steering DATSUN 510 1968 Service Repair Manual

CHAPTER

TWELVE

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149

DIfferentIal

Rear
axle
and

suspension

Codspnng

Shock
absorber

Rear

suspensIOn
arm

Rear
axle

shaft
Wheel

beanngs

Seals

Rear

spnng

Axle
case

SpecificatIons

CHAPTER
THIRTEEN

FRONT

AXLE
FRONT
SUSPENSION
AND
STEERING
168

Wheel
hub
and

bearmg

StabilIzer

TenSion
rod

Spnng
and
strut

assembly

Transverse
lInk

Lower
ball

Jomt
Front

suspension
adjustment

Wheel

alignment

Posture

adJustment

Steenng
system

SpeCificatIons

CHAPTER
FOURTEEN

BRAKES
187

Brake

pedal

Master

cylInder

Front
diSC
brakes

Rear
brakes

Front
drum
brakes
Wheel

cylInders

Brake

system
bleedIng

Handbrake

Service
data
and

speCificatIons

CHAPTER
FIFTEEN

BODY
ELECTRICAL
SYSTEM

Wmng

SWitches
and
fuses

Instrument

meters
and

panels

Heater
205

Wmdshleld

wipers

Wmdslueld
washers

Headlamps

WIrIng
diagrams

CHAPTER

SIXTEEN

BODY

223

Front

body
trIm

Bumpers

Hood
lock
control

Doors
Door
locks
and

regulators

Trunk
lId
and

rear

bumper

Seats

Tad

gate

INDEX

235

I

GENERAL
INFORMATION
5

Table
1
MAIN

SPECIFICATIONS
AND
DIMENSIONS
continued

Suspension
Rear
Sedan
Wagon
Pick

up

Manual
Automatic
Manual
Automatic
Manual

HypoJd
Hypoid
Hypold

ReCIrculating
ball
ReCIrculating
ball
ReCirculating
ball

DIsc
DIsc
Drum

Drum
Drum
Drum

Mechanical
rear
wheels
Mechanical
rear
wheels
Mechanical
rear
wheels

Independent
strut

type
Independent
strut

type
Independent
torsion
bar

with
tension
rods
and
with
tension
rods
and

stabilizer
stabilIZer

Independent
semi

trailing
Semi

elliptiC
leaf

spring
Semi

elliptic
leaf

spnng

arms
wrtII
coli

springs
and

shock
absorbers

5
6O
13
4PR
5
6O
13
4PR
600
14
6PRLT
ITEM

Transmission

Type

Final
Gear

Type

Steering
Gear

Type

Brake

Front

Rear

Parking
Brake

Suspension
Front

Tires

6
2
Q
1
C
S

PA
l
PlLlU

EN
4
1
AJ
E

Dt7
A

1
1
1

2
A
ru
r
f
f
A

I
III

r
c

o
I
pP
D

LA
I
tV
r
IL

c

W

L
L
l
G

ftiv
TJ

dE
IJ
S
prlc
I

u

F
l
e

p
f
vi
Ii

ftl
1
3

l

1t
J
p7
5

PrlV

B4dc
u
11
1

S
t
f
PT

f
L
UJ
ff
zr
F

T
ff

lfo

1oo

4

t

M

0

IY
AJ
to
BTOL

@
OD

2

lP

S

PAtl
pI
c

5
IN
G

ex
Sf

0103
I
D
0
3
O

j

oo

0
0
0
to

l
c

o

0
0

2
JP
t
UE

SEIT
A

C
1

J

16

CHAPTER

TIlREE

sary
Also
check
all

parts
for

mlSaltgnment
and

uneven
wear

TRANSMISSION

1

Difficult
to
mesh

gears

Make
certam
the

clutch

pressure
plate
and
re

lease

beanng
are
m

good
condItion
The
trouble

can
be

caused

by
worn

gears
shaft
and
or
bear

mgs
DISassemble
and

repaIr
as

requIred
Also

can
be
caused

by
msufficlent

operatmg
stroke

due

to
worn
or
loose

sltdmg
parts
or
a
defective

synchronIZer
DIsassemble

carefully

InSpect
and

replace
as

requIred

2
Gears

slip
out

of
mesh

Generally
thIS
trouble
occurs
when

the
mterlock

plunger
check
ball
and

or

spnng
IS
weakened

or
worn
The
trouble
can

also
be
caused

by
worn

fork
rod
ball

groove

damaged

bearings
or
dam

aged

gears
DIsassemble

carefully
mspect
and

replace
as

required

3
NOIse

If
nOISes
are
heard

wIth
the

engme
idlmg
and
the

clutch

disengaged
the
nOIse
IS

probably

conung

from
the

transmISSIOn
Several
Items

can
cause

nOISes

either

smgly
or
m
combmatIon

Check
the

qualIty
and

quantity
of
lubrIcant

in
the
trans

mISSIon

Replace
or

replenISh
as

necessary
Worn

bearIngs
wIll

usually
produce
a

lugh
humming
at

hIgh
speed
and

a

cycltc
knockIng
sound
at
low

speed
Worn

or

damaged
splInes
and

bushmgs

will
also
cause

nOIse

BRAKES

1
Brake

pedal

goes
to

floor

There

are
numerous
causes
for
thIS

includIng

excessIvely
worn

Itnmgs
aIr
in
the

hydraultc

sys

tem

leaky
brake
lmes

leaky
wheel

cylmders
or

leaky
or
worn

master

cylmder
Check
for
leaks

and
thIn
brake

linmgs
Bleed
and

adjust
the

brakes
If

thIS
doesn
t
cure
the
trouble

rebwld

wheel

cylmders
a
nd
or
master

cylmder

2

Spongy

pedal

Normally
caused

by
aIr
m
the

system
blee
d
and

adjust
the
brakes

3

Brakes

pull

Check

brake

adjustment
Also
check
for
contam
inated

brake

Itmngs
from
leaks

leaky
wheel

cyltnders
loose

caltpers
frozen

or
seIZed

pIstons

and
restrIcted
brake
lmes

or
hoses
In
addItion

check
front
end

alignment
and

suspensIOn
dam

age
such
as
broken
front

or
rear

sprmgs
shocks

etc
Check
condItIon

of
tIres

4
Brakes

squeal
or
chatter

Check
brake

lmmg
thickness

and
brake
drum

roundness
Ensure

that
the
shoes
have
cham

ferred
ends

and
are
not
loose

Inspect
the
condI

tion
of

the
rotors
on
the
front
wheel
dISC

brakes

to
make

certain

they
are
not
scored

or

damaged

Clean

away
all
dIrt
on
shoes

pads
rotors

or

drums

5

Draggmg
brakes

Check

brake

adjustment
includmg
handbrake

Check
for
broken
or

weak
shoe
return

springs

swollen
rubber

parts
due
to

unproper
brake
flUId

or
other
contammatIon

Clean
or

replace
de

fectIve

parts

6
Hard

pedal

Check
brake

linmgs
for

contammation
Also

check
for

restrIcted
brake
lines

and
hoses

7

High
speed
fade

Check

for
dIstorted
or
out
of
round
drums

and

contamInated
brake

lmmgs
Make

certam
the

recommended
brake
flUId
IS

used
Dram
entIre

system
and
refill
If
In
doubt

8

Pulsatmg
pedal

Check
for
dIStorted
or
out
of
round
drums

or

rotors
Check
for

excessIVe
brake

dISC
run
out

STEERING
AND

SUSPENSION

NOTE
Unusual

steermg
pullmg
or

wandermg
IS

usually
caused

by
bent

or
otherwise

mIsaligned

suspenszon

parts
Because

of
the

speCialized
equIp

ment

reqUired
to
evaluate
and

correct

these

faults
It
IS
recommended

t
tat

servIce
to

the

steermg
and

suspension

system
be

referred
to

your
Datsun

dealer

oca

quallfied
specrallst
m

thiS

field

1
VibratIOn

felt
m

steermg
wheel

VIbratIon
can
be
caused

by
several

thmgs
includ

ing
lll1proper
aIr

pressure
m
tIres

uneven
wear

TROUBLESHOOTING
17

of
tIre
loose
wheels

unproper
adjustment
or

wear
of
front
wheel

bearIngs
faulty
wheel

align

ment
or
wear
of
transverse
lInk
and
tension
rod

bushings
Inspect
all

parts
carefully
for
wear
or

damage

Replace
or

replUI
parts
as

required

2
Shock

transmltled

through
steering
wheel

This
is

usually
most
noticeable
when

traveling

over
bad
roads
at

relatively
high
speeds
Causes

Include

damage
to
the
idler
ann
insuffiCient

tIghtening
of

steenng
gear
box
wear
of
the
steer

Ing
linkage
and
wear
of
the

suspension
ball

joint

Inspect
all

parts
for
wear
or

damage
Refer
to

Chapter
ThIrteen
for
service
or

repair
you
can

perform
and
for

procedures
which
should
be

referred
to

your
deal
r

3

Shlmmymg

This
is

usually
most
noticeable
when
a

specIfic

speed
IS
attained
and
will

normally
repeat
at
that

speed
Causes
are

generally
unbalanced
wheels

unproper
adjustment
of

steenng
gear
insuffi

cient
backlash
malfunction
of
the
shock
ab

sorbers
or
loose
bolts
for
the
strut

mountIng

Reparr
or

replace
defective

parts
as

required

Refer
to

Chapter
Thirteen

4

Wandermg
of
car
m
one
dlrectlOnl

This

problem
can
be
caused

by
improper
air

pressure
loose
wheel

nuts
difference
in
tire
tread

wear
from
left

to

right
side
Incorrect

adjustment

of
wheel

bearings
defectIve
wheel

beanngs

collapsing
or

twistIng
of
front

spnng
or
Incorrect

wheel

alignment
Also

binding
of
the
brake

shoes
worn

bushings
in
the
transverse
link
or
the

tension
rod
and
deformation
of
s

enng

lInkage

and

suspension
link
can
cause
wander

Carefully

iuspect
all

parts
for
looseness
and
wear
and
re

place
or

repaIr
as

required
In
some
c
ases
a
de

fective
rear

suspension
may
also
cause
the

vehicle
to
wander

5

InstabIlity

Instability
can

be
caused

by
unproper
tIre

pres

sures
worn

bushings
in
the
transverse
link
and

tension
rod
mcorrect
wheel

alignment
worn

steenng
linkage
Incorrect

adjustment
of
steer

ing
gear
and
unbalanced
wheels

Inspect
all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required
6

Heavy
feelmg
m

steering

This
can
be
caused

by
improper
tIre

pressures

insuffiCient
or
contamInated
lubncant
in

gear

box

damage
or
insuffiCient

grease
In

suspeuslon

ball

Joint
damaged
or

badly
adjusted
wheel

bearIngs
worn
or

damaged
steermg
gear
dam

age
of

upper
strut

bearing
and
mterference
of

steenng
column
With
turn

signal
SWitch

Inspect

all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required

7
ExceSSIve

play
m

steermg
wheel

This
is

usually
caused

by
Incorrect

adjustment
of

the

steenng
gear
worn

bushings
in
the

steering

linkage
or
Idler
arm
mcorrect

adjustment
of
the

front
wheel

bearings
worn

bushIngs
in
the
trans

verse
lInk
and
tension
rod

Carefully
inspect
all

parts
for
wear
or

damage
Adjust
repair
or
re

place
as

reqUIred

TIRE
WEAR
ANALYSIS

Abnormal
tIre
wear
should

always
be
ana

lyzed
to
deternune
the

cause
The
most
common

are
Incorrect
tIre

pressure
improper
dnving

overloading
and

Incorrect
wheel

ahgDment

Figures
2A

through
2F

identify
wear

patterns

and
mdicate

likely
causes

Of

I

1

l

D

1

Undennflatlon
Worn
more
on
Sides
than
In

center

CHAPTER
THIRTEEN

FRONT
AXLE
FRONT

SUSPENSION

AND
STEERING

A
strut

type
front

suspension
IS
used
on

sedans
and

wagons
The
shock
absorber
and
the

spmdle
are
a

smgle
urnt
which
is

supported
by

a
coIl

spnng
on
the

upper
end

and

by
the
trans

verse
lInk
on
the
lower
end

Figures
1
2
nnd
3

are

exploded
dIagrams
of
the
axle
and

suspen

SIon

system
used

FIgure
1
Illustrates
the
axle

Figure
2
shows
the
sedan

suspenSlOn
and

FIgure

3
covers
the

wagon

Front

suspensIOn
on
the

pIck
up
IS
a
double

wIShbone

mdependent
deSign
which
uses
torsIon

bars

Figure
4
IS
a
cross
sectional
view

WHEEL
HUB
AND
WHEEL
BEARING

SEDAN
AND

WAGON

Wheel
Hub
nnd
Wheel

Bearing
Removal

Sednn
aud

Wagon

1
Jack

up
the
front
of
the
vehicle
and

support

It
on
stands

2
Remove
the
wheels

3
Detach
brake
hose
connector
at
frame

4
Remove

calIper
fiXlng
bolts
and
then

cahper

See

Figure
5

5
Remove
hub

cap
cotter

pin
and
front

spindle

nut
See

Figure
6

6
Remove
front
wheel

bearmg
washer
Detach

front
wheel
hub
and
rotor
ft

V

0

y

F
I

I

J

j

0
l
l

4

f

FRONT

AXLE
FRONT
SUSPENSION

AND
STEERING

173

Spindle
Nut

21
7

to
253ft
Ib

30to35kg
m

528

to
716

ft
Ib

7
3

to
9
9

kg
m

282

to
38

3
fl
Ib

3
9to
5
3

kg
m

195

to
26

8
fl
b

2
7to3
7

kg
m
Caliper
FIXing
Bolts

Rotor

Flxmg
Bolls

Back
Plate

fiXIng
Boft

STABILIZER
SEDAN

AND

WAGON

SfBbilizer

Removal
Sednn

and

Wagon

1
Refer
to

Figure
8
Remove
stabilizer
mount

bolts

1
from
both

Sides
of

the
transverse
hnk

2

Remove
the
bracket

bolts
2
and
stabilizer

Stabilizer

Inspection
nnd

Repair

1

Inspect
the
stablhzer
for
wear
and

damage

If

the
stabilIzer
has
been
bent

replace
It

2

Check

bushmgs
for
wear
and

damage
Re

place
as

reqUIred

Stabilizer

Installation

1

Reverse
the

procedure
used
m
removal

2

Torque

parts
as
follows

Transverse

link
Bracket
87to
123ft

lb

12

to
17

kg
m

137tol81ft
Ib

19
to25

kg
m
Frame
Bracket
TENSION
ROD

REMOVAL
INSPECTION

REPAIR
SEDAN
AND

WAGON

1

Refer
to

Figure
9
Remove
bolts
2

on
the

transverse
hnk

SIde
Remove
nuts
1

on
the

body
Iframe
side

2
Remove

tensIOn
rod

3

Inspect
tensIOn
rod
for
bends
or
cracks
Re

place
1f
defective

4

Inspect
rubber

bushings
for

damage
and

wear

Replac
l
as

reqwred

Tension
Rod
Installation

1
Install
tension
rod

m
the

reverse
order
used

m
removal

2

Torque
mountIng
bolts
as
follows

Frame
Bracket
Side

521
to

694
ft
Ib

72
to
96

kg
m

354
to

456ft
Ib

49

to
63

kg
m
Transverse
LInk
Side

SPRING

AND
STRUT

ASSEMBLY

SEDAN

AND

WAGON

Repair
and

serVicmg
requires
SpecIal
tools

not

usually
avaJlable
to
the
home
mechaniC
The

followmg
procedures
are
hmIted

to
removal

and

replacement
Disassembly
and

repair
should
be

referred

to
a
Datsun
dealer

FRONT
AXLE

FRONT
SUSPENSION
AND
STEERING
175

2
Remove
bolt

cormectIng
strut
and
knuckle

arm

3
Remove
cotter

pm
and
lower
ball

Joint

4

Separate
lower
ball

Jomt
from
knuckle
arm

5
Remove
bolts
for
lower
ball

Jomt
Separate

transverse
lmk
from
lower
ball

Joint

6

Inspect
ball

Jomt
and
dust
cover
for
wear
or

damage
Replace
as

requIred
If
end

play
m
the

aXial
dIrectIon
of
the
ball

Jomt
exceeds
00012

to
0
0136
m
0
03

to
0
6mm

replace
It

7
Install
ball

Jomt
m
the

reverse
of
removal

Grease
It

through
the

grease
mpple
Take

care

to
fill
the

caVity
slowly
so
that

grease
does

not

come
out
from
the

clamp

portIon

8

Torque
bolts
as
follows

Lower
Ball

JOint
to

Transverse
Link

Ball
Stud
Nut
13

7
to
18
1
fl
Ib

19
to
25
kgfm

398

to
55
0
fl
Ib

55

to
76

kgfm

43
4

to
57
8
flAb

60

to
80

kgfm

35
4
to
45
6
flAb

49
to
63
kgfm

87
to
12
3
fl
lb

12
to
17

kgfm
Knuckle
Ann
to
Strut

TenSion
Rod
to
Transverse

Link

Stabilizer
to
Transverse

Link

FRONT
SUSPENSION
ADJUSTMENT

AND
WHEEL
ALIGNMENT

SEDAN
AND

WAGON

Due
to
the

speclahzed
eqUIpment
required

front

suspensIOn
adJustment
and
wheel

ahgn

ment
should
be
referred
to
a
Datsun
dealer
or

front
end

speciahst
The

followmg
specmcations

apply
to
the
sedan
and

wagon

Sedan

Wagon

Caster
1
40
20
00

Camber
1
00
20
10

King
Pin
Incllnallon
8000
7050

Toe

In
0236
to
0
354
In
0118
to
0
236
In

6

to
9mm
3
to
6mm

Steenng
Angle
In
38
to
390
38

to
390

Steenng
Angle
Out
22030

to
330
30
220
30
to
330
30

Front
Axle
Removal

Pick
up

Refer
to

Figure
13
and

proceed
as
follows

1
Jack

up
vehIcle
and

support
it
With

stands

2
Remove
wheel
nuts
and
wheels

3
Remove
brake
hose
from
wheel

cylinder
@

@

1
Knuckle

spindle

2
Inner
wheel

beanng

3

Outer
wheel

beanng

4
011
seal

5
Wheel
hub

6
Washer

7
Spindle
nut

8

Beanng
cap

9
Brake
drum

10
Wheel
nut

11
Knuckle
spindle
support
12

KUlg
pin

13
Thrust

beanng

14
fulaum
bolt

15
Fulcrum
pin

16
Fulaum
bolt

17

King
pin
lock
bolt
or

nut

18
Collar

19
Knuckle
ann

20

King
pin
busllIng

4
Remove
the
brake
drum
Refer
to

Chapter

Fourteen

5
Remove

bearmg
cap
cotter

pin
and

spmdle

nut
from

spmdle
knuckle

6
Remove
wheel
hub
wheel

bearings
011
seal

and
collar
from

spmdle
knuckle

7
Remove
brake

assembly
from
knuckle

spin

dle

flange

8
Remove
knuckle

arm
from

spmdle
knuckle

See

Figure
14

9
Remove

kmg
pm
lock
bolt
See

Figure
15

10
Remove

plug
from
the

top
of

kmg
using
a

rod
or
other
SUItable
tool
The

plug
can
be

FRONT
AXLE
FRONT
SUSPENSION
AND

STEERING
177

5
Check
front
hub
for
cracks
and

damage
Re

place
1f
defectIve

6
Check
thrust

bearmg
for
wear

damage
rust

and
ease
of
rotatIon

Replace
1f
defectIve

Front

Suspension
Installation

1
Remstallation
is
the
reverse
of

removal

2

Apply
hght
coatIng
of
multI

purpose
grease

to
all

shdmg

parts

3
Install

bushmg
carefully
so
that

grease
groove

IS
on
the

upper
Side
and
the

bushmg
Joint
is
faced

rearward
Remove

grease
mpple
and
dn11

grease

hole

through
bushmg
through
hole
With
an

0
1181

m
3mm
dn11
Remove
metal

shaVlDgs

and
burrs
Ream
the
mner
d1ameter
of
the

bushing
to
07878
to
0
7888
m
20
010
to

20035mm

4
Install
thrust

bearmg
so
that
the
covered
face

Side
is

upward

5
Push

up
the
bottom
of
the

spmdle
hghtly

Measure
clearance
and
select
a

spmdle
shim
to

prOVide
the

followmg
clearance

standard
Clearance
0
001
In

004mm

ShIms
are
available
m
vanous
thicknesses

6
FIt

kmg
pm
and
make
certam
It

operates

smoothly

7

Apply
sealer
to
new

plug
and
install

8
Install

bearmg
outer
race
Fill
wheel
hub
and

hub

cap
With
multI

purpose
grease
Fill

space

between
wheel

bearing
rollers

and

grease
seal

hp
pocket
With
multI

purpose
grease
Make
cer

tam
wheel

beanngs
are
coated

completely

9

Apply
multI

purpose
grease
to

spmdle
shaft
wheel

bearmg
washer

and
to
the
wheel

bearmg

lock
nut

10
Make
certam
that
no
dIrt
or

foreign
matenal

IS

permitted
m
contact
with

parts
or

grease

dunng
assembly

Wheel

Bearing
Adjustment

1
Install

spindle
nut
and

torque
to
23
1
to
24
6

ft
lb
3
2
to
3

4

kg
m

2
Turn
wheel
hub

a
few
tImes
m
both
the
clock

Wise
and
counterclockwISe
directIon
Recheck

the

spmdle
nut

tighmess

3
Back
off

spmdle
nut
from
40
to
70

degrees

until
hole
m

spmdle
and
nut
COinCIde
Insert

cotter

pm
and
bend
over
around
nut

4
Turn
wheel
hub
a
few
turns
in
both
d1rectIons

to
seat

bearmg
Check
the

startmg
torque
of
the

hub
With
a

spring
gauge
as
shown

Figure
20

Startmg
torque
should
be
as
follows

New

Beanng
and
Seal
130
In

Ib
or
less

15
kgl
an

or
less

i

Used

Beanng
and
Seal
6
1
In
Ib
or
less

7
kgl
an
or
less

5

ReadJust
spmdle
nut
as

necessary
to
achieve

proper
startmg
torque
When
correct
mstall
the

hub

cap

Front

Suspension
Pick

up

Durmg
the

followmg
procedures
refer
to

FIg

ure
4
at
the

begmning
of
this

chapter

Front

Suspension
Removal

1
Jack

up
the
vehicle
and

support
It
With
stands

2
Remove
wheels
Remove
front
axle
as

pre

Viously
described

3
Remove
brake
hose
from
wheel

cylinder

FRONT
AXLE
FRONT
SUSPENSION
AND
STEERING
179

17
Remove
lower
lmk

torque
arm
and

torque

arm
bolt

Separate
torque
arm
from
lower
lmk

18
Dnve
out
lower
lmk

bushmg
from
bracket

Front

Suspension
Inspection
and

Repair

1
Check
the
shock
absorber
for
011

leakage
and

general
conditIon

Replace
1f
defects
are
found

2
Check

upper
and
lower

bushmgs
Replace
If

defective
or
worn

3
Install
screw

bushmg
to

upper
lmk

spmdle

and
fulcrum

pm
Measure
end

play
m

aXial

dIrection
If
end

play
exceeds
000
38
m

0
033mm

replace
upper
lmk

spmdle
fulcrum

pm
and
or
screw

bushmg

4
Check
dust
cover
for

damage
and
detenora

tIon

Replace
as

reqUIred

5
Check
threads
of

upper
lmk

spmdle
fulcrum

pm
and
screw

bushmg
RepaIr
or

replace
If

defective

6
Check
lower
lmk
and

upper
lmk

bushmgs
for

general
condition
and
wear

Replace
1f
defective
7
Check
torsion
bar
for
distortion
weakness

bends
and

general
conmtIon

Replace
If
de

fectIve

8
Check
tensIOn
rod
for
dIStortion
If
the

threaded

part
is

damaged
replace

9
Check
tenSiOn
bar
cushIOn
rubber

Replace
if

defective

10
Check
dust
seal
for
wear
and

damage
Re

place
as

requIred

11
Check
threaded

part
of

upper
lmk

spmdle

fulcrum

pm
and

screw

bushmgs
for
wear
and

damage
Replace
as

required

2
Check
lower
hnk

bushmg
and

upper
hnk

bushmg
for

SignS
of
wear
or

damage
Replace
as

reqwred

13
Check

torsIOn
bar
for
dlstorllon
and

general

condition

Replace
as

reqwred

14

Replace
rubber

bumper
If
weakened
or

damaged

15
Check

upper
and
lower
lmks
for
cracks

thread

damage
and

general
condition

RepaIr

or

replace
If
defectIve

Front

Suspension
Installation

1
Fit
lower
lmk

bushmg
to

lower
lmk

mountmg

bracket

usmg
a
SUItable
drlft

and
hanmIer

2
Install

torque
arm
on
lower
lmk

Torque

bolts
as
follows

181

to
224
fl
lb

25to31

kg
m

58
to
8
7
fl
Ib

08
to
12

kg
m

4

Tighten
screw

bushmg
on

upper
lmk
Install

grease
seal
and
dust
cover

Torque
to
173
5
to

1808
ft
lb
24
to

25

kg
m

5
Refer
to

Figure
27
Fill

upper
lmk
screw

bushmg
With
multi

purpose
grease
as
mdlcated

by
the
m

the
Illustration

Apply
grease
to
bush

mg
mtenor
Thread
on

upper
lmk

spmdle
to
the

dimenSIOn
mdIcated

6
Screw
front
and
rear
lInks

agaJnst
upper
hnk

spmdle
to
the

openmg
Width
mdlcated
Remove

the
filler

plug
while

fittIng
the
front
and

rear

lmks
Check
to
make

cectam
that
the

upper
link

spmdle
operates
smoothly

7
Remove
filler

plug
mstall

grease
mpple
and

inJect
grease
untIl
It
comes
out
from
dust

cover

Reinstall
filler

plug
Arm
Head

Serration
Boss

FRONT
AXLE
FRONT
SUSPENSION
AND
STEERING
181

18

TIghten
nut

on
rear
end
of
tension
rod
to

compress
rubber

bushings
to
1
315
m
334

fi2

mm
See

Figure
31

Torque
lock
nut
to
10
8
to

152ft
lb

1
5
to

2
1

kg
m

334mm
1315m

36
6
mm
1
441
m

19
Install
tensiOn
rod
bracket
on
frame
bracket

Tighten
nut
on
front
end
of
tensIOn
rod
untll
the

rubber

bushmgs
measure
1441
m
366mm

If
rubber

bushmgs
are

compressed
unequally

adJust
the

adJusting
nut
until

they
are

equal

Torque
the
bracket
bolt
to
108
to
152
ft
lb

1
5
to
2
1

kg
m

20
Install
shock
absorber

Torque
upper
lock

nut
to
10
8
to
152ft
lb

1
5
to
2
1

kg
m
and

lower
bolt
to
260
to
311ft
lb
36
to
43

kg
m

21
On
the
stabilizer

tighten
the
nut
until
the

dimenSIOn
shown
on

Figure
32
IS
correct

Torque

bracket
bolt
to
10
8
to
152ft
lb

1
5

to
2
1

kg
m

22
Grease
serratIon
on
both
ends
of
torSiOn
bar

and

mstalllt
on

torque
arm
Be
careful
to
use
the

correct

spnngs
They
are
marked
on
the
end

WIth
an
R
or
L
for

nght
and
left

23
Position
lower
hnk
to
ehmmate
clearance

between
lower
hnk
and
rubber

bumper
Install

spnng
anchor
on
torsIOn
bar
The

A
dImenSiOn

shown
m

Figure
33
should
be
3
86
m
98mm
S

M

2

E

E

D

@

24
Jack

up
spnng
anchor
and
msert
anchor

bolt
See

Figure
33

Tighten
nut
so
that
the
A

mmenslon
shown

IS
2
697
m
68
5mm

Torque

the
lock
nut

to
28
9
to
362ft
lb
4
to
5

kg
m

25
Check
the
vehicle

posture
and

adJust
as

necessary
AdJustment
IS
dIScussed
below

POSTURE
AD
JUSTMENT

Vehicle

posture
may
be
mcorrcct
due
to

weakened

sprmgs
or
other
defective
conmtions

If

adJustment
IS

necessary
proceed
as
follows

1
Jack

up
vehicle
and

support
It
on
stands

2
Place

a

Jack
near
the

sprmg
anchor
bolt
and

Jack
up
until
the

nuts
are
free
of

spnng
force

3
Refer
to

Figure
34
The
standard
H
d1men

Slon
shown
should
be
3
11
to
331
m
79
to

84mm
Without
load
and
2
15
m
54
5mm

WIth
standard
load
Standard
load
would
be
3

passengers
and
2
204
6
lb
1
000

kg
of

cargo