suspension and axle

SA–1
SUSPENSION AND AXLE
–
SUSPENSION AND AXLE
SA–2
SUSPENSION AND AXLE
–
TROUBLESHOOTING
TROUBLESHOOTING
Wander/pulls
Bottoming
Sways/pitches
Front wheel shimmy
Abnormal tire wear
SA–63
SA–10
Ball joint
Hub bearings
SA–3
SA–52
Shock absorber
Wheel
balance
SA–66
Stabilizer bar
Overloaded
SA–52
Springs
Suspension parts
SA–4
SA–6
Wheel alignment
Trouble
Steering
gear
SA–96
Cold tire inflation
pressure
Parts
Name
Steering linkage
SA–3
See Page
Tires
Use the table below to help you find the cause of the problem. The numbers indicate the priority
of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SA–3
SUSPENSION AND AXLE
–
GENERAL INSPECTION
GENERAL INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and for the proper inflation
pressure.
Cold inflation pressure:
See page SA–96
(b) Check the tire runout.
Tire runout:
1.0 mm (0.039 in.) or less
2. INSPECT WHEEL BALANCE
(a) Check and adjust the Off–the–car balance.
(b) If necessary, check and adjust the On–the–car bal–
ance.
Unbalance after adjustment:
8.0 g (0.018 Ib) or less
3. CHECK WHEEL BEARING LOOSENESS
(a) Check the backlash in bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.05 mm (0.0020 in.)
4.
5.
6.
7.
CHECK FRONT SUSPENSION FOR LOOSENESS
CHECK STEERING LINKAGE FOR LOOSENESS
CHECK BALL JOINT FOR EXCESSIVE LOOSENESS
CHECK SHOCK ABSORBERS WORK PROPERLY
•
Check for oil leaks
•
Check mounting bushings for looseness
•
Bounce the vehicle up and down several times to
stabilize the suspension.
SA–4
SUSPENSION AND AXLE
–
WHEEL ALIGNMENT
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
1. MEASURE VEHICLE HEIGHT
Front vehicle height:
SEDAN/COUPE:
Tire size
P195/70R14
Front
210 mm (8.27 in.)
P205/65 R15
213 mm (8.39 in.)
WAGON:
Tire size
P 195/70R 14
Front
210 mm (8.27 in.)
P205/65R15
214 mm (8.43 in.)
Measuring point:
Measure from the ground to the center of the front
side lower arm mounting bolt.
NOTICE: Before inspecting the wheel alignment, adjust
the vehicle height to specification.
If the vehicle height is not standard, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER – CASTER – KINGPIN GAUGE
ONTO VEHICLE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment
manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
SEDAN/COUPE
Cambar
(Left –right error)
–035’ ± 45’
(45’ or less)
WAGON
–0 35’±45’
(45’ or less)
Caster
(Left–right error)
1 10’ ±45’
(45’ or less)
1 05’±45’
(45’ or less)
Steering axis
inclination
13 05’ ±45’
1300’±45’
HINT: Camber, caster and steering axis inclination are
not adjustable. If measurements are not within speci–
fication, inspect the suspension parts for damaged
and/or worn out parts and replace them as necessary.
SA–5
SUSPENSION AND AXLE
–
WHEEL ALIGNMENT
4. INSPECT TOE–IN
Toe–in (total):
A+B 0 ± 0.2
(C–D 0 ± 2 mm, 0 ± 0.08 in.)
If the toe–in is not within specification, adjust it at
the tie rod end.
5. ADJUST TOE–IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right tie rod ends an equal amount to
adjust the toe–in.
HINT: Ensure that the lengths of the left and right tie
rod end length are the same.
Tie rod end length difference:
1.5 mm (0.059 in.) or less
(d) Torque the tie rod end lock nuts.
Torque: 74 N⋅m (750 kgf⋅cm, 54 ft⋅lbf)
(e) Place the boot on the seat and install the clamp.
HINT: Make sure that the boots are not twisted.
7. INSPECT WHEEL ANGLE
Wheel angle:
SEDAN/COUPE:
Tire size
Inside wheel
Outside wheel
(reference)
P195/70R14
37 20’± 2
32 10’
P205/65R15
3600’ ± 2
31 15’
WAGON:
Tire size
Inside wheel
Outside wheel
(reference)
P195/70R14
3720’ ± 2
32 15’
P205/65R15
36 00’ ± 2
31 20’
If the wheel angles differ from specification, check the
left and right tie rod end length.
Tie rod end length difference:
1.5 mm (0.059 in.) or less
SA–6
SUSPENSION AND AXLE
–
WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
7. MEASURE VEHICLE HEIGHT
Rear vehicle height:
SEDAN/COUPE:
Tire size
P 19 5/78 R 14
Rear
262 mm (10.31 in.)
P205/65R15
267 mm (10.51 in.)
WAGON:
Tire size
P195/70R14
Rear
272 mm (10.71 in.)
P205/65 R15
277 mm (10.91 in.)
Measuring point:
Measure from the ground to the center of the strut
rod mounting bolt.
NOTICE: Before inspecting the wheel alignment, adjust
the vehicle height to specification.
If the vehicle height is not standard, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER – CASTER – KINGPIN GAUGE
ONTO VEHICLE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment
manufacturer.
3. INSPECT CAMBER
Camber
(Left–right error)
SEDAN/COUPE
– 0 26’ ± 45’
(45’ or less)
WAGON
–0 15’ ± 45’
(45’ or less)
HINT: Camber is not adjustable, if measurement is not
within specification, inspect and replace the suspen–
sion parts as necessary.
4. INSPECT TOE–IN
Toe–in (total):
A+B 0.4 ± 0.2
(C – D 4 ± 2 mm, 0.16 ± 0.08 in.)
If the toe–in is not within the specification, adjust it
at the No.2 lower suspension arm.
SA–7
SUSPENSION AND AXLE
–
WHEEL ALIGNMENT
5. ADJUST TOE–IN
(a) Measure the length of the left and right No.2 lower
suspension arm.
Left–right difference:
1 mm (0.04 in.) or less
If the left–right difference is greater than the specifi–
cation, adjust the length.
(b) Loosen the lock nuts.
(c) Turn the left and right adjusting tubes an equal
amount to adjust toe–in.
HINT: One full turn of each adjusting tube will adjust
the toe–in by about O.6(6.7 mm, 0.264 in.).
(d) Torque the lock nuts.
Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf)
SA–8
SUSPENSION AND AXLE
–
FRONT AXLE
FRONT AXLE
DESCRIPTION
The wheel bearings are double–row angular ball bearings combined with the oil seal. They have
a small rolling resistance and are free from maintenance.
The preload of the bearings can be determined only by tightening the axle hub nut to a specified
torque, improving serviceability.
SA–9
SUSPENSION AND AXLE
–
FRONT AXLE
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09310–35010 Countershaft Bearing Replacer
Bearing removal
Axle shaft installation
09316–60010 Transmission & Transfer Bearing
Replacer
Dust deflector Installation
(09316–00010) Replacer Pipe
(09316–00040) Replacer “C“
09520–00031 Rear Axle Shaft Puller
09608–32010 Steering Knuckle Oil Seal
Replacer
Bearing installation
Axle hub installation
Dust deflector installation
09628–10011 Ball Joint Puller
Hub bolt removal
09628–62011 BaII ,Joint Puller
09950–00020 Bearing Remover
RECOMMENDED TOOLS
09905–00013 Snap Ring Pliers
EQUIPMENT
Dial indicator
Torque wrench
SA–10
SUSPENSION AND AXLE
–
FRONT AXLE
FRONT AXLE HUB
COMPONENTS
SA–11
SUSPENSION AND AXLE
–
FRONT AXLE
STEERING KNUCKLE WITH AXLE HUB
REMOVAL
1. JACK UP VEHICLE, REMOVE FRONT WHEEL
2. CHECK BEARING BACKLASH AND AXLE HUB DE–
VIATION
(a) Remove the 2 brake caliper set bolts.
(b) Hang up the brake caliper using wire, etc.
(c) Remove the disc.
(d) Place the dial indicator near the center of the axle hub
and check the backlash in the bearing shaft direction.
Maximum:
0.05 mm (0.0020 in.)
If greater than the specified maximum, replace the
bearing.
(e) Using a dial indicator, check the deviation at the
surface of the axle hub outside the hub bolt.
Maximum:
0.05 mm (0.0020 in.)
If greater than the specified maximum, replace the
axle hub.
3. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the disc and brake caliper.
(b) Remove the cotter pin and lock cap.
(c) While applying the brakes, remove the nut.
(d) Remove the brake caliper and disc.
4. w/ ABS:
REMOVE ABS SPEED SENSOR
Remove the ABS speed sensor from the steering knuckle.
5. LOOSEN NUTS ON LOWER SIDE OF SHOCK ABS–
ORBER
HINT: Do not remove the bolts.
SA–12
SUSPENSION AND AXLE
–
FRONT AXLE
6. DISCONNECT TIE ROD END FROM STEERING KNU–
CKLE
(a) Remove the cotter pin and remove the nut.
(b) Using SST, disconnect the tie rod end from the steer–
ing knuckle.
SST 09628–62011
7. DISCONNECT LOWER BALL JOINT FROM LOWER
ARM
Remove the bolt and the two nuts.
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 nuts and bolts on lower side of the
shock absorber.
(b) Remove the steering knuckle with axle hub.
FRONT AXLE HUB DISASSEMBLY
1. REMOVE DUST DEFLECTOR
Using a screwdriver, remove the dust deflector.
SA–13
SUSPENSION AND AXLE
–
FRONT AXLE
2. REMOVE LOWER BALL JOINT
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint.
SST 09628–62011
3. REMOVE AXLE HUB
(a) Using SST, remove the axle hub.
SST 09520–00031
(b) Using SST and a press, remove the inner race (outside)
from the axle hub.
SST 09950–00020
4. REMOVE DUST COVER
Remove the 4 bolts and dust cover–.
5. REMOVE BEARING FROM STEERING KNUCKLE
(a) Using snap ring pliers, remove the snap ring.
SA–14
SUSPENSION AND AXLE
–
FRONT AXLE
(b) Place the inner race on the outside of the bearing.
(c) Using SST and a hammer, remove the bearing.
SST 09310–35010
FRONT AXLE HUB ASSEMBLY
1. INSTALL BEARING
(a) Using SST and a press, install a new bearing to the
steering knuckle.
SST 09608–32010
(b) Using snap ring pliers, install a new snap ring.
2. INSTALL DUST COVER
Place the dust cover and torque the 4 bolts.
Torque: 8.3 N⋅m (85 kgf⋅cm, 74 in.⋅Ibf)
3. INSTALL FRONT AXLE HUB
Using SST and a press, install the axle hub.
SST 09310 – 35010, 09608 – 32010
SA–15
SUSPENSION AND AXLE
–
FRONT AXLE
4. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and torque the nut.
Torque: 123 N⋅m (1,250 kgf⋅cm. 90 ft⋅lbf)
(b) Install a new cotter pin.
5. INSTALL DUST DEFLECTOR
Using SST and a hammer, install a new dust deflector.
SST 09316–60010(09316–00010, 09316–00040)
09608–32010
HINT: Align the holes for the ABS speed sensor in the
dust deflector and steering knuckle.
STEERING KNUCKLE WITH AXLE HUB
INSTALLATION
1. INSTALL STEERING KNUCKLE
(a) Place the steering knuckle and temporarily install the
2 bolts and nut on lower side of shock absorber.
HINT: Coat the threads of nuts with engine oil.
(b) Connect the lower ball joint to the lower arm and
tighten the bolt and nuts.
Torque: 127 N⋅m (1,300 kgf⋅cm. 94 ft⋅lbf)
2. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle and
tighten the nut.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(b) Install a new cotter pin.
SA–16
SUSPENSION AND AXLE
–
FRONT AXLE
3. TORQUE BOLTS ON LOWER SIDE OF SHOCK ABS–
ORBER
Torque: 211 N⋅m (2,150 kgf⋅cm, 156 ft⋅Ibf)
4. w/ ABS:
INSTALL ABS SPEED SENSOR
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅Ibf)
5. INSTALL FRONT BRAKE CALIPER
(a) Install the disc.
(b) Install the brake caliper.
Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying the brakes, install the nut.
Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf)
(b) Install the lock cap and a new cotter pin.
7. INSTALL FRONT WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
8. INSPECT FRONT WHEEL ALIGNMENT
(SEE PAGE SA–4)
HUB BOLT REPLACEMENT
1. JACK UP VEHICLE AND REMOVE FRONT WHEEL
2. REMOVE FRONT BRAKE CALIPER AND DISC
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628 –10011
SA–17
SUSPENSION AND AXLE
–
FRONT AXLE
4. INSTALL HUB BOLT
(a) Install washer and nut to the hub bolt as shown in the
illustration.
(b) Install the hub bolt with torquing the nut. Install the
hub bolt with torquing the nut.
5. INSTALL FRONT DISC AND BRAKE CALIPER
Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅Ibf)
6. INSTALL FRONT WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf)
SA–18
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1mz–fe)
FRONT DRIVE SHAFT
(1 MZ–FE)
DESCRIPTION
The drive shaft has a cross–groove type CVJ (Constant Velocity Joint) on the differential side
and Rzeppa type CVJ on the wheel side.
SA–19
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09608–1 6041 Front Hub Bearing Adjusting Tool
(09608–02020) Bolt & Nut
(09608–02040) Retainer
09628–62011 Ball ,Joint Puller
Tie rod end
09726–10010 Lower Suspension Arm Bushing
Remover & Replacer
(09726–00030) Spacer
Drive shaft inboard joint
09923–00020 Hexagon 8 mm Wrench
09950–00020 Bearing Remover
Center drive shaft dust
cover
09521–24010 Drive Shaft Boot Clamping
Tool
09240–00020 Wire Gauge Set
09242–00190 Wire Gauge
RECOMMENDED TOOLS
09905–00012 Snap Ring No. 1 Expander
Corrected 6/07/01 – MH
For removing and installing snap
ring
SA–20
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
EQUIPMENT
Torque wrench
LUBRICANT
Drive shaft
Toyota type
Item
Outboard joint grease
Inboard joint grease
Capacity
120–130 g (4.2–4.6 oz.)
133–153 g (4.7–5.4 oz.)
SSM (SPECIAL SERVICE MATERIALS)
08826–00801 Seal Packing 1121,
THREE BOND 1121 or equivalent
Drive shaft inboard joint cover
SA–21
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
FRONT DRIVE SHAFT
COMPONENTS
SA–22
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
FRONT DRIVE SHAFT REMOVAL
NOTICE: The hub bearing could be damaged if it is sub–
jected to the vehicle weight, such as when moving the
vehicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the vehi–
cle weight on the hub bearing, first support it with SST.
SST 09608–16041(09608–02020, 09608–02040)
1. REMOVE FRONT FENDER APRON SEAL
2. REMOVE COTTER PIN, LOCK NUT CAP AND LOCK
NUT
(a) Remove the cotter pin and lock nut cap.
(b) Loosen the bearing lock nut while depressing the
brake pedal.
3. DRAIN TRANSAXLE OIL
4. DISCONNECT TIE ROD END FROM STEERING KNU–
CKLE
(a) Remove the cotter pin and nut from the tie rod end.
(b) Using SST, disconnect the tie rod end from the steer–
ing knuckle.
SST 09628–62011
5. DISCONNECT STABILIZER BAR LINK FROM
LOWER ARM
Remove the nut and disconnect the stabilizer bar link
from lower arm.
SA–23
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
6. DISCONNECT STEERING KNUCKLE FROM LOWER
BALL JOINT
(a) Remove the bolt and the 2 nuts.
(b) Disconnect the steering knuckle from the lower ball
joint.
7. LOOSEN 6 BOLTS HOLDING DRIVE SHAFT TO DIF–
FERENTIAL SIDE GEAR SHAFT OR CENTER DRIVE
SHAFT
(a) Place matchmarks on the drive shaft and side gear
shaft or center drive shaft.
NOTICE: Do not use a punch to mark the matchmarks.
Use paint, etc.
(b) Using SST, loosen the 6 hexagon bolts while depress–
ing the brake pedal.
SST 09923 – 00020
HINT: Do not remove the bolts, leave them finger tight
to avoid drop ping the drive shaft.
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
(a) Using a plastic hammer, discontinued the drive shaft
from the axle hub.
NOTICE: Cover the drive shaft boot with cloth to protect
it from damage.
(b) Push the front axle hub toward the outside of the
vehicle, and separate the drive shaft from the axle
hub.
9. REMOVE LH DRIVE SHAFT
(a) Using hub nut wrench and hammer handle or equiva–
lent, pull out the drive shaft as shown.
SA–24
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
(b) Using a screwdriver, remove the snap ring.
10. REMOVE RH DRIVE SHAFT
(a) Remove the bearing lock bolt.
(b) Using pliers, remove the snap ring, and pull out the
drive shaft.
SA–25
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
FRONT DRIVE SHAFT INSTALLATION
1. INSTALL LH DRIVE SHAFT
(a) Using pliers, install a new snap ring.
(b) Coat gear oil to the side gear shaft and differential
case sliding surface.
(c) Using a brass bar and hammer, tap in the drive shaft
until it makes contact with the pinion shaft.
HINT:
•
Before installing the drive shaft, set the snap ring
opening side facing downward.
•
Whether or not the side gear shaft is making
contact with the pinion shaft can be known by
the sound or feeling when driving it in.
2. CHECK INSTALLATION OF LH DRIVE SHAFT
(a) Check that there is 2–3 mm (0.08–0.12 in.) of play in
the axial direction.
(b) Check that the drive shaft can not be removed by
hand.
3. INSTALL RH DRIVE SHAFT
(a) Coat gear oil to the inboard joint and differential
sliding surface.
(b) Install the drive shaft to the transaxle through the
bearing bracket.
NOTICE: Do not damage the oil seal lip.
(c) Using pliers, install a new snap ring.
(d) Install a new bearing lock bolt and tighten it.
Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf)
SA–26
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
4. CONNECT DRIVE SHAFT TO AXLE HUB
Install the outboard joint side of the drive shaft to the
axle hub.
NOTICE: Do not damage the boot.
5. CONNECT STEERING KNUCKLE TO LOWER ARM
Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf)
6. TIGHTEN6 HEXAGON BOLTS
Using SST, tighten the6 hexagon bolts while depress–
ing the brake pedal.
SST 09043–88010
Torque: 65 N⋅m (660 kgf⋅cm, 48 ft⋅lbf)
7. CONNECT STABILIZER BAR LINK TO LOWER ARM
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
8. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle and
torque the nut.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(b) Install a new cotter pin.
HINT: If the cotter pin hole does not line up, correct by
tightening the nut by the smallest amount possible.
SA–27
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
9. INSTALL BEARING LOCK NUT, LOCK NUT CAP
AND NEW COTTER PIN
(a) Install and torque the bearing look nut
Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf)
(b) Install the lock nut cap and secure it with a new cotter
pin.
10. FILL TRANSAXLE WITH GEAR OIL
11. INSTALL FRONT FENDER APRON SEAL
12. CHECK FRONT WHEEL ALIGNMENT
FRONT DRIVE SHAFT DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the inboard and
outboard joints.
(b) Check to see that the inboard joint slides smoothly in
the thrust direction.
(c) Check to see that there is no significant play in the
radial direction of the inboard joint.
(d) Check the boot for damage.
2. DISCONNECT CENTER DRIVE SHAFT OR SIDE
GEAR SHAFT
(a) Using SST, remove the 6 bolts and 3 washers, and
disconnect the center drive shaft or side gear shaft
from the drive shaft.
SST 09923–00020
NOTICE: Do not compress the inboard boot.
(b) Remove the joint end cover gasket from the drive
shaft.
(c) Use bolts, nuts and washers to keep the inboard joint
together.
NOTICE: Tighten the bolts by hand to avoid scratching
the flange surface.
SA–28
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
3. TOYOTA TYPE:
REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
Using a screwdriver, remove the inboard and outboard
joint clamps.
GKN TYPE:
REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
(a) Using a boot clamp tool, draw hooks together and
remove the clamps.
(b) Using side cutters, cut the small boot clamps and
remove them.
4. DISASSEMBLE INBOARD JOINT
(a) Place matchmarks on the inboard joint and drive
shaft.
(b) Using a snap ring expander remove the snap ring.
SA–29
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
(c) Using SST, a socket wrench and a press, remove the
inboard joint from the drive shaft.
SST 09726–10010(09726–00030)
(d) Remove the bolts, nuts and washers.
(e) Using a screwdriver and a hammer, pry around the
whole perimeter of the inboard joint cover.
(f) Using a screwdriver, remove the inboard joint from
inboard joint cover.
NOTICE: When lifting the inboard joint, hold onto the
inner race and outer race.
5. REMOVE BOOTS
Remove the inboard joint boot and outboard joint
boot.
6. LH DRIVE SHAFT:
DISASSEMBLE SIDE GEAR SHAFT
Using a screwdriver, remove the dust cover.
7. RH DRIVE SHAFT:
DISASSEMBLE CENTER DRIVE SHAFT
(a) Using a press, press out the transaxle side dust cover.
SA–30
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
(b) Using SST and a press, press out the drive shaft side
dust cover.
SST 09950–00020
(c) Using snap ring pliers, remove the snap ring.
(d) Using a press, press out the bearing.
(e) Remove the snap ring.
FRONT DRIVE SHAFT ASSEMBLY
1. RH DRIVE SHAFT:
ASSEMBLE CENTER DRIVE SHAFT
(a) Install a new snap ring to the center drive shaft.
(b) Using a press and extension bar, press in a new
bearing.
(c) Using a snap ring expander, install a new snap ring.
SA–31
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
(d) Using a press, press in a new drive shaft side dust
cover.
HINT: The clearance between the dust cover and the
bearing should be kept in the range shown in the
illustration.
(e) Using a press, press in a new transaxle side dust
cover.
2. LH DRIVE SHAFT:
ASSEMBLE SIDE GEAR SHAFT
Using a press, press in a new dust cover.
3. INSTALL NEW OUTBOARD JOINT BOOT AND NEW
BOOT CLAMP
HINT:
•
Before installing the boot, wrap vinyl tape around
the spline of the shaft to prevent damaging the
boot.
•
Temporarily install the new boot and new clamps
to the outboard joint.
4. ASSEMBLE BOOT TO OUTBOARD JOINT
Before assembling the boot, pack in grease.
HINT: Use the grease supplied in the boot kit.
Grease capacity:
135–155 g (4.8–5.5 oz.)
5. INSTALL NEW BOOT CLAMPS AND INBOARD
JOINT BOOT
Temporarily install the 2 new boot clamps and inboard
joint boot.
SA–32
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
6. ASSEMBLE NEW INBOARD JOINT COVER
(a) Clean contacting surfaces of any residual packing
material using cleaner.
(b) Apply seal packing to the inboard joint cover as
shown in the illustration.
Seal packing:
Part No. 08826–00801. THREE BOND 1122 or equi–
valent
HINT: Avoid applying an excess amount to the sur–
face.
(c) Align the bolt holes of the cover with those of the
inboard joint, then insert the hexagon bolts.
(d) Use a plastic hammer to tap the rim of the inboard
joint cover into place. Do this in the order shown, and
repeat several times.
(e) Use bolts, nuts and washers to keep the inboard joint
together.
NOTICE: Tighten the bolts by hand to avoid scratching
the flange surface.
7. ASSEMBLE INBOARD JOINT
(a) Align the matchmarks placed before disassembly.
(b) Using a brass bar and hammer, tap the inboard joint
onto the drive shaft.
NOTICE: Check that the brass bar is touching the inner
race, and not the cage.
(c) Using a snap ring expander, install a new snap ring.
NOTICE: Work carefully so that the outer race does not
come off.
SA–33
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
8. ASSEMBLE INBOARD JOINT BOOT TO INBOARD
JOINT
Pack in grease to the inboard tulip and boot.
HINT: Use the grease supplied in the boot kit.
Grease capacity:
140–150 g (4.9–5.3 oz.)
9. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Be sure the boots are in the shaft groove.
(b) Ensure that the boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
452.352.0 mm (17.8090 0.079 in.)
(c) Holding the clamp near the closing hooks, using pliers,
position the holers in the clamp’s free end over the closing hooks.
(d) Secure clamp by drawing the closing hooks together.
(e) Check that the clamp at closed position is the same as
that shown in the illustration.
(f) Secure the clamp onto the boot.
(g) Place SST onto the clamp
SST 09521 – 24010
SA–34
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(1MZ–FE)
(h) Tighten SST so that the clamp is pinched.
HINT: Pinch the inboard side of the boot clamp, as shown in
the illustration.
NOTICE: Do not overtighten the SST.
(i) Using SST, adjust the clearance of the clamp.
SST 09240 – 00020
Clearance:
1.9 mm(0.0075 in.) or less
10. PACK IN GREASE TO CENTER DRIVE SHAFT OR
SIDE GEAR SHAFT
Pack grease into the center drive shaft or side gear
shaft.
Grease capacity:
50–60 g (1.8–2.1 oz.)
HINT: Use the grease supplied in the boot kit.
11. CONNECT DRIVE SHAFT AND CENTER DRIVE
SHAFT OR SIDE GEAR SHAFT
(a) Remove the bolts, nuts and washers.
(b) Align the matchmarks on the drive shaft and center
drive shaft or side gear shaft.
(c) Place a new gasket on the inboard joint.
(d) Install the center drive shaft or side gear shaft to the
drive shaft.
NOTICE: When moving the drive shaft, do not compress
the inboard boot.
(e) Install the 3 washers and 6 hexagon bolts, and using
SST, temporarily tighten them.
SST 09923–00020
12. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the inboard joint
and outboard joint.
(b) Check to see that inboard joint slides smoothly in the
thrust direction.
SA–35
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5s–fe)
FRONT DRIVE SHAFT
(5S–FE)
DESCRIPTION
The drive has a tripod type CVJ (Constant Velocity Joint) on the differential side and Rzeppa type
CVJ on the wheel side.
SA–36
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
PREPARATION
SST (SPECIAL SERVICE TOOLS)
0950fi–35010 Differential Drive Pinion Rear
Bearing Replacer
09608–1fi041 Front Hub Bearing Adjusting Tool
(09608–02020) Bolt & Nut
(09608–02040) Retainer
09628–62011 Ball ,Joint Puller
09950–00020 Bearing Remover
Tie rod end
Center drive shaft dust cover
09521–24010 Drive Shaft Boot Clamping Tool
09240–00020 Wire Gauge Set
(09242–00190) Wire Gauge
RECOMMENDED TOOLS
09905–00012 Snap Ring No. 1 Expander
EQUIPMENT
Torque wrench
For removing and installing snap
ring
SA–37
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
FRONT DRIVE SHAFT
COMPONENTS
SA–38
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
FRONT DRIVE SHAFT REMOVAL
NOTICE: The hub bearing could be damaged if it is sub–
jected to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it is
bearing first support it with SST.
SST 09608–16041(09608–02020,09608–02040)
1. REMOVE FRONT FENDER APRON SEAL
2. REMOVE COTTER PIN, LOCK NUT CAP AND LOCK
NUT
(a) Remove the cotter pin and lock nut cap.
(b) Loosen the bearing lock nut while depressing the
brake pedal.
3. DRAIN TRANSAXLE OIL
4. DISCONNECT TIE ROD END FROM STEERING KNU–
CKLE
(a) Remove the cotter pin and nut from the steering
knuckle.
(b) Using SST, disconnect the tie rod end from the steer–
ing knuckle.
SST 09628–62011
5. DISCONNECT STABILIZER BAR LINK FROM
LOWER ARM
Remove the nut and disconnect the stabilizer bar link
from lower arm.
SA–39
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
6. DISCONNECT STEERING KNUCKLE FROM LOWER
BALL JOINT
(a) Remove the bolt and the 2 nuts.
(b) Disconnect the steering knuckle from lower ball joint.
7. DISCONNECT DRIVE SHAFT FORM AXLE HUB
Using a plastic hammer, disconnect the drive shaft
from the axle hub.
NOTICE: Cover the drive shaft boot with cloth to protect
it from damage.
8. REMOVE LH DRIVE SHAFT
(a) Using hub nut wrench and hammer handle or an
equivalent, pull out the drive shaft as shown.
(b) Using a screwdriver, remove the snap ring.
9. REMOVE RH DRIVE SHAFT
(a) Remove the bearing lock bolt.
SA–40
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(b) Using pliers, remove the snap ring, and pull out the
drive shaft.
FRONT DRIVE SHAFT INSTALLATION
1. INSTALL LH DRIVE SHAFT
(a) Using a snap ring expander, install a new snap ring.
(b) Coat gear oil to the inboard joint tulip and differential
case sliding surface.
(c) Using a brass bar and hammer, tap in the drive shaft
until it makes contact with the pinion shaft.
HINT:
•
Before installing the drive shaft, set the snap ring
opening side facing downward.
•
Whether or not the drive shaft is making contact
with the pinion shaft can be known by the sound
or feeling when driving it in.
2. CHECK INSTALLATION OF LH DRIVE SHAFT
(a) Check that there is 2–3 mm (0.08–0.12 in.) of play in
the axial direction.
(b) Check that the drive shaft can not be removed by
hand.
3. INSTALL RH DRIVE SHAFT
(a) Coat gear oil to the inboard joint and differential
sliding surface.
(b) Install the drive shaft to the transaxle through the
bearing bracket.
NOTICE: Do not damage the oil seal lip.
(c) Using pliers, install a new snap ring.
SA–41
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(d) Install a new bearing lock bolt and tighten it.
Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf)
4. CONNECT DRIVE SHAFT TO AXLE HUB
Install the outboard joint side of the drive shaft to the
axle hub.
NOTICE: Do not damage the boot.
5. CONNECT STEERING KNUCKLE TO LOWER ARM
Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf)
6. CONNECT STABILIZER BAR LINK TO LOWER ARM
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
7. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle and
torque the nut.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(b) Install a new cotter pin.
HINT: (f the cotter pin hole does not line up, correct by
tightening the nut by the smallest amount possible.
SA–42
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
8. INSTALL BEARING LOCK NUT, LOCK NUT CAP
AND NEW COTTER PIN
(a) Install and torque the bearing lock nut.
Torque: 284 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf)
(b) Install the lock nut cap and secure it with a new cotter
pin.
9. FILL TRANSAXLE WITH FLUID
10. INSTALL FRONT FENDER APRON SEAL
11. CHECK FRONT WHEEL ALIGNMENT
FRONT DRIVE SHAFT DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard
joint.
(b) Check to see that the inboard joint slides smoothly in
the thrust direction.
(c) Check to see that there is not significant play in the
radial direction of the inboard joint.
(d) Check for damage to boots.
2. TOYOTA TYPE:
REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
(a) Using a screwdriver, remove the 4 boot clamps.
(b) Slide the inboard joint boot toward the outboard joint.
GKN TYPE:
REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
(a) Using a boot clamp tool, draw hooks together and
remove the 2 large clamps.
SA–43
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(b) Using side cutters, cut small boot clamp and remove
them.
(c) Slide the inboard joint toward the outboard joint.
3. DISASSEMBLE INBOARD JOINT TULIP
(a) Place matchmarks on the tripod and inboard joint tulip
or center drive shaft.
NOTICE: Do not punch the marks.
(b) Remove the inboard joint tulip or center drive shaft
from the drive shaft.
4. REMOVE TRIPOD JOINT
(a) Using a snap ring expander remove the snap ring.
(b) Using a snap ring expander, temporarily, slide the
snap ring toward the outboard joint side.
(c) Place matchmarks on the drive shaft and tripod.
(d) Using a brass bar and a hammer, remove the tripod
joint from the drive shaft.
SA–44
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(e) Using a snap ring expander, remove the snap ring.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
Slide out the two boots.
NOTICE: Do not disassemble the outboard joint.
6. REMOVE DUST COVER
LH Drive Shaft:
Using SST and a press, press out the dust cover from
the inboard joint tulip.
SST 09950–00020
RH Drive Shaft:
Using a press, press out the dust cover from the
center drive shaft.
7. RH DRIVE SHAFT:
DISASSEMBLE CENTER DRIVE SHAFT
(a) Using SST and a press, press out the dust cover.
SST 09950–00020
(b) Using a snap ring expander, remove the snap ring.
SA–45
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(c) Using a press, press out the bearing.
(d) Remove the snap ring.
FRONT DRIVE SHAFT ASSEMBLY
1. RH DRIVE SHAFT:
ASSEMBLE CENTER DRIVE SHAFT
(a) Install a new snap ring to the center drive shaft.
(b) Using a steel plate and press, press in the bearing.
(c) Using a snap ring expander, install a new snap ring.
(d) Using SST, an extension bar and press, press in a new
dust cover.
SST 09506 – 35010
HINT: The clearance between the dust cover and the
bearing should be kept in the range shown in the
illustration.
2. INSTALL DUST COVER
LH Drive Shaft:
Using a press, install a new dust cover.
SA–46
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
RH Drive Shaft:
Using a steel plate and press, press in a new dust
cover until the distance from the tip of the center
drive shaft to the dust cover falls within the specifica–
tion as shown in the illustration.
3. TEMPORARILY INSTALL OUTBOARD JOINT BOOT
AND NEW BOOT CLAMPS
Temporarily install the boot and 2 new boot clamps
for the outboard joint to the drive shaft.
HINT: Before installing the boot, wrap vinyl tape
around the spline of the drive shaft to prevent damag–
ing the boot.
4. TEMPORARILY INSTALL INBOARD JOINT BOOT
AND NEW BOOT CLAMPS
Temporarily install the boot and 2 new boot clamps
for the inboard joint to the drive shaft.
5. INSTALL TRIPOD JOINT
(a) Using a snap ring expander, install a new snap ring.
(b) Place the beveled side of the tripod joint axial spline
toward the outboard joint.
(c) Align the matchmarks placed before removal.
SA–47
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(d) Using a brass bar and hammer, tap in the tripod joint
to the drive shaft.
NOTICE: Do not tap the roller.
(e) Using a snap ring expander, install a new snap ring.
6. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, fill grease into the out–
board joint and boot.
HINT: Use the grease supplied in the boot kit.
Grease capacity:
TOYOTA Type:
120–130 g (4.2–4.6 oz.)
GKN Type:
140–160 9 (4.9–5.6 oz.)
Grease color:
Black
7. INSTALL INBOARD JOINT TULIP TO FRONT DRIVE
SHAFT
(a) Pack in the grease to the boot and inboard joint tulip.
HINT:– Use the grease supplied in the boot kit.
Grease capacity:
TOYOTA Type:
232–242 g (8.2–8.5 oz.)
GKN Type:
185–215 g (6.5–7.6 oz.)
Grease color:
Yellow ocher
SA–48
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(b) Align the matchmarks placed before removal, and
install the inboard joint tulip to the drive shaft.
(c) Install the boot to the inboard joint tulip.
S. TOYOTA TYPE:
ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Be sure the boot is in the shaft groove.
(b) Ensure that the boot is not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
LH 608.1 ±5.0 mm (23.941±0.197 in.)
RH 866.2±5.0 mm (34.102±0.197 in.)
(c) Using a screwdriver, bend the band and lock it as
shown in the illustration.
GKN TYPE:
ASSEMBLE BOOT CLAMPS TO BOTH BOOT
(a) Be sure the boots are in the shaft groove.
(b) Ensure that the boot is not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
LH609Z±2.0 mm (23.984±0.079 in.)
RH 880.8±2.0 mm (34.677±0.079 in.)
(c) Using a boot clamp tool, place pincer jaws in closing
hooks of large clamps.
(d) Secure clamp by drawing closing hooks together.
SA–49
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
(e) Check that the clamp at closed position is the same as
in the illustration.
(f) Secure the clamp onto the boot.
(g) Place SST onto the clamp.
SST 09521 – 24010
(h) Tighten SST so that the clamp is pinched.
HINT: Pinch the inboard side of the boot clamp, as shown in
the illustration.
NOTICE: Do not overtighten the SST.
(i) Using SST, adjust the clearance of the clamp.
SST 09240 – 00020
Clearance:
1.9 mm (0.075 in.) or less
Corrected 12/27/93
SA–50
SUSPENSION AND AXLE
–
FRONT SUSPENSION
FRONT SUSPENSION
DESCRIPTION
The front suspension is MacPherson strut type suspension with L–shape lower arm.
SA–51
SUSPENSION AND AXLE
–
FRONT SUSPENSION
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09316–60010 Transmission & Transfer Bearing
Replacer
Dust deflector installation
(09316–00010) Replacer Pipe
(09316–00040) Replacer ’C’
09608–32010 Steering Knuckle Oil Seal
Replacer
09628–62011 Ball Joint Puller
09727–00045 Arm Set “B”
09727–30020 Coil Spring Compressor
09729–22031 Front Spring Upper Seat Holder
RECOMMENDED TOOLS
09025–00010 Small Torque Wrench
EQUIPMENT
Torque wrench
Dust deflector installation
SA–52
SUSPENSION AND AXLE
–
FRONT SUSPENSION
FRONT SHOCK ABSORBER
COMPONENTS
SA–53
SUSPENSION AND AXLE
–
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAL
1. JACK UP VEHICLE AND REMOVE FRONT WHEEL
2. REMOVE BRAKE HOSE AND ABS SPEED SENSOR
WIRE (W/ ABS) FROM SHOCK ABSORBER
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Remove the 2 nuts and bolts and disconnect the
shock absorber from the steering knuckle.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
(a) Remove the 3 nuts on upper side of the shock ab–
sorber.
(b) Remove the shock absorber with coil spring.
5. REMOVE COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727–00045,09727–30020
NOTICE: When holding the shock absorber with the coil
spring removed, do not hold it by the spring lower seat.
Also, do not knock the spring lower seat.
(b) Install a bolt and 2 nuts to the bracket at the lower
portion of the shock absorber and secure it in a vise.
SA–54
SUSPENSION AND AXLE
–
FRONT SUSPENSION
(c) Using SST to hold the upper support remove the nut.
SST 09729–22031
(d) Remove the following parts.
•
Suspension upper support
•
Upper insulator
•
Coil spring
•
Spring bumper
•
Lower insulator
NOTICE: Do not disassemble the spring lower seat.
FRONT SHOCK ABSORBER INSPECTION
1. INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and
check that there is no abnormal resistance or unusual
operation sounds.
If there is any abnormality, replace the shock absorber
with a new one.
NOTICE: When discarding the shock absorber, use the
following procedure.
FRONT SHOCK ABSORBER DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder as shown to
remove the gas inside.
CAUTION: The gas coming out is harmless, but be careful
of chips which may fly up when drilling.
SA–55
SUSPENSION AND AXLE
–
FRONT SUSPENSION
FRONT SHOCK ABSORBER INSTALLATION
7. INSTALL LOWER INSULATOR ONTO SHOCK ABS–
ORBER
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727–00045,09727–30020
(b) Install the coil spring to the shock absorber.
HINT: Fit the lower end of the coil spring into the gap
of the lower seat.
4. INSTALL UPPER INSULATOR AND UPPER SUP–
PORT
(a) Install the upper insulator to the upper support.
SA–56
SUSPENSION AND AXLE
–
FRONT SUSPENSION
(b) Install the upper support to the piston rod.
(c) Using SST to hold the upper support, install a new nut.
SST 09729–20031
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(d) Rotate the upper support so that the lowest bolt on
the upper support is aligned with the projection part
of the spring lower seat shown in the illustration.
(e) Remove the SST.
HINT: After removing SST, again check the direction
of the upper support.
5. INSTALL SHOCK ABSORBER WITH COIL SPRING
Place the shock absorber and install the 3 nuts.
Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅lbf)
6. CONNECT SHOCK ABSORBER TO STEERING KNU–
CKLE
(a) Coat the threads of the nuts with engine oil.
(b) Install the 2 bolts and nuts.
Torque: 211 N⋅m (2,150 kgf⋅cm, 156 ft⋅lbf)
SA–57
SUSPENSION AND AXLE
–
FRONT SUSPENSION
7. INSTALL BRAKE HOSE AND ABS SPEED SENSOR
WIRE (W/ ABS) TO SHOCK ABSORBER
Brake hose
Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf)
ABS wire
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
8. INSTALL FRONT WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
9. INSPECT FRONT WHEEL ALIGNMENT
(See page SA–4)
SA–58
SUSPENSION AND AXLE
–
FRONT SUSPENSION
LOWER SUSPENSION ARM
COMPONENTS
SA–59
SUSPENSION AND AXLE
–
FRONT SUSPENSION
LOWER ARM REMOVAL
1. JACK UP VEHICLE AND REMOVE FRONT WHEEL
2. REMOVE FRONT FENDER APRON SEAL
3. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
4. DISCONNECT TIE ROD END FROM STEERING KNU–
CKLE
(a) Remove the cotter pin and remove the nut.
(b) Using SST, disconnect the tie rod end from the steer–
ing knuckle.
SST 09628–62011
5. REMOVE LEFT AND RIGHT STABILIZER END BRA–
CKETS FROM LOWER ARMS
6. DISCONNECT LOWER ARM FROM LOWER BALL
JOINT
Remove the bolt and 2 nuts.
SA–60
SUSPENSION AND AXLE
–
FRONT SUSPENSION
7. REMOVE DRIVE SHAFT PROM AXLE HUB
(a) Remove the drive shaft from the axle hub.
(b) Hang up the drive shaft using wire, etc.
NOTICE: Be careful not to damage the drive shaft boot
and ABS sensor rotor.
8. REMOVE LOWER ARM
(a) Remove the 2 bolts on front side of the lower arm.
(b) Remove the bolt and nut on rear side of the lower arm.
(c) Remove the lower arm.
(d) Remove the lower arm bushing stopper from the
lower arm shaft.
LOWER ARM INSTALLATION
1. INSTALL LOWER ARM
(a) Place the lower arm and temporarily install the rear
side bolt and nut
SA–61
SUSPENSION AND AXLE
–
FRONT SUSPENSION
(b) Install the lower arm bushing stopper to the lower arm
shaft.
(c) Install the 2 bolts on the front side of the lower arm.
Torque: 206 N⋅m (2,100 kgf⋅cm, 152 ft⋅lbf)
(d) Tighten the bolt on rear side of the lower arm.
Torque: 206 N⋅m (2,100 kgf⋅cm, 152 ft⋅lbf)
2. INSTALL DRIVE SHAFT TO AXLE HUB
3. CONNECT LOWER ARM TO LOWER BALL JOINT
Install the bolt and 2 nuts.
Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf)
4. INSTALL LEFT AND RIGHT STABILIZER END BRA–
CKETS TO LOWER ARMS
Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf)
SA–62
SUSPENSION AND AXLE
–
FRONT SUSPENSION
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle and
tighten the nut.
Torque: 49 N⋅m (500 kgf⋅cm. 36 ft⋅lbf)
(b) Install a new cotter pin.
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying the brakes, install the nut.
Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf)
(b) Install the lock cap and a new cotter pin.
7. INSTALL FRONT FENDER APRON SEAL
8. INSTALL FRONT WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf)
9. INSPECT FRONT WHEEL ALIGNMENT
(See page SA–4)
SA–63
SUSPENSION AND AXLE
–
FRONT SUSPENSION
LOWER BALL JOINT
COMPONENTS
SA–64
SUSPENSION AND AXLE
–
FRONT SUSPENSION
LOWER BALL JOINT REMOVAL
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
(See page SA–11)
2. REMOVE LOWER BALL JOINT
(a) Using a screwdriver, remove the dust deflector.
(b) Remove the cotter pin and nut.
(c) Using SST, remove the lower ball joint.
SST 09628–62011
LOWER BALL JOINT INSPECTION
1. INSPECT BALL JOINT FOR ROTATION CONDITION
(a) As shown, flip the ball joint stud back and forth 5
times before installing the nut.
(b) Using a torque gauge, turn the nut continuously one
turn per 2–4 seconds and take the torque reading on
the 5th turn.
Turning torque:
1.0–2.9 N⋅m (10–30 kgf⋅cm, 8.7–26 in.⋅lbf)
LOWER BALL JOINT INSTALLATION
1. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and tighten the nut.
Torque: 123 N⋅m (1,250 kgf⋅cm, 90 ft⋅lbf)
(b) Install a new cotter pin.
SA–65
SUSPENSION AND AXLE
–
FRONT SUSPENSION
2. INSTALL DUST DEFLECTOR
Using SST and a hammer, install a new dust deflector.
SST 09316–60010 (09316–00010, 09316–00040)
09608–32010
HINT: Align the hoses for the ABS speed sensor in the
dust deflector and steering knuckle.
3. INSTALL STEERING KNUCKLE WITH AXLE HUB
(See page SA–15)
SA–66
SUSPENSION AND AXLE
–
FRONT SUSPENSION
STABILIZER BAR
COMPONENTS
SA–67
SUSPENSION AND AXLE
–
FRONT SUSPENSION
STABILIZER BAR REMOVAL
1. JACK UP VEHICLE AND REMOVE LEFT AND RIGHT
FRONT WHEELS
2. REMOVE LEFT AND RIGHT FENDER APRON SEALS
3. DISCONNECT LEFT AND RIGHT TIE ROD ENDS
FROM STEERING KNUCKLES
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the steer–
ing knuckle.
SST 09628–62011
4. REMOVE LEFT AND RIGHT STABILIZER BAR LINKS
5. REMOVE LEFT AND RIGHT STABILIZER BAR BUSH–
INGS
(a) Remove the left and right bushing retainers.
(b) Remove the stabilizer bar bushings.
6. REMOVE EXHAUST FRONT PIPE
5S–FE Engine:
(See page EG–139)
1 MZ–FE Engine:
(See page EG–188)
7. REMOVE STEERING GEAR BOX MOUNTING BOLTS
AND NUTS
SA–68
SUSPENSION AND AXLE
–
FRONT SUSPENSION
8. REMOVE STABILIZER BAR
HINT: Lift the steering gear box and remove the stabi–
lizer bar.
STABILIZER BAR LINK INSPECTION
1. INSPECT BALL JOINT FOR ROTATION CONDITION
(a) Flip the ball joint stud back and forth 5 times as
shown in the illustration, before installing the nut.
(b) Using a torque gauge, turn the nut continuously one
turn every 2–4 seconds and take the torque reading
on the fifth turn.
Turning torque:
0.05–1.0 N⋅m (0.5–10 kgf⋅cm, 0.4–8.7 in.⋅lbf)
If not within specification, replace the stabilizer bar
link.
STABILIZER BAR INSTALLATION
1. POSITION STABILIZER BAR
HINT: Lift the steering gear box and position the
stabilizer bar.
2. INSTALL STEERING GEAR BOX MOUNTING BOLTS
AND NUTS
Torque: 181 N⋅m (1.850 kgf⋅cm, 134 ft⋅lbf)
3. INSTALL EXHAUST FRONT PIPE
SS–FE Engine:
(See page EG–139)
1 MZ–FE Engine:
(See page EG–189)
SA–69
SUSPENSION AND AXLE
–
FRONT SUSPENSION
4. INSTALL LEFT AND RIGHT STABILIZER BAR BUSH–
INGS
(a) Install the stabilizer bar bushings.
(b) Install the bushing retainers and bolts.
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
5. INSTALL LEFT AND RIGHT STABILIZER BAR LINKS
Torque: 39 N⋅m (400 kgf⋅cm. 29 ft⋅Ibf)
6. CONNECT LEFT AND RIGHT TIE ROD ENDS TO
STEERING KNUCKLES
(a) Connect the tie rod end to the steering knuckle and
tighten the nut.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(b) Install a new cotter pin.
7. INSTALL LEFT AND RIGHT FENDER APRON SEALS
8. INSTALL FRONT WHEELS AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf)
SA–70
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE
DESCRIPTION
The rear axle uses oil–sealed double–row angular ball bearings for wheel bearings.
There is no need for bearing grease maintenance or preload adjustment.
SA–71
SUSPENSION AND AXLE
–
REAR AXLE
PREPARATION
SST (SPECIAL SERVICE TOOLS)
EQUIPMENT
Dial indicator
Torque wrench
09608–32010 Steering Knuckle oil Seal
Replacer
Axle hub installation
(w/o A8S)
09628–10011 Ball Joint Puller
Hub bolt removal
09636–20010 Upper Ball Joint Dust Cover
Replacer
Axle hub installation
(w/o ASS)
09950–20017 Universal Puller
(w/o ABS)
SA–72
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE HUB
COMPONENTS
SA–73
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE HUB REMOVAL
1. JACK UP VEHICLE AND REMOVE REAR WHEEL
2. W/ DISC BRAKE:
REMOVE BRAKE CALIPER AND DISC
(a) Remove the 2 brake caliper set bolts.
(b) Hang up the brake caliper using wire, etc.
(c) Remove the disc.
3. w/ DRUM BRAKE:
REMOVE BRAKE DRUM
4. CHECK BEARING BACKLASH AND AXLE HUB DE–
VIATION
(a) Place the dial indicator near the center of the axle hub
and check the backlash in the bearing shaft direction.
Maximum:
0.05 mm (0.0020 in.)
If greater than the specified maximum, replace the
bearing.
(b) Using a dial indicator, check the deviation at the
surface of the axle hub outside the hub bolt.
Maximum:
0.47 mm (0.0028 in.)
If greater then the specified maximum, replace the
axle shaft and bearing.
6. REMOVE REAR AXLE HUB
(a) Remove the 4 bolts and rear axle hub.
(b) Remove the O–ring.
SA–74
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE HUB DISASSEMBLY
NOTICE: If equipped with ABS, do not disassemble the
rear axle shaft and bearing.
1. REMOVE LOCK NUT
(a) Using a hammer and chisel, release the nut caulking.
(b) Remove the lock nut.
2. REMOVE AXLE SHAFT FROM BEARING
(a) Using SST, remove the axle shaft from bearing.
SST 09950 – 20017
(b) Using SST, remove the inner race (outside) from the
axle shaft.
SST 09950–20017
REAR AXLE HUB ASSEMBLY
1. INSTALL AXLE SHAFT TO BEARING
(a) Using SST and a press, install the axle shaft to a new
bearing.
ST 09608–32010,09636–20010
(b) Install a new lock nut.
Torque: 123 N⋅m (1250 kgf⋅cm, 90 ft⋅lbf)
(c) Stake the lock nut.
SA–75
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE HUB INSTALLATION
1. INSTALL REAR AXLE HUB
(a) Install a new 0–ring.
HINT: Coat the 0–ring with MP grease.
(b) Install the rear axle hub with the 4 bolts.
Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅lbf)
2. w/ DISC BRAKE:
INSTALL DISC AND BRAKE CALIPER.
(a) Install the disc.
(b) Install the brake caliper.
Torque: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf)
3. w/ DRUM BRAKE:
INSTALL BRAKE DRUM
4. INSTALL REAR WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm. 76 ft⋅lbf)
HUB BOLT REPLACEMENT
1. JACK UP VEHICLE AND REMOVE REAR WHEEL
2. REMOVE REAR DISC OR DRUM
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628–10011
4. INSTALL HUB BOLT
Install washer– and nut to the hub bolt as shown in the
illustration, and install the hub bolt by tightening the
nut.
5. INSTALL REAR DISC OR DRUM
6. INSTALL REAR WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf)
SA–76
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE CARRIER
COMPONENTS
SA–77
SUSPENSION AND AXLE
–
REAR AXLE
REAR AXLE CARRIER REMOVAL
1. REMOVE REAR AXLE HUB
2. w/ DRUM BRAKE:
REMOVE BRAKE HOSE FROM SHOCK ABSORBER
3. REMOVE BACKING PLATE FROM REAR AXLE CAR–
RIER
Hang up the backing plate using wire, etc.
4. w/ ABS:
REMOVE ABS SPEED SENSOR
Remove the ABS speed sensor from rear axle carrier.
5. WAGON only:
REMOVE LSPV SPRING
Disconnect the LSPV spring from the lower arm.
6. REMOVE REAR AXLE CARRIER
(a) Loosen the 3 nuts.
HINT: Do not remove the bolts.
SA–78
SUSPENSION AND AXLE
–
REAR AXLE
(b) Remove the bolt and nut and disconnect the strut rod
from the rear axle carrier.
(c) Remove the 3 nuts and bolts.
(d) Remove the rear axle carrier.
REAR AXLE CARRIER INSTALLATION
1. INSTALL REAR AXLE CARRIER
(a) Place the rear axle carrier and temporarily install the 3
bolts and nuts.
(b) Connect the strut rod to the rear axle carrier.
(c) Temporarily install the bolt and nut.
(d) Torque the 3 nuts.
Lower side of shock absorber:
Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf)
Lower arm:
Torque: 181 N⋅m (1,850 kgf⋅cm, 134 ft⋅lbf)
SA–79
SUSPENSION AND AXLE
–
REAR AXLE
2. w/ ABS:
INSTALL ABS SPEED SENSOR
Install the ABS speed sensor to the rear axle carrier.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
3. WAGON only:
INSTALL LSPV SPRING
Connect the LSPV spring to the lower arm.
Torque: 13 N⋅m (130 kgf⋅cm, 9.4 ft⋅Ibf)
4. INSTALL BACKING PLATE AND REAR AXLE HUB
(a) Place the backing plate.
(b) Install a new O–ring.
(c) Install the rear axis hub.
Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅Ibf)
5. w/ DRUM BRAKE:
INSTALL BRAKE LINE TO SHOCK ABSORBER
Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf)
6. STABILIZE SUSPENSION
(a) Install the rear wheel and lower the vehicle.
(b) Bounce the vehicle up and down several times to
stabilize the suspension.
7. TORQUE STRUT ROD BOLT
(a) Jack up the vehicle and support the body.
(b) Remove the rear wheel.
(c) Support the rear axle carrier with a jack.
(d) Torque the bolt.
Torque: 113 N⋅m (1,150 kgf⋅cm, 83 ft⋅lbf)
8. INSTALL REAR WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
SA–80
SUSPENSION AND AXLE
–
REAR SUSPENSION
REAR SUSPENSION
DESCRIPTION
The rear suspension is a dual–link strut independent suspension type composed of two lower
arms in parallel at the side, and strut rods which extend forward.
SA–81
SUSPENSION AND AXLE
–
REAR SUSPENSION
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09727–30020 Coil Spring Compressor
09729–22031 Front Spring Upper Seat Holder
RECOMMENDED TOOLS
09025–00010 Small Torque Wrench
EQUIPMENT
Torque wrench
SA–82
SUSPENSION AND AXLE
–
REAR SUSPENSION
REAR SHOCK ABSORBER
COMPONENTS
SA–83
SUSPENSION AND AXLE
–
REAR SUSPENSION
REAR SHOCK ABSORBER REMOVAL
1. SEDAN/COUPE
REMOVE REAR SEAT AND PACKAGE TRAY TRIM
(SEE THE BO SECTION)
WAGON:
REMOVE REAR SIDE SEATBACK AND TONNEAU
SIDE COVER
(SEE PAGE BO SECTION)
2. JACK UP VEHICLE AND REMOVE REAR WHEEL
3. WAGON ONLY:
DISCONNECT LSPV SPRING FROM LOWER ARM
4. REMOVE ABS SPEED SENSOR WIRE (w/ ABS) AND
BRAKE HOSE FROM SHOCK ABSORBER
5. DISCONNECT STABILIZER BAR LINK FROM
SHOCK ABSORBER
6. REMOVE SHOCK ABSORBER WITH COIL SPRING
(a) Loosen the 2 nuts on lower side of shock absorber.
SA–84
SUSPENSION AND AXLE
–
REAR SUSPENSION
(b) Support the rear axle carrier with a jack.
(c) Remove the 3 nuts of upper support.
(d) Lower the rear axle carrier and remove the 2 bolts.
(e) Remove the shock absorber with coil spring.
7. REMOVE COIL SPRING
(a) Remove the cap.
(b) Using SST, compress the coil spring.
SST 09727–30020
(c) Install a bolt and 2 nuts to the bracket at the lower
portion of the shock absorber and secure it in a visa.
SA–85
SUSPENSION AND AXLE
–
REAR SUSPENSION
(d) Using SST to hold the upper support, remove the nut.
SST 09729–22031
(e) Remove the following parts.
•
Suspension upper support
•
Upper insulator
•
Coil spring
•
Spring bumper
•
Lower insulator
REAR SHOCK ABSORBER INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and
check that there is no abnormal resistance or unusual
operation sounds.
If there is any abnormality, replace the shock absorber
with a new one.
NOTICE: When discarding the shock absorber, use the
following procedure.
REAR SHOCK ABSORBER DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder as shown to
remove the gas inside.
CAUTION: The gas coming out is harmless, but be careful
of chips which may fly up when drilling.
REAR SHOCK ABSORBER INSTALLATION
1. INSTALL LOWER INSULATOR ONTO SHOCK ABS–
ORBER
SA–86
SUSPENSION AND AXLE
–
REAR SUSPENSION
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING
(a) Using SST, compress the coil spring
SST 09727–30020
(b) Install the coil spring to the shock absorber.
HINT: Fit the lower end of the coil spring into the gap
of the lower seat.
4. INSTALL UPPER INSULATOR AND UPPER SUP–
PORT
(a) Before installing the upper support and insulator,
apply the lithium or silicon based grease as shown in
the illustration.
(b) Install the upper insulator to the upper support.
HINT: Match the bolt of the upper support with the
cut–off part of the insulator.
SA–87
SUSPENSION AND AXLE
–
REAR SUSPENSION
(c) Install the upper support to the piston rod.
(d) Using SST to hold the upper support, install a new nut.
SST 09729–22031
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(e) Rotate the upper support and set it in the direction
shown in the illustration.
(f) Remove the SST.
HINT: After removing SST, again check the direction
of the upper support.
(g) Install the cap.
5. INSTALL SHOCK ABSORBER WITH COIL SPRING
Install the shock absorber and install the 3 nuts of
upper support.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅Ibf)
6. CONNECT SHOCK ABSORBER TO REAR AXLE CAR–
RIER
(a) Coat the threads of the nuts with engine oil.
(b) Install the 2 bolts and nuts.
Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf)
SA–88
SUSPENSION AND AXLE
–
REAR SUSPENSION
7. CONNECT STABILIZER BAR LINK TO SHOCK ABS–
ORBER
Torque: 64 N⋅m (650 kgf⋅cm, 47 ft⋅Ibf)
8. INSTALL ABS SPEED SENSOR WIRE (w/ ABS) AND
BRAKE HOSE TO SHOCK ABSORBER
Broke hose
Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf)
ABS wire
Torque: 5.4 N⋅m (55 kgf⋅cm. 48 in.⋅lbf)
9. WAGON only:
CONNECT LSPV SPRING FROM LOWER ARM
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
10. INSTALL REAR WHEEL AND LOWER VEHICLE
Torque: 103 N⋅m (1,050 kgf⋅cm. 76 ft⋅lbf)
11. SEDAN/COUPE:
INSTALL PACKAGE TRAY TRIM AND
REAR SEAT
(See the BO section)
WAGON:
INSTALL TONNEAU SIDE COVER AND REAR SIDE
SEATBACK
(See the BO section)
SA–89
SUSPENSION AND AXLE
–
REAR SUSPENSION
LOWER SUSPENSION ARM AND
STRUT ROD
COMPONENTS
SA–90
SUSPENSION AND AXLE
–
REAR SUSPENSION
4^T–06
LOWER SUSPENSION ARM AND STRUT
ROD REMOVAL
1. JACK UP VEHICLE AND REMOVE REAR WHEEL
2. REMOVE STRUT ROD
(a) Remove the 2 bolts and nuts.
(b) Remove the strut rod.
3. WAGON only:
DISCONNECT LSPV SPRING FROM LOWER ARM
4. REMOVE NO.2 LOWER SUSPENSION ARM
(a) Remove the 2 nuts and washers.
(b) Remove the No.2 lower suspension arm.
5. REMOVE LEFT AND RIGHT STABILIZER BUSHING
RETAINER
6. REMOVE EXHAUST CENTER PIPE AND TALE PIPE
5S–FE Engine:
(See page EG1–139)
1MZ–FE Engine:
(See page EG2–189)
7. REMOVE NO.1 LOWER SUSPENSION ARM
(a) Support the suspension member with a jack.
SA–91
SUSPENSION AND AXLE
–
REAR SUSPENSION
(b) Remove the 6 nuts and the left and right suspension
member lower stopper.
(c) Lower the suspension member.
(d) Remove the No. 1 lower suspension arm with the 2
bolts and the washer.
NO.2 LOWER SUSPENSION ARM
DISASSEMBLY
1. DISASSEMBLE NO.2 LOWER SUSPENSION ARM
(a) Loosen the 2 lock nuts.
(b) Turn the adjusting tube and disassemble the No.2
lower suspension arm.
(c) Remove the lock nuts from the arms.
NO.2 LOWER SUSPENSION ARM
ASSEMBLY
1. ASSEMBLE NO.2 LOWER SUSPENSION ARM
(a) Install the lock nuts to the arms.
(b) Turn the adjusting tube and assemble the No.2 lower
suspension arm.
SA–92
SUSPENSION AND AXLE
–
REAR SUSPENSION
HINT: When assembling the No.2 lower suspension
arm, try to make dimensions A and B shown in the
illustration as close as possible.
Maximum difference:
3 mm (0.12 in.)
(c) Adjust the No.2 lower suspension arm length by turn–
ing the adjusting tube.
Arm length:
584.2 mm (23.000 in.)
(d) Temporarily tighten the 2 lock nuts.
HINT: After adjusting the rear wheel alignment,
torque the lock nuts.
401W–06
LOWER SUSPENSION ARM AND STRUT
ROD INSTALLATION
1. INSTALL NO.1 LOWER SUSPENSION ARM
Install the No. 1 lower suspension arm with the washer
and the 2 bolts.
HINT: Face the paint mark to the rear.
2. INSTALL SUSPENSION MEMBER TO BODY
(a) Jack up the suspension member.
(b) Install the suspension member lower supports and the
6 nuts.
Nut A:
Torque: 51 N⋅m (520 kgf⋅cm, 38 ft⋅lbf)
Nut B:
Torque: 38 N⋅m (390 kgf⋅cm, 28 ft⋅lbf)
3. INSTALL LEFT AND RIGHT STABILIZER BUSHING
RETAINERS
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
4. INSTALL EXHAUST CENTER PIPE AND TALE PIPE
5S–FE Engine:
(See page EG1–139)
1MZ–FE Engine:
(See page EG2–189)
SA–93
SUSPENSION AND AXLE
–
REAR SUSPENSION
5. INSTALL NO.2 LOWER SUSPENSION ARM
(a) Install the No.2 lower suspension arm with the 3
washers.
HINT: Face the paint mark to the rear.
(b) Temporarily install the 2 lock nuts.
6. WAGON only:
CONNECT LSPV SPRING TO LOWER ARM
Torque: 13 N⋅m (130 kgf⋅cm, 9.4 ft⋅lbf)
7. INSTALL STRUT ROD
Place the strut rod and temporarily install the 2 bolts
and nuts.
8. TORQUE BOLTS AND NUTS
(a) Torque the nut on outside of the lower arm.
Torque: 181 N⋅m (1,850 kgf⋅cm, 134 ft⋅lbf)
(b) Install the rear wheel and lower the vehicle.
(c) Bounce the vehicle up and down several times to
stabilize the suspension.
(d) Jack up the vehicle and support the body with stands.
(e) Remove the rear wheel.
(f) Support the rear axle carrier with a jack.
(g) Torque the nut on inside of lower arm.
Torque: 181 N⋅m (1.850 kgf⋅cm, 134 ft⋅lbf)
SA–94
SUSPENSION AND AXLE
–
REAR SUSPENSION
(h) Torque the strut rod set bolts.
Torque: 113 N⋅m (1,150 kgf⋅cm, 83 ft⋅lbf)
9. INSTALL REAR WHEEL AND LOWER VEHICLE
10. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
(See page SA–6)
11. TORQUE NO.2 LOWER SUSPENSION ARM LOCK
NUTS
Torque: 56 N⋅m (570 kgf⋅cm. 41 ft⋅lbf)
SA–95
SUSPENSION AND AXLE
–
REAR SUSPENSION
STABILIZER BAR
COMPONENTS
STABILIZER BAR LINK INSPECTION
INSPECT BALL JOINT FOR ROTATION CONDITION
(a) Flip the ball joint stud back and forth 5 times as
shown in the illustration, before installing the nut.
(b) Using a torque gauge, turn the nut continuously one
turn every 2–4 seconds and take the torque reading
on the fifth turn.
Turning torque:
0.05–1.0 N⋅m (0.5–10 kgf⋅cm, 0.4–8.7in.⋅lbf)
If not within specification, replace the stabilizer bar
link.
SA–96
SUSPENSION AND AXLE
–
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
SEDAN/COUPE
Cold tire
inflation
pressure
Tire runout
Wheel balance
Front
Rear
Unbalance after adjustment
Vehicle
height
Front wheel
alignment
Pressure
Tire size
Height
Tire size
Front
Rear
Inside wheel
Outside wheel
(reference)
Toe – in (total)
Tire size
Wheel angle
Camber
Left–right error
Caster
Left–right error
Rear wheel
alignment
Front axle
Front suspension
Steering axis inclination
Toe–in (total)
Camber
Left – right error
Axle bearing backlash
Axle hub deviation
Lower ball joint turning torque
Stabilizer bar link turning torque
Rear axle
Axle bearing backlash
Axle hub deviation
Rear suspension
Stabilizer bar link turning torque
1l04727
SA–97
SUSPENSION AND AXLE
–
SERVICE SPECIFICATIONS
WAGON
Cold tire
inflation
pressure
Tire size
Pressure
Front
Rear
For all roads
including full
rated loads
Optional
inflation for
reduced loads
(1 or 4
passengers)
Tire runout
Wheel balance
Unbalance after adjustment
Vehicle
height
Front wheel
alignment
Height
Tire size
Front
Toe –in (total)
Tire size
Wheel angle
Camber
Left–right error
Caster
Left–right error
Rear wheel
alignment
Front axle
Steering axis inclination
Toe–in (total)
Camber
Left – right error
Axle bearing backlash
Axle hub deviation
Front suspension
Rear
Lower ball joint turning torque
Stabilizer bar link turning torque
Rear axle
Axle bearing backlash
Rear suspension
Axle hub deviation
Stabilizer bar link turning torque
Inside wheel
Outside wheel
(reference)
SA–98
SUSPENSION AND AXLE
TORQUE SPECIFICATIONS
FRONT
Part tightened
Tie rod end lock nut
Steering knuckle x Shock absorber
Steering knuckle x Brake caliper
Steering knuckle x Tie rod end
Axle hub nut
Ball joint x Lower arm
Ball joint x Steering knuckle
Steering knuckle x Disc brake dust cover
Drive shaft x Side gear shaft (1 MZ–FE)
Drive shaft center bearing lock bolt
Suspension upper support x Body
Suspension upper support x Piston rod
Brake hose x Shock absorber
ABS speed sensor wire x Shock absorber
Lower arm set bolt
Lower arm x Stabilizer bar link bracket
Stabilizer bar bushing retainer
Stabilizer bar link set nut
Steering gear box set bolt
Front exhaust pipe stay x Clamp (1 MZ–FE)
Front exhaust pipe stay x Body (1 MZ–FE)
REAR
Part tightened
Brake caliper x Rear axle carrier
Axle bearing set bolt
Bearing lock nut (w/o ABS)
Shock absorber x Rear axle carrier
Brake hose x Shock absorber
ABS speed sensor set bolt
ABS speed sensor wire x Shock absorber
Suspension upper support x Body
Suspension upper support x Piston rod
Lower suspension arm x Suspension member
Lower suspension arm X Rear axis carrier
Strut rod x Body
Strut rod x Rear axle carrier
Suspension member x Body (17mm)
Suspension member x Body (14mm)
LSPV spring x Lower suspension arm
Stabilizer bar bushing retainer
Stabilizer bar link set nut
–
SERVICE SPECIFICATIONS
SA–37
SUSPENSION AND AXLE
–
FRONT DRIVE SHAFT(5S–FE)
LUBRICANT
Drive shaft
Item
Capacity
Toyota type
Outboard joint grease
Inboard joint grease
120–130 g (4.2–4.6 oz.)
232–242 g (8.2–8.5 oz.)
GKN type
Outboard joint grease
Inboard joint grease
140–160 g (4.9–5.6 oz.)
185–215 g (6.5–7.6 oz.)