Toyota Tercel 4WD 1985

PR-1
P R O P E L L ES
RH A F T
(for 4WDl
Page
PRECAUTIONS
PR.2
TROUBLESHOOTING
PROPELLER
SHAFT
PR-2
PR.2
il:t'
ry*';
'"'"s, 'f,'
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SHAFT - Precautions,Troubleshooting,PropellerShaft
PROPELLER
PR-z
PRECAUTIONS
1.
As the universal ioint is a non-disassembly type' the

propeller shaft or intermediate shaft must be replaced
as an assembly in the event of universalioint trouble.
2.
Be careful not to grip the propeller shaft tube too tightly in the vise as this will cause deformation.
TROUBLESHOOTING
Noise
Page
Remedy
Possiblecause
Problem
Sleeveyoke splineworn
Replaceintermediateshaft
PR-3
Centerbearingworn
Replacecenter bearing
PR-3
Spiderbearingworn or stuck
Replaceintermediateshaft or
PR-3
propellershaft
Replacepropellershaft
Balancepropellershaft
PR-3
extensionhousingrear
Transmission
bushingworn
Replacebushing
TA.4O
Sleeveyoke splinestuck
Replaceintermediateshaft
PR-3
Centerbearingheight imProPer
Adjust bearingheight
Propellershaft runout
Vibration
Propellershaft unbalance
PR-3
SHAFT
PROPELLER
COMPONENTS
lntermediate Shaft
----
9-Height
Washer [ 430 (3il42t
Center SuPPortBering- -
Ffiffiiib-ntnl
O :
torque
: Tightening
Non-reasable part
ProPellershaft
w- -I- @
I
I
PROPELLER
SHAFT - PropellerShaft
PR.3
REMOVALAND DISASSEMBLYOF
PROPELLER
SHAFT
(See page PR-21
1.
DISCONNECTPROPELLER
SHAFT FLANGEFROM
COMPANIONFLANGEON DIFFERENTIAL
(a) Placematchmarkson the flanges.
(b) Removethe four bolts and nuts.
2.
REMOVETWO BOLTS HOLDINGCENTERSUPPORT

BEARINGTO BODY
3.
REMOVEPROPELLER
SHAFT WITH INTERMEDIATE
SHAFT
h) Pullout the yoke from the transmission.
(b) InsertSST in the transmission
to preventoil leakage.
s s T 0 9 3 2 5 - 12 0 r O
4.
SEPARATEPROPELLER
SHAFT AND INTERMEDIATE
SHAFT
(a) Placematchmarkson the flanges.
(b) Removethe four bolts and nuts.
5.
REMOVECENTERSUPPORTBEARINGFROM
INTERMEDIATE
SHAFT
(a) Usinga hammerand chisel,loosenthe stakedpart of
the nut.
(b) UsingSST to hold the flange,removethe nut.
ssT 09330-00020
PR-4
PROPELLER
(c) Placematchmarkson the flangeand shaft.
(d) Clampthe flangeyoke in a viseand tap off the shaft.

(e) Removethe center support bearing.
INSPECTION
OF PROPELLER
SHAFT
COMPONENTS
1.
INSPECTPROPELLER
AND INTERMEDIATE
SHAFTS
FORDAMAGEOR RUNOUT
Maximum runout: 0.8 mm (0.031 in.l
lf shaft runout is exceedsmaximum,replacethe shaft.
2.
INSPECTSPIDERBEARINGS
(a) Inspectthe spiderbearingsfor wear or damage.
(b) Checkthe spider bearingaxial play by turning the
yoke while holdingthe shaft tightly.
Bearingaxial play: O mm (0 in.l
lf necessary,replacethe intermediateshaft orland propellershaft.
3.
INSPECTCENTERSUPPORTBEARINGFORWEAR OR
DAMAGE
Checkthat the bearingturns freely.
lf the bearingis damaged,worn, or does not turn freely,
replaceit.
PROPELLER
PR.5
ASSEMBLYAND INSTALLATIONOF
PROPELLER
SHAFT
(See page PR-21
NOTE: When replacing parts, install them facing as
shown in the illustration.
fl
rthffihP
tuldi?ih
1.
INSTALLCENTERSUPPORTBEARINGON
INTERMEDIATE
SHAFT
lnstall the center support bearingwith the cutout on the
rear side.
2.
INSTALL FTANGEYOKE ON INTERMEDIATESHAFT

ta) Apply MP greaseto the splinesof the intermediate
shaft.
(b) Align the matchmarkson the yoke and shaft and
installthem.
(c) Using SST to hold the flange, tighten down a

nut to pressthe bearinginto position.
ssT09330-ooo20
Torque: 1,850 kg-cm (134 ft-lb, 181 N.ml
(d) Loosenthe nut.
(e) Torque the nut again.
Torque: 300 kg-cm (22 ft-\b,29 N.ml
(f) Using a hammerand punch, stake the nut.
PR-6
PROPELLER
SHAFT - PropeilerShaft
3.
ASSEMBTEPROPELLER
SHAFT AND
INTERMEDIATESHAFT
(a) Align the matchmarkson the flanges and connect
them with the four bolts and nuts.
Torque: 430 kg-cm (31 ft-|b,42 N.ml
4,
INSERTSLEEVEYOKE IN TRANSMISSION
{a) Apply MP greaseto the outsadediameterand splines
of the yoke.
(b) RemoveSST.
ssT 09325-12010
(c) Push the yoke into the transmission.
SST
5.
CONNECTPROPELLER
SHAFT FLANGETO
COMPANIONFLANGEON DIFFERENTIAL
(a) Align the matchmarkson the flangesand connectthe
them with the four bolts and nuts.
(b) Torguethe nuts.
Torque: 43O kg-cm (31 ft-tb,42 N.m)
6.
CONNECTCENTERSUPPORT
BEARINGTO BODY
ta) Place the height washer between the body and
center support bearing,and installthe two mount
bolts fingertight.
NOTE: Some vehiclesdo not have a height washer..
In this case, it is not necessaryto insert one.
Front1Centerof Center
Bearing
(b) Check that the bearingbracket is at right anglesto

the propellershaft Adjust the bracket if necessary.
(c) Checkthat the centerline of the centerbearingis set
to the centerlineof the bracketwhen the vehicleis in
a no-load condition.
Adjust the bracketif necessary.
(d) Torquethe mount bolts.
Torque: 375 kg-cm Q7 tt-ab,37 N.m)
FA.1
FRONTAXLE AND
SUSPENSION
TROUBLESHOOTING
FRONTWHEEL ALIGNMENT
AXLE HUB
FRONTDRIVE SHAFT
FRONTSHOCK ABSORBER
FRONTSUSPENSION
Ball Joints
Lower Arm
Stabilizer Bar
Page
FA-2
FA.3
FA-7
FA.13
F4.19
FA-23
FA.23
FA-24
F4.27
FRONTAXLE AND SUSPENSION- Troubleshooting
FA.2
TROUBLESHOOTING
Problem
Possiblecauss
Remedy
Page
FA-3
Steering gear out of adjustmentor broken
Replacetire or inflate tires to

proper pressure
Checkfront end alignment
Replacewheel bearing
Tightenor replacesuspension
part
Tightenor replacesteering
linkage
Adjust or repair steering gear
Vehicle overloaded
Shock absorberworn out
Springsweak
Checkloading
Replaceshock absorber
Replacespring
FA.19
FA.l9
Sways/pitches
Tires improperly inflated

Stabilizerbar bent or broken
lnflate tires to proper pressure

Replacestabilizerbar
FA-3
FA-27
FA-19
Front wheel shimmy
Tires worn or improperly inflated
FA-3
Steering gear out of adjustment or broken
Replacetire or inflate tires

to proper pressure
Balancewheel
Checkfront end alignment
Inspectball joint and bushing
Tightenor replacesteering
linkage
Adjust or repairsteeringgear

Alignmentincorrect
Suspensionparts worn
Inflate tires to proper pressure

Checktoe-in
Replacesuspensionpart
FA.3
FA-19
FA.3
Wanders/pulls
Tires worn or improperlyinflated

Alignmentincorrect
Wheel bearingworn
Front or rear suspensionparts loose or
broken
Steeringlinkageloosenor worn
Bottoming
Wheel out of balance

Alignmentincorrect
Wheel bearingworn
Balljoints or bushingworn
Steeringlinkageloosenor worn
Abnormaltire wear
FA-3
FA.8
sR-9
FA-19
FA.3
FA-8
FA.23
sR-9
FRONTAXLE AND SUSPENSION- FrontWheel Alignment
FA-3
FRONTWHEELALIGNMENT
1.
MAKE FOLLOWING CHECKS AND CORRECTANY

PROBLEMS
(d Check the tires for wear and proper inflation.
Cold tire inflationpressure kg/cm2(psi,kPa)
Tire size
FWD
4WD
1 4 5S R 1 3
3A-C 4-speed M/T
Others
Frontand Rear
2.2 (32.220l.
2.OQ8,2001
1 6 5S R1 3
1 . 8(26. 180)
1.8 (26, 180)
1 5 5S R1 3
2.OQ8,2001
1 7 5S R1 3
1.8 (26. 180)
1 5 5S R 1 3
(b) Checkthe front wheel bearingsfor looseness.

(d Checkthe wheelrunout.
Lateral runout: 1.2 mm (0.047 in.) or less
(d) Checkthe front suspensionfor looseness.
(e) Check the steeringlinkagefor looseness.
(f) Check that the front absorbers work properly by
using the standardbouncetest.
A2.
ADJUST TOE.IN
Adjust toe-in with a toe-in gauge by the following procedure.
(d Checkto seethat both right and left tie rods measure
the samein length.
Left-right error: 1.5 mm (0.059 in.l or less
Wry@=S
+=ruf,ffi
--A--
F--B--i
A = B
(b) Move the vehicleforward a few meterswith the front

positionon a levelplace.
wheelsin the straight-ahead
(c) Mark the center of each rear tread and measurethe
distancebetweenmarks of the right and left tires.
(d) Advancethe vehicletill the marks on the rear of the

tires come to the measuringheightsof the gaugeon
the front.
(e) Measurethe distancebetweenthe markson the front
of the tires.
Toe-in: lnspectionSTD -1 {- 1 mm
(-0.O4 + O.O4in.)
'ru,
!,.-!
FA.4

(f)
lf the toe-in is not within inspectionSTD, adjust the

toe-in.
(1) Loosenthe clamp.
el Removethe boot clip.
(3) Turn the left and right rack ends an equal

amountto adjust.
Wl Check that the length of the left and right tie

rods are the same.
fuwry'$
A = B
(5) Torquethe tie rod end clamp.

Torque: 195 kg-cm (14 ft-lb, 19 N'ml
(6) Placethe boot on the sealand clamp it.
NOTE: Checkthat the boot is not twisted.
3.
INSTALTWHEEL ALIGNMENTEOUIPMENT
Follow the specific instructionsof the equipmentmanufacturer.
- FrontWheelAlignment
FRONTAXLE AND SUSPENSION
Front
Rear (FWDI
4,
FA-5
INSPECTVEHICLE HEIGHT
mm (in.)
Vehicleheight
Tire size
Rear
Front
203.017.9921 287.O 1 1 . 2 9 9 )
1 4 5S R 1 3
208.0(8.189) 292.O 1 1 . 4 9 6 )
o Sedan 1 5 5 S R 1 3
1 6 5 / 7 0S R 1 3 204.0(8.O31) 288.0 1 1 . 3 3 9 )
3
2 0 7 ( 8 . 1 5 0 ) 308.5 12.146l.
Wagor 1 5 5SR 1 3
234.419.2281 273.O 10.748)
1 5 5S R 1 3
t 7 5 / 7 0 S R 1 3 235.4(9.268) 274.O 1 0 . 7 8 7 )
4WD
try to
lf height of the vehicleis not within specification,
levelit by shakingit down.lf the heightis still not correct,
parts.
checkfor bad springsand worn or loosesuspension
Rear (4WD)
5.
ADJUST CAMBER
Inspectionstandard Left-right error
Vehicle
FWD
camber:
Sedan
10'+ 30'
Wagon
s' + 30'
30' or less
40' -t- 30'
4WD
lf camberis out of tolerance,adjustby turningthe camber

adjustingcam.
(a) Loosenthe shock absorbermount nut.
(b) Turn the cam to adjust.
NOTE: Camberchangesabout20'with eachgraduation
of the cam.
(c) Tightento the specifiedtorque.
Torque: 1,45Okg-cm {105 ft-lb, 142 N'm)
More Camber
6.
AXIS INCLINATION
ADJUST STEERING
Inspectionstandard Left-righterror
Vehicle
Sedan
12'30' * 30'
Wagon
12035' + 30'
FWD
4WD
30' or less
1 1'50' -t- 30'
lf the steeringaxis inclinationis out of tolerance,inspect

and replaceany damagedor worn front s$rplnsionparts.
s[
FA.6
7.
ADJUSTCASTER
Caster
Front a-
w/ PS
2"40' + 30'
w/o PS
1'
Inspection
Sedan
3
lt-
Standard
Wagon
Inspectionstandard
3
<f
Left-righterror
Left-righterror
1'10'+ 30'
0045' + 30'
2"15' + 30'
30' or less
2"25' -+-30'
30' or less
lf the casteris not within specification,adjust by increasing or decreasingthe number of spacers.Do not install
more than two spacers.
Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml
NOTE: The casterwill change13' with each spacer.
8.
ADJUSTWHEELANGLE
Wheelangle
Insidewheel
Outsidewheel
Max.
36020' + 10
32040' + 1"
at 2Oo
21"30'
200
Spacer
w/o PS
Sedan
w/ PS
(o
o
=
|'lw/o PS
Max.
35050' !
10
32'55' f
10
at 20o
21"05'
20"
Max.
36013' + 10
32058' + 10
at 2Oo
21'25'
20"
Max.
35047' 1 1'
32050' =1"
at 20"
21"O9'
20"
Max.
36030' + 10
3 3 0 1 s ' +1 0
Wagon
wi PS
w/o PS
4WD
w/ PS
,'4o*
t:ry
at 200
2' 1"15'
20"
Max.
36020' + 10
33020' + 1'
at 2Oo
21005'
200
lf the steeringanglesdiffer from the standardspecification, check to see that the length of the left and right tie
rods are the same.
NOTE: lf the tie rod lengthsare not equal,the steering
anglecannot be adjustedpropedy.
lf the rie rod lengthswere changedto adjust the steering
anble,reinspectthe toe-in.
9.
--,-,-j:*-a
INSPECTSIDE SLIP WITH SIDE SLIP TESTER

Side slip: 3.O mm/m (O.118in./3.3 ft) or less
lf the side slip is not within specification,the toe-in or
front wheelalignmentmay not be correct.
t-
FRONTAXLE AND SUSPENSION- Axle Hub
AXLEHUB
COMPONENTS
1,450 (105, 142)
Disc BrakeCaliper
shocknusoruer-----'1 I
wheet
Bearins
n
l i f| f *
q$J t d
d^%J-
>>
*@r
r"o
rieRod
t.''"'lo:'t cam
\E
h^
*9@n^6g1'
:-\^'
Y9J'A
i:T:":it:i
ffi31?yrnnerRacel
l*ry
Dise
Brake
Dust
cover
Lt^:::l1l"ner
t"'" *1":iHJ"r,""l
-l
Race (NSK
rype)
Lock Nut Cap
a?6,
I
Outer Oit Seal
Ikg-cm (ft-lb, N.m)l : Tighteningtorque

O : Non-reusablepart
ir
/1"i"
Y&r-A
lSU
FA.7
n
FA.8
REMOVALOF FRONTAXLE HUB

1.
REMOVECOTTERPIN. BEARINGLOCKNUT CAP AND

LOCK NUT
(a) Removethe cotter pin and lock nut cap.
(b) Before removing the brake caliper,loosen the lock
nut while depressingthe brake pedal.
2.
REMOVEBRAKECALIPER
Removethe brake caliperfrom the steeringknuckleand
suspendit with wire.
3.
REMOVE
DISC
pLAy rN AxtAL DtREcnoN

4. *fi*frcr BEARTNG
'' Maximum: 0.05mm (O.OO2O
in.l
nC
t
rI
5.
DISCONNECTTIE ROD END FROM STEERING

KNUCKLE
(d Removethe cotter pin and nut.
(b) Using SST, disconnectthe tie rod end.
ssT 09610-20012
t
I
li
6.
)t5f'
7.
.. ...t
".-*ffi,i.,.*
f.isEl;-*r:
DISCONNECTSTEERINGKNUCI(Lernorrn*fucr
ABSORBER
(d Place matchmarks on the shock absorber lower
bracketand camberadjust cam.
(b) Removethe two boltsend nuts, and disconnectthe
steeringknuckle.
DISCONNECTLOWERARM FiOM STEERING

KNUCKLE
Removethe two bolts holdingthe balljoint to the steering
knuckle.
- Axle Hub
8.
REMOVEAXLE HUB FROM

UsingSST, removethe axle hub.
ssT 09950-20015
,. CAUTION: Cover the drive shaftrhl
(r':q
( protect it from damage.
\t;;
, +in f,rlve tl""ff\ii
!,ocr* d i t{" cIo*h to " .rr:'r,

g ra *e c* i t ro*r ata^4 1e.
R E P L A C E M E NOTF F R O N TA X L E H U B A N D
W H E E LB E A R I N G
(Seepage FA-7)
1.
REMOVEDUSTDEFLECTOR
removethe dust deflector.
Usinga screwdriver,
2.
REMOVEINNEROIL SEAL FROMSTEERING

KNUCKLE
UsingSST, pull ou.tthe oil seal.
ssr 09308-00010
3.
REMOVEHOLESNAP RING
Usingsnapring pliers,removethe hole snap ring.
4.
fr
,..F.
r:
REMOVETHREEBOLTS
Removethe three bolts holdingthe disc brakedust
to the steeringknuckle.
KNUCKLE
REMOVEAXLE HUQ FROMSTEERING
UsingSST,pushoff the axlehub.
ssT 09950-20015
6.
REMOVEDISCBRAKEDUSTCOVER
7.
REMOVEBEARINGINNERRACE'(INSIDE)
,f+
8.
REMOVE.
rlruen.qAbe(OUrSlOe)
BEARTNG
Using9ST, pull off the beaiing'innerrace.
r
ssT 09950;20015 t
,{
n.1
'
FA.1O
-'v7:'
- Axle Hub
9.
REMOVEOUTEROIL SEAL
UsingSST, pull out oil seal.
ssT 09308-00010
1O. REPLACE
WHEELBEARING
h) Firstplacethe inner race (outside)of the bearingin
the bearing
(b) UsingSST, pressout the bearing.
SST 09228-22O2Oand 09950-20015
'.tfi
(c) U$ilfi SST,prestffi a new bearing.

ssT 09309-3501
0
NOTE: Therearetwo typesof bearings;
KOYOandNSK.
H
r
F
E
1 1 . INSTALLOUTEROIL SEAL
h) Installthe bearinginnerrace (outside)beforeinstalling a pew oil seal.
(b) UsingSST,drivethe oil sealintothe steeringknuckle.
ssT 09515-35010
(c) Apply MP greaseto the oit seallip.
12. INSTALLDISCBRAKEDUSTCOVERONTOSTEERING
KNUCKLEWITH THREEBOLTS,
Apply liquidsealerto the dust coverand steeringknuckle
connectionbeforeassembly.
1 3 . INSTALLAXLE HUB
(a) Installnew innerracesinto the innerbearing.
(b) Using SST, ggss in the innerrace until it is tightty
againstthe sftlulder of the hub.
SST 09228-22O2Oand O9310-35010
NOTE: Do not interchangethe inner and outer races
when installing.
f r _
.,,iW;ffiqa-
*L-
__
+l
i'-:r':
'
- Axle Hub
FA-l1
1 4 . INSTALLHOLESNAP RING
Usingsnap ring pliers,installthe hole snap ring into the
steeringknuckle.
3.3 -+
1 5 . I N S T A L LI N N E RO I L S E A L
UsingSST,drive in a new bil seal.
ssT 09309-35010
NOTE: Tap in the oilseal3.3-t-0.1 mm (O.130+ 0.004
in.)from the end surface.
16. INSTALLDUST DEFLECTOR
Using SST, drive a new dust deflector into the steering
knuckle.
ssT o9316-60010
INSTALLATION
OF FRONTAXLE HUB
(See page FA-7)
1.
INSTALLAXLE HUB TO DRIVESHAFT

lnstallthe axle hub with the washerand lock nut. Do not
torquethe nut yet.
CAUTION: Be careful not to damagethe drive shaft
boot and oil seal lip.
2.
INSTALLAXLE HUB TO LOWERARM

Torque the*holdingtwo bolts the steering'knuckleto the
rowerarm.
Torque: 82O kg-cm (59 ft-lb, 80 Nrml
ilxb
3.
INSTALLDISC TO
'' .!
jG;','
T6i'
INSTALLSTEERING
KNUCKLETO SHOCKABSORBER
(a) Lower the stabilizerbar and assemblethe steerirfi"
knuckleto the shockabsorberlower bracket.
:l;;
4sft
'l
FA..12

(b) lnsert the bolts from the front side and align the
matchmarksof the camberadjust cam.
(c) Torque the bolts.
Torque: 1,450 kg-cm (105 ft-lb, 142 N'ml
5.
INSTALL BRAKECALIPERTO STEERINGKNUCKLE

Torque the bolts.
Torque: 970 kg-cm (70 ft-lb, 95 N.ml
6.
CONNECTTIE ROD END TO STEERINGKNUCKLE

Torque the nut and secureit with a new cotter pin.
Torque: 6O0 kg:cm (43 ft-lb, 59 N.m)
#
tr,
W
Vi
i
i
'\i.
7.
TOROUEBEAfriG LOCK NUT AND INSTALL LOCK

NUT CAP AND;COTTER?IN
(a) Torqrlethe lock nut wtriledepiUs.s.lng
the brakepedal.
Torque: 1,900 kg-cm (137 ft-lb, f86 N.m)
(b) Installthe lock nut cap affittsing plieib,.install
a new
cott*. pin.
+
8.
' i " . :"
I
lI .
f,'
l .
CHECKFRONTWHEEL ALIGNMENTf$6e page FA-3)

'-*+***n,.
it'
.,
.i
.:)".4..,,
FRONT AXLE AND SUSPENSION -
FA.13
Front Drive Shaft
FRONTDRIVESHAFT
R E M O V A LO F F R O N TD R I V ES H A F T
ShockAbsorber
DiscBrakeCaliper
Stiffener Plate
(Left Side Only)
ffi
- :
\ R\x+.
---
Tie Rod End---
Lower Arm
1.900 {137, 186}
torque
lRgrcmITi-|b,T.mi] : Tishtening
part
O : Non-reusable
1.
K N U C K EA N D
R E M O V ES T E E R I N G
AXLE HUB WITHOUTDISCONNECTING
LOWERARM
(Seestep 1 to 6 and 8 on page FA-81
2.
REMOVEFRONTDRIVESHAFT
(a) Removethe stiffener plate from the transaxleassemblyand"engine(left side only).
.t.
(b) UsingSST.anda hammer,tap out the front drive

shaft.
ssr 09648-16010
FRONTAXLE AND SUSPENSION- FrontDriveShaft
FA.l4
(d
After pulling out the shaft, leavethe SST inserted.

ssT 09563-16010
COMPONENTS
InboardJoint Shaft
DynamicDamper(LHShaft Only)
Boot
Tripod
L*lt,
.tf.
{ft
DriveShaft (with OutboardJoint)
O Non-reusablepart
DISASSEMBLY OF FRONT DRIVE SHAFT

1. REMOVE
SNAPR|NGFROMTNBOARD'OITI
,2. CHECK
DRIVE
SHAFT
(a) Check to see that there jS.po play in the outboard
' :*
joint.
(b) Checkto seethat inboardjoint slidessmoothlyin the
thrust direction.
(c) Check to see that there is no remarkableplay in the
radial directionof the inboardjoint.
(d Check for damageto the boot.
,,h
3.
DISASSEMBLEBOOTCLAMPS
FA-l5
4.
DISASSEMBLEINBOARDJOINT SHAFT
(d Place matchmarks on the inboard joint shaft and
drive shaft.
CAUTION: Do not use a punch.
(b) Removethe inboardjoint from the drive shaft.
5.
DISASSEMBLETRIPODJOINT
{a) Using snap ring pliers,removethe snap ring.
(d Usinga punchand hammerplacematchmarkson the
shaft and tripod.
Uniformily tap to remove the tripod joint from the

drive shaft.
CAUTION: Do not tap on the roller.
(d
6.
REMOVEFOLLOWINGPARTS:
(a) Removethe boot from the drive shaft
(b) Removethe clamp and dynamic damper (LH shaft
only.)
i,l_
n r n
Do not remove.
(c) Removethe two boot clamps from the boot of the

outboardjoint.
(d) Removethe boot from the outboardjoint.
CAUTION: Do not remove the outboard joint.
(e) Checkthe insideand outsideof the boot for damage.
-ffi,,.@,
FA-l6
ASSEMBLYOF FRONTDRIVESHAFT
(See page FA-l41
1.
PROVISIONALLYINSTALLBOOTAND BOOTCLAMP
TO OUTBOARDJOINT
NOTE: Beforeinstallingthe boot wrap vinyltape around
the splineof the shaft to preventdamagingthe boot.
2.
INSTALL DYNAMIC DAMPERAND CLAMP

(LH SHAFT onlyl
3.
PROVISIONALLYINSTALLBOOTAND CLAMP
(For INBOARDJOINTI TO DRIVESHAFT
4.
ASSEMBLEBOOTCLAMPS ONTO DRIVESHAFT
5.
ASSEMBLETRIPODJOINT
(a) Place the beveled side of the tripod axial spline
toward the outboardjoint.
V inylTape
406 mm
(15.98in.)
r
|
-^'re
t,-/
(b) Align the matchmarksplacedbefore disassembly.
(c) When replacingthe inboard joint, first align the

centerof the inboardjoint and outboardjoint.
(d) Using a brass bar and hammer,tap the tripod onto
the drive shaft.
I.{
FA-l7
6.
INSTALL NEW SNAP RING

Usingsnap ring pliers,installa new snapring.
7.
ASSEMBLEBOOTTO OUTBOARDJOINT SHAFT

Before assemblingthe boot pack in 24O g (0.5 lb) of
grease.
NOTE: Use the greasesuppliedin the boot kit.
8.
ASSEMBLEINBOARDJOINT TO DRIVESHAFT
(a) Packin 140 g (0.3 lb, 1.4 N) of grease.
Amount: Joint side 90 g {0.2 lOl
Boot side 50 g (0.1 lul
NOTE: Use the greasesuppliedin the boot kit.
(b) Align the matchmarksplacedbefore disassembly.

(c) lnstallthe inboardjoint shaft to the drive shaft.
(d) lnstall.lF Uoo, to the inboardjoint shaft.
9.
ASSEMBLE BOOTSCLAMP TO BOTH BOOTS

(d Be sure the boot is on the shaft groove.
(b) Installa new 4amp on the inboardjoint side around
the hollow pffin of the cover.
'\.
.-"
e_
FA-l8

(c) Bendthe clampand lock it as is shown in the figure.
(d) Check that the boot is not stretched or contracted

when the drive shaft is at specifiedlength.
Drive shaft length:
Right side Approx. 620 mm 124.41in.l
Left side Approx. 722 mm (28,43 in.)
Length
10. INSTALL NEW SNAP RINGTO INBOARDJOINT

SHAFT
INSTALLATIONOF FRONTDRIVESHAFT
(Seepage FA-l3)
1.
INSTALL DRIVESHAFT TO TRANSAXLEASSEMBLY

(a) Apply MP greaseto the oil seallip.
(b) lnstallthe drive shaft by tapping on the SST.
ssT 09648-16010
NOTE: Whether or not the drive shaft is contactingthe
pinion shaft can be know by its sound or feel when tapping it in.
2.
INSTALLSTIFFENERPLATE
lnstall the three bolts holding the stiffener plate to the
engineand transaxle.Torquethe bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N'm)
3.
INSTALLSTEERINGKNUCKEAND AXLE HUB

(See step 2 to 7 on page FA-l1 and 12)
4.
CHECKFOLLOWINGPARTS:
(d Checkthe boots for damage.
NOTE: Check the entire circumferenceof the boots.
(b) Check the length between the left and right shaft
drive shaft.
after installinq,.the
'
i":
-|*it
Length: Approjff{93 mm (7.60 in.)
5.
ALIGNMENT (See page FA-31

CHECKFRONT"WHEEL
"1.
FRONTAXLE AND SUSPENSION- FrontShock Absorber
FA-l9
FRONTSHOCKABSORBER
COMPONENTS
Cover
$-Dust
o@
g-ZA
-r-a
/:A-F
Ef
Suspension
Support
Seat
@-Dust
@-sprinsseat
CoilSpring
(ft-lb. N.m) : Tighteningtorque

| : Non-reusablepart
REMOVALDISASSEMBLYOF FRONTSHOCK
ABSORBERASSEMBLY
1.
DISCONNECTSTEERINGKNUCKLEFROM SHOCK
ABSORBER(See step 6 on page FA-81
2.
REMOVE SHOCK ABSORBER ASSEMBLY FROM

BODY
ii.
(d Removethe dust coverfrom the suspqnsionsupport.
(b) Loosenthe nut. Do not removethe nut yH"
FA-20
FRONT AXLE AND SUSPENSION -
FrontShockAbsorber
(c) Removethe three nuts holdingthe shockabsorberto

the body.
(d Removethe shock absorberassembly.
CAUTION: Cover the drive shaft boot with cloth to
avoid damage.
w/o PS
w/ PS and 4WD
3.
CLAMP SHOCKABSORBERIN VISE

Installa bolt and nuts to the bracketat the lower portionof
the shock absorbershelland secureit in a vise.
4,
REMOVECOIL SPRING
(d UsingSST, compressthe coil spring.
tr-;
W
ssr 09727-22032
(b) Hold the suspensionwith a screwdriveror such so

that it will not turn, and then removethe support nut.
(c) Removethe suspensionsupport, spring seat, spring
and dust cover.
FA.21
INSPECTIONOF FRONTSHOCKABSORBER
INSPECTOPERATIONOF SHOCK
(d Pull out the shock absorberpiston rod at a constant
speed and check to see that the pull feeling
throughoutthe stroke is the same.
b)
Checkto seethat thereis no changein the pullwhen

the piston rod is rapidlymoved up and down with a
strokeof 5 - 1O mm (0.20 - 0.39 in.).
ASSEMBLYAND INSTALLATIONOF FRONT

SHOCKABSORBER
ASSEMBLY
(Seepage FA-l91
1.
INSTALLBUMPER,COILSPRINGINSULATOR,
SPRINGSEAT AND DUST SEAL
(d Mount the shockabsorberin a vise.
(b) lnstallthe bumberto the piston rod.
(c) UsingSST, compressthe coil spring.
ssT 09727-22032
(d) Align the coil springend with the lower seat hollow
and install.
(d Align the springseatwith the pistonrod and install.
(fl lnstallthe dust sealon the springseat.
(g) Installthe suspension
supportwith a new nut.Do not
torque the nut yet.
2.
INSTALLSHOCKABSORBERTO BODY
Connectthree bolts holding the shock absorberto the
body. Torquethe nuts.
Torque: 24O kg-cm {17 ft-lb, 24 N.ml
FA-22
w/ PS and 4WD
4 r y . 6 .
l..:t
!r
3.
INSTALLSTEERING
KNUCKTE
TO SHOCKABSORBER
(Seestep 4 on pageFA-l1)
4.
NUT
TOROUESUSPENSIO\T
SUPPORT
Torque: 500 kg-cm(36 ft-|b,49 N.ml
5.
INSTALL DUST COVER

Pack the bearing in the suspensionsupport with MP
grease.Installthe dust cover.
eFg Ae . s l
c H E
C cA KM( BS pEe aR
FRONTAXLE AND SUSPENSION- Front Suspension
FA-23
FRONTSUSPENSION
COMPONENTS
a{Balljoint
*-<
-ry"
I 1,075(78, los) |
Bushing7 S--t
sro(5r,sot I
StabilizerBar
YooT.\
l l - @
|
t (
l-l
|
I
I
cottar
| |
so-|l
t BooCr,
Spacer
torque
Fs-AmTliET'fri| : Tishtenins
l:
part
Non-reugable
Ball Joints
INSPECTIONOF BALL JOINTS
1.
INSPECTBALL JOINTS FOREXCESSIVELOOSENESS

(d Jack up the tront of the vehicleand place a wooden
blockwith a heightof 18O - 2OOmm (7.09 - 7.87
in.) underone front tire.
(d Lower the jack until there is about half a load on the
front coil springs.Placestandsunderthe vehiclefor
safety.
(c) Make sure the front wheels are in a straightforward
position and block them with chocks.
(d) Move the lower arm up and down and checkthat the
balljoint has no excessiveplay.
Maximum balljoint vertical play: 0 mm (0 in.l
2.
INSPECTBALL JOINT DUST COVERSFOR DAMAGE

OR DETERIORATION
lf a problemis found,replacethe balljoint assembly.
'l
FRONTAXLE AND SUSPENSION- FrontSuspension
FA.24
3.
INSPECTBALL JOINT FORROTATIONCONDITION

(d Removethe balljoint. (Seepage FA-29)
(b) As shown in the figure, flip the ball joint stud back
and forth 5 times before installingthe nut
(d Using a torque gauge,turn the nut continuouslyone
turn each 2-4 secondsand take the torque reading
on the 5th turn.
Torque {turning}:
I - 25 kg-cm 17 - 21 in.-lb, 0.8 - 2'4 N'ml
lf the torque is not within specification,replacethe ball
ioint.
Lower Arm
(See page FA-23)
REMOVALOF LOWERARM
1.
DISCONNECTLOWERARM TO STEERINGKNUCKLE
Removethe two bolts holdingthe balljoint to the steering
knuckle.
2.
DISCONNECTSTABILIZERBAR END TO LOWER

ARM
Removethe stabilizerbar nut, retainerand cushion.
3.
REMOVELOWER ARM
(a) Jack up the opposite wheel until the vehicle body
lifts off the stands.
\7
(b) Loosenthe lower arm bolt, pry the lowerarm and pull
out the bolt.
(d Disconnectthe lower arm from the stabilizerbar.
CAUTTON: Be careful not to lose the caster adiust
spacer.
(d) UsingSST, disconnectthe ball joint from the lower

arm.
ssT 09950-20015
NOTE: Temporarilyinstallthe nut to preventthe balljoint
from fallingout.
FA.28
REPLACEMENT
OF LOWERARM BUSHING
1.
REMOVELOWERARM BUSHING
(a) Cut off the flangetip of the bushingas is shown in
the figure.
(b) Bend the remaining portions inward with a cold

chisel.
CAUTION: Be careful not to damage the flange.
(c) Bendin the flangetips and pull off the flangewith a

pair of pliers.
(d) UsingSST and a press,pressout the bushing.

ssT 09726-32010
2.
INSTALL LOWERARM BUSHING

Using SST and a press,pressthe bushinginto the arm.
ssr 09726-32010
CAUTION: Do not allow grease or oil to get on the
bushing.
FA.26
- FrontSuspension
FRONTAXLE AND SUSPENSTON
INSTALLATIONOF LOWERARM
1.
CONNECTLOWERARM TO BALL JOINT

lnstallthe lower arm to the ball joint with a nut.
Torque the nut and installa new cotter pin.
2.
INSTALLSPACER,RETAINER,CUSHIONAND
COLLAR
3.
CONNECTLOWERARM TO BODY
(d Passthe lower arm through the stabilizerbar.
(b) Connectthe lower arm with the bolt. Do not torque

the bolt yet.
(c) lnstallthe stabilizerbar with the cushion,washerand
a new nut. Do not torque the nut Yet.
4.
CONNECTLOWERARM TO STEERINGKNUCKLE
(a) Lowerthe stabalizer
bar and connectthe balljoint to
steeringknucklewith the two nuts.
FA-27
(b) Torque the nuts.

Torque: 820 kg-cm (59 ft-lb, 8O N.ml
5.
INSTALLTIREAND LOWERVEHICLE
Bouncethe vehicleto stabilizethe suspension.
;;.".r:,!""
- .ti'" .
6.
.q
TOROUENUT HOLDINGSTABILIZERBAR TO
LOWERARM
,#i{:
Torque: 1,O75kg-cm (78 ft-lb, lOb N.m)
!:rt
!'
7.
TOROUEBOLT HOLDINGLOWERARM TO BODY

Torque: 1,150 kg-cm (83 ft-tb, 113 N.ml
8.
CHECKFRONTWHEELALIGNMENT(See pase FA-31

o
'.
'*'
StabifizerBar
(See page FA-231
REMOVALOF STABILIZERBAR
1.
REMOVEENGINEUNDERCOVER
2.
REMOVEBOTH STABILIZERBAR BRACKETS

FROM CROSSMEMBER
a
FA.28

3.
DISCONNECTBOTH STABILIZERBAR ENDS

TO LOWERARM
4.
REMOVESTABILIZERBAR
CAUTION: Be careful not to lose the spacer.
INSTALLATIONOF STABILIZERBAR
1.
INSTALLSTABILIZERBAR END TO LOWERARM

(d lnstall the spacer, retainer, rubber and collar as
shown in the figure.
(b) Fingertighten a new stabilizerbar nut.
2.
INSTALL BRACKET TOGETHERWITH STABILIZER

BAR
Pry the bar forward and installthe brackets.
Torque the bolts.
Torque: rt4o kg-cm (32 ft-lb,43 N.ml
3.
TOROUENUT HOLDINGSTABILIZERBAR TO LOWER

ARM
Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml
NOTE: Bouncethe vehicleto stabilizethe suspension
before torquing the stabilizerbar nut.
4.
INSTALLENGINEUNDERCOVER
5.
CHECKFRONTWHEEL ALIGNMENT (See page FA-3)
RA.1
REARAXLE AND
SUSPENSION
(FWD}
TROUBLESHOOTING
REARWHEEL ALIGNMENT
REARAXLE HUB AND CARRIER
Sedan
Wagon
REARSUSPENSION
Rear Shock Absorber
SuspensionArm
Strut Rod
Page
RA-2
RA-3
RA.5
RA-5
RA-l2
RA.l6
RA.l7
RA.20
RA.23
(4wD)
TROUBLESHOOTING
REARAXLE SHAFT
DIFFERENTIAL
FOURLINK TYPE REARSUSPENSION
Coil Spring and Rear Shock Absorber
Lateral Control Rod
Upper and Lower Control Arm
Rear Stabilizer Bar
RA.24
RA-25
RA.28
RA'42
RA.43
RA.46
RA-48
RA.s1
'l
(FWD)
REARAXLEAND susPENstoN - Troubteshootinq
RA-2
(FWD}
TROUBLESHOOTING
Problem
Wanders/pulls
Bottoming
Sways/pitches
Abnormal tire wear
Possible cause
Remedy
Page
Tires worn or improperlyinflated
Replacetire or inflate tires to

proper pressure
RA-3
Alignmentincorrect
Checkalignment
RA.3
Wheel bearingadjusted too tight (Sedan) Adjust wheel bearing

Wheel bearingworn {Wagon)
RA-5
Rear suspensionparts loose or broken
Tightenor replacesuspension
parts
R A - s .1 7
Vehicle overloaded
Check loading
RA-17
Springweak
Replacespring
RA.17
Tires improperlyinflated
RA.3
RA.17
Tires improperlyinflated
RA-3
RA.17
Alignmentincorrect
Checktoe-in
RA.4
Suspensionparts worn
Replacesuspensionparts
R A - s ,1 7
RA-12
REARAXLE AND SUSPENSION- RearWheelAlignment(FwD)
RA.3
REARWHEELALIGNMENT(FWD}
1.
MAKE FOLLOWING CHECKS AND CORRECTANY

PROBLEM
(d Check the tires for wear and proper inflation.
(Seepage FA-3)
(b) Check the rear wheel bearingsfor looseness.

(c) Check the wheel runout.
Lateral runout: 1.2 mm {0.047 in.l or less
(d) Check the rear suspensionfor looseness.
(e) Use the standard bounce test to check if the rear
absorberswork properly.
2.
INSPECTVEHICLEHETGHT(See pase FA-51
3.
INSTALL WHEELALIGNMENTEOUIPMENT
Follow the specific instructions of the equipment
manufacturer.
INSPECTCAMBER
Inspection standard: -5' t 3O' (Sedanl
-10' t 3O'(Wagonl
Left-right error:
30'
lf not within specification, inspect and replace any
damagedor worn rear suspensionparts.
5.
ADJUST TOE-IN
(a) Measurethe distancebetweeneach wheel disc and
cam bolt center of the suspensionarm and check
that both are the same.
Left-right error: 3 mm (0.12 in.) or less
(b) Move the vehicleforward a few meterswith the rear

wheelsin the straight-aheadpositionon a levelplace.
(c) Mark the centerof each rear tread and measurethe
distancebetweenthe marksof the right and left tires.
(d) Advancethe vehicleuntil the markson the rearof the
tires come to the front.
NOTE: The toe-in shouldbe measuredat the samepoint
on the tire and at the same level.
RA.4
REARAXLE AND SUSPENSION- RearWheelAlignment(FWD)

(e) Measurethe distancebetweenthe markson the front
of the tires.
Toe-in:
Inspection STD 0 + 1 mm (0 + O.O4in.)
-A-
Front
B-A=Toe-in
B
(f)
lf not within specification,turn the left and right toein adjustingcams an equalamount to adjust.
NOTE: The toe-inwillchangeabout2 mm (0.08 in.)with
each graduationof the'cam (oneside).
6.
CHECKSIDESIIP WITH SIDESLIPTESTER

Side slip: 3.0 mm/m (0.118 in./3.3 ftl or less
lf the side slip is not within specification,
the toe-in may
not be correct.
REARAXLE AND SUSPENSION- RearAxle Hub and Carrier(FWD)
RA-s
REARAXLE HUB AND CARRIER(FWDI

Sedan
COMPONENTS
No. 1 SuspensionArm
No. 2 SuspensionArm
BrakeTube
Axle Hub (with Drum)
Bearins
\,outer
a\
*u..o"*
',,
W^I
|
Y
l
OuterRace
(lnnerBearing)
lkg-cm (ft-lb.N.m)l : Tighteningtorque
part
O : Non-reusable
Y*q@l
*ld
outernale
t
(OuterBearing)| a CoiterPin
Thruit Washer
REMOVALOF REARAXLE HUB AND CARRIER

1.
JACK UP VEHICLE
Jack up the vehicleand support the body with stands.
2.
REMOVEAXLE HUB
(a) Removethe cap, cotter pin, nut lock and nut.
(b) Removethe axle hub togetherwith the outer bearing
and thrust washer.
RA-6

3.
DISCONNECTBRAKETUBE FROMWHEELCYLINDER
Using SST, disconnectthe braketube.
ssT 09751-36011
4.
REMOVEAXLE SHAFT
Removethe bolts holdingthe axle shaft to the carrier,and
removethe axle shaft and rear brakeassembly.
5.
REMOVEAXLE CARRIER
(d Removethe bolt and nut holding the axle carrierto
the strut rod.
(b) Removethe bolt and nut holding the axle carrier to

the No.1 suspensionarm.
(d
Removethe bolt and nut holding the axle carrierto

the No.2 suspensionarm.
RA-7
(d) Removethe bolts and nuts holdingthe axle'carrierto

the shock absorber,and removethe axle carrier.
RAO233
REPLACEMENT
OF WHEEL BEARINGS
1.
REMOVEINNERBEARINGAND OIL SEAL

(a) Using a screwdriver,pry out the oil seal.
(b) Removethe innerbearingfrom the disc.
2,
REMOVEBEARINGOUTERRACES
Using SST, pressout the bearingraces.
SST 09608-16010 and 09608-20011
3.
INSTALLBEARINGOUTERRACES
UsingSST, carefullypressin new bearingraces.
SST 09608-16010 and 09608-20011
4.
FILL INSIDEOF AXLE HUB AND CAP WITH MP

GREASE
L:
RA-8
REARAXLE AND SUSPENSION- RearAxte Hub and Carrier(FWD)
5.
PACK BEARINGSWITH MP GREASE

(a) PlaceMP greasein the palm of your hand.
(b) Pack grease into the bearing, continuing until the
greaseoozes out from the other side.
(c) Do the same aroundthe bearingcircumference.
6.
INSTALL INNER BEARINGAND NEW OIL SEAL

(a) Placethe inner bearinginto the axle hub.
(b) Using SST, drive a new oil seal in the axle hub.
ssT 09608-2001 1
(c) Apply MP greaseto the oil seal.
INSTALLATIONOF REARAXLE HUB AND

CARRIER
(See page RA-51
1.
INSTALLAXLE CARRIER
(a) Placethe axlecarrierin position.
(b) Installthe two bolts and nuts holdingthe axle carrier
to the shock absorber.Torque the nuts.
Torque: 1,450 kg-cm (105 ft-lb, 142 N.m)
(c) Provisionally
installthe bolt and nut holdingthe axle
carrierto the No.2 suspensionarm.
NOTE: Be surethe lip of the nut is restingon the flange
of the suspensionarm-notover it.
(d) Provisionallyinstallthe bolt and nut holdingthe axle

carrierto the No.l suspensionarm.
NOTE: When installing,insert the lip of the nut into the
hole on the suspensionarm.
RA-g
(e) Provisionallyinstallthe bolt and nut holdingthe axle

carrierto the strut rod.
NOTE: When installing,insert the lip of the nut into the
groove on the bracket.
2.
INSTALL AXLE SHAFT

lnstall the axle shaft and rear brake assemblywith four
bolts. Torque the bolts.
3.
CONNECTBRAKETUBE TO WHEEL CYLINDER
RA0238
-36011
ssr 09751
Torque: 155 kg-cm (11 ft-lb. 15 N.m)
4.
INSTALLAXLE HUB ON SPINDLE

(a) Place the axle hub and outer bearing on the axle
shaft.
(b) Fill in MP grease between the outer bearing and
thrust washer.
(d lnstallthe thrust washer.
5.
ADJUST PRELOAD
(a) Installand torque the nut.
Torque: 300 kg-cm {22 tt-\b,29 N'ml
r.1
E4-10
REARAXLE AND SUSPENSION- RearAxle Hub and Canier (FWD)

(b) Snug down the bearingby turning the hub several
times.
(c) Loosenthe nut until it can be turnedby hand.

NOTE: Makesurethat thereis absolutelyno brakedrag.
(d) Measureand make a note of the rotation frictional

force of the oil seal.
Oil sealfrictionalforce: Approx. rtoog (0.9 lb, 3.9 Nl
(e) Tightenthe nut until the preloadis within specification.

Bearingpreload (while turning):
(fl
In addition to oil seal frictional force

400 - 1,000 g (0.9 - 2.2 tb,3.9 - 9.8 Nl
Insurethat the drum rotates smoothly.
6.
INSTALL NUT LOCK, COTTERPIN AND CAP

NOTE: lf the cotter pin hole does not line up, correct by
tighteningthe nut the smallestamount possible.
7.
FILL BRAKERESERVOIR
WITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM (See page BR-ZI

8.
RA-l1
TOROUEAXLE CARRIERMOUNT BOLTS

(a) Removethe standsand bouncethe vehicleto stabilize the suspension.
(b) Torque the mount bolts with the vehicleweight on

the suspension.
Torque: 89O kg-cm (64 ft-lb, 87 N.ml
9.
CHECKREARWHEELALIGNMENT
(See page RA-3)
r.1
REARAXLE AND.SUSPENSION- RearAxle Hub and Carrier(FWD)
RA-12
Wagon
COMPONENTS
RearBrakeAssembly
er+\
--<_:+,--/
->--:
No. 1 Suspension
| 0l
Arm
I
I
RearAxle Carrier
I
StrutRod
BearingInner
Race(lnside)
Axle Hub
BrakeDrum
fr@
,0,1rol
Bearing
t-lb. N'm)l : Tighteningtorque

REMOVALOF REARAXLE HUB AND CARRIER
MeasuringPoint
1.
REMOVEBRAKEDRUM
2.
CHECKBEARINGPLAY IN AXIAL DIRECTION

Limit: O.O5mm (O.OO2O
in.l
REARAXLEAND susPENstoN- RearAxleHubandcarrier(FwD)
RA-13
3.
DISCONNECTBRAKETUBE FROM WHEEL

CYLINDER
Using SST, disconnectthe braketube.
s s T 0 9 7 5 1- 3 6 0 11
4.
REMOVEREARAXLE HUB
(a) Removethe four bolts holding the axle hub to the
axle carrier, and remove the axle hub and brake
assembly.
(b) Removethe O-ring.
5.
REMOVEREARAXLE CARRIER
(See pages RA-6 and 7l
REPLACEMENT
OF REARAXLE HUB AND
WHEELBEARING
(See page RA-121
1.
R E M O V EN U T
(d Usinga chiseland hammer,unstakethe nut.
(b) Removethe nut.
2.
REMOVEAXLE SHAFTFROMAXLE HUB

UsingSST,pushthe axleshaft off the axlehub.
s s T 0 9 9 5 0 - 2 0 0 15
3.
REMOVEBEARINGINNERRACE(INSIDEI
4.
REMOVEBEARINGINNERRACE(OUTSIDE)
UsingSST, pull off the bearinginnerrace (outside)from
the axleshaft.
ssT 09950-20015
a
RA.14
REARAXLE AND SUSPENSION- RearAxIe Hub And Carrier(FWD)

5.
REMOVEOIL SEAL
6.
REMOVEBEARING
(a) First installthe innerrace (innerside)of the removed
bearing.
(b) Using SST, press out the bearing.
SST 09228-22O2Oand 09636-20010
7.
INSTALLBEARING
NOTE: Alwaysreplacethe bearingas an assembly.
(a) Apply MP greasearoundthe bearingouter race.
(b) Using SST, press a new bearinginto the bearing
case.
s s r 0 9 3 16 - 6 0 0 10
8.
INSTALLOIL SEAL
(a) UsingSST,drivean oil seal into the axle hub.
s s T o 9 3 10 - 3 5 0 10
(b) Apply MP greasebetweenthe oil seallip'
9.
INSTALL AXLE SHAFT

(d Installthe bearingboth side inner race.
(b) Using SST, pressthe inner race into the axle shaft.
SST 09228-22O2Oand 09636-2001O
REARAXLEAND susPENstoN- RearAxleHubandcarrier(FWD)
RA-ls
(c) Installand torque a new nut.

Torque: 1,25,Okg-cm (90 ft-tb, 123 N.ml
81 104
(d) Stake the nut.
INSTALLATION
OF REARAXLE HUB AND
CARRIER
(See page RA-l2)
1.
2.
INSTALLREARAXLE CARRIER
(See pages RA-8 and 9l
INSTATLREARAXLE HUB
(a) Installa new O-ringto the axle carrier.
(b) lnstallthe axle hub and rear brakeassemblywith the
four bolts.Torquethe bolts.
Torque: 820 kg-cm (59 ft-tb, 80 N.ml
3.

s s T 0 9 7 5 1- 3 6 0 11
Torque: 155 kg-cm (t 1 ft-lb, 15 N.m)
4.
INSTALLBRAKEDRUM
5.
FILL BRAKERESERVOIR
WITH BRAKEFLUID AND
BLEEDBRAKESYSTEM (See page BR-7)
6.
TOROUEAXLE CARRIERMOUNT BOLTS

(Seepage RA-111
7.
CHECKREARWHEEL ALTGNMENT{See page RA-3}
'
'
,"4'
r4 "'
a
RA-16
REARAXLE AND SUSPENSION- RearSuspension(FWD)
REARSUSPENSION(FWD}
COMPONENTS
g-
DustCover
a@supportNut
support
@-suspension
Insurator
V-upper
CoilSpring
2& 117,241
F-spring
Bumper
@-Lowerrnsurator
Shock Absorber
Assembly
1,45,01105 ,1421
BrakeDrum
andAxle
Carrier
Assembly
No. 2 SuspensionArm
No. 1 Bashing No. 1 SuspensionArm

N.ml : Tighteningtorque
REARAXLE AND SUSPENSTON- RearSuspension(FWD)
RA,l7
RearShock Absorber
(See page RA-l61
REMOVALOF REARSHOCKABSORBER
1.
REMOVESHOCKABSORBERCOVERAND PACKAGE
TRAY BRACKET
2.
REMOVEBRAKETUBE
(a) UsingSST,disconnectthe braketube from the wheel
cylinder.
ssT 09751-36011
(b) Using SST, removethe braketube from the flexible
hose.
ssT 09751-36011
3.
DISCONNECTFLEXIBLEHOSEFROM SHOCK
ABSORBER
4.
LOOSENNUT HOLDINGSUSPENSION
SUPPORTTO
SHOCKABSORBER
support.
h) Removethe dust coverfrom the suspension
(b) Loosenthe nut. Do not removethe nut yet.
5.
DISCONNECTSHOCKABSORBERFROMAXLE
CARRIER
Removethe bolts and nuts holdingthe shock absorberto
the axle carrierand disconnectthe absorber.
6.
REMOVESHOCKABSORBERFROM BODY
Removethe nuts holdingthe shock absorberto the body
and removethe shock absorber.
RA.l8

7.
REMOVECOIL SPRING
(d Installa bolt and nut to the bracketat the lower end
of the shock absorberand secureit in a vise.
e FI
ry
(d
UsingSST, compressthe coil spring.
ssr 09727-22032
(c) Removethe nut.

(d) Removethe suspensionsupport, upper insulatorcoil
spring,lower insulatorand bumper.
8.
1O mm (0.39in.)
HANDLINGOF SHOCKABSORBER
(a) Do not disassemble
the shock absorberbecausethe
cylinderis filled with gas.
(b) lf you replacea shock absorber,drill a 2.0 - 3.0 mm
(0.079- 0.118 in.) hole in the bottom of the replacedshockabsorber'scylinderto completelyrelease
the high pressuregas.ffhe gas is colorless,odorless
and not poisonous.However,when drilling,chips
may fly out so work carefully.)
(c) Handlethe shock absorbercarefully.Neverscoreor
scratchthe exposedpartof the pistonrod,and never
allow paint or oil to get on it.
(d) Do not turn the piston rod and cylinderwith the
shockabsorberextendedcompletely.
RA.l9
INSTALLATIONOF REARSHOCKABSORBER
1.
INSTALLSPRINGBUMPER,COILSPRING,
INSULATORAND SUSPENSIONSUPPORT
(a) Mount the shock absorberin a vise.
(b) Installthe lower insulatorto the lower seat of the
shock absorber.
(c) UsingSST, compressthe coil spring.
ssT 09727-22032
(d) Align the coil spring end with the lower insulator
hollow and installthe coil spring.
(e) lnstallthe springbumperand insulator.
(f) Align the suspensionsupportlower seat hollow and
lower insulaterhollow.
(g) Align the suspension
supportwith the pistonrod and
install.
(h) Align the suspensionsupportwith the shock absorber lower bracketas shown.
Lower Bracket
Suspension
Support
(i)
Provisionally
installa new nut.
2.
CONNECTSHOCKABSORBERTO BODY
Connectthe shock absorberwith three nuts.Torquethe
nuts.
Torque: 240 kg-cm {17 ft-lb, 24 N.m}
3.
INSTALLSHOCKABSORBERTO AXLE CARRIER

Installthe shock absorberwith two bolts and two nuts.
Torque the nuts.
Torque: 1,450 kg-cm (105 ft-tb, 142 N.m)
RA.20

4.
TOROUENUT HOLDINGSUSPENSIONSUPPORTTO
SHOCKABSORBER
(a) Torque the nut.
(b) Installthe dust cover on the suspensionsupport'
5.
INSTALL FLEXIBLE HOSE TO SHOCK ABSORBER

BRACKET
6.
INSTALL BRAKETUBE
7.
WITH BRAKEFLUIDAND
FILL BRAKERESERVOIR
BLEEDBRAKESYSTEM (See page BR-7)
8.
CHECKREARWHEEL ALIGNMENT (See page RA-3)
9.
INSTALL PACKAGE TRAY BRACKET AND SHOCK

ABSORBER
Arm
Suspension
(See page RA-l6)
REMOVALOF SUSPENSIONARM
1.
JACK UP VEHICLE
2.
REMOVENO.2 SUSPENSIONARM
(a) Removethe bolt and nut holdingthe suspensionarm
to the axle carrier.
(b) Removethe cam and bolt holding the suspension

arm to the body and removethe suspensionarm.
NOTE: (1) Rememberwhere the cam plate mark is
when removingthe suspensionarm.
Ql When removing,loosenthe bolt.Do not turn
the cam.

3.
RA.21
REMOVENO.l SUSPENSIONARM
(d Removethe bolt and nut holdingthe suspensionarm
to the axle carrier.
(b) Removethe bolt and nut holdingthe suspensionarm

to the body and removethe suspensionarm.
REPLACEMENT
OF NO.l BUSHING
"'wb
\-----7
1.
REMOVEBUSHING
UsingSST, pressout the bushing.
ssT 09726-32010
2.
INSTALL BUSHING
Using SST, pressin a new bushing.
\=/
ssr 09726-32010
CAUTION: Do not use a lubricant when pressing in
the bushing.
INSTALLATIONOF SUSPENSIONARM
1.
ARM
INSTALLNO.l SUSPENSION
(a) Connect the suspensionarm to the body with the
bolt and nut. Do not torque the bolt yet.
NOTE: Be sure the lip of the nut is restingon the flange
of the bracket,not over it.
REARAXLE AND SUSPENSION

(d
Connectthe suspensionarm to the axlecarrierwith

the bolt and nut. Do not torque the bolt yet.
NOTE: When connectingthe suspensionarm, insert the
lip of the nut into the hole on the suspension.
2.
INSTALL NO.2 SUSPENSIONARM

(a) Placethe suspensionarm in position.
(b) lnstall the cam and bolt holdingthe suspensionarm
to the body. Do not torque the bolt yet.
(c) Align the cam plate mark at the samepositionit was
before removal.
(d) Installthe bolt and nut holdingthe suspension

arm to
the axle carrier.Do not torque the bolt yet.
of the suspensionarm, not over it.
3.
TOROUESUSPENSIONARM SETTINGBOLTS
(a) Removethe stands and bouncethe vehicleto stabilize the suspension.
(d
Torque the setting bolts with the vehicleweight on

the suspension.
Torque: 89O kg-cm (64 ft-lb, 87 N.ml
4.
CHECKREARWHEEL ALTGNMENT(See page RA-31
RA-23
Strut Rod
(See page RA-l61
REMOVALOF STRUTROD
1.
JACK UP VEHICLE(Seepage RA-2OI
2.
REMOVESTRUTROD
(a) Removethe bolt and nut holdingthe strut rod to the
axle carrier.
b)
Removethe bolt and nut holdingthe strut rod to the

body and remove the strut rod.
INSTALLATIONOF STRUTROD
1.
INSTALLSTRUTROD
(a) Connectthe strut rod to the body with the bolt and
nut Do not torque the bolt yet.
of the bracket.
(b) Connectthe strut rod to the axlecarrierwith the bolt

and nut. Do not torquethe bolt yet.
NOTE: When connectingthe strut rod, align the lip of
the nut with the grooveon the bracket.
2.
TOROUESTRUT ROD SETTINGBOLTS

(a) Removethe standsand bouncethe vehicleto stabilize the suspension.
(b) Torque the setting bolts with the vehicleweight on
the suspension.
3.
CHECKREARWHEELALIGNMENT (See page RA-31
REARAXLE AND SUSPENSION- Troubleshooting(4WD)
RA.24
(4WD}
TROUBLESHOOTING
Problem
Oil leak at rear axle
Possible cause
Bottoming
Page
Oil sealsworn or damaged
Replaceoil seal
RA-25
Bearingretainer loose
Replaceretainer
RA-25
Rearaxle housingcracked
Repairas necessary
Oil leak at pinionshaft Oil leveltoo high or wrong grade
Noisein rear axle
Remedy
Drainand replaceoil
Oil sealworn or damaged
Replaceoil seal
RA-28
Companionflange looseor damaged
Tighten or replaceflange
RA-28
Oil levellow or wrong grade
Drainand replaceoil
Excessivebacklashbetweendrive pinion
and ring or side gear
Checkbacklash
RA-28
Ring,drive pinionor side gearsworn or

chipped
Drive pinionbearingworn
Checkgears
RA-28
Replacebearing
RA-28
Axle shaft bearingworn
Replacebearing
RA.25
Side bearing loose or worn
Tighten or replacebearings
RA-36
Vehicleoverloaded
Check loading
RA.43
Springsweak
Replacespring
RA.43
REARAXLE AND SUSPENSION- RearAxle Shaft (4WD)
RA-25
REARAXLE SHAFT (4WD)

COMPONENTS
Wheel
BrakeDrum
RearAxle Shaft
YV?@ dmi
oEnd Gasket
|
|
|
Casret|
O Retainer
|
I
lnnerRetainerl
WBearins
-r-/
outerRetainer
Bearing
[g-cm (tt-tu,trl'm)l : Tighteningtorque
<): Non-reusable
part
REMOVALOF REARAXLE SHAFT

1.
REMOVEWHEELAND BRAKEDRUM
2.
NUTS
REMOVEFOURBACKINGPLATEMOUNTING
REMOVEREARAXLE
Using SST, pull out the rear axle.
ssr 09520-ooo31
CAUTION: When pulling out the rear axle, be careful
not to damage the oil seal.
RA-26
REARAXLE AND SUSPENSION- RearAxte Shaft (4WD)
INSPECTION
AND REPAIROF REARAXLE
SHAFTCOMPONENTS
1.
INSPECTREAR AXLE SHAFT AND FLANGE FOR

WEAR, DAMAGEOR RUNOUT
Maximum shaft runout: 1.5 mm {0.059 in.}
Maximum flange runout: 0.1 mm (0.0O4in.)
lf the rear axle shaft or flange is damagedor worn, or if
theirrunoutis greaterthan maximum,replacethe rearaxle
shaft.
2.
INSPECT REAR AXLE BEARING FOR WEAR OR

DAMAGE
lf the bearingis damagedor worn, replaceit.
3.
REMOVEBEARINGINNERRETAINER
(a) Using a grinder,grind down the inner retainer.
(b) Usinga chiseland hammet cut off the retainerand
removeit from the shaft.
REMOVEBEARINGFROM SHAFT
UsingSST, pressthe bearingoff the shaft.
ssT 09527-20011
INSTALL BEARING OUTER RETAINER AND NEW

BEARINGON SHAFT
Using SST, presson the bearingouter retainerand new
bearing.
s s T 0 9 5 15 - 2 0 0 1 0
150'c
6.
lnnerRetainer
INSTALLBEARINGINNERRETAINERON SHAFT
(d Graduallyheat the bearinginner retainerto about
150'C (302'F)in an oil bath.
REARAXLE AND SUSPENSION- RearAxle Shaft (4WD)
RA..27
(b) While the innerretaineris still hot, pressthe retainer

on the shaft with SST.
ssT 09515-20010
NOTE: Be sure that there is no oil or greaseon the rear
axle shaft or retainer.
Facethe non-beveledside of the innerretainertoward the
bearing.
7.
INSPECTOIL SEAL FORWEAR OR DAMAGE

lf the seal is damagedor worn, replaceit.
8.
REMOVEOIL SEAL FROMAXLE HOUSING

Using SST, removethe oil seal.
ssT 09308-00010
9.
INSTALLNEW OIL SEAL IN AXLE HOUSING

(d Apply MP greaseto the oil seal.
(b) UsingSST,drivein the oil sealto a depthof 5.6 mm
(0.220ini.
ssr 09517-12010
Drivein
INSTALLATIONOF REARAXLE SHAFT

{See page RA-25}
1.
APPIY LIOUIDSEALEARTO BOTH SIDESOF

END AND RETAINERGASKETS
2.
PLACENEW END AND RETAINERGASKETSIN

POSTTtON
Facethe notch of the gasketdownward.
3.
INSTALLREARAXLE SHAFT IN HOUSING

(a) Facethe notch of the retainerdownward.
(b) Installthe rear axle shaft with four new self-locking
nuts.
Torque: 670 kg-cm (48 ft-tb, 66 N'm)
NOTE:
o Be careful not to damagethe oil seal.
o When insertingthe axle shaft, be careful not to hit or
dent the oil deflector insidethe axle housing.
4.
INSTALLBRAKEDRUM AND WHEEL
RA.28
- Differentiat(4WD)
REARAXLE AND SUSPENSTON
(4WD)
DIFFERENTIAL
COMPONENTS
PinionShaft
I
*:#ffi#6-PinionGear
DifferentialCase
Oil Slinger
DifferentialCarrier
-rb, N.m)l : Tighteningtorque

REARAXLE AND SUSPENSION- Differential(4WD)
RA.29
ON.VEHICLE
REPLACEMENT
OF OIL SEAL
1.
DISCONNECT
PROPELLER
SHAFTFROM
(Seepage PR-3)
DIFFERENTIAL
2.
REMOVECOMPANIONFLANGE
(See step 7 on page RA-31)
3.
REMOVEOIL SEAL AND OIL SLINGER

(d UsingSST, removethe oil sealfrom the housing.
ssT 09308-10010
(b) Removethe oil slinger.
4.
REMOVEFRONTBEARINGAND BEARINGSPACER
(See step 9 on page RA-311
5.
INSTALLNEW BEARINGSPACERAND FRONT

BEARING(See step 9 on page RA-391
6.
INSTALLOIL SLINGERAND NEW OIL SEAL

(a) lnstallthe oil singerfacingas shown.
(b) UsingSST, drivein a new oil sealas shown.
SST
1
ssr 09554-3001
Oil seal drive in depth: 1.0 mm (0.039 in.l
(c) Apply MP greaseto the oil seallip.
7,
INSTALLCOMPANIONFLANGE
8.
ADJUST DRIVEPINION
(See step 12 on page RA-4OI
9.
STAKEDRIVEPINIONNUT
10. CONNECTPROPELLER
SHAFTFLANGETO
COMPANIONFLANGE(See page PR-6)
5 mm (O.20in.)
1 1. CHECKDIFFERENTIAL
OIL LEVEL
Fillwith hypoidgearpil if necessary.
Oil grade: API GL-s hypoid gear oil
Viscosity: Above - 18'C (O"F) SAE 90
Below - 18'C (O"Fl SAE 8OW
or 8OW-90
Capacity: 1.O liters (1.1 US qts, 0.9 lmp. qts)
Torquethe filler plug.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
RA.30
REARAXLE AND SUSPENSION- Differential{4WD)
REMOVALOF DIFFERENTIAL
(See page RA-28)
1.
DRAIN DIFFERENTIAL
OIL
2.
REMOVEREARAXLE SHAFT (See page RA-25)
3.
DISCONNECTPROPELLER
SHAFT FROM
(Seepage RA-28)
DIFFERENTIAL
4.
REMOVEDIFFERENTIAL
CARRIERASSEMBLY
DISASSEMBLYOF DIFFERENTIAL
(See page RA-281
NOTE: lf the differentialis noisy,performthe following
pre-inspection
beforedisassembly
to determinethe cause.
lf the differentialhas severeproblems,disassembleand
repairas necessary.
1.
C H E C KR I N GG E A RR U N O U T
in.l
Maximum runout: 0.07 mm (O.OO28
lf the runoutis exceedsmaximum,replacethe ring gear.
2.
CHECKRINGGEARBACKLASH
- O.OO59in.)
Backlash: 0.10 - 0.15 mm (O.OO39
lf the backlashis not within specification,
adjustthe side
bearingpreloador repair as necessary.(Seestep 5 on
pageRA-36)
3,
INSPECTTOOTH CONTACT BETWEEN RING GEAR

AND DRIVEPINION (See step 6 on page RA-38)
Note the tooth contactingposition.
4.
CHECKSIDE GEARBACKLASH
Measurethe side gear backlashwhile holdingone pinion
gear toward the case.
Standardbacklash:
O.OZ- 0.15 mm (0.0008- 0.0059 in.)
lf the backlashis not within specification,
installthe correct thrust washers.
5.
CHECKDRIVEPINIONPRELOAD
Usinga torquewrench,measurethe preloadof the backlash betweenthe drive pinionand ring gear.
Preload: 4-7 kg-cm
{3.5 - 6.1 in.-lb,0.4 - O.7 N'm}
6.
CHECKTOTALPRELOAD
Usinga torquewrench,measurethe total preload.
Total preload:
In addition to drive pinion preload
2 - 4 kg-cm $.7 ' 3.5 in.-lb,O.2- O.4 N'm)
REARAXLE AND SUSPENSTON

- Differentiat(4WD)
7.
RA-31
(a) Usinga chiseland hammer,loosenthe stakedpart of
the nut.
(b) Using SST to hold the flange, removethe nut and
washer.
ssT 09330-00020
b) UsingSST,removethe companionflange.
ssT 09557-22022
8.
REMOVEOIL SEALAND OIL SLTNGER

h) UsingSST,removethe oil sealfrom the housing.
ssr 09308-10010
(b) Removethe oil slinger.
9.
REMOVEFRONTBEARINGAND BEARINGSPACER
(a) UsingSST, removethe front bearingfrom the drive
pinion.
ssT 09556-12010
(b) Removethe bearingspacer.
lf the front bearingis damagedor worn, replacethe bearing.
10. REMOVEDIFFERENTIAL
CASE FROM CARRIER
(d Put matchmarkson the bearingcap and differential
carrier.
(b) Removethe two adjustingnut locks.
(c) Removethe two bearingcaps and two adjustingnuts.
(d) Removethe two bearingouter races.
(d Removethe differentialcase.
RA.32

partsto show the location
NOTE: Tag the disassembled
for reassembly.
11. REMOVEDRIVEPINIONFROMDIFFERENTIAL
CARRIER
OF
INSPECTIONAND REPLACEMENT
DIFFERENTIAL
(See page RA-281
1.
REPLACEDRIVEPINIONREARBEARINGRACE
(a) UsingSST and a press,pull out the rear bearingfrom
the drive pinion.
ssT 09950-00020
(b) Installthe resuedthrust washeron the drive pinion

with the chamferedend facing the piniongear.
(c) UsingSST and a press,pressa new rear bearingon
the drivepinion.
ssT 09608-12010
2.
REPLACEDRIVEPINIONFRONTAND REARBEARING
OUTERRACES
(a) Using a brass bar and hammer,tap out the outer
race.
(b) UsingSST and a press,drive in a new outer race.
s s T 0 9 6 0 8 - 12 0 10
RA0062
REAR AXLE AND SUSPENSION 3.
Differential (4WD)
RA-33
IF NECESSARY,REPLACESIDE BEARINGS
(a) Using SST, remove the side bearing from the
differential case.
ssT 09502-10012
NOTE: On the differential case there are indentations
into which the ssT fits.
(b) UsingSST and a press,pressin a new bearing.
1
ssr 09608-2001
4.
INSPECTSIDEGEARBACKLASH
Measurethe side gear backlashwhile holdingthe other
side geartoward the case.
Standardbacklash: 0.02 - 0.15 mm
(0.0008 - 0.0059 in.)
5.
IF NECESSARY,
REPLACERINGGEAR,SIDEGEARS
A N D P I N I O NG E A R S
NOTE:
o lf the ring gear is to be used again,placematchmarks
beforeseparatingit.
o lf the ring gear or drive pinion are damaged,replace
them as a set.
(a) Lift the lock platesand removethe mount bolts.

(b) Usinga plastic-facedhammer,tap on the ring gearto
separateit from the differentialcase.
- Differential
(4WD)
REARAXLE AND SUSPENSION
RA.34
(c) Usinga pin punchand hammer,driveout the straight

pin foward the ring gear installationsurface.
(d) Removethe pinion shaft, pinion gerars,side gears
and thrust washers.
te) Installthe side gears,thrust washers,pinion gears

and shaft.
(f) Checkthe sidegear backlash.(Seepage RA-33)
Standardbacklash: O.O2- 0.15 mm
(0.0008 - O.OO59in.)
(g) lf the backlashis not within specification,

use thrust
washerof a differentthickness.
Thrustwasherthickness
1 . 5 0( 0 . 0 5 9 1 )
1.s5 (0.061
0)
1 . 6 0( 0 . 0 6 3 0 )
|
|
|
mm (in.)
r.65(0.0650)
t .70 (0.0669)
r.75(0.0689)
(h) Usinga pin punch and hammer,tap a new straight

pin throughthe caseand holein the pinionshaft.
(i) Stakethe pin and differentialcase.
RingGear
=-_-
&
(j)
(0
Cleanthe contactsurfaceof the differentialcase.

Graduallyheatthe ring gearto about 1OO'C(212"F1
in an oil bath.
CAUTION: Do not heat the ring gear above 1lO'C
(230"F).
- Differential
(4WD)
REARAXIE AND SUSPENSION
RA-35
(l)
Cleanthe contactsurfaceof the ringgearwith cleaning solvent.

(m) Then quicklyinstallthe ring gear on the differential
case.
(n) Coatthe ring gear mount bolts with gearoil.
(o) Installnew lock platesand the mount bolts.Tighten
the mountbolts uniformlyand a littleat a time. Torque the bolts.
(p) Checkthe ring gear runout.
Maximum runout: 0.07 mm (0.028 in.)
(q) Stakethe lock plate.
NOTE: Stakeone claw flush with the flat surfaceof the
nut. For the claw contactingthe protrudingportion of the
nut, stake (bend)only the half on the tighteningside.
A S S E M B L YO F D I F F E R E N T I A L
(Seepage RA-28)
1.
TEMPORARILY
ADJUST DRIVEPINIONPRELOAD
(a) lnstallthe followingparts:
o Drivepinion
o Frontbearing
NOTE: Assemblethe spacer,oil slingerand oil sealafter
adjustingthe gearcontactpattern.
(b) UsingSST,installthe companionflange.
ssT 09557-22022
(c) Adjust the drive pinion preload by tighteningthe

companion
flangenut.
UsingSST to hold the flange,tightenthe nut.
ssT 09330-00020
CAUTION: As there is no spacer,taghtena little at a
time, being careful not to overtighten.
a
RA-36

(d) Usinga torquewrench,measurethe preload.
Preload: New bearing
6.5 - 12.5 kg-cm
(5.6 - 1O.9in.-lb)
(0.6 - 1.2 N.ml
Reusedbearing 4 - 7 kg-cm
(3.5 - 6.1 in.-lb)
(0.4 - 0.7 N.ml
2.
INSTALL DIFFERENTIAL
CASE IN CARRIER
(d Place the bearing outer races on their respective
bearings.Make surethe left and right outer racesare
not interchanged.
(b) Installthe casein the carrier.
3.
INSTALLADJUSTINGNUTS
Installthe adjustingnuts on their respectivecarrier,making sure they are threadedproperly.
NOTE: Makesurethat thereis backlashbetweenthe ring
gear and drive pinion.
4,
INSTALL BEARINGCAPS
Align the matcfimarkson the cap and carrier.Screw in the
two bearingcap bolts two or three turns and pressdown
the bearingcap by hand.
NOTE: lf the bearingcap does not fit tightlyon the carrier, the adjustingnut threadsare not threadedproperly.
Reinstalladjustingnuts if necessary.
5.
ADJUST SIDE BEARINGPRELOAD

(a) Tighten the bearing cap bolts until the spring
washersare slightlycompressed.
(b) UsingSST, tighten the adjustingnut on the ring gear
side until the ring gear has a backlashof about 0.2
mm (0.0O8in.).
1
ssr 09504-oool
RA.37
(c) Using SST, firmly tighten the adjustingnut on the

drive pinionside.
1
ssr o9504-ooo1
(d) Checkthe ring gear backlash.
lf tighteningthe adjustingnut createsring gear backlash,
loosenthe nut so that backlashis eliminated.
(e) Placea dial indicatoron the top of the bearingcap on

the ring gear side.
(f) Adjust the sidebearingfor zero preloadby tightening
the other adjustingnut until the pointeron the indicator beginsto move.
(g) Tightenthe adjustingnut 1 - 1llznotchesfrom the

zero preloadposition.
(h) Using a dial indicator,adjustthe ring gear backlash

until it is within specification.
- O.OO59in.l
Backlash: 0.10 - 0,15 mm (O.OO39
NOTE: The backlashis adjustedby turning the left and
right adjustingnuts equal amounts.For example,loosen
the nut on the left side one notch and tightenthe nut on
the right side one notch.
(i)
Torque the bearingcap bolts.

Torque: 6OOkg-cm (43 ft-lb, 59 N.ml
RA.38
REARAXLE AND SUSPENSION- Differentiat(4WD)

(j)
(0
Recheckthe ring gear backlash.

Using a torque meter, measurethe total preload.
Total preload:
ln addition to drive pinion preload
2 - 4 kg-cm 11.7- 3.5 in.-lb, O.2 - 0.4 N.m)
Backlash: O.1O- O.15 mm (0.0039 - 0.O059 in.)
6.
INSPECT TOOTH CONTACT BETWEEN RING GEAR

AND DRIVEPINION
(a) Coat red lead on 3 or 4 teeth at three different positions of the ring gear.
(b) Hold the companionflange firmly and rotate the ring
gear in both directions.
(d lnspect the tooth pattern.
HeelContact
FaceContact
Selecta thrustwasherthat wilt brinq

- the
drive pinioncloserto the ring gear.
Selecta thrustwasherthat will shift the

drivepinionaway from the ring gear.
,rfl
RA.39
NOTE: lf adjustingthe meshingof the teeth of the drive

pinionand ringgearby changingthe extensionof the drive
pinion,selecta thrustwasherof the appropriatethickness
from the table below.
Drive pinionthrust washerthickness
2.24 (O.O882)
2.27 l}.O8e4l
2.30(0.0906)
2 . 3 3( 0 . 0 9 1 7 )
2.36(O.Os29)
2.39(0.0941)
2.42(0.0953)
2.45(0.096s)
|
I
I
|
|
I
|
mm (in.)
Z.+8(0.0976)
Z.S1(0.0988)
Z.S4(0.1000)
2 . 5 7( 0 . 1 0 1 2 )
Z.A0{0.1024)
2.63 (0.103s)
Z.A6(0.1047)
7.
8.
REMOVEFRONTBEARING
9.
INSTALL NEW BEARINGSPACERAND FRONT

BEARING
(d lnstall a new bearingspaceron the shaft.
(b) lnstallthe front bearingon the shaft.
10. INSTALLOIL SLINGERAND NEW OIL SEAL

(d Installthe oil slingerfacing as shown.
(b) UsingSST, drive in a new oil sealas shown.
ssT 09517-12010
Oil seal drive in depth: 1.0 mm (0.039 in.)
(d Apply MP greaseto the oil seallip.
Drive in depth
1 1 . I N S T A L LC O M P A N I O NF L A N G E
(a) UsingSST, installthe companionflange.
ssr 09557-22022
RA-/[()

(b) Coat the threadsof a new nut with MP grease.
(c) Using SST to hold the flange,tighten the nut.
Torque the nut.
ssr 09330-ooo20
Torque: 1,425 kg-cm (103 ft-lb, 140 N'ml
RAOO3
12. ADJUST DRIVEPINIONPRELOAD

Usinga torquewrench,measurethe preloadof the backlash betweenthe drive pinionand ring gear.
Preload: New bearing
6.5 - 12.5 kg-cm
(5.6 - 10.9 in.-lbl
(0.6 - 1.2 N'ml
Reused bearing 4 - 7 kg-cm
(3.5 - 6.1 in.-lbl
(0.4 - 0.7 N'ml
(a) lf preloadis exceedsspecification,

replacethe bear-
ing spacer.
(b) lf preloadis lessthan specification,retightenthe nut
130 kg-cm (9 ft-lb, 13 N.m) at a time until the
specifiedpreloadis reached.
lf the maximumtorque is exceededwhile retighteningthe
nut, replacethe bearingspacerand repeatthe preloadprocedure. Do not back off the pinion nut to reduce the
preload.
Maximum torque: 2,4OOkg-cm
(174 ft-lb, 235 N'm)
1 3 . CHECKDEVIATIONOF COMPANIONFLANGE
Maximum tateralrunout: 0.10 mm (0.0039in.l
Maximum radialrunout: 0.10 mm (0.0039in.l
14. STAKE DRIVEPINIONNUT
RA.41
15. INSTALLADJUSTINGNUT LOCKS

(a) Selecteithera lock plate No. 1 or No. 2 whichever
will fit the adjustingnuts.
(b) lnstallthe lock plateon the bearingcaps.
Torque: 55 kg-cm (48 in.-lb, 5.4 N'ml
INSTALLATIONOF DIFFERENTIAL
(See page RA-281
5 mm (0.2Oin.)
1.
CARRIERASSEMBLY
INSTALL DIFFERENTIAL
assemblyin
Installa new gasketandthe differentialcarrier
the axle and installthe twelve nuts. Torque the nuts.
2.
SHAFT FLANGETO
CONNECTPROPELLER
COMPANIONFLANGE(See page PR-61
3.
WITH
INSTALLREARPLUGAND FILL DIFFERENTIAL
GEAROIL
Torquethe drainplug.
Torque: 500 kg-cm (36 ft-|b,49 N'm)
Oil grade: API GL-s hypoid gear oil
Viscosity: Above - 18"C (O'Fl SAE 90
Below - 18'C (0"F) SAE 8OW
or 80W-90
Capacity: 1.0 liters (1.1 US qts, 0.9 lmp. qts)
Torquethe filler plug.
Torque: 500 kg-cm (36 ft-|b,49 N'ml
REARAXLE AND SUSPENSION- Four Link Type RearSuspension(4WD)
RA-42
(4WDI
FOURLINK TYPE REARSUSPENSION
COMPONENTS
fl,rooEz lrol
.ffi\
Upperlnsutator-{sH9
d@(
g
\-
Lateral Control Rod
\l
^
T
\nooo@
\
ll
a",,
,0.,"n@
l- 650t+?,54l_l
a, r
A/----_-9
raz,
nat].
I r,zoo
I
Lowertnrut.tor-@
f f
oDt r
Arm ',
uooe,Control
"i
aia
I
1 1v @
'wr=:i
@
@
b |
.g
et,6
E i*u
,Wte
ShockAbsorber
%=
e
F
v
?r
@.,a
i ,'
u.,
a^
@a
LowerControlArm
Rear StabilizerBar
-lb, N'm)l : Tightening torque
RA-43
Coil Springand RearShockAbsorber

(See page RA-421
REMOVALOF COILSPRINGAND SHOCK

ABSORBER
1.
JACK UP VEHICLE
Jack up the rear axle housingand support the body with
stands.Leavethe jack under the rear axle.
2.
REMOVEREARSHOCKABSORBER
(a) Removethe bolt holding the shock absorberto the
rearaxle housingand disconnectthe shock absorber.
(d
Removethe nuts holding the shock absorberto the

body, and removethe shock absorber.
3.
REMOVESTABILIZERBAR BUSHINGBRACKETS
Removethe bolts holdingthe stabilizerbar bushingto the
rear axle housing.
4.
DISCONNECTLATERALCONTROLROD FROM REAR

AXLE HOUSING
Removethe nut holdingthe lateralcontrol rod to the rear
axle housingand disconnectthe lateralcontrol rod.
RA-/14

5.
REMOVECOILSPRING
(a) Beginto lower the rearaxle housing.
NOTE: Be carefulnot to pull the brakeline and parking
brakecable.
(b) While loweringthe rearaxlehousing,removethe coil

springand the upperand lower insulators.
INSTALLATION
OF COILSPRINGAND
SHOCKABSORBER
1.
PUT LOWERINSULATORON AXLE HOUSING
2,
PUT UPPERINSULATORON COILSPRING
3.
INSTALLCOILSPRING
4.
CHECKPOSITIONOF LOWERINSULATOR
(a) Jack up the rearaxle housing.
(b) Checkthat the lower insulatoris installedcorrectly.
lf the insulatoris not in correctposition,reinstallthe
coil spring.
Rl-+S
5.
INSTALLLATERALCONTROLROD
In order, install a washer, bushing,spacer,lateralcontrol
rod, bushing,washerand nut on the rear axle housing.
Do not tighten the nut yet.
6.
INSTALLSHOCKABSORBER
b) Connectthe shockabsorberto the body with the nut.
Holdthe shaftwith an adjustablewrench.Torquethe
nut.
(b) Connectthe shock absorberto the rear axle housing

with the nut Torque the bolt.
Torque: 375 kg-cm (27 ft-\b,37 N.ml
7.
INSTALL STABILIZERBAR BUSHINGBRACKETSTO

REARAXLE
8.
STABILIZESUSPENSION
Removethe stands and bounce the car to stabilizethe
suspension.
RA-/t6

9.
TIGHTEN LATERALCONTROLROD NUT

h) Raisethe axle housinguntil the body is free from the
stands.
(b) Torque the lateralcontrol rod nut.
LateralControl Rod
(See page RA-421
REMOVALOF LATERALCONTROLROD
1.
SUPPORTREARAXLE HOUSING
Jack up the rear axle housingand support it with stands.
2.
DISCONNECTLATERAL CONTROLROD FROM REAR

AXLE HOUSING
Removethe nut holdingthe lateralcontrol rod to the rear
axle housing,and disconnectthe lateralcontrol rod.
3.
DISCONNECTLATERALCONTROLROD FROM BODY

Removethe nut holdingthe lateralcontrol rod to the body
and removethe lateralcontrol rod.
REPLACEMENT
OF LATERALCONTROLROD
BUSHING
1.
Remove
REMOVEBUSHING
Using SST, pressout the bushingfrom the lateralcontrol
rod.
ssT 09710-14012
NOTE: When insertingand removingthe bushing,press
or pull from the chamferedside as shown in the figure.

2.
Chamfer
RA.47
INSTALLBUSHING
Using SST and a press,press a new bushinginto the
lateralcontrol rod.
ssT 09710-14012
NOTE: Do not usea lubricantwhen pressingin the bushing.
INSTALLATIONOF LATERALCONTROLROD
1.
INSTALL LATERALCONTROLROD TO BODY

(a) Raisethe axle housinguntil the housingis free from
the stands.
RAO343
(b) Installthelateralcontrolrod to the bodywith the nut.
2.
INSTALL LATERAL CONTROL ROD TO REAR AXLE

HOUSING
(d Consecutivelyinstall the washer, bushing,spacer,
lateralcontrolarm, bushing,washerand nut on the
rear axle housing.
(b) Removethe stands and bounce the car to stabilize

the suspension.
RA-48

(d Jack up the axle housing.
(d) Torque the nut.
Torque:
Body side
1,2OOkg-cm (87 ft-lb, 1 18 N.m)
Axle housingside
650 kg-cm {47 ft-lb, 64 N.ml
Upperand Lower GontrolArm

(Seepage RA-421
REMOVALOF UPPERAND LOWERCONTROL

ARM
1.
JACK UP VEHICLE
Hold the rear axle housingwith a jack.
2.
REMOVEUPPERCONTROLARM
(a) Removethe bolt holdingthe uppercontrolarm to the
body.
(b) Removethe bolt holdingthe uppercontrolarm to the

rearaxlehousing,then removethe uppercontrolarm.
3.
REMOVELOWERCONTROLARM
(a) Removethe bolt holding the lower control arm to the
body.
REARAXLE AND SUSPENSION- FourLink Type RearSuspension(4WD)
nA-+g
(b) Removethe bolt holdingthe lowercontrolarmto the

rearaxlehousing,and then removethe lowercontrol
arm.
INSTALLATIONOF UPPERAND LOWER

CONTROLARM
1.
INSTALLUPPERCONTROLARM
(a) lnstall the upper control arm on the body with the
bolt and nut. Do not tightenthe nut yet.
(b) Installthe uppercontrolarm on the rearaxlehousing

with the bolt and nut. Do not tighten the nut yet.
2.
INSTALLLOWERCONTROLARM
(a) lnstallthe Iower control arm on the body with the
bolt and nut. Do not tightenthe nut yet.
(b) lnstallthe lowercontrolarm on the rearaxlehousing

with the bolt and nut. Do not tightenthe nut yet.
RA-50
REARAXLE AND SUSPENSION- FourLink Type RearSuspension(4WD)

3.
STABILIZESUSPENSION
Removethe stands and bounce the car to stabilizethe
suspension.
4.
JACK UP VEHICLE
Raise the axle housing until the body is free from the
stands.
5.
TIGHTENBOIT HOLDINGUPPERCONTROLARM TO
BODY
Torque the bolt.
Torque: 1,2OOkg-cm (87 ft-lb, 118 N.ml
6.
TIGHTENBOLT HOLDINGUPPERCONTROTARM TO
REARAXLE HOUSING
Torque the bolt.
Torque: 1,2OOkg-cm (87 ft-lb, 1 18 N.ml
7,
TIGHTENBOLTHOLDINGLOWERCONTROLARM TO
BODY
Torque the bolt.
Torque: 1,2OOkg-cm (87 ft-lb, 118 N.ml
8.
TIGHTENBOLTHOLDINGLOWERCONTROLARM TO
REARAXIE HOUSING
Torque the bolt.
Torque: 1,2OOkg-cm (87 ft-lb, 1 18 N.ml
ne-St
Rear Stabilizer Bar

(See page RA-421
REMOVALOF REARSTABILIZERBAR
1.
REMOVESTABILIZERBAR BUSHINGBRACKETS
2.
REMOVEREARSTABILIZERBAR FROM BODY
3.
DISCONNECTSTABILIZERBAR END FROM LINK
INSTALLATIONOF REARSTABILIZERBAR
1.
INSTATLSTABILIZERLINK TO BODY
Installthe link onto the body as shown.
2.
INSTALLSTABILIZERBAR TO LINK
Connectthe stabilizerbar on both sidesto the linkswith
bolts, collars,cushions,nut and new cotter pins.
Torque: 310 kg-cm (22 ft-\b,30 N'ml
3.
INSTALL BRACKETSTO REARAXLE HOUSING

Torque: 375 kg-cm 127ft-1b,37 N'm)
BR.1
BRAKESYSTEM
PRECAUTIONS
TROUBLESHOOTING
CHECKSAND ADJUSTMENTS
MASTERCYLINDER
BRAKE BOOSTER
FRONTBRAKE
REARBRAKE
Sedan
Wagon FWD
Wagon 4WD
BRAKEHOSESAND TUBES
Page
BR.2
BR-2
BR-6
BR.9
8R.14
8R.16
B,R.22
BR-22
8R.29
8R.36
8R.43
BRAKE SYSTEM - Precautions,Troubleshooting
BR-2
PRECAUTIONS
1.
2,
Care must be taken to replace each part properly as it

could affect the performance of the brake system and
result in a driving hazard.Replacethe parts with parts
of the same part number or equivalent.
ltnis very important to keep parts and the area clean
wltsn repairing the brake system.
TROUBLESHOOTING
Problem
Possible cause
Remedy
Page
Low or spongy pedal
Liningsworn
Leak in brake system
Mastercylinderfaulty
Air in brake system
Wheel cylinderfaulty
Pistonsealsworn or damaged
Rearbrake automaticadiusterfaulty
BR-16,22
Replacebrakeshoesor pads
BR-43
Repairleak
BR-9
replace
master
cylinder
Repairor
BR-7
Bleed brake system
8R.22
Repairwheel cylinder
BR-1
6
Repairbrakecalipers
B,R.22
Repairor replaceadjuster
Brakesdrag
Parkingbrakeout of adjustment
Parkingbrakewire binding
Boosterpush rod out of adjustment
Returnspringfaulty
Brake line restricted
Liningcrackedor distorted
Wheel cylinderor caliperpiston sticking
Automatic adjuster broken
Mastercylinderfaulty
Adjust parking brake

Repairas necessary
Adjust push rod
Replacespring
Repairas necessary
Replacebrakeshoe
Repairas necessary
Replaceadjuster
Repairor replacemastercylinder
BR.8

Oil or greaseon linings
Brakeshoes distorted, linings worn or
glazed
Drum or disc out of round
Return spring faulty
Wheel cylinderfaulty
Pistonfrozen in caliper
Disc brake pad sticking

Checkfor cause,replacelining
Replacebrakeshoes
FA-3
BR-16,22
BR-16,22
Replacedrum or disc
Replacespring
Repairwheel cylinder
Repaircaliper
Replacepads
BR-l8,22
BR-22
BR-18,22
BR.18
BR-16
Oil or grbaseon linings

Brakeshoesdistorted,liningsworn
or glazed,drums worn
Disc brake pads worn
Pistonfrozen in caliper
Brakebooster faulty
Brake line restricted
Checkfor cause,replacelining
Replacebrakeshoes
BR-I6,22
BR-16,22
Replacepads
Repaircaliper
Repairbooster
Repairas necessary
BR-16
BR-16
BR.14
Brakespull
Hard pedal but

brakes inefficient
BR.15
BR-22
BR-22
BR-18,22
BR-22
BR-9
BRAKE SYSTEM - Troubleshooting
BR.3
(Cont'd)
TROUBLESHOOTING
Problem
Snappingor clicking
noisewhen brakes
are applied
Scrapingor grinding
noise when brakes
are applied
Remedy
Possible cause
Page
Drum brakes- brakeshoesbinding

at backingplate ledges
Drum brakes- backingplateledges
worn
Drum brakes- looseor missing
hold down spring
Drum brakes- loose set bolt
at backingplate
Disc brakes- rust on front edge of
inboardshoes
Disc brakes- looseor missingpad
supportplate
Disc brakes- loose installation
bolt
Disc brakes- wear on slide bushing
Lubricate
BR-22
Replaceand lubricateledges
BR-22
Replace
BR-22
E,
Tisnteffit'
BR-22
Inspect lubricate,replaceif
necessary
BR.16
Replace
BR-1
6
Tighten
BR-1
6
Replace
BR-1
6
Worn brakelinings
Replace,refinishdrums or
rotors if heavilyscored
BR-16,22
Caliperto wheel or rotor interference
Replaceas required
Dust cover to rotor or drum

interference
Corrector replace
BR.1
8
r+i
BR-l8,22
other brakesystemcomponents:
Warped or bent brake backing
plate or splashshield,cracked
drums or rotors
lnspector service
BR-h1N,22
Tires rubbingagainstchassisand
body
Inspector service
%
:?*
a
?"t
BR-4
TROUBLESHOOTI
NG (Cont'd)
Problem
Squeaking,squealing
groaning or chattering noise when brakes
are applied
Note: Brake friction
materialsinherently
generatenoise and
heat in order to
dissipateenergy.
As a result
occasionalsqueal
is normalandis
aggravatedby severe
environmetalconditions such as cold,
heat, wetness, snow,
salt mud, etc.
This occasional
squealis not a functional problem and
does not indicate
any loss of brake
effectiveness
Squealingand
squeakingnoise
when brakes are
not applied
Possible cause
Remedy
Page
Brakedrums and liningsrotors and

pads worn or scored
Disc brakes - missing or damaged
brake pad anti-squealshim
Disc brakes - burred or rusted calipers
Inspect,serviceor repalce
BR-16,22
Replace
BR.l6
Cleanor deburr
Dirty, greased,contaminatedor
glazedlinings
Cleanor replace
BR-1
8
BR-16,22
lmproperliningparts
Inspectfor conect usage

replace
BR-'t6,22
Maladjustmentof brakepedalor
booster push-rod
Drum brakes- weak damagedor
incorrect shoe hold down springs, loose
or damagedshoe hold down spring pins
springsand groovedbackingplate
ledges
lnspectand adjust
BR-6,15
Inspect serviceor replace
8R.22
Bent or warped backingplate causing

interferencewith drum
Serviceor replace
BR-22
lmpropermachiningof drum causing

interferencewith backingplate or shoe
Replacedrum
8R.22
Maladjustmentof brakepedalor
booster push-rod
Inspectand adjust
BR-6,15
Poor return of brake booster or master

cylinderor wheel cylinder
Disc brakes - rusted, stuck
Inspect,serviceor replace
BR-g,15,22
Inspect lubricateas necessary
B R . 16
Other brakesystem,components:
Loose or extra parts in brakes
Inspect,service,replaceas
required
BR-16,22
Reardrum adjustmenttoo tight

causingliningto glaze
Worn, damagedor insufficiently
lubricatedwheel bearings
BR-5
(Cont'dl
TROUBLESHOOTING
Problem
Squealingand
squeakingnoise
when brakes are
not applied(cont'd)
Groaning,clicking
or rattling noise
when brakesare
not applied
Possible cause
Remedy
Page
Drum brakes- weak, damagedor

incorrectshoe hold down springs
Drum brakes- groovedbackingplate
ledges
BR-22
BR-22
lmproperpositioningof pad in caliper
Inspect and service
BR-l6
Outsidediameterof rotor rubbing

caliperhousing
BR-l6
Housinginstallationof disc brake

pad support plate
Correct
BR-16
Stonesor foreign materialtrapped

insidewheel covers
Removestones, etc.
BR-18,22
Loosewheel hub nuts
Tightento correct torque and replaceif stud holesare elongated
Disc brakes- failureof shim

Disc brakes- wear on slide bushing
Disc brakes- looseinstallation
bolt
lnspect,replaceif necessary
BR.16
Inspect,replaceif necessary
BR.16
Inspect,tighten if necessary
BR-16
Maladjustmentof brake pedalor

boosterpush-rod
Disc brakes - poor return of piston
lnspectand adjust
BR-6,15
BR.18
Drum brakes- looseor extra parts
Inspect removeor service
B,R.22
Worn, damagedor dry wheel bearings
lnspect lubricateor replace
BRAKE SYSTEM - Checksand

Stop Light Switch
CHECKSAND ADJUSTMENTS
OFBRAKEPEDAL
CHECKAND ADJUSTMENT
PedalPushRod
1.
CHECKTHAT PEDALHEIGHTIS CORRECT'AS

SHOWN
slreet:
Pedatheishtfromasphalt
PedalFreeplay
AsphaltSheet
PedatHeight
i#;:?ifil.,
IF NECESSARY.ADJUST PEDALHEIGHT
(a) Sufficientlyloosenthe stop light switch.
(b) Adjust the pedal height by turning the pedal push
rod.
(c) Returnthe stop light switch until it lightly contacts
the pedal stopper.
(d) After adjustingthe pedalheight,checkand adiustthe
pedal freePlay.
CHECKTHAT PEDAL FREEPLAYIS CORRECT,AS

SHOWN
(a) Stop the engineand depressthe brakepedal several
times until there is no more vacuum left in the
booster.
(b) Push in the pedaluntil the beginningof resistanceis
felt. Measurethe distance,as shown'
Pedaffreepfay: 3 - 6 mm (0.12 - O,24 in.l
NOTE: The pedal freeplay is the amount of the stroke
until the boosterair valveis moved by the pedalpush rod.
IF NECESSARY,ADJUST PEDALFREEPLAY
(a) lf incorrect adiust the pedal freeplayby turning the
pedal Push rod.
(b) Start the engineand check that pedalfreeplayexists.
(c) After adjustingthe pedal freeplay,check the pedal
height.
CHECKTHAT PEDAL RESERVEDISTANCEIS

CORRECT,AS SHOWN
(a) Releasethe parkingbrake.
(b) With enginerunning,depressthe pedaland measure
the pedal reservedistance,as shown.
Pedafreserve distance at 50 kg (11 O-21b,490 Nl:
More than 90 mm (3.54 in.l
lf incorrect,troubleshootthe brake system.
BRAKE SYSTEM - Checksand Adjustments
@ @
VV
1st
BR-7
OPERATIONALTEST OF BRAKE BOOSTER

NOTE: lf available,use a brake booster tester to check
the booster operatingcondition.
1.
OPERATINGCHECK
(a) Depress the brake pedal several times with the
engineoff, and check that there is no changein the
pedal reservedistance.
(b) Depressthe brake pedal and start the engine.lf the
pedal goes down slightly,operationis normal.
2.
AIR TIGHTNESS
(d Start the engineand stop it after one or two minutes.
Then depressthe brakepedalseveraltimes slowly.lf
the pedal goes down fartherest the first time, and
less the second and third time, the boo$ter is air
tight.
(b) Depressthe brakepedalwhile the engineis running,
and stop it with the pedal depressed.lf there is no
changein pedalreservetravel after holdingthe pedal
for thirty seconds,the booster is air tight.
2nd
BLEEDING
OF BRAKESYSTEM
NOTE: lf any work is done on the brakesystemor if air is
suspectedin the brake lines,bleed the system of air.
CAUTION: Do not let brake fluid remain on a painted
surface. Wash it off immediataly.
1.
FILL BRAKERESERVOIRS
WITH BRAKEFLUID
Checkthe reservoirafter bleedingeachwheel.Add fluid, if
necessary.
2,
CONNECTVINYL TUBE TO WHEEL CYLINDER

BLEEDERPLUG
lnsert the other end of the tube in a half-full containerof
brakefluid.
3.
BLEEDBRAKELINE
(a) Slowly pump the brakepedal severaltimes.
(b) While an assistantdepressesthe pedal, loosen the
bleederplug until fluid starts to runout.Then close
the bleederplug.
(c) Repeatthis procedureuntil thereare no moreair bubbles in the fluid.
Bleeder plug tightening torque:
85 kg-cm (74 in.-lb,8.3 N.m)
4.
FOREACH WHEEL
REPEATPROCEDURE
BRAKE SYSTEM - Checksand Adjustments
BR.8
CHECKAND ADJUSTMENTOF PARKING

BRAKE
1.
CHECKTHAT PARKINGBRAKE LEVERTRAVEL

IS CORRECT
Pull the parkingbrakeleverall the way up, and count the
numberof clicks.
Parking brake lever travel at 2O kg (44.1 lb, 196 Nl:
Sedan 5-Sclicks
Wagon 6-Sclicks
2.
IF NECESSARY,ADJUST PARKING BRAKE

NOTE: Before adjusting the parking brake, make sure
that the rear brakeshoe clearancehas been adjusted.
For shoe clearanceadjustment,see pagesBR-28,35 and
42.
(a) Removethe consolebox.
(d Loosenthe lock nut and turn the adjustingnut until
the travelis correct.
(d Tightenthe lock nut andinstallthe consolebox.
*r .;"
BRAKESYSTEM - MasterCylinder
BR-9
MASTERCYLINDER
REMOVALOF MASTERCYLINDER
Master Cylinder
BrakeFluidLevelWarningSwitch Connector
t) Gasket
II
1 s 5 ( 11 , 1 5 )
BrakeTube
-cm (ft-lb,
Tighteningtorque
O: Non-reusable
part
GAUTION: Do not let brake fluid remainon a painted
surface. Wash it off immediatoly.
1.
TAKE OUT FLUIDWITH SYRINGE
2.
DISCONNECTBRAKETUBES
j ,.
Usin! SST, disconnectthe brake tubes from tfie master
cylinderand 3-way union.
s s T 0 9 7 5 1 - 3 6 0 11
3.
REMOVEMASTERCYLINDER
(d Disconnectthe brakefluid levelwarningswitch connector.
(b) Removethe two nuts.
(c) Removethe mastercylinder,3-way unionand gasket
from the brake booster.
BRAKE SYSTEM - Master Cylinder
BR.lO
COMPONENTS
ReservorSet Screw
F
(r
I
I rzt{rtaz-l
SnapRing
%-Reservoir
9-.o
}N\ ryofltort""*
| |
RN
ry'jbTry^?
- + ) r l l l s c i o t
*"
\p-l
I
-^
O Gasket
e r Il
1 Piston(with SPring)
|
|
No.2pistonRins
^l
uprrng
I rootz,rot I
PistonStopperBolt
(ft-rb,N
: Tighteningtorque
DISASSEMBLYOF MASTERCYLINDER
1.
REMOVERESERVOIR
FROM CYLINDERHOUSING
(a) Removethe cap and strainer.
(d Removethe set screw.
(c) Pull out the reservoir.
2.
MOUNT CYLINDERHOUSINGIN VISE
3.
REMOVETWO GROMMETSFROM CYLINDER

HOUSING
4.
REMOVEPISTONSTOPPERBOLT
Using a screwdriver,push the pistons in all the way and
removethe piston stopper'bolt.
BRAKESYSTEM - MasterCylinder
5.
BR-11
REMOVETWO PISTONSAND SPRINGS

(d Using a screwdriverand snap ring pliers,removethe
snap ring.
(b) Placea rag on two wooden blocksand lightly tap the

cylinderflangebetweenthe blocksuntil the pistontip
protrudes.
(c) Removethe piston by hand,pulling straight out, not
at an angle.
NOTE: lf pulledout at an angle,there is a possibilityof
damagingthe cylinderbore.
ASSEMBLYOF MASTERCYLINDER
.g
G@D
t r
(See page BR-10)
.g
1.
APPLY LITHIUM SOAP BASE GLYCOLGREASE

TO RUBBERPARTSINDICATEDBY ARROWS
2.
INSTALLTWO SPRINGSAND PISTONS

CAUTION: Be careful not to damage the rubber lips
on the pistons.
(d lnsert the spring and pistons straight in, not at an
angle.
(b) Pushin the pistonand, usingsnapring pliers,install
the snap ring.
3.
INSTALL PISTONSTOPPERBOLT
Using a screwdriver,push the pistonsin all the way and
installthe piston stopperbolt with the gasket.Torquethe
bolt.
Torque: 100 kg-cm (7 ft-lb, 1O N.m)
OnmmU=$
BR-l2
BRAKE SYSTEM - MasterCylinder

4.
INSTALLTv\/O GROMMETSTO CYLINDERHOUSING
5.
INSTALLCAP AND STRAINERTO RESERVOIR
6.
INSTALL RESERVOIR
TO CYLINDERHOUSING
Pushthe reservoironto the cylinderand installthe screw.
Torque: 10 - 25 kg-cm
19 - 21 in.-lb,1.0 - 2.4 N.ml
CAUTION: Because the master cylinder and reservoir tank union is a grommet type, the set screw is
designed not to separate from the reservoir or cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or such when tightening.
'*i,.
BRAKE SYSTEM - MasterCylinder
BR-l3
INSTALLATIONOF MASTERCYLINDER
(See page BR-91
1.
CLEAN OUT GROOVEON LOWERINSTALLATION

SURFACEOF MASTERCYLINDER
2.
CHECKTHAT ''VP" MARK ON MASTERCYLINDER

BOOT IS IN CORRECTPOSITION
3.
ADJUST LENGTHOF BRAKEBOOSTERPUSH ROD

BEFOREINSTALLINGMASTERCYLINDER
(See page BR-151
4.
INSTALL MASTERCYLINDER
Installa new gasket,the mastercylinderand 3-way union
with the two nuts. Torquethe nuts.
*
5.
CONNECTBRAKETUBES
Using SST, connectthe braketubes to the mastercyliner
and 3-way union.Torque the nuts.
1
ssr 09751-3601
Torque: 155 kg-cm(11ft-lb, 15 N'ml
1?
6.
WITH BRAKEFLUID
FILL BRAKERESERVOIR
AND BLEEDBRAKESYSTEM {See page BR-71
7.
CHECKAND ADJUST BRAKEPEDAL(Seepage BR-61
8R.14
BRAKE SYSTEM - BrakeBooster
BRAKEBOOSTER
REMOVAL OF BRAKE BOOSTER
Brake Fluid Level Warning

Switch Connector
levis
II
dCI
f=s(lr='
1 3 0( 9 , 1 3 1
3-WayUnionl
5ll
BrakeBooster
(ft-lb,N.m) :Tighteningtorque
0 : Non-reusablepart
1.
REMOVEMASTERCYLINDER(See page Bn-gl
2.
DISCONNECTVACUUM HOSEFROM BRAKE

BOOSTER
3.
REMOVEDISTRIBUTORCAP
4.
REPEATPROCEDUREFOR EACH WHEEL
5.
REMOVEHEATERAIR DUCT
6.
DISCONNECTPEDAL RETURNSPRINGFROM
BRAKE PEDAL
7.
DISCONNECT PUSH ROD CLEVIS FROM BRAKE

PEDAL
Removethe clip and clevis pin.
8.
REMOVEBRAKE BOOSTER
Removethe four nuts, and pull out the brakebooster.
BRAKE SYSTEM - BrakeBooster
8R.15
INSTALLATIONOF BRAKE BOOSTER

(Seepage BR-l41
1.
PUSHROD
ADJUSTLENGTHOF BOOSTER
(a) Set SSTon the mastercylinderwith the gasketand
lowerthe pin untilits tip slightlytouchesthe piston.
ssr 09737-00010
(d
Tum SST upsidedown, and set it on the booster.
ssT 09737-OOO10
(c) Checkthat there is no clearancebetweenthe booster
push rod and pin head of SST.
Clearance: O mm (0 in.l
(d) Adjust the boosterpush rod lengthuntilthe push rod

lightly touches the pin head.
2.
INSTALL BRAKE BOOSTER

3.
INSTALL MASTER CYLINDER(See page BR-131
4.
CONNECTVACUUM HOSETO BRAKE BOOSTER
5.
CONNECTPUSH ROD CLEVISTO BRAKE PEDAL

Installthe clevis pin and clip.
6.
CONNECTPEDAL RETURNSPRINGTO PEDAL

SPRING
7.
INSTALL HEATERAIR DUCT
8.
INSTALL LOWERFINISHPANEL
9.
INSTALL IIA CAP
WITH BRAKEFLUID
1 0 . FILL BRAKERESERVOIR
AND BLEEDBRAKE SYSTEM (See page BR-71
1 1 . CHECK BRAKE PEDAL (See page BR-61
12. PERFORMOPERATIONALCHECK (See page BR-71
BR-l6
BRAKE SYSTEM - Front Brake
FRONTBRAKE
COMPONENTS
\\
Flexible Hose--\\
\\
[-5s ntzst I
\ > . ; l c o
Ja-'r
I
fa-l
235 117,231
900 165,88) j
Torque Plate
Leh
A\H)
RotorDisc
Anti-squealshim
\t__Anti-squeal
Spring
I
-cm (ft-lb,N.m)
8ao?36
I
I
REPLACEMENT
OF BRAKEPADS
.
lf a squeaking noise occurs while braking, inspect the

. brake pads. Brake squeak will occur when the gap between the pad wear indicatorplate and rotor disc reaches
about 2.5 mm (0.098 in.).
1.
REMOVEFRONTWHEET
Rqmove the wheel and temporarily fasten the rotdfudisc
;:E"'
with the wheel nuts.
2.
INSPECTPAD LININGTHICKNESS
Check the pad thicknessthrough the cylinder inspection
hole and replacepads if not within specification.
Standard
1O.0mm (0.394-in.l
Minimum
1.0 mm (0.039 in.)
'
l'-

3.
,ritl
t'i'.
ihffi:ir '
' $ ,
8R.17
REMOVECYLINDERFROM TOROUEPLATE
(a) Removethe two installationbolts from the torque
plate.
't'l
'|
t'r
(b) Remove the brake cylinder and suspend it so the

hose is not stretched.
NOTE: Do not disconnectthe brake hose.
4.
(a) Two anti-squealsprings
(b) Two brake pads
(d ."Twoanti-squealshims
(d) 'Two pad wear indicatorplates
(e) .'FoUr support plates
5.
CHECK ROTORDISC THICKNESS

(See*step2 on page BR-l91
@ \ r
ilPnn- )\
tPllli{1
q\r4J
BRo281
6.
CHECKROTORDISC RUNOUT
(See step 3 on page BR-2OI
7.
INSTALL NEW PAD SUPPORTPLATES
8.
INSTALL NEW PADS

(a) Installnew pad wear indicatorplatesto each pad.
NOTE: Be surethe arrow on the pad we*fiQicator plate
is pointing in the rotatingdirectionof thd diiHt_
(b) Installnew anti-squealshims to each pad.
l ' l
iffi
BR-l8
(c! Installthe pads onto each support plate'

9.
INSTALL NEW ANTI-SOUEALSPRINGS
10. INSTALLCYLINDER
(d Draw out a small amount of brake fluid from the
reservoir.
(b) Pressin piston with a hammer handleor such.
NOTE: Alwayschangethe pad on one wheel at a time as
there is possibilityof the opposite piston flying out
(c) Insertthe brakecylindercarefullyso the dust boot is
not wedged.
d[
t1.,
(d) lrfiiprrandtorquethe two instatlation

bolts.
FRoNr
t t. tNsrArL
Itr#
*12. CHECKTHATFLUIDTEVELIS AT "MAX" LINE
,iw
,i
SST
'-
t.t
'
REMOVALOF CYUTNDER
(See page BR-l61
1.
I'id
REMOVECYLINDER
(a) UsingSST, disconnectthe brakeline.
Use a containerto catch the brake fluid.
ssT 09751-36011
(b) Rembvethe two installationbolts and cylinder.
2.
REMOVEPADS (See step 4 on.page BR-l71
OF CYLINDER
DISASSEMBLY
(Seepage BR-l61
1.
"'L
i-
(a) Two slide bushings
(b) Four dust boots
(d Two collars
BRAKE SVSTEM - Front Brake
8R.19
2.
REMOVE
CYLINDER
BOOTSETRINGAND CYLINDER
BOOT
Usinga screwdriver,removethe set ring and boot.
3.
REMOVEPISTONFROM CYLINDER
(a) Put a piece of cloth or such betweenthe piston and
cylinder.
(d Use compressedair to remove the piston from the
cylinder.
WARNING: Do not place your fingers in front of the
piston when using compressed air.
4. - REMOVEPISTONSEAL FROM BRAKE CYLINDER

Using a screwdriver,removethe piston seal.
INSPECTIONAND REPAIROF FRONTBRAKE

COMPONENTS
1.
TNSPECT
PAD LININGTHICKNESS
Standard thickness: 10.O mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.l
Replacethe pad if the thicknessis lessthan minimum(the
1.0 mm slit is no longervisible)or if it shows signs of
unevenwear.
INSPECTROTORDISC THICKNESS
Standardthickness: 1 1.0 mm (0.433 in.l
Minimum thickness: 10.0 mm {0r39a in.}
lf the disc is scored or worn, or if thicknessis less than
minimum,repairor replacethe disc.
:t-$ixt
:r- , .-rr,
*i,
BR-2O

3.
INSPECTROTORDISC RUNOUT
Measurethe rotor disc runoutat 1O mm (0.39 in.)from the
outer edge of the rotor disc.
Maximum disc runout: 0.15 mm (0.0059 in.l
lf the runout is greaterthan maximum,replacethe disc.
NorE: Beforemeasuringthe runout checkthat the front
bearingplay is within specification.
4.
IF NECESSARY,REPLACEROTORDISC
(d Removethe torque plate from the knuckle.
(b) Removethe wheel nuts of the temporarilyinstalled
disc and pull off the rotor disc from the axle hub.
(c) Temporarilyinstall a new rotor disc with the wheel
nuts.
(d) Installthe torque plate onto the knuckle.
ASSEMBLYOF CYLINDER
(SeepageBR-161
1.
APPLYLITHUMSOAPBASEGLYCOLGREASE
TO PARTSINDICATEDBY ARROWS
2.
INSTALL PISTONSEAL AND PISTONIN CYLINDER
\
ti
3.
Q++, i,
INSTALL CYLINDERBOOTAND SET RING IN

CYLINDER

4.
BR-2;1,,,":l-
INSTALLCOLLAR,DUST BOOTAND CYLINDER

SLIDEBUSHING
(a) Installthecollarand dust boot into the brake"VlinOer.'"'f,.
(b) Check that the boot is securedfirmly to the brlkp
';1"t,
cylindergroove.
(c) Installthe bushinginto the boot.

(d) Checkthat the boot is securedfirmly to the bushing
groove.
t:' t;
INSTALLATION
OF CYLINDER
JS.t
(See page BR-l61
SST
1.
INSTALL PADS
(See steps 7 to 9 on pag6s BR-17 and 18)-i
2.
INSTALLCYLINDER
(See step 11 on page BR-271
3.
INSTALLFLEXIBLEHOSETO BRAKECYLINDER
4.
CONNECTFLEXIBLEHOSETO BRAKETUBE
Using SST, connect the flexible hose.
ssT 09751-36011
5.
FILL BRAKE RESERVOIR

WITH BRAKEFLUID
AND BLEED BRAKE SYSTEM (See page BR-71
,,,\$,
BRAKE SYSTEM - RearBrake(Sedan)
BR-22
REARBRAKE
Sedan
COMPONENTS
BackingPlate
Shoe
AdjustingShim
O C-Washer
Adjusting Lever
Spring
ReturnSpring
ob@
lGc.l?t-lb' Nrdl : Tishtenins

part
O: Non-reusable
REMOVALOF REARBRAKE
1.
INSPECTSHOELININGTHICKNESS
Removethe inspectionhole plug, and check the shoe lining thicknessthrough the hole.
lf less than minimum,replacethe shoes.
Standardthickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (O.039in.l
2.
REMOVEREARWHEEL
3.
REMOVEBRAKEDRUM
(See step 2 on page RA-51
lf the brakedrum cannot be easilyremoved,do the following procedure:
(d Insert a screwdriverthrough the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjustingbolt
(b) Using another screwdriver, reduce the brake shoe
adjustmentby turning the adiustingbolt.
BR-23
4.
REMOVESHOERETURNSPRING
Using a screwdriver,removethe return spring.
5.
REMOVESHOERETURNSPRINGCLAMP
Using a screwdriver,removethe clamp.
6.
REMOVEFRONTSHOE
(a) Removethe hold-down spring, retainersand pin.
(b) Disconnectthe anchor spring from the front shoe
and removeit.
7.
REMOVEANCHORSPRING
8.
REMOVEREARSHOE
(d Removethe hold-down spring, retainersand pin.
(b) Usingpliers,disconnectthe parkingbrakecablefrom
the leverand removethe rear shoe togetherwith the
strut.
9.
REMOVESTRUTFROM REARSHOE
(a) Removethe adjustinglever spring.
(b) Removethe strut.
10. REMOVEPARKINGBRAKELEVERAND AUTOMATIC

ADJUSTINGLEVERFROM REARSHOE
Usinga screwdriver,pry out the C-washerand removethe
shim and levers.
.,ea-24
BRAKETUBE FROMWHEELCYLINDER
1 1. DISCONNECT
Using SST, disconnectthe line. Use a containerto catch
the brakefluid.
1
ssr 09751-3601
12. REMOVEWHEETCYLINDER
Removethe two bolts and wheel cylinder.
PARTSFROM WHEEL
REMOVEFOLLOWING
CYLINDER:
(d Two boots
(b) Two pistons
(c) Two pistoncups
(d Spring
Ao@(
fl@oTu"/
v
/
l
|
sorins
I
l
Piston
OF REARBRAKECOMPONENTS
INSPECTION
1.
INSPECTBRAKEDRUM INSIDEDIAMETER
Standardinside diameter: 180.0 mm (7.087 in.)
Maximum insidediameter: 181.0 mm (7.126in.)
lf the drum is scored or worn, the brake drum may be
lathedto the maximuminsidediameter.
NOTE: Perform operations with the following parts
removed:
(d Oil seal
(b) lnnerand outer bearing
2.
INSPECTBRAKESHOE LINING THICKNESS

Minimum thickness: 1.0 mm (0.039 in.)
lf the shoe liningis lessthan minimumor shows signsof
unevenwear, replacethe brakeshoes.
NOTE: lf the thicknessof any brakeshoe is not within
replaceall of the brakeshoes.
specification,
8R.25
3.
INSPECTBRAKE LINING AND DRUM FOR PROPER

CONTACT
Replacethe brakeshoeor lathethe brakedrum as necess4ry.
4.
INSPECT WHEEL CYLINDER FOR CORROSIONOR

DAMAGE
5.
INSPECTBACKING PLATE FORWEAR OR DAMAGE
INSTALLATIONOF REARBRAKE
(See page BR-221
1.
APPLY LITHIUM SOAP BASE GILYCOLGREASE

TO FOTLOWINGPARTS:
(d Two piston cups
(b) Two pistons
,, ,
Apply Grease
't
..
2.
Ao@O
o@rT*1,,i""
lt
I
Boot
ASSEMBLEWHEELCYLINDER
(a) Installtwo new piston cups to the pistons.
(b) Install the two pistons and spring into the wheet
cylinder.Check that the flange of the pistons are
pointedinward.
(c) Installtwo new boots.
Spring
3.
INSTALL WHEELCYLINDER
Installthe wheelcylinderon the backingplatewith the two
bolts.
Torque: lOO kg-cm (7 ft-lb, 1O N.ml
4.

Using SST, connectthe braketube.
ssT 09751-36011
T o r q u e : 1 5 5 k g - c m( 1 1 f t - l b , 1 5 N . m l
a
BRAKE SYSTEM - RearBrake{Sedan)
BR-26
5.
APPLY HIGH TEMPERATUREGREASETO

FOLLOWINGPARTS:
(a) Backingplate and brake shoe contact points
(b) Anchor plate and brake shoe contact points
(c) Strut and adjustingbolt contact points

(d) Strut and brakeshoe contact points
6.
wl
INSTALL PARKING BRAKE LEVERAND AUTOMATIC

ADJUSTINGLEVERTO REARSHOE
(d Temporarilyinstall the levers with the shim and a
new C-washer.
(d Usinga feelergauge,measurethe clearancebetween
the shoe and lever.
Standardclearance: O - 0.35 mm (O - 0.0138 in.l
lf not within specification,adjust with a shim.
mm (in.)
Shim thicknesses
0.2 (0.008)
0.3 (0.012)
0.4 (0.016)
|
|
|
0.5 (0.020)
0.6 (0.024)
0.s (0.035)
(cl Using pliers,stake the C-washer.
7.
INSTALL STRUT ONTO REARSHOE

Set the strut in placeand intall the adjustinglever spring.
Left-handThreads
Front
B,R.27
Right-handThreads
oa)"
Front
r+
o V o
Left Wheel
Right Wheel
8.
INSTALL REARSHOE
CAUTION: Do not allow grease to get on the rubbing
face
(a) Using pliers,connect the parking brake cable to the
lever.
(b) Set the rear shoe in place with the end of the shoe
insertedin the wheelcylinderand the other end in the
anchorplate.
(c) Installthe pin and the shoe hold-down spring.
9.
INSTALL FRONTSHOE
GAUTION: Do not allow grease to get on the rubbing
face
(a) Installthe anchor spring betweenthe front and rear
shoes.
(b) Set the front shoe in placewith the end of the shoe
insertedin the wheel cylinderand the strut in place.
(c) Installthe shoe hold-down spring, retainersand pin.
1 0 . INSTALLSHOERETURNSPRINGCLAMP
1 1 . INSTALLSHOERETURNSPRING
Using a screwdriver,installthe return spring.
8R.28

12. CHECK OPERATIONOF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjusting bolt
turns.
lf the bolt does not turn, checkfor incorrectinstallationof
the rear brakes.
(b) Adjust the strut length to the shortest possible

amount.
(d lnstallthe drum.
(d) Pull the parkingbrakeleverall the way up.
ffi6
V\Fsz'
13. CHECK CLEARANCEBETWEENBRAKE SHOESAND

DRUM
h) Removethe drum.
(b) Measure the brake drum inside diameter and
diameter of the brake shoes. Check that the
differencebetweenthe diametersis the correctshoe
clearance.
Shoe clearance: 0.6 mm (0.O24 in.l
lf incorrect check the parkingbrake system.
14. INSTALL BRAKEDRUM AND ADJUST PRELOAD
(See page RA-61
15. INSTALL REARWHEEL
16. FILL BRAKERESERVOIR
WITH BRAKEFLUID
AND BLEEDBRAKESYSTEM (See page BR-71
17. CHECKFORFLUID LEAKAGE
Wagon FWD
COMPONENTS
/a
uu
Wheel Cylinder
ReturnSpring
BackingPlate
7-AutomaticAdjusti
Lever
gqJ\#*i'
\ J( \ \ N b
.-fl 4il)
1 0 0( 7 , r 0 l
Parkirfs
e,"x" /
RearShoe
Lever
-*__-a
tr&9)
///cc-
4//
Drum
-@@
Front Shoe
Anchor
sprins I LZ/
I
J.^h'
AdjustingLeverSpring
-.-Retainer
@ ^
@
Shoe Hold-DownSpring
kg-cm (ft-lb, N'm) :Tighteningtorque

| : Non-reusablepart
REMOVALOF REARBRAKE
1.
Removethe inspectionhole plug, and check the shoe lining thicknessthrough the hole.
lf less than minimum,replacethe shoes.
Minimum thickness: 1.0 mm (0.039 in.l
2.
REMOVEREARWHEEL
3.
REMOVEBRAKEDRUM
lf the brakedrum cannotbe easilyremoved,do the following procedure:
(d Insert a screwdriverthrough the hole in the backing
plate, and hold the automatic adiusting lever away
from the adjustingbolt.
(b) Using another screwdriver,reduce the brake shoe
adjustmentby turning the adjustingbolt.
4.
REMOVEFRONTSHOE
(d Using SST, disconnectthe return spring.
ssr 09703-30010
(d Removethe hold-down spring, retainersand pin.

(c) Disconnectthe anchor spring from the front shoe
and removeit
5.
REMOVEANCHORSPRING
6.
REMOVEREARSHOE
(a) Removethe hold-down spring, retainersand pin.
b) Using a screwdriver, disconnect the parking brake
cable from the anchor Plate.
(d Using pliers,disconnectthe parkingbrakecablefrom
the lever and remove the rear shoe together with the
strut.
7.
REMOVESTRUTFROMREARSHOE
(a) Removethe adiustingleverspring.
(d Removethe strut togetherwith the returnspring.
8.
REMOVEPARKINGBRAKELEVERAND
AUTOMATICADJUSTINGLEVERFROMREARSHOE
pry out the C-washerandremovethe
Usinga screwdriver,
shimand levers.
BRO337 BR0286
BRAKE SYSTEM - RearBrake(WagonFWD)

9.
8R.31
DISCONNECTBRAKETUBE FROM WHEEL

CYLINDER
the brakefluid.
10. REMOVEWHEELCYLINDER
6)o9o
I
Piston
11. REMOVEFOLLOWINGPARTSFROM WHEEL

CYLINDER:
(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring
Boot
INSPECTION
OF REARBRAKECOMPONENTS
1.
Standardinside diameter: 200.0 mm (7.874 in.l
Maximum insidediameter: 201.0 mm (7.913in.)
lathedto the maximuminsidediameter.
2.
INSPECTBRAKESHOELININGTHICKNESS
Standardthickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.Omm {0.039 in.l
unevenwear, replacethe brake shoes.
replacethe all of the brakeshoes.
specification,
oO"
INSPECTBRAKELININGAND DRUM FORPROPER

CONTACT
Replacethe brakeshoeor lathethe brakedrum as necess4ry.
o/' \
;z\o
4.
INSPECTWHEETCYLINDERFORCORROSION
OR
DAMAGE
5.
INSPECTBACKING PLATE FOR WEAR OR DAMAGE
(See page BR-291
Pistoncu'
^cloqO
fl@6alA"
Y
I
I
I
SPring
1.

TO FOLLOWINGPABTS:
(d Two piston cups
(b) Two pistons
2.
ASSEMBLEWHEEL CYLINDER
(a) lnstall two new piston cups to each piston, check
that the flangesof the cups are pointed inward.
(b) Install the two pistons and spring into the wheel
cylinder.
3.
INSTALLWHEEL CYLINDER
Installthewheelcylinderon the backingplatewith the two
bolts.
Torque: 1OOkg-cm (7 ft-lb, 1O N.ml
4.

Using SST, connect the braketube
ssT 09751-36011
Piston
Boot
BRAKE SYSTEM - RearBrake{WagonFWD)

5.
8R.33
APPLY HIGH-TEMPERATURE
GREASETO
FOLLOWINGPARTS:
H Backingplate and brakeshoe contact points
(b) Anchor plate and brakeshoe contact points
(c) Strut and adjusting bolt contact points

Shim
6.
INSTALL PARKINGBRAKE LEVERAND

AUTOMATIC ADJUSTING TEVERTO REARSHOE
(a) Temporarilyinstallthe leversand shim with a new Cwasher.
the shoe and lever.
Standard clearance: O - 0.35 mm (0 - 0.0138 in.l
Shim thicknesses
o.2
0.3
o.4
(0.008)
(0.012)
(0.016)
|
|
|
0.5
0.6
o.g
mm (in.)
(0.020)
(0.024)
(0.035)
(c) Using pliers,stake the C-washer.
7.
INSTALL STRUTONTO REARSHOE

Set the strut and return spring in place and install the
adjustinglever spring.
BR-34
BRAKE SYSTEM - RearBrake(Wagon FWD)
Right-handThreads
Left-handThreads
o/\o
Front
)"(r"(
Left Wheel
.|
Right Wheel
8.
INSTALT REARSHOE
CAUTION: Do not allow oil or groase to get on the
rubbing face.
(a) Using pliers,connect the parkingbrake cable to the
lever.
(b) Passthe parkingbrakecablethrough the notch in the
anchor plate.
(c) Set the rear shoe in place with the end of the shoe
anchor plate.
(d) Installthe hold-down spring, retainersand pin.
9.
INSTALL FRONTSHOE
CAUTION: Do not allow oil or grease to get on the
rubbing face.
(d lnstall the anchor spring betweenthe front and rear
shoes.
(c) Installthe hold-down spring,retainersand pin.
80939 8R0253
(d) Using SST, connect the return spring.
ssr 09703-30010
BRAKE SYSTEM - RearBrake(Wason FWD)
BR-35
1O. CHECKOPERATIONOF AUTOMATICADJUSTER

MECHANISM
(d Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjustingbolt
turns.
lf the bolt does not turn, check for incorrectinstallationof
the rear brakes.

amount.
(c) Installthe drum.
(d) Pull the parkingbrake lever all the way up.
1 1 . CHECKCLEARANCE
BETWEENBRAKESHOESAND
DRUM
(a) Removethe drum.
(b) Measurethe brake drum inside diameterand
differencebetweenthe diametersis the conectshoe
clearance.
Shoeclearance: 0.6 mm (0.024in.l
lf inconect checkthe parkingbrakesystem.
12. INSTALLBRAKEDRUM
1 3 . INSTALLREARWHEEL
14. FILI BRAKERESERVOIR
WITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM
(Seepage BR-71
1 5 . CHECKFORFLUIDLEAKAGE
BRAKE SYSTEM - RearBrake(Wagon4WD)
BR-36
Wagon 4WD
COMPONENTS
Strut and ReturnSpring

O C-Washer
Automatic AdjustingLever
arkingBrakeLever
Hold-down Spring
clip |
,u
{ATK
$ry"<'i
BackingPtate
///,
Front
Wheel Cylinder
6f,Aai""tins
Shim
RearShoe
shoe
lot
AnchorSpring
part
O: Non-reusable
REMOVALOF REARBRAKE
\
6\
\\
q \\\
Y((^W
*
F\\
-/
//
//l
//
1.
Removethe inspectionhole plug, and check the shoe lining thicknessthroughthe hole.
lf lessthan minimum,replacethe shoes.
Standardthickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2.
REMOVEREARWHEEL
3.
REMOVEBRAKEDRUM
lf the brakedrum cannotbe easilyremoved,do the following procedure:
(a) Inserta screwdriverthrough the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjustingbolt.
(d Using another screwdriver,reduce the brake shoe
adjustmentby turning the adjustingbolt.

4.
8R.37
REMOVEFRONTSHOE
(d Using SST, removethe return spring.
ssT 09703-30010
(b) Removethe hold-down spring.
(c) Removethe front shoe and the anchor spring.
5.
REMOVEREARSHOE
(a) Removethe hold-down spring.
(b) Usingpliers,disconnectthe parkingbrakecablefrom
the leverand removethe rear shoe togetherwith the
strut.
6.
REMOVESTRUTFROM REARSHOE
(a) Removethe adjustinglever spring.
(b) Removethe strut.
7.
REMOVEPARKINGBRAKE LEVERAND AUTOMATIC

ADJUSTINGLEVERFROM REARSHOE
Using a screwdriver,pry out the C-washerand removethe
shim and levers.
8.
DISCONNECT
BRAKETUBE FROMWHEELCYLINDER
the brakefluid.
1
ssr 09751-3601
9.
REMOVEWHEELCYLINDER
8R.38
t'"fon
cup
Piston
'"i.
^,
10. REMOVEFOLLOWINGPARTSFROM WHEEL

CYLINDER:
(a) Two boots
b) Two pistons
(c) Spring
*^m.GSDW)
lK3r)Y*
I
Am'Q)\gr---..SPring
\J/
INSPECTIONOF REARBRAKECOMPONENTS
-Z\"
(
,-\
1.
Standard inside diameter: 200.0 mm (7.874 in.l
Maximum inside diameter: 2O1.Omm (7.913 in.)
lathed to the maximuminsidediameter.
2.
INSPECTBRAKESHOELININGTHICKNESS
Minimum thickness: 1.0 mm {0.039 in.l
a\
< ) ( )

unevenwear, replacethe brakeshoes.
specification,replaceall of the brakeshoes.
3.
INSPECTBRAKE LINING AND DRUM FOR PROPER

CONTACT
Replacethe brakeshoe or lathe the brakedrum as neces-
sary.
4.
INSPECT WHEEL CYLINDER FOR CORROSIONOR

DAMAGE
5.
INSPECTBACKING PLATE FORWEAR OR DAMAGE
8R.39
(See page BR-361
1.

TO FOLLOWINGPARTS:
H Two piston cups
(d Two pistons
2.
ASSEMBLEWHEEL CYLINDER
(d Installtwo new piston cups to the pistons.
(d Install the two pistons and spring into the wheel
cylinder. Check that the flanges of the piston are
pointed inward.
Apply Grease
Pistoncup
'"i'
Piston
lKs^*@#@
d@*''*,J."n
3.
INSTALLWHEEL CYLINDER
Installthewheelcylinderon the backingplatewith the two
bolts.
Torque: lOO kg-cm (7 ft-lb, 1O N.ml
4.
CONNECTBRAKETUBE TO WHEELCYLINDER
Using SST, connectthe braketube.
ssT 09751-36011
5.
APPTYHIGH TEMPERATURE
GREASETO
FOLLOWINGPARTS:
(a) Backingplate and brakeshoe contact points
(b) Anchor plate and brakeshoe contact points
(d Strut and adjustingbolt contact points

BR.4O
BRAKE SYSTEM - Rear Brake (Wagon 4WD)

6.
INSTALL PARKING BRAKE LEVERAND AUTOMATIC

ADJUSTINGLEVERTO REARSHOE
(a) Temporarilyinstallthe leversand the shim and a new
C-washer.
the shoe and lever.
Standard clearance: O - 0.35 mm (O - 0.0138 in.)
mm (in.)
Shim thicknesses
0.2 (o.oo8)
o.3 (0.012)
o.4 (0.016)
|
I
I
0.5 (0.020)
0.6 (0.024)
o.s (0.035)
(c) Using pliers,stake the C-washer.
7.
Left-handThreads
INSTALLSTRUTONTO REARSHOE
Set the strut and return spring in place and installthe
adjustinglever spring.
Right-handThreads
Front
Front
pVe
Left Wheel
RightWheel
8RO256 8R0257

8.
8R.41
INSTALL REARSHOE
rubbing face.
H Using pliers,connect the parkingbrake cable to the
lever.
(b) Set the rear shoe in place with the end of the shoe
anchor plate.
(c) lnstall the pin and the shoe hold-down spring.
9.
INSTALL FRONTSHOE
rubbing face.
(a) Installthe anchor spring betweenthe front and rear
shoes.
(c) Installthe shoe hold-downspringand pin.

(d) Using SST, connect the return spring.
ssr 09703-30010
10. CHECK OPERATIONOF AUTOMATIC ADJUSTER

MECHANISM
(a) Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjusting bolt
turns.
lf the bolt does not turn, check for incorrectinstallationof
the rear brakes.
BRAKE SYSTEM - RearBrake (W

amount.
(c) Installthe drum.
(d) Pull the parkingbrakeleverall the way up.
1 1 . CHECK CLEARANCEBETWEEN BRAKE SHOES AND

DRUM
(a) Removethe drum.
(b) Measure the brake drum inside diameter and
difference betweenthe diametersis the correct shoe
clearance.
Shoe clearance: 0.6 mm (0.024 in.l
lf incorrect check the parkingbrakesystem.
12. INSTALL BRAKEDRUM AND REARWHEEL

1 3 . FILL BRAKERESERVOIR
WITH BRAKEFLUID
AND BLEEDBRAKE SYSTEM (See page BR-71
14. CHECKFORFLUID LEAKAGE
BRAKE SYSTEM - BrakeHosesand Tubes
BRAKEHOSESAND TUBES
DISCONNECTAND CONNECTHOSEAND
TUBE
1.
DISCONNECTHOSEAND TUBE
(a) Diconnectthe clip.
(b) Usinga wrenchto hold the hose,and SST to hold the
tube, disconnectthe tube and hose.
ssT 09751-36011
2.
CONNECTHOSEAND TUBE
(a) Connectthe hose and tube by hand.
(b) Usinga wrenchto hold the hose,and SST to hold the
tube, torque the connection.
\$-crio
ssT 09751-36011
(c) Installa new hoseclip.
INSPECTIONOF BRAKEHOSESAND TUBES

1.
INSPECTBRAKEHOSES
(a) Inspectthe hose for damage,cracksor swelling.
(b) Inspectthe threadsfor damage.
2.
INSPECTBRAKETUBES
(d Inspectthe tube for damage,cracks,dents or corrosion.
(b) Inspectthe threadsfor damage.

Toyota Tercel 4WD 1985

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Toyota Tercel 4WD 1985

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PR-1

As the universal ioint is a non-disassembly type' the

Washer [ 430 (3il42t

REMOVETWO BOLTS HOLDINGCENTERSUPPORT

(d) Clampthe flangeyoke in a viseand tap off the shaft.

INSTALL FTANGEYOKE ON INTERMEDIATESHAFT

(c) Using SST to hold the flange, tighten down a

(b) Check that the bearingbracket is at right anglesto

FRONTAXLE AND SUSPENSION- Troubleshooting

Steering gear out of adjustmentor broken

Replacetire or inflate tires to

Tires improperly inflated

lnflate tires to proper pressure

Front wheel shimmy

Tires worn or improperly inflated

Steering gear out of adjustment or broken

Replacetire or inflate tires

Tires improperly inflated

Inflate tires to proper pressure

Tires worn or improperlyinflated

Wheel out of balance

FRONTAXLE AND SUSPENSION- FrontWheel Alignment

MAKE FOLLOWING CHECKS AND CORRECTANY

1.8 (26. 180)

(b) Checkthe front wheel bearingsfor looseness.

(b) Move the vehicleforward a few meterswith the front

(d) Advancethe vehicletill the marks on the rear of the

FRONTAXLE AND SUSPENSION- FrontWheel Alignment

lf the toe-in is not within inspectionSTD, adjust the

(3) Turn the left and right rack ends an equal

Wl Check that the length of the left and right tie

(5) Torquethe tie rod end clamp.

Inspectionstandard Left-right error

40' -t- 30'

lf camberis out of tolerance,adjustby turningthe camber

1 1'50' -t- 30'

lf the steeringaxis inclinationis out of tolerance,inspect

FRONTAXLE AND SUSPENSION- FrontWheel Alignment

INSPECTSIDE SLIP WITH SIDE SLIP TESTER

FRONTAXLE AND SUSPENSION- Axle Hub

1,450 (105, 142)

Lock Nut Cap

Outer Oit Seal

Ikg-cm (ft-lb, N.m)l : Tighteningtorque

FRONTAXLE AND SUSPENSION- Axle Hub

REMOVALOF FRONTAXLE HUB

REMOVECOTTERPIN. BEARINGLOCKNUT CAP AND

pLAy rN AxtAL DtREcnoN

DISCONNECTTIE ROD END FROM STEERING

DISCONNECTLOWERARM FiOM STEERING

REMOVEAXLE HUB FROM

, +in f,rlve tl""ff\ii

!,ocr* d i t{" cIo*h to " .rr:'r,

REMOVEINNEROIL SEAL FROMSTEERING

(c) U$ilfi SST,prestffi a new bearing.

INSTALLAXLE HUB TO DRIVESHAFT

INSTALLAXLE HUB TO LOWERARM

FRONTAXLE AND SUSPENSION- Axle Hub

INSTALL BRAKECALIPERTO STEERINGKNUCKLE

CONNECTTIE ROD END TO STEERINGKNUCKLE

TOROUEBEAfriG LOCK NUT AND INSTALL LOCK

CHECKFRONTWHEEL ALIGNMENTf$6e page FA-3)

FRONT AXLE AND SUSPENSION -

Front Drive Shaft