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FRONT SUSPENSION
SECTION
FA
CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
FRONT SUSPENSION SySTEM
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts
Front Wheel Bearing
Front Wheel Alignment..
Drive Shaft
2
2
2
3
4
5
5
5
6
7
FRONT AXLE
Wheel Hub and Knuckle
Drive Shaft
FRONT SUSPENSION
Coil Spring and Strut Assembly
Stabilizer Bar
Transverse Link and Lower Ball Joint..
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
8
12
24
25
26
27
29
29
29
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.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Use flare nut wrench when removing or installing brake
tubes.
Always torque brake lines when installing.
SBR820B
Description
Removing tie-rod outer end and lower ball
joint
HT72520000
NT146
HT71780000
Spring compressor
NT144
ST35652000
Strut attachment
NT145
GG94310000
a: 10 mm (0.39 in)
NT406
KV38106700
KV381 06800
Differential
protector
NT147
FA-2
Description
Removing wheel hub
NT065
NT115
NT115
Attachment
Wheel alignment
NT148
Equivalent to GG94310000
G) Flare nut crows foot
GV Torque wrench
a: 10 mm (0.39 in)
NT360
FA-3
SEC. 391-400-401
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.
~~25.29
~
\
...\
Front
to.J : N. m (kg-m,
ft-Ib)
SFA715B
CD
@
Suspension member
Stabilizer bar
Drive shaft
@
@
@
Coil spring
Strut assembly
Knuckle
FA-4
(J)
Transverse link
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts
Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
Strut
Ball joint
SFA392B
a.
b.
c.
d.
e.
f.
SFA484A
FA-5
ON-VEHICLE SERVICE
Front Wheel Alignment
Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
SFA575B
PRELIMINARY
INSPECTION
TOE-IN
Front
Hub center
height
SFA614B
Lines parallel to
center line of body
Q
Front
SFA234AC
FA-6
ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
7.
a.
b.
Lock nut
c.
SFA486A
yf-\;
if
Front
----A Inside
B: Outside
\mll//
I
move vehicle
radius gauge
left; measure
more than 15
SFA439B
Drive Shaft
SFA108A
FA-7
FRONT AXLE
10
Front
CD
@
@
@
@
@
@~
Drive shaft
Inner grease seal
Knuckle
Baffle plate
ABS sensor
Wheel bearing assembly
(J)
Snap ring
Insulator
@
@
Adjusting cap
Cotter pin
Disc rotor
Wheel nut
@
@)
@
@
@
@
FA-8
FRONT AXLE
Wheel Hub and Knuckle (Conl'd)
3. Separate tie-rod from knuckle with Tool.
Install stud nut on stud bolt to prevent damage
to stud bolt.
4.
5.
bolts.
6.
7.
8.
SFA113AA
INSTALLATION
1. Install knuckle with wheel hub.
FA-9
FRONT AXLE
Wheel Hub and Knuckle (Cont'd)
3. Check wheel bearing axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
DISASSEMBL Y
CAUTION:
Wheel bearing
When replacing wheel bearing, replace wheel bearing assembly (inner races and outer race).
1. Remove bearing inner race (outside), then remove outer
grease seal.
SFA654A
FA-10
FRONT AXLE
Wheel Hub and Knuckle (Cont'd)
4.
SFA496A
INSPECTION
Wheel hub and knuckle
Check wheel hub and knuckle for cracks by using a magnetic
exploration or dyeing test.
Snap ring
Check snap ring for wear or cracks. Replace if necessary.
ASSEMBLY
1.
Wheel bearing
assembly
~ Knuckle
SFA951A
3.
grease.
4.
SFA747
Suitable tool
SFA620B
FA-11
FRONT AXLE
Wheel Hub and Knuckle (Cont'd)
5. Install inner grease seal.
Maximum load P:
10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
SFA953A
Drive Shaft
REMOVAL
1. Remove wheel bearing lock nut.
Brake caliper need not be disconnected.
Do not twist or stretch brake hose when moving components.
SFA090A
SFA1538
FA-12
FRONT AXLE
Drive Shaft (Coni' d)
4.
5.
6.
-For MITmodels
as shown at left.
-For AITmodels-
AfT model
Insert screwdriver
into transaxle
opening for right drive
shaft and strike with a hammer.
Be careful not to damage pinion mate shaft and side gear.
SFA730
FA-13
FRONT AXLE
Drive Shaft (Cont'd)
INSTALLATION
RH
Transaxle
side
SFA394BB
FA-14
FRONT AXLE
Drive Shaft (Cont'd)
COMPONENTS
GA and CD engine model
SEC. 391
Circular clip:
Circular clips should be properly meshed with differential side
gear (transaxle side) and with joint assembly (wheel side).
Make sure they will not come out.
Be careful not to damage boots. Use suitable protector or cloth
during removal and installation.
.~
,~
~
Transaxle
side
Wheel
side
\~
r-J\ Transaxle
~side
CD
@
@
@
@
Joint assembly
Boot
Boot band
Circular clip
Drive shaft
@
(J)
@
FA-15
@)
@
@
Spider assembly
Snap ring
Slide joint housing
Circular clip
~RONT AXLE
Drive Sh a f t (Cont'd)
SR20DE eng-me model
SEC. 391
Wheel
side (BF83)
20
r:~~
~'Vz~
@O
'
x I e side (TS83)
tOJ
25 . 35 (2 .6 3.6, 19 . 26)
@~ti~~o
f:~~
2!~
30.41
(3.1.4.2,22
- 301
tOJ : N-m
T
ransaxle
(kg-m, ft-Ib)
13 - 19 (13
side (0
S83)
. -
1.9, 9 14)
SFA716B
G)
@
@
Jo'Int assembly
Boot band
Boot
@
@
@
tJ)
@
Circular clip B
Drive shaft
Band
Dynamic dam
Boot
per
Boot band
@l
@
@
13'
\!'V
@
@
@l
@
Spi'd er assembly
Snap ring C
Slide
joint houslng
.
0
ust shield
Circular clip A
Snap ring A
Inner race
Cage
Ball
FA-16
Slide joint
S'
Ion shaft
@J
Snap ring E
houslng
'
, extenwith
@ Dust shield
@ Support bearing
@
@
@
Support bearin
Bracket
g retainer
Snap ring 0
Dust shield
FRONT AXLE
Drive Shaft (Cont'd)
OISASSEMBL Y
Transaxle
1.
2.
3.
SFA963
Transaxle
1.
2.
3.
to the
SFA476
4.
5.
SFA514A
Wheel side
CAUTION:
The joint on the wheel side cannot be disassembled.
1.
FA-17
on drive
FRONT AXLE
Drive Shaft (Cont'd)
Support bearing
1. Remove dust shield.
SFA692
INSPECTION
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for evidence of deformation or
other damage.
Drive shaft
Replace drive shaft if it is twisted or cracked.
FA-18
FRONT AXLE
Drive Shaft (Cont'd)
Boot
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.
side)
Check spider assembly for bearing, roller and washer damage. Replace spider assembly if necessary.
Check housing for any damage. Replace housing set and
spider assembly, if necessary.
Slide joint
TS70C
Stamped number
Part No.
00
39720-51 EOO
01
39720-51E01
02
39720-51 E02
03
39720-51 E03
Stamped number
Part No.
00
39720-61 EOO
01
39720-61 E01
SRA121A
TS79C
02
39720-61 E02
03
39720-61 E03
04
39720-61 E04
05
39720-61E05
06
39720-61 E06
if it is deformed
or damaged.
ASSEMBLY
FA-19
FRONT AXLE
Drive Shaft (Cont'd)
Wheel side
1. Install boot and new small boot band on drive shaft.
Cover drive shaft serration
during installation.
boot
SFA800
r:r
1..--*
- Wheel bearing
lock nut
SFA 130A
ZF80
ZF90
BF83
4. Make sure
amount of grease:
95 g (3.35 oz)
groove.
Set boot so that it does not swell and deform when its length
is "L,".
Length
SFA4568
"L/':
ZF80
ZF90
BF83
SFA4438
FA-20
FRONT AXLE
Drive Shaft (Cont'd)
Dynamic damper
Gasoline engine
1.
2.
B_1
side
while
Unit: mm (in)
.":JJ.Ci
ZF90/TS79C
ZF80/TS70C
Gasoline engine
ZF90/TS79C left side
RH
RH
Diesel
engine
LH
RH
BF83/TS83,
DS83
"A"
432 - 442
(17.01 - 17.40)
175.3 - 185.3
(6.90 - 7.30)
372.5 - 377.5
(14.67 14.86)
169 - 175
(6.65 - 6.89)
"B"
66 (2.60)
58 (2.28)
37 (1.46)
70 (2.76)
Transaxle
boot
SFA800
2.
3.
FA-21
FRONT AXLE
Drive Shaft (Co nt' d)
4.
SFA993
SFA395
Transaxle
boot
SFA800
2.
3.
Install ball cage, inner race and balls as a unit, making sure
the marks which were made during disassembly are properly aligned.
Install new snap ring "C".
SFA514A
4.
5.
6.
SFA149A
FA-22
FRONT AXLE
Drive Shaft (Co nt' d)
7.
and smaller
with a
SFA395
Support bearing
1.
Install bearing
into retainer.
2.
Suitable tool
SFA618
Suitable tool
SFA694
3.
4.
Transaxle side
SFA444B
FA-23
FRONT SUSPENSION
SEC. 391.400.401
When installing rubber parts, final tightening
must be carried out under unladen condition'
with tires on ground.
Fuel, radiator coolant a'1d engine 011full.
Spare tire, Jack, hand tools and mats In
designated positions.
~~
59.74
~.~
::'
.4: - 54)
9
(2.5 _ 3.0,
18 - 22)
~~
~
~~
~
~
9=:
@
~
L.~
~~
-----J
1/ ~
/~18-24
(1.8.2.4,13.17)
~.
&1
(@
~J~!~5
Front
SFA624B
CD
@
@
@
@
@
(J)
@
Spacer
Strut mounting insulator
@)
@
@
@
Strut assembly
Suspension member
@
@
@
Stabilizer bar
Stabilizer clamp
Connecting rod
Transverse link
Compression rod clamp
Drive shaft
FA-24
@
@
Knuckle
Cotter pin
@)
@
ABS sensor
Plain washer
Wheel bearing lock nut
Insulator
Adjusting cap
Cotter pin
@
@
@
@
FRONT SUSPENSION
Coil Spring and Strut Assembly
REMOVAL AND INSTALLATION
DISASSEMBL Y
1.
Set strut assembly on vise with Tool, then loosen piston rod
lock nut.
. Do not remove piston rod lock nut at this time.
2. Compress spring with Tool so that the strut mounting insulator can be turned by hand.
Suitable
bar
3.
SFA610B
INSPECTION
Shock absorber assembly
Check for smooth operation through a full stroke, both compression and extension.
Check for oil leakage on welded or gland packing portion.
Check piston rod for cracks, deformation or other damage.
Replace if necessary.
or
Thrust bearing
Coil spring
FA-25
or other damage.
Replace if
FRONT SUSPENSION
Coil Spring and Strut Assembly (Cont'd)
ASSEMBLY
When installing coil spring on strut, it must be positioned as
shown in the figure at left.
'
~Ud
SFA508A
Front
Outside of
vehicle
SFA957A
Stabilizer Bar
REMOVAL AND INSTALLATION
Remove stabilizer bar.
Inside of ..-1'.
vehicle
L..y'
SFA625B
FA-26
FRONT SUSPENSION
Stabilizer Bar (Cont'd)
Install stabilizer
placed.
View from B
OK
NG
SFA449BA
INSPECTION
ARA027
5.
6.
7.
SFA113AA
8.
FA-27
FRONT SUSPENSION
Transverse Link and Lower Ball Joint (Cont'd)
INSPECTION
,...............
SFA858A
FA-28
(50S)
General Specifications
Suspension type
Strut type
Double-acting hydraulic
Stabilizer
(Unladen*1)
GA engine and SR
engine models with
14-inch wheels
Applied model
Camber
.
Degree minute
(Decimal degree)
Caster
Minimum
-no'
Nominal
-0'35' (-0.58')
Degree minute
(Decimal degree)
Total toe-in
0'10' (0.1r)
Minimum
0'40' (0.6r)
1'25' (1.42')
2'10' (217")
Minimum
14'00' (14.00')
Nominal
14'45' (14.75')
Maximum
15'30' (15.50')
Minimum
0(0)
Nominal
Distance (A - B)
(-1.33')
Maximum
Nominal
Degree minute
(Decimal degree) Maximum
Kingpin inclination
CD engine and SR
engine models with
15-inch wheels
4 (0.16)
Minimum
0' (0.00')
Nominal
11' (0.18')
2 (008)
mm (in) Maximum
22' (0.37")
Maximum
Minimum
38'00' (38.00')
34'00' (34.00')
Nominal
4nO'
(41.00')
3rOO' (37.00')
Maximum
42'00' (42.00')
38'00' (38.00')
Nominal
34'00' (34.00')
31'00' (3100')
Full (urn'2
Outside
Degree minute
(Decimal degree)
'1' Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
'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 Ib) with engine
idle
FA-29
SA 20DE
GA14DE,
GA15DE
GA16DE,
CD20
AH
TS70C
TS79C
DS83
ZF80
ZF90
95.5 - 97.5
(376 - 3.84)
101.5 - 103.5
(4.00 - 4.07)
90.5 - 92.5
(3.563 - 3.642)
96 - 98
(3.78 - 3.86)
LH
Joint type
Transaxle side
Wheel side
Boot length
Boot length
Wheel side
TS83
BF83
mm (in)
Transaxle side L2
Wheel side L,
97 - 99
(3.82 - 3.90)
98 - 100
(3.86 - 3.94)
Transaxle side
94 - 96 (3.70 - 3.78)
Grease
g (oz)
Capacity
Transaxle side
Wheel side
110 - 120
(388 - 4.23)
155 - 165
(5.47 - 5.82)
95 (3.35)
115 - 125
(4.06 - 4.41)
115 - 135
(4.06 - 4.76)
130 - 150
(4.59 - 5.29)
WHEEL RUNOUT
WHEEL BEARING
Unit: mm (in)
Wheel bearing axial end play
limit
mm (in)
Wheel bearing lock nut
tightening torque
N'm (kg-m, ft-Ib)
Preload
N'm (kg-em, in-Ib)
At hub bolt
N (kg, Ib)
8.24 - 5737
(0.84 - 5.85, 1.85 - 12.90)
0(0)
Aluminum wheel
Steel wheel
Maximum radial
runout limit
0.3 (0.012)
0.5 (0.020)
Maximum lateral
runout limit
03 (0.012)
0.8 (0.031)
Wheel type
FA-30