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FRONT AXLE
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FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 FRONT HUB AND KNUCKLE ASSEMBLY . 13
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INNER SHAFT, HOUSING TUBE . . . . . . . . . . 24
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FREEWHEEL CLUTCH ASSEMBLY,

DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FREEWHEEL CLUTCH ASSEMBLY . . . . . . . 31
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 10
Wheel Bearing Backlash Check . . . . . . . . . . . . . . 10 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 34
Front Axle Total Backlash Check . . . . . . . . . . . . . 10 SOLENOID VALVE, VACUUM PIPE, VACUUM
Front Axle Gear Oil Level Check . . . . . . . . . . . . . 11 TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Differential Carrier Oil Seal Replacement . . . . . . 11
FRONT DIFFERENTIAL MOUNT . . . . . . . . . . 51
Solenoid Valve Operation Check . . . . . . . . . . . . . . 12

26-2 www.WorkshopManuals.co.uk
FRONT AXLE - General Information
GENERAL INFORMATION
The front axle consists of the front hubs, knuckles, NOTE
drive shaft, wheel bearings, ball joints, front U.J. is an abbreviation of Under cut Joint.
differential, and freewheel clutch. D A vacuum-type freewheel clutch has been
The features are: adopted in the freewheel mechanism. Its
D The structural method of press fitting unit solenoid valve and actuator switch powertrain
bearing into the front hub is applied. between 2WD and 4WD.
D The wheel bearing uses a taper roller unit D The differential support method is a four-point
bearing. For vehicles with ABS, a rotor for elastic support method which reduces vibration
detecting the wheel speed is press-fitted to and noise.
the U.J. outer wheel.
D Drive shafts incorporate U.J.-B.J.-type constant
velocity ball joint has high power transmission
efficiency and reduces vibration and noise.
Item Specification
Wheel Wheel bearing type Taper roller type unit bearing
bearings
Bearing (outside diameter ´ inside diameter) 88 ´ 50
mm
Drive Joint type Outside U.J.
shaft
Inside D.O.J.
Shaft length*1 ´ Shaft diam- Right 353 ´ 28*2, 361.5 ´ 26*3
eter mm
Left 323 ´ 28*2, 330 ´ 26*3
Inner Shaft length ´ Shaft diameter mm 389.2 ´ 31.5
shaft
Bearing (outside diameter ´ inside diameter) 62 ´ 35
mm
NOTE
*1: The shaft length indicates the length between the center points of each joint.
*2: 4M41-M/T
*3: 4D56, 4M41-A/T, 6G74 GDI
FRONT DIFFERENTIAL
Item Specification
Reduction gear type Hypoid gear
Reduction ratio 4.900*1, 3.917*2, 4.100*3, 4.300*4
Differential gear type Straight bevel gear
Number Drive gear 49*1, 47*2, 41*3, 43*4

of teeth
Drive pinion 10*1,*3,*4, 12*2
Side gear 14
Pinion gear 10
NOTE
*1: 4D56
*2: 4M41-A/T
*3: 4M41-M/T
*4: 6G74 GDI

www.WorkshopManuals.co.uk
FRONT AXLE - General Information 26-3
Bearing (outside diameter ´ inside Side 80.0 ´ 45.2

diameter) mm
Front 68.3 ´ 30.2
Rear 72.2 ´ 36.5
STRUCTURAL DIAGRAM
Front differential
Drive shaft (R.H.) Knuckle
Freewheel clutch
Drive shaft (L.H.)
DRIVE SHAFT
(L.H.) Knuckle
Differential side Wheel side
D.O.J. type U.J. type
Hub
Unit bearing
(R.H.) Plastic ABS rotor

Differential side U.J. boot
D.O.J. type

FRONT AXLE - Service Specifications/Lubricants
SERVICE SPECIFICATIONS
Item Standard value Limit
Wheel bearing axis backlash mm - 0
Front axle total backlash mm - 11
Solenoid valve resistance W 36 - 46 -
Hub rotation starting torque N×m - 1.75
Setting of D.O.J. boot length mm 80 ± 5 -
Opening dimension of the spe- When the B.J. boot band 2.9 -
cial tool (MB991561) mm (small) is crimped.
When the B.J. boot band 3.2 -

(big) is crimped.
Crimped width of the B.J. boot band mm 2.4 - 2.8 -
Crimped height of B. J. boot band (big) mm - 9.5
Final drive gear backlash mm 0.11 - 0.16 -
Drive gear runout mm - 0.05
Differential gear backlash mm 0 - 0.076 0.2
Drive pinion turning torque N×m Without oil seal 0.83 - 1.19 -
With oil seal Companion flange (oil seal contact -

surface) with anti-rust oil
0.93 - 1.128
Companion flange (oil seal contact -

surface) with gear oil
0.97 - 1.32
LUBRICANTS
Items Specified lubricants Quantity
Front differential gear oil Hypoid gear oil API classification GL-5 or higher, SAE 1.2 L
viscosity No. 90, 80W
D.O.J. boot grease Repair kit grease 4M41-M/T:135 ± 10 g

4M41-A/T, 6G7:
100 ± 10 g
U.J.boot grease Repair kit grease 4M41-M/T:180 ± 10 g

4M41-A/T, 6G7:
135 ± 10 g

FRONT AXLE - Sealants/Special Tools 26-5
SEALANTS
Items Specified sealants Remarks
Contact surface of differential cover and 3M ATD Part No. 8661 or equivalent Semi-drying sealant
differential carrier
Vent plug
Freewheel clutch assembly
Drive gear threaded hole 3M Stud Locking 4170 or equivalent Anaerobic sealant
SPECIAL TOOLS
Tool Number Name Use
MB990925 Bearing and oil D Press-fitting of housing tube dust seal
seal installer set D Press-fitting of oil seal
D Removal and installation of drive pinion
front & rear bearing outer race
D Checking of drive gear tooth contact
MB990955 Oil seal installer D Press-fitting of housing tube dust seal

(Used together with MB990938)
MB991113 or Steering linkage D Disconnection of ball joint

MB990635 puller
MB990767 Front hub & flange Hub fixiation

yoke holder
MB990998 Front hub remover Inspection of hub rotation starting torque

& installer
MB991561 Boot band clipping Resin boot band installation

tool
MB990906 Drive shaft attach- Removal and installation of inner shaft (Used
ment together with MB990211)

FRONT AXLE - Special Tools

B MB990590 Rear axle shaft oil D Removal of differential carrier oil seal
A: MB990212 seal remover D Removal and installation of inner shaft
B: MB990211 A: Adapter (Used together with MB990906)
B: Sliding hammer
A
MB990560 Bearing remover D Removal and press-fitting of inner shaft

bearing
D Removal of freewheel clutch bearing
MB990909 Working base Support of front differential carrier assembly
MB991116 Adapter Support of front differential carrier assembly
MB990810 Side bearing puller D Removal of side bearing inner race

D Removal of companion flange
MB990811 Differential side

bearing cap
MB990850 End yoke holder Removal and installation of companion flange
MB990339 Bearing puller Removal of drive pinion front bearing inner race
MB990648 Bearing remover

FRONT AXLE - Special Tools 26-7

MB991171 Pinion height gauge D Inspection of drive pinion rotation starting
A: MB990819 set torque
B: MB991170 A: Drive pinion D Measurement of drive pinion height
gauge assembly
B: Cylinder gauge
A B
MB990685 Torque wrench D Inspection of hub rotation starting torque

D Measurement of drive pinion rotation
starting torque
MB990326 Preload socket
MB990802 Bearing installer D Press-fitting of drive pinion front bearing

inner race
D Press-fitting of side bearing inner race
MB990031 Drive pinion oil seal Press-fitting of drive pinion oil seal
or installer
MB990699
MB990813 Tap Removal of adhesive
MB990799 Ball joint remover Installation of freewheel clutch bearing

and installer
MB991168 Differential oil seal Installation of freewheel clutch oil seal

installer

FRONT AXLE - Special Tools

MB990890 Rear suspension Installation of freewheel clutch bearing
or bushing base
MB990891
MD999547 Oil seal installer Removal of front differential mount insulator

<Front, rear L.H.>
MD999570 Crankshaft front oil Removal of front differential mount insulator

seal installer <Rear R.H.>
MB990947 Lower arm bush Press fitting of front differential mount insulator
arbor <Front, rear L.H.>
MB990847 Rear suspension

bush remover &
installer base
MB990981 Mount bush re-

mover & installer
ring
MB991318 Lower arm bush Press fitting of front differential mount insulator
arbor <Rear R.H.>
MB991183 Bush arbor
MB990843 Draglink bush re-

mover & installer

FRONT AXLE - Special Tools 26-9
MB990925
Tool box
C Brass bar
B
A Bar (snap-in type)
Installer adapter
Contents of tool O.D. mm Contents of tool O.D. mm

(MB990925) (MB990925)
A MB990926 39 A MB990933 63.5
MB990927 45 MB990934 67.5
MB990928 49.5 MB990935 71.5
MB990929 51 MB990936 75.5
MB990930 54 MB990937 79
A MB990931 57 B MB990938 -
A MB990932 61 C MB990939 -

FRONT AXLE - On-vehicle Service
ON-VEHICLE SERVICE
WHEEL BEARING BACKLASH CHECK
1. Remove the caliper assembly and hold it with wires to
prevent it from falling.
2. Remove the brake disk from hub.
3. Set the dial gauge as shown in the diagram and move

the hub in the axis to measure backlash.
Limit: 0 mm
4. If the backlash exceeds the limit value, disassemble hub
knuckle to check each component. If front hub assembly
bearing is faulty, replace the front hub assembly.
FRONT AXLE TOTAL BACKLASH CHECK

When the iginition switch is in LOCK(OFF) position, front
wheel comes to stop after turning the propeller shaft by hand
due to the force applied to front wheel actuator. Inspect the
vehicle in the following procedure:
1. Turn the ignition switch to LOCK(OFF) position, and then
put the transfer shift lever to the 2H position.
Caution
Do not jack up the vehicle.
2. Turn the propeller shaft until a click is heard.

Mating marks 3. Turn the companion flange clockwise until all play is
removed. Make mating marks on the dust cover of the
companion flange with that on the differential carrier.
4. Turn the companion flange anti-clockwise until all play

is removed and measure the amount of distance through
which the mating marks moved.
Limit: 11 mm

FRONT AXLE - On-vehicle Service 26-11
5. If the amount of movement exceeds the limit value, check
the following.
(1) Final drive gear backlash
(2) Differential gear backlash
(3) Play in the serrations and splines of the side gears,
drive shaft, inner shaft and drive flange
FRONT AXLE GEAR OIL LEVEL CHECK
Remove the filler plug, and check the gear oil level. Check
that gear oil level is not 8 mm below the bottom of filler plug
8 mm hole.
Upper limit Specified gear oil:
Hypoid gear oil API classification GL-5 or higher, SAE
viscosity No. 90, 80W [Quantity: 1.2 L]
Lower limit
DIFFERENTIAL CARRIER OIL SEAL

MB990590 REPLACEMENT
1. Remove the drive shaft <L.H.>. (Refer to P.26-16.)
2. Remove the oil seal with special tools.
3. Install new oil seal with the special tools.
MB990934 MB990938
4. Apply multi-purpose grease to lip of oil seal to install

drive shaft <L.H.>. (Refer to P.26-16)
Caution
1. Be careful not to damage the lip of oil seal
2. Replace the circlip attached to the spline of DOJ
side of drive shaft <L.H.> with a new one.

FRONT AXLE - On-vehicle Service
SOLENOID VALVE OPERATION CHECK

1. Remove the vacuum hoses (blue stripe, yellow stripe)
from the solenoid valves.
Solenoid valve B
2. Disconnect the harness connectors.
Solenoid valve A
3. Connect a hand vacuum pump to solenoid valve A and

carry out the following inspections.
(1) Even if the hand pump is operated with no other
operation, no negative pressure develops.
(2) Negative pressure does not develop when battery
Check valve voltage is applied to solenoid valve A. Meanwhile,
negative pressure is maintained when the vacuum
Vacuum tank
hose of solenoid valve B is blocked by bending.
(3) When battery voltage is applied to solenoid valves
A and B, negative pressure is maintained.
Solenoid valve A
Vacuum
hose
Solenoid valve B
4. Connect the hand vacuum pump to solenoid valve B.

Apply negative pressure and carry out the following
inspections.
Check valve (1) With no other operation, negative pressure is
Vacuum tank
maintained.
(2) When battery voltage is applied to solenoid valve
B, negative pressure disappears.
(3) When battery voltage is applied to solenoid valve
A, negative pressure disappears.
Solenoid valve A 5. Measure the resistance of the solenoid valves.
Standard value: 36 - 46 W
Solenoid valve B

FRONT AXLE - Hub and Knuckle Assembly 26-13
HUB AND KNUCKLE ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Press dust cover with a finger to check for crack or
damage in ball joint dust cover.
10
113 ± 10 N×m
4 74 ± 14 N×m
6
39 ± 4 N×m
13
12
5
9
255 ± 29 N×m
2
147 ± 29 N×m
8 1
8.9 ± 1.9 N×m
11
3
7
5.0 ± 1.0 N×m
Removal steps 8. Dust cover

1. Hub cap AB" 9. Tie rod end, hub and knuckle assembly
AA" "AA 2. Castle nut connection
"AA 3. Washer AB" 10. Upper arm, hub and knuckle assembly
4. Brake hose & vehicle speed sensor connection
clamp bracket AB" 11. Lower arm, hub and knuckle assembly
5. Wheel speed sensor <vehicles with connection
ABS> 12. Rotor protector <vehicles with ABS>
6. Disc brake assembly 13. Hub and knuckle assembly
7. Brake disc

FRONT AXLE - Hub and Knuckle Assembly
REMOVAL SERVICE POINTS

AA" CASTLE NUT REMOVAL
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage when castle nut is
loosened.
MB990767
AB" TIE ROD END, HUB AND KNUCKLE ASSEMBLY

MB991113 or
MB990635 /UPPER ARM, HUB AND KNUCKLE ASSEMBLY
/LOWER ARM, HUB AND KNUCKLE ASSEMBLY
Nut DISCONNECTION
Cord Caution
1. Do not remove nut from ball joint but loosen it and
use special tools instead to avoid possible damage
to ball joint threads.
2. Hang special tools with ropes to prevent them from
Ball joint falling.
INSTALLATION SERVICE POINT

Washer "AA WASHER/CATSLE NUT INSTALLTION
1. Direct the flat side of a washer to a castle nut to install.
2. Tighten castle nut fully with special tools.

MB990767 Caution
weight to avoid possible damage to wheel bearing
before tightening castle nut fully.
3. If the pin hole does not align with another, tighten the
pin to 284 N×m and find the nearest hole then bend the
sprit pin to fit in.
255 ± 29 N×m
INSPECTION
MB990998 INSPECTION OF HUB ROTATION STARTING TORQUE
1. Tighten special tools in hub and knuckle assembly to
Bolt the specified torque.
255 ± 29 N×m
Secure bolt and
tighten nut.

FRONT AXLE - Hub and Knuckle Assembly 26-15
2. Measure the hub rotation starting torque with special tools.
Limit: 1.75 N×m or less
3. Hub rotation starting torque must be under the limit value
and there should be no roughness when rotating the
hub.
MB990326
WHEEL BEARING BACKLASH CHECK

1. Secure knuckle in a vice to measure backlash in wheel
MB990998 bearing.
Limit: 0 mm
2. If the limit value of backlash in hub axis cannot be obtained
when tightened to the specified torque (255 ± 29 N×m),
check mounting bolt for hub and knuckle assembly. If
no defects are found, replace hub assembly.
255 ± 29
N×m
DISASSEMBLY AND REASSEMBLY
88 ± 10 N×m
Disassembly steps
1. Knuckle
2. Front hub assembly

FRONT AXLE - Drive shaft
DRIVE SHAFT
Pre-removal and Post-installation Operations
D Removal and Installation of Under Cover and Skid D Removal and Installation of Front Brake Assembly
Plate (Refer to GROUP 42.) (Refer to GROUP 35A.)
D Connection and Disconnection of Shock Absorber D Connection and Disconnection of Knuckle and Tie
and Stabilizer Link in the Lower Arm Side (Refer to Rod End (Refer to GROUP 37 - Steering Gear
GROUP 33 - Lower Arm.) Linkage.)
60 ± 10 N×m
<R.H.> 7
25 ± 4 N×m
<L.H.> 7
4
3
1
2
5 255 ± 29 N×m
Removal steps
1. Hub cap 6. Upper arm and upper arm ball joint
AA" "BA 2. Castle nut connection
"BA 3. Washer AB" "AA 7. Drive shaft
4. Brake hose and vehicle speed sensor 8. Circlip <L.H.>
clamp bracket
5. Wheel speed sensor <vehicles with
ABS>

FRONT AXLE - Drive shaft 26-17
AA" CASTLE NUT REMOVAL
Caution
weight to avoid possible damage when a castle nut is
loosened.
MB990767
AB" DRIVE SHAFT REMOVAL

Caution
When pulling the drive shaft out from the differential
carrier, be careful that the spline part of the drive shaft
does not damage the oil seal.
INSTALLATION SERVICE POINTS

"AA DRIVE SHAFT INSTALLATION
Caution
Do not damage the oil seal of the differential carrier by
the drive shaft splines.
"BA WASHER/CASTLE NUT INSTALLATION

Washer 1. Fit washer in castle nut with its smaller side facing the
castle nut.
2. Tighten up castle nut with special tools.

MB990767 Caution
weight to avoid possible damage before tightening
up castle nut.
3. In this case, if the pin holes do not match, tighten the
nut to 284 N×m and find the most suitable hole to bend
the nut with a split pin.
255 ± 29 N×m

FRONT AXLE - Drive Shaft
INSPECTION
D Check the boot for damage or deterioration.
D Check the ball joint for operating condition and excessive
looseness.
D Check the splines for wear or damage.
D Check the differential carrier oil seal (L.H.) for damage.

FRONT AXLE - Drive Shaft 26-19
Caution
Never disassemble the U.J. assembly except when replacing the U.J. boot.
12
4 <L.H.>
3 12 2
8
13 5 6 3 5 10
11
1
7 9
U.J. Repair kit
4 <R.H.>
11
2
1
12 3 5 4 3
2 5
1 12 3 5 6
7 7 2
2 13 12
1 1
8
9
10
U.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
D.O.J. U.J.
4
11
Grease: repair kit grease Grease: Repair kit grease

Quantity: <U.J.>4M41-M/T: 180 ± 10 g (90 ± 5 g inside joint, 90
± 5 g inside boot), 4M41-A/T, 4D5 6G7:135 ± 10 g (65 ± 5 g inside
joint, 70 ± 5 g inside boot) <D.O.J.>4M41-M/T: 135 ± 10 g (75
± 5 g inside joint, 60 ± 5 g inside boot), 4M41-A/T, 4D5 6G7:100
± 10g (60 ± 5 g inside joint, 40 ± 5 g inside boot)
Caution
Do not mix old and new or different types of grease, as a special grease is used in the joint.
Disassembly steps AA" "AA 7. D.O.J. boot

"BA 1. D.O.J. boot band (small) 8. U.J. boot band (small)
"BA 2. D.O.J. boot band (large) 9. U.J. boot band (large)
3. Circlip 10. U.J. boot
4. D.O.J. outer race 11. U.J. assembly
5. Snap ring 12. Circlip <L.H.>
6. Inner race, cage and ball assembly 13. Circlip <L.H.>

DISASSEMBLY SERVICE POINT

AA" D.O.J. BOOT REMOVAL
Plastic tape Wrap plastic tape around the spline part on the U.J. assembly
so that D.O.J. boot is not damaged when they are removed.
REASSEMBLY SERVICE POINTS

"AA D.O.J. BOOT INSTALLATION
Install boot after wrapping plastic tape around the spline part
on the U.J. assembly.
"BA D.O.J. BOOT BAND/D.O.J. BOOT BAND

A INSTALLATION
1. Position the D.O.J. outer race so that the distance between
the boot bands is at the standard value.
Standard value (A): 80 ± 5 mm
2. Remove part of the D.O.J. boot from the D.O.J. outer
Boot band (small)
race to release the air pressure inside the boot.
Boot band (large)
U.J. BOOT (RESIN BOOT) REPLACEMENT

1. Remove the boot bands (large and small).
NOTE
The B.J. boot bands cannot be re-used.
2. Remove the B.J. boot.
3. Install the small part on the plastic boot aligning the groove
of the shaft.

MB991561 4. Turn the adjusting bolt on the special tool so that the
Stopper size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm>
Tighten the adjusting bolt.
W <If it is smaller than 2.9 mm>
Loosen the adjusting bolt.
Adjusting bolt NOTE
(1) The value of W will change by approximately 0.7
mm for each turn of the adjusting bolt.
(2) The adjusting bolt should not be turned more than
once.
5. Install the U.J. boot band (small) to the U.J. boot.
6. Use the special tool to crimp the U.J. boot band (small).
Caution
(1) Secure the drive shaft in an upright position and
clamp the part of the U.J. boot band to be crimped
securely in the jaws of the special tool.
(2) Crimp the U.J. boot band until the special tool
touches the stopper.
MB991561
7. Check that crimping amount (A) of the U.J. boot band

is at the standard value.
A Standard value (A): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step (4) according
to the following formula, and then repeat the
operation in step (6).
W = 5.5 mm - A
Example: If A = 2.9 mm, then W = 2.6 mm.

<If the crimping amount is smaller than 2.4 mm>

Remove the U.J. boot band, readjust the value
of (W) in step (4) according to the following
formula, and then repeat the operations in
steps (5) and (6) using a new B.J. boot band.
W = 5.5 mm - A
Example: If A = 2.3, then W = 3.2 mm.
8. Check that the U.J. boot band is not sticking out past
the place where it has been installed.
If the U.J. boot band is sticking out, remove it and then
repeat the operations in steps (4) to (7) using a new
U.J. boot band.
9. Fill the inside of the U.J. boot with the specified amount
of the specified grease.
Specified grease: Repair kit grease
Amount to use:
Vehicles with 4M41-M/T: 180 ± 10 g
(90 ± 5 g inside joint, 90 ± 5 g inside boot)
Vehicles with 4M41-A/T, 4D5 6G7: 135 ± 10 g
(65 ± 5 g inside joint, 70 ± 5 g inside boot)
10. Install the large diameter part on the plastic boot alighning
the groove of the shaft.
11. Follow the same procedure as in step (4) to adjust the
size of the opening (W) on the special tool so that it
is at the standard value.
Standard value (W): 3.2 mm
12. Install the U.J. boot band (large) to the U.J. boot.
13. Use the special tool to crimp the U.J. boot band (large)
in the same way as in step (6).
14. Check that the crimping amount (B) of the U.J. boot band
is at the standard value and that the crimping amount
(C) of the U.J. boot band is at the limited value
Standard value (B): 2.4 - 2.8 mm
Limit (C): 9.5 mm
C

<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step (11) according
to the following formula, and then repeat the
operation in step (13).
W = 5.8 mm - B
Example: If B = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the U.J. boot band, readjust the value
of (W) in step (11) according to the following
formula, and then repeat the operations in
steps (12) and (13) using a new U.J. boot band.
W = 5.8 mm - B
Example: If B = 2.3 mm, then W = 3.5mm.
15. Check that the U.J. boot band is not sticking out past
the place where it has been installed.
If the U.J. boot band is sticking out, remove it and then
repeat the operations in steps (12) to (14) using a new
U.J. boot band.

FRONT AXLE - Inner Shaft, Housing Tube
INNER SHAFT, HOUSING TUBE

Caution
*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
Pre-removal and Post-installation Operation

D Under Cover and Skid Plate Removal and
Installation
D Drive Shaft <R.H.> Removal and Installation (Refer
to P.26-16.)
12 ± 2 N×m
69 ± 9 N×m*
2
1 8 9
12 ± 2 N×m
6 90 ± 10 N×m
25 ± 5 N×m
69 ± 9 N×m* 10
89 ± 9 N×m
5
17 ± 3 N×m 4
3
Removal steps
AA" "BA 1. Inner shaft AB" "AA D Loosening and tightening of differential
2. Clip mounting insulator bolt
3. Collar D Support the differential by a
4. Pin transmission jack.
5. Actuator assembly 8. Differential mounting bracket <R.H.>
6. Vacuum tank assembly 9. Breather pipe
7. Engage switch assembly 12. Housing tube

FRONT AXLE - Inner Shaft, Housing Tube 26-25
MB990906
AA" INNER SHAFT REMOVAL
Caution
When pulling the inner shaft out from the front differential
carrier, be careful that the spline part of the inner shaft
does not damage the oil seal.
MB990211
AB" DIFFERENTIAL MOUNTING INSULATOR BOLT

LOOSENING
Loose the bolt shown in the diagram.

D A "AA DIFFERENTIAL MOUNTING INSULATOR BOLT
TIGHTENING
Tighten the bolts shown in the diagram in the serivce
specification in the order of A, B, C, D or A, C, B, D.
C
Tightening torque: 69 ± 9 N×m
B Caution
Place the vehicle on the ground after temporarily tighten
bolts to prevent bushes from twisting and fully tighten
the bolts in the unladen condition.
"BA INNER SHAFT INSTALLATION
Caution
Be careful not to damage the lip of the dust seal and
oil seal.

FRONT AXLE - Inner Shaft
3
5
3 5
2
4
Disassembly steps
1. Inner shaft 4. Housing tube
AA" "CA 2. Bearing "AA 5. Dust seal
"BA 3. Dust cover
DISASSEMBLY SERVICE POINT

AA" BEARING REMOVAL
1. Bend the outside periphery of dust cover inward with
a hammer.
2. After the special tool has been installed as shown, tighten

A
the nut of the special tool until the portion “A” of the
special tool touches the bearing outer race.
MB990560

FRONT AXLE - Inner Shaft 26-27
3. Press out the inner shaft from the bearing.
MB990560

"AA DUST SEAL INSTALLATION
Press-fit the new dust seal into the housing tube by using
MB990938
the special tools, until it is flush with the housing tube end
face.
MB990955
"BA DUST COVER INSTALLATION

Using a steel pipe, force a new dust cover onto the inner
shaft.
Steel pipe
Steel pipe mm
Overall length 50
Outside diameter 75
Wall thickness 4
"CA BEARING INSTALLATION
MB990560

FRONT AXLE - Freewheel Clutch Assembly, Differential Carrier
FREEWHEEL CLUTCH ASSEMBLY, DIFFERENTIAL CARRIER

Caution
Pre-removal and Post-installation

D Under Cover and Skid Plate Removal and Installation D Drive Shaft Removal and Installation
D Gear Oil Draining and Refill (Refer to P.26-11.) (Refer to P.26-16.)
D Inner Shaft Removal and Installation
(Refer to P.26-24.)
4
69 ± 9 N×m*
90 ± 10 N×m
8 1
4 60 ± 10 N×m59 ± 9 N×m
25 ± 5 N×m
7
2
6 11
69 ± 9 N×m* 5
9
2
89 ± 9 N×m
69 ± 9 N×m* 10
128 ± 9 N×m
Sealant:
3M ATD Part No. 8661 or 12
equivalent
3
Removal steps
AA" "BA 1. Front propeller shaft connection 7. Freewheel engage switch assembly
2. Front frame and differential bracket "AA 8. Differential mounting bracket <R.H.>
connection and housing tube assembly
3. Front frame and No.2 crossmember 9. Freewheel clutch assembly
assembly connection "AA 10. Differential mounting bracket <L.H.>
4. Vacuum hose 11. Differential carrier
5. Collar 12. No.2 crossmember assembly
AB" 6. Pin

FRONT AXLE - Freewheel Clutch Assembly, Differential Carrier 26-29
Mating marks
AA" FRONT PROPELLER SHAFT DISCONNECTION
Make the mating marks on the flange yoke and the differential
carrier companion flange and then remove the front propeller
shaft.
Caution
Joint boot
1. Be careful not to damage joint boot by cramping with
the bent propeller shaft joint.
2. Hang propeller shaft with wires to prevent it from
falling.
Cloth
Propeller
shaft Joint assembly
(BJ)
Dust cover Collar AB" PIN REMOVAL

1. Remove one side of dust cover mounting part on the
Vaccum Actuator Assembly.
2. Match a pin with a pin hole and remove the pin with
with a punch.
Pin

D A
"AA DIFFERENTIAL MOUNTING BRACKET
ASSEMBLY TIGHTENING
Tighten differential mounting insulator in the order of A, B,
C, D or A, C, B, D as shown in the left diagram.
C
"BA FRONT PROPELLER SHAFT INSTALLATION

Install the front propeller shaft so that the mating marks of
the flange yoke and the differential carrier companion flange
are aligned.
Caution
Do not tighten fasteners without removing grease from
threads because fastner threads covered with oily
products could become loose.

FRONT AXLE - Freewheel Clutch Assembly, Differential Carrier
INSPECTION
FREEWHEEL ENGAGE SWITCH
Ball Shaft (switch) Terminal No. 1 Terminal No. 2

position
OFF ON
Pressed (ON)
Released (OFF)

FRONT AXLE - Freewheel Clutch Assembly 26-31
FREEWHEEL CLUTCH ASSEMBLY
12 11
12
10
10
4
13
7
3
2
9 9
5
6
8
Disassembly steps
AA" 1. Main shaft 8. Shift rod
2. Clutch sleeve "CA 9. Oil seal
3. Spacer AB" "BA 10. Clutch gear
AA" "EA 4. Bearing AB" "BA 11. Bearing
"DA 5. Spring pin "AA 12. Oil seal
6. Snap ring 13. Clutch housing
7. Shift fork
A
DISASSEMBLY SERVICE POINTS
MB990560 AA" MAINSHAFT/BEARING REMOVAL
1. After the special tool has been installed as shown, tighten
the nut of the special tool until the portion “A” of the
special tool touches the bearing outer race.

FRONT AXLE - Freewheel Clutch Assembly
2. Press out the mainshaft from the bearing.

Caution
MB990560 Do not allow the mainshaft to drop.
AB" CLUTCH GEAR/BEARING REMOVAL

1. Use a press and steel plate to remove the clutch gear
Iron and bearing together.
2. Use a press to hold the supports against the bearing

inner race, and separate the clutch gear and bearing.

MB991168 "AA OIL SEAL INSTALLATION
Use the special tool to tap the oil seal until it is flush with
Clutch housing the clutch housing.
Oil seal
"BA BEARING/CLUTCH GEAR INSTALLATION

MB990799 1. Use the special tool to press-fit the bearing to the shoulder
of the clutch gear.
Bearing
Clutch gear

FRONT AXLE - Freewheel Clutch Assembly 26-33
2. Use the special tool to press-fit the bearing to the side
MB990890 of the clutch housing.
or
MB990891 Caution
Place the special tool against the outer race of the
Clutch
bearing.
housing
"CA OIL SEAL INSTALLATION

MB990938
Oil seal
MB990926
Clutch
housing
"DA SPRING PIN INSTALLATION

Tap the spring pin from the chamfered side of the shift rod
until the projection length becomes length shown in the
illustration.
Spring pin
0 - 1 mm Chamfer
"EA BEARING INSTALLATION

Press-fit the bearing to the shoulder of the mainshaft.
Mainshaft

FRONT AXLE - Differential Carrier
DIFFERENTIAL CARRIER
DISASSEMBLY
7
16 10 8
21 17
18
9
12
11
13
15 14
20
19
1 29
30
6
25
24 23 26
28 2 22
27
5 4 3
Disassembly steps
AA" D Inspection before disassembly 15. Drive pinion
1. Cover AH" 16. Oil seal
AB" 2. Differential case assembly AH" 17. Drive pinion rear bearing inner race
3. Side bearing spacer AH" 18. Drive pinion rear bearing outer race
4. Side bearing outer race AI" 19. Drive pinion front bearing outer race
AC" 5. Side bearing inner race 20. Oil seal
AD" 6. Drive gear 21. Differential carrier
AE" 7. Self-locking nut AJ" 22. Lock pin
8. Washer 23. Pinion shaft
AF" 9. Drive pinion assembly 24. Pinion gear
10. Companion flange 25. Pinion washer
11. Drive pinion spacer 26. Side gear
12. Drive pinion rear shim (for turning 27. Side gear spacer
torque adjustment) 28. Filler plug
AG" 13. Drive pinion front bearing inner race 29. Drain plug
14. Drive pinion front shim (for pinion 30. Differential case
height adjustment)

FRONT AXLE - Differential Carrier 26-35
DISASSEMBLY SERVICE POINTS
AA" INSPECTION BEFORE DISASSEMBLY
MB990909 and
MB991116 1. Remove the cover and gasket.
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.
DRIVE GEAR BACKLASH

1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 - 0.16 mm
2. If the backlash is not within the standard value, adjust
the drive gear backlash (See P.26-47).
3. After the adjustment, inspect the drive gear tooth contact.
DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.
Attachment DIFFERENTIAL GEAR BACKLASH

Wedge 1. While locking the side gear with the wedge, measure
the differential gear backlash with a dial indicator on the
pinion gear.
Standard value: 0 - 0.076 mm
Limit: 0.2 mm
Side gear Repeat the same procedure for both pinion gears.
thrust spacer
Side gear
thrust spacer

2. If the backlash exceeds the limit, adjust by using the

side gear thrust spacers.
3. If adjustment is impossible, replace the side gear and
pinion gear as a set.
DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
2. Insert the brass between the differential carrier and the

MB990939 differential case, and then rotate the companion flange
by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximate 2.5 -
3.0 N×m) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.

Standard tooth contact pattern Problem Solution
1 Narrow tooth side Tooth contact pattern resulting from

2 Drive-side tooth surface (the excessive pinion height
side applying power during
forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the 2
side applying power during 2 1 1 4
4
reverse movement)
3 3
2 1 4 Increase the thickness of the drive
The drive pinion is positioned too far
pinion rear shim, and position the
from the centre of the drive gear.
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
3 ment, position the drive gear farther
from the drive pinion.
Tooth contact pattern resulting from

insufficient pinion height
2 1 2 1
4 4
3 3
Decrease the thickness of the drive
The drive pinion is positioned too
pinion rear shim, and position the
close to the centre of the drive gear.
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.
NOTE
Checking the tooth contact pattern is the way to If, even after adjustments have been made, the
confirm that the adjustments of the pinion height correct tooth contact pattern cannot be obtained,
and backlash have been done properly. Continue it means that the drive gear and the drive pinion
to adjust the pinion height and backlash until the have become worn beyond the allowable limit.
tooth contact pattern resembles the standard Replace the gear set.
pattern.

AB" DIFFERENTIAL CASE ASSEMBLY REMOVAL

Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing outer races.
NOTE
Keep the right and left side bearings and side bearing adjusting
spacers separate, so that they do not become mixed at the
time of reassembly.
MB990810 AC" SIDE BEARING INNER RACE REMOVAL

NOTE
There are two notches provided (at the differential case side)
MB990811
for the claw part of the special tool; use the special tool at
that position.
If notches of special tools touch the end of differential case
and fail to hook with inner race, file the notches to be able
to hook with inner race.
AD" DRIVE GEAR REMOVAL

1. Make the mating marks to the differential case and the
drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
Mating marks
AE" SELF-LOCKING NUT REMOVAL
MB990850
AF" DRIVE PINION ASSEMBLY REMOVAL

MB990810
1. Make mating marks on the drive pinion and companion
flange.
Caution
The mating mark made on the companion flange must
not be on the coupling surface of the flange yoke
and the front propeller shaft.
Companion
flange 2. Pull out the drive pinion together with the special tool.

MB990339
AG" DRIVE PINION FRONT BEARING INNER RACE
REMOVAL
MB990648
MB990939 AH" OIL SEAL/DRIVE PINION REAR BEARING INNER

RACE/DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
AI" DRIVE PINION FRONT BEARING OUTER RACE

MB990939 REMOVAL
AJ" LOCK PIN REMOVAL
Punch

REASSEMBLY
20
23
18 15
17 17
18 5
20
Differential gear set Final drive gear set

15
12 13 14
59 ± 5 N×m*
1 11
4
216 ± 29 N×m
83 ± 5 N×m
10
9
8
7
5 6
2
3
28 65 ± 5 N×m 29
18 ± 3 N×m
16
23
19
20 21
17
22
30 50 ± 10 N×m 27 18 24
25 26
Reassembly steps
1. Differential carrier "FA D Differential gear backlash adjustment
"AA 2. Oil seal 17. Side gear spacer
"BA 3. Drive pinion front bearing outer race 18. Side gear
"CA 4. Drive pinion rear bearing outer race 19. Pinion washer
"DA D Pinion height adjustment 20. Pinion gear
5. Drive pinion 21. Pinion shaft
6. Drive pinion front shim (for pinion "GA 22. Lock pin
height adjustment) "HA 23. Drive gear
7. Drive pinion front bearing inner race "IA 24. Side bearing inner race
8. Drive pinion spacer 25. Side bearing outer race
"EA D Drive pinion turning torque adjustment "JA D Drive gear backlash adjustment
9. Drive pinion rear shim (for turning 26. Side bearing spacer
torque adjustment) 27. Differential case assembly
10. Drive pinion assembly 28. Cover
11. Drive pinion rear bearing inner race 29. Drain plug
12. Oil seal 30. Filler plug
13. Companion flange
14. Washer NOTE
15. Self-locking nut Specified torque with astarisks means that it is
16. Differential case covered with oil.

Lubrication, Sealing and Adhesive Points
(Apply
tocircum-
ference of
oil seal
lip)
f 2 - 3 mm
(Apply to
circumference
of oil seal lip)
Sealant: Adhesive:
3M ATD Part No. 8663 3M Stud Locking 4170 or
orequivalent equivalent

"AA OIL SEAL INSTALLATION
MB990938
MB990934
Oil seal

"BA DRIVE PINION FRONT BEARING OUTER RACE

INSTALLATION
MB990938
MB990936
MB990938 "CA DRIVE PINION REAR BEARING OUTER RACE

INSTALLATION
MB990934
"DA PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
tool.
2. Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.
MB990819
Washer
3. Tighten the nut of the special tool while measuring the

MB990819 turning torque of the drive pinion. Gradually keep
tightening the nut of the special tool until the turning torque
of the drive pinion (without oil seal) is at the standard
value.
Standard value:
(Without oil seal)
Bearing division Bearing lubrication Turning torque
New None (With 0.83 - 1.19 N×m
anti-rust agent)
NOTE
The special tool cannot be turned a full revolution, so
MB990685 turn it several times within the range of movement to
MB990326 run in the bearing, and then measure the turning torque.

Notch MB991170 4. Clean the side bearing hub.
5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
A NOTE
Always check that the notch is in the shown position
and that the special tools are touching firmly against the
side bearing hub.
6. Use a thickness gauge to measure the clearance (A)
between the special tools.
Thickness gauge MB990819
7. Remove the special tools (MB991170, MB990819).

8. Use a micrometer to measure the special tool in the places
(B, C) shown in the illustration.
MB991170 C
9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C - 1/2D - 100.0
11. Fit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
Drive MB990802
pinion race by using the special tool.
front
shim
MB990802
"EA DRIVE PINION TURNING TORQUE ADJUSTMENT

Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion spacer, the drive pinion rear shim, the
drive pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.

2. Tighten the companion flange to the specified torque by

216 ± 29 N×m using the special tool.
MB990850
3. Measure the drive pinion turning torque (without the oil

MB990326
MB990685 seal) by using the special tools.
Standard value:
(Without oil seal)
anti-rust agent)
4. If the drive pinion turning torque is not within the range

of the standard value, adjust the preload by replacing
the drive pinion rear shim (s) or the drive pinion spacer.
NOTE
When selecting the drive pinion rear shims, if the number
of shims is large, reduce the number of shims to a minimum
Identification by selecting the drive pinion spacers. Also, select the
colour drive pinion spacer from the following two types.
Drive pinion spacer height Identification colour
(mm)
56.67 White
57.01 -
NOTE
Apply gear oil around the circumference of companion
flange (and the mating surface of oil seal) when press
fitting oil seal into companion flange.
5. Remove the companion flange and drive pinion again.

Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990031 the oil seal.
or
MB990699

6. Install the drive pinion assembly and companion flange
with mating marks properly aligned, and tighten the
216 ± 29 N×m
companion flange self-locking nut to the specified torque
MB990850 by using the special tools.
7. Measure the drive pinion turning torque (with the oil seal)
MB990685 MB990326
by using the special tools.
Standard value:
(With oil seal)
anti-rust agent)
Gear oil applied 0.97 - 1.32 N×m
8. If the drive pinion turning torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal.
"FA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT

1. Assemble the side gears, side gear spacers, pinion gears
and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
Attachment
3. Insert a wedge between the side gear and the pinion
Wedge shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 - 0.076 mm
Side gear
Limit: 0.2 mm
thrust spacer 5. If the differential gear backlash exceeds the limit, adjust
Side gear thrust the backlash by installing thicker side gear spacers.
spacer

6. If adjustment is not possible, replace the side gears and

pinion gears as a set.
7. Measure the differential gear backlash once again, and
confirm that it is within the limit.
"GA LOCK PIN INSTALLATION

1. Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch at two points.
"HA DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning the special tool (tap M10
x 1.25), and then clean the threaded holes by applying
compressed air.
MB990813
3. Apply the specified adhesive to the threaded holes of

the drive gear.
Specified adhesive:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 83 ± 5 N×m
"IA SIDE BEARING INNER RACE INSTALLATION

Piece of
Piece of metal metal
MB990802
MB990802

"JA DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE
Select side bearing spacers with the same thickness for
both the drive pinion side and the drive gear side.
2. Push the differential case assembly to one side, and

measure the clearance between the gear carrier and the
side bearing adjusting spacer with a thickness gauge.
3. Measure the thickness of the side bearing adjusting

spacers on one side, select two pairs of spacers which
correspond to that thickness plus one half of the clearance
plus 0.05 mm, and then install one pair each to the drive
pinion side and the drive gear side.
Clearance/2 ± 0.05 mm
= Thickness of the spacer on one
side
4. Install the side bearing adjusting spacers and differential

case assembly, as shown in the illustration, to the gear
carrier.
5. Tap the side bearing adjusting spacers with the special

tool to fit them to the side bearing outer race.
MB990939

6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
7. With the drive pinion locked in place, measure the drive

gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11 - 0.16 mm
If backlash is too small 8. Change the side bearing adjusting spacers as illustrated,
Thinner Thicker
and then adjust the drive gear backlash between the
spacer spacer drive gear and the drive pinion.
NOTE
When increasing the number of side bearing adjusting
spacers, use the same number for each, and as few
as possible.
Thicker Thinner
spacer spacer
If backlash is too large
9. Check the drive gear and drive pinion for tooth contact. If
poor contact is evident, make adjustment. (Refer to P.
26-39.)
10. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
11. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12. If adjustment is not possible, replace the differential case
or replace the drive gear and drive pinion as a set.

FRONT AXLE - Solenoid Valve, Vacuum Pipe, Vacuum Tank 26-49
SOLENOID VALVE, VACUUM PIPE, VACUUM TANK
7
11
<6G7>
2 6
12
9.0 ± 1.0 N×m
3 1 12 ± 2 N×m
8
10
9 10 7
10 9
<4M4>
2 6 5
9.0 ± 1.0 N×m 1
3
8
12 ± 2 N×m 4
10 12 ± 2 N×m
14
<4D5> 11
7
1 18
10
2 6 19
9.0 ± 1.0 N×m
15 17
13
3 12 ± 2 N×m
8 1
10 16
9
10 21
17 ± 3 N×m
10
20
Solenoid valve assembly, Vacuum 12. Vacuum pipe assembly (6G7)

tank assembly removal steps 13. Vacuum pipe assembly (4D5)
"AA 1. Vacuum hose (white stripe) 14. Vacuum hose
"AA 2. Vacuum hose (blue stripe) 15. Vacuum terminal
"AA 3. Vacuum hose (yellow stripe) 16. Breather pipe
4. Vacuum pipe assembly 17. Vacuum tank assembly
5. Vacuum hose assembly Vacuum actuator assembly removal
6. Vacuum pipe assembly steps
7. Breather cap "AA 18. Vacuum hose (blue stripe) connection
8. Solenoid valve assembly "AA 19. Vacuum hose (yellow stripe) connec-
"BA 9. Check valve tion
10. Vacuum hose AA" 20. Pin
11. Vacuum hose 21. Vacuum actuator assembly

FRONT AXLE - Solenoid Valve, Vacuum Pipe, Vacuum Tank
Dust cover Collar REMOVAL SERVICE POINT

AA" PIN REMOVAL
1. Remove one side of dust cover mounting part on vacuum
actuator assembly.
2. Match collar of pin hole with that of another pin hole
to remove a pin with a punch.
Pin

"AA VACUUM HOSE INSTALLATION
Match collar of each pipe of vacuum hose and solenoid valve
and vacum pipe and assemble them.
"BA CHECK VALVE INSTALLATION

Install so that air direction arrow points to the vacuum side.
Vacuum side Solenoid

valve side
Air direction arrow

FRONT AXLE - Front Differential Mount 26-51
FRONT DIFFERENTIAL MOUNT
Caution
Pre-removal and Post-installation

D Under Cover and Skid Plate Removal and Installation D Drive Shaft Removal and Installation
D Gear Oil Draining and Refill (Refer to P.26-11.) (Refer to P.26-16.)
D Inner Shaft Removal and Installation
(Refer to P.26-24.)
59 ± 9 N×m
69 ± 9 N×m*
128 ± 9 N×m
1 4
23 ± 4 N×m
5
69 ± 9 N×m*
128 ± 9 N×m
89 ± 9 N×m
89 ± 9 N×m
69 ± 9 N×m*
2
Differential mount bracket Differential mount bracket

assembly(L.H./R.H.) removal steps assembly (rear) removal steps
D Drive shaft assembly removal (refer 3. No.2 crossmember
to P.26-16) 4. Differential support bracket
"AA 1. Differential mount bracket assembly D Differential carrier & housing assembly
(R.H.) "AA 5. Differential mount bracket assembly
"AA 2. Differential mount bracket assembly (rear)
(L.H.)

FRONT AXLE - Front Differential Mount

D A "AA DIFFERENTIAL MOUNT BRACKET ASSEMBLY
INSTALLATION
Tighten the bolts shown in the diagram with the specified
torque in the order of A, B, C, D or A, C, B, D.
C
B
MD999547
DIFFERENTIAL MOUNTING INSULATOR
REPLACEMENT
DIFFERENTIAL MOUNTING BRACKET
<L.H., R.H.-FRONT, REAR>
1. Remove insulator with special tools.
MB990947 L.H., R.H. - Front 2. By using special tools along with a hydraulic press, press
MB990847 fit each insulator to adjust until the hollow part faces as
shown and the difference between dimensions A, B should
MB990981 be within 0.7 mm.
A
Rear
DIFFERENTIAL MOUNT BRACKET <R.H.-REAR>

1. Remove the insulator with the special tool.
MD999570
MB991318 2. By using special tools along with a hydraulic press, press

MB991183
fit each insulator to adjust until the hollow part faces as
shown and the difference between dimensions C, D should
MB990843
be within 0.7 mm.
R.H. - Rear
C

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 FRONT HUB AND KNUCKLE ASSEMBLY . 13

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INNER SHAFT, HOUSING TUBE . . . . . . . . . . 24

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FREEWHEEL CLUTCH ASSEMBLY,

Purchased from www.WorkshopManuals.co.uk

Differential gear type Straight bevel gear

Number Drive gear 49*1, 47*2, 41*3, 43*4

Purchased from www.WorkshopManuals.co.uk

Bearing (outside diameter ´ inside Side 80.0 ´ 45.2

Rear 72.2 ´ 36.5

Drive shaft (R.H.) Knuckle

Drive shaft (L.H.)

(R.H.) Plastic ABS rotor

Purchased from www.WorkshopManuals.co.uk

Wheel bearing axis backlash mm - 0

Front axle total backlash mm - 11

Solenoid valve resistance W 36 - 46 -

Hub rotation starting torque N×m - 1.75

Setting of D.O.J. boot length mm 80 ± 5 -

When the B.J. boot band 3.2 -

Crimped width of the B.J. boot band mm 2.4 - 2.8 -

Crimped height of B. J. boot band (big) mm - 9.5

Final drive gear backlash mm 0.11 - 0.16 -

Drive gear runout mm - 0.05

Differential gear backlash mm 0 - 0.076 0.2

With oil seal Companion flange (oil seal contact -

Companion flange (oil seal contact -

D.O.J. boot grease Repair kit grease 4M41-M/T:135 ± 10 g

U.J.boot grease Repair kit grease 4M41-M/T:180 ± 10 g

Purchased from www.WorkshopManuals.co.uk

Freewheel clutch assembly

MB990955 Oil seal installer D Press-fitting of housing tube dust seal

MB991113 or Steering linkage D Disconnection of ball joint

MB990767 Front hub & flange Hub fixiation

MB990998 Front hub remover Inspection of hub rotation starting torque

MB991561 Boot band clipping Resin boot band installation

Purchased from www.WorkshopManuals.co.uk

Tool Number Name Use

MB990560 Bearing remover D Removal and press-fitting of inner shaft

MB990909 Working base Support of front differential carrier assembly

MB991116 Adapter Support of front differential carrier assembly

MB990810 Side bearing puller D Removal of side bearing inner race

MB990811 Differential side

MB990850 End yoke holder Removal and installation of companion flange

MB990648 Bearing remover

Purchased from www.WorkshopManuals.co.uk

Tool Number Name Use

MB990685 Torque wrench D Inspection of hub rotation starting torque

MB990326 Preload socket

MB990802 Bearing installer D Press-fitting of drive pinion front bearing

MB990813 Tap Removal of adhesive

MB990799 Ball joint remover Installation of freewheel clutch bearing

MB991168 Differential oil seal Installation of freewheel clutch oil seal

Purchased from www.WorkshopManuals.co.uk

Tool Number Name Use

MD999547 Oil seal installer Removal of front differential mount insulator

MD999570 Crankshaft front oil Removal of front differential mount insulator

Number Drive gear 491, 472, 413, 434