FRONT AXLE

Click on the applicable bookmark to selected the required model year

 26-1

FRONT AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Solenoid Valve Operation Check . . . . . . . . . . . . . 12

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 HUB AND KNUCKLE ASSEMBLY . . . . . . . . . . 14

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 5 MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 28

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 10 FREE-WHEELING CLUTCH ASSEMBLY . . . . 45

Wheel Bearing Axial Play Check . . . . . . . . . . . . . 10
SOLENOID VALVE, VACUUM PIPES AND
Front Axle Total Backlash Check . . . . . . . . . . . . . 10 VACUUM TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front Axle Gear Oil Level Check . . . . . . . . . . . . . . 11
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . 11 FRONT DIFFERENTIAL MOUNT . . . . . . . . . . . 50
Differential Carrier Oil Seal Replacement . . . . . . 11
26-2 FRONT AXLE – General Information

GENERAL INFORMATION
The front axle consists of the hub assembly, drive D For vehicles with ABS, the ABS rotor for
shaft, inner shaft, front differential, and detecting the wheel speed has been pressed
free-wheeling clutch. in the B.J. joint.
The features are: D The axle is supported by the ball bearing and
D The free-wheeling mechanism enables 2WD the front hub, which is pressed in the knuckle
and 4WD to be switched over during driving, axle housing.
thus improving fuel efficiency and reducing D The ball bearing is of a double-row angular
vibration at the 2WD mode. contact ball bearing which features high thrust
D The drive shaft uses a B.J.-D.O.J.-type constant load resistance.
velocity ball joint which has high power D The differential carrier is supported elastically
transmission efficiency and reduces vibration at three points, thus reducing vibration and
and noise. noise.

FRONT AXLE
Item Specifications
Wheel bearing Type Double-row angular contact ball bearing
Bearing (O.D. I.D.) mm 74 40
Drive shaft Joint type Outer B.J.
Inner D.O.J.
Shaft length*1 Shaft diameter Right side 316 24*2, 293 24*3
mm
Left side 435 24*2, 428 24*3
Inner shaft Shaft length Shaft diameter mm 383 25
Bearing (O.D. I.D.) mm 62 35

NOTE
*1: shows the distance between the centres of the joints.
*2: A/T
*3: M/T
FRONT DIFFERENTIAL
Item Specifications

Drive gear type Hypoid gear

Reduction ratio 4.875
Differential gear type Straight bevel gear
Number of teeth Drive gear 39
Drive pinion 8
Side gear 14
Pinion gear 10
Bearing (O.D. I.D.) mm Side 72.0 35.0*1, 80.0 45.0*2
Front 62.0 25.0*1, 64.0 30.0*2
Rear 72.0 35.0*1, 76.0 36.5*2

NOTE
*1: A/T
*2: M/T
 FRONT AXLE – General Information 26-3
CONSTRUCTION DIAGRAM

Front differential

Free-wheeling clutch
Differential mount
bracket (LH)

Differential mount
crossmember

Drive shaft (RH)

Drive shaft (LH)

Ball joint

Drive shaft
Knuckle
(LH) Brake disc
Differential side D.O.J. B.J.

(RH) Plastic BJ boot ABS rotor

Differential side Hub

Ball bearing

Dust cover
26-4 FRONT AXLE – Service Specifications/Lubricants

SERVICE SPECIFICATIONS
Items Standard value Limit

Front axle total backlash mm – 5

Wheel bearing axial play mm – 0.2

Solenoid valve resistance Ω 36 – 46 –

Hub rotation starting torque Nm 1.6 –

Setting of D.O.J. boot length mm 80 ± 3 –

Special tool (MB991561) opening With B.J. boot band (small) 2.9 –
dimension mm crimped

With B.J. boot band (large) 3.2 –

crimped

B.J. boot crimping dimension mm 2.4 – 2.8 –

Clearance between B.J. boot (large) and step on B.J. housing mm 0.1 – 1.55 –

Final drive gear backlash mm 0.11 – 0.16 –

Drive gear runout mm – 0.05

Differential gear backlash mm 0 – 0.076 0.2

Drive pinion turning Without oil seal When replacing 0.88 – 1.17*1, –
torque Nm (with anti-rust agent) 0.29 – 0.49*2

When replacing or reusing 0.39 – 0.49*1 –

(with gear oil applied) 0.147 – 0.245*2

With oil seal When replacing 0.98 – 1.27*1 –

(with anti-rust agent) 0.49 – 0.69*2

When replacing or reusing 0.49 – 0.58*1 –

(with gear oil applied) 0.343 – 0.441*2

NOTE
*1: A/T
*2: M/T

LUBRICANTS
Items Specified lubricants Quantity

Gear oil Front differential Hypoid gear oil API classification GL-5 0.83 ȏ
or higher SAE viscosity No
No.90,
90 80W
Free-wheeling clutch 0.12 ȏ

D.O.J. Repair kit grease <A/T> 85 g

<M/T> 100 g

B.J. Repair kit grease <A/T> 85 g

<M/T> 110 g
 FRONT AXLE – Sealants and Adhesives/Special Tools 26-5
SEALANTS AND ADHESIVES
Items Specified sealants and adhesives Remarks

Front housing assembly and free- 3M ATD Part No.8661 or equivalent Semi-drying sealant
wheeling hosing assembly

Front housing assembly and differen-

tial carrier

Vent plug

Differential cover

Drive gear and differential case 3M Stud Locking 4170 or equivalent Anaerobic sealant
mating surface

SPECIAL TOOLS
Tool Number Name Use
MB991618 Hub bolt remover Hub bolt removal

MB990767 Front hub and Hub fixing

flange yoke holder

MB991115 Oil seal installer D Front axle hub oil seal press-fitting (Used
together with MB990938)
D Housing tube dust seal press-fitting

MB991406 or Steering linkage Ball joint disconnection

MB991113 puller

MB990241 Axle shaft puller Drive shaft removal

A: MB990242 A: Puller shaft
B
B: MB990244 B: Puller bar

MB991354 Puller body

26-6 FRONT AXLE – Special Tools

Tool Number Name Use

MB991056 or Knuckle arm Hub removal
MB991355 bridge

A: MB991017 A, B: Front hub D Hub removal and press-fitting.

A
B: MB990998 remover and in- D Wheel bearing provisional holding
C: MB991000 staller (MB991000, which belongs to MB990998,
C: Spacer should be used as a spacer.)
B
C

MB990810 Side bearing puller D Side bearing inner race removal

D Companion flange removal

MB990925 Bearing and oil D Outer wheel bearing inner race installation
seal installer set D Oil seal installation
D Front housing assembly oil seal installation
D Drive pinion front and rear bearing outer
race removal and installation
D Final drive gear backlash check

A MB991045 Bush remover Wheel bearing pressing-in

A: MB991050 installer (Used together with base B)
A: Base (B)

MB991387 Bush remover Outer oil seal pressing-in

installer

MB991389 Bush remover Inner oil seal pressing-in

base

MB991561 Boot band clipping Plastic boot band installation

tool
 FRONT AXLE – Special Tools 26-7

Tool Number Name Use

MB990673 Front bearing Bearing removal
remover

MB990663 Rear axle shaft Bearing installation

bearing and retain-
er ring installer

MB990909 Working base Differential carrier fixing

assembly

MB990850 End yoke holder Companion flange removal and installation

MB990560 Rear axle shaft Drive pinion bearing inner race removal
bearing remover

MB990835 Dummy pinion set D Drive pinion rotation starting torque check
A: MB990836 A: Drive D Drive pinion height measurement <A/T>
B: MB990392 pinion gauge
assembly
B B: Cylinder gauge
A

MB990326 Pre-load socket Drive pinion turning torque measurement

MB990901 Pinion height Pinion height adjustment <M/T>

A: MB990903 gauge set

MB991170 Cylinder gauge Pinion height adjustment <M/T>

26-8 FRONT AXLE – Special Tools

Tool Number Name Use

MB990829 Pinion and side D Drive pinion rear bearing inner race
bearing installer pressing-in
D Side bearing inner race pressing-in

MB990727 Oil seal installer Drive pinion oil seal pressing-in

MB991015 Knuckle oil seal Oil seal pressing-in

installer

MB990799 Ball joint remover Free-wheeling clutch gear and bearing installa-
and installer tion

MD999547 Oil seal installer Front differential mount insulator <front>

removal

MD999570 Crankshaft front oil Front differential mount insulator <rear>

seal installer removal

MB990947 Lower arm bushing Front differential mount insulator <front>

arbour pressing-in

MB990847 Rear suspension

bushing remover
and installer base

MB990981 Mount bushing

remover and
installer ring
 FRONT AXLE – Special Tools 26-9

Tool Number Name Use

MB991318 Lower arm bushing Front differential mount insulator <rear>
arbour pressing-in

MB991183 Bushing arbour

MB990843 Drag link bushing

remover and
installer

GENERAL Engine lifter Supporting the engine assembly when the

SERVICE differential carrier is removed and installed
TOOL
MZ203827

MB990925
Tool box
C Brass bar

B
A Bar (snap-in type)
Installer adapter

Type Tool number O.D. mm Type Tool number O.D. mm

A MB990926 39 A MB990933 63.5

MB990927 45 MB990934 67.5

MB990928 49.5 MB990935 71.5

MB990929 51 MB990936 75.5

MB990930 54 MB990937 79

MB990931 57 B MB990938 –

MB990932 61 C MB990939 –
26-10 FRONT AXLE – On-vehicle Service

ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
1. Remove the disc brake caliper and suspend it with a
wire.
2. Remove the brake disc from the front hub.

3. Attach a dial gauge as shown in the illustration, and then

measure the axial play while moving the hub in the axial
direction.
Limit: 0.2 mm
4. If axial play exceeds the limit, disassemble the hub and
knuckle to inspect each component.

FRONT AXLE TOTAL BACKLASH CHECK

If the propeller shaft is rotated by hand while the ignition
switch is OFF, the front wheel actuator will lock the front
wheels. To prevent this, follow the procedures below:
1. Turn the ignition switch to the OFF position, and then
place the transfer shift lever in the 2H position to lock
the front wheels.
Caution
Do not jack up the vehicle.
2. Rotate the propeller shaft until a click is heard to lock
the free-wheeling differential.
Mating marks 3. Rotate the propeller shaft fully clockwise, and then make
mating marks on the companion flange dust cover and
the gear carrier.

4. Rotate the propeller shaft fully anticlockwise, and measure

the difference between the mating marks with a scale.
Limit: 5 mm
5. If the measured value exceeds the limit value, check
the following.
D Final drive gear backlash
D Differential gear backlash
D Play in the serrations and spline of the side gears,
drive shaft, inner shaft and drive flange
 FRONT AXLE – On-vehicle Service 26-11
FRONT AXLE GEAR OIL LEVEL CHECK
Top up the specified gear oil if the gear oil level does not
reach the bottom of the filler plug.
Specified gear oil:
Hypoid gear oil API classification GL-5 or
higher, SAE viscosity No.90, 80W
NOTE
SAE 90 for 10 °C or higher, SAE80 for 10 °C or
lower
Capacity:
Front differential: Approx. 0.83 ȏ
Free-wheeling clutch: 0.12 ȏ

HUB BOLT REPLACEMENT

MB990767
1. Rotate the hub to align each hub bolt with the cutout
MB991618 section of the dust cover, and push out each hub bolt
while locking the hub with the special tool.

2. To press in the hub bolt, install each hub bolt at the

cutout section of the dust cover, and tighten the hub
MB990767 bolt with the hub nut as shown.

DIFFERENTIAL CARRIER OIL SEAL

Flat-tipped screwdriver
Oil seal REPLACEMENT
1. Remove the front housing assembly. (Refer to P.26-26.)
2. Remove the drive shaft <RH>. (Refer to P.26-19.)
3. Use a flat-tipped screwdriver or the like to remove the
oil seal.
26-12 FRONT AXLE – On-vehicle Service

4. Use the special tools to install a new oil seal.

MB990938

MB991115

5. Apply multi-purpose grease to the oil seal lip, and then

install the right drive shaft (Refer to P.26-19) and the
front housing assembly (Refer to P.26-26).
Caution
(1) Be careful not to scratch the oil seal lip.
(2) Always replace the circlip, which is installed on
the D.O.J.-side spline of the right drive shaft, with
a new one.

SOLENOID VALVE OPERATION CHECK

1. Remove the vacuum hoses (blue stripe, yellow stripe)
from the solenoid valves.
2. Disconnect the harness connectors.
Solenoid valve A

Solenoid valve B

3. Connect a hand vacuum pump to solenoid valve A, and

carry out the following inspections.
(1) When battery voltage is not applied to any terminals,
the negative pressure is not be held.
(2) The negative pressure is not held when battery voltage
is applied to solenoid valve A. However, when the
Check valve
vacuum hose of solenoid valve B is restricted by
Vacuum tank bending it, the pressure is held.
(3) The negative pressure is held when battery voltage
is applied to solenoid valves A and B.

Solenoid
valve A

Vacuum
hose
Solenoid valve B
 FRONT AXLE – On-vehicle Service 26-13
4. Connect a hand vacuum pump to solenoid valve B. Apply
negative pressure and carry out the following inspections.
(9) When battery voltage is not applied to any terminals,
Check valve the negative pressure is held.
Vacuum tank (10)When battery voltage is applied to solenoid valve
B, the negative pressure is not held.
(11) When battery voltage is applied to solenoid valve
A, the negative pressure is not held.
5. Measure the resistance of solenoid valves A and B.
Solenoid
valve A Standard value: 36 – 46 Ω

Solenoid valve B
26-14 FRONT AXLE – Hub and Knuckle Assembly

HUB AND KNUCKLE ASSEMBLY

REMOVAL AND INSTALLATION
Post-installation Operation
Press the Dust Cover with a Finger to Check Whether
the Dust Cover is Cracked or Damaged.

10 108 – 127 Nm

9
59 – 71 Nm

59 – 71 Nm

1
11
3

90 – 110 Nm

9 Nm
8 6 196 – 255 Nm
2 5

Removal steps
1. Disc brake assembly AB" 8. Tie rod end and hub/knuckle
2. Brake disc assembly connection
3. Wheel speed sensor <Vehicles with AC" 9. Drive shaft and hub/knuckle
ABS> assembly connection
4. Dust cover 10. Strut assembly and hub/knuckle
AA" "AA 5. Castle nut assembly connection
"AA 6. Washer 11. Hub/knuckle assembly
AB" 7. Lower arm and hub/knuckle
assembly connection

REMOVAL SERVICE POINTS

AA" CASTLE NUT REMOVAL
Caution
Never apply the vehicle weight to the wheel bearing while
the castle nut is loosened. If the vehicle weight is applied,
the wheel bearing will be damaged.

MB990767
 FRONT AXLE – Hub and Knuckle Assembly 26-15

MB991113 or
AB" TIE ROD END/LOWER ARM REMOVAL
MB991406 Caution
1. Only loosen the ball joint nut, but do not remove it.
Nut
Use the special tool.
Cord 2. Suspend the special tool with a cord to prevent it
from dropping.

Ball joint

MB990244 AC" DRIVE SHAFT REMOVAL

(three
pieces) Use the special tools when the drive shaft can not be separated
MB990767 from the knuckle easily due to seizure.

MB991354
MB990242

INSTALLATION SERVICE POINTS

Washer
"AA WASHER/CASTLE NUT INSTALLATION
1. Face the chamfered side of the washer against the castle
nut.

2. Use the special tool to tighten the castle nut securely.

196 – 255 Nm
Caution
Never apply the vehicle weight to the wheel bearing
while the castle nut is loosened. If the vehicle weight
is applied, the wheel bearing will be damaged.
3. If the split pin hole is not aligned with the castle nut slit,
always tighten the nut further within a torque of 255 Nm,
and assemble the split pin in the first aligned slit and
MB990767 the hole.
26-16 FRONT AXLE – Hub and Knuckle Assembly

DISASSEMBLY AND REASSEMBLY

Lip

1
3 2
4 1
6
5
2
4

Disassembly steps Reassembly steps

1. Inner oil seal 6. Knuckle
AA" 2. Hub "AA 4. Wheel bearing
3. Snap ring 3. Snap ring
AB" 4. Wheel bearing "BA 5. Outer oil seal
5. Outer oil seal 2. Hub
6. Knuckle "CA D Hub rotation starting torque check
"DA D Wheel bearing axial play check
"EA 1. Inner oil seal

DISASSEMBLY SERVICE POINTS

MB991056 or
MB991355
MB991017 AA" HUB REMOVAL
Caution
When the hub is removed, the wheel bearing may be
damaged. Therefore, if the hub is withdrawn, the wheel
bearing should be always be replaced with a new one.
Tighten the nut while
MB991000 holding the bolt,
(MB990998)

AB" WHEEL BEARING REMOVAL

Wheel bearing
outer inner 1. Pry the outer oil seal at the shown positions with a
race screwdriver so that the jaws of the special tool can hook
the wheel bearing outer inner race.

Outer oil seal

 FRONT AXLE – Hub and Knuckle Assembly 26-17
2. Use the special tool to remove the wheel bearing outer
MB990810 inner race from the hub.
Caution
Be careful not to drop the hub when the outer inner
race is pressed out.

Outer inner
race

3. Assemble the removed outer inner race to the wheel

MB990938 bearing, and then use the special tools to remove the
wheel bearing.
Outer inner race
MB990932

MB991056 or MB991355

REASSEMBLY SERVICE POINTS

MB990938
"AA WHEEL BEARING INSTALLATION
MB991050 Caution
When the wheel bearing is pressed in, its outer race should
be pushed in.

MB991387 "BA OUTER OIL SEAL INSTALLATION

"CA HUB ROTATION STARTING TORQUE CHECK

MB991000 1. Tighten the special tools to the specified torque to press
MB991017 (MB990998)
the hub into the knuckle.
2. Rotate the hub so that the hub is lubricated sufficiently.
Bolt

196 – 255 Nm
Tighten the nut
while holding the
bolt.
26-18 FRONT AXLE – Hub and Knuckle Assembly

3. Use the special tool to measure the hub rotation starting

torque.
Limit: within 1.6 Nm
4. Make sure that the hub rotation starting torque is within
the limit, and the hub turns smoothly.

MB990326

"DA WHEEL BEARING AXIAL PLAY CHECK

MB991000
(MB990998) 1. Clamp the knuckle in a vise, and measure the axial play
while moving the hub in the axial direction.
196 – 255 Nm Limit: 0.2 mm
2. If the limit value can not be obtained after tightening
the special tool within 196 – 255 Nm, the wheel bearing,
the knuckle and the hub may be improperly assembled.
Disassemble these parts to replace the bearing, and then
MB991017
assemble them again.

MB991389 "EA INNER OIL SEAL INSTALLATION

 FRONT AXLE – Drive Shaft 26-19
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
On the vehicles with ABS, when the drive shaft is removed or installed, be careful not to interfere
with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage.

Pre-removal Operation Post-installation Operation

D Disengage the Stabilizer Link from the Strut Bar D Press the Dust Cover with a Finger to Check
(Refer to GROUP 33 – Strut Bar and Lower Arm.) Whether the Dust Cover is Cracked or Damaged.
D Brake Disc Removal (Refer to P.26-14.) D Engage the Stabilizer Link with the Strut Bar (Refer
to GROUP 33 – Strut Bar and Lower Arm.)
D Brake Disc Installation (Refer to P.26-14.)

6 <LH> 59 – 71 Nm

2
59 – 71 Nm

6 <RH> 7
3
1
196 – 255 Nm

Removal steps
AA" "AA 1. Castle nut AB" 5. Lower arm and hub/knuckle
"AA 2. Washer assembly connection
AB" 3. Tie rod end and hub/knuckle AC" 6. Drive shaft
assembly connection 7. Circlip
4. Wheel speed sensor

REMOVAL SERVICE POINTS

AA" CASTLE NUT REMOVAL
Caution
Never apply the vehicle weight to the wheel bearing while
the castle nut is loosened. If the vehicle weight is applied,
the wheel bearing will be damaged.

MB990767
26-20 FRONT AXLE – Drive Shaft

MB991113 or
AB" TIE ROD END AND HUB/KNUCKLE
MB991406 ASSEMBLY/LOWER ARM AND HUB/KNUCKLE
ASSEMBLY DISCONNECTION
Nut
Caution
Cord 1. Only loosen the ball joint nut, but do not remove it.
Use the special tool.
2. Tie the special tool with a cord not to let it fall off.

Ball joint

D.O.J. AC" DRIVE SHAFT REMOVAL

1. For the left side drive shaft, pry the D.O.J. stepped part
with a tyre lever, and then withdraw the drive shaft from
the free-wheeling hub assembly.
Caution
Always use a tyre lever. When the drive shaft is
Stepped part withdrawn from the B.J. assembly, the D.O.J. may
be damaged.
Tyre lever
2. For the right side drive shaft, install the drive shaft with
the castle nut loosely. Then pull the strut, the hub/knuckle
assembly and the lower arm towards you, and then
MB990244 withdraw the drive shaft from the front differential.
(Three) Caution
MB990767
Be sure to maintain the drive shaft horizontally not
to bend the D.O.J. at extreme angle when the drive
shaft is withdrawn.
3. If it is difficult to withdraw the drive shaft from the
hub/knuckle assembly, use the special tools.

MB991354
MB990242

Caution
MB991000 Do not apply the vehicle weight to the wheel bearing
(MB990998) as possible while the drive shaft is removed. If it is
impossible, use the special tool to hold the the wheel
MB991017
bearing as shown in the illustration.

INSTALLATION SERVICE POINT

"AA WASHER/CASTLE NUT INSTALLATION
Refer to P. 26-15.
 FRONT AXLE –    26-21
DISASSEMBLY AND REASSEMBLY
Caution
The B.J. assembly is non-serviceable and requires replacement if defective. B.J. boot can be replaced.

12
4 <RH>
3
5 6
13

13
4 <LH> 2 11
1

4
11

Grease: Repair kit grease

Grease: Repair kit grease Quantity:
<A/T> B.J.: 85 g (40 g for joint, 45 g for boot)
D.O.J.: 85 g (50 g for joint, 35 g for boot)
<M/T> B.J.: 110 g (55 g for joint, 55 g for boot)
D.O.J.: 100 g (60 g for joint, 40 g for boot)
Caution
The joint is filled with a special grease. Do not mix the grease with an old one or other grease.

   
  
    
 
 
   



B.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
26-22 FRONT AXLE – Drive Shaft

Disassembly steps AA" "AA 7. D.O.J. boot

"BA 1. D.O.J. boot band (small) 8. B.J. boot band (small)
"BA 2. D.O.J. boot band (large) 9. B.J. boot band (large)
3. Circlip 10. B.J. boot
4. D.O.J. outer race 11. B.J. assembly
5. Snap ring 12. Circlip
6. Inner race, cage, ball assembly 13. Dust cover

DISASSEMBLY SERVICE POINT

AA" D.O.J. BOOT REMOVAL
Wrap a plastic tape around the B.J. assembly spline to
prevent the boot from damage.

REASSEMBLY SERVICE POINTS

"AA D.O.J. BOOT INSTALLATION
Wrap a plastic tape around the B.J. assembly spline to
prevent damage, and then install the boot.

"BA D.O.J. BOOT BAND/BOOT BAND INSTALLATION

1. Slide the D.O.J. outer race so that the distance between
the boot bands meet the standard value in order to adjust
the air amount inside the D.O.J. boot.
Standard value (A): 80 ± 3 mm
2. Remove the boot partially from the D.O.J. outer race
in order to bleed the air from the boot.
A

B.J. BOOT (PLASTIC BOOT) REPLACEMENT

1. Remove the boot bands (small and large).
NOTE
The boot bands are non-reusable parts.
2. Remove the plastic boot.
 FRONT AXLE – Drive Shaft 26-23
3. Position the plastic boot small end so that one drive shaft
groove is visible.

MB991561 4. Turn the adjusting bolt of the special tool so that the
Stopper opening distance (W) meets the standard value.
Standard value (W): 2.9 mm
<More than 2.9 mm>
Tighten the adjusting bolt.
(W)
<Less than 2.9 mm>
Loosen the adjusting bolt
Adjusting bolt NOTE
(1) Turning the adjusting bolt changes the opening
distance (W) by approx. 0.7 mm.
(2) Do not turn the adjusting bolt more than one turn.

5. Butt the boot band (small) against the boot end projection
Boot so that a certain clearance (A) is obtained.
A

Boot band (small)

Projection

6. Use the special tool to crimp the boot band (small).

Caution
(1) Secure the drive shaft in an upright position and
clamp the part of the B.J. boot band to be crimped
securely in the jaws of the special tool.
(2) Crimp the B.J. boot band until the special tool
stopper closes.

MB991561
26-24 FRONT AXLE – Drive Shaft

7. Check that the crimping amount (B) of the B.J. boot band
is at the standard value.
B
Standard value (B): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 4 according
to the following formula, and then repeat the
operation in step 6.
W = 5.5 mm – B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step 4 according to the following
formula, and then repeat the operations in
steps 5 and 6 using a new B.J. boot band.
W = 5.5 mm – B
Example: If B = 2.3 mm, then W = 3.2 mm.
8. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 4 to 7 using a new B.J.
boot band.

9. Fill the inside of the B.J. boot with the specified amount
of the specified grease.
Specified grease: Repair kit grease
Amount to use:
<A/T> 85 g (50 g for joint, 35 g for boot)
<M/T> 110 g (55 g for joint, 55 g for boot)

10. Position the boot so that the difference between the boot
C big end and the housing stepped part (C) meets the
standard value.
Standard value (C) : 0.1 – 1.55 mm
11. Follow the same procedure as in step 4 to adjust the
size of the opening (W) on the special tool so that it
is at the standard value.
Standard value (W): 3.2 mm

12. Place the B.J. boot band (large) against the projection
at the edge of the boot, and then secure it so that there
Boot Projection is a clearance left as shown by (D) in the illustration.
Boot band (large) 13. Use the special tool to crimp the B.J. boot band (large)
in the same way as in step 6.

D
 FRONT AXLE – Drive Shaft 26-25
14. Check that the crimping amount (E) of the B.J. boot band
is at the standard value.
Standard value (E): 2.4 – 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 11 according
to the following formula, and then repeat the
operation in step 13.
E
W = 5.8 mm – E
Example: If E = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. boot band, readjust the value
of (W) in step 11 according to the following
formula, and then repeat the operations in
steps 12 and 13 using a new B.J. boot band.
W = 5.8 mm – E
Example: If E = 2.3 mm, then W = 3.5 mm.
15. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 12 to 14 using a new B.J.
boot band.
26-26 FRONT AXLE – Main Shaft

MAIN SHAFT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Drive Shaft Removal and Installation (Refer to
P.26-19.)
D Free-wheeling Clutch Housing Assembly Removal
and Installation (Refer to P.26-45.)
D Gear Oil Draining and Refilling (Refer to P.26-11.)

17 Nm

3
88 Nm

9
5

7 8
98 – 118 Nm
4

(Apply to the lip)

(Apply to the lip)

Sealant:
3M ATD Part No.8661 or equivalent 6

Removal steps
1. Vacuum pipe assembly "CA 6. Oil seal
2. Vacuum hose assembly AA" "BA 7. Bearing
3. Vacuum actuator assembly 8. Main shaft
4. Inner shaft assembly "AA 9. Oil seal
5. Front housing assembly
 FRONT AXLE – Main Shaft 26-27
REMOVAL SERVICE POINT
MB990673 AA" BEARING REMOVAL
Install the special tool as shown in the illustration, and use
a press to drive out the bearing from the main shaft.

MB990938
INSTALLATION SERVICE POINTS
MB990926
"AA OIL SEAL INSTALLATION

"BA BEARING INSTALLATION

MB990663

"CA OIL SEAL INSTALLATION

MB990938
MB990927
26-28 FRONT AXLE – Differential Carrier

DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Drive Shaft Removal and Installation D Gear Oil Draining and Refilling (Refer to P.26-11.)
(Refer to P.26-19.)
D Stabilizer Bar Removal and Installation
(Refer to GROUP 33A.)

1
93 Nm*
49 – 59 Nm
5

103 Nm 103 Nm

3
4 93 Nm*
2

88 Nm

59 – 69 Nm 59 – 69 Nm
49 Nm

98 – 118 Nm*

Sealant:
3M ATD Part No.8661 or
equivalent
Removal steps
AA" D Support the Engine Assembly 4. Differential mount bracket assembly
1. Front propeller shaft connection <RH>
2. Front differential assembly and 5. Differential carrier
differential mount crossmember 6. Differential mount crossmember
assembly assembly
3. Free-wheeling clutch assembly
 FRONT AXLE – Differential Carrier 26-29
MZ203827 REMOVAL SERVICE POINT
AA" ENGINE ASSEMBLY SUPPORT
Use the special tool to raise the engine assembly until the
mount insulators are free from load.

DISASSEMBLY




 
















  



  
 

Disassembly steps 16. Drive pinion front shim

D Inspection before disassembly (For drive pinion height adjustment)
1. Cover 17. Drive pinion
2. Vent plug AG" 18. Oil seal
3. Bearing cap AG" 19. Drive pinion rear bearing inner race
AA" 4. Differential case assembly AG" 20. Drive pinion rear bearing outer
5. Side bearing spacer race
6. Side bearing outer race AH" 21. Drive pinion front bearing outer
AB" 7. Side bearing inner race race
AC" 8. Drive gear 22. Oil seal
AD" 9. Self-locking nut 23. Differential carrier
10. Washer AI" 24. Lock pin
AE" 11. Drive pinion assembly 25. Pinion shaft
12. Companion flange 26. Pinion gear
13. Drive pinion spacer 27. Pinon washer
14. Drive pinion rear shim 28. Side gear
(For drive pinion rotation torque 29. Side gear spacer
adjustment) 30. Filler plug
AF" 15. Drive pinion front bearing inner 31. Drain plug
race 32. Differential case
26-30 FRONT AXLE – Differential Carrier

INSPECTION BEFORE DISASSEMBLY

1. Remove the cover.
MB990909
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.

DRIVE GEAR BACKLASH

1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 – 0.16 mm
2. If the backlash is not within the standard value, adjust
the backlash of the final drive gear (Refer to P.26-42).
3. After adjustment, inspect the drive gear tooth contact.

DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.

Wedge
DIFFERENTIAL GEAR BACKLASH
1. While locking the side gear with the wedge, measure
the differential gear backlash with a dial indicator on the
pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear
spacer Repeat the same procedure for other pinion gear.
Side
gear
spacer
 FRONT AXLE – Differential Carrier 26-31
2. If the backlash exceeds the limit, adjust the differential
gear backlash (Refer to P.26-41).
3. If adjustment is impossible, replace the side gear and
pinion gear as a set.

DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.

2. Insert the special tool between the differential carrier and

the differential case, and then rotate the companion flange
MB990939 by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximately 2.5 –
2.9 Nm) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
26-32 FRONT AXLE – Differential Carrier

Standard tooth contact pattern Problem Solution

1 Narrow tooth side Tooth contact pattern resulting from

2 Drive-side tooth surface (the side excessive pinion height
applying power during forward
movement)
3 Wide tooth side
4 Coast-side tooth surface (the 2 1 4
side applying power during re- 2 1 4
verse movement)

3 3

Increase the thickness of the drive

The drive pinion is positioned too far
pinion rear shim, and position the
from the centre of the drive gear.
2 1 4 drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.

3 Tooth contact pattern resulting from

insufficient pinion height.

2 1 4 2 1 4

3 3

Decrease the thickness of the drive

The drive pinion is positioned too
pinion rear shim, and position the
close to the centre of the drive gear.
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.

NOTE
Checking the tooth contact pattern is the way to If, even after adjustments have been made, the
confirm that the adjustments of the pinion height correct tooth contact pattern cannot be obtained,
and backlash have been done properly. Continue it means that the drive gear and the drive pinion
to adjust the pinion height and backlash until the have become worn beyond the allowable limit.
tooth contact pattern resembles the standard Replace the gear set.
pattern.
 FRONT AXLE – Differential Carrier 26-33
DISASSEMBLY SERVICE POINTS
AA" DIFFERENTIAL CASE ASSEMBLY REMOVAL
Remove the differential case assembly with a hammer handle
or the like.
Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing outer races.
NOTE
Keep the right and left side bearing outer races and side
bearing spacers separate, so that they do not become mixed
at the time of reassembly.

MB990810
AB" SIDE BEARING INNER RACE REMOVAL
NOTE
There are two notches provided (at the differential case side)
for the jaws of the special tool; use the special tool at that
MB990811
position.
If the special tool jaws cannot be inserted between the
differential case and the bearing inner race, file the jaw tips
as necessary.

AC" DRIVE GEAR REMOVAL

1. Make the mating marks on the differential case and the
drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
Mating marks

AD" SELF-LOCKING NUT REMOVAL

MB990850
26-34 FRONT AXLE – Differential Carrier

MB990810 AE" DRIVE PINION ASSEMBLY REMOVAL

1. Make mating marks on the drive pinion and the companion
flange.
Caution
The mating mark must not be on the coupling surface
of the companion flange and the front propeller shaft.
Companion 2. Use the special tool to drive out the drive pinion.
flange

AF" DRIVE PINION FRONT BEARING INNER RACE

REMOVAL

MB990560

MB990939 AG" OIL SEAL/DRIVE PINION REAR BEARING INNER

RACE/DRIVE PINION REAR BEARING OUTER
RACE REMOVAL

AH" DRIVE PINION FRONT BEARING OUTER RACE

MB990939 REMOVAL

A I" LOCK PIN DRIVE OUT

Punch
 FRONT AXLE – Differential Carrier 26-35
REASSEMBLY

 








 


Differential gear set Final drive gear set










78 – 88 Nm
   


186 Nm

34 – 39 Nm*




 49 Nm








 59 – 69 Nm
35 Nm 





Reassembly steps
1. Differential carrier 15. Self-locking nut
"AA 2. Oil seal 16. Differential case
"BA 3. Drive pinion front bearing outer "FA D Differential gear backlash adjustment
race 17. Side gear spacer
"CA 4. Drive pinion rear bearing outer 18. Side gear
race 19. Pinion washer
"DA D Drive pinion height adjustment 20. Pinion gear
5. Drive pinion 21. Pinion shaft
6. Drive pinion front shim (for drive "GA 22. Lock pin
pinion height adjustment) "HA 23. Drive gear
7. Drive pinion front bearing inner "IA 24. Side bearing inner race
race 25. Side bearing outer race
8. Drive pinion spacer "JA D Final drive gear backlash adjustment
"EA D Drive pinion rotation torque adjustment 26. Side bearing spacer
9. Drive pinion rear shim (for drive 27. Differential case assembly
pinion rotation torque adjustment) 28. Bearing cap
10. Drive pinion assembly 29. Vent plug
11. Drive pinion rear bearing inner race 30. Cover
12. Oil seal 31. Drain plug
13. Companion flange 32. Filler plug
14. Washer

NOTE
The fasteners marked by * should be tightened when the
differential gear oil is applied.
26-36 FRONT AXLE – Differential Carrier

LUBRICATION, SEALANT AND ADHESIVE POINTS

(Apply to the (Apply

entire circumfer- to the
ence of the lip entire
Sealant: circum-
3M ATD Part No. 8661 or ference
equivalent of the lip

f 2 – 3 mm

Sealant: Adhesive:
3M ATD Part No. 8661 or 3M Stud Locking 4170 or
equivalent equivalent

REASSEMBLY SERVICE POINTS

MB990938 "AA OIL SEAL INSTALLATION

MB991115
 FRONT AXLE – Differential Carrier 26-37
"BA DRIVE PINION FRONT BEARING OUTER RACE
INSTALLATION
MB990938

MB990926

MB990938 "CA DRIVE PINION REAR BEARING OUTER RACE

INSTALLATION
MB990929

"DA DRIVE PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
MB990836 tool.
(MB990835)
<A/T> 2. Install the special tool, drive pinion front and rear bearing
MB990903
<M/T> inner races to the gear carrier.

MB990835
<A/T> Washer

3. Tighten the nut of the special tool while measuring the

MB990903 <M/T> rotation torque of the drive pinion. Gradually keep
MB990835 <A/T> tightening the nut of the special tool until the rotation
torque of the drive pinion (without oil seal) is at the standard
value.
Standard value:
Bearing division Bearing lubrication Rotation torque
Nm
New None (With 0.88 – 1.17*1
anti-rust agent) 0.29 – 0.49*2
New or reused Gear oil applied 0.39 – 0.49*1
0.147 – 0.245*2
NOTE
*1: A/T
*2: M/T
26-38 FRONT AXLE – Differential Carrier

MB990326 NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to
run in the bearing, and then measure the rotation torque.

MB991170 <M/T> 4. Clean the side bearing hub.

Notch
MB990392 <A/T> 5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
NOTE
A
Always check that the notch is in the shown position
and that the special tools are touching firmly against the
side bearing hub.
6. Use a thickness gauge to measure the clearance (A)
Thickness MB990903 <M/T> between the special tools.
gauge MB990836 <A/T>

7. Remove the special tools.

8. Use a micrometer to measure the special tool in the places
C (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C–1/2D–86.0

11. Fit the selected drive pinion front shim(s) to the drive
Drive
pinion, and press-fit the drive pinion front bearing inner
pinion MB990829 race by using the special tool.
front
shim

MB990829
 FRONT AXLE – Differential Carrier 26-39
"EA DRIVE PINION ROTATION TORQUE
ADJUSTMENT
Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion spacer, the drive pinion rear shim, the
drive pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.

2. Use the special tool to hold companion flange, and then

186 Nm tighten the self-locking nut to the specified torque.

MB990850

MB990326 3. Measure the drive pinion rotation torque (without the oil
seal) by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque Nm
New None (With 0.88 – 1.17*1
anti-rust agent) 0.29 – 0.49*2
New/reused Gear oil applied 0.39 – 0.49*1
0.147 – 0.245*2

NOTE
*1: A/T
*2: M/T

4. If the drive pinion rotation torque is not within the range

of the standard value, adjust it by replacing the drive
pinion rear shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion rear shims, if the number
A of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers. Also, select the
Identification drive pinion spacer from the following two types.
colour
26-40 FRONT AXLE – Differential Carrier

Drive pinion spacer Identification colour

height (A) mm
46.67*1 White
47.01*1 –
57.72*2 –
57.08*2 Red
NOTE
*1: M/T
*2: A/T
5. Remove the companion flange and drive pinion again.
Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990727 the oil seal.

6. Install the drive pinion assembly and companion flange

with mating marks properly aligned, and use the special
186 Nm tool to hold the companion flange, and then tighten the
MB990850 self-locking nut to the specified torque.

MB990326 7. Measure the drive pinion rotation torque (with the oil seal)
by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque Nm
New None (With 0.98 – 1.27*1
anti-rust agent) 0.49 – 0.69*2
New/reused Gear oil applied 0.49 – 0.58*1
0.343 – 0.441*2
NOTE
*1: A/T
*2: M/T
8. If the drive pinion rotation torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal installation condition.
 FRONT AXLE – Differential Carrier 26-41
"FA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Follow the procedures below to adjust the differential gear
backlash.
1. Assemble the side gears, side gear spacers, pinion gears
and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.

Wedge
3. Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 – 0.076 mm
Limit: 0.2 mm
Side gear
thrust spacer Repeat the steps above for the other pinion gear.
Side gear 5. If the differential gear backlash exceeds the limit, adjust
thrust spacer
the backlash by changing the side gear spacers.
6. If adjustment is not possible, replace the side gears and
pinion gears as a set.
7. Confirm that the differential gear backlash is correct, and
that the differential gear turns smoothly.

"GA LOCK PIN INSTALLATION

1. Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch at two points.

"HA DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning a tap (M10 x 1.25), and then
clean the threaded holes by applying compressed air.

M10 1.25 (pitch)

26-42 FRONT AXLE – Differential Carrier

3. Clean the drive gear attaching surface, and then apply

the specified adhesive to the threaded holes of the drive
gear.
Specified sealant:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the differential case with the
mating marks properly aligned.
5. Tighten the drive gear attaching bolts provisionally, and
then tighten them to the specified torque in a diagonal
sequence.
Tightening torque: 78 – 88 Nm

"IA SIDE BEARING INNER RACE INSTALLATION

Metal Use the special tool to press the side bearing inner race
Metal into the differential case.

MB990829
MB990829

"JA DRIVE GEAR BACKLASH ADJUSTMENT

Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE
Select side bearing spacers with the same thickness for
both the drive gear sides.

2. Push the differential case assembly to one side, and

measure the clearance between the gear carrier and the
side bearing spacer with a thickness gauge.
 FRONT AXLE – Differential Carrier 26-43
3. Measure the thickness of the side bearing spacers on
one side, select two pairs of spacers which correspond
to that thickness plus one half of the clearance plus 0.05
mm, and then install one pair each to the drive pinion
side and the drive gear side.

Clearance/2 + 0.05 mm
= Thickness of the spacer on one
side

4. Install the selected side bearing spacers and differential

case assembly, as shown in the illustration, to the gear
carrier.

5. Tap the side bearing spacers with the special tool to fit
them to the side bearing outer race.

MB990939

6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.

7. With the drive pinion locked in place, measure the drive

gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11 – 0.16 mm
26-44 FRONT AXLE – Differential Carrier

If backlash is too small 8. Change the side bearing spacers as illustrated, and then
Thinner
adjust the drive gear backlash.
Thicker
spacer spacer NOTE
When increasing the number of side bearing spacers,
decrease the same number of the side bearing spacers
for opposite side.
9. Check the drive gear and drive pinion for tooth contact.
Thicker Thinner If poor contact is evident, make adjustment. (Refer to
spacer spacer P. 26-31.)
If backlash is too large

10. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.
Limit: 0.05 mm
11. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12. If adjustment is not possible, replace the differential case
or replace the drive gear and drive pinion as a set.
 FRONT AXLE – Free-wheeling Clutch Assembly 26-45
FREE-WHEELING CLUTCH ASSEMBLY
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Gear Oil Draining and Refilling (Refer to P.26-11.)
D Drive Shaft Removal and Installation
(Refer to P.26-19.)

5 2 – 3 mm
1
4 Sealant:
3M ATD Part No.8661 or equivalent
35 Nm

49 – 59 Nm
49 Nm 93 Nm*

59 – 69 Nm 3
103 Nm

Removal steps
AA" 1. Pin 4. Free-wheeling clutch housing
2. Free-wheeling engage switch assembly
assembly 5. Collar
3. Differential mount bracket assembly
<LH>

Collar Dust cover

REMOVAL SERVICE POINT
AA" PIN REMOVAL
1. Remove the one side of the dust cover from the vacuum
actuator assembly.
2. Align the pin with the pin hole of the collar, and then
Pin drive out the pin with a punch.
26-46 FRONT AXLE – Free-wheeling Clutch Assembly

INSPECTION
FREE-WHEELING ENGAGE SWITCH CONTINUITY
CHECK

Shaft Shaft (switch) position Terminal number

OFF ON
1 2

Pushed (ON)
Contact point Electrode Released (OFF)

DISASSEMBLY AND REASSEMBLY

4 5
5 3
6
2

1
8

13
10
11
12
7 9

11
13

(Apply to the lip)

Disassembly steps
"DA 1. Clutch sleeve 8. Circlip
2. Snap ring AA" "BA 9. Bearing
3. Shift fork assembly 10. Bearing
"CA 4. Spring pin 11. Clutch gear
5. Shift rod "AA 12. Oil seal
6. Shift fork 13. Free-wheeling clutch housing
7. Clutch gear assembly
 FRONT AXLE – Free-wheeling Clutch Assembly 26-47
DISASSEMBLY SERVICE POINT
AA" BEARING REMOVAL
Position the bearing inner race on a support. Then use a
press to separate the clutch gear from the bearing.
Support

MB990938 MB991015 REASSEMBLY SERVICE POINTS

"AA OIL SEAL INSTALLATION

MB990799 "BA BEARING INSTALLATION

Use the special tool to press-fit the bearing to the shoulder
of the clutch gear.

Spring pin "CA SPRING PIN INSTALLATION

Insert the spring pin into the pin hole (with chamfered surface)
of the shift rod, and then tap the spring pin in as shown
in the illustration.

0 – 1 mm Shift rod
Shift fork

"DA CLUTCH SLEEVE INSTALLATION

Face the clutch sleeve tapered side towards the drive shaft
to install the clutch sleeve.
Drive shaft Differential carrier
side side

Taper side
26-48 FRONT AXLE – Solenoid Valve, Vacuum Pipes and Vacuum Tank

SOLENOID VALVE, VACUUM PIPES AND VACUUM TANK

REMOVAL AND INSTALLATION

1
7

6
3

2
1

4 1

1
1 8
5

10
9

12
17 Nm

11
1

1. Vacuum hose Vacuum actuator assembly removal

"AA 2. Vacuum hose <blue stripe> steps
"AA 3. Vacuum hose <yellow stripe> "AA 9. Vacuum hose <blue stripe>
4. Vacuum pipe assembly connection
5. Vacuum pipe assembly "AA 10. Vacuum hose <yellow stripe>
6. Solenoid valve assembly connection
"BA 7. Check valve AA" 11. Pin
8. Vacuum tank assembly 12. Vacuum actuator assembly
 FRONT AXLE – Solenoid Valve, Vacuum Pipes and Vacuum Tank 26-49
REMOVAL SERVICE POINT
Collar Dust cover
AA" PIN REMOVAL
1. Remove the one side of the dust cover from the vacuum
actuator assembly.
2. Align the pin with the pin hole of the collar, and then
Pin drive out the pin with a punch.

INSTALLATION SERVICE POINTS

" AA VACUUM HOSE INSTALLATION
Connect the vacuum hoses, the solenoid valve and the
vacuum pipes according to their identification colours.

" BA CHECK VALVE INSTALLATION

Face the arrow mark to the vacuum side.

Solenoid
Vacuum side valve side

Arrow mark indicating

ventilation direction
26-50 FRONT AXLE – Front Differential Mount

FRONT DIFFERENTIAL MOUNT

REMOVAL AND INSTALLATION
Caution
1. To remove the differential mount crossmember assembly, support the front differential assembly
with a jack.
2. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.

103 Nm
4
3
42 Nm

98 – 118 Nm*

2
1
42 Nm 93 Nm*
103 Nm

Differential mount bracket assembly 2. Differential mount bracket assembly

(front) removal steps <Rear – LH>
D Free-wheeling clutch assembly 3. Differential mount bracket
removal (Refer to P. 26-45.) <Rear – RH>
1. Differential mount bracket assembly Differential mount crossmember
<front> assembly removal steps
Differential mount bracket assembly D Front propeller shaft removal (Refer
(LH, RH) removal steps to GROUP 25.)
D Drive shaft assembly removal 4. Differential mount crossmember
(Refer to P. 26-19.) assembly
 FRONT AXLE – Front Differential Mount 26-51

MD999547
DIFFERENTIAL MOUNT INSULATOR
REPLACEMENT
FRONT
1. Use the special tool to drive out the insulator.

MB990947 2. Use the special tools and a press to press-fit the insulators
MB990847
so that their hollow portion points to the shown direction
and the insulator protrudes evenly (Distance A is equal
MB990981
to distance B).

REAR
1. Use the special tool to drive out the insulator.
MD999570

MB991318 2. Use the special tools and a press to press-fit the insulators
so that their hollow portion points to the shown direction
MB991183
and the insulator protrudes evenly (Distance C is equal
MB990843 to distance D).

D
NOTES
26-1 FRONT AXLE – General/General Information

GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE
 The front differential reduction gear ratio has been changed due to the introduction of 2000-mL engine.
 The service procedure has been changed since the wheel bearing has been changed from the previous
oil seal separate type to the integrated type.

Inner oil seal

<abolished>
Snap ring

Wheel bearing Knuckle

<Oil seal inte- Outer oil seal
grated> <abolished>
Hub

 The solenoid valve for the free-wheeling mechanism has been changed.
Waterproof type connector
New Old

GENERAL INFORMATION
FRONT DIFFERENTIAL
Item New Old
Reduction ratio 4.636*1, 4.900*2 4.875

Number Drive gear 51*1, 49*2 39

of teeth
Drive pinion 11*1, 10*2 8

NOTE
*1: M/T, *2: A/T
 FRONT AXLE – Hub and Knuckle Assembly 26-2
HUB AND KNUCKLE ASSEMBLY
DISASSEMBLY AND REASSEMBLY

2
3

4
1

Disassembly steps B A 3. Wheel bearing

D  Hub rotation starting torque check 4. Knuckle
C  Wheel bearing axial play check
NOTE
A 1. Hub
The disassembly service points are the same as
B 2. Snap ring before.

REASSEMBLY SERVICE POINTS

Only the service procedure below has been added. The other
service procedures are the same as before.
B SNAP RING INSTALLATION
The notch in the snap ring should face down.
Caution
The sealing performance between the snap ring and the
Snap ring
bearing seal can be ensured by making the snap ring
face down. If the snap ring notches face toward the
different direction, the sealing performance may be
impaired.
 26-1

FRONT AXLE
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Front Axle Total Backlash Check . . . . . . . . . . . . . . . 5

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 FRONT AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . 7

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . 9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VACUUM PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

26-2 FRONT AXLE – General/General Information

GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the addition of the vehicles with 1800-MPI
engine. Other service procedures are the same as before.
GENERAL INFORMATION
FRONT AXLE
Item 1800-MPI
Drive shaft Shaft length* Shaft diameter Right side 316 24
mm
Left side 435 24
Front axle shaft Shaft length Shaft diameter mm 389 25
Bearing (O.D. I.D.) mm 62 35

NOTE
*: shows the distance between the centres of the joints.

FRONT DIFFERENTIAL
Item 1800-MPI

Reduction ratio 4.636*1, 5.111*2

Number of teeth Drive gear 51*1, 46*2
Drive pinion 11*1, 9*2
Bearing (O.D. I.D.) mm Side 72.0 35.0
Front 62.0 25.0
Rear 72.0 35.0

NOTE
*1: M/T
*2: A/T
 FRONT AXLE – General Information/Service Specifications/Lubricant 26-3
CONSTRUCTION DIAGRAM

Front axle assembly

Differential mount
bracket (LH) Differential mount
crossmember

Front differential

Drive shaft (RH)

Drive shaft (LH)

SERVICE SPECIFICATIONS
Items Standard value Limit

Drive pinion turning Without oil seal When replacing 0.88 – 1.17 –
torque N·m (with anti-rust agent)

When replacing or reusing 0.39 – 0.49 –

(with gear oil applied)

With oil seal When replacing 0.98 – 1.27 –

(with anti-rust agent)

When replacing or reusing 0.49 – 0.58 –

(with gear oil applied)

LUBRICANT
Items Specified lubricants Quantity

D.O.J./B.J. Repair kit grease 85 g

26-4 FRONT AXLE – Special Tools

SPECIAL TOOLS
Tool Number Name Use
MB991115 Oil seal installer Front axle oil seal press-fitting (Used together
with MB990938)

MB990673 Front bearing Bearing removal

remover

MB990663 Rear axle shaft Bearing installation

bearing and retain-
er ring installer

MB990850 End yoke holder Companion flange removal and installation

MB990835 Dummy pinion set D Drive pinion rotation starting torque check
A: MB990836 A: Drive D Drive pinion height measurement
B: MB990392 pinion gauge
assembly
B B: Cylinder gauge
A

MB990326 Pre-load socket Drive pinion turning torque measurement

MB990829 Pinion and side D Drive pinion rear bearing inner race
bearing installer pressing-in
D Side bearing inner race pressing-in

MB990727 Oil seal installer Drive pinion oil seal pressing-in

 FRONT AXLE – Special Tools/On-vehicle Service 26-5

MB990925
Tool box
C Brass bar

B
A Installer bar (snap-in type)
Installer adapter

Type Tool number O.D. mm Type Tool number O.D. mm

A MB990926 39 A MB990933 63.5

MB990927 45 MB990934 67.5

MB990928 49.5 MB990935 71.5

MB990929 51 MB990936 75.5

MB990930 54 MB990937 79

MB990931 57 B MB990938 –

MB990932 61 C MB990939 –

Mating marks ON-VEHICLE SERVICE

FRONT AXLE TOTAL BACKLASH CHECK
1. Place the transmission shift lever in the neutral position,
apply the parking brake and then jack up the vehicle.
2. Manually turn the propeller shaft clockwise as far as it
will go and make mating marks on the companion flange
dust cover and the differential carrier.

3. Manually turn the propeller shaft anti-clockwise as far as it

will go and measure the movement of the mating marks.
Limit: 5 mm
4. If the backlash exceeds the limit, remove the differential
carrier assembly, and then carry out the following checks.
D Final drive gear backlash
D Differential gear backlash
D Play in the serrations and spline of the side gears,
drive shaft, inner shaft and drive flange
26-6 FRONT AXLE – Drive Shaft

DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY
Caution
The B.J. assembly is non-serviceable and requires replacement if defective. B.J. boot can be replaced.

12
4 <RH>
3
5 6
13

13
4 <LH> 2 11
1

4
11

Grease: Repair kit grease

Grease: Repair kit grease Quantity: B.J.: 85 g (40 g for joint, 45 g for boot)
D.O.J.: 85 g (50 g for joint, 35 g for boot)

Caution
The joint is filled with a special grease. Do not mix the grease with an old one or other grease.

12 3 13 4
5 2 35
1 12 3 5 6
7 7
2 2
1 13 12 1
8
9
10

B.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
 FRONT AXLE – Drive Shaft/Front Axle Shaft 26-7
Disassembly steps 9. B.J. boot band (large)
"BA 1. D.O.J. boot band (small) 10. B.J. boot
"BA 2. D.O.J. boot band (large) 11. B.J. assembly
3. Circlip 12. Circlip
4. D.O.J. outer race 13. Dust cover
5. Snap ring NOTE
6. Inner race, cage, ball assembly Removal and installation service points are the same
AA" "AA 7. D.O.J. boot as before.
8. B.J. boot band (small)

FRONT AXLE SHAFT

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Drive Shaft Removal and Installation
D Gear Oil Draining and Refilling

88 ± 10 N·m

9
2 10
8
6
108 ± 10 N·m
7
5
3 4

9 4

(Apply to
the lip)

Sealant: (Apply to the lip)

3M ATD Part No.8661 or equivalent

Removal steps
D Front differential assembly and 5. Snap ring
differential mount crossmember 6. Front axle shaft
assembly(Refer to P.26-9) 7. Clip
1. Vacuum pipe assembly "BA 8. Oil seal
2. Vacuum hose assembly AA" "AA 9. Bearing
3. Front axle assembly 10. Front housing assembly
"CA 4. Oil seal
26-8 FRONT AXLE – Front Axle Shaft

REMOVAL SERVICE POINT

MB990673 AA" BEARING REMOVAL
Install the special tool as shown in the illustration, and use
a press to drive out the bearing from the main shaft.

INSTALLATION SERVICE POINTS

"AA BEARING INSTALLATION
MB990663

MB990938
"BA OIL SEAL INSTALLATION

MB990927

"CA OIL SEAL INSTALLATION

MB990938
MB991115
 FRONT AXLE – Differential Carrier 26-9
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully
tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D Drive Shaft Removal and Installation
D Stabilizer Bar Removal and Installation
D Gear Oil Draining and Refilling

93 ± 15 N·m*

54 ± 4 N·m

1
103 ± 15 N·m
3 2
88 ± 5 N·m
4
5

49 ± 9 N·m
88 ± 10 108 ± 10 N·m*
64 ± 4 N·m N·m
93 ± 15 N·m*

Sealant:
3M ATD Part No.8661 or
equivalent
Removal steps
AA" D Support the Engine Assembly 5. Differential carrier
1. Front propeller shaft connection 6. Differential mount crossmember
2. Front differential assembly and assembly
differential mount crossmember NOTE
assembly
Removal service points are the same as before.
3. Front axle assembly
4. Differential mount bracket assembly
<RH>
26-10 FRONT AXLE – Differential Carrier

DISASSEMBLY AND REASSEMBLY

Service procedures except following are the same as before.
MB990836 REASSEMBLY SERVICE POINTS
(MB990835) "DA DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special
MB990835 tool.
Washer 2. Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.

3. Tighten the nut of the special tool while measuring the

MB990835
rotation torque of the drive pinion. Gradually keep
tightening the nut of the special tool until the rotation torque
of the drive pinion (without oil seal) is at the standard
value.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.88 – 1.17
anti-rust agent)
New or reused Gear oil applied 0.39 – 0.49

MB990326 NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to run
in the bearing, and then measure the rotation torque.

4. Clean the side bearing hub.

Notch MB990392 5. Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.
NOTE
A
Always check that the notch is in the shown position and
that the special tools are touching firmly against the side
bearing hub.
6. Use a thickness gauge to measure the clearance (A)
Thickness MB990836 between the special tools.
gauge
 FRONT AXLE – Differential Carrier 26-11
7. Remove the special tools.
8. Use a micrometer to measure the special tool in the places
C (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge

Bearing cap and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion
front shim by the following formula, and then select a
D shim which most closely matches this thickness.
E = A + B + C – 1/2D – 86.0

11. Fit the selected drive pinion front shim(s) to the drive pinion,
Drive
and press-fit the drive pinion front bearing inner race by
pinion MB990829 using the special tool.
front
shim

MB990829

"EA DRIVE PINION ROTATION TORQUE

ADJUSTMENT
Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install
the drive pinion spacer, the drive pinion rear shim, the
drive pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.

2. Use the special tool to hold companion flange, and then

186 ± 29 N·m tighten the self-locking nut to the specified torque.

MB990850
26-12 FRONT AXLE – Differential Carrier

MB990326 3. Measure the drive pinion rotation torque (without the oil
seal) by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.88 – 1.17
anti-rust agent)
New/reused Gear oil applied 0.39 – 0.49

4. If the drive pinion rotation torque is not within the range

of the standard value, adjust it by replacing the drive pinion
rear shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion rear shims, if the number
A of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers. Also, select the drive
Identification pinion spacer from the following two types.
colour
Drive pinion spacer Identification colour
height (A) mm
57.72 –
57.08 Red

5. Remove the companion flange and drive pinion again.

Then, after inserting the drive pinion rear bearing inner
race into the gear carrier, use the special tool to press-fit
MB990727 the oil seal.

6. Install the drive pinion assembly and companion flange

with mating marks properly aligned, and use the special
186 ± 29 N·m
tool to hold the companion flange, and then tighten the
MB990850 self-locking nut to the specified torque.
 FRONT AXLE – Differential Carrier/Vacuum Pipes 26-13
MB990326 7. Measure the drive pinion rotation torque (with the oil seal)
by using the special tool.
Standard value:
Bearing division Bearing lubrication Rotation torque
N·m
New None (With 0.98 – 1.27
anti-rust agent)
New/reused Gear oil applied 0.49 – 0.58

8. If the drive pinion rotation torque is not within the standard

value, check the tightening torque of the companion flange
self-locking nut and the oil seal installation condition.

VACUUM PIPES
REMOVAL AND INSTALLATION

3 1

1
2

1
Removal step
1. Vacuum hose 3. Vacuum pipe assembly
2. Vacuum pipe assembly 4. Breather cap
NOTES