FRONT AXLE 4C-1

PROPELLER SHAFT AND AXLE

SECTION 4C
FRONT AXLE
Contents
GENERAL DESCRIPTION ...................................4C-2
NHR Front Drum Brake Model (4 × 2 Model) ....4C-2
NKR Front Drum Brake Model (Rear Single Tire) (4 ×
2 Model).............................................................4C-2
NKR Front Drum Brake Model (Rear Dual Tire) (4 × 2
Model)................................................................4C-3
NPR, NQR Front Drum Brake Model (4 × 2 Model)...4C-3
NKR Front Disc Brake Model (4 × 2 Model) ......4C-4
NPR Front Disc Brake Model (5 studs) (4 × 2 Model) ....4C-4
NPR, NQR Front Disc Brake Model (6 studs) (4 × 2
Model)................................................................4C-5
NKR Front Disc Brake Model (Independent
Suspension, 4 × 2 Model)..................................4C-5
Front Axle (4 × 4 Model) ....................................4C-6
Front Final Drive (244mm (9.6 in.) Size) ...........4C-7
Front Drive Shaft (Birfield Joint) ........................4C-7
Free Wheel Hub (Manual Type) ........................4C-8
ON-VEHICLE SERVICE .....................................4C-10
Front Hub and Brake Drum (4 × 2 Model) .......4C-10
Front Hub and Disc (4 × 2 Model, 293 & 310mm Disc) ....4C-15
Front Hub, Disc and Knuckle (4 × 2, Independent
Suspension Model)..........................................4C-21
Front Axle Assembly (4 × 2 Model) .................4C-27
Knuckle and King Pin (4 × 2 Model) ................4C-30
Free Wheel Hub (Manual Locking Hub) (4 × 4 Model) .....4C-37
Front Hub and Brake Drum (4 × 4 Model) .......4C-42
Spindle and Drive Shaft (4 × 4 Model).............4C-48
Knuckle and King Pin (4 × 4 Model) ................4C-52
Front Differential Assembly (4 × 4 Model) .......4C-59
Front Axle Assembly (4 × 4 Model) .................4C-61
UNIT REPAIR .....................................................4C-65
Front Differential ..............................................4C-65
4C-2 FRONT AXLE

GENERAL DESCRIPTION
NHR Front Drum Brake Model (4 × 2 Model)

N4A0220E

NKR Front Drum Brake Model (Rear Single Tire) (4 × 2 Model)

N4A0332E
 FRONT AXLE 4C-3
NKR Front Drum Brake Model (Rear Dual Tire) (4 × 2 Model)

N4A0222E

NPR, NQR Front Drum Brake Model (4 × 2 Model)

N4A0223E
4C-4 FRONT AXLE
NKR Front Disc Brake Model (4 × 2 Model)

N4A0224E

NPR Front Disc Brake Model (5 studs) (4 × 2 Model)

N4A0225E
 FRONT AXLE 4C-5
NPR, NQR Front Disc Brake Model (6 studs) (4 × 2 Model)

N4A0226E

NKR Front Disc Brake Model (Independent Suspension, 4 × 2 Model)

N4A0227E
4C-6 FRONT AXLE
Front Axle (4 × 4 Model)

N4A0228E

Legend
1. Front final drive 9. King pin cover
2. Front axle tube end boot 10. Front axle hub inner bearing
3. Shim 11. Front axle hub outer bearing
4. Knuckle arm 12. Free wheel hub
5. Front axle knuckle 13. Front axle hub
6. Front drive shaft 14. Front hub oil seal
7. King pin bearing 15. Spindle
8. King pin

The front axle is full floating axle tube type with Birfield joints. The front axle supports the weight of the front of the
vehicle and transfers it to the front tires. It also functions as a part of the steering system. The front axle is also de-
signed to transmit the driving force to the front wheels in the four wheels drive mode.
 FRONT AXLE 4C-7
Front Final Drive (244mm (9.6 in.) Size)

N4A0229E

The differential system employs a hypoid gearing which is higher in strength and durability and quieter in operation
than the spiral bevel gears to lower the center of gravity of the vehicle thereby improving running stability. The differ-
ential gear box which includes the side gears and pinion gears is mounted to the differential carrier via the two (2)
taper roller bearings. The final drive gear reduces and changes axial rotary force (drive power) of transfer output to
rectangular direction, and also it distributes the power to the drive wheels.

Front Drive Shaft (Birfield Joint)

N4A0230E

Legend
A. Birfield section 3. Ball
1. Outer shaft 4. Inner shaft
2. Outer ring 5. Inner ring

The drive power from the reduction and differential is transmitted from the outer drive shaft to the outer ring of Birfield
joint to its ball to its inner ring to the inner drive shaft finally to drive the tire. When the vehicle is steered the balls
automatically move according to the steering angle thereby operating as a complete constant velocity joint.
4C-8 FRONT AXLE
Free Wheel Hub (Manual Type)

N4A0231E

Legend
1. Retainer 5. Lock spring
2. Lock spring 6. Hub lock clutch
3. Handle 7. Hub lock ring
4. Drive shaft 8. Hub lock inner

The free wheel hub, a hub lock device installed on the hub, transmits engine torque to the front wheels by engaging
the dog clutch in the 4-wheel drive mode, or disengages the dog clutch in the 2-wheel drive mode to make free the
front wheel drive system, so that it can improve fuel economy and reduce noise.
Engagement or disengagement of dog clutch is done by handle operation.
 FRONT AXLE 4C-9

N4A0233E

Legend
1. Retainer
2. Lock spring
3. Handle
4. Drive shaft
5. Hub lock clutch
6. Hub lock ring
7. Hub lock inner

[Operational Description]
(FREE status)
As the handle is rotated in the FREE direction, a lock
spring assembled in the handle also rotates. Since the
retainer lug moves along the slant face of lock spring,
the hub lock clutch calked to the retainer is disengaged
from lock inner, resulting in free status. If, however, the
hub lock clutch is not disengaged from lock inner due to
spline resistance, the lock spring is compressed to store
spring force. Upon elimination of spline resistance, the
hub lock clutch is disengaged by means of spring force.
(LOCK status)
As the handle is rotated in the LOCK direction, the re-
tainer lug moves along the slant face of lock spring, and
the hub lock clutch is engaged with lock inner, resulting
in lock status. If, however, phase between hub lock
clutch and lock inner is not coincident, the lock spring is
compressed to store spring force. Upon coincidence of
phase, the hub lock clutch is engaged by means of
spring force.
4C-10 FRONT AXLE

ON-VEHICLE SERVICE
Front Hub and Brake Drum (4 × 2 Model)

N4A0234E

Legend
A. NHR, NKR models (rear single and dual small tire) 7. Outer bearing
B. NKR, NPR models (rear dual tire) 8. Oil seal
1. Wheel and tire 9. Inner bearing
2. Hub cap 10. Inner bearing outer race
3. Hub bearing nut 11. Outer bearing outer race
4. Lock washer 12. Brake drum
5. Hub with brake drum assembly 13. Hub
6. Distance piece
 FRONT AXLE 4C-11
Removal
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
2. Hub Cap
When removing hub cap, exercise care so as not
to scratch or distort hub fitting face.

N4A0237E

6 studs
Hub Remover: 9-8521-0115-0 (NHR, NKR rear
small tire)

N4A0235E

3. Hub Bearing Nut

Hub Nut Wrench: 5-8840-2015-0

N4A0238E

6. Distance Piece
7. Outer Bearing
8. Oil seal
9. Inner Bearing
N4A0236E
10. Inner Bearing Outer Race
Drive out the inner bearing outer race together with
4. Lock Washer the oil seal with a proper bar through two notches.
5. Hub with Brake Drum Assembly
5 studs
Hub Remover: 5-8840-2016-0
4C-12 FRONT AXLE
Installation
1. Hub
2. Brake Drum
Tighten the brake drum wheel nuts to the specified
torque.

Tighten:
Wheel nut to
• Brake lining width 75 mm: 343 N⋅m (35 kg⋅m / 253
lb⋅ft)
• Brake lining width 100 mm: 392 N⋅m (40 kg⋅m / 289
lb⋅ft)

N4A0239E

11. Outer Bearing Outer Race

12. Brake Drum
13. Hub

Inspection and Repair

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

N4A0243E

3. Outer Bearing Outer Race

4. Inner Bearing Outer Race
N4A0241E
 FRONT AXLE 4C-13

Bearing Outer Race Installer

Parts No. Remarks
All 9-8522-1148-0 Grip
NHR 5-8840-2023-0 Inner Bearing
NKR 5-8840-2025-0 Outer Bearing
NPR 5-8840-2024-0 Inner Bearing
NQR 5-8840-2026-0 Outer Bearing

N4A0245E

5. Inner Bearing
6. Oil Seal
Drive the oil seal into the hub flush with the hub end
surface.
7. Outer Bearing
8. Distance Piece
9. Hub with Brake Drum Assembly
10. Lock Washer
11. Hub Bearing Nut
N4A0244E
Check the brake lining clearances first to avoid fric-
Apply grease (1) in the hub and bearing rollers tion loss.
Adjust the hub bearing preload at the wheel pin.
Hub Grease Amount g (oz)
Hub Bearing Preload (at Wheel Pin)
Hub Hub cap
N (kg/lb)
Rear Single and
NHR 55 (1.9) 30 (1.1)
Dual Small Tire 9.8 — 34.3
New
(1.0 — 3.5/2.2 — 7.7)
Rear Single and NHR
NKR 80 (2.8) 7.8 — 22.5
Dual Small Tire Reused
40 (1.4) (0.8 — 2.3/1.8 — 5.0)
NKR Rear Dual Tire 90 (3.2)
11.8 — 26.5
NPR NQR 160 (5.6) New
(1.2 — 2.7/2.6 — 5.9)
NKR
6.9 — 21.6
Reused
(0.7 — 2.2/1.5 — 4.8)
9.8 — 34.3
New
NPR (1.0 — 3.5/2.2 — 7.7)
NQR 4.9 — 19.6
Reused
(0.5 — 2.0/1.1 — 4.4)

Hub Nut Wrench: 5-8840-2015-0

In case of misalignment of locking hole, align in di-
rection of retightening.
4C-14 FRONT AXLE

N4A0246E

12. Hub Cap

13. Wheel and Tire
 FRONT AXLE 4C-15
Front Hub and Disc (4 × 2 Model, 293 & 310mm Disc)

N4A0265E

Legend
1. Hub cap 9. Inner bearing
2. Cotter pin 10. Disc
3. Nut 11. Inner bearing race
4. Washer 12. Outer bearing race
5. Outer bearing 13. Stud
6. Hub and disc assembly 14. Hub
7. Spacer 15. Dust shield
8. Oil seal 16. Adapter
4C-16 FRONT AXLE
Removal 1) Use an inner hex wrench (1) to loosen the disc
Preparation: fixing bolts.
Jack up and support the vehicle on stands. 2) Remove the disc from the hub.
1. Hub cap
Use a lever to pry the hub cap from the hub.

N4A0266E

11. Inner Bearing Race

N4A0248E
12. Outer Bearing Race
2. Cotter Pin Use a hammer and a brass bar (1) to remove the
3. Nut inner race and the outer race from the hub.
Use a wrench to remove the nut.

N4A0267E

N4A0249E
13. Stud
4. Washer Place hub on a suitable work surface and remove
the studs (1) by using a hammer.
5. Outer Bearing
6. Hub and Disc Assembly
1) Turn the caliper assembly up and around the
guide pin.
2) Remove the hub and disc assembly from the
knuckle.
7. Spacer
8. Oil Seal
9. Inner Bearing
10. Disc
 FRONT AXLE 4C-17
Disc
Use a vernier caliper to measure the disc thickness.
If the measured value is less than the specified limit, the
disc must be replaced.
Disc thickness,
Standard: 42.0 mm (1.654 in)
Limit: 39.0 mm (1.535 in)

N4A0268E

14. Hub
15. Dust Shield
16. Adapter

Inspection and Repair

Make the necessary adjustments, repairs, and part re- N4A0270E
placements if excessive wear or damage is discovered
during inspection. Installation
Visual Inspection 1. Adapter
Inspect the following parts for cracking, deformation,
and corrosion. Tighten:
Adapter fixing bolt to 162 N⋅m (16.5 kg⋅m / 119 lb⋅ft)
2. Dust Shield
Tighten:
Dust shield fixing to 13 N⋅m (1.3 kg⋅m / 113 lb⋅ft)
3. Hub
Apply the specified amount of the approved grease
to the hub cavity (1).
Grease amount: 160 g (5.6 oz)

N4A0269E

Legend
1. Hub
2. Disc
3. Inner bearing race
4. Outer bearing race
5. Inner bearing
6. Outer bearing
N4A0271E
7. Wheel pins
4. Inner Bearing Race
4C-18 FRONT AXLE
5. Inner Bearing 8. Stud
6. Oil Seal Insert a stud (1) using a hammer.
1) Use a hammer and the installer (1) to install the
inner bearing race (2) to the hub.
Be sure that the race is completely seated in
the hub.
Installer: 5-8840-2235-0

N4A0274E

9. Disc
1) Install the disc to the hub.
2) Use an inner hex wrench (1) to tighten the disc
N4A0272E
bolts to the specified torque.
Tighten:
2) Apply grease to the inner bearing. Disc bolt to 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
3) Install the inner bearing to the hub.
4) Use a plastic hammer to carefully tap the oil
seal into place.
The oil seal surfaces must be flat.
Use a new oil seal.
7. Outer Bearing Race
Use a hammer and the installer (1) to install the
outer bearing race (2) to the hub.
Be sure that the race is completely seated in the
hub.
Installer: 5-8840-2026-0

N4A0266E

10. Spacer
11. Hub and Disc Assembly
12. Outer Bearing
1) Turn the caliper assembly up and around the
guide pin.
2) Install the spacer and the hub and disc assem-
bly to the knuckle.
3) Apply grease to the outer bearing.
4) Install the bearing to the hub.
N4A0273E
 FRONT AXLE 4C-19

N4A0259E N4A0275E

13. Washer 5) Align the nut slot with the knuckle cotter pin
14. Nut hole.
15. Cotter Pin If necessary, slightly tighten the nut to align the
slot and the hole.
1) Install the washer to the hub.
6) Insert the cotter pin to the slot and hole.
2) Tighten the nut until you are unable to manually
rotate the hub and disc assembly. 7) Bend back the cotter pin to lock the nut.
8) Return the caliper assembly to its original posi-
tion.
9) Tighten the lock pin bolt (1) to the specified
torque.
Use a new cotter pin.

Tighten:
Lock pin bolt to137 N⋅m (14 kg⋅m / 101 lb⋅ft)

N4A0249E

3) Loosen the nut.

4) Attach a spring balancer (1) to one wheel pin.
Gradually retighten the nut until the hub and
disc assembly bearing is adjusted to the speci-
fied preload.
Hub bearing preload,
New Hub bearing: 17 — 31 N (1.7 — 3.2 kg / 3.7 — 7.1 N4A0262E

lb)
16. Hub Cap
Reused Hub bearing: 14 — 28 N (1.4 — 2.9 kg / 3.1 —
6.4 lb) 1) Apply LOCTITE or liquid gasket to the engage-
ment part with hub.
2) If severe deformation is found, replace with a
new one.
4C-20 FRONT AXLE
3) Apply the specified amount of the approved
grease to the hub cap.
Grease amount: 40 g (1.4 oz)
4) Use a plastic hammer to install the hub cap to
the hub.

N4A0263E
 FRONT AXLE 4C-21
Front Hub, Disc and Knuckle (4 × 2, Independent Suspension Model)

N4A0276E

Legend
1. Wheel and tire 7. Oil seal
2. Hub cap 8. Inner bearing
3. Hub nut 9. Hub
4. Thrust washer 10. Disc
5. Hub and disc assembly 11. Back plate
6. Outer bearing 12. Knuckle
4C-22 FRONT AXLE
Removal 6. Outer Bearing
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
Remove the disc brake caliper assembly (1) with
brake hose and wire it to frame.

N4A0279E

Legend
1. Outer bearing

N4A0277E 7. Oil Seal

8. Inner Bearing
2. Hub Cap
3. Hub Nut
4. Thrust Washer
5. Hub and Disc Assembly
Remove the hub and disc assembly from the
knuckle.

N4A0280E

Legend
1. Oil seal
2. Inner bearing
N4A0278E
• Drive out the bearing outer races using with a
proper bar through two notches.
Legend
1. Hub and disc assembly
2. Thrust washer
3. Cotter pin
4. Hub cap
5. Hub nut
 FRONT AXLE 4C-23

N4A0281E N4A0283E

9. Hub • Remove the two bolts fixing the lower link end
10. Disc and remove the knuckle together with the lower
link end.
• If need, separate the hub on disc.
Torx bit (T70): 5-8840-2368-0 • Remove the lower link end from the knuckle.
11. Back Plate

N4A0284E

N4A0282E
Inspection and Repair
Make the necessary adjustments, repairs, and part re-
Legend placements if excessive wear or damage is discovered
1. Bolt during inspection.
2. Hub Visual Inspection
3. Disc Inspect the following parts for cracking, deformation,
and corrosion.
12. Knuckle
• Disconnect the tie rod end joint and upper link
end joint from the knuckle.
Tie Rod End Remover: 5-8840-2017-0
4C-24 FRONT AXLE
• Lower link end bolt to 219 N⋅m (22.3 kg⋅m / 161 lb⋅ft)
• Upper link joint nut to 205 N⋅m (20.9 kg⋅m / 151 lb⋅ft)
• Tie rod joint nut to 108 N⋅m (11 kg⋅m / 80 lb⋅ft)
• Discard used cotter pin and install new one.
2. Back Plate
Tighten:
Back plate bolt to 13 N⋅m (1.3 kg⋅m / 113 lb⋅ft)
3. Disc
4. Hub
Tighten:
Disc bolt to
• M14: 155 N⋅m (15.8 kg⋅m / 114 lb⋅ft)
• M16: 219 N⋅m (22.3 kg⋅m / 163 lb⋅ft)

N4A0285E

Legend
1. Hub
2. Disc
3. Inner race
4. Outer race
5. Inner bearing
6. Outer bearing
7. Wheel pins

Disc
Use a vernier caliper to measure the disc thickness.
If the measured value is less than the specified limit, the
disc must be replaced.
Disc thickness, N4A0282E
Standard: 35.0 mm (1.38 in)
Limit: 33.5 mm (1.32 in)
Legend
1. Bolt
2. Hub
3. Disc

Be sure that the race is completely seated in the

hub.
Outer Bearing Outer Race Installer: 5-8840-2026-0

N4A0286E

Installation
1. Knuckle
Tighten:
• Lower link joint nut to 377 N⋅m (38.4 kg⋅m / 278 lb⋅ft)
 FRONT AXLE 4C-25

N4A0287E N4A0288E

Be sure that the race is completely seated in the 5. Inner Bearing

hub. Apply grease (multipurpose type) to the inner bear-
Inner Bearing Outer Race Installer: 5-8840-2235-0 ing.
6. Oil Seal
Use a hammer and installer to install the oil seal.
The oil seal surfaces must be flat.
Use a new oil seal.
Oil Seal Installer: 5-8840-2235-0

N4A0260E

Apply the specified amount of the multipurpose

type grease (1) to the hub cavity.
Grease amount: 96 g (3.4 oz)
N4A0289E

Legend
1. Inner bearing
2. Oil seal
3. Flat
4. Hub

7. Outer Bearing
8. Hub and Disc Assembly
1) Install the hub and disc assembly to the knuck-
le.
2) Apply grease (multipurpose type) to the outer
bearing (1).
4C-26 FRONT AXLE
3) Install the bearing to the hub.

N4A0292E

N4A0290E
5) Align the nut slot with the knuckle cotter pin
9. Thrust Washer hole.
If necessary, slightly tighten the nut to align the
10. Hub Nut
slot and the hole.
1) Install the thrust washer (1) and hub nut (2).
6) Discard used cotter pin and install new cotter
pin.
11. Hub Cap
1) Apply LOCTITE or liquid gasket to the engage-
ment part with hub.
2) If severe deformation is found, replace with a
new one.
3) Apply the specified amount of the approved
grease (Multipurpose type) to the hub cap.
Grease amount: 40 g (1.4 oz)
4) Install the disc brake caliper assembly to the
knuckle.
Tighten:
Disc brake caliper bolt to 219 N⋅m (22.3 kg⋅m / 161 lb⋅ft)

N4A0291E

2) Tighten the nut until you are unable to manually

rotate the hub and disc assembly.
3) Loosen the nut.
4) Attach a spring balancer to one wheel pin.
Gradually retighten the nut until the hub and
disc assembly bearing is adjusted to the speci-
fied preload.
Hub bearing preload,
NHR new bearing: 14 — 28 N (1.4 — 2.9 kg⋅m / 3 — 6
lb⋅ft)
NKR new bearing: 12 — 26 N (1.2 — 2.7 kg⋅m / 3 — 6
lb⋅ft)
NHR ⋅ NKR reused bearing: 7 — 22 N (0.7 — 2.2 kg⋅m /
2 — 5 lb⋅ft) N4A0293E
 FRONT AXLE 4C-27

Legend
1. Bolt
2. Disc brake caliper assembly

12. Wheel and Tire

Front Axle Assembly (4 × 2 Model)

N4A0294E

Legend
1. Wheel and tire 4. Drag link
2. Brake flexible hose 5. U-bolt
3. Shock absorber 6. Front axle assembly
4C-28 FRONT AXLE
Removal
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
2. Brake Flexible Hoses
Loosen the nut (2), then pry off a clip (1).

N4A0297E

6. Front Axle Assembly

Installation
1. Front Axle Assembly
2. U-bolt and Nut
N4A0295E Position the U-bolts and helper rubber on the leaf
spring assemblies and jack up the front axle. When
3. Shock Absorber tightening the nuts, apply oil as necessary to pre-
4. Drag Link vent damaging the threads.
Disconnect the drag link, using a special tool.
Tighten:
Remover: 5-8840-2017-0
U-bolt nut to
• NQR: 196 N⋅m (20 kg⋅m / 145 lb⋅ft)
• NHR, NKR, NPR: 127 N⋅m (13 kg⋅m / 94 lb⋅ft)

N4A0296E

5. U-Bolt
Loosen the U-bolts after setting jack against the N4A0297E
front axle. If the U-bolts are heavily rusted, apply a
generous amount of oil to the threads before loos- 3. Drag Link
ening them to prevent seizure. Tighten drag link nut to specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.

Tighten:
Drag link nut to 167 N⋅m (17 kg⋅m / 123 lb⋅ft)
 FRONT AXLE 4C-29
4. Shock Absorber
Refer to illustration for installation of shock absorb-
er, nut, washer and rubber bushing (1).

N4A0299E

5. Brake Flexible Hose

Set first the wheels in the straight going position,
then attach the flexible hose to the bracket without
torsion using a (1).
Connect the pipe, then tighten the nut (2) to the
specified torque.

Tighten:
Brake flexible hose to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)

N4A0300E

Perform bleeding operation after installation of the

brake flexible hoses.
Refer to Section 5 “Service information” for brake
fluid air bleeding procedure.
Also inspect wheel alignment after completion of
front axle removal and installation.
6. Wheel and Tire
4C-30 FRONT AXLE
Knuckle and King Pin (4 × 2 Model)

N4A0418E

Legend
1. Wheel and tire 9. Key bolt
2. Hub with brake drum 10. Plate plug
3. Cover 11. King pin
4. Wheel brake assembly 12. Knuckle
5. Tie rod assembly 13. Shim
6. Knuckle arm 14. Thrust bearing
7. Tie rod arm 15. I-beam
8. King pin cover
 FRONT AXLE 4C-31
Removal
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
2. Hub with Brake Drum
3. Cover
4. Wheel Brake Assembly
5. Tie Rod Assembly
Remover
Driver Side: 5-8840-2017-0
Assistant Side: 5-8840-2018-0

N4A0305E

10. Plate Plug

11. King Pin
Remover:
NHR 5-8840-2021-0
NKR, NPR 5-8840-2022-0
NQR 5-8840-2022-0

N4A0303E

6. Knuckle Arm
7. Tie Rod Arm
Remover: 5-8840-2019-0
Drive out with a heavy hammer.

N4A0306E

12. Knuckle
13. Shim
14. Thrust Bearing
15. I-Beam

Inspection and Repair

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
N4A0304E during inspection.
Visual Check
8. King Pin Cover Inspect the following parts for wear, damage or other ab-
9. Key Bolt normal conditions.
Remover: 5-8840-2020-0 • I-beam
• Knuckle
4C-32 FRONT AXLE
• Knuckle arm, tie rod arm
• Tie rod, tie rod end
• King pin, bushing, thrust bearing and shims
• Joint ball
• Front hub, bearing and oil seal
• Brake drum
• Brake shoe, lining etc.
I-Beam (when removed from the vehicle)
1. Fit the king pin or test bar (1) into the king pin hole.
2. Stretch a cord (2) across the centers of king pin or
test bars.
3. Check to see if the cord is in line with the centers
of the center bolt holes (3) in the spring seat when
looked down from above the cord.

N4A0310E

6. Stretch a cord (1) and check the following dimen-

sions.

‘05 model mm (in)

θ H1 H2 H3 L1 L2
97 135.3 260 690
NHR
(3.8) (5.3) (10.2) (27.2)
97 134.4 260 690
NKR
(3.8) (5.3) 25.2 (10.2) (27.2)
12°
83 120.4 (0.99) 315 860
NPR
(3.3) (4.7) (12.4) (33.9)
83 120.4 315 860
NQR
(3.3) (4.7) (12.4) (33.9)
N4A0308E

4. Also check to see if the king pins or test bar are in

good parallel alignment as viewed from the side.

N4A0311E

Cracks in Knuckles
N4A0309E Check the knuckles for cracks or damage paying a par-
ticular attention to the areas indicated by arrows.
5. Check to see if the king pin holes is worn. Use a magnetic flaw detector or red check.
 FRONT AXLE 4C-33
• NHR King Pin Diameter
A: 30 mm (1.19 in) • NHR
B: 40 mm (1.57 in) A: 25.0 mm (0.984 in)
• NKR, NPR, NQR B: 24.9 mm (0.980 in)
A: 35 mm (1.38 in) • NKR, NPR, NQR
B: 50 mm (1.97 in) A: 30.0 mm (1.181 in)
B: 29.9 mm (1.177 in)

N4A0312E

N4A0314E
Knuckle Arm and Tie Rod Arm
Check tapered portion of the knuckle arms and tie-rod Clearance between King Pin and Bushing
arms for abnormal contact in the following manner.: Standard: 0.06 mm (0.0024 in)
Apply a thin coat of red check evenly to the tapered por- Limit: 0.15 mm (0.0059 in)
tion of the shaft and insert the shaft into the tapered
hole. Remove the shaft and check impression of contact Notice:
obtained on the shaft. Install the king pin bushing by aligning its grease hole
Correction or parts replacement is necessary if the con- with grease fitting hole in the knuckle.
tact is uneven or if contact area is smaller than 3/4 of the
entire length of the shaft.

N4A0315E

N4A0313E
Fit of king pin into the king pin bushing can be checked
in the following manner.
Clamp the knuckle with king pin bushings in a vise and
Legend insert the king pin into the bushings. Check for radial
1. Contact are is longer than 3/4 of the entire play by moving the king pin in direction at a right angle
length of the shaft. to its axis, then move the king pin endwise with finger.
4C-34 FRONT AXLE

N4A0316E N4A0318E

If fitting of king pin into the bushing is too tight, carefully

cut inner face of the bushing with a reamer, so that up- Legend
per and lower holes in the knuckle are well centered. 1. Case

4. Shim
Check the clearance between the knuckle and
front axle.
Standard: 0 — 0.10 mm (0 — 0.004 in)
Limit: 0.20 mm (0.0079 in)
Shim available thickness, 0.50, 0.55, 0.60, 0.65, 0.70,
0.80, 0.90 mm (0.019, 0.022, 0.024, 0.026, 0.028,
0.031, 0.035 in)

N4A0317E

Installation
1. I-Beam
2. Knuckle
3. Thrust Bearing
1) Apply grease.
2) Turn the bearing case-side upward.
N4A0319E

5. King Pin
1) Apply grease.
2) Align the key groove with the key bolt hole in
the front axle.
3) After installing the king pin, check that the
knuckle turns smoothly.
 FRONT AXLE 4C-35

N4A0320E N4A0322E

6. Key Bolt 9. Tie Rod Arm

Tighten: 10. Knuckle Arm
Key bolt to 32 N⋅m (3.3 kg⋅m / 24 lb⋅ft) Tighten:
Knuckle arm nut to 441 N⋅m (45 kg⋅m / 325 lb⋅ft)
After tightening, stake nut.
Use a new nut.

N4A0321E

7. King Pin Cover

8. Plate Plug
Drive the plate plug upward into position with an N4A0323E

appropriate bar fitted against the lower end.

11. Tie Rod Assembly
Use a new nut.

Tighten:
Tie rod end nut to 186 N⋅m (19 kg⋅m / 137 lb⋅ft)
Be sure to install a new cotter pin. If the hole and the slot
are not aligned, turn in the direction of tightening to align
them.
4C-36 FRONT AXLE

N4A0324E

12. Wheel Brake Assembly

13. Cover
Tighten:
Wheel brake bolt to 69 N⋅m (7 kg⋅m / 51 lb⋅ft)

N4A0325E

14. Hub with Brake Drum

15. Wheel and Tire
 FRONT AXLE 4C-37
Free Wheel Hub (Manual Locking Hub) (4 × 4 Model)

N4A0326E

Legend
1. Screw 10. Handle
2. Cover assembly 11. Ring
3. Snap ring and shim 12. Cover
4. Bolt 13. Inner snap ring
5. Body assembly 14. Body
6. Clutch assembly 15. Outer snap ring
7. Inner snap ring 16. Ring
8. Tension spring 17. Spacer
9. Inner snap ring 18. Inner hub lock
4C-38 FRONT AXLE
Removal At this time, the lug of clutch retainer gets stuck
1. Screw by the L-shaped part at the edge of tension
spring (0 it is pinched by double parts of tension
2. Cover Assembly
spring).
Set handle into “FREE” position and then remove
cover assembly.
(During removal, take care not to damage the
flange on rear side of cover. Remove wheel (tire)
as necessary.)

N4A0329E

2) Under the condition of 1) above, rotate further

the clutch assembly clockwise while pushing it
(B).
N4A0327E Consequently, the clutch retainer lug is freed
from the L-shaped part at the edge of tension
3. Snap Ring and Shim spring (C).
Confirm the quantity of shims.
Do not try to further disassemble the clutch as-
sembly.

N4A0328E

4. Bolt N4A0330E

5. Body Assembly 7. Inner Snap Ring

Remove the body assembly using a push bolt (M10
8. Tension Spring
× 1.5).
Remove the snap ring and then remove the tension
During removal, do not damage the flange of body spring from the cover.
by hitting with a screwdriver or the like.
9. Inner Snap Ring
6. Clutch Assembly
10. Handle
1) With the handle in FREE position, hold the cov- Remove the inner snap ring and then remove the
er and rotate fully the clutch assembly clock- handle from the cover.
wise as shown (A).
 FRONT AXLE 4C-39
11. Ring 2. Inspect the inner snap ring of cover for local wear
Remove the ring from the handle. in the mounting groove.
12. Cover 3. Inspect the tension spring for wear, damage or
break.

N4A0331E
N4A0331E
13. Inner Snap Ring
Clutch Assembly
1. Inspect the retainer of clutch assembly for play in
the calked parts (3 places).
Re-calk if the axial play exceeds 0.1 mm.
2. Inspect the clutch teeth for crack, wear or damage,
and also the retainer lug for break or wear. Replace
the assembly if clutch or retainer is defective.

N4A0332E

14. Body
Remove the inner snap ring from the back of body.
15. Outer Snap Ring
16. Ring
Remove the outer snap ring that joints inner and
ring, so that they are separated. N4A0334E
17. Spacer
18. Inner Hub Lock Body Assembly
1. Inspect the body, ring, inner snap ring, outer snap
Inspection and Repair ring and inner hub lock for crack, wear or damage
Make the necessary adjustments, repairs, and part re- particularly in the teeth.
placements if excessive wear or damage is discovered 2. Inspect the inner snap ring mounting groove of the
during inspection. hub lock body and the outer snap ring mounting
Cover Assembly groove of the hub lock inner for an uneven wear.
1. Inspect the cover and handle for presence of crack
or damage particularly in a sliding part.
4C-40 FRONT AXLE

N4A0335E N4A0336E

Installation 2) Make sure that the inner snap ring is installed

1. Inner Hub Lock properly.
2. Spacer 11. Tension Spring
3. Ring 1) Apply grease (Multipurpose type) to the tension
spring.
4. Outer Snap Ring
Apply grease (Multipurpose type) to each part of in- 2) Insert the tension spring into the cover assem-
ner hub lock and install it to the hub lock ring bly with the nail of spring engaged with the
(flange should face rear side), then fix it with outer groove.
snap ring. There is no discrimination such as face or back
in the tension spring.
5. Body
6. Inner Snap Ring
1) Install the inner hub lock to hub lock ring, then
to the body, and fix them with inner snap ring.
2) Make sure that the inner hub lock and outer
snap rings are installed properly.
7. Cover
8. Ring
Apply grease (Multipurpose type) to the ring and in-
stall the ring to the handle.
Make sure that the ring is free from torsion.
9. Handle
10. Inner Snap Ring
1) Install the handle to the cover, and fix with inner
snap ring.

N4A0337E

12. Inner Snap Ring

Fix the tension spring with inner snap ring.
13. Clutch Assembly
1) With the retainer lugs met with L-shaped parts
(3 places) at the edge of tension spring (A),
push and rotate spirally the retainer (B) so that
it is pinched by springs (C).
 FRONT AXLE 4C-41
Measurement of axial play of front drive shaft
After installation of body assembly, measure axial play
of front drive shaft. If it is out of the standard range, ad-
just with shims listed below.
Standard play: 0 — 0.5 mm (0 — 0.020 in)
Kind of shims, 1.0, 0.5, 0.3 mm (0.039, 0.020, 0.012 in)

N4A0338E

2) The clutch must be in retract status when the

handle is set in FREE position.
3) Install the clutch assembly to the cover, and
measure the dimension “A” to confirm that it
satisfies the standard. N4A0340E
FREE status: 22.4 — 23.7 mm (0.88 — 0.93 in)
LOCK status: 32.6 — 33.9 mm (1.28 — 1.33 in) 16. Snap Ring and Shim
Install the snap ring properly.
17. Cover Assembly
Apply adhesive (Three Bond 1215 or equivalent) to
the flange surface of the cover assembly.
18. Screw
With the handle in FREE position (clutch is disen-
gaged), adjust three grooves of body and tighten
the screws to the specified torque after applying
adhesive (LOCTITE 242 or equivalent) to the
threads.

Tighten:
Screws to 6 N⋅m (0.6 kg⋅m / 52 lb⋅ft)
<Inspection of free wheel hub locking operation>
1. With the handle in FREE position, rotate the front
drive shaft. Normal if no load is applied.
2. With the handle in LOCK position, rotate the front
N4A0339E drive shaft. Normal if load is applied.
14. Body Assembly • Reference value
Load of front drive shaft: 3 N⋅m (0.3 kg⋅m / 26 lb⋅ft)
1) Apply grease (Multipurpose type) to the teeth of
hub lock body assembly. 3. Return the handle from LOCK to FREE position,
rotate the front drive shaft. Normal if no load is ap-
2) Apply adhesive (LOCTITE 515 or equivalent) to
plied.
the flange surface of the body assembly.
<Inspection of hub lock handle operating force>
15. Bolt The handle should be operated smooth and be moder-
Apply adhesive (LOCTITE 242 or equivalent) to the ate in functioning when it is operated two or three times.
threads of body assembly fixing bolts, and tighten [Reference] Handle operating force:10 kg⋅cm or less at
them to the specified torque. 10°C or above 100 kg⋅cm or less at −30°C.
Tighten:
Body assembly bolt to 98 N⋅m (10 kg⋅m / 72 lb⋅ft)
4C-42 FRONT AXLE
Front Hub and Brake Drum (4 × 4 Model)

N4A0341E

Legend
A. Inside drum fixing type 7. Front axle hub inner bearing
B. Outside drum fixing type 8. Front hub oil seal
1. Wheel and tire 9. Front axle hub inner bearing outer race
2. Front locking hub set 10. Front axle hub outer bearing outer race
3. Front hub bearing lock washer 11. Front wheel pin and nut (Inside drum fixing type)
4. Front hub bearing lock nut 12. Brake drum
5. Front hub and brake drum assembly 13. Front axle hub
6. Front axle hub outer bearing 14. Front wheel pin and nut (Outside drum fixing type)
 FRONT AXLE 4C-43
Removal 8. Front Hub Oil Seal
Preparation: When removing the oil seal, hit the outer flange of
Jack up and support the vehicle on stands. oil seal. The oil seal must not be reused.
1. Wheel and Tire
2. Front Locking Hub Set
Refer to “FREE WHEEL HUB” previously in this
section.
3. Front Hub Bearing Lock Washer
4. Front Hub Bearing Lock Nut
Front Hub Bearing Lock Nut Wrench:
5-8840-2182-0

N4A0344E

9. Front Axle Hub Inner Bearing Outer Race

N4A0342E

5. Front Hub and Brake Drum Assembly

Hub Remover: 9-8521-0187-0

N4A0345E

10. Front Axle Hub Outer Bearing Outer Race

Remove the outer race by driving out race from the
hub with a brass drift inserted behind race in notch-
es in the hub.
11. Front Wheel Pin and Nut (Inside Drum Fixing Type)
Remove nuts and hit with hammer, or use a press
to remove wheel pin.
Remove the wheel pin as necessary.
N4A0343E 12. Brake Drum
13. Front Axle Hub
6. Front Axle Hub Outer Bearing
14. Front Wheel Pin and Nut (Outside Drum Fixing
7. Front Axle Hub Inner Bearing
Type)
If the inner bearing is left on the spindle side,
Remove nuts and hit with hammer, or use a press
gouge from left and right with a screwdriver, and if
to remove wheel pin.
floating up, pull to remove it.
Remove the wheel pin as necessary.
4C-44 FRONT AXLE
Inspection and Repair
Make necessary adjustments, repairs, and part replace-
ment if excessive wear or damage is discovered during
inspection.
Front Axle Hub
1. Inspect the inner surface of front axle hub.
Inspect the fitting portions of front axle hub bearing
outer race and hub lock body assembly for crack,
damage or wear.
2. Inspect the outer surface of front axle hub.
Inspect the flange and oil seal fitting portion for
crack, deformation or damage.

N4A0348E

Front Hub Bearing Lock Nut

Inspect the bearing lock nut threads and contact surfac-
es for excessive wear, warpage, and other damage.
Light damage to the contact surfaces can be repaired
with an oil stone or a piece of fine sandpaper.

N4A0346E

Bearing
Inspect the bearing for excessive wear, abnormal noise,
rough rotation, and seizure

N4A0349E

Installation
1. Front Wheel Pin and Nut (Outside Drum Fixing
Type)
If a wheel pin is replaced or removed, tighten the
nut to the specified torque and calk the nut at three
places per pin.

Tighten:
Front wheel pin nut to 392 N⋅m (40 kg⋅m / 289 lb⋅ft)
N4A0347E

Front Hub Bearing Lock Washer

Inspect the lock washer for wear, deformation or crack,
and also the lug for break.
 FRONT AXLE 4C-45
7. Front Hub Oil Seal
1) Apply grease (Multipurpose type) to the oil seal
lip inner circumferences.
2) Use the oil seal installer to install the oil seal to
the hub.
Oil Seal Installer: 5-8840-2187-0
During installation of oil seal, do not press or hit
it other than outer flange of seal.

N4A0350E

2. Front Axle Hub

3. Brake Drum
On the model with outside drum fixing type, tighten
the brake drum bolts to the specified torque.

Tighten:
Brake drum bolt to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
4. Front Wheel Pin and Nut (Inside Drum Fixing Type) N4A0352E

Tighten the nut to the specified torque and calk the

Apply the specified amount of the approved grease to
nut at three places per pin.
the hub cavity, the outer bearing and the inner bearing.
Tighten: Grease amount: 200 g (7.1 oz) per each side
Front wheel pin nut to 392 N⋅m (40 kg⋅m / 289 lb⋅ft) 8. Front Axle Hub Inner Bearing
Install the inner bearing to the spindle.
5. Front Axle Hub Outer Bearing Outer Race
9. Front Axle Hub Outer Bearing
6. Front Axle Hub Inner Bearing Outer Race
Install the outer bearing to the front hub assembly.
Use the bearing outer race installer to install the
outer race to the hub. 10. Front Hub and Brake Drum Assembly
Inner Bearing Outer Race Installer: 11. Front Hub Bearing Lock Nut
Install the hub bearing lock nut with (1) slits facing
5-8840-2184-0
outside, and tighten provisionally.
Outer Bearing Outer Race Installer:
5-8840-2183-0

N4A0353E

N4A0351E
4C-46 FRONT AXLE
<Adjustment of Hub Bearing Preload> 6) Align the axle case groove (1) with the closest
1) Turn the hub to the left and right several times bearing nut slit.
to establish bearing conformity.
2) Use the bearing nut wrench to tighten the bear-
ing nut until the hub can not be manually rotat-
ed.
Bearing Nut Wrench:5-8840-2182-0
3) Loosen the bearing nut until hub rotates easily.

N4A0356E

Notice:
If it is difficult to align the axle case and bearing nut,
slightly tighten the bearing nut.
12. Front Hub Bearing Lock Washer
N4A0354E Engage the lug of lock washer with a notch in the
spindle.
4) Set the spring balancer to the wheel pin in the
position shown in the illustration. Apply adhesive (LOCTITE 242 or equivalent) to the
Gradually retighten the nut until the hub bear- threads of lock washer bolt, and tighten the hub
ing is adjusted to the specified preload. bearing lock nut with lock washer.
Hub bearing preload, Tighten:
New Hub bearing: 17 — 31 N⋅m (1.7 — 3.2 kg⋅m / 3.7 — Lock washer bolt to 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
7.1 lb⋅ft)
Reused Hub bearing: 14 — 28 N⋅m (1.4 — 2.9 kg⋅m / 3.1 In order to ensure locking, equally spaced 48 slits
— 6.4 lb⋅ft) are scribed on the hub bearing lock nut. The
tapped holes in hub bearing lock nut will meet ei-
ther hole in lock washer (two holes provided at
symmetric position) if a slit of hub bearing lock nut
is aligned with the notch center at the threads of
spindle end.
Under this condition, tightening the bolts fix surely
the hub bearing lock nut.

N4A0355E

5) Rotate the hub several times to the right and

left.
Measure the bearing preload a second time.
 FRONT AXLE 4C-47

N4A0357E

13. Front Locking Hub Set

Refer to “FREE WHEEL HUB” previously in this
section.

Tighten:
Front locking hub set bolt to 98 N⋅m (10.0 kg⋅m / 72 lb⋅ft)

N4A0358E

14. Wheel and Tire

4C-48 FRONT AXLE
Spindle and Drive Shaft (4 × 4 Model)

N4A0359E

Legend
1. Wheel and tire 4. Front brake assembly
2. Front locking hub set 5. Spindle
3. Front axle hub, brake drum and related parts 6. Front drive shaft assembly
 FRONT AXLE 4C-49
Removal
Preparation:
Jack up and support the vehicle on stands.
1. Wheel and Tire
2. Front Locking Hub Set
Refer to “FREE WHEEL HUB” previously in this
section.
3. Front Axle Hub, Brake Drum and Related Parts
Refer to “FRONT HUB and BRAKE DRUM (4 × 4
Model)” previously in this section.
4. Front Brake Assembly
1) Remove fixing bolts and front oil shield cover,
then the brake assembly.
The front oil shield cover, spindle and back
plate are tightened together.
2) Using a wire, sling the brake assembly to the
frame to hold. At this time, take care not to N4A0361E
damage or bend the brake hose.
6. Front Drive Shaft Assembly
Pull and remove the front drive shaft to your side.

N4A0360E

5. Spindle N4A0362E
Hitting lightly the spindle end with a wood or plastic
hammer, remove the spindle from knuckle. Inspection and Repair
Do not use an iron hammer. Special care should be Make the necessary adjustments, repairs, and part re-
taken to protect the threads at the spindle end from placements if excessive wear or damage is discovered
damage. during inspection.
Spindle
1. Inspect the whole of the spindle for crack, wear or
damage.
Replace the spindle if any abnormal condition is
noticeable.
Use a visible dye-penetrant flaw detection method
or a magnetic flaw detector.
4C-50 FRONT AXLE

N4A0363E N4A0365E

2. Inspect the front axle shaft thrust washer or bush- 2. Inspect the front drive shaft spline for wear or dis-
ing for wear and damage. tortion.
Replace the front drive shaft assembly if wear or
distortion is found.

N4A0364E

Front Drive Shaft Assembly N4A0099E

1. Inspect the front drive shaft for bending or distor-
tion. 3. Inspect the stopper contact face (on the spindle’s
side) for wear or damage.
 FRONT AXLE 4C-51

N4A0366E N4A0367E

4. Moving the front drive shaft joint as shown, inspect 2. Spindle

for smooth operation or presence of excessive 1) Apply MoS2 contained type grease to the sur-
play. faces of the thrust washer and bushing of spin-
Replace the front drive shaft assembly if it does not dle.
move smoothly or there is excessive play. 2) Apply adhesive (LOCTITE 515 or equivalent) to
the spindle flange, and install the spindle to the
knuckle. At this time, a bolt hole of the spindle
should be met with that of knuckle.
3. Front Brake Assembly
1) Install the front oil shield cover with a cut in out-
er surface facing inside.
2) Apply adhesive (LOCTITE 242 or equivalent) to
the threads of fixing bolts and tighten them to
the specified torque.
Tighten:
Front brake assembly fixing bolt to 98 N⋅m (10 kg⋅m / 72
lb⋅ft)
4. Front Axle Hub, Brake Drum and Related Parts
Refer to “FRONT HUB and BRAKE DRUM (4 × 4
Model)” previously in this section.
5. Front Locking Hub Set
N4A0367E Refer to “FREE WHEEL HUB” previously in this
section.
Installation
6. Wheel and Tire
1. Front Drive Shaft Assembly
1) Apply the MoS2 contained type grease into the
universal joint.
Grease amount: 94 — 106 g (3.3 — 3.7 oz)
2) Install the front drive shaft assembly into the
front axle case.
During installation, take care not to damage the
oil seal lip on the front axle case side.
To install, bend the front drive shaft as shown,
and moving the shaft a little to the left or right,
push it into the spline on the differential side
gear.
4C-52 FRONT AXLE
Knuckle and King Pin (4 × 4 Model)

N4A0368E

Legend
1. Wheel and tire 13. King pin bearing shim
2. Front locking hub set 14. Bearing distance collar
3. Front axle hub, brake drum and relative parts 15. Front axle lower king pin
4. Front brake assembly 16. Front axle upper king pin
5. Spindle 17. Front axle knuckle
6. Front drive shaft assembly 18. King pin receiver
7. Tie rod end 19. Knuckle oil seal
8. Front axle tube end boot holder 20. Front axle tube end boot
9. Front axle tube end boot 21. Front axle tube end boot holder
10. Knuckle oil seal 22. Front axle tube end boot band
11. Knuckle arm and tie rod arm 23. Front axle shaft oil seal
12. King pin cover 24. King pin bearing
 FRONT AXLE 4C-53
Removal
Preparation:
Jack up and support the vehicle on the stands.
1. Wheel and Tire
2. Front Locking Hub Set
Refer to “FREE WHEEL HUB” previously in this
section.
3. Front Axle Hub, Brake Drum and Relative Parts
Refer to “FRONT HUB and BRAKE DRUM (4 × 4
Model)” previously in this section.
4. Front Brake Assembly
5. Spindle
6. Front Drive Shaft Assembly
7. Tie Rod End
8. Front Axle Tube End Boot Holder
Remove the front axle tube end boot holder at the
back of knuckle. (The front axle tube end boot hold- N4A0370E

er is divided into two pieces in horizontal direc-

11. Knuckle Arm and Tie Rod Arm
tions.)
12. King Pin Cover
9. Front Axle Tube End Boot
Remove the front axle tube end boot fixing bolts, 13. King Pin Bearing Shim
and peel and shift the boot toward the differential. Confirm the quantity of shims and components
when removing the knuckle arm, tie rod arm and
king pin cover.

N4A0369E

10. Knuckle Oil Seal N4A0371E

1) Remove the outer side of oil seal holder. (The

14. Bearing Distance Collar
oil seal holder outer is divided into two pieces in
vertical direction.) 15. Front Axle Lower King Pin
Attach a bar to the center recess of king pin from
2) Shift the oil seal toward the front axle tube end
tube end (spherical part) of front axle case, and hit
boot (on Differential side).
with a hammer to remove the king pin downward.
3) Remove the inner side of oil seal holder. (The
oil seal holder inner is divided into two pieces in
horizontal direction.)
4C-54 FRONT AXLE

N4A0372E N4A0374E

16. Front Axle Upper King Pin 20. Front Axle Tube End Boot
17. Front Axle Knuckle 21. Front Axle Tube End Boot Holder
1) From under the knuckle, hit a bar attached to 22. Front Axle Tube End Boot Band
the upper king pin to remove the outer race of Loosen and remove the tube end boot band.
king pin bearing first. Avoid frequent removal of tube end boot band ex-
2) At this time, support the knuckle with both cept when it is to be replaced or removal is neces-
hands and raise it to remove to your side. sary for servicing.
3) Again hit the king pin to remove. 23. Front Axle Shaft Oil Seal
The oil seal must not be reused.
24. King Pin Bearing
Remove the bearing with a press.
Some components are different between upper
and lower king pin bearings (1), and do not confuse
them.

N4A0373E

18. King Pin Receiver

19. Knuckle Oil Seal
Remove the oil seal from the front axle case.
At this time, make sure the direction of oil seal.
N4A0375E
 FRONT AXLE 4C-55
Inspection and Repair King Pin Bearing
Make the necessary adjustments, repairs, and part re- Inspect the bearing for wear, seizure, damage and
placements if excessive wear or damage is discovered rough rotation.
during inspection. Replace any flawed or damaged bearing.
Front Axle Tube End
Inspect the front axle case tube end sphere for crack,
wear, damage or rust. Slight rust of sphere should be
polished with a sand paper.
To check the tube end sphere for crack, use a red-check
or a magnetic flaw detector.
If a crack is found, replace the front axle case assembly.

N4A0378E

Knuckle Arm
Tie Rod Arm
King Pin Cover
Inspect the knuckle arm, tie rod arm and king pin cover
for cracks, damage or wear.
Replace the these parts if any abnormal condition is
N4A0376E
noticeable.
Front Axle Knuckle To check the arm for crack, use a visible dye-penetrant
Inspect the whole of the knuckle for cracks, wear or flaw detection method or a magnetic flaw detector.
damage using a magnetic flaw detector or red-check. Replace the arm if a crack is found.
Replace the knuckle if any abnormal condition is notice-
able.

N4A0379E

Front Axle Tube End Boot

N4A0377E
Inspect the front axle tube end boot and replace if
King Pin broken. It should be replaced if even one hole or crack is
Inspect the king pin for cracks. found.
Use a magnetic flaw detector or red-check. Oil Seal
Replace king pin, if any cracks are found. Inspect the oil seal, and replace it if its lip is damaged,
worn or hardened.
4C-56 FRONT AXLE

N4A0380E N4A0391E

Front Axle Tube End Boot Holder, Oil Seal Holder 2. Front Axle Tube End Boot Holder
Inspect the oil seal holder and front axle tube end boot 3. Front Axle Tube End Boot
holder, and replace if excessive deformation or rust is 1) Apply gear oil GL-5 grade (SAE90) to the entire
found. surface of front axle tube end sphere.
2) Warm the front axle tube end boot to 70 —
80°C with hot water.
3) Reverse the front axle tube end boot, and in-
stall into the front axle case. During this work,
do not touch the front axle tube end boot by
bear hand because it is too hot.
4) After installation in the front axle case, remove
the moisture immediately.
5) Return the front axle tube end boot to original
form, and insert the leading end of boot into the
front axle tube end boot groove of the front axle
case.
4. Knuckle Oil Seal
5. Front Axle Tube End Boot Band
1) Fix the boot with front axle tube end boot band.
Wind the front axle tube end boot band twice
N4A0390E and tighten it up to eliminate looseness.
2) Then, calk the center of fitting on the front axle
Installation tube end boot band with a punch.
1. Front Axle Shaft Oil Seal 3) Turn back the front axle tube end boot band at
1) Drive in the oil seal to the dimension as shown. the fitting, and again calk the center of front
Take care not to damage the oil seal lip. axle tube end boot band.
2) Apply grease (Multipurpose type) to the oil seal 4) Cut the front axle tube end boot band at the end
lip. face of fitting.
Oil seal drive in depth (L): 0 — 0.5 mm (0 — 0.020 in)
 FRONT AXLE 4C-57

N4A0392E N4A0393E

8. King Pin Receiver

Legend
9. King Pin Bearing
1. Bend
Install the king pin bearing to the king pin. For the
2. Calking point upper side, install the receiver, king pin bearing in
3. Punch this order.
4. Front axle tube end boot 10. Front Axle Knuckle
5. Fitting
1) Install the knuckle to the front axle. (Holding the
Install the oil seal to the front axle. (Apply Multipur- knuckle with both hands, align the upper hole of
pose type grease, to the entire surface of oil seal, knuckle to the upper king pin bearing and lower
and install it with care not to damage the oil seal lip. it slowly while passing the lower king pin bear-
ing.)
In installing the oil seal, position the spring side on
the differential side.) 2) Install upper and lower king pin bearing outer
races. (Fit the king pin bearing outer race com-
6. Front Axle Upper King Pin
pletely with the knuckle, and hit lightly the outer
7. Front Axle Lower King Pin race until it gets stuck.)
1) Seal multi-purpose grease NLGI No.2 in the
king pin bearing.
2) Install only the king pins (both upper and lower)
in the front axle case.
3) Align the locking groove of the king pin with the
locking pin on the front axle tube end surface,
and then drive in the king pin.

N4A0394E

11. Bearing Distance Collar

12. King Pin Bearing Shim
13. King Pin Cover
14. Knuckle Arm and Tie Rod Arm
4C-58 FRONT AXLE
1) Install the knuckle arm (or tie rod arm) and the
king pin cover. (Install the distance collar and
shim in this order. Then, install knuckle arm (or
tie rod arm) and the king pin cover and fix pro-
visionally with bolts. Use the number of shims
that were removed previously, and tighten the
bolts lightly. At this time, do not apply LOCTITE
to the shims, arms and king pin cover yet.
2) Tighten the bolts on knuckle arm (or tie rod
arm) and king pin cover to the specified torque
while turning the knuckle to the left and right
several times to run-in the king pin bearing.
Tighten:
Knuckle arm, tie rod arm and king pin cover bolt to147
N⋅m (15 kg⋅m / 108 lb⋅ft)

N4A0396E

<Tighten completely the knuckle arm (or tie rod arm)

and king pin cover>
1) Remove each arm and king pin cover once,
and apply adhesive (LOCTITE 515 or equiva-
lent) to the shims, each arm and king pin cover
evenly.
2) Tighten fixing bolts to the specified torque.
Tighten:
Knuckle arm, tie rod arm and king pin cover bolt to147
N⋅m (15 kg⋅m / 108 lb⋅ft)
3) Reconfirm the preload.
If it is out of standard, readjust by repeating the
above steps.
N4A0395E 15. Knuckle Oil Seal
1) Install the inner oil seal holder to the knuckle.
<Adjustment of Front Axle Knuckle Preload>
Install the inner oil seal holder in longitudinal di-
1) Hook a spring balance to the edge of knuckle rection.
arm (or tie rod arm), and pull it in tangential di-
2) Install the oil seal, then the outer oil seal holder.
rection to check if the spring balance reading at
Install the outer oil seal holder in vertical direc-
the start of movement is within the standard
tion (a mating face should be shifted 90°
range.
against the inner holder).
(Measure preload in tangential direction.)
16. Front Axle Tube End Boot
Front axle knuckle preload, 3.1 — 5.5 N (6.8 — 12.1 kg
/ 30.4 — 53.9 lb) 17. Front Axle Tube End Boot Holder
Install the front axle tube end boot, and tighten
2) If it does not satisfy the standard, adjust with
bolts to the specified torque via the front axle tube
shims.
end boot holder.
Shim thickness available: 0.3 mm (0.01 in)
Install the front axle tube end boot holder in longi-
3) After adjustment, measure the preload again.
tudinal direction.

Tighten:
Front axle tube end boot holder bolt to 6 N⋅m (0.6 kg⋅m
/ 52 lb⋅ft)
 FRONT AXLE 4C-59
22. Front Axle Hub, Brake Drum and Relative Parts
Refer to “FRONT HUB and BRAKE DRUM (4 × 4
Model)” previously in this section.
23. Front Locking Hub Set
Refer to “FREE WHEEL HUB” previously in this
section.
24. Wheel and Tire

N4A0397E

18. Tie Rod End

19. Front Drive Shaft Assembly
20. Spindle
21. Front Brake Assembly

Front Differential Assembly (4 × 4 Model)

N4A0398E

Legend
1. Propeller shaft assembly 3. Front axle case bolt
2. Front drive shaft assembly 4. Front differential assembly
4C-60 FRONT AXLE
Removal
Support the front axle with a suitable jack and chassis
stands.
Drain the front axle case by removing the drain plug on
the lower part of the front axle case.
1. Propeller Shaft Assembly
Remove the propeller shaft assembly.
2. Front Drive Shaft Assembly
Refer to “Spindle and Drive Shaft” previously in this
section.
3. Front Axle Case Bolt
Put jack under the center of front axle then remove
the front axle case bolts.
4. Front Differential Assembly
Remove the front differential assembly from the
front axle case.

N4A0399E

Installation
1. Front Differential Assembly
Clean the faces of the front axle case and the final
drive carrier.
Apply the recommended liquid gasket (Three Bond
1215 or its equivalent) to the sealing side of the
front axle case and the final drive carrier.
2. Front Axle Case Bolt
Attach the front final drive assembly to the front
axle case and tighten the bolts.

Tighten:
Front axle case bolt to 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
3. Front Drive Shaft Assembly
4. Propeller Shaft Assembly
Fill the axle case with hypoid gear lubricant to just
below the filler hole.
Lubricant capacity, 2.7 liter (2.9 US qt / 2.4 Imp qt)
 FRONT AXLE 4C-61
Front Axle Assembly (4 × 4 Model)

N4A0400E

Legend
1. Wheel and tire 5. Brake flexible hose
2. Shock absorber 6. Stabilizer assembly
3. Drag link 7. Front propeller shaft
4. Tie rod assembly 8. Leaf spring U-bolt
4C-62 FRONT AXLE
Removal Draw setting marks (1) on the front and rear flang-
Preparation: es.
Jack up and support the vehicle on stands. Also, draw setting marks as shown if the propeller
1. Wheel and Tire shaft is removed at the spline yoke.
2. Shock Absorber
Remove lower side of shock absorber.

N4A0403E

8. Leaf Spring U-Bolt

N4A0401E
1) Put jack under the center part of front axle then
3. Drag Link remove the U-bolts.
Remove the drag link (on the knuckle arm side). 2) Lower the front axle assembly and roll out to-
4. Tie Rod Assembly ward the front of vehicle.
Remove the tie rod assembly (with relay lever at- Use care so as not to cause damage to brake
tached). Refer to STEERING LINKAGE (4 × 4 hose, back plate and front axle tube end boot.
Model) in section 3B.
5. Brake Flexible Hose
Remove a clip on the brake hose bracket.
After the hose is disconnected, prevent brake fluid
running out and invasion of foreign matters.

N4A0404E

9. Front Axle Assembly

Installation
1. Front Axle Assembly
N4A0402E 2. Leaf Spring U-Bolt
Align a hole in the center of spring seat in the front
6. Stabilizer Assembly
axle case with the center bolt of leaf spring, and
Refer to STABILIZER in section 3C.
tighten the leaf spring U-bolt.
7. Front Propeller Shaft
 FRONT AXLE 4C-63

Tighten:
U-bolt nut to 126 N⋅m (12.9 kg⋅m / 93 lb⋅ft)

N4A0407E

Perform bleeding operation after installation of the

N4A0405E brake flexible hoses.
Refer to “Service information” for brake fluid air
3. Front Propeller Shaft bleeding procedure.
Tighten: 6. Tie Rod Assembly
Front propeller shaft bolt to 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft) Refer to STEERING LINKAGE (4 × 4 Model).
7. Drag Link
Refer to STEERING LINKAGE (4 × 4 Model).
8. Shock Absorber
Tighten:
Shock absorber under side nut to 95 N⋅m (9.7 kg⋅m / 70
lb⋅ft)

N4A0406E

4. Stabilizer Assembly
1) Refer to STABILIZER.
5. Brake Flexible Hose
Set first the wheels in the straight going position,
then attach the flexible hose to the bracket without
N4A0409E
torsion using a clip (1).
Connect the pipe, then tighten the nut (2) to the 9. Wheel and Tire
specified torque.
Tighten:
Tighten: Wheel nut to 441 N⋅m (45 kg⋅m / 325 lb⋅ft)
Brake flexible nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
4C-64 FRONT AXLE
6 studs

N4A0410E
 FRONT AXLE 4C-65

UNIT REPAIR
Front Differential
Major Components

N4A0411E

Legend
1. Bearing cap 9. Distance piece
2. Side bearing outer race 10. Drive pinion
3. Differential cage assembly 11. Inner bearing inner race
4. Side bearing inner race 12. Inner bearing outer race
5. Backlash and preload adjusting shim 13. Pinion depth adjusting shim
6. Flange nut 14. Oil seal
7. Flange 15. Outer bearing inner race
8. Bearing preload adjusting shim 16. Outer bearing outer race
4C-66 FRONT AXLE
Disassembly
1. Bearing Cap
Set the differential assembly onto a special fixture.
Apply a setting mark (1) to the side bearing cap
and differential carrier.
Fixture: 5-8840-2029-0
Base: 5-8840-0003-0

N4A0138E

7. Flange
8. Bearing Preload Adjust Shim
9. Distance Piece
10. Drive Pinion
11. Inner Bearing Inner Race
Remover: 5-8840-0015-0
N4A0136E

2. Side Bearing Outer Race

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

N4A0139E

12. Inner Bearing Outer Race

13. Pinion Depth Adjusting Shim
14. Oil Seal
N4A0137E 15. Outer Bearing Inner Race
16. Outer Bearing Outer Race
3. Differential Cage Assembly Drive out the inner bearing outer race or the outer
4. Side Bearing Inner Race bearing outer race together with the outer bearing
Remover: 9-8521-0061-0 inner race and oil seal by using a proper bar
Adapter: 5-8840-2031-0 through two notches.
5. Backlash and Preload Adjusting Shim
6. Flange Nut
Holding wrench: 9-8511-1507-0
 FRONT AXLE 4C-67
(Outer): 9-8522-1197-0
Grip: 9-8522-1148-0

N4A0140E

REASSEMBLY
N4A0142E
Measurement of ring gear run-out.
Install dummy bearing into the differential assembly, Assemble the inner bearing inner race to the dum-
then install these parts in the differential carrier. Install my pinion shaft, then install these parts into the
and tighten the bearing cap. carrier.
Dummy bearing: 9-8522-1137-0 Dummy Pinion Shaft: 9-8522-1603-0
Tighten:
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m / 80 lb⋅ft)
Ring gear run-out,
Standard: 0.05 mm (0.002 in)
Limit: 0.2 mm (0.008 in)

N4A0143E

Install the outer bearing inner race flange, washer

and dummy nut.
Lubricate the bearing before tighten the dummy
nut.
N4A0141E
Dummy Nut: 9-8522-1624-0
1. Outer Bearing Outer Race
2. Pinion Depth Adjusting Shim
3. Inner Bearing Outer Races
Adjustment of drive pinion engagement depth.
Install the inner and outer bearing outer races with-
out shims into the differential carrier using a bench
press.
Installer (Inner): 9-8522-1196-0
4C-68 FRONT AXLE
Install dummy bearing on dummy shaft and install
these parts into the carrier. Install and tighten the
bearing cap.
Dummy Shaft: 9-8522-1138-0
Dummy Bearing: 9-8522-1137-0

Tighten:
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m / 80 lb⋅ft)

N4A0144E

Legend
1. Coupling driver
2. Outer bearing
3. Dummy pinion shaft
4. Inner bearing
5. Shim
N4A0146E
Tighten the dummy nut until specified preload are
required to rotate the bearing. Measure the clearance (t) with a feeler gauge.
Bearing preload, The clearance (t) is equal to the shim in thickness.
New bearing: 16 — 29 N (1.6 — 3.0 kg / 3.5 — 6.6 lb) Thickness of shim available: 2.12, 2.16 ... 2.52, 2.56 mm
Used bearing: 8 — 14.5 N (0.8 — 1.5 kg / 1.8 — 3.3 lb) (0.083, 0.085 ... 0.099, 0.100 in)

Tighten:
Bearing starting to
• New bearing: 0.69 — 1.27 N⋅m (7.0 — 13.0 kg⋅cm /
6.1 — 11.3 lb⋅in)
• Used bearing: 0.35 — 0.64 N⋅m (3.5 — 6.5 kg⋅cm /
3.1 — 5.7 lb⋅in)

N4A0147E

Remove dummy pinion, dummy shaft, dummy

bearing and inner bearing outer race.
Install pinion depth adjusting shim of specified
thickness in position between the inner bearing
outer race and the carrier, then install the inner
N4A0145E bearing outer race.
Installer: 9-8522-1196-0
Grip: 9-8522-1148-0
 FRONT AXLE 4C-69

N4A0148E N4A0150E

4. Inner Bearing Inner Race 7. Drive Pinion

Installer: 9-8522-0018-0 8. Distance Piece (NKR model)
Apply gear oil to the pinion shaft before installing fi- 9. Bearing Preload Adjusting Shim
nal drive pinion assembly into carrier. Use a dummy nut until specified bearing preload is
obtained.
Bearing preload,
New bearing: 16 — 29 N (1.6 — 3.0 kg / 3.5 — 6.6 lb)
Used bearing: 8 — 14.5 N (0.8 — 1.5 kg / 1.8 — 3.3 lb)
Tighten:
Bearing starting to
• New bearing: 0.69 — 1.27 N⋅m (7.0 — 13.0 kg⋅cm /
6.1 — 11.3 lb⋅in)
• Used bearing: 0.35 — 0.64 N⋅m (3.5 — 6.5 kg⋅cm /
3.1 — 5.7 lb⋅in)

N4A0149E

5. Outer Bearing Inner Race

6. Oil Seal
Installer: 5-8840-2047-0

N4A0145E

Tighten:
Dummy nut to 270 N⋅m (27.5 kg⋅m / 199 lb⋅ft)
4C-70 FRONT AXLE

N4A0151E N4A0151E

Thickness of shim available: 1.53, 1.56 ... 2.07, 2.10 mm Install the bearing caps after checking to make
(0.060, 0.061 ... 0.081, 0.082 in) certain setting marks (1) applied at disassem-
10. Flange bly are in alignment.
11. Flange Nut Tighten:
Once specified bearing preload is obtained by Bearing cap bolt to 108 N⋅m (11.0 kg⋅m / 80 lb⋅ft)
dummy nut, remove dummy nut and replace with
flange nut.
Tighten the flange nut until specified bearing pre-
load and nut torque.
Using special tool, stake the flange nut at two
points.
Punch: 5-8840-2293-0

N4A0152E

• Set the dial indicator and measure the backlash

between the drive pinion and ring gear at the
foot portion of the ring gear.
Backlash: 0.15 — 0.20 mm (0.006 — 0.008 in)

N4A0145E

12. Backlash and Preload Adjusting Shim

1) Adjustment of Backlash
• Install dummy bearing in the differential cage
assembly, then install differential cage assem-
bly and ring gear into the differential carrier.
 FRONT AXLE 4C-71

N4A0153E N4A0155E

• To adjust backlash, loosen bearing cap bolts

slightly and move the dummy bearing (1) as
necessary.
A clearance should not be provided between
dummy bearing and bearing fitting face of the
differential cage.

N4A0154E

2) Inspection of drive pinion and ring gear tooth

contact.
• Apply a thin coat of red check to faces of the 7
— 8 teeth of the ring gear.
• Check the impression of contact obtained on
the ring gear teeth and make necessary adjust-
ment as described below if the contact is abnor-
mal.
4C-72 FRONT AXLE

TOOTH CONTACT CASE ADJUSTMENT PROCEDURE

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

Ring gear is too close to 1. Move the drive pinion in to-

the drive pinion. ward the ring gear by de-
creasing thickness of pinion
depth adjusting shims.
2. Adjust the backlash by
moving ring gear away from
the drive pinion.
N4A0158E N4A0162E

Ring gear is too far away 1. Move the drive pinion away
from drive pinion. from the ring gear by in-
creasing thickness of pinion
depth adjusting shims.
2. Adjust the backlash by
moving ring gear in toward
the drive pinion.
N4A0159E N4A0163E

3) Selection of Preload Adjusting Shim

• Measure the clearance between the differential
carrier and right and left side (dummy) bearings
by using a feeler gauge.
Carefully note the relationship between the val-
ues obtained through measurement at each
side and dummy bearings.

N4A0164E

• Measure the thickness of dummy bearing and

side bearing.
Comparison should be made between the
thicknesses of dummy bearing and side bear-
ing installed in the same position.
 FRONT AXLE 4C-73

N4A0165E N4A0166E

Legend Legend
1. Dial gauge A. Measured clearance
2. Dummy bearing A′. Shim installed position
3. Side bearing
13. Side Bearing Inner Race
When side bearing is thinner: Installer: 5-8840-2050-0
A + (dummy bearing thickness − side bearing Grip: 9-8522-1608-0
thickness) = (X)
When side bearing is thicker:
A − (side bearing thickness − dummy bearing
thickness) = (X)
• (X) + 0.025 = Shim thickness
Allowance for bearing preload at one side =
0.025
• Example of calculation

mm (in.)
Measured Clearance A: +0.85 (+0.033)
Suppose that the side bearing is
−0.05 (−0.002)
thicker [thinner] than dummy
[+0.05 (+0.002)]
bearing by 0.05 mm
An allowance for bearing pre-
+0.025 (+0.0009)
load:
Thickness of shims to be 0.825 (0.032) N4A0167E
installed: [0.925 (0.036)]
14. Differential Cage Assembly and Ring Gear
Thickness of shim available: 0.25, 0.30, 0.35, 0.5 mm 15. Side Bearing Outer Race
(0.009, 0.012, 0.014, 0.019 in) 16. Bearing Cap
1) Install bearing caps by aligning setting marks
(1) applied at disassembly.
Tighten:
Bearing cap bolt to 108 N⋅m (11.0 kg⋅m / 80 lb⋅ft)
4C-74 FRONT AXLE

N4A0168E N4A0170E

2) Recheck the backlash. If measurement indi-

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

N4A0169E

Recheck the ring gear for run-out at the rear

face.
If the amount of run-out is excessive, repeat the
disassembly and reassembly steps.
Ring gear run-out,
Standard: 0.05 mm (0.002 in)
Limit: 0.2 mm (0.008 in)
 FRONT AXLE 4C-75
Differential Cage Assembly

N4A0412E

Legend
1. Differential cage B 5. Differential pinion
2. Side gear 6. Side gear
3. Thrust washer 7. Thrust washer
4. Spider 8. Differential cage A and ring gear
4C-76 FRONT AXLE
Disassembly
1. Differential Cage B
Apply a setting mark (1) to the differential cage as-
sembly.

N4A0173E

Clearance between Differential Pinion and Spider

Standard: 0.07 — 0.13 mm (0.003 — 0.005 in)
Limit: 0.2 mm (0.008 in)
N4A0171E

2. Side Gear
3. Thrust Washer
4. Spider
5. Differential Pinion
6. Side Gear
7. Thrust Washer
8. Differential Cage A and Ring Gear

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage or any other abnormal conditions are found
through inspection.
Visual Check
Inspect the following parts for wear, damage or other ab-
normal conditions.
• Gear N4A0174E

• Bearing Clearance between Side Gear and Differential Cage

• Oil seal Standard: 0.05 — 0.11 mm (0.002 — 0.004 in)
• Differential cage Limit: 0.25 mm (0.01 in)
• Drive pinion cage
• Parts organizing limited slip differential assembly
Ring Gear Replacement
The ring gear should always be replaced with drive pin-
ion as a set.
When installing ring gear, apply stud lock to the thread-
ed holes and bolts after treatment of the bolts with prim-
er N.
Tighten:
Ring gear bolt to 127 N⋅m (13.0 kg⋅m / 94 lb⋅ft)
 FRONT AXLE 4C-77
2) Fasten the differential cages A and B so that
the setting marks (1) are correctly aligned.
Tighten:
Differential cage bolt to 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)

N4A0175E

Legend
1. Side gear
2. Differential cage N4A0413E

Play in Splines between Side Gear and Axle Shaft 3) Measure the clearance between the back face
Standard: 0.02 — 0.12 mm (0.0008 — 0.005 in) of the side gear and the differential cage B by
Limit: 0.25 mm (0.01 in) inserting a feeler gauge (1) through the hole on
the cage B.
Clearance: 0.13 — 0.18 mm (0.005 — 0.007 in)

N4A0176E

Reassembly
N4A0177E
1. Differential Cage A and Ring Gear
2. Thrust Washer When the clearance exceed a limit, replace the
3. Side Gear thrust washer or side gear.
4. Differential Pinion
5. Spider
6. Thrust Washer
7. Side Gear
8. Differential Cage B
1) Apply oil to the threaded portion of the bolts be-
fore installation.