check oil DATSUN 210 1979 Owners Manual

they
are
worn

damaged
or
otherwise

faulty
and
how

they
are
affected
Re

pair
or

replace
all

faulty

parts
which

ever
is

necessary

1
Check

gear
teeth

for

scoring

cracking
or

chipping
and
make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault

is
evident

replace

parts
as

required

Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a

set

therefore
should
either

part
be

damaged

replece
as
a
set

2
Check

pinion
shaft
and

pinion

mates
for
scores
and

signs
of
wear

and

replace
as

required

F
oUow
the
same

procedure
for
side

gear
and
their
seats
on
differential

case

3

Inspect
all

bearing
races
and
roU

ers
for

scoring
chipping
or
evidence
of

excessive
wear

They
should
be
in

tiptop
condition
such
as
not
worn
and

with
mirror

like
surfaces

Replace
if

there
is
a

shadow
of

doubt
on
their

efficiency
as
an

incorrect

bearing
op

eration

may
result
in
noises
and

gear

seizure

4

Inspect
thrust
washer
faces
SmaU

faults
can
be

corrected
with

sand

paper
If

pinion
mate
to
de

gear

backlash
exceeds

specified
value
re

place
thrust

washers

Pinion

mate
to
side

gear
backlash

0
10
to
0
20
mm

0
0039
to
0
0079
in

5

Inspect
gear
carrier
and
differ

ential
case
for
cracks
or
distortion
If

either

condition
is
evident

replace

Jaulty

parts

6
As
a

general
rule
oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY
AND

ADJUSTMENT

Assembly
can
be
done
in
the

reverse
order
of

disassembly
The

foUowing
directions
for

adjustment

and

usage
of

special
tools
enable
to

obtain
a

perfect
differential

operation
Propeller
Shaft
Differential
Carrier

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
washers
and

the

like
to
install
them

correctly

2

Thoroughly
clean
the

surfaces
on

which
shims

washers

bearings
and

bearing
caps
are
installed

3

Apply
gear
oil
when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

ASSEMBLY
OF

DIFFERENTIAL
CASE

1

Assemble

pinion
mates
side

gears

and
thrust
washers
in
differential
case

2
Fit

pinion
shaft
to
differential

case

so
that
it

meets
lock

pin
hole

3

Adjust
pinion
mate

to
ide

gear

backlash
or
the
clearance
between
the

rear
face
of
side

gear
and

thrust

washer
to
the

specified
value

by

selecting
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

0
10
to
0
20

mm

10
0039
to
0
0079
in

PD023

Fig
PD

l1
Measuring
Clearance

Side

gear
thrust

washer

Thickness
mm
in

0
785
0
0309

0
835
0

0329

0

885
0
0348

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it
is

secured
into

place

5

Apply
oil

to

gear
tooth
surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6

Place

ring

gear
on
differential
case

and
install
bolts
and
lock

straps
Tor

que
bolts
to

specification
and
bend

up

lock

straps

PO
5
tiJ
Tightening
torque

Ring
gear
bolt

6
0
to
7
0

kg
m

43
to
51
ft
Ib

CAUTION

e
Use

only
genuine
ring
gear
bolts

end
new
lock

straps

b

Tighten
bolts
in
criss
crilss
fashion

lightly

tapping
around
bolt
heads

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
Side
Bear

ing
Adjust
Weight
ST3250S000

Weight
mock
ST3250
I

000
and

Master

Gauge
ST325020oo
or
suit

able

standard

gauge
17
5
nun
0
689

in

thickness
and

a

weight
block
2
5

kg
5
5
Ib

prior
to
installation

Standald

bearing
width

17
5
mm
10
689
in

y

ST32501000

8
Select
side

bearing
shims
re

ferring
to

Adjustment
of
Side

Bearing

Shims

9
Press
fit
side

bearing
cone
into

differential
case

using
Gear
Carrier

Side

Bearing
Drift
ST33220oo0
and

Adapter
ST33052000

w

I
ST33220000

PD244
1000

ST33052000

Fig
PD
13

lnatalling
Side

Bearing

Cone

ADJUSTMENT
OF
DRIVE

PINION
HEIGHT

Adjust
the

pinion
height
with

wash

er

provided
between
rear

bearing
inner

race

and
the
back
of

piliion

gear

J

Press
fit

front
and
rear

bearing

outer
races
into

gear
carrier

using

Drive

Pinion
Outer
Race
Drift

STJ070
I
000

and
Bar
ST30611000

2

Fit
rear

bearing
on

gear
carrier

and
install

Dwnmy
Shaft
on
rear
bear

ing
and

place

Height
Gauge
on

gear

carrier

STJII21000

Height
gauge

KV38

103500

Height
gauge
spacer

ST3
II

22000

Dummy
shaft

KV3gl03600

Dummy
shaft

spacer

ST3112tOOO

PD461

Fig
PD
14

AqjUlting
Pinion

Height

3
Measure
the

clearance
N
be

tween
the

tip
end
of

height
gauge
and

the
end
surface
of

dummy
shaft

using

a
thickness

gauge

P0322

Fig
PD
15
Meo

uring
Clearance

4

The

proper
thickness
of

pinion

height

adjusting
washers
can

be
obtain

ed
from
the

following
formula
Propeller
Shaft

Differential
Carrier

T
W
N

HxO
01
OJ8

Where

T

Required
thickness
of

pinion

heightedjusting
w

shers

W

Thickness
of

temporarily
insert

ed
washer
mm

Be
sure
to
use
washer
of
2
74

0

1079
or
2
77
0

1091
or

2
80
0
1102
mm
in

thick

ness

N

Measured
clearance
between

height
gauge
and

dummy
shaft

face
mm

H

Figure
marked
on
the
drive

pinion
head

Note

e

Figure
H
is

e
dimensional
variation

in

units
of
1
100

mm

egainst
stand

ard
measurement

b
If
value

signifying
H
is

not

given

regard
it
as
zero
and

compute

Head

number

Hl

P0186
Set
number

Fig
PD
16
Variation
Number
on

Drive
Pinion

Examples
of

calculation

EX
I

W
2

74mmN
0
30mmH
1

T
W
N
H
x

0
01
0
18

2
74

0
30
I

x
0
01
OJ8

3

04
0

19

2
85

The
correct
washer
thickness
is

2

86

mm

EX
2

W
2
77

mm
N

0
21

mm
H
0

T
W
N
HxO
01
OJ8

2
77
0
21

OxO
0I

OJ8

2
98
0
18

2
80

The
correct
washer
thickness
is

2
g0
mm

PD
6
EX
3

W
2

80
mm

N
0
48
mm

H
2

T
W

N
HxO
OI
OJg

2
80
OA8
2
x
0

01
OJ8

3
28
0
20

3
08

The
correct
washer
thickness
is

3
07
mm

Pinion

height
adjusting
washer

Thickness
mm
in

2
74
OJ
079
3
01
0

1185

2
77
OJ09I

3
04
0
1197

2

80
OJ
102
3
07
0
1209

2

83
0
1114

3
10

0
1220

2
86
OJ
126
3J3
0
1232

2
89
0
1138

3
16
0
1244

2
92
OJ
150
3

19
0
1256

2
95
0
1161

3
22
OJ
268

2
98

0
1173
3
25
O
l2g0

5
Fit
detennined

pinion
height
ad

justing
washer
in

drive

pinion
and

press
fit
rear

bearing
inner

race
in
it

using
Drive
Pinion

Bearing
Drift

Bar
STJ0600000

Note
After

assembly
check
to

see

thet
tooth
contact
is
correct
If
Dot

readjust

ADJUSTMENT
OF

DRIVE

PINION

PRELOAD

Adjust
the

preload
of

drive

pinion

with

collapsible
spacer

This

procedure
has

nothing
to
do

with
thickness

of

pinion

height
ad

justing
washer

Note

Collapsible

spacer
oil

seal
and

pinion
nut

cannot
be

reused

I
After

adjusting
pinion

height

lubricate
front

bearing
with

gear
oil

and

place
it
in

gear
carrier

2

Install
a
new
oil
seal
in

gear

carrier

using
Oil
Seal

Fitting
Tool

ST33400001

Lubricate

cavity
between
seal

lips

with
recommended

multi

purpose

grease
when

installing

3
Place
a

new

collapsible
spacer
on

drive

pinion
arid

lubricate

pinion
rear

bearing
with

gear
oil

4
Insert

companion
flange
into
oil

seal
and
hold
it

firmly
against
pinion

front
bearing
cone
From
the

rear
of

the

gear
carrier
insert

drive

pinion

into

companion
flange

5
Ascertain
that

threaded

portion

of
drive

pinion
and
new

drive

p
ion

nut
are
free
from
oil
or

grease

6

Holding

companion
flange
with

Drive
Pinion

Flange
Wrench

STJ1530000

tighten
nut
and
then

pull
drive

pinion
into

front

bearing

cone
and
into

flange

As
drive

pinion
is

pulled
into
front

bearing
cone
drive

pinion
end

play
is

reduced
While
there
is

still
end

play
in

drive

pinion
companion
flange
and

cone
will
be
fell

to
bottom
out
This

indicates
that

bearing
cone
and
com

panion
flange
have
bottomed
on

col

lap
ible

spacer

From
this

point
a

much
greater

torque
must
be

applied
to
turn

pinion

nut
since

spacer
must
be

collapsed

Also
from
this

point
nut

hould
be

tightened
very
slowly
and
drive

pinion

end

play
checked
often
0
that

pinion

bearing
preload
does

not
exceed
the

limits

When

the
drive

pinion
end

play
has

been
eliminated
the

specified
preload

i

being
approached

CAUTION

00
not
decrease

preload
by
loosen

ing
pinion
nut
This
will
remove

compression
between

pinion
front

end
rear

bearing
cones
and

collapsibla

spacer
and

may
permit
front
bear

ing
cone
to
turn
on
drive

pinion

Moreover
nut
becomes
loose

7
Turn
drive

pinion
in

both
direc

lions
several
times

to
set

bearing

rollers

Then

adjust
bearing
preload
to

specification
using
Preload

Gauge

STJ127S000

iil
Tightening
tOlque

Pinion
nut

14
to

30

kg
m

101
to
217
ft
lb

D

iY8

pinion
preload

with

oil
seal

6
0
to
8
0

kg
cm

5
2

to
6
9
in
Ib
Propeller
Shaft
Differential
Carrier

P0447

Fig
PD

17

Measuring
Pinion

Preload

If
this

specification
is

exceeded

replace
collapsible
spacer

Note
Preload
of
used

bearing
is
the

same
value
as

that
of
new

bearing

ADJUSTMENT

OF
SIDE

BEARING
SHIMS

I

If

hypoid

gear
set

gear
carrier

differential
case
or

side

bearing
ha

been

replaced
adjust
the
ide

bearing

preload
with

adjusting
him

The

required
thickness
of

adjusting

shim
can
be
calculated

by
the

follow

ing
formulas

T
A

C
D
H

xO
OI

020
E

T2
B
D
H
xO
Ol
0

20

F

Where

T

Required
thickness
of
left

side

bearing

adjusting
shim

mm

T

2
Required
thickness
of

right

side

bearing
adjusting
shim

mm

A

Figure
marked
on
the
left

side

bearing

housing
of

gear

carrier

B

Figure
marked

on
the

right

side

bearing
housing
of

gear

carrier

C

D

Figures
marked
on
the
dif

ferential
case

E
F

These
are
differences
in

width

of
left

or

right
side

bearing

against
the
tandard
width

mm

H

Figure
marked
on
the

ring

gear

PD
7
Figures
for
A
B
C
D
and
H
are

dimensional
variations
in
units

of

1
100
mm

against
each
standard

measurement

F

MarkS

MarkC
D

L

P0214

Fig
PD
18

Thickness

of
Shim
on

Left
and

Right
Sides

PD190

Fig
PD
19
Variation
Number
on

Ring
Gear

Examples
of
calculation

EX
1

A
I
B

2
C
2
D
3

E
0
02

mm
F
0
01
mm

H
2

Left
side

T
A

C
D
H
xO

OI

0
20
E

I
2
3
2
x

0
01

0
20
0
02
0
26

rnm

The
correct

shims
are
0
05

plus

three

pieces
of
0
07
mm
thick

Right
side

T2
B

D
W
xO
QI

0
20
F

2
3
2
x

0
01

0
20
0
01
0
16

mm

The
correct

shims
are
0
10

plus

0
07
mm
thick

EX

2

A
0

B
3

C
I
D
2

E

O
I
F

0
08
H
I

Left
side

T
A

C
D
H

xO
OI

0

20
E

0
H

2
1

x
0

01

0
20

0
11

0
0
20

0
1

0
31

The

correct
shims

are
0
10

plus

lI
re
e

pi

ce
s
of

9
Q7
I
Il1I
thick

Right
side

T2
B
D
H
xO
OI

020
F

3
2
I
xO

01

0
20

0
08

0
02
0
20
0

08

0
30

The
correct

shims
are
0
10

plus

0

20
mm
thick

Note

If
w1ues

sigoifying
A
B
C
D

and
H

are
not

giVen
regard
them

as

zero
end

compote

After

essembly
clteek
to
see
that

preload
and
backlesb
ere
correct

If
not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

0
05
0

0020

0
07
0

0028

0
1
0
0
0039

0
20
0
0079

0
50
0

0197

2
Fit
determined

side

bearing
ad

justing
shim
on
differential
case
and

press
fit
left
and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST3322OO00
and

Adapter

ST33052000

3
Install
differential
case

assembly

into

gear
carrier

tapping
with
a
rubber

mallet

4

Align
mark
on

bearing
cap
with

that
on

gear
carrier
and
install

bearing

cap
on
carrier

And

tighten
bolts
to

specified
torque
Propeller
Shaft
Differential
Carrier

@Tightenirig
tOrque

Side

bealingcap
bolts

5
0

to
6

0

kg
m

36
to
43
ft
b

5

M
easure
L

dimension
between

left
and

right
bearing

cap
edges
with

a
micrometer

e

cljmension

153
40
to
153
45

mm

6

0394
to
6
0413

inl

PD271

Fig
PD
20

Measuring
L
Dimension

6
Measure

ring
gear
to
drive

pinion

backlash

If
backlash
is

too
smaU
decrease

thickness
of
left
shim
and

increase

thickness
of

right
shim

by
the
same

amount

If
backlash
is

too

great
reverse
the

above

procedure

Ring
gear
to
drive

pinion
backlash

0
10

to
0
15
mm

0

0039
to
0
0059
in

PD272

Fig
PD
21
Mea

uring
Backlash

7
At

the
same
time

check
side

bearing
preload
Bearing
preload

should

be

specified
torque

If

preload
does
not
accord
with
tJiis

specification

adjust
it

with
side
bear

ing
shims

PD
B
Side

bealing
preload

8

to
10

kg
cm

6
9

to
8
7
in

bl

At

ring
geer
bolt

1
5
to
1
9

kg

3
3
to
4
2
Ibl

8
Check

and

adjust
the
tooth
con

t

c

pattern
of

ring

gear
and
drive

pinion

I

Thoroughly
clean

ring
and
drive

pinion
gear
teeth

2
Paint

ring
gear
teeth

lightly
and

evenly
with
a
mixture
of

recommend

ed

powder
and
oil
of
a
suitable
consist

ency
to

produce
a

contactpaUern

3
Rotate

pinion
through
several

revolutions
in
the
forward
and

reverse

direction
until
a
definite
contact

pat

tern
i

developed
on

ring
gear

4

When
contact

pattern
is

in

correct
readjust
thickness

oLadjust

ing
shim

Be
sure
to

wipe
off

powder
com

pletely
upon
completion
of

adjust

ment

5
Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

foUowing

manner

Contact

pettern

a
Heel
contact

To
correct
increase
thickness
of

drive

pinion
adjusting
washer
in

order

to

bring
drive

pinion
close
to

ring
gear

P0193

Fig
PD
22
Heel
Contact

b
Toe
contact

To

correct
reduce
thickness
of

drive

pinion

adjusting
washer
in
order

to
make
drive

pinion
go

away
from

ring
gear

t
PD194

Fig
PD
23
Toe

Contact

c
Flank
contact

Adjust
in
the
same
manner
as
in

b

t

P019S

Fig
PD
24
Flank
Contact

d
Face

contact

Adjust
in
the

same
manner
as
in
3

cf

P0196

Fig
PD
25
Face
Contact

e

Correct
tooth
contact

P0197

Fig
PD
26
Correct
Contact

Note

Change
in
thickness
of

adjust

ing
WlI8her
is

accompanied
by

change
in
backlash
Check
it

when

insteIIing
gear
Propeller
Shaft

Differential
Carrier

INSTALLATION

Installation

can
be
done
in
the

re

verse
order
of
removal

ifl
Tightening

torque

Gear
carrier
to

rear
axle

case

fixing
bolt

1
7
to
2
4

kg
m

12
to
17

ft
lbl

Drain
and
filler

plug

6
to
10

kg
m

43
to
72
ft
lbl

Gear
oil

quantity

0
9
liter
1

U
US

pt

1

Imp
pt

Note

a

Discard

gear
carrier

gasket
after

remom

Do
not

apply
sealant
to
the

gasket

b

Apply
sealant
to
bolts

securing
gear

carrier
case
to
rear

axle

housing

REPLACEMENT
OF

FRONT
OIL

SEAL

When

replacing
front

oil
seal

do
as

follows

1
Remove

differential
carrier

assem

bly
and
mount
it

on
Differential
Car

rier
Attachment
ST06320000

This
work

can
be
done

by
referring

to
Removal

procedure

2
Remove

side

bearing

caps
and

take
out
differential
case

assembly

Remove
drive

pinion
nut
and
extract

drive

pinion
assembly
Remove
oil

seal

These
works
can
be
done

by
re

ferring
to

Disassembly

procedure

PD
9
3
Install
a

new
oil
seal
in

gear
car

rier

using
Oil
Seal

Fitting
Tool

ST3340000l

Lubricate

cavity
between
seal

lips

with

recommended
multi
purpose

grease
when

installing

4
Place

a
new

collapsible

spacer
on

drive

pinion
and
lubricate

pinion
rear

bearing
with

gear
oil

5
Insert

companion
flange
into
oil

seal
Insert
drive

pinion
into
com

panion
flange
from

rear
of

gear
carrier

and
secure
them
in

position
by

tightening
nut
to

given
torque
con

firming
specified
preload

These
works
can
be
done

by
re

ferring
to

Adjustment
of

Drive
Pinion

Preload

procedure

6
Install
differential
case

assembly

into

gear
carrier

Measure
L

dimen

sion

backlash
with

specification

adjust
them
with
side

bearing
shims

The
works

can
be
done

by
re

ferring
to

Adjustment
of
Side

Bearing

Shims

procedure

7

Reinstall
differential

gear
carrier

assembly
rear
axle
shafts
and

pro

peller
shaft
Fill

up
differential
carrier

with

correct

gear
oil

CAUTION

a

Replacement
of
front
oil
seal
with

differential
carrier

assembly
install

ed
on
car
must
not
be
ellowed

due

to
used

collapsible
spacer
on

iu
model

b
Whenever

front
oil
seal
is

replaced

collepsible

spacer
must
be

replaced

Front
Axle

Front

Suspension

INSPECTION
AND
ADJUSTIVIENT

INSPECTION

Inspect
in
accordance
with

periodic

maintenance
schedule

Block
rear
wheels
with
chocks

2

Jack

up
the
front

of

car
and

support
it
with

safety
stands

Refer
to

Section
GI
for

lifting

points
and

towing

3

Shaking
each
fiont
wheel

by

grasping
the

upper
and

lower
surfaces

of
the
tires
check

suspension
parts
for

looseness
wear
or

damage
Tighten
aU

loose
bolts
and

nuts
to
the

specified

torque
Replace
all
worn

parts
as

described
under
Front

Suspension

4

Check
wheel

bearings
If

there
is

any
axial
end

play
adjust

bearings
to

specifications

Replace
worn
or

damaged
bearings

as
described
under
Front

Axle

S
Check

strut
for
oil

leakage
or

damage

ADJUSTMENT

WHEEL

BEARING

Block

rear
wheels
with
chocks

2

Jack

up
the
front
of
car
and

support
it

with

safety
stands

3

Remove
brake

pads
Refer
to

Section
BR
for

pad
replacement

4

Remove
hub

cap
cotter

pin
ad

justing

cap
and
wheel

bearing
nut

S

Sparingly
apply
recommended

multi

purpose

grease
to
threaded

por

tion

of

spindle
and

contact
surface

between
wheel

bearing
washer
and

outer
wheel

bearing

6

Tighten
wheel

bearing
nut

using

a
suitable

torque
wrench

P
Tightening

torque

Wheel

bearing
nut

3
0
to
3
5

kll
m

22

to
25
ft

Ibl
Fig
FA

Tighlening
Wheel

Bearing

Nul

7
Turn

wheel
hub
several
times
in

both
directions
to

seat
wheel

bearing

correctly

again
tighten
wheel

bearing

nut
to
the
above

torque

8
Turn
back
wheel

bearing
nut
A

degrees

Return

engle
AU

900

Install

adjusting
cap
and

align
any

of
its
slots
with
hole
in

spindle
If
the

above

procedure
fails
to

align
hole
and

slot

together
then

tighten
lock

nut
as

much
as
I

S

degrees
until
hole
in

spindle
is

aligned
with

eny
slot

CAUTION

00
not

overtighten
wheel

bearing
nuts

as
this

can
cause
wheel

bearing
seizure

9
Turn

hub
in
both

directions
two

or
three
times

measuring
its

turning

torque
and

axial

play
to

ee
if

they
are

within
the

specified
range
If

they
are

not

adjust

Axial

play

Omm

Din

Wheel

bealing
starting
torque

With

new

gleaS8
l8al

A

measured
et

wheel

bearing

nut

less
than
7

kg
cm

G
1
in
Ibl

FA
2
AJ
measuled
et
wheel
hub

bolt

Less
then
1
2

kg
12
G
Ibl

With
u
ed

gr
seal

AJ
measured

at
wheel

bealing

nut

1
0
to
4
5

kg
cm

0
9
to
3
9
in
b

AJ
measuled
at

wheel
hub

bolt

0

17
to
0
79

kg

0
37
to
1
741bl

FA413

Fig
FA
2
Metr

uring
Bearing
Starting

Torq
ue

Repeat
above

procedures
until
cor

rect

starting
torque
is

obtained

Note

a

Correctly
meas
e
rotation

slar
ting

force

toward

tangential
direction

against
hub
bolt

b

Above

figures
do
not

include

dragging
resistance
with

pads
re

moved
on
disc
brake
models

c

Any

slightest
wheel

bearing
axial

play
cannot
be
tolerated

10
Insert
new
cotter

pin
with
the

legs
through
hese
two

parts
spread

legs
away
from
each
other

against
sides

of
wheel

bearing
nut

Fig
FA
3

Installing
Coller
Pin

II
Install
hub

cap
with
new
Q

ring

and
wheel

WHEEL
ALIGNMENT

Correct
front
wheel

alignment
as

sures

proper
car

handling
characteris

tics

and
minimum

steering
effort
with

the
least

amount
of
tire

wear
Before

adjusting
front
wheel

alignment
be

sure
to
make

preliminary
inspection
of

front
end

parts

Tire

pressure
and
balance

Wheel

bearings
and
wheel

bearing

nuts

Steering
gear

play

Steering
gear
housing
loose
at
frame

Steering
linkage
and
connections

Shock
absorber

operation

If

wrong
repair
or

replace
the

damaged
portion
or

parts

When

using
equipment
for
front

wheel

alignment
inspection
follow
the

instructions
furnished
with

equipment

Note

Inspection
should
be

made
with

the
car
set
Ievel
and
at
curb

weight

Cember
end
caster

Camber
and
caster
are

preset
at

factory
and

cannot
be

adjusted

The

car

requires
only
toe
in

and
car

posture
adjustment

Note
If
camber

or
caster

alignment
is

not
within

specifications
check
as

sociated

parts
Repair
or

replace
as

necessary
Front
Axle
Front

Suspension

Toe
In

Measure
toe
in
and

adjust
as
neces

sary
For

adjustment
carry
out
the

following
procedure

1

With

steering
wheel
at

its

straight

ahead

position
check
front
wheels
to

see
if

they
are
set
in

straight
ahead

positions

2
Toe
in

can
be

adjusted
by

varying

length
of

steering
side
rods

Note

a
Loosen

lock
nuts
and

turn
left
and

right
side

rods

equally

b

Turning
side
rods
in
forward
direc

tion
of

car
inaeases
toe
in

c
If
side
rods
have
been

disassembled

set
at

specified
distance
A

be

forehand
when

reassembling

d
Be
sure
to
s
w
side
rods
into
ball

joint
sockets

more
than
20
mm

0
79
in

A
315
mm
12
40
in

EfJK

Toe
in
Unladen

1
to
3
mm

0

04
to
0
12
in

Unladen
means

the

following

conditions

Tankful
of
fuel
radiator
filled
and

engine
oil
full

Spare
tire

jack
hand
tools
mats
in

design
position

All

tires
inflated
to

specified

pres

sure

All
excessive
mud
dirt
and
road

deposit
accumulations

away
from

chassis
and

underbody

3
After
correct
toe
in
is

obtained

tighten
side
rod

adjusting
nuts

FA
J
Toe
in

A
B

Toe
in

28
Lines

parallel
to

center
line
of

body

8

F

A696

FA724

Fig
FA
4

Adj
ting
Toe
in

r

II
Li
1
t

Fig
FA

5
Side
Rod
T

Side
lod

edjusting
nl

8

to
10
0

kg

58
to
72
ft

1
Drive

caf
r

whet
ls
ride

01
properly

2

Gauge
sh

steenng
whe

tion

3
Rota

right
an

on
lOner

Tu

corre

i
I

rf

c

Ji
1

A

JI
U

2

7181

JOck

CL

C

S

Support
strut

assembly
with
a

jack
or
suitable
stand
and
remove

three
nuts

securing
strut
to

hoodledge

Strut
assembly
and

spring
can
then
be

removed
as
a
unit

DISASSEMBLY

When

disassembling
a

strut
extra

caution
should
be
exercised
to
avoid

dirt
and
dust

getting
inside
strut
This

dirt
and
dust
is
loaded
with
abrasive

which
if
enters
strut
causes
internal

leak
and

premature
wear
of

moving

parts

I
Secure
Strut

Steering
Gear

Housing
Attachment
KV48100300
in

a
vise
and
install
strut
on
attachment

2

Set

up
Spring
Compressor

ST3S6S
100
I

on

spring
Compress

spring
just
far

enough
to

permit
turn

ing
of
strut

mounting
insulator

by

hand
Remove

self

locking
nut

FA658

Fig
FA
18

Comprt
ingSpring

3
Remove

lock
nut

on

top
of

piston

rod
remove

mounting
insulator
strut

mounting
bearing
dust

seal

spring

seat

spring
and

bumper
rubber

CAUTION

Be

sure
to
hook

special
tool

8135651001

evenly
on
a

minimum

of
three
coils

Paying
attention
not
to

damage
piston
lod
Front
Axle
Front

Suspension

AJ

r

ST3565S001

F

A059
k

j

h

Fig
FA
19

Removing
Mounting

Insulator

4

Retract

piston
rod

by
pushing
it

down
until
it
bottoms
Remove

gland

packing
with
Gland

Packing
Wrench

ST3SS00001

A

ST35500001

1J

FA209
KV48
100300

Fig
FA

20
Removing
Gland

Packing

Note

Clean

gland

pecking
of

mud

and
other

foreign
perticles
accumu

lated

5
Remove

O

ring
from

top
of

pis

ton
rod

guide
bushing

6
Lift
out

piston
rod

together
with

cylinder

Note
Do
not
remove

pistion
rod

quickly
as
this
will
cause
oil
to

spurt
out

FA275

Fig
FA

21

Removing
Pi
ton
Rod

and

Cyliilder

FA
7
Note

Piston
rod

piston
rod

guide

and

cylinder
are

adjusted
to

provide

precision
mating
sutfeces
and

should
be
handled
as
a

matched
set

7
Drain

fluid

thoroughly
from
inner

cylinder
and
discard

8

Wash
aU

parts
in

suitable
solvent

9
Drain
fluid

thoroughly
from

outer

casing

Note
This

operation
is

very
im

portant
since

performance
of
strut

varies
with
amount
of
fluid
filled

within
strut

INSPECTION

I

Replace
gland
packing
O

ring
and

fluid
whenever

strut
is
disassembled

2

Wash
aU

perts
except
for
non

metallic

parts
with
suitable
solvent

and

dry
with

compressed
air

3
Blow
dirt
and
dust

off
of
non

metallic

parts
using
compressed
air

Note

a

Oil

oozing
out
at
and
around

gland

pecking
does
not
call

for
strut

maintenance
If
oil
leaks

past
pring

sest

check

piston
rod
and

gland

pecking
to
cxirrect
the
cause
of

problem
If
oil

leakage
occurs

on

welded

portion
of
outer
strut

casing

replace
strut
outer

casing

essembly

b
If
hock
absorber
itself
is

malfunc

tioning
replace
as
an

assembly
in

cluding

piston
rod

cylinder
bot

tom
valve
and

guide
bushing

Outer
ce
in

Check
outer

casing
for
evidences
of

deformation

cracking
or
other
dam

age
If

necessary
discard

Strut
mountln
In
uletor

Replace
if
cemented
rubber
to

metal

joints
are
melted
or
cracked

Rubber

parts
should
also
be

replaced

if
deteriorated

Strut
mountln
beerln

Replace
if

inspection
reveals
abnor

mal
noise
or
excessive
rattle
in
axial

direction

FA731

Fig
FA
35

Removing
Wwer
Arm

8

Remove

suspension
ball

joint

from
lower
arm

9
Place

knuckle
arm
in

a
vise
Re

move

suspension
ball

joint
from

knuckle
arm

using
a

press

@

I

r
662

Fig
FA

36

Remouing
Suspension
Ball

Joint

10
Withdraw
lower
arm

bushing

from
transverse
link

using
Front

Lower
Arm

Bushing
Replacer
Set

ST36720000
and
a

press

Mrl
o

o

o

0

F

A669

Fig
FA
37

Removing
Wwer

Am

BuNUng

INSPECTION

Lower
arm

I

Repair
or

replace
lower
arm
if

deformed

cracked
or

damaged
Front
Axle
Front

Suspension

2

Replace
bushing
if

excessively

worn

or
cracked

3

Make
sure

mating
surface
of
bush

ing
is

clean
and
free
from
oil
or

grease

apply

soapy
water
to

bushing
to
facili

tate

installation

Lower
bell

Joint

I
Ball

joint
is
assembled

at

factory

and

cannot
be
disassembled
Check

ball
stud

turning

torque
with
nut
in

place
on
ball

stud

If
it

is
far
from

specifications

replace

liJ
Turning
torque

New

parts

40
to
100

kg
cm

35
to
87
in

Ibl

Used

parts

More
than
20

kg
cm
117
in

Ibl

lUJ

F

A333

Fig
FA
38
Lower
Ball
Joint

2
Check

condition
of
dust
cover
If

it
is

cracked

excessively
replace
ball

joint

3
Lubricate

ball

joint
with
recorn

mended

multi

purpose
grease

To

lubricate

remove

plug
and
in

stall

grease
nipple

Pump
grease
slowly
until
old

grease

is

completely
forced

out
After

greasing
reinstall

plug

Note

When
a

high
pressure
grease
gun

used

operate
it

carefully
so
that

grease
is

injected
slowly
and
new

grease
does
not

DOme
out
from

clamp
portion

INSTALLATION

Install
lower
arm
and

suspension

ball

joint
in
reverse
order
of

removal

FA
l
Lower

erm
buahln

I
Before

installing

bushing
rub
off

rust
or

paint
drops
from
insi

e
collar

on
lower
arm

with

emery

paper

2

Using
Replacer
Set
ST36720000

insert

bushing
with

a

press
until
end

face
of

bushing
is

aligned
with
collar

on
lower
arm

ST36720000

I
I
HA734

Fig
FA
39

Installiff
l
Wwer
Ami

Bu
hi1f
I

Lower
erm
end
atebIllzer
ber

To

install
lower

arm
and
stabilizer

bar

temporarily
tighten

securing
bolts

Then

tighten
bolts
to

specifications
at

curb

weight
with
tires

on

ground

liJ

Tightening
torque

Bell

joint
socket

to

lower
arm

5
1
to
6
1

kg
m

37
to
44
ft
Ibl

Bell

joint
socket
to
lowel

arm
with
tension
rod

5
1
to
6
1

kg
m

37
to
44
ft
Ibl

Bell

joint
to
knuck
le

arm

5
5

to
10
0

kg
m

140
to
72
ft
Ibl

Lower
IIrm
bolt
nut

3
9
to
5
0

kg
m

28

to
36
ft
Ibl

Side

lod
ball

joint
to

knuckle
arm

3
0

to
7
0

kg
m

122
to
51
ft

lbl

Steering
knuckle

erm
to

stlut

7
3
to

9
9

kg
m

53
to
72
ft
Ibl

Front
Axle
Front

Suspension

Condition

Instability
of
car

Stiff

steering
wheel

Checking
up
procedure

Jack

up
front
wheels
detach
the

steering

gear
arm

and

operate
the

steering
wheel

and

If
it
is

light
check

steering
linkage
and

suspension
parts

If
it
is

heavy
check

steering
gear
and

steering
column

parts

Excessive

steering
wheel

play

Noises
Probable

cause

Improper
tire

pressure

Worn
rubber

bushings
for
transverse
link
and

tension
rod

Incorrect
wheel

alignment

Worn

or
deformed

steering
linkage
and

suspension
link

Incorrect

adjustment
of

steering
gear

Deformed
or

unbala
1ced
wheel

Improper
tire

pressure

Insufficient
lubricants
or

mixing
impurities

in

steering
gear
box
or

excessively
worn

steering
linkage

Stiff
or
damaged

suspension
ban

joint
or

lack
of

grease

Worn

or

incorrectly
adjusted
wheel

bearing

Worn
or

damaged
steering
gear
and

bearing

Incorrectly
adjusted
steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Damaged
strut

mounting
bearing

Damaged
or
stiff

piston
or
shock
absorber

piston
rod

in
the
strut

Interference
of

steering
column
with

turn

signal
switch

Incorrectly
adjusted
steering
gear
housing

Worn

steering
linkage

Improperly
fitted

gear
housing

Incorrectly

adjusted
wheel

bearing

Worn
transverse
link

and
tension
rod

bushings

Improper
tire

pressure

Insufficient

lubricating
oil
and

grease
for

suspension
ball

joint
and

steering
linkage
or

their

breakage

Loose

steering
gear
bolts
linkage
and
sus

pension
parts

Faulty
shock
absorber

inside
the
strut

Faulty
wheel

bearing

Worn

steering

linkage
and

steering
gear

Worn
transverse
link
and
tension
rod

bushings

Broken

or

collapsed
coil

spring

FA
17
Corrective
action

Adjust

Replace

Adjust

Replace

Adjust

Correct
or

replace

Adjust

Replenish
grease
or

replace
the

part

Replace

Replace
or

adjust

Repalce

Adjust

Replace

Adjust

Replace

Replace

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubri

cating
oil
and

grease

or

replace

Retighten

Replace

Replace

Replace

Replace

Replace