,) Disassembly steps 1. Cover 19. Companion flange 2 Bearing cap 20. Drive pinion rear shim (for preload <<“ 3. Differential case assembly adjustment) 4 Side bearing adjusting spacer 21. Dive pinion spacer 5. Side bearing outer race 8. Look pin 24. Drive pinion 10. Pinion shaft 25. Oil seal 11. Pinion gear 26. Drive pinion rear bearing inner race 12 Pinion washer > 27. Drive pinion rear bearing outer 18. Side gear race 14 Side gear thrust spacer <> 28, Drive pinion front bearing outer 15. Differential case race <=> 16. Companion flange self-locking nut 29. Oil seal 17, Washer 30. Gear carrior <> 18. Drive pinion assembly 31. Vent plug 32. Packing TSB RevisionFRONT AXLE -— Differenti i} Zui urraaao: I Carrier 26-43 DISASSEMBLY SERVICE POINTS “4p DIFFERENTIAL CASE ASSEMBLY REMOVAL Use a hammer handle to take out the differential case assembly. Caution When taking out the differential case assembly, be careful not to drop and damage the side bearing outer races. NOTE Keep the right and left side bearings and side bearing adjusting spacers separate in order to be able to distinguish them for reassembly. “48> SIDE BEARING INNER RACE REMOVAL Use the special tools to pull out the side bearing inner races. <4C> DRIVE GEAR REMOVAL (1) Make mating marks on the differential case and drive gear. (2) Loosen the drive gear mounting bolts in diagonal sequence to remove the drive gear. 40> Lock PIN REMOVAL Drive out the lock pin with @ punch NOTE ‘The removed side gears and the left and right side gear thrust spacers should be retained for reassembly.| wirsoat73 Front bearing outer race ear bearing outer race FRONT AXLE — Differential Carrier <4ED COMPANION FLANGE SELF-LOCKING NUT REMOVAL Use the special tool to hold the companion flange, and then remove the companion flange self-locking nut <4F> DRIVE PINION ASSEMBLY REMOVAL (1) Make mating marks on the drive pinion and companion flange. Caution ‘The mating mark made on the companion flange must not be on the coupling surface of the flange yoke and the front propeller shaft. (2) Drive out the drive pinion together with the drive pinion spacer and the drive pinion shims. -4GP DRIVE PINION FRONT BEARING INNER RACE REMOVAL Use the special tools to pull out the front bearing inner race. 4H DRIVE PINION REAR BEARING OUTER RACE/ DRIVE PINION FRONT BEARING OUTER RACE REMOVAL (1) Use the brass rod to drive out the drive pinion rear bearing Outer race from the gear carrier. (2) Drive out the front bearing outer race in the same manner. INSPECTION ‘Check the companion flange for wear or damage. Check the oil seal for wear or deterioration. Check the bearings for wear or discoloration, Check the gear carrier for cracks. ‘Check the drive pinion and drive gear for wear or orar= Check the side gears, pinion gears and pinion shat wear or damage. © Check the side gear spline for wear or damage. ery TSB RevisionFRONT AXLE - Differential Carrier bad DB pa po REASSEMBLY @e reat 19 hm 44 fUlbs, Reassembly steps 4. Packing 2. Vent plug 3. Gear carrier 4 Oll seal 5. Drive pinion front bearing outer race Drive pinion rear bearing outer race Pinion height adjustment Drive pinion Drive pinion front shim (for pinion height adjustment) Drive pinion front bearing inner D-4_© Drivepinion rotation torqueadiustment 10, Drive pinion rear bearing inner race 41 Ol seal 42, Drive pinion rear shim (lor turning torque adjustment) 43, Drive pinion spacer 14. Drive pinion assembly 15. Companion flange 16. 17, 1B 18. 21 peas Ded 24 bad 25. Did 26. 27 bid oe u 20 19 20 R g seme 7 cecorane Washer Companion flange self-locking nut Differential case Side gear thrust spacer Side gear Pinion washer Pinion gear Differential gear backlash adjustment Pinion shaft Lock pin Drive gear ‘Side bearing inner race ‘Side bearing outer race Final crive gear backlash adjustment Sige bearing adjusting spacer Differential case assembly Bearing cap Cover TSB Revision26-46 FRONT AXLE -— Differential Carrier LUBRICATION, SEALING AND ADHESION POINTS: nE018 Sealant: 3M_ATD Part No. 8663 or equivalent | Sealant: | SHT'ATD part No. 8663 oF equivalent ‘Adhesive 3M Stud Locking 4170 oF equivalent TSB RevisionFRONT AXLE - Differential Carrier Ene eEy a4 MB9e0938 MBes0304 Oil seal Front bearing outer race 110102 + fa hk MB990938 ‘sag00006-4) MB920004 ‘we990905-3 MB9a0205-2 ¥MB990905-1 115980901 ‘TSB Revision 26-47 REASSEMBLY SERVICE POINTS DAOIL SEAL INSTALLATION Use the special toot to insert the oil seal, and then apply a thin coat of multi-purpose grease to the lip of the oil seal -B-DRIVE PINION FRONT BEARING OUTER RACE/ DRIVE PINION REAR BEARING OUTER RACE INSTALLATION Use the special tools to press-fit the drive pinion front bearing ouler races into the gear carrier. NOTE Carry out press-fiting carefully so as not to tlt the outer race. P-C-4PINION HEIGHT ADJUSTMENT Adjust the drive pinion height as follows: (1) Install the special tools and the drive pinion front and rear bearing inner races into the gear carrier in the order shown in the illustration. (2) Tighten the handle of the special too! until the standard value for the drive pinion rotation torque is obtained.26-48 FRONT AXLE - Differential Carrier MBe90205-1 FEE zoos Drive pinion front shim $* ws9a0g05-« (03590907) 2u1Wse8 (3) Use the special tools to measure the drive pinion rotation torque (without the oil seal) Standard value: ‘Bearing type _| Bearing lubrication | Rotation torque None | 03-0.5 Nm (With anti-rust agent) | 2.6—4.3 in.los. Gearotappted | 915-0%5Ne New New or reuse NOTE 1. Gradually tighten the handle of the special tool while checking the drive pinion preload 2, Because one rotation cannot be made when the special tool is in contact with the gear carrier, move ita few times and, after seating the bearing, measure the rotation torque. (4) Position the special tool in the side bearing seat of the gear cattier, and then select a drive pinion front shim of a thickness which corresponds to the gap between the special tools, NOTE 1. Be sure to clean the side bearing seat thoroughly. When positioning the special tool, check that the cut-out sections of the special tool are in the position shown in the illustration, and check that the special tool is in close contact with the side bearing se 2, When selecting the drive pinion front shims, ke , the number of shims to a minimum. (6) Fit the selected drive pinion front shim(s) to the drive pinion, and then use the special tool to press-fit the drive pinion’ front bearing inner race,FRONT AXLE - Differential Carrier 26-49 )>D-4DRIVE PINION ROTATION TORQUE ADJUSTMENT Adjust the drive pinion rotation torque by the following procedure, Without oil seal (1) Insert the drive pinion into the gear carrier, and then install the drive pinion spacer, drive pinion rear shim, drive pinion rear bearing inner race and companion flange in that order from the front of the carrier. NOTE Do not install the oil seal. (2) Use the special tool to tighten the companion flange to the specified torque. (3) Use the special tools to measure the drive pinion rotation torque (without the oil seal). Standard value: Bearing ype] Bearnglubrication | Rotation torque New None) 08-05 Nm van anrst agen) | 28-8: ns Neworreuse | Gearcilappied | 0352075 Nr (4) Ifthe drive pinion rotation torque is not within the standard value range, adjust the preload by replacing the drive pinion front shim(s) or the drive pinion spacer. NOTE When selecting the drive pinion rear shims, if the number of shims is large, reduce the number of shims to.a minimum by solecting the appropriate drive pinion spacers. Ident. : Giton ‘Aiso, select the dive pinion spacer ftom the following Color two types. Comite) aeeee Hem I Types 55.67 (2.231) With identification Height of drive pinion spacer | color mam (i.) 57.01 (2.248) | No identification | color ‘TSB RevisionFRONT AXLE - Differential Carrier Mrra04180 Nx same <= io (6) Remove the companion flange and drive pinion again. With oil seal (1) After setting the drive pinion rear bearing inner race, use special tool to drive the oil seal into the front lip of the gear carrer. (2) Apply multi-purpose grease to the contact surfaces of the companion flange oil seal and the washer companion flange. (@) Install the drive pinion assembly and companion flange with the mating marks properly aligned. Using the special tools, tighten the companion fiange self-locking nut to the specified torque. (4) Use the special tools to measure the drive pinion rotation ‘torque (with the oil seal) to confirm that the drive pinion preload is at the standard value. Standard value: Bearing type | Bearing lubrication | Rotation torque Nea: None [05-0.7 Nm (With anti-rust agent) | 4.3~6.1 in.lbs. 0.85-0.45 Nm Neworreuse | Gearcilapplied | 995045 Nr (5) If the measured value is not within the standard value range, check for incorrect installation of the oil seal or incorrect tightening of the self-locking nut. TSB RevisionFRONT AXLE - Differential Carrier 26-51 —] ~—sODEDIFFERENTIAL GEAR BACKLASH ADJUSTMENT (1) Assemble the side gears, side gear thrust spacers, pinion ‘gears and pinion washers into the differential case. (2) Provisionally install the pinion shatt. NOTE Do not drive in the lock pin yet. (3) Insert a wedge between the side gear and the pinion shaft to lock the side gear. (4) Use a dial indicator to measure the differential gear backlash on the pinion gear. Standard value: 0.076 mm (.0030 in.) or less Limit: 0.2 mm (,0079 in.) Side gear (5) I the differential gear backlash exceeds the limit, adjust fe thrust spacer the backlash by installing thicker side gear thrust spacers. laa gear (6) Measure the differential gear backlash again, and check sit spacer eau) that it is within the limit. If adjustment is not possible, replace the side gears and pinion gears as @ set. (1) Align the pinion shaft lock pin hole with the differential ‘case lock pin hole, and then drive in the lock pin. rs (2) Sake ne ook inva @ punch ‘on bah ses > j DF LOCK PIN INSTALLATION je | > © -fieoaa? >G-DRIVE GEAR INSTALLATION (1) Clean the drive gear mounting bolts. (2) Remove the adhesive which is adhering to the threaded holes of the drive gear by tuming the tap tool (tap M10x1.25), and then clean the threaded holes by applying compressed air. TSB RevisionFRONT AXLE - Differential Carrier zis! 2 (002 = Thickness of the = spacer on ane side |, Glearance _ 005mm in) zuy2u (2) Apply specified adhesive to the threaded holes of the drive gear, Specified adhesive: 3M Stud Locking Part No. 4170 or equivalent (4) Install the drive gear to the differential case so that the mating marks are properly aligned. Tighten the bolts to the specified torque in a diagonal sequence. D-HqSIDE BEARING INNER RACE INSTALLATION Use the special tool to press-fit the side bearing inner races into the differential case. D-I-¢ FINAL DRIVE GEAR BACKLASH ADJUSTMENT Adjust the final drive gear backlash by the following procedure. (1) Install side bearing spacers which are thinner than those removed to the side bearing outer races, and then in the differential case assembly to the gear carrier. NOTE Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side. (2) Push the differential case assembly to one side, and then measure the clearance between the gear carrier and the side bearing adjusting spacer with a feeler gage. (8) Measure the thickness of the side bearing adjusting spacers on one side, select two pairs of spacers which correspond to that thickness plus one haif of the thickness plus 0.05 mm (.002 in.), and then install one pair each lo the drive pinion side and the drive gear side, [SB RevisionFRONT AXLE - Differential Carrier 26-53 (4) Install the side bearing adjusting spacers and differential case assembly to the gear carrier as shown in the illustration, (6) Tap the side bearing adjusting spacers with a brass bar to press-fit them to the side bearing outer race. (6) Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap. (7) With the drive pinion locked in place, use a dial indicator to measure the final drive gear backlash on the drive gear. NOTE Measure at four points or mote on the circumference of the drive gear. ‘Standard value: 0.11-0.16 mm (,0043-.0063 in.) Toaciashis too small (8) Change the side bearing adjusting spacers as shown Trier] in the ilustration, and then adjust the final crive gear inet | Reece backlash between the dive gear and the drive pinion. spacer nH NOTE ‘When increasing the number of side bearing adjusting spacers, use the same number for each side, and use as few spacers as possible, preeeise| | Ramer (9) Check the tooth contact of the drive gear and drive pinion. eal [eee IF poor contact is evident, carry out adjustment. (Refer backlash is toolarge 1184 to P.26-39.) TSB Revision26-54 FRONT AXLE — Differential Carrier (10)Measure the drive goar runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm (,0020 in.) | (11)If the drive gear runout exceeds the limit, remove the ditlerental case and the ive gears, move them to different positions and then reinstall them. ‘TSB Revision27-1 REAR AXLE CONTENTS AXLE ASSEMBLY . AXLE SHAFT . DIFFERENTIAL CARRIER .... Ditferential Case GENERAL SPECIFICATIONS LUBRICANTS . ON-VEHICLE SERVICE . ‘Axle Housing Oil Seal Replacement 12 ‘Axle Shaft End Play Check seseTl Gear Oil Level Check . 1" arose Hub Bolt Replacement ........ 1 Rear Axle Total Backlash Check -. 10 Rear Differential Lock Detection Switch Check... ratte. Rear Differential Lock System Air Leakage ChE a sin va 13 REAR DIFFERENTIAL LOCK . SEALANTS AND ADHESIVES ........ SERVICE SPECIFICATIONS .. SPECIAL TOOLS. TROUBLESHOOTING ......-27-2 REAR AXLE - General Specifications/Service Specifications GENERAL SPECIFICATIONS «Conventional differential> Items Specifications ‘Axle housing type Banjo type eect | Axle shaft Supporting type | Seméfioating type Diferential Diferentialsize | NOS Reduction gear type Hypoid gear Reduction ratio 4.272 Pinion gear type 2 pinion* or 4 pinion NOTE ‘Without rear differential lock SERVICE SPECIFICATIONS zrvo00s0266 items Standard value Lit Rear axe total backlash mm (in) = 5 (20) ‘Axle shaft end play mam (in) 0.25 (0088) = | Provusing length of stabilizer bar mounting boltmm (in) | 15-17 (59-67) = Press-fiting force of retainer N (ibs.) Initial press-force 49,000 (11,016) = Final press-fting force {98,000- 108,000 - (22,031-24,273) Clearance of snap ring and retainer mm (in.) (0.185 (.0065) or less = Final drive gear backlash mm (in.) 0.13-0.18 (,0051-.0071) | - Drive gear runout mm (in) - 0.05 (.002) Differential gear backlash mm (in) 0.10-0.25 (004-01) | ~ 0.6-0.9 (6.2-7.8) - Drive pinion | Without ol'seal | With anti-rust agent rotation torque (new) Neils) | | With gear oil applied | (now or used) 04-05 (3.5-4.3) - | With oi seal (new) ‘With antivust agent With gear oll applied (new or used) (095-1.15 (74-100) | ~ 065-075(56-65) | -ems ‘Standard value Limit Fear axl total backlash mm (in) = 5 (20) Dale shaft end play mm Gn) 0.25 (0008) a Protruding length of stabiizer bar mounting bolt mm Gn) _| 1517 (S9—67) . Presesiting force ofetainer | inal press-force | 49,000 (1,016) 2 N (Ibs.) Final prese-fiting force | $8,000—108,000 = (22,031-24,279) (Clearance of snap rng and retainer mm (i) 0.166 (006s) orless | - Rear differential lock air pump pressure kPa (psi) 25-40 (4-6) = Final drive gear backlash mm (in.) 0.12-0.18 (.0047—.0071) | - Dive gear runout mm (in) : 0.05 002) Differential gear backiash mm (in) 0.18-0.20(005-,008) _| - Drive pinion ‘Without oil seal | With anti-rust agent 0.6-0.9 (5.2-7.8) x rotation torque (new) Nm (nibs) With gear oil applied | 0.4-0.5 (3.5-4.3) = | (new or used) With oil seal With anti-rust agent 0.85-1.15 (7.4-10.0) - (new) With gear ollappied | 065-075 (56-65) |- (new or used) LUBRICANTS arvois Terns [Soccer [canny 8) Fear axle gear oll | Hypo gear ol 3283) SEE asco | SAE viscosity No. 90, 80W | SEALANTS AND ADHESIVES arootnea ems Specified sealants and adhesives Bearing case SM ATD Par No, 8663 or equivalent Differential carrier mounting surface of axle housing Drive gear threaded hole ‘3M Stud Locking Part No. 4170 or equivalent [TSB Revision27-4 REAR AXLE — Special Tools SPECIAL TOOLS Too! ‘Tool number andname | Supersession ‘Application | MBso1618 = | Hub bolt remover | — Removal of hub bolt Sliding hammer MB990767 1MB990767-01 Holding of axle shaft Holding of companicn flange End yoke holder I Bs90241 ‘MB920241-01 or “| Removal of axle shaft General service tool (use with MB990211-01) ‘Axle puller | | MB990211 7 MB990211-01 Removal of axle shaft (use with MB990241-01) | Femoval of axle housing oll seal and bearing case wean $a Fecaga ni oaraae mont Bening ad ot sea | Pera sk al [Souk st cat | wes | E8838, Pe © | Bossey ke ption font mrnbes ; wasn ao aE Faso a Taig oT | Prue face Sua cod Handle | Pressing of drive pinion rear cosa | Presse Se ain font | Citigate MB991552 |= Removal of axle shaft bearing ; Soma ae FI ta vn cas | me | 'MB991601 |- Removal of axle shaft bearing

9. Rear differential lock position hamess connector 216-245 Nm *\ 459-181 fs, Seattle 98-108 Nm xs 15.Nm 11 fs, 216-245 Nm 159-161 fubs. soseo217 10. Speed sensor (Refer to GROUP 35C ~ Wheel speed Sensor.) 4A PD 11. Rear propeller shatt PC 12 Stabilizer bar mounting bolt PB 13. Lower am DA 14. Latoral rod 45. Shock absorber (lower part only)

LOWER ARM REMOVAL ‘After supporting the axle assembly by floor jacks, remove the lower arm. <4C> AXLE ASSEMBLY REMOVAL Draw out the axle assembly toward the rear of the vehicle. Caution Secure the axle assembly to the jack or equivalent. The ‘axle assembly is heavy and unstable and may fall causing damage to the assembly, surrounding equipment, or injuring the installer. INSTALLATION SERVICE POINTS DA LATERAL ROD INSTALLATION Install the lateral rod from the axle housing side. >B-4LOWER ARM INSTALLATION Lower arm Insiall the washers (facing as shown in the figure) to the lower arm. E “ont up }>C-4STABILIZER BAR MOUNTING BOLT INSTALLATION Stabilizer bar ‘When installing the stabilizer bar to the stabilizer bar bracket, ‘estalaionbot| check that the amount of projection of the stabilizer bar installation bolt is within the standard value range. Standard value (A): 15-17 mm (.59-.67 in.) ubberbushing Joint cup: Joint cup Calar— abetusning| DD-IREAR PROPELLER SHAFT INSTALLATION ‘Align the mating marks on the flange yoke and the companion stabiizor bar soint cup flange to install the rear propeller shaft ee ‘TSB Revision27-16 REAR AXLE - Axle Shaft AXLE SHAFT rroness REMOVAL AND INSTALLATION Post-installation Operation © Air Bleeding trom Brake Lines ‘© Parking Brake Lover Stroke Adjustment (Wehicies without ABS: Refer to GROUP 5A — (Roter to GROUP 36 ~ On-vericee Service.) Or-vehicle Service.) {Yetiles wi ABS: Reterto GROUP35C-On-vehicle service) 49-59 Nm = 36-43 flbs. & EEeTa 1 ‘9m L a 57 12) 20 mi9 / ees TEBE, : mer! i é @ a fecuaies eee Paci pe ore Oe at oho a Beata ESE, coco oes pete aed oe ea Fe reat 15 oars ee 5 Ean pote cae eae o> | Sena ae eee oe a ers) eee peg io ores adn ey re Se hae Seay Boa cong 11, Bearing inner race (inner) F< 8. Snap ring <> 12. Bearing inner race (outer) 7. Axle shaft assembly cee ee ee ui ies a aon is Ra oo Se ceerg bala 08 a ae ce eat 4 eee, | erga arses ta eens oe + ions pees <> 20. Oil sealREAR AXLE - Axle Shaft 27-17 'UBRICATION AND SEALING POINTS Ine02"5 cane sete all la REMOVAL SERVICE POINTS <4A> AXLE SHAFT ASSEMBLY REMOVAL Pull the rear axle shaft with rear brake assembly attached It the rear axie shaft is difficult remove, use special tools, mpeodent 48> RETAINER REMOVAL (1) Remove one retainer bolt from the backing plate.REAR AXLE - Axle Shaft (2) Apply gummed cloth tape around the edge of the bearing case for protection (8) As shown in the figure, hold the axle shaft. Using a grit shave off a point of its circumference locally until the wall thickness become as follows: © 1.0-2.0 mm (.04-.08 in.) for axle shatt side © 2.0 mm (.08 in.) for bearing side Caution Be careful not to damage the bearing case and the axle shaft. (4) Fix the axle shaft and shave off the remaining 2.0 mm (08 in.) on the side of the bearing of the retainer. Caution Be careful not to damage the bearing case and the axle shaft. (5) Cut in with a chisel the place where the retainer ring has been shaven and remove the retainer. Caution Be careful not to damage the axle shaft. MB931552, e99%601 peo Plate Maadieo1 (Cb AXLE SHAFT SUB ASSEMBLY REMOVAL (1) Adjust the height of the hanger. Then install the washers, plate and nuts in that order as shown in the figure. i} NOTE | If the bar of special tool (MB991552) is short, connect a the extension bar (MB991601) to adjust the height of eS the hanger. Eeai9 (2) Place the end of the bolt against the canter of the axle soe shaft, and then tighten the nuts to remove the axle shaft from the bearing case assembly. Caution The hanger and plate must be placed so that they are parallel. ‘TSB RevisionREAR AXLE — Axle Shaft 27-19 <4D> BEARING INNER RACE (OUTER) REMOVAL Install special too! as shown in the illustration, and then use a press lo remove the bearing inner race (outer) from the axle shaft <4E> BEARING OUTER RACE REMOVAL _— Reinstall the bearing inner race that was removed previously. we990709 Use special tool and press to remove the beating outer race. Bearing cuter race <4F> OIL SEAL REMOVAL Fomove the oil seal from the end of rear axle housing using special tool, if necessary. egg02t1 INSTALLATION SERVICE POINTS D>AOIL SEAL INSTALLATION Drive the new oil seal into the rear axle housing end by using special tools. »B-(BEARING OUTER RACE INSTALLATION (1) Apply the multi-purpose grease to the external surface of the bearing outer race. (2) Press-fit the bearing outer race into the bearing case Me990800 by using special tools. zueorr7 ‘TSB Revision27-20 REAR AXLE — Axle Shaft MB909036 Panne & Ade shat =< : “Pa Retainée ‘TSB Revision COIL SEAL INSTALLATION (1) Apply multi-purpose grease to the outside of the oil (2) Using special tools, press-fit the oil seal until itis flaw with the end of the bearing case. (3) Apply multi-purpose grease to the lip of the oil seal D-D-(BEARING INNER RACE (INNER) INSTALLATION (1) Pass the axle shaft through the bearing inner race, the bearing case and the second bearing inner race in that order. (2) Using special tool, press-fit the bearing inner race to the axle shaft Caution 1. Both bearing inner race sets should be press-fitted together. 2. The left and right lengths of the axle shaft are different [approx. 7 mm (.28 in.)] in vehicles with rear differential lock. The right side is longer, so be careful when installing. DE RETAINER PRESS-FITTING Using special tool, press-fit the retainer onto the axle shaft Check that the press-fiting force is at the standard value. If the initial press-fitting force is less than the standard value, replace the axle shaft. Standard value: Initial press-fitting force 49,000 N (11,016 Ibs.) or more Final press-fitting force 98,000 ~ 108,000 N (22,031 - 24,279 Ibs.)REAR AXLE - Axle Shaft 27-21 D>F-q SNAP RING INSTALLATION am} A (1) After instaling the snap ring, measure the clearance (A) between the snap ring an the retainer with a thickness gage. Check that itis within the standard values. | oo Standard value (A): 0.166 mm (,0065 in.) or less (2) If the clearance exceeds the standard value, change the Srap ting Retainer snap ring so that the ciearance is at the standard value “Thickness of sap ring mm (in) | Identification color : sens 2.17 (0854) = 2.01 (0791) Yellow 7185 (0728) Blue 1.69 (0865) Purple 153 (0602) Red - Example: Clearance 2.0 mm (.08 in.) Standard value 0 - 0.166 mm (0 - .0065 in.) Thickness of snap ring 2.01 mm (.0791 in.) INSPECTION prron260018 ‘© Check the dust cover for deformation or damage. © Check the oil seal for damage. © Check the inner and outer bearings for seizure, discoloration and rough raceway surface. © Check the axle shaft for cracks, wear and damage. TSB Revision27-22 REAR AXLE ~ Rear Differential Lock REAR DIFFERENTIAL LOCK REMOVAL AND INSTALLATION i i sf “a Nin 10 fabs, Rear differential lock air pump and hose removal stops. © Second Seal (Refer to GROUP 524 ~"Second Seat) 4. Bracket 2. Rear diferential lock air pump 3. Air hose 4. Air hose 5. Hose bracket & Position hamess Rear differential lock contro! unit removal steps © Quarter trim lower (Refer to GROUP S2A - Trims.) 7. Rear differential lock control unit Rear differential lock switch removal 8. Rear differential lock switch Rear differential lock detection switch removal 8. Rear differential lock detection switch (Refer to P27-29,) ‘TSB RevisionREAR AXLE — Rear Differential Lock 27-23 cca REAR DIFFERENTIAL LOCK CONTROL UNIT 1 Airhose {as shor as possibie) SF Battery P_-Toinn To the ciferenal Pressure D sage Release valve 1 ‘othe siferential ‘EODs6 Pressure switch INSPECTION REAR DIFFERENTIAL LOCK AIR PUMP 4. Connect the pressure gage to the air pump discharge oullet nozzle, via the air hose and T-jint 2. Install air hose to the differential 3. Apply battery positive voltage to the air pump connector. 4, Measure the time between when the pump starts and stops operating, and if it stops within 5 seconds, the pressure switch inside the pump is normal. 5. Measure the pressure 10-20 seconds after the pump has stopped. Standard value: 25-40 kPa (4~6 psi.) If the pressure is within the standard value, the release valve inside the pump is normal. 6. Check that the pump does not begin operating for 5 minutes after it has stopped. 7. If the inspection for 4—6 is normal, then the pump is fully operational. zrao0os0013 Measure the terminal voltages under each condition, 2. With the control unit connected to the harness and the probe inserted into the rear of the hamess connector, carry out the voltage measurements between terminal (6) (ground terminal) and each other terminal 1 3)4 5 7/8} 9410) TENET rspecon em [tspecton Gonction [Fermin vonage : Ignition switch WH) Tgaiion sich 167) OFF ov ON Batiay postive volage | 9 Rear differential lock [ON side | Ignition switch: ON | ON side or OFF side | OV 1 switch JOFF side ‘When in neutral Battery positive voltage Fear Gierental lock indicator | Tgiion awighwON | Rear aiterental B |g y oF locked Rear aiferental Te cae : Fea [Batley pete vonage z Vehicle speed eed swiich | Selec Dor" (iatgoan end aveToward | gy slowly Fear Giferenial ioc detecTon [lontion wich ON | Rear aHerenlal & | 9 y i Switch locked 4 ear diferental [ee Battery positive voltage Tear difrental ok a pump | igniln state ON | When ing or Rol ee . | | a Battery postive voltag | When releasing [OW ‘Center Gifereniial lock opera- | Ignition switch: ON | Center diferential is = 5 | tion detection switch free Battery bositvelvotiage Center diferent | y | it locked27-24 REAR AXLE — Rear Differential Lock CM [2] aléfsiel OFF. ON REAR DIFFERENTIAL LOCK SWITCH CONTINUITY mone Switch postion eee Switch position ee (eeaa| tice: [eee ON oo OFF SL] eee REAR DIFFERENTIAL LOCK DETECTION SWITCH 4. Connect an ohmmeter to the detection switch connector. 2. The tear differential lock detection switch is in good condition when the rod of the detection switch is pulled, there should be continuity, and when it is retumed to its normal position, no continuity. NOTE Remove the differential carrier in order to replace the tear differential lock detection switch. (Refer to P.27-29.) TSB RevisionREAR AXLE — OIFFERENTIAL CARRIER AEMOVAL AND INSTALLATION Differential Carrier reooz0or36 Pre-removal Operation 2 Ditlerental Gear Oil Draining 1180081 Sealant: 3M ATD Part No, 8863 or equivalent | wore Appy the specified sealant tothe differential gr mounting surface of the anve ROUSING fs shown inthe lustravions. Removal steps Rear brake assembly Brake disc Parking brake cable end Rear axle shaft assembly Oring Parking brake cable attaching bolt Post.inetallation Operation ‘Ai Bleeding from Brake Lines (Veneles without ABS" Refer to GROUP 5A — Onwvehicle Servco,) (ehiles with ABS: Refer to GROUP 35C — Qr-vehicle Sanice.) Parking Brake Lever Stroke Adustment (Geter 1o GROUP 36 — On-vehicie Service) Diferential Gear Oil Filing (Reter to P27-11,) REAR PROPELLER SHAFT REMOVAL Make mating marks on the flange yoke of the rear propeller shaft and the companion flange of the differential case. Caution ‘Suspend the propeller shaft from the body with wire, etc. to avoid spilling transmission fluid and to avoid injury from falling propeller shaft when not secured. <4C> DIFFERENTIAL CARRIER REMOVAL Remove the mounting nuts. Strike the lower part of differential carrier assembly with a piece of wood several times to loosen the assembly. Remove the assembly. Caution 1. Donot remove the uppermost nut but keep it loosened all the way to the stud bolt end. 2. Use care not to strike the companion flange. INSTALLATION SERVICE POINT D-AREAR PROPELLER SHAFT INSTALLATION Align the mating marks on the flange yoke and the companion flange to install the rear propeller shatt. INSPECTION BEFORE DISASSEMBLY zr20020085 Hold the working base in a vice, and install the differential carrier to the special tool. a ‘TSB RevisionREAR AXLE - Differential Carrier 27-27 FINAL DRIVE GEAR BACKLASH With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: Vehicles without rear differential lock 0.13-0.18 mm (.0051-.0071 in.) Vehicles with rear differential lock 0.12-0.18 mm (.0047-.0071 in.) DRIVE GEAR RUNOUT Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm (.002 in.) FINAL DRIVE GEAR TOOTH CONTACT Refer to GROUP 26-Differential Carrier. REAR DIFFERENTIAL LOCK 1. Connect an air hose, pressure gage and air regulator, for adjusting the compressed air pressure, to the actuator Pipe. 2, Adjust the compressed air pressure with the air regulator until the pressure gage shows a pressure of approximately 25 kPa (4 psi. ‘TSB Revision27-28 REAR AXLE -~ Differential Carrier TSB Revision 3. Use the special tool to gently turn only the side gear of one side of the axle 1/4~1/2 tums. NOTE 1. The lock will not operate when both side gears turn together, even when air pressure is supplied. The side gear on one side of the axle must be tumed so that the clutch will mesh (lock). 2. To unlock, shut supply of air pressure, and gently tum the side gear on one side of the axle 1/4—1/2 tums. 4, Measure the rotation torque of the companion flange, and check the lock condition and free condition of the rear differential, ir differ T is Rear differential | Companion flange Nm (ftlbs.) (N (s.)] operation | Locked | Doesn't tum at 49 (6) (1.117 (46)) Free [Turns at ass than 49 (86) [7,411 (243)REAR AXLE — Differential Carrier 27-29 DISASSEMBLY zrncon0149 Inspection Betore Disassembly (i) Final Drive Gear Inspection (Rofor to P27-27,) (2) Final Drive Gear Tooth Contact Inspection {2} Dave Gear Aurrout Inepacton (Refer to P.27-27.) (Rler to 27-27.) (3) Diterential Gear Backlash Inspection (Reler 10 27-27.) 21: Drive pinion rear bearing inner race 5, Hose" 22! Drive pinion rear shim I 6. Air pipe assembly (A)" (For adjusting drive pinion height) I 7. Bye bolt” 23, Drive pinion I 8 Air pipe assembly (B)* 24. Companion flange ] 9. Gasket” cp 25. Oil seal 10. Actuator assembly 28. Drive pinion tear bearng outer race <> 13, Side bearing inner race 29. Rear differential lock detection

18. Drive pinion assembly27-30 REAR AXLE - Differential Carrier DISASSEMBLY SERVICE POINTS 44> SIDE BEARING NUT REMOVAL Use the special tool to remove the side bearing nut, — 48> SIDE BEARING INNER RACE REMOVAL _ Use the special tools to pull out the side bearing inner races. 990810 ox ee 7 cvs “€CP DRIVE GEAR REMOVAL (1) Make mating marks on the differential case and drive gear. (2) Loosen the drive gear mounting bolts in diage sequence to remove the drive gear. 40> SELF-LOCKING NUT REMOVAL Use the special tool to hold the companion flange, and then Temove the companion flange self-locking nut. “4E> DRIVE PINION ASSEMBLY REMOVAL (1) Make mating marks on the drive pinion and companion flange. (2) Drive out the drive pinion together with the drive pinion spacer and the drive pinion front shims. Caution Do not make mating marks on the contact surf. ‘of the companion flange and propeller shaft.REAR AXLE — Differential Carrier MD998e01 Rear bearing outer race Front beating Oil seal: Front bearing cuter race 27-31 <4F> DRIVE PINION REAR BEARING INNER RACE REMOVAL Use the special tools to pull out the drive pinion rear bearing inner race. <4G> OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE/DRIVE PINION REAR BEARING OUTER RACE REMOVAL, (1) Use a brass rod to drive out the drive pinion front bearing ‘outer race from the gear cartier together with the drive pinion front bearing inner race and the oil seal (2) Drive out the drive pinion rear bearing outer race in the same manner. raoorooene INSPECTION Wash the disassembled parts in cleaning solvent, dry them using compressed air, and then check the following areas. © Check the companion flange for wear or damage. Check the oll seal for wear or deterioration. Check the bearings for wear or discoloration. Check the differential case for cracks. Check the drive pinion and drive gear for wear or cracks. Check the side gears, pinion gears and pinion shaft for wear or damage. Check the side gear spline for wear or damage. eccce TSB Revision27-32 REASSEMBLY REAR AXLE -— Differential Carrier 9 ua 20 21 7 Ribs ep 12 Ribs . 8 ism 470 6 Nm 18 Nm HW tbe, 1 at \ fits. 14 ts, 19. ‘55-65 Nm ae A DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION Use the special tools to press-fit the drive pinion front bearing outer race into the gear carrier. Caution The bearing outer race must be fitted using a press to avoid tilt and distortion. a ‘TSB Revision27-34 REAR AXLE - Differential Carrier b-B-4DRIVE PINION REAR BEARING OUTER RACE ee INSTALLATION Using special tools, press-fit the drive pinion rear Besta egpt4ss outer race into the gear carrier. Caution The bearing outer race must be fitted using a press to avoid tilt and distortion. D>C-qDRIVE PINION HEIGHT ADJUSTMENT ‘Adjust the drive pinion height as follows: peaoaos. (1) Install special tools and the drive pinion front and rear {04899090101} bearing inner races into the gear cartier in the order shown rra1se99 in the illustration. i MiT31 3836, (2) Tighten the handle of the special too! until the standard e aB990305-2 eres value for the drive pinion rotation torque is obtained 1MB920905-1 (14390807-01) (8) Measure the drive pinion rotation torque (without oil seal). ‘ya90000-1 Standard value Bearing type | Bearing lubrication | Rotation torque New None (With anti-rust | 0.6—0.9 Nm ) agent) 52-7.8inbs. _ | New orreuse | Gear ol appl 0.4=05Nm 3 bo. soon NOTE 1. Gradually tighten the handle of the special tool while checking the drive pinion rotation torque. 2, The one rotation cannot be made when the special tool is in contact with the gear carrier. So move it a few times and, after seating the bearing, measure the rotation torque. (4) Position the special tool in the side bearing seat of the gear carrier, and then select a drive pinion rear shim of a thickness which corresponds to the gap between the special tools. p291504 Done pao a 113990005-4REAR AXLE — Differential Cai 27-35 NOTE 1. Be sure to clean the side bearing seat thoroughly. When positioning the special tool, check that the cut-out sections of the special tool are in the position shown in the illustration, and also check that the special tool is in close contact with the side bearing seat 2. When selecting the drive pinion front shims, keep the number of shims to a minimum, (5) Fit the selected drive pinion rear shim(s) to the drive pinion, and then use the special tool to press-fit the drive pinion’ rear bearing inner race. >D-4DRIVE PINION BEARING PRELOAD ADJUSTMENT Adjust the drive pinion rotation torque by using the following procedure’ Without oil seal (1) Insert the drive pinion front shim(s) between the drive pinion spacer and the drive pinion rear bearing inner race. (2) Using special tools, tighten the companion flange to the specified torque, NOTE Do not install the oil seal (8) Measure the drive pinion rotation torque (without the oil seal), Standard value: TSB Revision Bearing type | Bearing lubrication | Rotation torque | New | None (With anti-rust | 0.6-0.9 Nm agent) 52-78 inibs. New orreuse | Gearollapplied | 04-05 Nm 85-43 ins.27-36 REAR AXLE —~ Differer Carrier Identiicator seler zumoose MIT304180 anicoo (4) Ifthe drive pinion rotation torque is not within the standard value range, adjust the rotation torque by replacing drive pinion’ front shim(s) or the drive pinion spacer NOTE When selecting the drive pinion front shims, if the number of shims is large, reduce the number of shims to a minimum by selecting the appropriate drive pinion spacers. Also, select the drive pinion spacer from the following two types. Height of drive pinion spacer mm (in.)_| Identification color 52.50 (2.067) Yellow 52.84 (2.080) [Rea (5) Remove the companion flange and drive pinion again With oil seal (1) After setting the drive pinion front bearing inner race, use the special tool to drive the oil seal into the front lip of the gear carrier. (2) Apply a thin coat of clean multi-purpose grease to the ‘companion flange contact surfaces of the washer and the oil seal contacting surface before installing the drive pinion assembly, (G) Install the drive pinion assembly and companion flange with the mating marks propery aligned. Using the special tools, tighten the companion flange selt-ocking nut to the specified torque.REAR AXLE - Differential Carrier 27-37 (4) Ifthe drive pinion rotation torque is not within the rage of the standard value, adjust the rotation torque by replacing the drive pinion front shim(s) or the drive pinion spacer. Standard value: Bearing ype | Bearing lubrication | Rotation torque New None (With ant-ust | 0.85~1.15 Nm | agent) | 7.4-10.0 in.ibs, Neworreuse | Gearolappled [065-075 in 6-65 nbs }>E-4 DRIVE GEAR INSTALLATION (1) Clean the drive gear mounting bolts. (2) Remove the adhesive which is adhering to the threaded holes of the drive gear by turning the tap tool (M12 x 1.25), and then clean the threaded holes by applying compressed air. (3) Apply specified adhesive to the threaded holes of the drive gear. Specified adhesive: ‘3M Stud Locking Part No. 4170 or equivalent (4) Install the drive gear to the differential case so that the mating marks are propery aligned. Tighten the bolts to the specified torque in a diagonal sequence. )>F-q SIDE BEARING INNER RACE INSTALLATION weooes2 Using special tool, pressvft the side bearing inner races into the differential case. Caution When only one side bearing inner race is installed, place a load on the differential case only. TSB Revision27-38 REAR AXLE - Differential Carrier D-G-4BEARING CAP INSTALLATION Align the mating marks on the gear cartier and the be: cap, and then tighten the bearing cap. wB990201 D-H Pe ty 9 190092 Cou, Differential gear set 5 e016 Disassembly steps “~ 1. Screw 9. Pinion gear 2 Case A 10. Washer 8, Side gear spacer (RH) 41. Side gear (LH) 4. Side gear (RH) 12, Side gear spacer (LH) Bq © Backlash adjustment on differential 48. Spring washer ear case Aside 44. Spring <> Differential gear backlash check 18. Drive'cam 5. Lock pin Ad © Backlash adjustment on differential 6. Pinion shatt-a ‘gear case B side 7. Pinion shaft-B 16. Case B 8. Pinion shaft holder TSB RevisionREAR AXLE — 27-41 ential Carrier Diterentat case Differential case Mating maths zi00107 DISASSEMBLY SERVICE POINTS dA SCREW REMOVAL (1) Make mating marks. NOTE ‘The mating marks are represented by one of the following methods. © Engraving by a punch or electric pen © Icential Arabic numerals. (2) Evenly loosen 4 screws on case A and B to remove. (3) Set case B downward and remove case A, side gear spacer (RH) and side gear (RH). NOTE Check differential gear backlash to determine necessity of disassembling side (RH) and onward. <4} DIFFERENTIAL GEAR BACKLASH CHECK Check differential gear backlash as follows. (4) Insert cloth wrapped screwdriver through side of case B and lock side gear (LH) and pinion gear. (one picce). (2) Contact dial gauge on pinion gear facing the locked pinion gear and measure backlash within the standard value. NOTE Measure 2 pinion gears. Standard value: Conventional differential 0.10-0.25 mm (.004-.01 in.) Rear differential lock 0.15-0.20 mm (.005~.008 in.) (8) When backlash exceeds the standard value, adjust side gear spacer (LH). NOTE If backlash is within the standard value, assure appropriate gear spacer (RH) thickness and assemble cifferential case assembly. REASSEMBLY SERVICE POINTS DA 4, Differential mounting bracket (F.H.) (Refer lo GROUP 26 — Drive Shaft) <4AD 5, Differential mounting bracket “> 2. Differential mounting bracket (LLH.) 6. Dilferential support bracket 3 mor shalt (Paar GROUP 2 — Inner Shaf REMOVAL SERVICE POINT <4Ap DIFFERENTIAL MOUNTING BRACKET (L1H.)/ DIFFERENTIAL MOUNTING BRACKET (R.H.)/ DIFFERENTIAL MOUNTING BRACKET REMOVAL While supporting the differential carrier with a jack, remove the differential mounting bracket NOTE Support the differential carrier with a jack until the differential mounting bracket is installed, INSPECTION szv001800r1 © Check the differential mounting brackets for deformation ‘or damage. © Check the differential support bracket for deformation or damage. © Check insulators for cracks, separation or deformation. = TSB RevisionFRONT 33-1 SUSPENSION CONTENTS FRONT SUSPENSION . ELECTRONICALLY-CONTROLLED SUSPENSION (ECS) ... ELECTRONICALLY—CONTROLLED SUSPENSION (ACTIVE PREVIEW ECS) . NOTE The tinted sections are not included in this manual. 330, 338 33¢33-2 NOTES33A-1 FRONT SUSPENSION CONTENTS CONTROL SWITCH .... 221 CONTROL UNIT GENERAL SPECIFICATIONS .. LOWER ARM . sie soo 14 Front Lower Arm Bushing Replacement 16 Lower Arm Ball Joint Dust Cover Replacement 16 Rear Lower Arm Bushing Replacement 15 ON-VEHICLE SERVICE . Ball Joint Dust Cover Check Front Wheel Alignment Check and Adjustment 8 SEALANTS AND ADHESIVES ... 3 SERVICE SPECIFICATIONS 2 SHOCK ABSORBER AND UPPER ARM . Upper Arm Ball Joint Dust Cover Replacement : " 18 SPECIAL TOOLS . STABILIZER BAR . Stabilizer Link Ball Joint Dust Cover Replacement a 19 TORSION BAR . ‘TROUBLESHOOTING Stabilizer Link Ball Joint Dust Cover Replacement a33A-2 FRONT SUSPENSION - General Specifications/Service Specifications GENERAL SPECIFICATIONS ‘SUSPENSION TYPE Items [ Speciication ‘Suspension system [independent double wishbone wih torsion bar and elesoni shock absorer TORSION BAR Items ‘Specifications Lengthx0.D. mm (in.) 1807.5%26.4 (51.476% 1,089) ‘Spring constant (wheel position) N/mm (lbsJin.) 29 (162) TORSION BAR Items Specifications: Lengthx0.D. mm (in.) 1907.5%27.2 (61.476x 1.071) ‘Spring constant (whee! position) Nimm (IbsJin.) 33 (185) SHOCK ABSORBER Items Vehicles without remote-controlied variable shock absorbers Vehicles with remote-controlled vari= able shock absorbers Type Hydraulic, cylindrical, double-acting Hydraulic, cylindrical, double-acting i | | Contraction | type [ype with iom-pressure nitrogen gas Max. length mm (in) 345 (18.6) 345 (18.8) Min length mm (i) 225 (8.9) 2900.1) ‘Stroke mm (in) | 120 (4.7) 115 (4.5) | Damping force | Expansion —_» 2,530 (569) Hard: 3,236 (728) [at 0.3 m/sec Medium: 2,550 (573) (O9ttisec| Sot: 1.746 (283) N lbs.) 1,079 (243) Hard: 1,285 (289) Medium: 1,030 (232) Soft: 628 (141) SERVICE SPECIFICATIONS Items Standard value | Limit “Toosin ~ | Atthe center of tre tread mm (in.) 35235 (142.14) | ~ ‘At the rim of dise wheel mim (in) 1831.8 (072.07) |— |Toe-in angle (per wheel) Or017 = “Toe-out angle on tur (inner whee! when | 21°56" - outer wheel is at 20") | Camber o°40'= 30" = Caster 3°00'21°00" =Service Specifications/ FRONT SUSPENSION — Sealants and Adhesives/Special Tools 33A-3 "tems ] Standard value | Limit Kingpin incination 14°52 = Side slp mm tn.) 03 (05.12) = ‘Upper ball joint breakaway torque Nm (in.lbs.) 0.8-3.5 (7-30) | - ‘Shock absorber attaching | Normal shock absorber 7-2 (04-08) | - soo, THE TROUBLESHOOTING CHART SELECTION Check the malfunction symptoms according to the following flow chart, and inspect according to the inspection chart Check with the engine iding, 1 eg | see cepacia ace When the shock absorber contol swich | "eter to Troubleshooting Char (1) position is changed, do the indicators op- (malfunctions related to the indicators) | brate normaly eens) ooo s M H | Lr : e005 Yes ie When the control switch positon is_ "Refer to Troubleshooting Chart 2) changed while the vehicle isbeingrocked (malfunctions related to the dampers) up and down, does the damping force | (P338-6,) | change? (Carry out at the 4 locations at | front and rear, left and right) TSB RevisionFRONT SUSPENSION — ‘Troubleshooting CHART CLASSIFIED BY TROUBLE SYMPTOM {OUBLESHOOTING CHART [1] (MALFUNCTIONS RELATED TO THE INDICATORS) 33A-5 and (2) are normal Trovble Inspection Nomal | Probable Cause symptom condition Even when (1) Disconnect the shock absorber control | The Te Open reuit in fuse No. 1 in Switched to. switch connector and ground harness | indicator the junction block 3 (Soh) connector terminal (), iluminates. |e Malfunction of light-emitting mode, the diode Insiestor Open circuit inthe ames doas not between the combination meter iluminate and either the junction bidck oF the ‘shock absorber contol | Sitch {@) Disconnect the shock absorber control Continuty | Malfunction of shock absorber guftch connector and check for continuy control switch Botwwaon sven connector terminals (4) ~- (2) when the switch is set to S (Soft). (®) When the resuits of inspection tems (1) | ~ @ Open circuit in the hamess and (2) ate normal between the contol switch anc the ground Income! ground connection Evenwhen (1) Disconnect the shock absorber control/ The Open circus in fuse No. 11 in Switched to.” switch connector and ground harness, incicator the junction block (Mesum) connector terminal (5). iluminates. | Malfunction of light-emitting mode. the diode ‘ndiestor © Open circuit inthe hamess does not between the combination meter tlumnate and either the junction block or the shock absorber control suteh (@) Disconnect the shock absorber conttol| Continuity | Malfunction of shock absorber Switch connector and check for continuity contol santch between ‘switch connector terminals (8) | 2) wnen the sults set to M (Medium), (3) When the results of inspection items (1) | — Open circuit in the hamess between the shock absorber ‘control switch and the ground © Incorrect ground connection ‘TSB RevisionTroubleshoot 33A-6 FRONT SUSPENSION — eae cc ee Sieh [resem | HH [No.3 Coninuty [Ne coneuty Ne eorinay | [No.7 hecominay | Gontnoly [Neary | [No.2 Nocona [Ne contty | Cory T [yes When 12V is applied to harness connector ter- | minal (@) of the shock absorber control unit, | does the damping force change over? Yes No (Open circuit in the harness between the shack absorber control unit and the ground (Open circuit in the hams between the shock absorber control unit and the shock absorber control switch ‘Open orshortcircuitinihehamessbetweenthe | actuator and either the shock absorber control Unit or the shock absorber control switch Incorrect shack absorber control unit connec- tion, oF malfunction of shock absorber contro! unit33A-8 FRONT SUSPENSION Troubleshooting Left quarter pane! SHOCK ABSORBER CONTROL UNIT SIGNAL CIRCUIT INSPECTION (1) Disconnect the shock absorber control unit connew.., and inspect the connector at the harness side. Thais atslel7 84+: Battery Positive Voltage Terminal Connection | Measure: | Tester | Check eondton | Standara No | Gestation | ment | conection + [Ground | Continuity] (y= | Gonstaniy "Contin | | Ground | 2 | Shock absorber | Continuity] (2) | Shock absorber coro! | § (Soft mode) | No continuity Control switch Ground | swich condition | (Wer) j | (tedium mode) | No eoninuty | | (Hard mode) __| Continuity 7 ‘Shock absorber | Continuity) (7)— | Shock absorber control_| S (Soft mode) | No continuity control switch Ground | Switch conation (Medium) | M (Medium mode) | Continuity H (Hard mode) | No continuity 3 | Shock absorber | Continuiy] (@)- | Shock absorber contol |S (Soft mode) | Continuity control witch Ground | swtch eonaton ee ee (Sot) M (Medium mode) | No continuity Hi (arsmode) | No coninaty [Powersupply | Votage |(@)= | loin awitch | OFF [ov Grouna t | [on [ee (2) Connect the shock absorber control unit and inspect. Terminal] Connection | Measure- | Tester | Check condition Standard No.” | destination | ment | connection © | Shock absorber | Vottage | (6) | Seconds ater operating the shock absorber | Approx. ti actuaer | Ground | control sutch | Condon xeon above [av TSB RevisionFRONT SUSPENSION — On-vehicle Service 33A-9 ose | ON-VEHICLE SERVICE atonon0ns2 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT TOE-IN 1. Measure the toe-in, Standard value: At the center of tire tread 3,523.5 mm (142.14 in.) At the rim of dise wheel 1,841.8 mm (.074.07 in.) Toe angle (per wheel) 0°-0°17" 2. If the tos-in is not within the standard value, adjust the toe-in by tuming the left and right tie rod tumbuckles by the same amount (in opposite directions). Caution The difference between the left and right tie rods should not exceed 5 mm (2 in.). 3. After adjusting, use a turning radius gage to confirm that the steering Wheel turning angle is within the standard value range. (Refer to GROUP 37A.) TOE-OUT ANGLE ON TURNS To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, itis advisable to check the tow-out angle on tums in adcition to the wheel alignment. Conduct this test on the left turn as well as on the right turn Standard valu 21°56" (inner wheel when outer wheel at 20°) CAMBER Standard value: (0°40"=30" (Left/right deviation within 30°) 4. Adjust the camber by increasing or decreasing the thickness of the adjusting shim provided between the upper arm shaft and the crossmember. NOTE © Standard thickness of the shim is 4 mm (.16 in.) © The number of shims is three or less, Camber adjustment shim (yellow plating) Part number Thickness mm (in) MB176288, 7.0 (.039) MB176289 2.0 (079) ‘TSB Revision33A-10 FRONT SUSPENSION ~ On-vehicle Service CASTER Standard value: 3°00"s:1° (Leftiright deviation within NOTE 1. Caster is pre-set at the factory and cannot be adjusted. 2. If the caster is not within the standard value, replace bent or damaged parts. KINGPIN INCLINATION Standard value: 14°52" SIDE SLIP Measure the side slip with a side slip tester. Standard value: 0:3 mm (0+.12 in.) BALL JOINT DUST COVER CHECK ——xxzecona 1. Check the dust cover for cracks or damage by pushing it with finger. 2, If the dust cover is cracked or damaged, replace upper arm, lower arm, or stabilizer link assembly. NOTE Cracks or damage of the dust cover may cause damage of the ball joint [TSB RevisionFRONT SUSPENSION - Shock Absorber and Upper Arm 33A-11 SHOCK ABSORBER AND UPPER ARM sazo0zs0064 sEMOVAL AND INSTALLATION Post-installation Operation '# Press tne dust cover witha finger to check whether the dust cover le cracked of dameges. ‘© Wheel Alignment Inspection and Adjustment (Roler to P3383) © Brake line Blesding (Vehicles without ABS: Refer ta. GROUP 354 — On-vehicle Service \Vehicis with ABS: Reler to GROUP 85¢ ~ Onvvehicle Service.) 308 Nm 11 fllbs. 80 tebe. a ce ‘Upper arm ball jaict Sealant: 3M ATD Part No. 8661 coooseas or equivalent ‘Shock absorber removal steps DB 1. Actuator (Vehicles with remote 5, Brake hose connection Controlled variable shock absorbers) BD 6. Upper ball jont and knuckle PB 2, Shock absorbers connection 7 Brake nose clip és ' 8. Rebound stopper eee eee 81 Speed sensor bracket ‘© Bump stopper and bump stopper Wehicles with ABS) bracket clearance adjustment 10. Rebound stopper (Filer to PS3A-18) 11. Shim “> 3, Anchor arm assembly adjusting nut Ad 12, Upper arm 4. Hose clip 48, Upper ball joint TSB Revision33A-12 FRONT SUSPENSION — Shock Absorber and Upper Arm REMOVAL SERVICE POINTS 4A ANCHOR ARM ASSEMBLY ADJUSTING NUT LOOSENING Loosen the anchor bolt of the torsion bar all the way. NOTE When the anchor arm assembly adjusting nut is loosened, use a jack to support the lower arm of the side to be loosened to make the work easier. 48> UPPER BALL JOINT AND KNUCKLE DISCONNECTION Use the special tool to disconnect the upper arm ball joint from the knuckle. Caution 1. Be sure to tie the cord of the special tool to the nearby part. 2, The nut should only be loosened, not removed. INSTALLATION SERVICE POINTS DPAUPPER ARM INSTALLATION Install the upper arm so that the “OUT” mark on the up~ ~~ arm shaft is facing toward the outside of the vehicle,FRONT SUSPENSION - Shock Absorber and Upper Arm 33A-13 Eager Normal Shock a absorber zawsss Remote-controlled variable shock absorber] Actuator mounted surface We Nut 5 J washer ever ‘Shock a sooo: std ene a 2iasent ——— 4A fra = ——esces )-B-4SHOCK ABSORBER/ACTUATOR (VEHICLES WITH REMOTE CONTROLLED VARIABLE SHOCK ABSORBER) INSTALLATION Tighten the shock absorber installation nut_so that the dimensions showin in the illustration (A and B) are at the standard values. Standard value ‘A: 1-2 mm (.04~.08 in.) B: 1.5-2.5 mm (.06~.10 in.) Caution When tightening the nut, be careful not to bend the stud pin of the washer assembly. INSPECTION BALL JOINT BREAKAWAY TORQUE CHECK 4. Alter shaking the ball joint stud several times, install the fut to the siud and use the special tool to measure the breakaway torque of the ball joint Standard value: 0.8-3.5 Nm (7-30 in.tbs.) 2. When the measured value exceeds the standard value, replace the ball joint 3. When the measured value is lower than the standard value, check that the ball joint tums smoothly without excessive play. If 0, it is possible to use that ball joint. UPPER ARM BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with finger 2. If the dust cover is cracked or damaged, replace the upper arm. (Refer to P.S3A-11.) NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover. UPPER ARM BALL JOINT DUST COVER REPLACEMENT aozancomie Only when dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Apply multipurpose grease to the interior of dust cover ‘and the upper arm ball joint. 2, Secure the dust cover to the upper arm ball joint with fing. 3. Press the dust cover with a finger to check whether the dust cover is cracked or damaged.33A-14 FRONT SUSPENSION — Lower Arm LOWER ARM sa200280—-0) REMOVAL AND INSTALLATION Postinstallation Operation fe Press ine cust cover witha finger to check whether the dust cover is eracked or camaged. ‘© Wheel alignment Inspection and Adjustment (ter to P3389.) 108 Flos.” | | ie. Som 0 eo 125609 Removal steps 1. Under skid plate 7. Shock absorber mounting bolts 2. Under cover 8, Lower arm shaft © Bump stopper and bump stopper 8. Anchor arm B bracket clearance adjustment 40 Lower arm (Refer to P33A-18,) 11. Bump stopper 3. Torsion bar (Refer to P:39A-17,) 42; Lower ball joint 4. Splt pin

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