Toyota Tercel 1985 Скачать руководство пользователя страница 626

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Содержание Tercel 1985

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Страница 475: ...PR 1 PROPELLER SHAFT for4WDl PRECAUTIONS TROUBLESHOOTING PROPELLER SHAFT Page PR 2 PR 2 PR 2 r il t ry s f gu ...

Страница 476: ...orn Centerbearingworn Spiderbearingworn or stuck Replace intermediate shaft Replace centerbearing Replace intermediate shaft or propeller shaft PR 3 PR 3 PR 3 Vibration Propeller shaft runout Propeller shaftunbalance Transmission extension housingrear bushing worn Sleeveyokesplinestuck CenterbearingheightimProPer Replace propellershaft Balance propellershaft Replace bushing Replace intermediate sh...

Страница 477: ...PPORT BEARING TO BODY 3 REMOVEPROPELLER SHAFT WITH INTERMEDIATE SHAFT h Pullout the yokefrom the transmission b InsertSSTin the transmission to prevent oil leakage ssT 09325 1 20rO 4 SEPARATE PROPELLER SHAFTAND INTERMEDIATE SHAFT a Placematchmarks on the flanges b Removethe four bolts and nuts 5 REMOVECENTER SUPPORT BEARINGFROM INTERMEDIATE SHAFT a Usinga hammer andchisel loosen thestakedpartof th...

Страница 478: ...umrunout 0 8 mm 0 031in l lf shaft runoutis exceedsmaximum replacethe shaft 2 INSPECT SPIDERBEARINGS a Inspectthe spiderbearings for wearor damage b Checkthe spiderbearingaxialplay by turningthe yokewhileholdingthe shafttightly Bearingaxial play O mm 0 in l lf necessary replacethe intermediateshaft orland pro pellershaft 3 INSPECT CENTER SUPPORT BEARINGFORWEAROR DAMAGE Checkthat the bearingturns f...

Страница 479: ...he centersupportbearingwith the cutout on the rearside 2 INSTALLFTANGEYOKEON INTERMEDIATE SHAFT ta Apply MP greaseto the splinesof the intermediate shaft b Align the matchmarkson the yoke and shaft and installthem c UsingSST to hold the flange tightendown a nut to pressthe bearinginto position ssT09330 ooo20 Torque 1 850 kg cm 134 ft lb 181 N ml d Loosenthe nut e Torquethe nut again Torque 300 kg ...

Страница 480: ...nectthe them with the four bolts and nuts b Torguethe nuts Torque 43Okg cm 31 ft tb 42 N m 6 CONNECT CENTER SUPPORT BEARING TO BODY ta Placethe height washer betweenthe body and centersupport bearing and installthe two mount boltsfingertight NOTE Somevehiclesdo not havea heightwasher In this case it is not necessary to insertone b Checkthat the bearingbracketis at right anglesto the propellershaft...

Страница 481: ...NT AXLEAND SUSPENSION TROUBLESHOOTING FRONTWHEELALIGNMENT AXLE HUB FRONTDRIVESHAFT FRONTSHOCKABSORBER FRONTSUSPENSION Ball Joints Lower Arm Stabilizer Bar Page FA 2 FA 3 FA 23 FA 24 FA 7 FA 13 F4 19 FA 23 F4 27 ...

Страница 482: ...mproperlyinflated Stabilizerbar bentor broken Shock absorberworn out lnflate tires to proper pressure Replace stabilizer bar Replace shockabsorber FA 3 FA 27 FA 19 Frontwheelshimmy Tires worn or improperlyinflated Wheelout of balance Shockabsorberworn out Alignmentincorrect Wheel bearingworn Balljointsor bushingworn Steeringlinkageloosenor worn Steeringgear out of adjustmentor broken Replace tire ...

Страница 483: ...the steeringlinkagefor looseness f Check that the front absorberswork properly by usingthe standardbouncetest ADJUSTTOE IN Adjust toe in with a toe ingaugeby the followingpro cedure d Checkto seethat both rightandleft tie rodsmeasure the samein length Left right error 1 5 mm 0 059 in l or less Movethe vehicleforwarda few meterswith the front wheelsinthestraight ahead positionon a levelplace Mark t...

Страница 484: ...he left and right rack ends an equal amountto adjust Wl Checkthat the length of the left and right tie rods arethe same 5 Torquethe tie rod endclamp Torque 195 kg cm 14 ft lb 19 N ml 6 Placethe boot on the sealandclampit NOTE Checkthat the boot is not twisted 3 INSTALTWHEELALIGNMENTEOUIPMENT Follow the specific instructionsof the equipmentmanu facturer fuwry A B ...

Страница 485: ...senthe shockabsorber mountnut b Turnthe camto adjust NOTE Camber changes about20 with eachgraduation of the cam c Tightento the specified torque Torque 1 45Okg cm 105ft lb 142 N m 6 ADJUSTSTEERING AXIS INCLINATION Vehicle Inspection standard Left righterror FWD Sedan 12 30 30 30 or less Wagon 12035 30 4WD 11 50 t 30 lf the steering axisinclination is out of tolerance inspect andreplace anydamaged ...

Страница 486: ... 1 at 2Oo 21 30 200 w PS Max 35050 10 3 2 5 5 f 1 0 at 20o 21 05 20 Wagon w o PS Max 3 6 0 1 3 1 0 3 2 0 5 8 1 0 at 2Oo 21 25 20 wi PS Max 35047 1 1 3 2 0 5 0 1 at 20 21 O9 20 4WD w o PS Max 36030 10 3 3 0 1 s 1 0 at 200 2 1 15 20 w PS Max 3 6 0 2 0 1 0 33020 1 at 2Oo 21005 200 lf the steeringanglesdiffer from the standardspecifica 4o tion checkto seethat the lengthof the left and right tie t ry r...

Страница 487: ...soruer 1 I I i I wheet Bearins n t d l i f f q J d J r rieRod r o E h t lo t cam 9 n 6g1 i T it i Y9J A ffi31 yrnnerRacel l ry Dise Brake Dust cover t 1 iHJ r l Lt l1l ner Race NSK rype l a 6 I i OuterOitSeal LockNut Cap i r 1 i Y r A l S U Ikg cm ft lb N m l Tighteningtorque O Non reusable part ...

Страница 488: ...DISC fi frcr BEARTNG pLAyrNAxtALDtREcnoN Maximum 0 05mm O OO2O in l 5 DISCONNECT TIE RODEND FROMSTEERING KNUCKLE d Removethe cotter pin and nut b UsingSST disconnectthe tie rod end ssT09610 20012 Le rnorrn fucr 6 DISCONNECT STEERING KNUCI nC t r Y I I t I I li t 5 f ABSORBER d Place matchmarks on the shock absorber lower bracketand camberadjustcam b Removethe two boltsend nuts anddisconnectthe ste...

Страница 489: ... removethe dustdeflector REMOVE INNEROIL SEALFROMSTEERING KNUCKLE UsingSST pullou tthe oil seal ssr 09308 0001 0 REMOVE HOLESNAPRING Usingsnapringpliers removethe holesnapring REMOVE THREE BOLTS Remove the threeboltsholdingthe discbrakedust to the steering knuckle F REMOVE AXLEHUQFROMSTEERING KNUCKLE r UsingSST pushoff the axlehub ssT 09950 2001 5 6 REMOVE DISCBRAKEDUSTCOVER 7 REMOVE BEARING INNER...

Страница 490: ...e bearinginnerrace outside beforeinstall ing a pew oil seal b UsingSST drivetheoilsealintothesteering knuckle ssT 09515 35010 c ApplyMP greaseto the oit seallip INSTALLDISCBRAKEDUSTCOVER ONTOSTEERING KNUCKLE WITH THREEBOLTS Applyliquidsealer to the dustcoverandsteering knuckle connection beforeassembly INSTALLAXLE HUB a Installnew innerracesinto the innerbearing b UsingSST ggss in the innerraceunt...

Страница 491: ...he steering knuckle ssTo9316 60010 INSTALLATION OF FRONT AXLEHUB SeepageFA 7 1 INSTALLAXLEHUBTO DRIVESHAFT lnstallthe axlehubwith the washerandlock nut Do not torquethe nut yet CAUTION Be careful not to damagethe drive shaft boot and oil seal lip 14 1 5 2 INSTALLAXLE HUB TO LOWERARM Torquethe holdingtwo bolts the steering knuckleto the ilxb rowerarm Torque 82Okg cm 59 ft lb 80 Nrml 3 INSTALLDISCTO...

Страница 492: ...ue 970 kg cm 70 ft lb 95 N ml 6 CONNECT TIE RODENDTO STEERING KNUCKLE Torquethe nut and secureit with a new cotter pin Torque 6O0kg cm 43 ft lb 59 N m i i tr b W Vi i i TOROUEBEAfriG LOCKNUT AND INSTALLLOCK NUT CAP AND COTTER IN a Torqrlethe locknutwtriledepiUs s lng the brakepedal Torque 1 900 kg cm 137ft lb f86 N m b Install the locknutcapaffittsing plieib install a new 7 cott pin 8 CHECKFRONTWH...

Страница 493: ...ITi b T mi Tishtening torque O Non reusable part DiscBrakeCaliper 1 900 137 186 LowerArm t 1 REMOVE STEERING KNUCKE AND AXLEHUBWITHOUTDISCONNECTING LOWERARM Seestep 1 to 6 and8 on pageFA 81 2 REMOVE FRONTDRIVESHAFT a Removethe stiffenerplatefrom the transaxleas semblyand engine leftsideonly b UsingSST anda hammer tap out the front drive shaft ssr 09648 16010 k ...

Страница 494: ...AFT a Check to see that therejS po play in the outboard joint b Checkto seethat inboardjoint slidessmoothlyin the thrust direction c Checkto seethat there is no remarkable play in the radialdirectionof the inboardjoint d Checkfor damageto the boot 3 DISASSEMBLEBOOTCLAMPS COMPONENTS DynamicDamper LHShaft Only L lt t f ft DriveShaft withOutboard Joint O Non reusable part InboardJoint Shaft Tripod Bo...

Страница 495: ...singa punchandhammerplacematchmarks onthe shaft and tripod d Uniformilytap to removethe tripod joint from the driveshaft CAUTION Do not tap on the roller 6 REMOVEFOLLOWINGPARTS a Removethe boot from the driveshaft b Removethe clamp and dynamicdamper LH shaft only i l_ n r n c Removethe two boot clampsfrom the boot of the outboardjoint d Removethe boot from the outboardjoint CAUTION Do not remove t...

Страница 496: ...ngthe boot INSTALLDYNAMIC DAMPERAND CLAMP LH SHAFTonlyl PROVISIONALLY INSTALLBOOTAND CLAMP ForINBOARDJOINTITO DRIVESHAFT ASSEMBLEBOOTCLAMPSONTODRIVESHAFT ASSEMBLETRIPODJOINT a Place the beveledside of the tripod axial spline toward the outboardjoint b Align the matchmarksplacedbeforedisassembly When replacingthe inboardjoint first align the centerof the inboardjoint and outboardjoint Usinga brassb...

Страница 497: ...EINBOARDJOINT TO DRIVESHAFT a Packin 140 g 0 3lb 1 4 N of grease Amount Joint side 90 g 0 2 lOl Boot side 50 g 0 1 lul NOTE Usethe greasesuppliedin the boot kit b Align the matchmarksplacedbeforedisassembly c lnstallthe inboardjoint shaft to the driveshaft d lnstall lF Uoo to the inboardjoint shaft 9 ASSEMBLEBOOTSCLAMP TO BOTHBOOTS d Be surethe boot is on the shaft groove b Installa new 4amp on th...

Страница 498: ...lnstallthe driveshaft by tappingon the SST ssT 09648 16010 NOTE Whether or not the drive shaft is contactingthe pinionshaft can be know by its soundor feel when tap pingit in INSTALLSTIFFENER PLATE lnstallthe three bolts holdingthe stiffener plate to the engineandtransaxle Torquethe bolts Torque 400 kg cm 29 ft lb 39 N m INSTALLSTEERING KNUCKEAND AXLE HUB Seestep 2 to 7 on page FA l1 and 12 4 CHEC...

Страница 499: ... 1 DISCONNECT STEERING KNUCKLEFROMSHOCK ABSORBER Seestep 6 on page FA 81 2 REMOVE SHOCK ABSORBERASSEMBLY FROM BODY ii d Removethedust coverfrom the suspqnsion support b Loosenthe nut Do not removethe nut yH Dust Cover o g ZA r a A F Suspension Support Ef Dust Seat sprinsseat W Tighteningtorque Non reusable part CoilSpring ft lb N m ...

Страница 500: ...with cloth to avoid damage 3 CLAMPSHOCKABSORBER IN VISE Installa bolt andnutsto the bracketat the lowerportionof the shockabsorber shelland secureit in a vise 4 REMOVECOILSPRING d UsingSST compress the coil spring ssr 09727 22032 b Hold the suspension with a screwdriveror such so that it will not turn andthenremovethe supportnut c Removethe suspension support springseat spring and dust cover tr W ...

Страница 501: ... OF FRONT SHOCKABSORBER ASSEMBLY Seepage FA l91 1 INSTALLBUMPER COILSPRING INSULATOR SPRINGSEATAND DUSTSEAL d Mountthe shockabsorber in a vise b lnstallthe bumberto the pistonrod c UsingSST compress the coil spring ssT 09727 22032 d Alignthe coil springendwith the lowerseathollow andinstall d Alignthe springseatwith the pistonrod andinstall fl lnstallthe dustsealon the springseat g Install thesusp...

Страница 502: ...TEERING KNUCKTE TOSHOCK ABSORBER Seestep4 on pageFA l1 4 TOROUE SUSPENSIO T SUPPORT NUT Torque 500 kg cm 36ft b 49 N ml 5 INSTALLDUSTCOVER Pack the bearingin the suspension support with MP grease Installthe dust cover 4 r y 6 c H E c K C A M B E R S e e p a g e F A s l l t b r ...

Страница 503: ...ck up the tront of the vehicleandplacea wooden blockwith a heightof 18O 2OOmm 7 09 7 87 in underonefront tire d Lowerthe jack untilthereis abouthalf a loadon the front coil springs Placestandsunderthe vehiclefor safety c Makesurethe front wheelsare in a straightforward positionand blockthem with chocks d Movethe lowerarm up anddown andcheckthat the balljoint hasno excessive play Maximum balljoint ...

Страница 504: ...ball ioint LowerArm Seepage FA 23 REMOVAL OFLOWER ARM 1 DISCONNECT LOWERARM TO STEERING KNUCKLE Removethe two boltsholdingthe balljointto the steering knuckle 2 DISCONNECT STABILIZER BAR ENDTO LOWER ARM Removethe stabilizerbar nut retainerandcushion 3 REMOVELOWERARM a Jack up the oppositewheel until the vehiclebody lifts off the stands b Loosenthe lowerarmbolt prythe lowerarmandpull out the bolt d...

Страница 505: ... Bend the remainingportions inward with a cold chisel CAUTION Be careful not to damagethe flange c Bendin the flangetips andpulloff the flangewith a pair of pliers d UsingSSTanda press pressout the bushing ssT 09726 32010 INSTALLLOWERARM BUSHING UsingSST and a press pressthe bushinginto the arm ssr 09726 32010 CAUTION Do not allow greaseor oil to get on the bushing 2 ...

Страница 506: ...g cm 58 ft lb 78 N m 2 INSTALLSPACER RETAINER CUSHIONAND COLLAR 3 CONNECT LOWERARM TO BODY d Passthe lowerarm throughthe stabilizerbar b Connectthe lower arm with the bolt Do not torque the bolt yet c lnstallthe stabilizer barwith the cushion washerand a new nut Do not torquethe nut Yet 4 CONNECT LOWERARM TO STEERING KNUCKLE a Lowerthe stabalizer barandconnectthe balljointto steeringknucklewith th...

Страница 507: ...e the suspension 6 TOROUENUT HOLDINGSTABILIZER BARTO LOWERARM i Torque 1 O75kg cm 78 ft lb lOb N m r t 7 TOROUEBOLTHOLDINGLOWERARM TO BODY Torque 1 150kg cm 83 ft tb 113 N ml 8 CHECKFRONTWHEELALIGNMENT Seepase FA 31 o t StabifizerBar Seepage FA 231 REMOVALOFSTABILIZER BAR 1 REMOVE ENGINE UNDERCOVER 2 REMOVEBOTHSTABILIZER BAR BRACKETS FROMCROSSMEMBER r ti q ...

Страница 508: ...ainer rubber and collar as shown in the figure b Fingertighten a new stabilizerbar nut 2 INSTALL BRACKETTOGETHERWITH STABILIZER BAR Pry the barforward and installthe brackets Torquethe bolts Torque rt4o kg cm 32 ft lb 43 N ml 3 TOROUENUT HOLDINGSTABILIZER BARTO LOWER ARM Torque 1 O75kg cm 78 ft lb 105 N ml NOTE Bouncethe vehicleto stabilizethe suspension beforetorquingthe stabilizerbar nut 4 INSTA...

Страница 509: ... RearShock Absorber SuspensionArm Strut Rod 4wD TROUBLESHOOTING REARAXLE SHAFT DIFFERENTIAL FOURLINK TYPEREARSUSPENSION Coil Springand RearShockAbsorber Lateral Control Rod Upper and Lower Control Arm RearStabilizerBar Page RA 2 RA 3 RA 5 RA 5 RA l2 RA l6 RA l7 RA 20 RA 23 RA 24 RA 25 RA 28 RA 42 RA 43 RA 46 RA 48 RA s1 ...

Страница 510: ...ace wheelbearing Tightenor replacesuspension parts RA 3 RA 3 RA 5 RA 12 RA s 17 Bottoming Vehicleoverloaded Shockabsorber worn out Springweak Checkloading Replace shockabsorber Replace spring RA 17 RA 17 Sways pitches Tires improperlyinflated Shockabsorber worn out Inflatetires to proper pressure Replace shockabsorber RA 3 RA 17 Abnormal tire wear Tiresimproperly inflated Shock absorberworn out Al...

Страница 511: ...ment manufacturer INSPECT CAMBER Inspection standard 5 t 3O Sedanl 10 t 3O Wagonl Left right error 30 lf not within specification inspect and replace any damagedor worn rearsuspension parts ADJUSTTOE IN a Measurethe distancebetweeneachwheeldisc and cam bolt centerof the suspensionarm and check that both arethe same Left right error 3 mm 0 12 in or less b Movethe vehicleforwarda few meterswith the ...

Страница 512: ...spection STD 0 1 mm 0 O O4in f lf not within specification turn the left andrighttoe in adjustingcamsan equalamountto adjust NOTE Thetoe inwillchangeabout2 mm 0 08in with eachgraduation of the cam oneside 6 CHECKSIDESIIP WITH SIDESLIPTESTER Side slip 3 0 mm m 0 118in 3 3ftl or less lf the sideslip is not withinspecification the toe inmay not be correct ...

Страница 513: ...tthe body with stands 2 REMOVEAXLE HUB a Removethe cap cotter pin nut lock and nut b Removethe axlehubtogetherwith the outerbearing andthrust washer No 1 Suspension Arm No 2 Suspension Arm BrakeTube Axle Hub withDrum outer Bearins a u o W I Y Y q ll outernale t ld Outer Bearing a CoiterPin ThruitWasher OuterRace lnnerBearing lkg cm ft lb N m l Tightening torque O Non reusable part ...

Страница 514: ... REMOVEAXLE SHAFT Removethe bolts holdingthe axleshaftto the carrier and removethe axleshaft and rearbrakeassembly 5 REMOVEAXLE CARRIER d Removethe bolt and nut holdingthe axle carrierto the strut rod b Removethe bolt and nut holdingthe axle carrierto the No 1 suspension arm d Removethe bolt and nut holdingthe axle carrierto the No 2 suspension arm ...

Страница 515: ...T OFWHEELBEARINGS 1 REMOVE INNERBEARING AND OILSEAL a Usinga screwdriver pry out the oil seal b Remove the innerbearingfrom the disc 2 REMOVEBEARING OUTERRACES UsingSST pressout the bearingraces SST09608 16010 and09608 20011 3 INSTALLBEARING OUTERRACES UsingSST carefully pressin new bearingraces SST09608 16010and09608 20011 4 FILLINSIDEOFAXLEHUB AND CAPWITH MP GREASE L ...

Страница 516: ...MP greaseto the oil seal INSTALLATION OF REARAXLE HUBAND CARRIER Seepage RA 51 1 INSTALLAXLE CARRIER a Placethe axlecarrierin position b Installthe two boltsandnuts holdingthe axlecarrier to the shock absorber Torquethe nuts Torque 1 450 kg cm 105 ft lb 142 N m c Provisionally installthe bolt andnut holdingthe axle carrierto the No 2suspension arm NOTE Besurethe lip of the nut is restingon the fla...

Страница 517: ...lnstallthe axle shaft and rear brakeassemblywith four bolts Torquethe bolts Torque 820 kg cm 59 ft lb 80 N ml 3 CONNECTBRAKETUBETO WHEELCYLINDER ssr 09751 3601 1 Torque 155 kg cm 11 ft lb 15 N m 4 INSTALLAXLE HUB ON SPINDLE a Placethe axle hub and outer bearingon the axle shaft b Fill in MP grease between the outer bearingand thrust washer d lnstallthe thrustwasher 5 ADJUST PRELOAD a Installandtor...

Страница 518: ...of the oil seal Oil sealfrictionalforce Approx rtoog 0 9 lb 3 9 Nl e Tightenthe nut untilthe preloadis withinspecifica tion Bearingpreload while turning In addition to oil seal frictional force 400 1 000g 0 9 2 2 tb 3 9 9 8 Nl fl Insurethat the drum rotatessmoothly 6 INSTALL NUT LOCK COTTERPIN AND CAP NOTE lf the cotter pin holedoesnot lineup correctby tighteningthe nut the smallestamountpossible ...

Страница 519: ... FWD RA l1 8 TOROUE AXLE CARRIER MOUNT BOLTS a Removethe standsandbouncethe vehicleto stabil izethe suspension b Torquethe mount bolts with the vehicleweight on the suspension Torque 89O kg cm 64 ft lb 87 N ml 9 CHECKREARWHEELALIGNMENT Seepage RA 3 ...

Страница 520: ..._ No 1 Suspension I Arm I I Bearing Inner I Race lnside StrutRod RearAxle Carrier I fr 0 1rol I I AxleHub Bearing t lb N m l Tightening torque O Non reusable part BrakeDrum Measuring Point REMOVAL OFREAR AXLEHUBANDCARRIER 1 REMOVE BRAKEDRUM 2 CHECKBEARINGPLAY IN AXIAL DIRECTION Limit O O5mm O OO2O in l ...

Страница 521: ...b and brake assembly b Removethe O ring 5 REMOVEREARAXLE CARRIER Seepages RA 6 and 7l REPLACEMENT OF REARAXLE HUBAND WHEELBEARING Seepage RA 121 1 REMOVE NUT d Usinga chiseland hammer unstake the nut b Removethe nut 2 REMOVE AXLESHAFTFROMAXLEHUB UsingSST pushthe axleshaftoff the axlehub ssT 09950 2001 5 3 REMOVEBEARINGINNERRACE INSIDEI 4 REMOVE BEARING INNERRACE OUTSIDE UsingSST pulloff the bearin...

Страница 522: ...LLBEARING NOTE Alwaysreplace the bearingasan assembly a ApplyMP greasearoundthe bearing outerrace b UsingSST press a new bearinginto the bearing case ssr 09316 6001 0 8 INSTALLOIL SEAL a UsingSST drivean oil sealintothe axlehub ssT o9310 3501 0 b ApplyMP greasebetweenthe oil seallip 9 INSTALL AXLE SHAFT d Installthe bearingboth side innerrace b UsingSST pressthe innerraceinto the axleshaft SST0922...

Страница 523: ...9l 2 INSTATLREARAXLE HUB a Installa newO ringto the axlecarrier b lnstallthe axlehubandrearbrakeassembly with the four bolts Torquethe bolts Torque 820 kg cm 59 ft tb 80 N ml 3 CONNECT BRAKETUBETO WHEELCYLINDER ssT 09751 36011 Torque 155 kg cm t 1 ft lb 15 N m 4 INSTALLBRAKEDRUM 5 FILLBRAKERESERVOIR WITH BRAKEFLUIDAND BLEEDBRAKESYSTEM Seepage BR 7 6 TOROUE AXLE CARRIER MOUNT BOLTS SeepageRA 111 7 ...

Страница 524: ...ustCover a supportNut suspension support s V upper Insurator CoilSpring 2 117 241 F spring Bumper v Lowerrnsurator Shock Absorber Assembly 1 45 01105 1421 Brake Drum andAxle Carrier Assembly No 2 Suspension Arm No 1 Bashing No 1 Suspension Arm N ml Tighteningtorque O Non reusable part ...

Страница 525: ...etubefrom the flexible hose ssT 09751 36011 3 DISCONNECT FLEXIBLE HOSEFROMSHOCK ABSORBER 4 LOOSENNUT HOLDINGSUSPENSION SUPPORT TO SHOCKABSORBER h Remove thedustcoverfromthe suspension support b Loosen the nut Do not removethe nut yet 5 DISCONNECT SHOCKABSORBER FROMAXLE CARRIER Removethe boltsandnuts holdingthe shockabsorberto the axlecarrierand disconnectthe absorber 6 REMOVESHOCKABSORBER FROMBODY...

Страница 526: ...disassemble the shockabsorber because the cylinderis filledwith gas b lf you replace a shockabsorber drilla 2 0 3 0 mm 0 079 0 118 in holein the bottomof the rep lacedshockabsorber s cylinder to completely release the highpressure gas ffhe gasis colorless odorless and not poisonous However when drilling chips mayfly out so work carefully c Handle the shockabsorber carefully Neverscoreor scratchthe...

Страница 527: ... insulator hollowandinstallthe coil spring e lnstallthe springbumperand insulator f Alignthe suspension supportlowerseathollowand lowerinsulater hollow g Alignthesuspension supportwith the pistonrodand install h Alignthe suspension supportwith the shockabsor ber lower bracketas shown i Provisionally installa new nut 2 CONNECT SHOCKABSORBER TO BODY Connectthe shockabsorber with threenuts Torquethe ...

Страница 528: ...EDBRAKESYSTEM SeepageBR 7 8 CHECKREARWHEELALIGNMENT SeepageRA 3 9 INSTALL PACKAGE TRAY BRACKET AND SHOCK ABSORBER Suspension Arm Seepage RA l6 REMOVALOF SUSPENSION ARM 1 JACK UPVEHICLE Jack up the vehicleand supportthe body with stands 2 REMOVENO 2SUSPENSION ARM a Removethe bolt andnut holdingthe suspension arm to the axlecarrier b Removethe cam and bolt holding the suspension arm to the body and ...

Страница 529: ...LACEMENT OF NO l BUSHING 1 REMOVE BUSHING UsingSST pressout the bushing ssT 09726 32010 2 INSTALLBUSHING UsingSST pressin a new bushing ssr 09726 32010 CAUTION Do not use a lubricantwhen pressingin the bushing INSTALLATION OF SUSPENSION ARM 1 INSTALLNO l SUSPENSION ARM a Connectthe suspensionarm to the body with the bolt and nut Do not torquethe bolt yet NOTE Besurethe lip of the nut is restingon ...

Страница 530: ...arm to the body Do not torquethe bolt yet c Align the cam platemarkat the samepositionit was beforeremoval d Install theboltandnutholdingthesuspension armto the axlecarrier Do not torquethe bolt yet NOTE Besurethe lip of the nut is restingon the flange of the suspension arm not over it 3 TOROUESUSPENSION ARM SETTINGBOLTS a Removethe standsand bouncethe vehicleto stabi lizethe suspension d Torqueth...

Страница 531: ...rut rod to the body with the bolt and nut Do not torquethe bolt yet NOTE Besurethe lip of the nut is restingon the flange of the bracket b Connect thestrutrodto the axlecarrier with the bolt andnut Do not torquethe bolt yet NOTE When connecting the strut rod alignthe lip of the nut with the grooveon the bracket 2 TOROUESTRUTRODSETTINGBOLTS a Removethe standsandbouncethe vehicleto stabil izethe sus...

Страница 532: ...eor damaged Drainand replaceoil Replace oil seal Tightenor replaceflange RA 28 RA 28 Noisein rearaxle Oil levellow or wrong grade Excessive backlashbetweendrivepinion and ringor sidegear Ring drivepinionor sidegearsworn or chipped Drivepinionbearingworn Axle shaft bearingworn Side bearinglooseor worn Drainand replaceoil Checkbacklash Checkgears Replacebearing Replacebearing Tightenor replacebearin...

Страница 533: ...t YV dmi r oEnd Gasket WBearins outerRetainer ORetainer Casret I lnner Retainerl REARAXLE SHAFT 4WD COMPONENTS REMOVALOF REARAXLE SHAFT 1 REMOVE WHEEL ANDBRAKE DRUM 2 REMOVE FOUR BACKING PLATE MOUNTING NUTS REMOVEREARAXLE UsingSST pullout the rearaxle ssr 09520 ooo31 CAUTION When pulling out the rearaxle be careful not to damagethe oil seal ...

Страница 534: ...BEARING FOR WEAR OR DAMAGE lf the bearingis damagedor worn replaceit REMOVEBEARINGINNERRETAINER a Usinga grinder grinddown the innerretainer b Usinga chiseland hammet cut off the retainer and removeit from the shaft REMOVEBEARINGFROMSHAFT UsingSST pressthe bearing off the shaft ssT 09527 2001 1 INSTALL BEARING OUTER RETAINERAND NEW BEARING ON SHAFT UsingSST presson the bearingouterretainer and new...

Страница 535: ... AXLE HOUSING d Apply MP greaseto the oil seal b UsingSST driveinthe oil sealto a depthof 5 6 mm 0 220ini ssr 0951 7 12010 INSTALLATION OF REARAXLE SHAFT Seepage RA 25 1 APPIY LIOUIDSEALEAR TO BOTHSIDESOF ENDAND RETAINER GASKETS 2 PLACENEW ENDAND RETAINER GASKETSIN POSTTtON Facethe notch of the gasketdownward 3 INSTALLREARAXLE SHAFTIN HOUSING a Facethe notch of the retainerdownward b Installthe re...

Страница 536: ...A 28 REARAXLE AND SUSPENSTON Differentiat 4WD DIFFERENTIAL 4WD COMPONENTS Pinion Shaft I ffi 6 Pinion Gear Differential Case Oil Slinger rb N m l Tightening torque O Non reusable part DifferentialCarrier ...

Страница 537: ...SLINGER AND NEW OIL SEAL a lnstall the oil singer facingas shown b UsingSST drivein a new oil sealas shown ssr 09554 3001 1 Oil seal drive in depth 1 0 mm 0 039in l c ApplyMP greaseto the oil seallip 7 INSTALLCOMPANION FLANGE Seestep 11 on pageRA 39 8 ADJUSTDRIVEPINION Seestep 12 on pageRA 4OI 9 STAKEDRIVEPINIONNUT 10 CONNECT PROPELLER SHAFTFLANGE TO COMPANIONFLANGE Seepage PR 6 11 CHECKDIFFERENTI...

Страница 538: ...LASH Backlash 0 10 0 15 mm O OO39 O OO59 in lf the backlash is not withinspecification adjustthe side bearingpreloador repairas necessary Seestep 5 on pageRA 36 3 INSPECTTOOTH CONTACTBETWEENRING GEAR AND DRIVEPINION Seestep 6 on pageRA 38 Notethe tooth contactingposition 4 CHECKSIDEGEARBACKLASH Measure the sidegearbacklash while holdingone pinion geartoward the case Standardbacklash O OZ 0 15 mm 0...

Страница 539: ...sealfrom the housing ssr 09308 10010 b Remove the oil slinger 9 REMOVE FRONTBEARING AND BEARING SPACER a UsingSST removethe front bearing from the drive pinion ssT 09556 12010 b Remove the bearing spacer lf the front bearing is damaged or worn replace the bear ing 10 REMOVEDIFFERENTIAL CASEFROMCARRIER d Put matchmarks on the bearingcap and differential carrier b Removethe two adjustingnut locks c ...

Страница 540: ...EARBEARINGRACE a UsingSSTanda press pullout the rearbearingfrom the drivepinion ssT09950 00020 b Installthe resuedthrustwasheron the drivepinion with the chamfered endfacingthe piniongear c UsingSSTanda press pressa new rearbearingon the drivepinion ssT 09608 12010 REPLACE DRIVEPINIONFRONT AND REARBEARING OUTERRACES a Usinga brassbar and hammer tap out the outer race b UsingSSTanda press drivein a...

Страница 541: ... 2001 1 4 INSPECT SIDEGEARBACKLASH Measure the sidegearbacklash whileholdingthe other sidegeartowardthe case Standardbacklash 0 02 0 15 mm 0 0008 0 0059in 5 IF NECESSARY REPLACE RINGGEAR SIDEGEARS AND PINION GEARS NOTE o lf the ringgearis to be usedagain placematchmarks beforeseparating it o lf the ring gear or drive pinionare damaged replace them as a set a Lift the lock platesandremovethe mountb...

Страница 542: ... O O2 0 15 mm 0 0008 O OO59 in g lf the backlash is not withinspecification usethrust washerof a differentthickness Thrustwasherthickness mm in 1 50 0 0591 r 65 0 0650 1 s5 0 061 0 t 70 0 0669 1 60 0 0630 r 75 0 0689 h Usinga pin punchand hammer tap a new straight pinthroughthe caseandholein the pinionshaft i Stakethe pin anddifferential case j Cleanthe contactsurfaceof the differential case 0 Gra...

Страница 543: ...takeoneclawflushwith the flat surfaceof the nut Forthe clawcontactingthe protrudingportionof the nut stake bend only the half on the tighteningside ASSEMBLY OFDIFFERENTIAL Seepage RA 28 1 TEMPORARILY ADJUSTDRIVEPINIONPRELOAD a lnstallthe followingparts o Drivepinion o Frontbearing NOTE Assemble the spacer oil slingerandoil sealafter adjusting the gearcontactpattern b UsingSST install the companion...

Страница 544: ...spective carrier mak ing surethey arethreadedproperly NOTE Makesurethat thereis backlash betweenthe ring gearanddrivepinion 4 INSTALLBEARING CAPS Alignthe matcfimarks on the capandcarrier Screwin the two bearingcap boltstwo or threeturnsand pressdown the bearingcap by hand NOTE lf the bearing capdoesnot fit tightlyon the car rier the adjustingnut threadsare not threadedproperly Reinstall adjusting...

Страница 545: ...he sidebearingfor zeropreloadby tightening the otheradjustingnutuntilthe pointeron the indica tor beginsto move g Tightenthe adjustingnut 1 1llznotchesfrom the zeropreloadposition h Usinga dialindicator adjustthe ringgearbacklash untilit is withinspecification Backlash 0 10 0 15 mm O OO39 O OO59 in l NOTE The backlashis adjustedby turningthe left and right adjustingnutsequalamounts For example loo...

Страница 546: ... O 15mm 0 0039 0 O059in 6 INSPECTTOOTH CONTACT BETWEEN RING GEAR AND DRIVEPINION a Coatred leadon 3 or 4 teethat threedifferentposi tions of the ring gear b Holdthe companionflangefirmly androtatethe ring gearin both directions d lnspectthe tooth pattern HeelContact FaceContact Selecta thrustwasherthat wiltbrinqthe drivepinioncloserto the ring gear rfl Selecta thrustwasherthat will shiftthe drivep...

Страница 547: ...ron the shaft b lnstallthe front bearing on the shaft 10 INSTALLOILSLINGER AND NEW OILSEAL d Installthe oil slingerfacingas shown b UsingSST drivein a new oil sealas shown ssT 09517 12010 Oil seal drive in depth 1 0 mm 0 039 in d Apply MP greaseto the oil seallip 11 INSTALL COMPANION FLANGE a UsingSST installthe companion flange ssr 09557 22022 7 8 9 Drive in depth Drivepinionthrustwasherthickness...

Страница 548: ... Reusedbearing 4 7 kg cm 3 5 6 1 in lbl 0 4 0 7 N ml lf preloadis exceeds specification replace the bear ing spacer lf preloadis lessthan specification retightenthe nut 130 kg cm 9 ft lb 13 N m at a time until the specifiedpreloadis reached lf the maximumtorqueis exceeded while retightening the nut replacethebearingspacerandrepeatthepreloadpro cedure Do not back off the pinion nut to reduce the pr...

Страница 549: ...Install a newgasketandthedifferentialcarrier assembly in the axleand installthe twelvenuts Torquethe nuts Torque 315 kg cm 23 ft lb 31 N m 2 CONNECT PROPELLER SHAFTFLANGETO COMPANIONFLANGE Seepage PR 61 3 INSTALLREARPLUGAND FILLDIFFERENTIAL WITH GEAROIL Torquethe drainplug Torque 500 kg cm 36 ft b 49 N m Oil grade API GL s hypoidgear oil Viscosity Above 18 C O Fl SAE 90 Below 18 C 0 F SAE 8OW or 8...

Страница 550: ... lrol ffi Upperlnsutator sH9 I d g LateralControl Rod l l 650t 54l_l T l l n o o o A _ 9 a r f f I r zoo raz nat I a g I uooe Control Arm o t r 1 1 a 0 n Lower tnrut tor D aia I i v i o wr i b g e t 6 E i u W t e q ShockAbsorber a n v e e F v u r a i a a LowerControlArm lb N m l Tighteningtorque Rear StabilizerBar ...

Страница 551: ...MOVEREARSHOCKABSORBER a Removethe bolt holdingthe shock absorberto the rearaxlehousinganddisconnectthe shockabsorber d Removethe nuts holdingthe shockabsorberto the body and removethe shockabsorber 3 REMOVESTABILIZER BAR BUSHINGBRACKETS Removethe boltsholdingthe stabilizerbarbushingto the rearaxlehousing 4 DISCONNECTLATERALCONTROLROD FROM REAR AXLE HOUSING Removethe nut holdingthe lateralcontrolro...

Страница 552: ...g the rearaxlehousing removethe coil springandthe upperandlowerinsulators INSTALLATION OFCOILSPRING AND SHOCKABSORBER 1 PUTLOWERINSULATOR ON AXLE HOUSING 2 PUTUPPER INSULATOR ON COILSPRING 3 INSTALLCOILSPRING 4 CHECKPOSITION OF LOWERINSULATOR a Jackup the rearaxlehousing b Checkthat the lowerinsulator is installed correctly lf the insulator is not in correctposition reinstall the coilspring ...

Страница 553: ...e nut yet 6 INSTALLSHOCKABSORBER b Connect theshockabsorber to thebodywiththenut Holdtheshaftwith anadjustable wrench Torquethe nut Torque 250 kg cm 18 ft lb 25 N m b Connectthe shockabsorberto the rearaxlehousing with the nut Torquethe bolt Torque 375 kg cm 27 ft b 37 N ml 7 INSTALLSTABILIZER BAR BUSHINGBRACKETS TO REARAXLE 8 STABILIZESUSPENSION Removethe standsand bouncethe car to stabilizethe s...

Страница 554: ...portit with stands 2 DISCONNECTLATERALCONTROLRODFROM REAR AXLE HOUSING Removethe nut holdingthe lateralcontrolrod to the rear axle housing and disconnectthe lateralcontrolrod 3 DISCONNECT LATERALCONTROLRODFROM BODY Removethe nut holdingthe lateralcontrolrodto the body and removethe lateralcontrolrod REPLACEMENT OF LATERALCONTROL ROD BUSHING 1 REMOVE BUSHING UsingSST pressout the bushingfrom the la...

Страница 555: ...hebush ing INSTALLATIONOF LATERALCONTROLROD 1 INSTALL LATERALCONTROLRODTO BODY a Raisethe axlehousinguntilthe housingis free from the stands b Installthelateralcontrol rodto the bodywith the nut INSTALL LATERAL CONTROLROD TO REAR AXLE HOUSING d Consecutively installthe washer bushing spacer lateralcontrolarm bushing washerand nut on the rearaxlehousing b Removethe standsand bouncethe car to stabil...

Страница 556: ...Arm SeepageRA 421 REMOVAL OFUPPER ANDLOWER CONTROL ARM 1 JACK UP VEHICLE Jack up the vehicleand supportthe body with stands Holdthe rearaxle housingwith a jack 2 REMOVEUPPERCONTROLARM a Removethe bolt holdingthe uppercontrolarmto the body b Remove thebolt holdingthe uppercontrolarmto the rearaxlehousing thenremove the uppercontrolarm 3 REMOVELOWERCONTROLARM a Removethe bolt holdingthe lower contro...

Страница 557: ...PER CONTROL ARM a lnstallthe uppercontrol arm on the body with the bolt andnut Do not tightenthe nut yet b Install the uppercontrolarmon the rearaxlehousing with the bolt and nut Do not tightenthe nut yet 2 INSTALLLOWERCONTROL ARM a lnstallthe Iowercontrolarm on the body with the bolt and nut Do not tightenthe nut yet b lnstallthe lowercontrolarmon the rearaxlehousing with the bolt andnut Do not t...

Страница 558: ...tands 5 TIGHTENBOIT HOLDINGUPPER CONTROL ARM TO BODY Torquethe bolt Torque 1 2OO kg cm 87 ft lb 118 N ml 6 TIGHTENBOLTHOLDINGUPPER CONTROT ARM TO REARAXLE HOUSING Torquethe bolt Torque 1 2OO kg cm 87 ft lb 118 N ml 7 TIGHTENBOLTHOLDINGLOWERCONTROL ARM TO BODY Torquethe bolt Torque 1 2OOkg cm 87 ft lb 118 N ml 8 TIGHTENBOLTHOLDINGLOWERCONTROL ARM TO REARAXIE HOUSING Torquethe bolt Torque 1 2OOkg cm...

Страница 559: ... FROMBODY 3 DISCONNECT STABILIZER BAR END FROMLINK INSTALLATION OF REARSTABILIZER BAR 1 INSTATLSTABILIZER LINK TO BODY Installthe linkonto the bodyas shown 2 INSTALLSTABILIZER BARTO LINK Connectthe stabilizer baron both sidesto the linkswith bolts collars cushions nut and new cotter pins Torque 310 kg cm 22 ft b 30 N ml 3 INSTALLBRACKETS TO REARAXLE HOUSING Torque 375 kg cm 127ft 1b 37 N m ...

Страница 560: ...EM PRECAUTIONS TROUBLESHOOTING CHECKSAND ADJUSTMENTS MASTERCYLINDER BRAKEBOOSTER FRONTBRAKE REARBRAKE Sedan Wagon FWD Wagon 4WD BRAKEHOSESAND TUBES Page BR 2 BR 2 BR 6 BR 9 8R 14 8R 16 B R 22 BR 22 8R 29 8R 36 8R 43 ...

Страница 561: ...ted Liningcrackedor distorted Wheelcylinderor caliperpistonsticking Automatic adjusterbroken Mastercylinderfaulty Adjust parkingbrake Repairas necessary Adjustpushrod Replace spring Repairas necessary Replace brakeshoe Repairas necessary Replace adjuster Repairor replacemastercylinder BR 8 BR 1 5 BR 22 BR 22 BR 18 22 BR 22 BR 9 Brakespull Tires improperlyinflated Oil or greaseon linings Brakeshoes...

Страница 562: ...lt Discbrakes wearon slidebushing Lubricate Replace and lubricateledges Replace E Tisnteffit Inspect lubricate replaceif necessary Replace Tighten Replace BR 22 BR 22 BR 22 BR 22 BR 1 6 BR 1 6 BR 1 6 BR 1 6 Scrapingor grinding noisewhen brakes areapplied Worn brakelinings Caliperto wheel or rotor interference Dust coverto rotor or drum interference other brakesystemcomponents Warpedor bentbrakebac...

Страница 563: ...ncorrectshoe hold down springs loose or damagedshoeholddown springpins springsand groovedbackingplate ledges Inspect serviceor repalce Replace Cleanor deburr Cleanor replace Inspectfor conect usage replace lnspectand adjust Inspect serviceor replace BR 16 22 BR l6 BR 1 8 BR 16 22 BR t6 22 BR 6 15 8R 22 Squealing and squeaking noise when brakesare not applied Bentor warpedbackingplatecausing interf...

Страница 564: ... 22 BR l6 BR l6 BR 16 Groaning clicking or rattling noise when brakesare not applied Stonesor foreignmaterialtrapped insidewheelcovers Loosewheel hub nuts Discbrakes failureof shim Discbrakes wearon slidebushing Discbrakes looseinstallation bolt Maladjustment of brakepedalor boosterpush rod Disc brakes poor return of piston Drumbrakes looseor extraparts Worn damagedor dry wheelbearings Removestone...

Страница 565: ... brakepedalseveral times until there is no more vacuum left in the booster b Pushin the pedaluntil the beginningof resistance is felt Measurethe distance as shown Pedaffreepfay 3 6 mm 0 12 O 24in l NOTE The pedalfreeplayis the amountof the stroke untilthe boosterairvalveis movedby the pedalpushrod IF NECESSARY ADJUST PEDALFREEPLAY a lf incorrect adiustthe pedalfreeplayby turningthe pedalPushrod b ...

Страница 566: ...pedaldepressed lf there is no changein pedalreserve travelafter holdingthe pedal for thirty seconds the boosteris air tight BLEEDING OFBRAKE SYSTEM NOTE lf anywork isdoneon the brakesystemor if airis suspectedin the brakelines bleedthe systemof air CAUTION Do not let brake fluid remain on a painted surface Wash it off immediataly 1 FILL BRAKERESERVOIRS WITH BRAKEFLUID Checkthe reservoir afterbleed...

Страница 567: ... brake lever travel at 2O kg 44 1 lb 196 Nl Sedan 5 Sclicks Wagon 6 Sclicks 2 IF NECESSARY ADJUST PARKINGBRAKE NOTE Before adjustingthe parking brake make sure that the rearbrakeshoeclearance has beenadjusted Forshoeclearance adjustment seepagesBR 28 35 and 42 a Remove theconsole box d Loosen the locknutandturnthe adjusting nutuntil thetravelis correct d Tightenthelocknutandinstalltheconsole box r...

Страница 568: ...ngtorque GAUTION Do not let brakefluid remainon a painted surface Wash it off immediatoly 1 TAKEOUTFLUIDWITH SYRINGE 2 DISCONNECT BRAKETUBES j Usin SST disconnectthe braketubesfrom tfie master cylinderand3 wayunion ssT 09751 3601 1 3 REMOVEMASTERCYLINDER d Disconnect the brakefluid levelwarningswitch con nector b Removethe two nuts c Remove themastercylinder 3 wayunionandgasket from the brakeboost...

Страница 569: ... I rootz rot I e r l ft rb N O Non reusable part PistonStopperBolt Tighteningtorque O Gasket DISASSEMBLY OF MASTERCYLINDER 1 REMOVERESERVOIR FROMCYLINDERHOUSING a Removethe cap and strainer d Removethe set screw c Pullout the reservoir 2 MOUNTCYLINDER HOUSING IN VISE 3 REMOVETWO GROMMETSFROMCYLINDER HOUSING 4 REMOVEPISTONSTOPPER BOLT Usinga screwdriver push the pistonsin all the way and removethe ...

Страница 570: ...of damaging the cylinderbore ASSEMBLYOF MASTERCYLINDER Seepage BR 10 1 APPLYLITHIUMSOAPBASEGLYCOLGREASE TO RUBBER PARTSINDICATEDBY ARROWS 2 INSTALLTWO SPRINGS AND PISTONS CAUTION Be careful not to damagethe rubber lips on the pistons d lnsertthe springand pistonsstraightin not at an angle b Pushin the pistonand usingsnapring pliers install the snapring INSTALLPISTONSTOPPER BOLT Usinga screwdriver ...

Страница 571: ...r ontothe cylinderandinstallthe screw Torque 10 25 kg cm 19 21 in lb 1 0 2 4 N ml CAUTION Becausethe master cylinder and reser voir tank union is a grommet type the set screw is designednot to separatefrom the reservoiror cylinder and will not tighten down the reservoir Therefore there is a clearanceat point A Do not insert washers or such when tightening 4 5 i ...

Страница 572: ...ORE INSTALLINGMASTERCYLINDER Seepage BR 151 4 INSTALLMASTERCYLINDER Installa newgasket the mastercylinder and3 way union with the two nuts Torquethe nuts Torque 130 kg cm 9 ft lb 13 N ml 5 CONNECTBRAKETUBES UsingSST connectthe braketubesto the mastercyliner and 3 way union Torquethe nuts ssr 09751 3601 1 Torque 155 kg cm 11ft lb 15 N ml 1 6 FILLBRAKERESERVOIR WITH BRAKEFLUID AND BLEEDBRAKESYSTEM S...

Страница 573: ...h Connector BrakeBooster BRAKEBOOSTER 1 REMOVEMASTERCYLINDER SeepageBn gl 2 DISCONNECT VACUUM HOSEFROM BRAKE BOOSTER 3 REMOVEDISTRIBUTOR CAP 4 REPEATPROCEDURE FOREACHWHEEL 5 REMOVEHEATERAIR DUCT 6 DISCONNECT PEDALRETURNSPRINGFROM BRAKEPEDAL 7 DISCONNECT PUSH ROD CLEVIS FROM BRAKE PEDAL Removethe clip and clevispin 8 REMOVEBRAKEBOOSTER Removethe four nuts and pullout the brakebooster ...

Страница 574: ...ST Clearance O mm 0 in l d Adjustthe boosterpushrod lengthuntilthe pushrod lightlytouchesthe pin head 2 INSTALL BRAKEBOOSTER Torque 130 kg cm 9 ft lb 13 N ml 3 INSTALL MASTERCYLINDER Seepage BR 131 4 CONNECTVACUUM HOSETO BRAKEBOOSTER 5 CONNECTPUSHRODCLEVISTO BRAKEPEDAL Installthe clevispin andclip 6 CONNECTPEDALRETURNSPRINGTO PEDAL SPRING INSTALL HEATERAIR DUCT INSTALLLOWERFINISHPANEL INSTALLIIA C...

Страница 575: ...m 0 098in 1 REMOVEFRONTWHEET Rqmovethe wheel and temporarilyfasten the rotdfu disc with the wheelnuts E 2 INSPECT PAD LININGTHICKNESS Checkthe pad thicknessthrough the cylinderinspection holeand replacepadsif not within specification Standard Minimum 1O 0mm 0 394 in l 1 0 mm 0 039 in _ 5s ntzst I FlexibleHose l c o Ja I r fa l 235 117 231 900 165 88 j Torque Plate Leh A H RotorDisc Anti squeal shi...

Страница 576: ...queal springs b Two brakepads d Twoanti squeal shims d Two pad wear indicatorplates e FoUrsupportplates CHECKROTORDISCTHICKNESS See step2 on page BR l91 CHECKROTOR DISCRUNOUT Seestep 3 on page BR 2OI INSTALL NEW PAD SUPPORTPLATES 4 5 6 7 INSTALL NEW PADS a Installnew pad wear indicatorplatesto eachpad NOTE Besurethe arrowon the padwe fiQicator plate is pointingin the rotatingdirectionof thd diiHt_...

Страница 577: ...ylindercarefullyso the dust boot is not wedged t1 d lrfiiprrandtorquethetwo instatlation bolts Torque 255 kg cm 18ft lb 25 N ml tt tNsrArL FRoNr Itr 12 CHECK THATFLUID TEVEL ISAT MAX LINE I iw i REMOVAL OFCYUTNDER Seepage BR l61 1 REMOVE CYLINDER a UsingSST disconnect the brakeline Usea containerto catch the brakefluid ssT 09751 36011 b Rembvethe two installationbolts and cylinder 2 REMOVEPADS See...

Страница 578: ...r REMOVEPISTONSEAL FROMBRAKECYLINDER Usinga screwdriver removethe pistonseal INSPECTION AND REPAIR OF FRONTBRAKE COMPONENTS 1 TNSPECT PAD LININGTHICKNESS Standardthickness 10 Omm 0 394 in Minimum thickness 1 0 mm 0 039 in l Replace the pad if the thicknessis lessthanminimum the 1 0 mm slit is no longervisible or if it shows signsof unevenwear INSPECTROTORDISCTHICKNESS Standardthickness 11 0 mm 0 4...

Страница 579: ...fication 4 IF NECESSARY REPLACE ROTORDISC d Removethe torqueplatefrom the knuckle b Removethe wheel nuts of the temporarilyinstalled disc and pull off the rotor disc from the axlehub c Temporarilyinstalla new rotor disc with the wheel nuts d Installthe torqueplateonto the knuckle Torque 900 kg cm 65 ft lb 88 N m ASSEMBLYOF CYLINDER SeepageBR 161 1 APPLYLITHUMSOAPBASEGLYCOL GREASE TO PARTS INDICATE...

Страница 580: ...he boot is securedfirmly to the bushing groove t t INSTALLATION OFCYLINDER JS t SeepageBR l61 1 INSTALLPADS Seesteps 7 to 9 on pag6sBR 17and 18 i 2 INSTALLCYLINDER Seestep 11 on page BR 271 3 INSTALLFLEXIBLE HOSETO BRAKECYLINDER Torque 235 kg cm 17 ft lb 23 N m 4 CONNECTFLEXIBLE HOSETO BRAKETUBE UsingSST connectthe flexiblehose ssT 09751 36011 Torque 155 kg cm 11 ft lb 15 N ml 5 FILLBRAKERESERVOIR...

Страница 581: ...e shoelin ing thicknessthroughthe hole lf lessthan minimum replacethe shoes Standardthickness 4 0 mm 0 157 in l Minimum thickness 1 0 mm O 039in l 2 REMOVEREARWHEEL 3 REMOVEBRAKEDRUM Seestep 2 on page RA 51 lf the brakedrumcannotbeeasilyremoved do the follow ing procedure d Inserta screwdriverthrough the holein the backing plate and hold the automaticadjustingleveraway from the adjustingbolt b Usi...

Страница 582: ...or spring from the front shoe and removeit REMOVEANCHORSPRING 8 REMOVEREARSHOE d Removethe hold downspring retainersand pin b Usingpliers disconnect the parkingbrakecablefrom the leverandremovethe rearshoetogetherwith the strut 9 REMOVESTRUTFROMREARSHOE a Removethe adjustingleverspring b Removethe strut 10 REMOVEPARKINGBRAKELEVERAND AUTOMATIC ADJUSTINGLEVERFROMREARSHOE Usinga screwdriver pryout th...

Страница 583: ...TER Standardinsidediameter 180 0 mm 7 087 in Maximuminsidediameter 181 0mm 7 126in lf the drum is scored or worn the brake drum may be lathedto the maximuminsidediameter NOTE Perform operations with the following parts removed d Oil seal b lnnerandouterbearing 2 INSPECT BRAKESHOELININGTHICKNESS Standardthickness 4 0 mm 0 157 in l Minimum thickness 1 0 mm 0 039 in lf the shoeliningis lessthanminimu...

Страница 584: ... FOTLOWING PARTS d Two pistoncups b Two pistons t 2 ASSEMBLEWHEELCYLINDER a Installtwo new pistoncupsto the pistons b Installthe two pistonsand spring into the wheet cylinder Checkthat the flangeof the pistonsare pointedinward c Installtwo new boots 3 INSTALLWHEELCYLINDER Installthewheelcylinderon the backingplatewith thetwo bolts Torque lOO kg cm 7 ft lb 1ON ml 4 CONNECTBRAKETUBETO WHEELCYLINDER ...

Страница 585: ...EVERAND AUTOMATIC ADJUSTINGLEVER TO REARSHOE d Temporarilyinstallthe leverswith the shim and a new C washer d Usinga feelergauge measure the clearance between the shoeand lever Standardclearance O 0 35 mm O 0 0138 in l lf not within specification adjustwith a shim Shimthicknesses mm in 0 2 0 008 0 5 0 020 0 3 0 012 0 6 0 024 0 4 0 016 0 s 0 035 cl Usingpliers stakethe C washer INSTALLSTRUTONTO REA...

Страница 586: ...oe insertedinthewheelcylinderandthe otherendinthe anchorplate c Installthe pin andthe shoe hold downspring 9 INSTALLFRONTSHOE GAUTION Do not allow greaseto get on the rubbing face a Installthe anchorspringbetweenthe front and rear shoes b Set the front shoein placewith the end of the shoe insertedin the wheelcylinderandthe strut in place c Installthe shoehold downspring retainersand pin INSTALLSHO...

Страница 587: ...d lnstallthe drum d Pullthe parkingbrakeleverall the way up 13 CHECKCLEARANCE BETWEENBRAKESHOESAND DRUM h Removethe drum b Measure the brake drum inside diameter and diameter of the brake shoes Check that the differencebetweenthe diametersis the correctshoe clearance Shoe clearance 0 6 mm 0 O24in l lf incorrect checkthe parkingbrakesystem 14 INSTALLBRAKEDRUM AND ADJUST PRELOAD Seepage RA 61 15 INS...

Страница 588: ... 1 INSPECTSHOELININGTHICKNESS Removethe inspectionholeplug andcheckthe shoelin ing thicknessthroughthe hole lf lessthan minimum replacethe shoes Standardthickness 4 0 mm 0 157 in l Minimum thickness 1 0 mm 0 039 in l 2 REMOVEREARWHEEL 3 REMOVEBRAKEDRUM lf the brakedrumcannotbeeasilyremoved do thefollow ing procedure d Inserta screwdriver throughthe hole in the backing plate and hold the automatica...

Страница 589: ...ersand pin b Using a screwdriver disconnect the parking brake cablefrom the anchorPlate d Usingpliers disconnectthe parkingbrakecablefrom the leverandremovethe rearshoetogetherwith the strut 7 REMOVE STRUT FROMREAR SHOE a Remove theadiusting leverspring d Remove thestruttogetherwith thereturnspring 8 REMOVE PARKING BRAKELEVER AND AUTOMATIC ADJUSTING LEVER FROMREAR SHOE Usingascrewdriver pryouttheC...

Страница 590: ...KECOMPONENTS 1 INSPECT BRAKEDRUMINSIDEDIAMETER Standardinsidediameter 200 0 mm 7 874in l Maximuminsidediameter 201 0 mm 7 913in lf the drum is scoredor worn the brake drum may be lathedto the maximuminsidediameter 2 INSPECT BRAKESHOELININGTHICKNESS Standardthickness 4 0 mm 0 157 in Minimum thickness 1 Omm 0 039 in l lf the shoeliningis lessthanminimumor showssignsof unevenwear replacethe brakeshoe...

Страница 591: ...wo pistons 2 ASSEMBLEWHEELCYLINDER a lnstall two new piston cups to each piston check that the flangesof the cups arepointedinward b Install the two pistons and spring into the wheel cylinder c Installtwo new boots 3 INSTALLWHEELCYLINDER Installthe wheelcylinder onthe backing platewiththetwo bolts Torque 1OOkg cm 7 ft lb 1ON ml 4 CONNECT BRAKETUBETO WHEELCYLINDER UsingSST connectthe braketube ssT ...

Страница 592: ... AUTOMATIC ADJUSTINGTEVERTO REARSHOE a Temporarily installthe leversandshimwith a newC washer d Usinga feelergauge measure theclearance between the shoeand lever Standardclearance O 0 35 mm 0 0 0138 in l lf not within specification adjustwith a shim Shim thicknesses mm in o 2 0 008 0 5 0 020 0 3 0 012 0 6 0 024 o 4 0 016 o g 0 035 c Usingpliers stakethe C washer 7 INSTALLSTRUTONTO REARSHOE Set the...

Страница 593: ...horplate c Set the rearshoe in placewith the end of the shoe insertedinthe wheelcylinderandthe otherendin the anchorplate d Installthe hold downspring retainers and pin INSTALLFRONTSHOE CAUTION Do not allow oil or grease to get on the rubbing face d lnstallthe anchorspringbetweenthe front and rear shoes b Set the front shoe in placewith the end of the shoe insertedin the wheelcylinderandthe strut ...

Страница 594: ... possible amount Installthe drum Pullthe parkingbrakeleverall the way up CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM a Remove thedrum b Measurethe brake drum inside diameterand diameterof the brake shoes Check that the difference between thediameters istheconectshoe clearance Shoeclearance 0 6 mm 0 024in l lf inconectchecktheparking brakesystem INSTALL BRAKE DRUM INSTALL REAR WHEEL FILI BRAKE RES...

Страница 595: ...HOELININGTHICKNESS Removethe inspectionholeplug andcheckthe shoelin ing thickness throughthe hole lf lessthan minimum replace the shoes Standardthickness 4 0 mm 0 157 in Minimum thickness 1 0 mm 0 039 in 2 REMOVEREARWHEEL 3 REMOVEBRAKEDRUM lf the brakedrumcannotbeeasilyremoved do thefollow ing procedure a Inserta screwdriverthroughthe hole in the backing plate and hold the automaticadjustinglevera...

Страница 596: ...rakecablefrom the leverandremovethe rearshoetogetherwith the strut 6 REMOVESTRUTFROMREARSHOE a Removethe adjustingleverspring b Removethe strut 7 REMOVEPARKINGBRAKELEVERAND AUTOMATIC ADJUSTINGLEVERFROMREARSHOE Usinga screwdriver pry out the C washerandremovethe shim and levers DISCONNECT BRAKETUBEFROMWHEELCYLINDER UsingSST disconnectthe line Usea containerto catch the brakefluid ssr 09751 3601 1 R...

Страница 597: ...dor worn the brakedrum may be lathedto the maximuminsidediameter 2 INSPECTBRAKESHOELININGTHICKNESS Standardthickness 4 0 mm 0 157 in l Minimum thickness 1 0 mm 0 039 in l lf the shoeliningis lessthanminimumor showssignsof unevenwear replacethe brakeshoes NOTE lf the thickness of any brakeshoeis not within specification replaceall of the brakeshoes 3 INSPECTBRAKE LINING AND DRUM FOR PROPER CONTACT ...

Страница 598: ...nges of the piston are pointedinward c Installtwo new boots 3 INSTALLWHEELCYLINDER Installthe wheelcylinder onthebacking platewiththetwo bolts Torque lOO kg cm 7 ft lb 1ON ml 4 CONNECTBRAKETUBETO WHEELCYLINDER UsingSST connectthe braketube ssT 09751 36011 Torque 155 kg cm 11 ft lb 15 N ml 5 APPTYHIGHTEMPERATURE GREASE TO FOLLOWING PARTS a Backingplateand brakeshoecontactpoints b Anchor plateand br...

Страница 599: ... the shoeand lever Standard clearance O 0 35 mm O 0 0138 in lf not within specification adjustwith a shim Shimthicknesses mm in 0 2 o oo8 0 5 0 020 o 3 0 012 I 0 6 0 024 o 4 0 016 I o s 0 035 c Usingpliers stakethe C washer 7 INSTALLSTRUTONTOREARSHOE Set the strut and return spring in place adjustingleverspring and installthe Left handThreads Right handThreads pVe Front f Front Left Wheel RightWhe...

Страница 600: ...TSHOE CAUTION Do not allow oil or grease to get on the rubbing face a Installthe anchorspringbetweenthe front and rear shoes b Set the front shoein placewith the end of the shoe insertedin the wheelcylinderand the strut in place c Installthe shoehold downspringandpin d UsingSST connectthe returnspring ssr 09703 30010 10 CHECK OPERATIONOF AUTOMATIC ADJUSTER MECHANISM a Move the parkingbrakeleverof ...

Страница 601: ... DRUM a Removethe drum b Measure the brake drum inside diameter and diameter of the brake shoes Check that the differencebetweenthe diametersis the correctshoe clearance Shoe clearance 0 6 mm 0 024 in l lf incorrect checkthe parkingbrakesystem INSTALLBRAKEDRUM AND REARWHEEL FILLBRAKERESERVOIR WITH BRAKEFLUID AND BLEEDBRAKESYSTEM Seepage BR 71 CHECKFORFLUIDLEAKAGE 1 1 12 13 14 ...

Страница 602: ... CONNECTHOSEAND TUBE a Connectthe hoseand tube by hand b Usingawrenchto holdthe hose andSSTto holdthe tube torquethe connection ssT09751 3601 1 Torque 155 kg cm 11 ft lb 15 N ml c Installa new hoseclip INSPECTION OF BRAKEHOSESAND TUBES 1 INSPECT BRAKEHOSES a Inspectthe hosefor damage cracksor swelling b Inspectthe threadsfor damage 2 INSPECTBRAKETUBES d Inspectthe tubefor damage cracks dentsor cor...

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