FRONT AXLE &

FRONT SUSPENSION

GI
MA

SECTION

FA

EM
LC
EC

CONTENTS
PRECAUTIONS AND PREPARATION............................2
Precautions ..................................................................2
Special Service Tools ..................................................2
Commercial Service Tools ...........................................3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................4
NVH Troubleshooting Chart.........................................4
FRONT SUSPENSION SYSTEM ....................................5
ON-VEHICLE SERVICE ..................................................6
Front Axle and Front Suspension Parts ......................6
Front Wheel Bearing....................................................6
Front Wheel Alignment ................................................7
Drive Shaft .................................................................12
FRONT AXLE ................................................................13
Manual-lock Free-running Hub ..................................14
Auto-lock Free-running Hub ......................................15

Description ............................................................15
Inspection ..............................................................16
Trouble Diagnosis For Noise ................................17
Wheel Hub and Rotor Disc........................................17
Knuckle Spindle .........................................................19
Drive Shaft .................................................................22
Shock Absorber .........................................................28
Torsion Bar Spring .....................................................28
Stabilizer Bar .............................................................30
Upper Link .................................................................31
Lower Link .................................................................32
Upper Ball Joint and Lower Ball Joint .......................33
SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
General Specifications...............................................34
Inspection and Adjustment ........................................34

FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX

PRECAUTIONS AND PREPARATION

Precautions

When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
Use flare nut wrench when removing and installing brake
tubes.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Always torque brake lines when installing.

SBR686C

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name

Description

ST29020001
(J24319-01)
Gear arm puller

Removing ball joint for knuckle spindle

a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)

NT694

HT72520000
(J25730-B)
Ball joint remover

Removing tie-rod outer end

a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)

NT546

KV401021S0
(

)
Bearing race drift

Installing wheel bearing outer race

NT153

Removing and installing wheel bearing lock nut

KV40105400
(J36001)
Wheel bearing
lock nut wrench
NT154

Removing and installing lower link bushing

KV40106800
(

)
Lower link bushing
puller
NT685

FA-2

PRECAUTIONS AND PREPARATION

Commercial Service Tools
Tool name

GI

Description

1 Flare nut crowfoot

2 Torque wrench

Removing and installing each brake piping

MA
EM

a: 10 mm (0.39 in)

NT360

LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX

FA-3

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

DRIVESHAFT

TIRES

X X

X X

X X X X X

Noise, Vibration
Shake

FRONT AXLE Noise

AND FRONT
Shake
SUSPENSION
Vibration

Symptom

REAR AXLE AND REAR SUSPENSION

TIRES
ROAD WHEEL
BRAKES
STEERING

SUSPECTED PARTS
(Possible cause)

FRONT AXLE AND FRONT SUSPENSION

Reference page

Excessive joint angle

Joint sliding resistance
Imbalance
Improper installation, looseness
Shock absorber deflection or damage
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer bar fatigue
Wheel bearing damage
Out-of-round
Incorrect air pressure
Uneven tire wear
Deformation or damage
Non-uniformity
Incorrect tire size
PROPELLER SHAFT
DIFFERENTIAL
DRIVESHAFT

FA-24

FA-5
FA-28

FA-27
FA-7
FA-30
FA-6
FA-7

NVH in PD section
NVH in PD section
Refer to DRIVESHAFT in this chart.
Refer to FRONT AXLE AND FRONT
SUSPENSION in this chart.
NVH in RA Section
Refer to TIRES in this chart.
Refer to ROAD WHEEL in this chart.
NVH in BR section
NVH in ST section

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X X X X X

X X X X X X

X X X

X X X X X

X X X X

X X X X X

X X

X X X X X

Shimmy

X X X X

Judder

X X X

Poor quality ride

or handling

X X X X X

X X X X X
X X X X X

X X X

X X X

Noise

X X

X X X X X

Shake

X X

X X X X

Vibration

X X X

X X X

X X

X X X

X X

Shimmy

X X

X X X X X X

X X X

Judder

X X

X X X X

X X X

Poor quality ride

or handling

X X

X X X X

ROAD WHEEL Noise

X X

X X X

X X

X X

Shake

X X

X X

X X

Shimmy, Judder

X X

X X

X X

Poor quality ride

or handling

X X

X X

X: Applicable

FA-4

FRONT SUSPENSION SYSTEM

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
ASU058

FA-5

ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts

SMA525A

Check front axle and front suspension parts for excessive play,
cracks, wear and other damage.

Shake each front wheel to check for excessive play.

If looseness is noted, adjust wheel bearing end play, then
check ball joint end play.

Make sure that the cotter pin is inserted.

Retighten all nuts and bolts to the specified torque.

: Refer to FRONT SUSPENSION SYSTEM, FA-5.

Check front axle and front suspension parts for wear, cracks
and other damage.

Check shock absorber for oil leakage and other damage.

Check suspension ball joint for grease leakage and ball joint
dust cover for cracks and other damage.

ASU018

Front Wheel Bearing

Check that wheel bearings operate smoothly.

Check axial end play.
Axial end play: 0 mm (0 in)
Adjust wheel bearing preload if there is any axial end play or
wheel bearing does not turn smoothly.

SMA571A

PRELOAD ADJUSTMENT
Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
Adjust wheel bearing preload as follows:
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry.

SRA417

2.

Apply multi-purpose grease sparingly to the following parts:

Threaded portion of spindle
Contact surface between wheel bearing washer and outer
wheel bearing
Grease seal lip
Wheel hub (as shown at left) 18 - 23 g (0.63 - 0.81 oz)

AFA166

FA-6

ON-VEHICLE SERVICE
Front Wheel Bearing (Contd)
3.
4.
5.
6.

GI
Tighten wheel bearing lock nut with Tool.
: 78 - 98 Nm (8 - 10 kg-m, 58 - 72 ft-lb)
Turn wheel hub several times in both directions.
Loosen wheel bearing lock nut so that torque becomes 0 Nm MA
(0 kg-m, 0 ft-lb).
Retighten wheel bearing lock nut with Tool.
EM
: 0.5 - 1.5 Nm (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb)
LC

AFA148

7.
8.
9.

Turn wheel hub several times in both directions.

Retighten wheel bearing lock nut with Tool.
: 0.5 - 1.5 Nm (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb)
Measure wheel bearing axial end play.
Axial end play: 0 mm (0 in)

EC
FE
CL
MT

SFA845B

10. Measure starting force A at wheel hub bolt.

AT
TF
PD
FA

SMA580A

11. Install lock washer by tightening the lock nut within 15 to 30 RA

degrees.
12. Turn wheel hub several times in both directions to seat wheel
BR
bearing correctly.
13. Measure starting force B at wheel hub bolt. Refer to step 10.
14. Wheel bearing preload C can be calculated as shown below.

ST

C=BA

SFA830

RS
Wheel bearing preload C:
7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 lb)
15. Repeat steps 3 through 14 until correct axial end play and
BT
wheel bearing preload are obtained.
16. Tighten screws.
: 1.2 - 1.8 Nm (0.12 - 0.18 kg-m, 10.4 - 15.6 in-lb)
HA
17. Install free-running hub.

Front Wheel Alignment

Before checking front wheel alignment, make a preliminary inspec- EL
tion (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
IDX
tools and mats in designated positions.

FA-7

ON-VEHICLE SERVICE
Front Wheel Alignment (Contd)
PRELIMINARY INSPECTION
Aluminum Wheel
1.
2.

SFA975B

3.
4.
5.
6.

Check tires for wear and proper inflation.

Check wheels for deformation, cracks and other damage.
If deformed, remove wheel and check wheel runout.
a. Remove tire from aluminum wheel and mount on a tire balance machine.
b. Set dial indicators as shown in the illustration.
Wheel runout average (Dial indicator value):
Refer to SDS, FA-34.
Check front wheel bearings for looseness.
Check front suspension for looseness.
Check steering linkage for looseness.
Check that front shock absorbers work properly by using the
standard bounce test.

Steel Wheel
1.
2.

3.
4.
5.
6.

7.
a.
b.
c.
d.
AFA171

Check tires for wear and proper inflation.

Check wheels for deformation, cracks and other damage.
If deformed, remove wheel and check wheel runout.
a. Remove tire from steel wheel and mount wheel on a tire
balance machine.
b. Set two dial indicators as shown in the illustrations.
c. Set each dial indicator to 0.
d. Rotate wheel, and check dial indicators at several points
around the circumference of the wheel.
e. Calculate runout at each point as shown below.
Radial runout = (A+B)/2
Lateral runout = (A+B)/2
f. Select maximum positive runout value and the maximum
negative value.
Add the two values to determine total runout.
In case a positive or negative value is not available, use the
maximum value (negative or positive) for total runout.
Wheel runout:
Refer to SDS, FA-34
Check front wheel bearings for looseness.
Check Front suspension for looseness.
Check steering linkage for looseness.
Check that front shock absorbers work properly by using the
standard bounce test.

Measure vehicle height (Unladen): H = A B mm (in)

Refer to SDS, FA-35.
Exercise the front suspension by bouncing the front of the
vehicle 4 or 5 times to ensure that the vehicle is in a neutral
height attitude.
Measure wheel alignment.
Refer to SDS, FA-35.
If wheel alignment is not as specified, adjust vehicle posture.
Refer to SDS, FA-35.
Adjust wheel alignment.
Refer to SDS, FA-35.

FA-8

ON-VEHICLE SERVICE
Front Wheel Alignment (Contd)
CAMBER, CASTER AND KINGPIN INCLINATION

GI

Before checking camber, caster or kingpin inclination, move

vehicle up and down on turning radius gauge to minimize
MA
friction. Ensure that the vehicle is in correct posture.

Measure camber, caster and kingpin inclination of both right

and left wheels with a suitable alignment gauge and adjust in EM
accordance with the following procedures.
Camber, Caster and Kingpin inclination:
Refer to SDS, FA-35.

LC

SFA894

In the following two cases, temporarily tighten the adjusting

bolts while aligning the matching marks with the slits as shown
in the figure at the left and measure the camber, caster and
kingpin inclination:
(1)
When replacing the upper link or other suspension
parts with new ones
(2)
When matching marks were not painted on adjusting
bolts before suspension disassembly procedures
If matching marks were already painted during suspension
disassembly, align the matching marks with the slits, then temporarily tighten the adjusting bolts. Measure the camber, caster
and kingpin inclination.

EC
FE
CL
MT
AT
TF
PD
FA

SFA817B

ADJUSTMENT
Both camber and caster angles are adjusted by adjusting bolts.
If the kingpin inclination is outside specifications, check the
front suspension parts for wear or damage. Replace faulty
parts with new ones.
2. From the measured value, read the coordinate (or: graduation)
at the intersecting point in the graph.
a. If the coordinate (or: graduation) at the intersecting point is
positive, move the pin outward by turning the corresponding
adjusting bolt by the indicated graduation.
b. If the coordinate (or: graduation) at the intersecting point is
negative, move the pin inward by turning the corresponding
adjusting bolt by the indicated graduation.
After properly moving the pin(s), tighten the front and rear
adjusting bolts to specifications.
3. Re-measure to ensure that the camber and caster are within
specified tolerances.
[Example]
a. Measured values corresponding with the two values indicated
below:
Camber angle: 006 (0.10)
Caster angle: 210 (2.17)
b. Apply the above two values to the graph and determine point
A.

RA

1.

SFA817B

FA-9

BR
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BT
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IDX

ON-VEHICLE SERVICE
Front Wheel Alignment (Contd)
c.

The coordinate (or: graduation) indicates that both the front

and rear adjusting bolts must be turned outward by 3 graduations.
Turn the adjusting bolts by the amount corresponding with the
3 graduations.

AFA170

TOE-IN

SFA614B

Measure toe-in using the following procedure.

WARNING:

Always perform the following procedure on a flat surface.

Make sure that no one is in front of the vehicle before

pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both tires at
the same height of hub center. This mark is a measuring point.
4. Measure distance A (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180
degrees (1/2 turn).

If the wheels have rotated more than 180 degrees (1/2

turn), try the above procedure again from the beginning.
Never push vehicle backward.
6. Measure distance B (front side).
Total toe-in:
Refer to SDS, FA-35.

SFA234AC

FA-10

ON-VEHICLE SERVICE
Front Wheel Alignment (Contd)
7.
a.
b.

GI
Adjust toe-in by varying the length of both steering tie-rods.
Loosen lock nuts.
Adjust toe-in by turning both the left and right tie-rod tubes
MA
equal amounts.
EM
LC

ASU020

Make sure that the tie-rod bars are screwed into the tie-rod EC
tube more than 35 mm (1.38 in).
Make sure that the tie-rods are the same length.
FE
Standard length (A = B):
297.6 mm (11.72 in)
c. Tighten clamp bolts or lock nuts, then torque them.

CL

MT
ASU021

FRONT WHEEL TURNING ANGLE

1.
2.

SFA439BA

3.

Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest properly on turning radius gauge.
Rotate steering wheel all the way right and left; measure turning angle.
On power steering models, turn steering wheel to full lock and
apply force (at circumference of steering wheel) of 98 - 147 N
(10 - 15 kg, 22 - 33 lb) with engine at idle.
Do not hold the steering wheel at full lock for more than
15 seconds.
Wheel turning angle (Full turn):
Refer to SDS, FA-35.
Adjust stopper bolt if necessary.

AT
TF
PD
FA
RA
BR
ST
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BT
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IDX

FA-11

ON-VEHICLE SERVICE
Front Wheel Alignment (Contd)
Standard length L2:
Except P265/70R15 tire:
26.5 mm (1.043 in)
(Length before cap is mounted)
P265/70R15 tire:
30.0 mm (1.2 in)
(Length before cap is mounted)

AFA169

Drive Shaft

Check for grease leakage and damage.

SFA901

FA-12

FRONT AXLE
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
AFA168

FA-13

FRONT AXLE
Manual-lock Free-running Hub

AFA174

REMOVAL AND INSTALLATION

1.

Set knob of manual-lock free-running hub in the FREE position.

2. Remove manual-lock free-running hub.
3. When installing manual-lock free-running hub, make sure the
hub is in the FREE position.
Apply multi-purpose grease to the parts shown in the above
illustration.
4. Check operation of manual-lock free-running hub after installation.
SFA936

INSPECTION

Check that the knob moves smoothly and freely.

Check that the clutch moves smoothly in the body.

FA-14

FRONT AXLE
GI

Auto-lock Free-running Hub

DESCRIPTION
Auto-lock free-running hubs are locked by placing the transfer case
into the 4WD mode and moving the vehicle. They are unlocked by
placing the transfer case into the 2WD mode and moving the
vehicle in reverse gear in a straight line for at least 2-3 meters
(7-10 feet).
In most cases, the ratcheting noise sometimes heard in auto-lock
free-running hubs occurs when one hub is locked and the opposite
hub is unlocked. The noise is heard in the side opposite to the
locked hub. For example, if the noise is heard at the left front wheel,
the right front hub is still locked and is not unlocking. This condition may be caused by a mechanical condition in one of the hubs
or by incorrect operation on the part of the vehicle driver, for
example by not backing up in a straight line to unlock the hubs, by
not backing up enough, or by shifting into 4WD at too high a vehicle
speed, etc.
The ratcheting noise does not necessarily cause damage to the
good hub. If the noise is caused by incorrect operation, counsel the
driver of the vehicle. If replacement is necessary, replace only the
defective part. It is not necessary to replace auto-lock free-running
hubs in pairs.
Use the trouble diagnosis chart to isolate the cause of the noise.
Refer to TROUBLE DIAGNOSIS FOR NOISE, FA-17.

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST

AAX008

RS
BT
HA
EL
IDX

FA-15

FRONT AXLE
Auto-lock Free-running Hub (Contd)
REMOVAL AND INSTALLATION
1.
2.
3.
4.
5.

SFA828B

Set auto-lock free-running hub in the FREE position.

Remove auto-lock free-running hub assembly.
Remove snap ring.
Remove spindle washer and fixed cam assembly.
Install fixed cam assembly.
Be sure to align the tabs of the fixed cam assembly to the
notches of the knuckle.
6. Place the spindle washer and then the snap ring over the axle
shaft and position them between the 2 locking grooves.
7. While supporting the axle shaft behind the knuckle, use an
appropriate sized deep socket to securely seat the snap ring
into the inner locking groove.
CAUTION:
Visually verify that the snap ring is fully seated into the locking groove.
8. After installing auto-lock free-running hub, check operation.
During installation, apply recommended grease to the parts
shown in the above illustration.

INSPECTION
AFA143

1.
2.

Check axle axial end play. Refer to INSTALLATION, FA-26.

Inspect fixed cam (thrust washer) assembly. If this part shows
evidence of galling or heat damageusually caused by too
little axle axial end playreplace as necessary. Check axle
axial end play if this part is replaced. Refer to
INSTALLATION, FA-26.
3. Inspect hub assembly. Hold inner splines with a finger and spin
the outer body. If the hub shows signs of damage, or if there
is excessive metallic clicking when the hub is spun, replace
with a new one.
NOTE:
New hubs are greased during manufacture. No additional grease
is required.
New hubs are supplied with fixed cam assemblies.
CAUTION:
Any hub, the original or a new one, should go onto the axle
freely by hand and fit flush against its seat. If it does not fit
flush, do not pull the hub into place by tightening the bolts.
The hub is possibly misaligned inside and tightening the bolts
will cause damage. Remove the hub and turn to align correctly
before continuing.
4. Once the repair is completed, test drive to check for correct
operation and the absence of noise.

FA-16

FRONT AXLE
Auto-lock Free-running Hub (Contd)
GI

TROUBLE DIAGNOSIS FOR NOISE

Symptom

Possible cause
1. Shifting into 4WD at higher speeds is
difficult and may cause damage to the
transfer case

Ratchet noise in hub after shifting the

transfer case into 4WD at speeds higher
than 40 km/h (25 MPH).

Repair order
1. Stop the vehicle or decrease speed to
less than 40 km/h (25 MPH). Return the
transfer case lever to the 2H position
once, then re-shift to the 4H position.
Move forward until both hubs lock.
1. Make sure the 4WD lamp on the dash
is ON when shifting into 4WD. Slow
or stop the vehicle. Shift into 2H, then
back to 4H. Move forward until the hubs
lock.

Ratchet noise in hub after shifting or

attempting to shift the transfer case into
4WD at speeds less than 40 km/h (25
MPH).

1. Transfer case was not fully engaged or

shifting was stopped halfway so that
only one hub locked

Ratchet noise in hub after shifting the

transfer case into 4WD on snowy or
muddy roads or on slopes.

1. If the rear wheels slip during the hub

locking operation, noise can occur in
the hubs

1. Reduce engine speed and drive forward

slowly. The hubs will lock evenly and
the noise will stop.

Ratchet noise in hub after shifting the

transfer case into 2WD and backing up to
unlock the hubs.

1. The hubs may not be fully released

1. Stop the vehicle, make sure the transfer

case lever is fully in the 2H position,
then back up slowly in a straight line at
least 2-3 meters (7-10 feet)

Ratchet noise in hub when driving in

extremely cold weather.

1. Shift the transfer case into 4H and drive

1. The viscosity of differential oil grows
the vehicle for 10 minutes or more to
higher in extreme cold, increasing the
warm the differential oil. Then shift to
possibility that one hub may lock. A
2WD and back up in a straight line for
lower viscosity differential fluid may be
at least 2-3 meters (7-10 feet) to disenrequired for extreme cold temperatures.
gage the hubs.
See owners manual

Continual ratchet noise in one wheel when 1. A hub may be mechanically locked,
moving forward.
either by damage or misinstallation

1. Remove hubs and inspect. Refer to

Inspection, FA-16. Pay special attention to the hub opposite the noisy side.
The ratcheting does not necessarily
cause damage to the good hub.

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA

Wheel Hub and Rotor Disc

REMOVAL AND INSTALLATION
1.

RA
BR

Remove free-running hub assembly.

Refer to Auto-lock Free-running Hub, FA-15, or Manual-lock
Free-running Hub, FA-14.
2. Remove brake caliper assembly without disconnecting ST
hydraulic line.
Be careful not to depress brake pedal, or piston will pop out. RS
Make sure brake hose is not twisted.
SFA825B

3.

Remove lock washer.

BT
HA
EL
IDX

AFA167

FA-17

FRONT AXLE
Wheel Hub and Rotor Disc (Contd)
4.

Remove wheel bearing lock nut with Tool.

AFA141

5. Remove wheel hub and wheel bearing.

Be careful not to drop outer bearing.
6. After installing wheel hub and wheel bearing, adjust wheel
bearing preload.
Refer to PRELOAD ADJUSTMENT, Front Wheel Bearing,
ON-VEHICLE SERVICE, FA-6.

SFA827B

DISASSEMBLY

Remove bearing outer races with suitable brass bar.

FA858

INSPECTION
Thoroughly clean wheel bearings and wheel hub.

Wheel bearings

Make sure wheel bearings roll freely and are free from noise,
cracks, pitting and wear.

Wheel hub

Check wheel hub for cracks by using a magnetic exploration

or dyeing test.

ASSEMBLY
1.

Install bearing outer race with Tool until it seats in hub.

AFA156

FA-18

FRONT AXLE
Wheel Hub and Rotor Disc (Contd)
2.

Install the sensor rotor using suitable drift and press. (Models GI
with ABS)
Always replace sensor rotor with new one.
Pay attention to the direction of front sensor rotor as shown in MA
figure.

EM
LC
SBR400DA

3.

Pack multi-purpose grease in wheel hub and hub cap.

EC
FE
CL
MT

AFA166

4.
5.

AT
Apply multi-purpose grease to each bearing cone.
Pack grease seal lip with multi-purpose grease, then install it
into wheel hub with suitable drift.
TF

PD
FA
SFA459B

Knuckle Spindle
REMOVAL
1.
2.

RA
BR

Remove free-running hub assembly.

Refer to Auto-lock Free-running Hub, FA-15, or Manual-lock
Free-running Hub, FA-14.
ST
Remove wheel hub and rotor disc.
Refer to Wheel Hub and Rotor Disc, FA-17.

RS
SFA828B

3.

Separate drive shaft from knuckle spindle by slightly tapping

drive shaft end.

BT
HA
EL
IDX

AFA165

FA-19

FRONT AXLE
Knuckle Spindle (Contd)
4. Separate tie-rod from knuckle spindle with Tool.
Install stud nut conversely on stud bolt so as not to damage
stud bolt.

AFA139

5.
a.

Separate knuckle spindle from ball joints.

Loosen (do not remove) upper and lower ball joint tightening
nuts.

SFA829B

b.

Separate knuckle spindle from upper and lower ball joint studs
with Tool.
During above operation, never remove ball joint nuts which
are loosened in step (a) above.
Tool:
HT72520000 (J25730-B)

SFA079

c. Remove ball joint tightening nuts.

Support lower link with jack.
d. Remove knuckle spindle from upper and lower links.

INSPECTION
Knuckle spindle

Check knuckle spindle for deformation, cracks and other damage by using a magnetic exploration or dyeing test.

SFA830B

Needle bearing

Check needle bearing for wear, scratches, pitting, flaking and

burn marks.

FA-20

FRONT AXLE
Knuckle Spindle (Contd)
INSTALLATION

GI

1. Install needle bearing into knuckle spindle.

Make sure that needle bearing is facing in the proper direction. MA
Apply multi-purpose grease.

EM
LC
AFA164

Install knuckle spindle to upper and lower ball joints with lower EC
link jacked up.
CAUTION:
Make sure that oil and grease do not come into contact with FE
tapered areas of ball joint, knuckle spindle and threads of ball
joint.
CL
3. Connect tie-rod to knuckle spindle.
2.

MT
SFA831B

After installing knuckle spindle, adjust wheel bearing preload. AT

Refer to PRELOAD ADJUSTMENT, Front Wheel Bearing,
ON-VEHICLE SERVICE, FA-6.
TF
5. After installing drive shaft, check drive shaft axial end play.
Do not reuse snap ring once it has been removed.
Refer to Drive Shaft, FA-22.
PD

4.

FA
AFA163

RA
BR
ST
RS
BT
HA
EL
IDX

FA-21

FRONT AXLE
Drive Shaft

SFA874-B

REMOVAL
1.

Remove free-running hub or drive flange and snap ring. Refer

to Auto-lock Free-running Hub, FA-15, or Manual-lock Freerunning Hub, FA-14.
2. Remove torsion bar spring. Refer to Torsion Bar Spring,
FRONT AXLE, FA-28.
3. Remove shock absorber lower fixing bolt.
4. Remove lower link fixing bolts.
Support lower link with jack.

SFA832B

5.

Remove bolts fixing drive shaft to final drive.

6.

Separate drive shaft from knuckle spindle by slightly tapping

end of drive shaft.

SFA236

SFA833B

FA-22

FRONT AXLE
Drive Shaft (Contd)
DISASSEMBLY

GI

Final drive side (TS82F)

1.
2.

Remove plug seal from slide joint housing by lightly tapping MA

around slide joint housing.
Remove boot bands.

EM
LC
SFA880

3.

Move boot and slide joint housing toward wheel side, and put EC
matching marks.

FE
CL
MT
SFA963

4.

Remove snap ring.

AT
TF
PD
FA

SFA964

5.

Detach spider assembly with press.

RA
BR
ST
RS

SFA392

BT

6. Draw out boot.

Cover drive shaft serration with tape to prevent damaging the
boot.
HA

EL
IDX
SFA799

FA-23

FRONT AXLE
Drive Shaft (Contd)
Wheel side (ZF100)
CAUTION:
The joint on the wheel side cannot be disassembled.

Before separating joint assembly, put matching marks on drive

shaft and joint assembly.

Separate joint assembly with suitable tool.

Be careful not to damage threads on drive shaft.

Remove boot bands.

SFA455

INSPECTION
Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation and other
damage.

Drive shaft
Replace drive shaft if it is twisted or cracked.

Boot
Check boot for fatigue, cracks and wear. Replace boot with new
boot bands.

Joint assembly (Final drive side)

Replace any parts of double offset joint which show signs of

scorching, rust, wear or excessive play.
Check serration for deformation. Replace if necessary.
Check slide joint housing for any damage. Replace if necessary.

Joint assembly (Wheel side)

Replace joint assembly if it is deformed or damaged.

ASSEMBLY

After drive shaft has been assembled, ensure that it

moves smoothly over its entire range without binding.
Use NISSAN GENUINE GREASE or equivalent after every
overhaul.

Final drive side (TS82F)

1.

Install new small boot band, boot and side joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damaging
boot during installation.

SFA800

FA-24

FRONT AXLE
Drive Shaft (Contd)
2.

3.

Install spider assembly securely, making sure marks are prop- GI

erly aligned.
Press-fit with spider assembly serration chamfer facing
MA
shaft.
Install new snap ring.

EM
LC
SFA397

4.
5.

EC
Pack with grease.
Specified amount of grease:
95 - 105 g (3.35 - 3.70 oz)
Make sure that the boot is properly installed on the drive shaft FE
groove. Set the boot so that it does not swell or deform when
its length is L1.
CL
Length L1: 95 - 97 mm (3.74 - 3.82 in)
MT

SFA460BA

Lock new large boot band securely with a suitable tool, then AT
lock new small boot band.
7. Install new plug seal to slide joint housing by lightly tapping it.
TF
Apply sealant to mating surface of plug seal.
6.

PD
FA
SFA443B

Wheel side (ZF100)

RA

1. Install new small boot band and boot on drive shaft.

Cover drive shaft serration with tape to prevent damaging BR
boot during installation.

ST
RS
SFA800

2.

BT

Set joint assembly onto drive shaft by lightly tapping it.

Install joint assembly securely, ensuring that marks which were
made during disassembly are properly aligned.
HA

EL
IDX
SFA884

FA-25

FRONT AXLE
Drive Shaft (Contd)
3.
4.

5.
6.

Pack drive shaft with specified amount of grease.

Specified amount of grease:
135 - 145 g (4.76 - 5.11 oz)
Make sure that the boot is properly installed on the drive shaft
groove. Set the boot so that it does not swell or deform when
its length is L2.
Length L2: 96 - 98 mm (3.78 - 3.86 in)
Lock new large boot band securely with a suitable tool.
Lock new small boot band.

SFA473BA

INSTALLATION
1.

Apply multi-purpose grease.

SFA887

SFA846

2. Install bearing spacer onto drive shaft.

Make sure that the bearing spacer is facing in the proper direction.
3. After installing wheel hub and wheel bearing, adjust wheel
bearing preload. Refer to PRELOAD ADJUSTMENT, Front
Wheel Bearing, ON-VEHICLE SERVICE, FA-6.
4. When installing drive shaft, adjust drive shaft axial end play by
selecting a suitable snap ring.
a. Install fixed cam assembly and spindle washer.
b. Temporarily install new snap ring on drive shaft in the same
thickness as it was installed before removal.
c.
d.
e.

LFA016

Set dial gauge on drive shaft end.

Measure axial end play of drive shaft.
Axial end play:
0.10 - 0.45 mm (0.004 - 0.0177 in)
If axial end play is not within the specified limit, select another
snap ring.

1.1
1.5
1.9
2.3

mm
mm
mm
mm

FA-26

(0.043
(0.059
(0.075
(0.091

in)
in)
in)
in)

1.3 mm (0.051 in)

1.7 mm (0.067 in)
2.1 mm (0.083 in)

FRONT AXLE
Drive Shaft (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
ASU059

FA-27

FRONT AXLE
Shock Absorber
REMOVAL AND INSTALLATION
1.
2.

Support lower link with jack.

Remove bolt and nut that hold shock absorber.

INSPECTION

SFA836B

Except for nonmetallic parts, clean all parts with suitable solvent
and dry with compressed air.
Use compressed air to blow dirt and dust off of nonmetallic parts.

Check for oil leakage and cracks. Replace if necessary.

Check piston rod for cracks, deformation and other damage.

Replace if necessary.

Check rubber parts for wear, cracks, damage and deformation.

Replace if necessary.

Torsion Bar Spring

REMOVAL
1.
2.

AFA140

Move dust cover.

Paint matching marks on the torsion bar spring and the corresponding arm.
Always use paint to place the matching mark; do not scribe
the affected parts.
3. Measure anchor bolt protrusion L and remove the lock nut
and adjusting nut.
Before removing the nuts, ensure that twisting force is eliminated from the torsion bar springs.

SFA837B

AFA161

4.

Remove torsion bar spring.

Remove torque arm fixing nuts, then withdraw torsion bar
spring forward with torque arm.

AFA160

FA-28

FRONT AXLE
Torsion Bar Spring (Contd)
INSPECTION

GI

Check torsion bar spring for wear, twist, bend and other damage.
Check serrations of each part for cracks, wear, twist and other MA
damage.
Check dust cover for cracks.

EM
LC

INSTALLATION AND ADJUSTMENT

EC

Adjustment of anchor arm adjusting nut is in tightening direction only.

FE
Do not adjust by loosening anchor arm adjusting nut.
1. Coat multi-purpose grease on the serration of torsion bar
spring.
CL
2. Place lower link in the position where bound bumper clearance
C is 0.
Clearance C: 0 mm (0 in)
MT
SFA549

AT
3. Install torsion bar spring with torque arm.
Be sure to install right and left torsion bar springs correctly.
4. While aligning the anchor arm with the matching mark, install TF
the anchor arm to the torsion bar spring.
If a new torsion bar spring or anchor arm is installed, adjust
anchor arm length to the dimension indicated in the figure at PD
the left.
Standard length G:
25 - 39 mm (0.98 - 1.54 in)
FA

SFA854

RA
BR
ST
RS
AFA159

BT
HA
EL
IDX

FA-29

FRONT AXLE
Torsion Bar Spring (Contd)
5.

6.
AFA161

7.
a.
b.

8.

9.

Tighten the adjusting nut so the torsion bar length corresponds

with dimension L previously measured during torsion bar
removal. Tighten the lock nut to specifications.
If a new torsion bar spring or anchor arm is installed, tighten
the adjusting nut to the dimension indicated in the figure at the
left, then tighten the lock nut to specifications.
Standard length L:
70 mm (2.76 in)
Bounce vehicle with tires on ground (Unladen) to eliminate
friction of suspension.
Measure vehicle posture H.
Exercise the front suspension by bouncing the front of the
vehicle 4 or 5 times to ensure that the vehicle is in a neutral
height attitude.
Measure vehicle posture ... Dimension H.
H = A B mm (in) Unladen
Refer to WHEEL ALIGNMENT (Unladen), SDS,
FA-35.

If height of the vehicle is not within allowable limit, adjust

vehicle posture.
Refer to WHEEL ALIGNMENT (Unladen), SDS,
FA-35.
Check wheel alignment if necessary.
Refer to WHEEL ALIGNMENT (Unladen), SDS,
FA-35.

AFA171

Stabilizer Bar
REMOVAL

Remove stabilizer bar connecting bolts and clamp bolts.

INSPECTION

Check stabilizer bar for twist and deformation.

Replace if necessary.
Check rubber bushing for cracks, wear and deterioration.
Replace if necessary.

AFA158

FA-30

FRONT AXLE
Stabilizer Bar (Contd)
INSTALLATION

GI

Install bushing outside of white mark painted on stabilizer.

MA
EM
LC
SFA841B

Upper Link

EC

REMOVAL
1. Remove shock absorber. Refer to Shock Absorber, FA-28.
2. Separate upper ball joint stud from knuckle spindle.
Support lower link with jack.
Refer to Knuckle Spindle, FRONT AXLE, FA-19.

FE
CL
MT

SFA836B

3.

Put matching marks on adjusting bolts and remove adjusting AT

bolts.

TF
PD
FA
SFA842B

INSTALLATION
1.

2.
3.
4.

While aligning the adjusting bolts with the matching marks,

install the upper link.
If a new upper link or any other suspension part is installed,
align the matching mark with the slit as indicated in the figure
at the left, then install the upper link.
Refer to Front Wheel Alignment, ON-VEHICLE SERVICE,
FA-7.
Install shock absorber.
Tighten adjusting bolts under unladen condition with tires on
ground.
After installing, check wheel alignment. Adjust if necessary.
Refer to FA-7.

RA
BR
ST
RS
BT
HA
EL
IDX

SFA817B

FA-31

FRONT AXLE
Upper Link (Contd)
DISASSEMBLY

Press out upper link bushings.

INSPECTION

Check adjusting bolts and rubber bushings for damage.

Replace if necessary.
Check upper link for deformation and cracks. Replace if necessary.

SFA843B

ASSEMBLY
1. Apply soapsuds to rubber bushing.
2. Press upper link bushing.
Press bushing so that the flange of bushing securely contacts
the end surface of the upper link collar.

SFA102

Lower Link
REMOVAL AND INSTALLATION
1.

SFA837B

Remove torsion bar spring. Refer to REMOVAL, Torsion Bar

Spring, FA-28.
Make matching marks and measure dimension L when loosening adjusting nut until there is no tension on torsion bar
spring.
2. Remove shock absorber lower fixing bolt.
3. Remove stabilizer bar connecting bolt.
4. Separate drive shaft from front final drive.
Refer to Drive Shaft, FRONT AXLE, FA-22.
5. Separate lower link ball joint from knuckle spindle.
Refer to Knuckle Spindle, FRONT AXLE, FA-19.

AFA161

6.

Remove front lower link fixing bolts.

ASU028

FA-32

FRONT AXLE
Lower Link (Contd)
7.
8.

GI
Remove bushing of lower link spindle from frame with Tool.
After installing lower link, adjust wheel alignment and vehicle
height. Refer to Front Wheel Alignment, ON-VEHICLE
MA
SERVICE, FA-7.

INSPECTION
Lower link and lower link spindle

Lower link bushing

EM

Check for deformation and cracks. Replace if necessary.

Check for distortion and damage. Replace if necessary.

LC

AFA138

Upper Ball Joint and Lower Ball Joint

EC

REMOVAL AND INSTALLATION

Separate knuckle spindle from upper and lower links.

Refer to Knuckle Spindle, FRONT AXLE, FA-19.

INSPECTION

AFA136

FE
CL

Check joints for play. If ball is worn and play in axial direction
is excessive or joint is hard to swing, replace as a upper link
MT
or lower link.
Axial end play C:
Upper link
AT
0 mm (0 in)
Lower link
0.2 mm (0.008 in) or less

TF

Check dust cover for damage.

Replace dust cover and dust cover clamp if necessary.

PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX

FA-33

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Independent double wishbone
torsion bar spring

Suspension type
Shock absorber type

Double-acting hydraulic

Stabilizer

Standard equipment

Inspection and Adjustment

WHEEL BEARING

UPPER BALL JOINT

Wheel bearing lock nut

Vertical end play C

Tightening torque
Nm (kg-m, ft-lb)
Retightening torque after
loosening wheel bearing lock nut
Nm (kg-m, ft-lb)
Axial end play

0.5 - 1.5
(0.05 - 0.15, 0.4 - 1.1)

mm (in)

Vertical end play C

mm (in)

degree

15 - 30

Starting force at wheel hub bolt

N (kg, lb)

Wheel bearing preload at wheel hub

bolt
N (kg, lb)
7.06 - 20.99
(0.72 - 2.14, 1.59 - 4.72)

BA

WHEEL RUNOUT AVERAGE

Wheel type
Radial runout limit
mm (in)
Lateral runout limit
mm (in)

Aluminum

Steel

0.3 (0.012)

0.8 (0.031)

0.3 (0.012)

0.8 (0.031)

0 (0)

LOWER BALL JOINT

0 (0)

Starting force at wheel hub bolt

N (kg, lb)
Turning angle

mm (in)

78 - 98
(8 - 10, 58 - 72)

FA-34

0.2 (0.008 in) or less

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Contd)
GI

WHEEL ALIGNMENT (Unladen*1)

Camber

Minimum

006 (0.10)

Nominal

036 (0.60)

Maximum
Degree minute
(Decimal degree) Left and right difference
Caster

Minimum
Nominal

210 (2.17)
240 (2.67)

Nominal

1048 (10.80)

mm (in)
Angle (left plus right)
Radial tire

Full turn*2
Outside

EC

1118 (11.30)
Minimum

3 (0.12)

Nominal

4 (0.16)

Maximum

5 (0.20)

Minimum

15 (0.25)

Nominal

20 (0.33)

Maximum

25 (0.42)

Wheel turning angle

Inside

45 (0.75) or less
1018 (10.30)

Radial tire

EM
LC

Minimum

Total toe-in

Degree minute
(Decimal degree)

45 (0.75) or less

Maximum

Degree minute
(Decimal degree) Maximum

Distance (A - B)

106 (1.10)

140 (1.67)

Degree minute
(Decimal degree) Left and right difference
Kingpin inclination

MA

FE
CL
MT

Except P265/70R15

P265/70R15

Minimum

3306 (33.10)

3100 (31.00)

Nominal

3506 (35.10)

3300 (33.00)

Degree minute
(Decimal degree) Maximum

3506 (35.10)

3300 (33.00)

Minimum

3112 (31.20)

2900 (29.00)

Nominal
Degree minute
(Decimal degree) Maximum

3312 (33.20)

3100 (31.00)

3312 (33.20)

3100 (31.00)

AT
TF
PD

Vehicle posture
Lower arm pivot height (H)

mm (in)

45.5 - 49.5 (1.791 - 1.949)

FA
RA
BR
ST
AFA171

RS

*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

BT
HA
EL
IDX

FA-35

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Contd)
DRIVE SHAFT

Drive shaft axial end play

Drive shaft joint type

Drive shaft axial end play

Final drive side

TS82F

Wheel side

ZF100

Fixed joint axial end play

limit
mm (in)
Diameter

mm (in)

Drive shaft end snap ring

1 (0.04)
Thickness mm (in)

mm (in)

Wheel side (D1)

1.1
1.3
1.5
1.7
1.9
2.1
2.3

29.0 (1.142)

Grease
Nissan genuine grease or
equivalent

Quality
Capacity

g (oz)

Final drive side

95 - 105 (3.35 - 3.70)

Wheel side

135 - 145 (4.76 - 5.11)

Boot length

0.10 - 0.45 mm
(0.004 - 0.0177 in)

95 - 97 (3.74 - 3.82)

Wheel side (L2)

96 - 98 (3.78 - 3.86)

39253-88G10
39253-88G11
39253-88G12
39253-88G13
39253-88G14
39253-88G15
39253-88G16

*: Always check with the Parts Department for the latest parts
information.

mm (in)

Final drive side (L1)

(0.043)
(0.051)
(0.059)
(0.067)
(0.075)
(0.083)
(0.091)

Part No.*

SFA877A

FA-36