Workshop Manual: No - LGPRO-WE-1111

2011MY
2011MY
WORKSHOP MANUAL PROPELLER SHAFT AND AXLE

WORKSHOP MANUAL
PROPELLER SHAFT AND AXLE
No.LGPRO-WE-1111
LGPRO-WE-1111_Maegaki 11.7.25 2:07 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A GENERAL INFORMATION
0B MAINTENANCE AND LUBRICATION
1 HEATING AND AIR CONDITIONING 00 SERVICE INFORMATION
1A HEATING AND VENTILATION
2 FRAME AND CAB 00 SERVICE INFORMATION
2 CAB AND FRAME
3 STEERING, SUSPENSION, WHEELS 00 SERVICE INFORMATION
AND TIRES 3A FRONT END ALIGNMENT
3B1 POWER STEERING
3B2 MANUAL STEERING
3B3 STEERING LINKAGE
3B4 STEERING COLUMN
3C FRONT SUSPENSION
3D REAR SUSPENSION
3E WHEELS AND TIRES
4 PROPELLER SHAFT AND AXLE 00 SERVICE INFORMATION
4A PROPELLER SHAFT
4B REAR AXLE
4C FRONT AXLE
5 BRAKES 00 SERVICE INFORMATION
5A HYDRAULIC BRAKES
5C PARKING BRAKES
5E EXHAUST BRAKE
6 ENGINE 00 SERVICE INFORMATION
6A GENERAL ENGINE MECHANICAL
6A1 4JB1/4JB1-TC-ENGINE
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM
6F ENGINE EXHAUST
6G TURBOCHARGER
7 MANUAL TRANSMISSION AND CLUTCH 00 SERVICE INFORMATION
7B MANUAL TRANSMISSION
7C CLUTCH
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(LEFT HAND DRIVE MODEL)
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(RIGHT HAND DRIVE MODEL)
9 SEAT BELT, SRS AIRBAG 9A SEAT BELT
LGPRO-WE-1111_Maegaki 11.7.25 2:07 PM ページ 2
LGPRO-WE-1111.book 1 ページ２０１１年７月２７日　水曜日　午前９時１９分
SERVICE INFORMATION 00-1

SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING .......................................... 00-2
Propeller Shaft................................................... 00-2
Rear Axle........................................................... 00-2
MAIN DATA AND SPECIFICATIONS ................... 00-3
SERVICE STANDARD.......................................... 00-4
SERVICING .......................................................... 00-6
FIXING TORQUE.................................................. 00-7
Propeller Shaft................................................... 00-7
Front Hub and Brake Drum (4 × 2 Model) ......... 00-8
Front Axle, Knuckle and King Pin (4 × 2 Model) 00-9
Rear Hub, Brake Drum and Axle Shaft
(Single Tire Model; Full Floating Type)............ 00-10
Rear Hub, Brake Drum and Axle Shaft
(Dual Tire, Models; Full Floating Type) ........... 00-11
Rear Differential Assembly (244 mm).............. 00-12
Rear Differential Assembly (292 mm).............. 00-13
SPECIAL TOOLS................................................ 00-14
Propeller Shaft................................................. 00-14
Rear Axle......................................................... 00-14
Front Axle ........................................................ 00-17
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Propeller Shaft
PROBLEM POSSIBLE CAUSE CORRECTION

Noises from Propeller 1. Worn spline yoke. 1. Replace the spline yoke.
Shaft 2. Worn or stuck spider bearing. 2. Replace the center bearing.
3. Worn center bearing. 3. Replace the center bearing.
Vibration from Propel- 1. Incorrect shaft run-out. 1. Replace the propeller shaft.
ler Shaft 2. Out of shaft balance. 2. Adjust the shaft balance.
3. Stuck spline yoke. 3. Replace the spline yoke.
Rear Axle
PROBLEM POSSIBLE CAUSE CORRECTION

Oil Leak at Front Axle 1. Worn or defective oil seal. 1. Replace the oil seal.
or Rear Axle
2. Axle housing cracked. 2. Repair or replace.
Oil Leak at Pinion Shaft 1. Too much gear oil. 1. Correct the oil level.
2. Oil seal worn or defective. 2. Replace the oil seal.
3. Pinion flange loose or damaged. 3. Tighten or replace.
Noises in Rear Axle 1. Insufficient gear oil. 1. Replenish the gear oil.
2. Wrong or poor grade gear oil. 2. Replace the gear oil.
3. Drive pinion to ring gear backlash incor- 3. Adjust the backlash.
rect.
4. Worn or chipped ring gear, pinion gear 4. Replace the ring gear, pinion gear or
or side gear. side gear
5. Pinion shaft bearing worn. 5. Replace the pinion shaft bearing.
6. Wheel bearing worn. 6. Replace the wheel bearing.
7. Differential bearing loose or worn. 7. Tighten or replace.
MAIN DATA AND SPECIFICATIONS

Propeller Shaft
Bearing retention method Inside snap ring

Spider length mm (in) 69 (2.72)
Spider outside dia. mm (in) 18.46 (0.73)
Tube-outside dia.
diameter × thickness mm (in) 68.9 × 2.0 (2.71 × 0.08)
Flange bolt size M10
Flange bolt P.C.D. mm (in) 85 (3.35)
Rear Axle
Single Tire
Rear axle type Banjo full floating
Gear type Hypoid
Number of differential pinion 4
Ring gear pitch diameter mm (in) 244 (9.6)
Amount of hub grease (each wheel) g (oz) 280 (9.9)
Oil capacity lit (US qt/Imp qt) 2.7 (2.9/2.4)
Dual Tire
Rear axle type Banjo full floating
Gear type Hypoid
Number of differential pinion 4
Ring gear pitch diameter mm (in) 292 (11.5)
Amount of hub grease (each wheel) g (oz) 285 (10.1)
Oil capacity lit (US qt/Imp qt) 3.0 (3.2/2.6)
SERVICE STANDARD
Items Service Standard Limit

PROPELLER SHAFT
Outside Diameter of Spi- mm (in) 18.46 (0.73) 18.36 (0.72)
der Pin
Propeller Shaft Run-Out mm (in) 0.5 (0.02) or less 1.0 (0.039)
Play between the Sleeve mm (in) 0.1 (0.0039) 0.3 (0.012)
Yoke and the Propeller
Shaft Spline
Play in the Universal Joint mm (in) 0.1 (0.0039) —
REAR AXLE SHAFT
Axle Shaft Run-Out mm (in) — 1.0 (0.039)
Axle Shaft Flange Run- mm (in) — 0.15 (0.006)
Out
REAR DIFFERENTIAL 244 mm 292 mm 244 mm 292 mm
Pinion Bearing Preload
New Bearing N (kg/lb) 16-29 (1.6-3.0/ 13-25 (1.3-2.6/ —
3.5-6.6) 2.9-5.7)
Used Bearing N (kg/lb) 8-14.5 (0.8-1.5/ 6.5-12.5 (0.65- —
1.8-3.3) 1.3/1.5-2.9)
Pinion Bearing Starting Torque
New Bearing N⋅m (kg⋅cm/ 0.69-1.27 (7- 0.98-1.96 (10- —
lb⋅in) 13/6.1-11.3) 20/8.7-17.4)
Used Bearing N⋅m (kg⋅cm/ 0.35-0.64 (3.5- 0.49-0.98 (5- —
lb⋅in) 6.5/3.1-5.7) 10/4.3-8.7)
Ring Gear Backlash mm (in) 0.15-0.20 0.18-0.23 —
(0.006-0.008) (0.007-0.009)
Ring Gear Run-Out mm (in) 0.07 (0.003) 0.07 (0.003) 0.2 (0.008) 0.2 (0.008)
Clearance between the mm (in) 0.07-0.13 0.07-0.13 0.2 (0.008) 0.2 (0.008)
Differential Pinion and the (0.003-0.005) (0.003-0.005)
Spider
Clearance between the mm (in) 0.05-0.11 0.05-0.11 0.25 (0.01) 0.25 (0.01)
Side Gear and the Differ- (0.002-0.004) (0.002-0.004)
ential Cage
Play in Splines between mm (in) 0.02-0.12 0.08-0.15 0.25 (0.01) 0.3 (0.012)
the Side Gear and the (0.0008-0.005) (0.003-0.006)
Axle Shaft
Clearance between the mm (in) 0.13-0.18 0.21-0.28 —
back face of the Side (0.005-0.007) (0.008-0.011)
Gear and the Differential
Cage
REAR HUB
Rear Hub Bearing Pre- N (kg/lb) 42-52 (4.3-5.3/ 38-48.0 (3.9- —
load 9.5-11.7) 4.9/8.6-10.8)
Items Service Standard Limit

FRONT HUB
Front Hub Bearing Pre-load
New Bearing and New Oil N (kg/lb) Rear dual tire: —
Seal 9.8-34.3 (1.0-3.5/2.2-7.7)
Rear single tire:
11.8-36.3 (1.2-3.7/2.7-8.2)
Reused Bearing and New N (kg/lb) 4.9-19.6 (0.5-2.0/1.1-4.4) —
Oil Seal
SERVICING
Change The Rear Differential Gear Oil
1. Remove the drain plug (1) and filler plug (2) and,
drain the gear oil.
N4A0001E
2. Tighten the drain plug to specified torque.
Tighten:
Drain plug to 78 N⋅m (8.0 kg⋅m / 57 lb⋅ft)
3. Fill the rear axle case with hypoid gear lubricant, to
just below the filler hole.
Rear Axle Case Oil Capacity L (US qt/Imp qt)

244 mm Diff. 2.7 (2.9/2.4)
292 mm Diff. 3.0 (3.2/2.6)
Notice:
Limited Slip Differential (LSD)-Friction Type Model:
Use GL-5 LSD gear lubricant together with LSD Lubri-
cant Additive (ISUZU part No. 8-01052-358-0, GM part
No. #1052358) or equivalent.
Quantity
LSD Lubricant additive, 112 g (4 oz)
4. Tighten the filler plug to specified torque.
Tighten:
Filler plug to 78 N⋅m (8.0 kg⋅m / 57 lb⋅ft)
FIXING TORQUE
Propeller Shaft
Rear propeller shaft
LNWB40LF000401

Front Hub and Brake Drum (4 × 2 Model)
LNWB40LF000501
Legend
A. Rear single tire B. Rear dual tire

Front Axle, Knuckle and King Pin (4 × 2 Model)
LNWB40LF000601

Rear Hub, Brake Drum and Axle Shaft (Single Tire Model; Full Floating Type)
LNWB40LF001001

Rear Hub, Brake Drum and Axle Shaft (Dual Tire, Models; Full Floating Type)
LNWB40LF000901

Rear Differential Assembly (244 mm)
LNWB40LF000701
Legend
A. Apply stud lock C. Apply oil
B. Apply gear oil to bolt thread

Rear Differential Assembly (292 mm)
LNWB40LF000801
Legend
A. Apply stud lock B. Apply gear oil to bolt thread
SPECIAL TOOLS
Propeller Shaft Tool Number /
Illustration
Description / Remarks
Tool Number /
Illustration
9-8522-1188-0 / Rear
hub bearing nut wrench
9-8529-2101-0 / Drive {For 70mm (2.8 in.)}
pinion flange bracket
9852211880
9852921010
Rear Axle 5-8840-2830-0 / Ring

gear bolt wrench
Tool Number /
Illustration
5884028300
5-8840-2027-0 / Univer-
sal puller 9-8529-2101-0 / Drive
pinion flange yoke
bracket
5884020270
9852921010
9-8521-0116-0 / Rear
hub remover 9-8511-1507-0 (J-29042)
/ Drive pinion flange
holding wrench
9852101160
9851115070
9-8521-2501-0 / Rear
hub remover 5-8840-0015-0 (J-22912-
01) / Drive pinion inner
bearing remover
9852125010
5884000150
5-8840-2864-0 / Step
plate adapter set 9-8522-1196-0 / Drive
pinion inner bearing
outer race installer
5884028640
9852211960
Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2046-0 / Drive
pinion inner bearing 9-8521-0061-0 / Differen-
outer race installer (For tial side bearing remover
292mm)
5884020460 9852100610
9-8522-1197-0 / Drive 5-8840-2031-0 / Differen-

pinion outer bearing tial side bearing remover
outer race installer adaptor
9852211970 5884020310
9-8522-1613-0 / Drive
9-8521-2701-0 / Differen-
pinion outer bearing
tial side bearing remover
outer race installer (For
adaptor
292mm)
9852216130 9852127010
9-8522-0018-0 / Drive
5-8840-2050-0 / Differen-
tial side bearing installer
inner race installer
9852200180 5884020500
9-8522-1615-0 / Drive
9-8522-1614-0 / Differen-
tial side bearing installer
inner race installer
9852216150 9852216140
5-8840-2047-0 / Drive 9-8522-1603-0 / Dummy

pinion oil seal installer pinion shaft
5884020470 9852216030
9-8522-1607-0 / Drive 9-8522-1624-0 / Dummy

pinion oil seal installer nut
9852216070 9852216240
Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks
9-8522-1609-0 / Rear
9-8522-1138-0 / Dummy
hub inner bearing outer
shaft
race installer
9852211380 9852216090
9-8522-1195-0 / Rear
9-8522-1137-0 / Dummy
hub outer bearing outer
bearing (2 pcs required)
race installer
9852211370 9852211950
9-8522-1610-0 / Rear
5-8840-2293-0 (J-39209)
hub outer bearing outer
/ Punch: End nut lock
race installer
5884022930 9852216100
9-8522-1606-0 / Rear
hub bearing nut wrench 9-8522-1608-0 / Grip
{For 74mm (2.9 in.)}
9852216060 9852216080
9-8521-0092-0 / Rear
hub inner bearing 9-8522-1148-0 / Grip
remover
9852100920 9852211480
9-8522-1607-0 / Rear
5-8840-0084-0 (J-2619-
hub oil seal installer (For
01) / Sliding hammer
292mm)
9852216070 5884000840
9-8522-1194-0 / Rear
hub inner bearing outer
race installer
9852211940

Front Axle Tool Number /
Illustration
Tool Number /
Illustration
5-8840-2022-0 / King pin

remover
5-8840-2015-0 / Front
hub nut wrench
5884020220
5884020150
9-8521-0187-0 / Front
hub remover (6 studs)
5-8840-2016-0 / Front
hub remover (5 studs)
9852101870
5884020160
5-8840-2920-0 / Grip
5-8840-2017-0 / Tie rod
end remover (driver side)
5884029200
5884020170
5-8840-2922-0 / Bushing
repair tool (φ30)
5-8840-2018-0 / Tie rod
end remover (assist side)
5884029220
5884020180
5-8840-2863-0 / Driver
5-8840-2019-0 / Tie rod tool set
arm & knuckle arm
remover
5884028630
5884020190
5-8840-2020-0 / King pin

key bolt remover
5884020200
MEMO
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PROPELLER SHAFT 4A-1

SECTION 4A
PROPELLER SHAFT
Contents
GENERAL DESCRIPTION ................................... 4A-2
Rear Drive Propeller Shaft................................. 4A-2
ON-VEHICLE SERVICE ....................................... 4A-3
Rear Drive Propeller Shaft
(Long Wheel Base Models) ............................... 4A-3
(Short Wheel Base Models)............................... 4A-4
UNIT REPAIR ....................................................... 4A-7
Universal Joint ................................................... 4A-7
4A-2 PROPELLER SHAFT
GENERAL DESCRIPTION
Short Wheel Base Models
N4A0232E
Long Wheel Base Models
N4A0017E
ON-VEHICLE SERVICE
Rear Drive Propeller Shaft (Long Wheel Base Models)
N4A0019E
Legend
1. Differential side nut 4. Transmission side nut
2. Center bearing side nut 5. Center bearing bracket
3. 2nd propeller shaft 6. 1st propeller shaft

Rear Drive Propeller Shaft (Short Wheel Base Models)
N4A0414E
Legend
1. Differential side nut 3. Transmission side nut
2. Propeller shaft assembly

Removal
Preparation:
• Since the propeller shaft assembly is carefully bal-
anced, a setting mark (1) should be applied to the
joints (1st propeller shaft and parking brake drum,
1st propeller shaft and 2nd propeller shaft, 2nd pro-
peller shaft and final drive flange), before removal
in to original position.
N4A0021E
4. 2nd Propeller Shaft
Tighten:
Center bearing side nut to
• M10: 63 N⋅m (6.4 kg⋅m / 46 lb⋅ft)
• M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
N4A0020E
1. Differential Side Nut

2. Center Bearing Side Nut
3. 2nd Propeller Shaft
4. Transmission Side Nut
5. Center Bearing Bracket
6. 1st Propeller Shaft
Installation
1. 1st Propeller Shaft
2. Center Bearing Bracket
3. Transmission Side Nut
Tighten:
Transmission side nut to
• M10: 63 N⋅m (6.4 kg⋅m / 46 lb⋅ft) N4A0022E
• M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)


5. Center Bearing Side Nut
Tighten:
Center bearing bracket bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
6. Differential Side Nut
Tighten:
Differential side nut to
• M10: 63 N⋅m (6.4 kg⋅m / 46 lb⋅ft)
• M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
N4A0023E
UNIT REPAIR
Universal Joint
LNWB4AMF000101
Legend
A. Inside Type 1. Grease fitting
QKR 55 2. Snap ring
3. Needle roller bearing
4. Spider
5. Flange yoke

Disassembly
Preparation:
Since the propeller shaft assembly is carefully balanced,
a setting mark (1) should be applied to the joints, before
disassembly.
N4A0028E
4. Spider
5. Flange Yoke
Inspection and Repair

Make necessary correction or parts replacement if wear,
damage or any other abnormal conditions are found
through inspection.
Visual Check
Inspect following parts for wear, damage or other abnor-
mal conditions.
Notice:
When any part of the journal assembly requires replace-
ment, be sure to replace the entire assembly.
N4A0027E
• Spider
1. Grease Fitting • Needle roller bearing
2. Snap Ring • Yoke
3. Needle Roller Bearing • Flange
Tap out the bearing by applying a shock to the shoulder
of the yoke, using a copper hammer. • Center bearing
Remove the needle roller bearings remaining in position • Cushioning rubber
by tapping lightly on the spider. • Bracket
Remove the remaining bearings in the similar manner. Outside Diameter of Spider Pins
mm (in)
Standard Limit
18.46 (0.73) 18.36 (0.72)
N4A0030E N4A0032E
Propeller Shaft Run-Out Lubrication

Support the propeller shaft at its ends and check for run- Universal Joints
out by holding the probe of a dial indicator agains the Universal joints are drilled and provided with a lubrica-
center part of the shaft. tion fitting through which the lubricant travels to all four
If the amount of run-out it beyond the standard value for bearing caps, direct to the needle bearing.
assembly, correct with a bench press or replace with a Needle bearings are protected against lubricant leakage
new one. and the entrance of foreign matter by seals.
Standard: 0.5 mm (0.02 in) or less 1) Lubricate with a chassis lubricant.
Limit: 1.0 mm (0.039 in) 2) When greasing the joint, a flow of grease at all
four trunnion seals must be visible to ensure lu-
brication of the U-joint. If grease does not ap-
pear at all four trunnion seals, the universal
joint should be rotated while applying lubricant
under pressure to relieve any air lock inside the
joint which would prevent lubricant from reach-
ing the bearing area.
N4A0031E
Play in Splines in Normal Direction of Rotation

Check the amount of play (1) in the sleeve yoke (2) and
propeller shaft (3) splines in direction of rotation using a
pointed feeler gauge.
Standard: 0.1 mm (0.0039 in)
Limit: 0.3 mm (0.012 in)
N4A0036E
Sliding Spline Sections

Apply grease gun pressure to the lubrication fitting until
lubricant appears at the pressure relief hole (1) as
shown in the figure. Now cover the pressure relief hole
with your finger and continue to apply pressure until

grease appears at the sleeve yoke seal as shown in the
figure. Notice:
Excessive greasing could make the bearing difficult to
install or make accurate data unobtainable for the selec-
tion of the right snap ring.
Assemble the spider to the flange yoke. Using the
spider as a guide, install the needle roller bearing
into the hole in the arm of the flange yoke by press
or tapping with a soft-faced hammer.
Caution:
• The needle roller bearing cannot be installed
smoothly if is set at an incorrect angle with the
flange.
• Excessive hammering will damage the needle roll-
er bearing.
N4A0037E
Reassembly
1. Flange Yoke
The flange yoke at end of the propeller shaft should
be in alignment with the spline yoke as illustrated.
The direction of the flange yoke at each end of the
propeller shafts (setting mark) are in alignment.
N4A0039E
Eliminate the clearance between snap ring and bearing

by striking the yoke with a hammer.
N4A0416E
Legend
1. Correct
2. Incorrect
2. Spider
3. Needle Roller Bearing
Apply MoS2 grease to lip of the oil seal and needle
roller bearing. N4A0040E
Align setting marks and join the yokes.


Install the grease fitting at an angle of approximately 40
degrees to the spider. The parts should be so installed
that all grease fittings are pointed upward.
N4A0041E
4. Snap Ring
Discard used snap ring and install new one.
N4A0043E
When the bearing is fitted into position, select and install
the snap ring of suitable thickness so that the end play
of the spider pin is held within 0.1 mm (0.0039 in).
Thickness of Snap Ring Available mm (in)

Snap ring thickness Identification color
1.5 (0.059) Blue
1.53 (0.060) White
1.59 (0.063) Yellow
1.62 (0.064) Green
1.68 (0.066) Not colored
Notice:
Be sure to use snap rings of the same thickness on both
sides.
N4A0042E
5. Grease Fitting
N4A0048E
Legend
1. Lock nut 4. Coupling driver
2. Lock washer 5. Center bearing assembly
3. Washer assembly
Disassembly
1. Lock Nut
2. Lock Washer
3. Washer Assembly
4. Coupling Driver
Apply alignment marks on the flange and tube as-
sembly.

5. Center Bearing Assembly Reassembly
Notice: 1. Center Bearing Assembly
The center bearing can not be disassembled. Install the center bearing assembly so that the
grease fitting side is faced toward the coupling driv-
er side.
When pressing in the center bearing, the bearing
should be pressed through a coupling driver to
avoid bearing damage.
N4A0049E
Legend
1. Lock nut
2. Lock washer N4A0046E
3. Washer assembling
4. Coupling driver
Legend
5. Center bearing assembly
1. Propeller shaft
2. Oil seal
3. Coupling driver
4. Center bearing
5. Rubber
6. Lock nut
Apply bearing grease to lip of the oil seal and center

bearing.
Amount of grease required, 20 — 25 g (0.7 — 0.9 oz)
2. Coupling Driver
Be sure to align the setting marks described before
disassembling.
3. Washer Assembly
4. Lock Washer
Discard used lock washer and install new one.

5. Lock Nut
Set a special tool into a vice then attach the propel-
ler shaft assembly.
Flange bracket: 9-8529-2101-0
Tighten:
Lock nut to 118 N⋅m (12 kg⋅m / 87 lb⋅ft)
N4A0047E
After tightening the lock nut to specified torque, bend a

part of the lock washer to the nut side.
N4A0050E
Legend
1. Lock nut
2. Lock washer
3. Coupling driver
4. Washer assembly
REAR AXLE 4B-1

SECTION 4B
REAR AXLE
Contents
GENERAL DESCRIPTION ................................... 4B-2
Hub and Drum ................................................... 4B-2
Differential Carrier Assembly............................. 4B-4
ON-VEHICLE SERVICE ....................................... 4B-6
Rear Hub and Brake Drum
(Single Tire Model; Full Floating Type).............. 4B-6
Rear Hub and Brake Drum
(Dual Tire Models; Full Floating Type) ............ 4B-11
Rear Axle Assembly ........................................ 4B-21
Differential Assembly
(Single Tire and Dual
Tire Models; Full Floating Type) ...................... 4B-24
UNIT REPAIR ..................................................... 4B-26
244 mm Rear Differential................................. 4B-26
292 mm Rear Differential................................. 4B-38
4B-2 REAR AXLE
GENERAL DESCRIPTION
Hub and Drum
Single Tire (Full Floating Type)
N4A0052E
REAR AXLE 4B-3

Dual Tire
N4A0053E
4B-4 REAR AXLE

Differential Carrier Assembly
244 mm (9.6 in) size
N4A0054E
REAR AXLE 4B-5

292 mm (11.5 in) size
N4A0055E
4B-6 REAR AXLE
ON-VEHICLE SERVICE
Rear Hub and Brake Drum (Single Tire Model; Full Floating Type)
N4A0076E
Legend
1. Wheel and tire 7. Hub assembly
2. Brake drum 8. Outer bearing
3. Axle shaft 9. Inner oil seal
4. Outer oil seal 10. Inner bearing
5. Lock washer 11. Hub
6. Bearing lock nut
REAR AXLE 4B-7

Removal
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
2. Brake Drum
3. Axle Shaft
Remove the collar by tapping on the upper face of
the axle shaft with a hammer, then remove the axle
shaft.
N4A0079E
7. Hub Assembly
Remover: 9-8521-0116-0
If the hub inner bearing and the hub inner oil seal
remain on the axle tube, remove the hub inner
bearing using a special tool.
Remover: 9-8521-0092-0
N4A0077E
4. Outer Oil Seal

Take out the hub outer oil seal using a screwdriver.
N4A0080E
8. Outer Bearing
9. Inner Oil Seal
10. Inner Bearing
Drive out the hub inner bearing outer race together
N4A0078E with the hub inner bearing inner race and the hub
inner oil seal by using a proper bar through two
5. Lock Washer
notches.
6. Bearing Lock Nut
Wrench: 9-8522-1188-0
4B-8 REAR AXLE
N4A0081E N4A0083E
11. Hub 3. Inner Oil Seal

Installer: 9-8522-1607-0
Installation Grip: 9-8522-1608-0
1. Hub
2. Inner Bearing
Install the bearing outer race.
Installer: 9-8522-1194-0
Grip: 9-8522-1148-0
If removed outer bearing outer race, install the
bearing outer race.
Installer: 9-8522-1195-0
Grip: 9-8522-1148-0
N4A0082E
4. Outer Bearing
5. Hub Assembly
6. Bearing Lock Nut
Install the bearing lock nut, and temporarily tighten
it with extra-tight force.
Caution:
Set the bearing lock nut so that its surface with the slit is
N4A0082E facing outside and install it.
Apply specified grease into the bearing and grease

well in the hub.
Amount of grease: 280 g (9.8 oz)
REAR AXLE 4B-9

4) Put a string around the wheel pins, hang a
spring balancer on the string end, and gently
pull it in a tangent direction. Make adjustments
by tightening the bearing lock nut until the pre-
load reaches the specified value.
Caution:
If the pre-load is unstable, rotate the hub several times,
stop the rotation completely and carry out measurement
again. If it still does not become stable, re-perform the
procedures from procedure “1)”.
Hub bearing pre-load
42 - 52 N (4.3 - 5.3 kg / 9.5 - 11.7 lb)
LNW23CSH016301
7. Adjust the hub bearing pre-load.

1) Turn the hub to the left and right several times
to stabilize the bearing.
2) Using the wrench: 9-8522-1188-0, tighten the
bearing lock nut by turning the hub by hand, un-
til the hub does not turn.
Caution:
Make sure to turn the hub when tightening as it will pre-
vent the bearing from becoming damaged. Also, make
sure to gently tighten the bearing lock nut, and never to
use an air tool for tightening.
LNW93CSH002401
5) After adjusting the rotation starting force, turn

the hub to the left and right several times to re-
check the pre-load.
6) With the rotation starting force adjusted, align
the closest marking line of the bearing lock nut
slit to the center of the lock groove in the axle
case threaded portion.
Caution:
If the slit does not align, turn the bearing lock nut in the
tightening direction to align it.
9-8522-1188-0
LNW64BSH000101
3) Loosen the bearing lock nut, and confirm that

the hub rotates smoothly.
If the hub does not turn at this time, use the re-
mover: 9-8521-0116-0 to pull back the hub.
Caution:
Make sure to fully loosen the bearing lock nut. If loosen-
ing is insufficient, a correct check will not be possible.
4B-10 REAR AXLE

9. Outer Oil Seal
10. Axle Shaft
Tighten:
Axle shaft nut to 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
11. Brake Drum
12. Wheel and Tire
Tighten:
Wheel nut to 170 N⋅m (17 kg⋅m / 123 lb⋅ft)
LNW23CSH016501
8. Lock Washer
Securely install the lock washer claw in the lock
groove of the axle case threaded portion, and use
the lock bolt to tighten and fasten the bearing lock
nut and lock washer.
Caution:
There are 48 equally-distanced slits on the bearing lock
nut to make the lock secure and easier. By aligning the
marking lines on the bearing lock nut to the center of the
axle case threaded portion grooves, the bearing nut lock
bolt installation screw holes and either of the bolt holes
of the lock washers match (symmetrically in 2 positions).
Therefore, use the bolt to tighten the positions to secure-
ly lock the bearing lock nut.
2 1
LNW23CSH016601
Legend
1. Lock Washer
2. Lock Bolt
REAR AXLE 4B-11

Rear Hub and Brake Drum (Dual Tire Models; Full Floating Type)
N4A0421E
Legend
1. Wheel and tire 8. Inner oil seal
2. Axle shaft 9. Inner bearing
3. Outer oil seal 10. Inner bearing outer race
4. Lock washer 11. Outer bearing outer race
5. Bearing lock nut 12. Wheel pin
6. Outer bearing 13. Hub
7. Hub and brake drum 14. Brake drum
4B-12 REAR AXLE

Removal
Preparation:
N4A0091E
3. Outer Oil Seal

Use a pry bar to pry the oil seal from the axle case.
N4A0089E
1. Wheel and Tire

Right side wheel nut (1) have right hand threads
and left side wheel nut (2) have left hand threads.
N4A0092E
4. Lock Washer
5. Bearing Lock Nut
Use the lock nut remover to remove the lock nut.
N4A0090E
Lock Nut Remover:
2. Axle Shaft 9-8522-1188-0 (For lock bolt P.C.D. 70 mm (2.8
Use the axle shaft remover and the sliding hammer in.))
to remove the axle shaft. 9-8522-1606-0 (For lock bolt P.C.D. 74 mm (2.9
Axle Shaft Remover: 5-8840-2027-0 in.))
Sliding Hammer: 5-8840-0084-0
REAR AXLE 4B-13
N4A0093E N4A0096E
6. Outer Bearing 8. Inner Oil Seal

If the bearings are to be reinstalled, tag each bear- 9. Inner Bearing
ing with the fitting position from which it was re- 10. Inner Bearing Outer Race
moved.
11. Outer Bearing Outer Race
Use a hammer and a brass bar (2) to drive the out-
er races (3) from the hub (1) at the two points
shown in the illustration.
N4A0094E
7. Hub and Brake Drum

Use the rear hub remover to remove the hub and
the brake drum. N4A0097E
Rear Hub Remover: 12. Wheel Pin

9-8521-2501-0 1) Set the rear hub with brake drum (1) to the
wheel with tire (2) previously removed from the
vehicle.
Turn the wheel pin nuts (3) counterclockwise to
loosen them.
2) The pin nuts are loosened counterclockwise on
both sides of the vehicle.
4B-14 REAR AXLE

Axle Shaft Run-Out
Limit, 1 mm (0.039 in)
N4A0098E
3) Remove the brake drum from the rear hub.

N4A0100E
4) Discard the wheel pins and nuts.
The wheel pins and nuts cannot be reused. Axle Shaft Flange Run-Out
13. Hub Limit, 0.15 mm (0.00591 in)
14. Brake Drum

Make necessary adjustments, repairs, and part replace-
ment if excessive wear or damage is discovered during
inspection.
Axle Shaft Spline
Inspect the spline for wear, damage or other abnormal
conditions.
N4A0101E
N4A0099E
REAR AXLE 4B-15

Hub Lock Washer
Inspect the oil seal and bearing fitting faces for exces- Inspect the lock washer for excessive wear, cracks,
sive wear and damage. warpage, and other damage.
Inspect the wheel pin threads and stud bolt threads for
excessive damage and cracks.
N4A0104E
N4A0102E Bearing Lock Nut

Inspect the bearing lock nut threads and contact surfac-
Bearing es for excessive wear, warpage, and other damage.
Inspect the bearing for excessive wear, abnormal noise, Light damage to the contact surfaces can be repaired
rough rotation, and freezing. with an oil stone or a piece of fine sandpaper.
N4A0103E N4A0105E
4B-16 REAR AXLE

Installation
1. Brake Drum
2. Hub
1) Clean the hub inside and outside surfaces.
2) Apply bearing grease to the hub cavity.
Hub bearing grease amount, 285 g (10.1 oz)
N4A0108E
3) Wheel Pin Nut Torque

343 N⋅m (35 kg⋅m / 253 lb⋅ft)
4) Caulk three portions of each wheel nut to pre-
vent them from loosening.
N4A0106E
3. Wheel Pin
1) Right side hub wheel pins (1) have right hand
threads and left side hub wheel pins (2) have
left hand threads.
N4A0109E

5. Inner Bearing Outer Race
Use the bearing outer race installer and the drive
handle to install the outer race to the hub.
Outer Bearing Outer Race Installer:
N4A0107E 9-8522-1195-0
(Outer race outside diameter 92 mm (3.6 in))
2) Install the wheel pins (3) to the hub (4).
Note the installation direction shown in the illus- 9-8522-1610-0
tration. (Outer race outside diameter 97.6 mm (3.8 in))
Tap the wheel pin into the hub with a hammer. Drive Handle:
9-8522-1608-0
Inner Bearing Outer Race Installer:
9-8522-1194-0
(Outer race outside diameter 101.6 mm (4 in))
9-8522-1609-0
REAR AXLE 4B-17

(Outer race outside diameter 108 mm (4.3 in))
Drive Handle:
9-8522-1148-0
N4A0112E
8. Hub and Brake Drum

1) Wipe away any oil or other foreign material
N4A0110E from the brake linings and the brake drum in-
side surfaces.
6. Inner Bearing
Apply an ample coat of bearing grease between 2) Clean the rear axle case tip.
the inner race and the roller cage. 3) Install the hub assembly to the rear axle case.
N4A0111E N4A0113E
7. Inner Oil Seal 9. Outer Bearing

1) Apply grease to the oil seal lip inner and outer Apply an ample coat of bearing grease between
circumferences. the inner race and the roller cage.
2) Use the oil seal installer and the drive handle to
install the oil seal to the hub.
Oil Seal Installer:
9-8522-1607-0
Drive Handle:
9-8522-1608-0
4B-18 REAR AXLE
N4A0111E LNW64BSH000201
10. Bearing Lock Nut 3) Loosen the bearing lock nut, and confirm that
Install the lock nut with the notched line facing out. the hub rotates smoothly.
If the hub does not turn at this time, use the hub
remover (P.C.D. 116 mm (4.57 in) 8 holes): 9-
8521-2501-0, the hub remover screw: 9-8521-
2401-0 and the step plate adapter: 5-8840-
2864-0 (No.8065) or the hub remover (P.C.D.
110 mm (4.33 in) 6 holes) to pull back the hub.
Caution:
Make sure to fully loosen the bearing lock nut. If loosen-
4) Put a string around the wheel pins, hang a
by tightening the bearing lock nut until the pre-
Caution:
If the pre-load is unstable, rotate the hub several times,
N4A0114E stop the rotation completely and carry out measurement
Hub Bearing Preload Measuring Method procedures from procedure “1)”.
1) Turn the hub to the left and right several times
to stabilize the bearing. Hub Bearing Pre-load N (kg/lb)
2) Using the bearing nut wrench (lock bolt P.C.D.
Wheel Pin 139.7 mm (5.5 in) 61.1 — 75.6 (6.2 —
70 mm (2.8 in)): 9-8522-1188-0 or the bearing
P.C.D. 7.7/13.7 — 17)
nut wrench (lock bolt P.C.D. 74 mm (2.9 in)): 9-
8522-1606-0, tighten the bearing lock nut by 170 mm (6.7 in) 50.2 — 62.2 (5.1 —
turning the hub by hand, until the hub does not 6.3/11.2 — 13.9)
turn. 184.15 mm (7.25 46.3 — 57.4 (4.7 —
Caution: in) 5.9/10.4 — 13)
Make sure to turn the hub when tightening as it will pre- 203.2 mm (8.0 in) 42 — 52 (4.3 — 5.3/
vent the bearing from becoming damaged. Also, make 9.5 — 11.7)
sure to gently tighten the bearing lock nut, and never to
222.25 mm (8.75 38 — 48.0 (3.9 —
in) 4.9/8.6 — 10.8)
REAR AXLE 4B-19
LNW93CSH002501 N4A0118E
5) After adjusting the rotation starting force, turn 12. Outer Oil Seal
the hub to the left and right several times to re- Apply grease to the oil seal lip inner and outer cir-
check the pre-load. cumferences.
6) With the rotation starting force adjusted, align 13. Axle Shaft
the closest marking line of the bearing lock nut 1) Clean the axle shaft.
slit to the center of the lock groove in the axle 2) Apply gear oil to the axle shaft spline.
case threaded portion.
3) Insert the axle shaft into the axle case.
Caution: Take care not to damage the oil seal.
If the slit does not align, turn the bearing lock nut in the
tightening direction to align it.
N4A0119E
LNW23CSH017701
11. Lock Washer

1) Install the lock washer (6) with the lock washer
tabs inserted to the axle case grooves.
2) Install the lock bolts (7) to prevent the bearing
nut from loosening.
3) Check that the lock washer tabs (8) are insert-
ed to the axle case grooves.
4B-20 REAR AXLE

4) Tighten the axle shaft nuts to the specified
torque a little at a time in the numerical order
shown in the illustration.
Tighten:
Axel shaft nut to 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
N4A0120E
14. Wheel and Tire

Tighten:
Wheel nut to
• 500 N⋅m (50 kg⋅m / 362 lb⋅ft)
REAR AXLE 4B-21

Rear Axle Assembly
N4A0122E
Legend
1. Rear flexible hose 4. Nut and washer
2. Rear propeller shaft 5. U-bolt
3. Rear shock absorber 6. Rear axle assembly
4B-22 REAR AXLE

Removal
Preparation:
1. Rear Flexible Hose
Loosen the nut (1), then ply off a clip (2).
N4A0125E
Installation
1. Rear Axle Assembly
2. U-bolt
N4A0123E
3. Nut and Washer
When tightening the nuts apply oil as necessary to
2. Rear Propeller Shaft prevent damaging the threads.
3. Rear Shock Absorber Tighten:
Remove the shock absorber lower end. U-bolt nut to 177 N⋅m (18 kg⋅m / 130 lb⋅ft)
4. Nut and Washer
If the U-bolt are heavily rusted, apply a generous
amount of oil to the threads when turning them
loose the prevent seizure.
N4A0126E
N4A0124E
5. U-bolt
6. Rear Axle Assembly
Move to the rear axle side.
REAR AXLE 4B-23

4. Rear Shock Absorber 6. Rear Flexible Hose
Refer to the drawing for parts installation. To install, follow the disassemble procedure in re-
verse order.
Tighten:
Shock absorber lower nut Tighten:
• Single tire: 61 N⋅m (6.2 kg⋅m /45 lb⋅ft) Flare nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
• Dual tire: 95 N⋅m (9.7 kg⋅m / 70 lb⋅ft)
N4A0129E
N4A0127E
Perform bleeding operation after installation of the
brake flexible hoses.
Legend Refer to Section 5 “Service information” for brake
1. Rubber bushing oil air bleeding procedure.
5. Rear Propeller Shaft

Connect the propeller shaft assembly after tighten-
ing U-bolt nuts.
Tighten:
Propeller shaft nut
• M10: 63 N⋅m (6.4 kg⋅m / 46 lb⋅ft)
• M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
N4A0128E
4B-24 REAR AXLE

Differential Assembly (Single Tire and Dual Tire Models; Full Floating Type)
N4A0132E
Legend
1. Propeller shaft 3. Differential assembly
2. Axle shaft
REAR AXLE 4B-25

Removal 2. Axle Shaft
Preparation: Tighten:
Drain the oil from the axle case. Axle shaft nut to 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
1. Propeller Shaft
3. Propeller Shaft
2. Axle Shaft
3. Differential Assembly Tighten:
To remove, turn push bolt into threaded holes in Propeller shaft nut to
the differential carrier, so that differential assembly • M10: 62.7 N⋅m (6.4 kg⋅m / 46 lb⋅ft)
is lifted off the position. • M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
N4A0133E
Installation
1. Differential Assembly
Apply liquid gasket (BELCO BOND No. 4 or equiv-
alent) to the joining faces of the axle case and car-
rier.
Tighten:
Differential carrier bolt and nut to 64 N⋅m (6.5 kg⋅m / 47
lb⋅ft)
N4A0134E
4B-26 REAR AXLE
UNIT REPAIR
244 mm Rear Differential
Major Components
LNWB4BLF000501
Legend
A. QKR 9. Distance piece
1. Bearing Cap 10. Drive pinion
2. Side bearing outer race 11. Inner bearing inner race
3. Differential cage assembly 12. Inner bearing outer race
4. Side bearing inner race 13. Pinion depth adjusting shim
5. Backlash and preload adjusting shim 14. Oil seal
6. Flange nut 15. Outer bearing inner race
7. Flange 16. Outer bearing outer race
8. Bearing preload adjusting shim
REAR AXLE 4B-27

Disassembly
1. Bearing cap
Set the differential assembly onto a special fixture.
Apply a setting mark (1) to the side bearing cap
and differential carrier.
Fixture: 5-8840-2029-0
Base: 5-8840-0003-0
N4A0138E
7. Flange
8. Bearing Preload Adjusting Shim
9. Distance Piece
10. Drive Pinion
11. Inner Bearing Inner Race
Remover: 5-8840-0015-0
N4A0136E
2. Side Bearing Outer Race

After removal, keep right and left side bearing as-
semblies separate to maintain inner and outer race
combinations.
N4A0139E

13. Pinion Depth Adjusting Shim
14. Oil Seal
N4A0137E 15. Outer Bearing Inner Race
3. Differential Cage Assembly Drive out the inner bearing outer race or the outer
4. Side Bearing Inner Race bearing outer race together with the outer bearing
Remover: 9-8521-0061-0 inner race and oil seal by using a proper bar
Adapter: 5-8840-2031-0 through two notches.
5. Backlash and Preload Adjusting Shim
6. Flange Nut
Holding wrench: 9-8511-1507-0
4B-28 REAR AXLE

Installer (inner): 9-8522-1196-0
(Outer): 9-8522-1197-0
Grip: 9-8522-1148-0
N4A0140E
Reassembly
Measurement of ring gear run-out
N4A0142E
Install dummy bearing into the differential assembly,
then install these parts in the differential carrier. Assemble the inner bearing inner race to the dum-
Install and tighten the bearing cap. my pinion shaft, then install these parts into the
Dummy bearing: 9-8522-1137-0 carrier.
Tighten: Dummy Pinion Shaft: 9-8522-1603-0
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m / 80 lb⋅ft)
Ring gear run-out,
Limit: 0.2 mm (0.008 in)
N4A0143E
Install the outer bearing inner race, flange, washer

and dummy nut.
Lubricate the bearing before tighten the dummy
N4A0141E nut.
Dummy Nut: 9-8522-1624-0
2. Pinion Depth Adjusting Shim
3. Inner Bearing Outer Races
Adjustment of drive pinion engagement depth.
Install the inner and outer bearing outer races with-
out shims into the differential carrier using a bench
press.
REAR AXLE 4B-29

Install dummy bearing on dummy shaft and install
these parts into the carrier. Install and tighten the
bearing cap.
Dummy Shaft: 9-8522-1138-0
Dummy Bearing: 8-8522-1137-0
Tighten:
N4A0144E
Legend
1. Coupling driver
2. Outer bearing
3. Dummy pinion shaft
4. Inner bearing
5. Shim
N4A0146E
Tighten the dummy nut until specified preload are
required to rotate the bearing. Measure the clearance (t) with a feeler gauge.
Bearing preload The clearance (t) is equal to the shim in thickness.
New bearing: 16 — 29 N (1.6 — 3.0 kg / 3.5 — 6.6 lb) Thickness of shim available, 2.12, 2.16 ... 2.52, 2.56 mm
Used bearing: 8 — 14.5 N (0.8 — 1.5 kg / 1.8 — 3.3 lb) (0.083, 0.085 ... 0.099, 0.100 in)
Tighten:
Starting to
• New bearing: 0.69 — 1.27 N⋅m (7.0 — 13.0 kg⋅cm /
6.1 — 11.3 lb⋅in)
• Used bearing: 0.35 — 0.64 N⋅m (3.5 — 6.5 kg⋅cm /
3.1 — 5.7 lb⋅in)
N4A0147E
Remove dummy pinion, dummy shaft, dummy

bearing and inner bearing outer race.
Install pinion depth adjusting shim of specified
thickness in position between the inner bearing
outer race and the carrier, then install the inner
N4A0145E bearing outer race.
Installer: 9-8522-1196-0
Grip: 9-8522-1148-0
4B-30 REAR AXLE
N4A0148E N4A0150E
4. Inner Bearing Inner Race 7. Drive Pinion

Installer: 9-8522-0018-0 8. Distance Piece
Apply gear oil to the pinion shaft before installing fi- 9. Bearing Preload Adjusting Shim
nal drive pinion assembly into carrier. Use a dummy nut until specified bearing preload is
obtained.
Bearing preload
New bearing: 16 — 29 N (1.6 — 3.0 kg / 3.5 — 6.6 lb)
Used bearing: 8 — 14.5 N (0.8 — 1.5 kg / 1.8 — 3.3 lb)
Tighten:
Starting to
• New bearing: 0.69 — 1.27 N⋅m (7.0 — 13.0 kg⋅cm /
6.1 — 11.3 lb⋅in)
N4A0149E
5. Outer Bearing Inner Race

6. Oil Seal
Installer: 5-8840-2047-0
N4A0145E
Tighten:
Dummy nut to 270 N⋅m (27.5 kg⋅m / 199 lb⋅ft)
REAR AXLE 4B-31

Install the bearing caps after checking to make
certain setting marks (1) applied at disassem-
bly are in alignment.
Tighten:
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m /80 lb⋅ft)
N4A0151E
Thickness of shim available, 1.53, 1.56 ... 2.07, 2.10 mm

(0.060, 0.061 ... 0.081, 0.082 in)
10. Flange
11. Flange Nut
(QKR only for distance piece) N4A0152E
Once specified bearing preload is obtained by

• Set the dial indicator and measure the backlash
dummy nut, remove dummy nut and replace with
between the drive pinion and ring gear at the
flange nut.
foot portion of the ring gear.
Tighten the flange nut until specified bearing pre- Backlash, 0.15 — 0.20 mm (0.006 — 0.008 in)
load and nut torque.
Using special tool, stake the flange nut at two
points.
Punch: 5-8840-2293-0
N4A0153E
• To adjust backlash, loosen bearing cap bolts

slightly and move the dummy bearing (1) as
N4A0151E necessary.
A clearance should not be provided between
12. Backlash and Preload Adjusting Shim dummy bearing and bearing fitting face of the
1) Adjustment of Backlash differential cage.
• Install dummy bearing in the differential cage
assembly, then install differential cage assem-
bly and ring gear into the differential carrier.
4B-32 REAR AXLE

• Check the impression of contact (Right contact)
obtained on the ring gear teeth and make nec-
essary adjustment as described below if the
contact is abnormal.
N4A0154E
2) Inspection of drive pinion and ring gear tooth

contact.
• Apply a thin coat of red check to faces of the 7 N4A0155E
— 8 teeth of the ring gear.
TOOTH CONTACT CASE ADJUSTMENT PROCEDURE

Drive pinion is too far 1. Move the drive pinion in to-
away from ring gear. ward the ring gear by de-
creasing the thickness of
pinion depth adjusting
shims.
2. Adjust the backlash by
moving ring gear away
N4A0156E N4A0160E
from the drive pinion.
Drive pinion is too close to 1. Move the drive pinion away
the ring gear. from the ring gear by in-
creasing thickness of pin-
ion depth adjusting shims.
moving ring gear in toward
the drive pinion.
N4A0157E N4A0161E
Ring gear is too close to 1. Move the drive pinion in to-

the drive pinion. ward the ring gear by de-
creasing thickness of
shims.
N4A0158E N4A0162E
Ring gear is too for away 1. Move the drive pinion away
from drive pinion. from the ring gear by in-
the drive pinion.
N4A0159E N4A0163E
REAR AXLE 4B-33

3) Selection of Preload Adjusting Shim When side bearing is thinner:
• Measure the clearance (A) between the differ- A+(dummy bearing thickness−side bearing
ential carrier and right and left side (dummy) thickness)=(X)
bearings by using a feeler gauge. When side bearing is thicker:
Carefully note the relationship between the val- A−(side bearing thickness−dummy bearing
ues obtained through measurement at each thickness)=(X)
side and dummy bearings. • (X)+0.025=Shim thickness
Allowance for bearing preload at one
side=0.025
Example of calculation mm (in)

Measured Clearance A: +0.85 (+0.033)
Suppose that the side bearing is
−0.05 (−0.002)
thicker [thinner] than dummy
[+0.05 (+0.002)]
bearing by 0.05 mm (0.002 in)
An allowance for bearing pre-
+0.025 (+0.0009)
load:
Thickness of shims to be 0.825 (0.032)
installed: [0.925 (0.036)]
Thickness of shim available, 0.25, 0.30, 0.35, 0.5 mm

(0.009, 0.012, 0.014, 0.019 in)
N4A0164E
• Measure the thickness of dummy bearing and

side bearing.
Comparison should be made between the
thicknesses of dummy bearing and side bear-
ing installed in the same position.
N4A0166E
Legend
A. Measured clearance
A′. Shim installed position
13. Side Bearing Inner Race

Installer: 5-8840-2050-0
N4A0165E
Grip: 9-8522-1608-0
Legend
1. Dial gauge
2. Dummy bearing
3. Side bearing
4B-34 REAR AXLE
N4A0167E N4A0169E
14. Differential Cage Assembly Recheck the ring gear for run-out at the rear face.
15. Side Bearing Outer Race If the amount of run-out is excessive, repeat the
16. Bearing Cap disassembly and reassembly steps.
1) Install bearing caps by aligning setting marks Ring gear run-out,
(1) applied at disassembly. Standard: 0.05 mm (0.002 in)
Limit: 0.2 mm (0.008 in)
Tighten:
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m /80 lb⋅ft)
N4A0170E
N4A0168E
2) Recheck the backlash. If measurement indi-

cates that the backlash deviates from the spec-
ified range, make an adjustment by shifting the
position of shims in use without varying the total
thickness.
REAR AXLE 4B-35

Differential Cage Assembly
N4A0381E
Legend
1. Differential cage B 6. Thrust piece
2. Side gear 7. Side gear
3. Thrust washer 8. Thrust washer
4. Spider 9. Differential cage A and ring gear
5. Differential pinion gear
Disassembly
1. Differential Cage B
Apply a setting mark (1) to the differential cage as-
sembly.
2. Side Gear
3. Thrust Washer
4. Spider
5. Differential Pinion Gear
6. Thrust Piece
7. Side Gear
8. Thrust Washer
9. Differential Cage A and Ring Gear
N4A0171E
4B-36 REAR AXLE

Inspection and Repair Clearance between Differential Pinion and Spider
Make necessary correction or parts replacement if wear, Standard: 0.07 — 0.13 mm (0.003 — 0.005 in)
damage or any other abnormal conditions are found Limit: 0.2 mm (0.008 in)
through inspection.
Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.
• Gear
• Bearing
• Oil seal
• Differential cage
• Drive pinion cage
• Parts organizing limited slip differential assembly
Ring Gear Replacement
The ring gear should always be replaced with drive pin-
ion as a set.
When installing ring gear, apply stud lock to the thread-
ed holes and bolts after treatment of the bolts with prim-
er N.
N4A0174E
Tighten:
Ring gear bolt to 127 N⋅m (13.0 kg⋅m / 94 lb⋅ft) Clearance between Side Gear and Differential Cage
Standard: 0.05 — 0.11 mm (0.002 — 0.004 in)
Limit: 0.25 mm (0.01 in)
N4A0173E
N4A0175E
Legend
1. Side gear
2. Differential cage
REAR AXLE 4B-37

Play in Splines between Side Gear and Axle Shaft
Tighten:
Standard: 0.02 — 0.12 mm (0.0008 — 0.005 in)
Differential cage bolt to 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
Limit: 0.25 mm (0.01 in)
N4A0413E
N4A0176E
Reassembly 3) Measure the clearance between the back face

of the side gear and the differential cage B by
1. Differential Cage A and Ring Gear inserting a feeler gauge (1) through the hole on
2. Thrust Washer the cage B.
3. Side Gear Clearance, 0.13 — 0.18 mm (0.005 — 0.007 in)
4. Thrust Piece
5. Differential Pinion Gear
6. Spider
7. Thrust Washer
8. Side Gear
1) Apply oil to the threaded portion of the bolts be-
fore installation.
2) Fasten the differential cages A and B so that
the setting marks (1) are correctly aligned.
N4A0177E
When the clearance exceed a limit, replace the

thrust washer or side gear.
4B-38 REAR AXLE

292 mm Rear Differential
Major Components
N4A0178E
Legend
1. Lock plate 6. Drive pinion cage assembly
2. Bearing cap 7. Shim
3. Adjust nut 8. Pilot bearing retainer
4. Side bearing outer race 9. Pilot bearing
5. Differential cage assembly
REAR AXLE 4B-39

Disassembly
1. Drive Pinion Cage Assembly
N4A0137E
8. Pilot Bearing Retainer

N4A0180E 9. Pilot Bearing
Legend
Reassembly
1. Setting mark 1. Pilot Bearing
2. Pinion cage 2. Pilot Bearing Retainer
3. Shim The fixing nut should be on the inboard side of the
case.
2. Shim
Tighten:
3. Lock Plate Retainer nut to 6 N⋅m (0.6 kg⋅m / 41 lb⋅ft)
4. Bearing Cap
Set the differential assembly onto a special fixture.
Apply a setting mark to the right and left side bear-
ing caps to prevent interchanging.
N4A0181E
3. Differential Cage Assembly

N4A0179E Install the outer and inner races, so that original
combination is maintained.
5. Adjust Nut
Keep the side bearing outer race and inner races
separate to prevent interchanging.
7. Differential Cage Assembly
4B-40 REAR AXLE
N4A0137E N4A0183E
5. Bearing Cap Side Bearing Preload Adjustment

Install the bearing caps by aligning setting marks Attach a spring balance to the head of the ring gear
(1) applied at disassembly. tightening bolt, pull it to the connecting direction, and ad-
just force to start rotating the gear (rotating impetus) by
turning the adjust nut.
Bearing preload (292 mm differential)

N.S.K. bearing:
• New bearing: 6.0 — 13.0 N (0.6 — 1.3 kg / 1.3 — 2.9 lb)
• Used bearing: 3.0 — 7.0 N (0.3 — 0.7 kg / 0.7 — 1.6 lb)
KOYO bearing:
• New bearing: 12.0 — 18.0 N (1.2 — 1.8 kg / 2.7 — 4.0
lb)
• Used bearing: 6.0 — 9.0 N (0.6 — 0.9 kg / 1.3 — 2.0 lb)
N4A0182E
6. Adjust Nut
1) Threaded groove in nut should be properly
aligned with threaded groove in the carrier.
2) Tighten the adjust nuts so that they can be
turned after installing and semi-tightening bear-
ing caps.
Tighten:
N4A0187E
REAR AXLE 4B-41

Inspection of Ring Gear for Run-Out Backlash between Drive Pinion and Ring Gear
• 292 mm differential Backlash,
Standard: 0.05 mm (0.002 in) 292 mm differential: 0.18 — 0.23 mm (0.007 — 0.009 in)
Limit: 0.2 mm (0.008 in)
N4A0186E
N4A0184E
Inspection of Drive Pinion and Ring Gear Tooth
7. Shim Contact
8. Drive Pinion Cage Assembly • Apply a thin coat of red check to the faces of the 7
Install the shim removed and pinion aligning the oil — 8 teeth of the ring gear.
hole or setting mark applied on removal. • Check the impression of contact (Right contact)
obtained on the ring gear teeth and make neces-
Tighten: sary adjustment as described below if the contact
Drive pinion cage bolt to is abnormal.
• 292 mm differential: M12 bolt to 69 N⋅m (7.0 kg⋅m / 51 Adjusting shims available,
lb⋅ft), M14 bolt to 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) • 292 mm differential: 0.10, 0.12, 0.14, 0.16, 0.18, 0.20
mm (0.004, 0.0047, 0.0055, 0.0055, 0.0063, 0.0079
in)
N4A0185E
N4A0155E
4B-42 REAR AXLE
TOOTH CONTACT CASE ADJUSTMENT PROCEDURE

Drive pinion is too far 1. Move the drive pinion in to-
away from ring gear. ward the ring gear by de-
creasing the thickness of
shims.
N4A0156E N4A0160E
Drive pinion is too close to 1. Move the drive pinion away
the ring gear. from the ring gear by in-
the drive pinion.
N4A0157E N4A0161E
Ring gear is too close to 1. Move the drive pinion in to-

the drive pinion. ward the ring gear by de-
creasing thickness of
shims.
N4A0158E N4A0162E
Ring gear is too for away 1. Move the drive pinion away
from drive pinion. from the ring gear by in-
the drive pinion.
N4A0159E N4A0163E
9. Tighten the bearing cap bolts.

Tighten:
Bearing cap bolt to
• 292 mm differential: 108 N⋅m (11 kg⋅m / 80 lb⋅ft)
Recheck the backlash after tightening the bearing cap
bolts.
N4A0188E
REAR AXLE 4B-43

10. Lock Plate
Tighten:
Lock plate bolt to
• 292 mm differential: 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
The lock plates are available in 2 different kinds to per-
mit gradual adjustment by 1/2 notch of the adjust nut.
N4A0189E
Differential Cage Assembly
N4A0190E
Legend
1. Side bearing inner race 6. Differential pinion
2. Differential cage B 7. Side gear
3. Side gear 8. Thrust washer
4. Thrust washer 9. Differential cage A and ring gear
5. Spider
4B-44 REAR AXLE

Disassembly Inspection and Repair
1. Side Bearing Inner Race Make necessary correction or parts replacement if wear,
Remover: damage or any other abnormal conditions are found
9-8521-0061-0 (292 mm) through inspection.
Adapter: Visual Check
Inspect the following parts for wear, damage or other ab-
9-8521-2701-0
normal conditions.
• Gear
• Bearing
• Oil seal
• Differential cage
• Drive pinion
Ring Gear Replacement
The ring gear should always be replaced together with
the drive pinion as a matched set.
When installing ring gear, apply stud lock to the thread
holes and bolts after treatment of the bolts with primer N.
Ring gear bolt wrench;
5-8840-2830-0 (for 292 mm differential)
Tighten:
Ring gear bolt to
• 292 mm differential: M12 bolt (E12) to 127 N⋅m (13
N4A0191E kg⋅m / 94 lb⋅ft), M14 bolt to 181 N⋅m (18.5 kg⋅m / 133
lb⋅ft)
Apply a setting mark before removing the differen-
tial cage B to ensure reassembly into original posi-
tion.
N4A0194E
N4A0192E
3. Side Gear
4. Thrust Washer
5. Spider
6. Differential Pinion
7. Side Gear
8. Thrust Washer
9. Differential Cage A and Ring Gear
REAR AXLE 4B-45

Clearance between Spider and Differential Pinion Play in Spline between Side Gear and Axle Shaft
• 292 mm differential • 292 mm differential
Standard: 0.07 — 0.13 mm (0.003 — 0.005 in) Standard: 0.08 — 0.15 mm (0.003 — 0.006 in)
Limit: 0.2 mm (0.008 in) Limit: 0.3 mm (0.012 in)
N4A0174E N4A0176E
Clearance between Side Gear and Differential Cage REASSEMBLY

• 292 mm differential 1. Differential Cage A and Ring Gear
Standard: 0.05 — 0.11 mm (0.002 — 0.004 in) 2. Thrust Washer
Limit: 0.25 mm (0.01 in) 3. Side Gear
4. Differential Pinion
5. Spider
6. Thrust Washer
7. Side Gear
1) Install by aligning setting marks.
2) Apply oil to threaded portion of bolts before in-
stallation.
Tighten:
Differential cage B nut to
• 292 mm differential: 54 N⋅m (5.5 kg⋅m / 39.8 lb⋅ft)
3) Measure the clearance between the back face
of the side gear and the differential cage B by
inserting a feeler gauge through the hole on the
cage B.
N4A0175E Clearance,
292 mm differential: 0.21 — 0.28 mm (0.008 — 0.011 in)
When the clearance exceed a limit, replace the thrust
Legend washer or side gear.
1. Side gear
2. Differential gear
4B-46 REAR AXLE

9. Side Bearing Inner Race
Installer: 9-8522-1614-0
Grip: 9-8522-1148-0
N4A0197E
N4A0198E
Drive Pinion Cage Assembly
N4A0199E
Legend
1. Flange nut 6. Oil seal
2. Flange 7. Outer bearing inner race
3. Drive pinion 8. Outer bearing outer race
4. Collapsible spacer 9. Inner bearing outer race
5. Inner bearing inner race 10. Pinion cage and O-ring
REAR AXLE 4B-47

Disassembly
1. Flange Nut
Flange Bracket: 9-8529-2101-0
N4A0202E

10. Pinion Cage and O-ring
N4A0200E
Reassembly
2. Flange
1. Pinion Cage and O-ring
3. Drive Pinion Discard used O-ring and install a new one.
4. Collapsible Spacer 2. Inner Bearing Outer Race
5. Inner Bearing Inner Race Installer:
Remover: 5-8840-0015-0 5-8840-2046-0 (292 mm)
Grip:
9-8522-1608-0
N4A0201E
6. Oil Seal
7. Outer Bearing Inner Race N4A0203E
8. Outer Bearing Outer Race 3. Outer Bearing Outer Race

Drive out the outer bearing outer race together with Installer:
the outer bearing inner race and oil seal or the in-
9-8522-1613-0 (292 mm)
ner bearing outer race by using a proper bar
through the two notches. Grip:
9-8522-1608-0
4. Outer Bearing Inner Race
4B-48 REAR AXLE

5. Oil Seal 10. Flange Nut
Installer: Discard used flange nut and install a new one at re-
9-8522-1607-0 (292 mm) assembly.
Grip: Adjustment of bearing preload.
9-8522-1608-0 1) Tighten the flange nut to a torque of 245 N⋅m
(25 kg⋅m/181lb⋅ft).
2) Adjust bearing preload by tightening the flange
nut until specified preload is obtained.
3) The flange nut should be within the specified
range when specified preload is obtained.
Tighten:
Flange nut to
• 292 mm differential: 324 — 480 N⋅m (33 — 49 kg⋅m /
238 — 354 lb⋅ft)
Apply oil to seated surface of nut when tightening.
Preload at Cage Fixing N (kg/lb)

Hole
13 — 25 (1.3 — 2.6/2.9 —
New bearing
5.7)
292 mm
6.5 — 12.5 (0.65 — 1.3/
Used bearing
N4A0204E 1.5 — 2.9)
Legend Starting Torque N⋅m (kg⋅cm/lb⋅in)

1. Installer
2. Oil seal 0.98 — 1.96 (10.0 — 20.0/
New bearing
8.7 — 17.4)
3. Outer bearing 292 mm
0.49 — 0.98 (5.0 — 10.0/
Used bearing
6. Inner Bearing Inner Race 4.3 — 8.7)
Installer:
9-8522-1615-0
N4A0206E
N4A0205E
4) Using special tool, stake the flange nut at two
points.
7. Collapsible Spacer
Punch: 5-8840-2293-0
Discard used collapsible spacer and install a new
one.
8. Drive Pinion
9. Flange
FRONT AXLE 4C-1

SECTION 4C
FRONT AXLE
Contents
GENERAL DESCRIPTION ...................................4C-2
Rear Single Tire (4 × 2 Model) ..........................4C-2
Rear Dual Tire (4 × 2 Model) .............................4C-2
ON-VEHICLE SERVICE .......................................4C-3
Front Hub and Brake Drum (4 × 2 Model) .........4C-3
Front Axle Assembly (4 × 2 Model) ...................4C-8
Knuckle and King Pin (4 × 2 Model) ................4C-11
4C-2 FRONT AXLE
GENERAL DESCRIPTION
Rear Single Tire (4 × 2 Model)
N4A0332E
Rear Dual Tire (4 × 2 Model)
N4A0222E
FRONT AXLE 4C-3
ON-VEHICLE SERVICE
Front Hub and Brake Drum (4 × 2 Model)
N4A0234E
Legend
A. Rear single tire models 7. Outer bearing
B. Rear dual tire models 8. Oil seal
1. Wheel and tire 9. Inner bearing
2. Hub cap 10. Inner bearing outer race
3. Hub bearing nut 11. Outer bearing outer race
4. Lock washer 12. Brake drum
5. Hub with brake drum assembly 13. Hub
6. Distance piece
4C-4 FRONT AXLE

Removal
Preparation:
1. Wheel and Tire
2. Hub Cap
When removing hub cap, exercise care so as not
to scratch or distort hub fitting face.
N4A0237E
6 studs
Hub Remover: 9-8521-0187-0
N4A0235E
3. Hub Bearing Nut

Hub Nut Wrench: 5-8840-2015-0
LNWB4CSH000801
6. Distance Piece
7. Outer Bearing
8. Oil seal
9. Inner Bearing
N4A0236E
Drive out the inner bearing outer race together with
the oil seal with a proper bar through two notches.
4. Lock Washer
5. Hub with Brake Drum Assembly
5 studs
Hub Remover: 5-8840-2016-0
FRONT AXLE 4C-5

Installation
1. Hub
2. Brake Drum
Tighten the brake drum wheel nuts to the specified
torque.
Tighten:
Wheel nut to
• 343 N⋅m (35 kg⋅m / 253 lb⋅ft)
N4A0239E

12. Brake Drum
13. Hub

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
N4A0242E
Visual Check
Inspect the following parts for wear, damage or other ab- When replacement of hub or drum is completed,
normal conditions. stake 3 portions of each wheel pin nut.
• Hub This illustration is based on 5 studs.
• Hub bearing, oil seal
• Knuckle spindle
• Brake
• Brake shoe, lining etc.
(REAR SINGLE TIRE MODELS)
Check bolt for looseness.
N4A0243E

N4A0241E
4C-6 FRONT AXLE

10. Lock Washer
Bearing Outer Race Installer 11. Hub Bearing Nut
Parts No. Remarks Adjust the pre-load of the hub bearing.
5-8840-2863-0 (No.90) Inner Bearing 1) Turn the hub to the left and right several times
to stabilize the bearing.
5-8840-2863-0 (No.72) Outer Bearing
2) Using the hub nut wrench: 5-8840-2015-0,
tighten the hub bearing nut by turning the hub
by hand, until the hub does not turn.
Caution:
Make sure to turn the hub when tightening as it will pre-
vent the bearing from becoming damaged. Also, make
sure to gently tighten the hub bearing nut, and never to
3) Loosen the hub bearing nut, and confirm that
the hub rotates smoothly.
If the hub does not turn at this time, use the hub
remover (5 studs): 5-8840-2016-0 or hub re-
mover (6 studs): 9-8521-0187-0 to pull back the
hub.
Caution:
Make sure to fully loosen the hub bearing nut. If loosen-
N4A0244E 4) Put a string around the wheel pins, hang a
Apply grease (1) in the hub and bearing rollers
by tightening the hub bearing nut until the pre-
Hub Grease Amount g (oz)
Hub Hub cap
Caution:
110 (3.9) 35 (1.2) If the pre-load is unstable, rotate the hub several times,
stop the rotation completely and carry out measurement
procedures from procedure “1)”.
Hub Bearing Pre-load N (kg/lb)

9.8 — 34.3
New
Rear (1.0 — 3.5/2.2 — 7.7)
dual tire 4.9 — 19.6
Reused
(0.5 — 2.0/1.1 — 4.4)
11.8 — 36.3
New
Rear (1.2 — 3.7/2.7 — 8.2)
single tire 4.9 — 19.6
Reused
(0.5 — 2.0/1.1 — 4.4)
N4A0245E
5. Inner Bearing
6. Oil Seal
Drive the oil seal into the hub flush with the hub end
surface.
7. Outer Bearing
8. Distance Piece
9. Hub with Brake Drum Assembly
FRONT AXLE 4C-7
LNW93CSH004201
5) After adjusting the rotation starting force, turn

the hub to the left and right several times to re-
check the pre-load.
6) Install the cotter pin and bend it firmly. If the hub
nut groove and cotter pin hole do not align,
align the hole with the minimum tightening di-
rection for the hub nut.
Caution:
Use a new cotter pin.
12. Hub Cap
13. Wheel and Tire
4C-8 FRONT AXLE

Front Axle Assembly (4 × 2 Model)
N4A0294E
Legend
1. Wheel and tire 4. Drag link
2. Brake flexible hose 5. U-bolt
3. Shock absorber 6. Front axle assembly
FRONT AXLE 4C-9

Removal
Preparation:
1. Wheel and Tire
2. Brake Flexible Hoses
Loosen the nut (2), then pry off a clip (1).
N4A0297E
6. Front Axle Assembly
Installation
1. Front Axle Assembly
2. U-bolt and Nut
N4A0295E Position the U-bolts and helper rubber on the leaf
spring assemblies and jack up the front axle. When
3. Shock Absorber tightening the nuts, apply oil as necessary to pre-
4. Drag Link vent damaging the threads.
Disconnect the drag link, using a special tool.
Tighten:
Remover: 5-8840-2017-0
U-bolt nut to 127 N⋅m (13 kg⋅m / 94 lb⋅ft)
N4A0296E
N4A0297E
5. U-Bolt
3. Drag Link
Loosen the U-bolts after setting jack against the
Tighten drag link nut to specified torque, with just
front axle. If the U-bolts are heavily rusted, apply a
enough additional torque to align cotter pin holes.
generous amount of oil to the threads before loos-
ening them to prevent seizure. Install new cotter pin.
Tighten:
Drag link nut to 167 N⋅m (17 kg⋅m / 123 lb⋅ft)
4C-10 FRONT AXLE

4. Shock Absorber
Refer to illustration for installation of shock absorb-
er, nut, washer and rubber bushing (1).
N4A0299E
5. Brake Flexible Hose

Set first the wheels in the straight going position,
then attach the flexible hose to the bracket without
torsion using a (1).
Connect the pipe, then tighten the nut (2) to the
specified torque.
Tighten:
Brake flexible hose to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
N4A0300E
Perform bleeding operation after installation of the

brake flexible hoses.
Refer to Section 5 “Service information” for brake
fluid air bleeding procedure.
Also inspect wheel alignment after completion of
front axle removal and installation.
6. Wheel and Tire
FRONT AXLE 4C-11

Knuckle and King Pin (4 × 2 Model)
N4A0418E
Legend
1. Wheel and tire 9. Key bolt
2. Hub with brake drum 10. Plate plug
3. Cover 11. King pin
4. Wheel brake assembly 12. Knuckle
5. Tie rod assembly 13. Shim
6. Knuckle arm 14. Thrust bearing
7. Tie rod arm 15. I-beam
8. King pin cover
4C-12 FRONT AXLE

Removal
Preparation:
1. Wheel and Tire
2. Hub with Brake Drum
3. Cover
4. Wheel Brake Assembly
5. Tie Rod Assembly
Remover
Driver Side: 5-8840-2017-0
Assist Side: 5-8840-2018-0
N4A0305E
10. Plate Plug

11. King Pin
Remover: 5-8840-2022-0
N4A0303E
6. Knuckle Arm
7. Tie Rod Arm
Remover: 5-8840-2019-0
Drive out with a heavy hammer.
LNWB4CSH000901
12. Knuckle
13. Shim
14. Thrust Bearing
15. O-ring or Oil Seal
Remove the O-ring or oil seal from the knuckle king
pin hole.
16. King Pin Bushing
• Remove the king pin bushing (upper) (3) from the
outside of the knuckle (4) toward the inside using
the grip: 5-8840-2920-0 (1) and bushing repair tool
(φ30): 5-8840-2922-0 (A) (2).
N4A0304E • Remove the king pin bushing (lower) (5) as well in
the same way.
8. King Pin Cover
Notice:
9. Key Bolt
Do not use the spacer: 5-8840-2922-0 (B) included in
Remover: 5-8840-2020-0
the contents of the bushing repair tool during removal.
FRONT AXLE 4C-13
2
3
LNW73CSH006901 N4A0308E
17. I-Beam 4. Also check to see if the king pins or test bar are in
good parallel alignment as viewed from the side.
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Visual Check
Inspect the following parts for wear, damage or other ab-
normal conditions.
• I-beam
• Knuckle
• Knuckle arm, tie rod arm
• Tie rod, tie rod end
• King pin, bushing, thrust bearing and shims
• Joint ball
• Front hub, bearing and oil seal
• Brake drum
• Brake shoe, lining etc.
N4A0309E
I-Beam (when removed from the vehicle)
1. Fit the king pin or test bar (1) into the king pin hole.
2. Stretch a cord (2) across the centers of king pin or
test bars.
3. Check to see if the cord is in line with the centers
of the center bolt holes (3) in the spring seat when
looked down from above the cord.
4C-14 FRONT AXLE

5. Check to see if the king pin holes is worn. Cracks in Knuckles
Check the knuckles for cracks or damage paying a par-
ticular attention to the areas indicated by arrows.
Use a magnetic flaw detector or red check.
A: 35 mm (1.38 in)
B: 50 mm (1.97 in)
N4A0310E
6. Stretch a cord (1) and check the following dimen-

sions.
mm (in)
N4A0312E
θ H1 H2 H3 L1 L2
Knuckle Arm and Tie Rod Arm
RHD 97 134.4 25.2 260 690 Check tapered portion of the knuckle arms and tie-rod
12°
VEHICLE (3.8) (5.3) (0.99) (10.2) (27.2) arms for abnormal contact in the following manner.:
LHD 97 135.0 27.2 260 690 Apply a thin coat of red check evenly to the tapered por-
7°15′
VEHICLE (3.8) (5.3) (1.07) (10.2) (27.2) tion of the shaft and insert the shaft into the tapered
hole. Remove the shaft and check impression of contact
obtained on the shaft.
Correction or parts replacement is necessary if the con-
tact is uneven or if contact area is smaller than 3/4 of the
entire length of the shaft.
N4A0311E
N4A0313E
Legend
1. Contact are is longer than 3/4 of the entire
length of the shaft.
FRONT AXLE 4C-15

King Pin Diameter
Limit: 29.9 mm (1.177 in)
N4A0316E
If fitting of king pin into the bushing is too tight, carefully

cut inner face of the bushing with a reamer, so that up-
N4A0314E
per and lower holes in the knuckle are well centered.
Clearance between King Pin and Bushing
Limit: 0.15 mm (0.0059 in)
Notice:
Install the king pin bushing by aligning its grease hole
with grease fitting hole in the knuckle.
N4A0317E
Installation
1. I-Beam
2. King Pin Bushing
Upper side
Use the grip: 5-8840-2920-0, bushing repair tool
N4A0315E
(φ30): 5-8840-2922-0 (A) and (B) to tap in the king
Fit of king pin into the king pin bushing can be checked pin bushing (upper), so that it is flush with the
in the following manner. knuckle.
Clamp the knuckle with king pin bushings in a vise and Notice:
insert the king pin into the bushings. Check for radial
• Align the grease fitting hole positions of the knuckle
play by moving the king pin in direction at a right angle
and king pin bushing (upper).
to its axis, then move the king pin endwise with finger.
• Confirm that the oil seal installation section has a
2.5 mm (0.098 in) clearance.
4C-16 FRONT AXLE
1 1
2
3 2 3
5 4
a
5
LNW73CSH007001 LNW73CSH007101
Legend Legend
1. Grip 1. Grip
2. Bushing repair tool (A) 2. Bushing repair tool (A)
3. Bushing repair tool (B) 3. King pin bushing (lower)
4. King pin bushing (upper) 4. Knuckle
5. Knuckle 5. Workbench
a. 2.5 mm (0.098 in)
3. Knuckle
Lower side 4. Oil Seal
Use the grip: 5-8840-2920-0, bushing repair tool • Assemble a new oil seal (1) straight to the knuckle
(φ30): 5-8840-2922-0 (A) to tap in the king pin king pin hole as shown in the diagram.
bushing (lower), so that it is flush with the knuckle
• Insert the oil seal from the side of the metal section
(I-beam side).
with white markings.
Notice:
Caution:
• Align the grease fitting hole positions of the knuckle
An oil seal has a front and back side. If it is assembled
and king pin bushing (lower).
from the opposite direction, grease will not be dis-
charged, causing rust, etc.
LNW83CSH000701
FRONT AXLE 4C-17

• Install it so that the seal metal surface is flush with 6. Shim
the knuckle machined surface. Check the clearance between the knuckle and
front axle.
Caution:
If there are protrusions, the thrust washer may become Standard: 0 — 0.10 mm (0 — 0.004 in)
damaged after assembling the I-beam. Limit: 0.20 mm (0.0079 in)
Shim available thickness, 0.50, 0.55, 0.60, 0.65, 0.70,
0.80, 0.90 mm (0.020, 0.022, 0.024, 0.026, 0.028,
0.031, 0.035 in)
4 2
LNW83CSH000801
Legend N4A0319E
1. Metal bushing
2. Oil seal metal surface 7. King Pin
3. Oil seal installer (φ35 - 40mm (1.38 - 1.57 in)) 1) Apply grease.
4. Knuckle machined surface 2) Align the key groove with the key bolt hole in
the front axle.
5. Thrust Bearing 3) After installing the king pin, check that the
1) Apply grease. knuckle turns smoothly.
2) Turn the bearing case-side upward.
N4A0320E
N4A0318E
Legend
1. Case
4C-18 FRONT AXLE

8. Key Bolt 11. Tie Rod Arm
Tighten: 12. Knuckle Arm
Key bolt to 32 N⋅m (3.3 kg⋅m / 24 lb⋅ft) Tighten:
Knuckle arm nut to 441 N⋅m (45 kg⋅m / 325 lb⋅ft)
After tightening, stake nut.
Use a new nut.
N4A0321E
9. King Pin Cover

10. Plate Plug
Drive the plate plug upward into position with an N4A0323E
appropriate bar fitted against the lower end.

13. Tie Rod Assembly
Use a new nut.
Tighten:
Tie rod end nut to 186 N⋅m (19 kg⋅m / 137 lb⋅ft)
Be sure to install a new cotter pin. If the hole and the slot
are not aligned, turn in the direction of tightening to align
them.
N4A0322E
N4A0324E
FRONT AXLE 4C-19

14. Wheel Brake Assembly
15. Cover
Tighten:
Wheel brake bolt to 88 N⋅m (9 kg⋅m / 65 lb⋅ft)
N4A0325E
16. Hub with Brake Drum

17. Wheel and Tire
MEMO
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LGPRO-WE-1111_奥付_68648 2011.7.12 2:08 PM ページ 1
Published: Jul., 2011 All rights reserved.

First Edition
WORKSHOP MANUAL
Issued by ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LGPRO-WE-1111_奥付_68648 2011.7.12 2:08 PM ページ 2
2011MY
2011MY
WORKSHOP MANUAL PROPELLER SHAFT AND AXLE

WORKSHOP MANUAL
No.LGPRO-WE-1111

Workshop Manual: No - LGPRO-WE-1111

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2011MY

WORKSHOP MANUAL PROPELLER SHAFT AND AXLE

PROPELLER SHAFT AND AXLE

SERVICE INFORMATION 00-1

PROPELLER SHAFT AND AXLE

00-2 SERVICE INFORMATION

PROBLEM POSSIBLE CAUSE CORRECTION

PROBLEM POSSIBLE CAUSE CORRECTION

SERVICE INFORMATION 00-3

MAIN DATA AND SPECIFICATIONS

Bearing retention method Inside snap ring

00-4 SERVICE INFORMATION

Items Service Standard Limit

SERVICE INFORMATION 00-5

Items Service Standard Limit

00-6 SERVICE INFORMATION

2. Tighten the drain plug to specified torque.

Rear Axle Case Oil Capacity L (US qt/Imp qt)

SERVICE INFORMATION 00-7

00-8 SERVICE INFORMATION

SERVICE INFORMATION 00-9

00-10 SERVICE INFORMATION

SERVICE INFORMATION 00-11

00-12 SERVICE INFORMATION

SERVICE INFORMATION 00-13

00-14 SERVICE INFORMATION

Rear Axle 5-8840-2830-0 / Ring

SERVICE INFORMATION 00-15

Tool Number / Tool Number /

9-8522-1197-0 / Drive 5-8840-2031-0 / Differen-

5-8840-2047-0 / Drive 9-8522-1603-0 / Dummy

9-8522-1607-0 / Drive 9-8522-1624-0 / Dummy

00-16 SERVICE INFORMATION

Tool Number / Tool Number /

SERVICE INFORMATION 00-17

5-8840-2022-0 / King pin

5-8840-2020-0 / King pin

PROPELLER SHAFT 4A-1

PROPELLER SHAFT AND AXLE

4A-2 PROPELLER SHAFT

Long Wheel Base Models

PROPELLER SHAFT 4A-3

4A-4 PROPELLER SHAFT

PROPELLER SHAFT 4A-5

4. 2nd Propeller Shaft

1. Differential Side Nut

• M12: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)

4A-6 PROPELLER SHAFT

PROPELLER SHAFT 4A-7

4A-8 PROPELLER SHAFT

Inspection and Repair

PROPELLER SHAFT 4A-9

Propeller Shaft Run-Out Lubrication

Play in Splines in Normal Direction of Rotation

Sliding Spline Sections

4A-10 PROPELLER SHAFT

Eliminate the clearance between snap ring and bearing

Align setting marks and join the yokes.