REAR SUSPENSION

CONTENTS
TOOLS....................................................................................................... RSU-1
LEAF SUSPENSION ................................................................................. RSU-3
CONSTRUCTION ................................................................................. RSU-3
DISASSEMBLY AND REASSEMBLY.................................................... RSU-4
INSPECTION ........................................................................................ RSU-6
TRUNNION TYPE SUSPENSION............................................................. RSU-8
CONSTRUCTION ................................................................................. RSU-8
DISASSEMBLY AND REASSEMBLY ................................................... RSU-9
INSPECTION ...................................................................................... RSU-11
REPAIR AND REPLACEMENT........................................................... RSU-12 RSU
SERVICE DATA ....................................................................................... RSU-16
SPECIFICATIONS............................................................................... RSU-16
SPRING STRUCTURE ....................................................................... RSU-16
SERVICE DATA................................................................................... RSU-17
TIGHTENING TORQUE ...................................................................... RSU-18
 TOOLS

Tool name and number Description Shape

T-type socket
Used when installing and removing the spring clip bolt.
99535 Z0005

Bushing replacer Used when replacing the spring pin and shackle bush-
99888 Z0012 (35 mm) ing.

Used to remove and press the torque rod bushing

(105 mm) of the trunnion type suspension.
Replace tool
99888 Z0065
Used to remove and press the stabilizer bushing (105
mm) of the air suspension.

Used to remove the trunnion seat bushing of the trun-

Bushing remover
nion type suspension.
99896 Z0005
Dimension D: 108 mm

Used to press the trunnion seat bushing of the trunnion

Bushing replacer assembly
type suspension.
99883 Z0007
Dimension D Dimension L [mm]: 110 182

RSU-1
 Tool name and number Description Shape
Used to remove or press the stabilizer bushing of the air
Removal and installation suspension and the torque rod bushing of the trunnion
tool for stabilizer bushing type suspension.
99880 Z000B
1. 99881 Z0003 1. Movable wooden stand with the tools assembly sup-
a. 99884 Z0002 port stand
b. 99884 Z0003 a. Movable wooden stand
2. 99884 Z0004 b. Tool assembly support stand
3. 99884 Z0005 2. Hydraulic cylinder
4. 99883 Z0012 3. Hydraulic pump
5. 99897 Z0013 4. Tool (puller) assembly
6. 99888 Z0107 5. Press-in tool joint (Used to pull out the bushing.)
7. 99888 Z010A 6. Bushing press-in tool (For front)
8. 99888 Z0109 7. Bushing press-in tool (For rear)
9. 99888 Z0110 8. Bushing press-in stopper (For front)
10.99897 Z0011 9. Bushing press-in stopper (For rear)
11.99897 Z0012 10. Bushing receiving tool (For front)
12.99884 Z0006 11. Bushing receiving tool (For rear)
12. Bushing holding tool (Used to press-in the bushing.)

In combination with the installation/removal tool (99880

Z000B) for the stabilizer bushing, used to disassemble
Puller set or press-in the torque rod bushing (105 mm) of the
99881 Z0005 trunnion type suspension
Part A: Receiving tool adapter (Used for removal)
Part B: Bushing press-in stopper (Used for press-in)

1. Replacer
Used to install or remove the C-type retaining ring of the
99888 Z000D
center bushing (bushing outside diameter: 85 mm) of
2. Holder
the V-rod.
99897 Z0009

1. Replacer
Used to install or remove the C-type retaining ring of the
99888 Z0106
side bushing (bushing outside diameter: 75 mm) of the
2. Holder
V-rod.
99897 Z0010

RSU-2
 LEAF SUSPENSION
CONSTRUCTION
GKB series

RSU-3
DISASSEMBLY AND REASSEMBLY
GKB series

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Nut 2 U-bolt 3 Pad
4 Spring (Shackle) pin 5 Shim 6 Spring (Shackle) pin
7 Shim 8 Shackle 9 Spring (Shackle) pin
10 Spring assembly 11 Contact sheet

RSU-4
Key point of disassembly
1. Lowering the center portion of the spring by using a press
machine, remove the clip bolts by the T-type socket (99535
Z0005).
2. Removing the center bolt, return the press machine slowly and
then disassemble the leaf spring.

3. Remove the bushing by using the bushing replacer (99888

Z0012).

Key point of reassembly

1. As in the case of disassembly, install the center bolt by press-
ing securely using the press machine. Gradually increasing
pressure of the press machine, install the leaf spring.
Center bolt
Tightening torque [N•m {kgf•m}]: 108 - 127 {11 - 13}

2. Tighten the clip bolt with the specified torque using the T-type
socket (99535 Z0005).
Clip bolt
Tightening torque [N•m {kgf•m}]: 49 - 59 {5 - 6}

3. When pressing the bushings of the spring and shackle, use

the bushing replacer (99888 Z00012).

RSU-5
INSPECTION
Clean all disassembled parts in cleaning solvent. Check carefully
for scratches, cracks, etc. Replace faulty parts with new ones.
Leaf spring
When wear of the leaf has reach to 15% or more of the original
thickness (while new), replace with a new one.

Spring (shackle) pin outside diameter

Unit: mm
Maintenance standard Service limit
34.98 - 35.00 34.5

Spring (shackle) pin bushing inside diameter

Unit: mm
Maintenance standard Service limit
35.0 - 35.1 36.0

Clearance between spring (shackle) pin and bushing

Unit: mm
Maintenance standard Service limit
0 - 0.12 1.0

RSU-6
Side clearance between shackle and spring bracket S
(L1)
Unit: mm
Maintenance standard Service limit Remarks
0.05 - 0.70 – Adjust with shims

Side clearance between shackle and spring (L2)

Unit: mm
Maintenance standard Service limit Remarks
0.05 - 0.70 – Adjust with shims

RSU-7
 TRUNNION TYPE SUSPENSION
CONSTRUCTION
CWB, GWB series

RSU-8
DISASSEMBLY AND REASSEMBLY
CWB, GWB series

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Torque rod (Rear upper) 2. Torque rod (Front upper) 3. Torque rod (Front lower)
4. Torque rod (Rear lower) 5. Torque rod bushing 6. Torque rod bracket
7. Nut 8. U-bolt 9. Pad
10. Spring 11. Nut 12. Center bolt
13. Bolt 14. Spacer 15. Rivet
16. Clip 17. Grease nipple 18. Bolt
19. Cover 20. Side plate 21. Shim
22. Thrust washer 23. Spring seat 24. Bushing
25. Thrust washer 26. Dowel pin 27. Thrust washer
28. Oil seal 29. O-ring 30. Bumper rubber
31. Spacer 32. Knock bolt & nut 33. Knock bolt & nut(if equipped)
34. Trunnion shaft 35. Trunnion bracket

RSU-9
Key point of disassembly
NOTE
 As for replacement of the torque rod bushing, see the
replacement of rubber bushing of repair and replace-
ment. Securely lock the center of the spring by using the
press machine. After removing the center bolt, disassem-
ble the leaf spring.

Key point of reassembly

1. Securely locking the center of the spring by using the press
machine, install the center bolt. Tightening the center bolt and
the nut with the specified torque, remove the spring assembly
from the press machine and stake 2 points of the threads
which are protruded from the nut top face.

2. Tighten after applying oil to the threads of the U-bolt and the
seat of the nut.
3. When installing the trunnion shaft to the trunnion bracket, be
sure to confirm the position of the knock bolt hole.
NOTE
 The trunnion shaft is embossed with the mark R.H.

4. Adjust the end plate of the trunnion shaft (spring seat).

 Measure the distance between the trunnion shaft end and the
spring seat (thrust washer). (L on the figure).
 Select shims which make the thickness of L + end play.
Shims thickness: 0.2, 0.4, 0.6 mm
Unit: mm
Item Maintenance standard Service limit
End play of trunnion shaft 0.1 - 0.2 –

RSU-10
INSPECTION
Clean all disassembled parts in cleaning solvent. Check carefully
for scratches, cracks, etc. Replace faulty parts with new ones.
Leaf spring
When wear of the leaf has reached to 15% or more of the original
thickness (while new), replace with a new one.
Trunnion shaft outside diameter
Unit: mm
Maintenance standard Service limit
99.93 - 99.98 99.4

Trunnion shaft bushing inside diameter

Unit: mm
Maintenance standard Service limit
100.10 - 100.24 100.6

Clearance between trunnion shaft and bushing

Unit: mm
Maintenance standard Service limit
0.12 - 0.31 1.0

Thickness of thrust washer

Unit: mm
Maintenance standard Service limit
4.95 - 5.05 –

RSU-11
REPAIR AND REPLACEMENT
REPLACEMENT OF TORQUE ROD BUSHING
Torque rod bushing (when using fixed press machine)
1. Remove the torque rod from a vehicle.
2. Remove the bushing with the press, using the replace tool
(99888 Z0065).
NOTE
 Use a press machine whose capacity is 98 kN {10,000
kgf} or more.

3. Align the matching mark of the bushing with the collar groove.

4. Install the bushing with the press, using the replace tool
(99888 Z0065).
NOTE
 Use a press machine whose capacity is 98 kN {10,000
kgf} or more.

RSU-12
Torque rod bushing (when using the installation and
removal tools for the stabilizer bushing)
Removal
1. Remove the torque rod from a vehicle.
2. Prepare the installation and removal tools for the stabilizer
bushing (99880 Z000B) and puller set (99881 Z0005).
Setting the bushing receiving tool (99897 Z0011) and the
receiving stand adaptor (Part A of 99881 Z0005) on the puller
assembly, install the air hose to the hydraulic pump.

3. Set the bushing (torque rod) to the bushing receiving tool.

4. Install the press-in tool joint (99897 Z0013) and the bushing
press-in tool (99888 Z0107).

5. Starting the hydraulic pump, move the bushing press-in tool

close to the bushing. Making alignment, restart the hydraulic
pump to pull out the bushing.

RSU-13
Installation
1. Set the bushing receiving tool (99897 Z0011) and the bushing
press-in stopper (Part B of 99881 Z0005) on the puller assem-
bly.
NOTE
 Before inserting the bushing, check the inside of the
bushing collar and wipe off rust/dirt.

2. Set the puller assembly on the torque rod.

3. Align the matching mark of the torque rod bushing and the one
of the torque rod, attach to the bushing collar. From the oppo-
site site and through the puller assembly, lock the bushing by
using the bushing holding tool (99884 Z0006).
NOTE
 Make sure that the bushing press-in tool is installed.

4. Install the ram on the bushing press-in tool (99888 Z0107).

NOTE
 Never use the bushing press-in tool joint for press-in
work.
5. Starting the hydraulic pump, move the bushing press-in tool
close to the bushing. Making alignment of them, press in fur-
ther.

RSU-14
6. Press in until the bushing touches the bushing press-in stop-
per.
NOTE
 When the bushing is inserted half-way through, remove
the bushing holding tool.
7. On completion of the press-in work, make sure that the match-
ing marks meet properly.

REPLACEMENT OF SPRING SEAT (TRUNNION SHAFT)

BUSHING
Spring seat (trunnion shaft) bushing
Removal
Place the spring seat on a press, set the bushing remover (99896
Z0005) and drive out the bushing with the press.

Installation
Place the spring seat on a press, set the bushing replacer assem-
bly (99883 Z0007) and press fit the bushing until the bushing and
spring seat top surface are matched at the spring seat.

RSU-15
 SERVICE DATA
SPECIFICATIONS
Vehicle series GKB
Suspension type Axle type
Spring type Semi-elliptic leaf spring type (Shackle type)
Spring construction
See the item Spring structure
(Length Width Thickness Number of leaf)
Shock absorber type Telescopic twin tube type
Stabilizer type –

Vehicle series CWB, GWB

Suspension type Axle type
Spring type Semi-elliptic leaf spring type (Trunnion type)
Spring construction
See the item Spring structure
(Length Width Thickness Number of leaf)
Shock absorber type –
Stabilizer type –

SPRING STRUCTURE
Unit: mm
Spring construction
Vehicle series Model Description
(Length Width Thickness Number of leaf)
23 1
R.H.D. Tractor M: 1600 90 
GKB 25 2 –
(Leaf spring type suspension)
L.H.D. H: 1170 90  18 3
R.H.D. 20 2 21 2
Cargo
1400 90  21 8 1400 90  23 8
L.H.D. (Trunnion type suspension)
20 1 21 3
CWB
R.H.D. 20 3 21 2
Dump, Mixer
1400 90  22 8 1400 90  23 8
L.H.D. (Trunnion type suspension)
20 2 21 3
R.H.D. 20 2 21 2
Tractor
GWB 1400 90  21 8 1400 90  23 8
L.H.D. (Trunnion type suspension)
20 1 21 3

RSU-16
SERVICE DATA
LEAF SUSPENSION (GKB SERIES)
Unit: mm
Item Maintenance standard Service limit Remarks
Spring (shackle) pin outside diameter 34.98 - 35.00 34.5
Spring (shackle) pin bushing inside diameter 35.0 - 35.1 36.0
Clearance between spring (shackle) pin and
0 - 0.12 1.0
bushing
Side clearance between shackle and spring
0.05 - 0.70 – Adjust with shims
bracket
Side clearance between shackle and spring 0.05 - 0.70 – Adjust with shims
Leaf wear – 15% of leaf thickness Compared with a new one

TRUNNION TYPE SUSPENSION (CWB, GWB SERIES)

Unit: mm
Item Maintenance standard Service limit Remarks
Trunnion shaft outside diameter 99.93 - 99.98 99.4
Trunnion shaft bushing inside diameter 100.10 - 100.24 100.6
Clearance between trunnion shaft and bushing 0.12 - 0.31 1.0
Thickness of thrust washer 4.95 - 5.05 –
Leaf wear – 15% of leaf thickness Compared with a new one
End play of trunnion shaft 0.1 - 0.2 –

RSU-17
TIGHTENING TORQUE
Tightening torque
Item Remarks
N•m kgf•m
Apply oil to bolt threads
Leaf suspension GKB 589 - 637 60 - 65
U-bolt, Nut and the seat of the nut.
Trunnion type suspension CWB, GWB 716 - 843 73 - 86
Center bolt 108 - 127 11 - 13
Clip bolt 49 - 59 5-6
Spring pin (shackle) mounting bolt 39 - 49 4-5
Trunnion bracket mounting bolt/nut 200 - 260 20.5 - 26.5
Torque rod mounting bolt/nut 197 - 264 20 - 27
Trunnion type Trunnion shaft side plate mounting bolt 216 - 235 22 - 24
suspension Torque rod bracket mounting bolt/nut 88 - 118 9 - 12
Bolt 255 - 343 26 - 35
Trunnion shaft locking bolt/nut
Nut 334 - 441 34 - 45

RSU-18