1983 Subaru EA81

TAB LE OF CONTENTS

SUBARU

1600 I BOO

FOREWORDThis service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU 1600 and 1800 series. This manual completely covers the proce. dures . for maintenance, disassembling, reassembling, inspection and adjustment of components and troubleshooting for gUidance of both the fully qualified and the less-experienced mechanics. . Please peruse and utilize this manual fully to ensure complete maintenance and repair work for satisfying our customers by keeping their vehicles in op-timum condition. When replacement of parts during maintenance is needed , be su :~e to use SUBARU genuine parts. All information, illustrations and specifications contained in this manual are based on the latest product infonnation available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

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AU,

and are trademarks of FUJI HEAVY INDUSTRIES LTD . Copyright 1982 FUJI HEAVY INDUSTRIES LTD.

-8-

fI

Not to be reproduced in whole or in part without the prior written permission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN .

CHAPTER'iJGENERAL INFORMATIONp.1- 1. GENERAL SPECIFICATIONS ................................................................ 1- 21- 2. VEHICLE IDENTIFICATION NUMBERS (V.I.N.) ................................. 1- 4 1. Applicable V.I.N. of This Manual.......................................................... 1- 4

2. The Meaning of V.I.N. .......................................................................... 1- 61- 3. IDENTIFICATION NUMBERS ................................................................ 1- 6

1. Vehicle Identification Number .............................................................. 1- 62. Engine Serial Number ... 1- 8

3. Transmission Serial Number ................................................................. 1- 61- 4.1. Safety Certification Plate ..................................................................... 1-

. LARE LS .................................................................................................... 1- 8.~'"

~'""t

i

2. Vehicle Emi.ion Control Information Labels ...................................... 1- 6

3. Emission Data Label (California Models Only) .................~~............... 1- 64. VehicleldentiflCltion Number Plate ............................. L ...........~t ."'\;;

' ' '.1_

5. Color Code Label ................................................ 1- 1 1- 6. RECOMMENDED LUBRICANTS ........................................................... 1- 7 1- 6. RECOMMENDED SEALANTS, ADHESIVES AND ,..~'.

GREASES ..... 1- 8

1- 7. TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS ......... 1- 9 , 1- 8. OPENING ENGINE HOOD .................................................................... 1-10

1- 9. LIFTING POINTS AND PROCEDURE ................................................. 1-10 1. Pantograph Jack .................................................................................. 1-10 2. GarageJack ......................................................................................... 1-113. Lift ...................................................................................................... 1-11

1-10. TOWING HOOKS ................................................................................... 1-12

B.I1I1

-----~----.-----~--~~-~-~."........,--

........

--.---~--~-~~~-~-~----.~-~-

----._.r'r~

----...,.,

--

-

1800 Station Wagon DL 5MT GL 5MT AT 4WD DL 4MT Dfr 4WD GL AT

1600 Hatchback STD 4MT Overall length Overall width Overall height DL 5MT GL 5MT AT

1800

1600

1800

1600 Hardtop--

Sedan4WD STD 4MT 4WD GL Dfr DL 5MT GL 5MT AT

I

~

--

-

BRAT 4WD DL 4MT Dfr 4WD GLI

D

1\..

DL 5MT

GL 5MT AT

\

~

AT

I

4425 4425 4285 4285 4285 4300 4425,1 4270 4280 4250 4270 4250 3985 4010 3995 3995 mm 3985 (in) (156.9) (156.9) (157.9) (157.3) (157.3) (167.3) (168.1) (167.3) (168.1) (168.5) (169.3) (168.7) (168.7) (168.7) (174.2) (174.2) (174.2) mm (in) mm (in)r

1610 (63.4) 1365 (53.7)

1610 (63.4) 1365 (53.7)

1615 (63.6)

1620 (63.8)

1620 (63.8)

1410 1365 (53.7) (55.7)

1610 (63.4) ---- I-----1415 1365 (55.7) (53.7)

1615 (63.6) 1365 (53.7)

1610 (63.4) 1350 (53.1)

1615 (63.6) 1350 (53.1)

1610 (63.4) 1390 (54.7)

1615 (63.6) 1390 (54.7)

1620 (63.8) 1440 (56.7)

1620 (63.8) 1445 (56.9)

1620 (63.8) 1445 (56.9)

1635 (64.4) 1440 (56.7)

1635 (64.4) 1445 (56.9)

1635 I (64.4) 1445 (56.9)

".. 3 ._. -

en

I

n ,. _.

Co)

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mm Length (in) Compartment

1700 (66.9)

1700 (66.9)

1700 (66.9)

1700 (66.9)

1700 (66.9)

1750 (68.9)

1750 (68.9)

1750 (68.9)

I ['~~-"]two_u CalJ0 space atfour . .Is

'1500 '1500 '1500 '1500 .' 1500 960 960 (59.1) (59.1) (37.8) (37.8) 1750 (59.1) (59.1) (59.1) (68.9) .2 785 .2 785 .2 785 .2 785 .2 785 $1610 '1610 (30.9) (30.9) (30.9) (30.9) (30.9) (63.4) (63.4) '1290 1345 (50.8) (53.0) .11320 (52.0) 1105 (43.5) 2460 (96.9)--

960(37.8) '1610 (63.4)

.0 ::I

m Z m::D

r."

Z

~ is

CalJspace

Width

BRAT - rear CUlO bed only

~~

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

'1290 '1290 '1290 .11290 (50.8) (50.8) (50.8) (50.8)

01300 (51.2) 1300 (51.2)

::D

1300 .21320 .11320 .21320 .21320 (51.2) (52.0) (52.0) (52.0) (52.0)

~ 0Z

3:

H'gh mm el t (in)

1115 (43.9) 2380 (93.7) 1330 (52.4) 1345 (53.0) 165 (6.5)-

1115 (43.9) 2380 (93.7) 1330 (52.4) 1345 (53.0) 165 (6.5)

1115 (43.9)

1115 (43.9)

1115 (43.9) 2370 (93.3) 1335 (52.6) 1370 (53.9) 210 (8.3)

1115 (43.9) 2460 (96.9) 1330 (52.4) 1345 (53.0) 165 (6.5)

1115 (43.9) 2460 (96.9) 1330 (52.4) 1345 (53.0) 165 (6.5)

1105 (43.5) 2460 (96.9)

.3

860 .3 860 .3 860 . l 860 .3 860 (33.9) (33.9) (33.9) (33.9) (33.9) 2455 (96.7) 1325 (52.5) 2455 (96.7) 1325 (52.5) 2445 (96.3) 1310 (51.6) 2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3) 2445 (96.3) 1335 (52.6)

2445 (96.3) 1310 (51.6) 2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3)

2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3)

WheelbaseFront Tread Rear Minimum road clearance

mm (in) mm (in) mm (in)

2380 '2370 (93.7) (93.3) 1330 (52.4) 1345 (53.0) 165 (6.5) 1310 (51.6) 1345 (53.0) 205 (8.1)

1330 1330 (52.4) (52.4) 1345 1345 (53.0) (53.0) 165 (6.5) 165 (6.5)

1345 (53.0) 175 (6.9)

1345 1340 (53.Q) (52.8) 175 (6.9) 205 (8.1)

1365 1340 (53.7) (52.8) 205 (8.1) 205 (8.1)

--

mm(in)

.': Between rear end of seat and rear gate .': Between back panel and rear gate

1600 Hatchback STD 4MT DL 5MT GL 5MT AT.. I

1800

1600

1800

1600 Hardtop

1800 Station Wagon DL 5MT GL 5MT AT.. I

Sedan 4WD STD 4MT 4WD GL Dfr DL 5MT GL 5MT AT.. I

BRAT 4WD GL Dfr AT 4WD DL 4MT Dfr 4WD GL AT

DL 5MT

GL 5MT AT.. I

4WD DL 4MT

Front

f"~~GL4)lit;

Curb weight *

.

617 626 596 603 kg 622 631 583 587 592 615 587 592 599 (lb) (1285) (1295) .., 615 (1305) (1355) (1295) .. 1 624 (1305) ..1 626 (1320) .. , 624 (1330) (1370) (1390) (1315) (1360) (1380) (1355) (1375) (1375) (1380)' .. I

603 (1330)

610 (1345)

615 (1335)

612 (1350)

m Z m

C)

w

~

!C

GLF models SMTofDL model and ATofGL& GLF models

Rear

kg (Ib)

347 (765)

347 (765)

384 .., 367 (845) (810).. I

359 (790)

.. I

399 (880)

379 (835)

383 (845)

.. I

.. 1

365 387 (805) (855)

474 469 469 422 .. , 379 (930) .. , 442 (1035) (1035) (1045) (835) (975).. I

374 (825)

.. I

435 (960)

391 (860)

401 (885)

406 (895)

r."

::D

Z

o

Total

kg 930 (Ib) (2050)

934(2~0)

1032 1018 1021 987 1072 1091 1105 976 1014 966 957 (2150) (2235) (2130) ..21011 (2110) .. , 1005 (2250) "'1066 (2365) (2405) (2435) (217 5) (2245) (2275) ..2 982 (2165) (2350) (2230) (2215)

962 (2120)

.. I

993 (2190)

989 (2180)

.. 11048 (2310)

::D

i:

o z

~

Front Gross Vehicle weight Rear Total

780 780 kg 780 803 780 780 796 803 803 780 780 803 803 803 803 803 803 (Ib) (1770) (1770) (1770) (1720) (1720) (1770) (1770) (1770) (1770) (1770) (1770) (1720) (1720) (1755) (1720) (1720) (I 720) kg 658 658 658 680 680 658 658 658 658 (lb) (1450) (1450) (1450) (1500) (1500) (1450) (1450) (1450) (1450) 789 789 789 789 796 744 762 789 (1640) (1680) (1740) (1740) (1755) (1740) (1740) (1740)

1569 1569 kg 1461 1461 1461 1461 1461 1461 1547 1569 1592 1569 1565 1569 1461 1461 1461 (Ib) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3410) (3450) (3460) (3460) (3510) (3460) (3460) (3460)- -

* Vehicle with optional eqUipment is out of this specifications.

_.

__.-

__________

______

~

________________

~

_____ __________.~1

~

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____________

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)

GENERAL INFORMATION

12. Vehicle Identification Numbers (V.I.N.)1. Applicable V.I.N. of This Manual 1600 cc Engine 2-Door Hatchback 2-DoO Hatchback 4-Door Sedan Hardtop 1800 cc Engine 2-DoO Hatchback 2Door Hatchback 2-Door Hatchback 2-DoO Hatchback 4-Door Sedan 4Door Sedan Hardtop Hardtop Station Wagon Station Wagon Station Wagon Station Wagon Station Wagon Station Wagon BRAT BRAT BRAT GL GL 4WDSTD 4WDGL GL GL GL GL DL GL GL 4WDDL 4WDGL 4WDGL 4WDDL 4WDGL 4WDGL (SMT) (AT) (4MT) (4MT. Dual-range) (SMT) (AT) (SMT) (AT) (SMT) (SMT) (AT) (4MT) (4MT, Dual-range) (AT) (4MT) (4MT, Dual.range) (AT) J J J J F F F F 1 1 2 2 A A A A F F F F 4 4 5 5 3 3 1 3 B B B B X X X X D D D D B C D E 1 1 1 1 STD DL DL DL (4MT) (SMT) (SMT) (SMT) J F 1 A F 2 1 B X D A 1 0 J F 1 A F 2 2 B X D B 1 0

o0 o0

0 1 and after 0 1 and after1 and after

J F 1 A B 2 2 B X DB 2 0 0

o0

J F 1 A W 2 2 B X D B 3 0 0 0 0 1 and after

0 0 0 0

0 0 0 0

o0 o0 o0 o0 o0 o0

1 1 1 1

and after and after and after and after

J F 1 A B 4 3 B X D B 2 0 0 J F 1 A B 4 3 B X D C 2 0 0

1 and after 1 and after

J F 1 AW 4 3 B X DB 3 o 0 0 0 1 and after J F 1 AW 4 3 B X DC 3 0 0 o 0 1 and after J J J J J J F F F F F F 1 1 1 2 2 2 AM AM AM AM AM AM 4 4 4 5 5 5 2 3 3 2 3 3 B B B B B B X X X X X X DB DB DC DD DE DF 4 4 4 4 4 4

o0 o0 o0 o0 o0 o0

o00 0

o0 o00 0 o0

1 1 1 1 1 1

and after and after and after and after and after and after

J F 2 AT 5 2 BX DD 5 J F 2 AT 5 3 BX DE 5 J F 2 AT 5 3 B X DF 5

o0 o0 o0 o0 o0 o0

1 and after 1 and after 1 and after

Abbreviations used 4MT: 4-speed manual transmission SMT: Sspeed manual transmission AT: Automatic transmission

1-4

GENERAL INFORMATION

2. The Meaning of V.I.N . . - - - - - - - - - - - - - - - - - - - - - - - - : - - - - - - Maker identifier , . - - - - - - - - - - - - - - - - - - - - - - Vehicle attribute Vehicle identification ..--""'---." .-,_---lL--_-., I'- - - - ' - - - - - , JFIAF2 BXDAIOOOOI

_---=----------[ Sequential number 100001 and after 200001 and after 300001 and after 400001 and after 500001 and after

Hatchback 4-Ooor Sedan Hardtop Station Wagon BRAT

Plant of manufacture and transmission type A: Gunma manufacture - 4MT B : Gunma manufacture - 5MT C : GUnma manufacture - AT D: Gunma manufacture - 4WD 4MT E : Gunma manufacture - 4WD 4MT, Dual-range F : Gunma manufacture - 4WD AT Model year D: 1983 Check digit othru 9 and X, varies Weight class B: 3,000 to 4,000 lb GVWR Model1 Standard model 2 : DLmodel 3 : GLmodel

Series and engine type 1 : 1300 cc engine 2 1600 cc engine 3 1600 cc engine 4WD 4 1800 cc engine 5 1800 cc engine 4WD Body type F : Hatchback B : 4-Ooor Sedan W: Hardtop M: Station Wagon T : BRAT Line restraint type A : Fuji Subaru line and seat belts B : Fuji Subaru line and air bag Type of vehicle 1 : Passenger vehicle 2 : Multipurpose passenger vehicle Manufacturer and make Fuji Heavy Industries Ltd. SUBARU

t-5

GENERAL INFORMATION

~13.

Identification Numbers

1. Vehicle Identification NumberThe vehicle identification number is stamped on the bulkhead panel of the engine compartment.

OM442

Fig. 12 Engine serial number location

Fig. 11 V.I.N. location Fig. 1-3tA-075

3. Transmission Serial 2. Enaine SerialNumberThe engine serial number is stamped on the righ t side of the crankcase at the front.

NumberThe transmission number label is stuck on the right upper surface of main case (MT) or converter housing (AT).

NOTE: Engine, transmission and vehicle identification numbers are used for factory communications such as Technical information, Service bulletins and other information.

14. Labels1. Safety CertificationPlateSafety certification plate is stuck near the driver's side door striker.

2. Vehicle EmissionControl Information LabelsVehicle emission control information labels are stuck under the engine hood.Certification label High altitude label (Altitude kit equipped vehicle only)

3. Emission Data Label(California Models Only)

Fig.

'6 Emission data label

Vacuum connections lIbel

OM.819

Fig.

1-4 Safety cartification plate

Fig. 1-5 Vehicle emission control labels

I

1-6

GENERAL INFORMATION

4. Vehicle Identification Number Plate

5. Color Code Label

OM820

Fig.

'-7

Vehicle identification number plate

Fig. ,-8 Colorcade label

1-5. Recommended LubricantsAPI ITEMCIa.

SAE viscosity No. and Applicable Temperature("P)("C)

aficllion

-30" -34

0 -180

30" 0"

60" 16

90"32 40y

J-.

130, 20W40, 20W-SO Engine oil

-

SE SF

-way clutch Oil pan Control valve Connecting shell

16 17 18 19 20 21 22 23 24 25 26 27 28 29

Transmission cover Oil pump Reverse clutch Brake band Transmission case Forward clutch Center support Low & reverse brake Planetary gear Parking gear Governor drive shaft Governor shaft Onl>-way clutch Final reduction case

A13-398

Fig_ 7-4

7-9

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

redluC1tiOll----Transmission case section-..,.>------ Transfer case section - - - - - - - I case section

1 2 3 4 5 6 7 8 9 10

Stator shaft Impeller Turbine Stator Turbine shaft Torque converter Oil pump drive shaft Converter housing Crown gear Drive pinion 11 Reduction gear 12 Oil seal holder

13 One-way clutch

14 15 16 17 18 19 20 21 22 23 24

Control valve Connecting shell Oil pump Oil pump carrier Reverse clutch Brake band Transmission case Forward clutch Center support Low & reverse brake Planetary gear

25 26 27 28 29 30 31 32 33 34 35

Parking gear Speedometer & governor drive gear Governor shaft Final reduction case Oil pan Transfer drive shaft Transfer gear Intermediate case Transfer clutch Rear drive shaft Extension caseA13-399

Fig. 7-5

7-10~>''''~"'.~"'''''~"''~"4'''"'_''''''-~J,.,~''''~"",,,",n"'f-""

_''''',.....'' 1"11_ _'

_ _ _- - _ ,...._ _ _.......""''''''''..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- ,


2. Construction and Operation1 4WD AT

1.

Construction

1) Overall ConstructionThe 4WD automatic transmission is basically composed of the conventional SUBARU 1800 automatic transmission, the transfer gear and rear wheel hydraulic driving clutch attached to the rear end of the transmission, and the hypoid pinion and transfer gear are connected by the transfer drive shaft. The transmission route of power is unchanged from that of the SUBARU 1800 4WD model (with manual transmission).

case and transmission case have been changed thoroughly, and an oil seal holder has been newly introduced in the reduction drive gear portion. The hydraulic clutch, planetary gear, control valve and other elementary components of the automatic transmission section are unchanged from those of the current automatic transmission.

3) Rear Drive Portion1) Transfer The transfer consists of a hydraulic multi-disc clutch, transfer clutch valve and solenoid, and these units are housed in the extension case together with the transfer gear.

Hydraulic multi-disc

Extension case

2) Front Drive PortionThe basic construction is unchanged from the current automatic transmission. Along with the adoption of a 4 wheel drive system, the final reduction

Transfer gear

A13-400

A13-401

Fig. 7-6 Transfer

The current to the solenoid is controlled by the 4WD selector switch located on the selector lever.4WD selector switch (pushbutton type) Selector lever

CHECKERUNITl

Fuse

Ignition switch

4WD pilot lamp (on instrument panel)

Fusible link

*

Checker unit is tightened together with intermittent wiper unit by one screw at the back of instrument panel.

4WD selector valve (4WD-FWD) Battery

Fig. 7-7 Transfer clutch control system

Al3-402

7-11

AUTOMATIC TRANSMISSION AND DIFFERENTIAL2) Rear differential The rear differential is unchanged from the SUBARU 1800 4WD (manual type). The difference in gear ratio with the front side differential is adjusted by the transfer gear (gear ratio 37/39 = 0.948) so that the front and rear wheels will rotate at the same speed. 3) Transfer clutch control circuit The transfer clutch circuit and transfer valve have been added to the line pressure circuit between the oil pump discharge side and control valve. Along with this change, the oil supply circuit to the torque converter and the lubricating circuit to the clutch and planetary gear portions have been partially modified.

AT for 83 MY Torque converter Lubrication to rear portion -r.:::::::;;t---I"""rr (c1 utches) Oil pump

AT for 82 MY and before Transfer (4WD) Torque converter Oil pump

r---------,II

I

Oil cooler

Lubrication

X Lubrication to front portion (planetary one-way clutch)

portion (planetary one-way clutch)

Pressure X Drain Restriction regulator

valve1~~~~

'*

A13-403

Fig. 7-8 Comparison of hydraulic circuits

4) Transfer valve The transfer valve is an of-off valve which opens and clbses the line pressure circuit to the transfer clutch, and this valve is operated by the solenoid. In the FWD mode, the solenoid push rod and valve are set at the right side by the spring positioned on the left side, and the line pressure to the clutch is disconnected. If the solenoid is energized by depressing of the 4WD selector switch, the push rod is activated and the valve is pressed to the left against the pressure of the spring. As the valve is moved,

the transfer clutch circuit opens while the drain circuit closes, and the line

pressure is led to the transfer clutch circuit to engage the transfer clutch.

Transfer clutch

Line pressure

A13-404

Fig. 7-9 Transfer valve

7-12I III 11".'''~4

....... -." .....

".-'1' 41-'' ' ' ' ' ' '_ _ 1'''''''''''1t..._____- - -__ ,q_ _ , ...

fJ1"'---_______________

-~


2. Operation1) Front Wheel Drive (FWD) The line pre~sure to the transfer clutch is disconnected by the transfer valve, and the clutch is kept in the disconnected state. All power is transmitted from the transmission to the front wheels through the front hypoid gear. During operation, both the drive member and driven member of the transfer clutch are rotating at the same speed.

Torque converter

r - - - - - - - --,I

Transfer (4WD)

. Oil pumpl L ub ncatlOn I to r~ar I-F.~:t---,t-=;r-portlon

I

II

(clutches)

ILL.;:::=;~ IOil cooler

I I

II I

xLubrication to front portion (planetary one-way clutch)

I I I I IClosed

I

L _______ J

Transfer valve

I I

Pressure X regulator valve X

Manual valve (line pressure)

X : Drain..L : Restriction TA13-405

Fig. 7-10 Hydraulic circuit in FWD mode

Torque converter

Oil pump Transfer clutch

Rear drive shaft

Front differential

Front hypoid pinion

Transfer drive shaft

Extension shaftA13-406

Fig. 7-11 Transmission of power in FWD mode

7-13

AUTOMATIC TRANSMISSION AND DIFFERENTIAL2) 4-wheel Drive (4WD)Torque converter Transfer (4WD) r--------,

If the pushbutton on the selector lever is set to the 4WD position from the FWD position, the transfer valve opens the circuit to the transfer clutch as the solenoid is activated, and, at the same time, the green 4WD pilot lamp illuminates on the meter panel. The line pressure, led through; transfer pipe .... intennediate case .... rear drive shaft, connects the transfer clutch (hydraulic clutch). The power is branched to the front and to the rear on the front hypoid pinion. The power branched to the rear from the shaft end of the pinion is led through; transfer drive shaft .... transfer gear .... transfer clutch .... rear drive shaft .... propeller shaft .... rear differential, and transmitted to the rear wheels.These characteristics have been established as being necessary to transmit the power from the engine to the rear wheels. If an excessive brake torque is created on the front and rear wheels in a tight cornering operation, the transfer clutch acts as a torque limitter (that is, the clutch slips), and weakens the braking torque, and also protects the driving members. As shown in the characteristic curve in the figure, the torque limiting function is more effective when the line pressure is lower (that is, when the throttle opening is smaller).

Oil pump' Lubrication I of rear I -F=:=::;=+--+f:""""'I1- portion --~~~(clutch)

I ,

I I

,

J~~b'Oil cooler

II

I

xLubrication of front portion (planetary one-way clutch)

II

III

I

I: Transfer valve L ________

J

I

1..:::== -+X :Drain : } : Restriction

Manual valve (line pressure)

A13-407

Fig. 7-12 Hydraulic circuit in 4WD modeTorque converter Oil pump Rear dr i ve shaft

/

Front hypoid pinion

Transfer drive shaft

Extension case

A 13-408

Fig. 7-13 Transmission of power in 4WD mode

3) Characteristics of Transfer ClutchThe line pressure is applied to the transfer clutch, and the clutch capacity varies, like the other hydraulic clutches, with the throttle opening and vehicle speed, as shown in the characteristic curve in the figure.Throttle full open

A13-409

o

490 (5,71)

981 (10,142)

Line pressure kPa (kg/cm 2 , psi)

Fig. 7-14 Characteristics of the transfer clutch (before o range "cut down")

l __

II"-,,,_~:=::.-=-;},

..

,,~~,"fj"'f

w ' ................ ....ffif

TF_.,..._-__. .

7-14-1flliii _ _....................... " " , _. ."':_ _ _ _'f _ _ _ _ _ _ _ _ _ _ _ _ _- _ "'i -... : _


3. Precautions for 4WD automatic transmission1) Be sure to use recommended au tomatic transmission fluid (A TF). The use of any other fluid may cause chattering of the transfer clutch. 2) If the driving mode is changed from 4WD to FWD while making a turn, a light shock may be felt in the vehicle body. This shock is caused by the releasing of the tight corner braking feature, and is a normal phenomenon. A similar shock may also be felt when changing from 4WD to FWD after a sudden stop. 3) If the pilot lamp remains off even after operating the 4WD selector switch, the 4WD operating electrical circuit may be faulty; the circuit must be checked and repaired.

4) If the front wheels must be engaged with the front end of the vehicle jacked up, or on a roller, be sure to set the 4WD selector switch to the FWD position, or disconnect the transfer solenoid harness connector in the engine compartment. Remember, if the switch is kept in the 4WD position, the vehicle may be moved as the engine is started. When disconnecting the harness in the engine compartment, use extreme care not to confuse the connectors. 5) The use of different sized tires will cause a shock when releasing the 4WD mode even when driving straight ahead, or will result in deteriorated fuel consumption. Be sure to use tires of the same size on all of four wheels. The tire inflation pressure must be set to the specifications. 6) When attempting to get out of a immobile state by switchback opera-

tion (switchover between "D" and "R"), avoid racing the engine with the lever set in the N position. 7) If the engine or transmission has failed, the vehicle must be towed with the front wheels lifted up. In such an event, the 4WD selector switch must be set in the FWD position.

A13-411

Fig. 7-15 Transfer solenoid harness connector

2 LOCK UP TORQUE CONVERTER1. ConstructionAn installation drawing in which the centrifugal lock up clutch is built into the torque converter and a view of the shoe section as seen from the front of the engine are shown below. This lock up clutch transmits torque by the centrifugal force acting on the shoes that slide along the inner circumference of the turbine cover. It has a very simple construction, consisting of five components: shoes and weights with paper facings pasted on their outer surfaces, two leaf springs (main and retractor springs) and pins. Eight shoes are used.Centrifugal lock-up clutch

Fig. 7-16

A13-413

7-15


CD

@ @ @

1 2 3 4 5

Shoe Main spring Retractor spring Weight

Pin

Fig. 717

A13-414

Operation of each component Shoe ... The shoe rotates at the same speed as the torque converter turbine, and slides along the inner circumference of the turbine cover. The shoe sometimes becomes completely engaged with the turbine cover, however, it usually slides in a half-clutch condition. The engine torque is transmitted from the turbine cover through the shoe to the reaction plate and then to the output shaft. Paper is used for the facing. Weight ... Using the centrifugal force produced by the rotation of the weight, the clutch transmits torque. The weight's primary purpose is to increase the transfer torque capacity in the medium- and low-speed ranges. Main spring '" The centrifugal force acting on the weight is transmitted to the shoe through the main spring. In the medium- and low-speed ranges, the load of the spring increases in proportion to the centrifugal force of the weight, so that torque capacity also increases. In the medium- and highspeed ranges, however, the spring load becomes constant regardless of the centrifugal force of the weight, functioning as a torque limiter. Retractor spring '" This spring always functions to pull the shoe inward, which, in the low-speed range where the centrifugal force is small, prevents the shoe from touching the drum. Pin ... The pin fixes the shoe in place so that it will not come off the reaction plate, and also serves as the weight stopper.

2. Operation1) First range (low-speed, nonoperating range) Because the return force of the retractor spring is greater than the centrifugal force acting on the shoe and weight, the shoe is drawn inward and kept away from the drum. Thus, torque is not transmitted through the shoe. As the revolution increases and when the centrifugal force becomes greater than the return force of the spring, the shoe contacts the drum and begins to transfer torque (lower figure).

greater part of it pushes the shoe through the main spring, working as the power that transmits torque. On the other hand, the centrifugal force acting on the shoe itself becomes the force that pushes the drum regardless of the movements of the weight. Therefore, the press of the shoe necessary to transmit torque in this range becomes: Shoe's centrifugal force + (Weight's centrifugal force - Retractor spring's return force). When the speed of rotation goes still higher, the centrifugal force of the weight increases further, and the main spring deflects more, both ends of the weight butt against the pins (through the retractor spring), so that the weight will not move toward the circumference.

A13415"

/

/

/

/

/

/

/

/

Fig. 7-19A13-416

Fig. 7-18

2) Second range (medium- and lowspeed range, centrifugal clutch range) The centrifugal force of the weight deflects the main spring, and the weight floats up off the concavity at each end of the shoe (portion @ in

Fig. 7-19).Although a portion of the weight's centrifugal force is transmitted from the retractor spring to the pin, the

3) Third range (medium- and highspeed ranges, torque limiter range) Because the speed of rotation is high, the weight is stopped, completely pressed against the pins at both ends. The centrifugal force acting on the weight at this time is carried directly from the weight to the pins and then to the reaction plate, and therefore it is not transmitted to the shoe. Accordingly, in this range the transfer torque of the clutch is the frictional force produced by the centrifugal force of.II

,

!

j

11

. _I"

, I , "I,

~

. ,..

l,-~-~

. . _. - ........... '~...,.H

!_1-""'!~---

.'_.___,.. _..

7-16

11

'.11_..... ........__________________ , ",... , ,,

II

AUTOMATIC TRANSMISSION AND DIFFERENTIALthe shoe. The increasing rate of torque due to an increase in the rotational speed is considerably lower than in the second range; consequently, this is what is called a torque limiter condition. Further, the centrifugal force of the main spring is balanced and offset by the force with which the spring is pushed, and there is no change in the force pushing the shoe. 4) Fourth range (high-speed range) The main spring deflects outward due to its own centrifugal force, and separates from the weight. Thus, the upward pressing load with which the weight pushes the spring dies away. In the third range the centrifugal force of the main spring is offset by the pressing load of the weight. In the fourth range, however, because the centrifugal force of the main spring is carried to the shoe as it is, the transfer torque of the clutch greatly increases as does the torque capacity somewhat increases accordingly.

A13-419

Fig. 7-21

A13418

Fig. 7-20

7-17


3 OIL PRESSURE CIRCUIT

Brake

r---------,

Transfer (4WD)

I

I

Transfer

II

III

I

clutch:

I

III

I

II I

(.1 '>

Pressure Regulating Valve

Manual

Valve ',2) p

Note: Marked X are Dra.n _ _ _ _ Line pressure (Governor feed pressure) Governor pressure Torque converter pressure and lubrication Throttle pressureGovernor

Valve

Fig. 7-22

A13420

7-18 I I

II

~I~'

"d-""-"~"4l

I ... ,j,-i=-~""f-=~....

-v - ...... ....... 'q"'-"""IT"'_"'_WR- -... 'fi"""'---_Sff_ _ _.. .

n_""''''''.......... ... ,""" --________.... .______-"4 ,,""'

~

Jr.-;


3. TroubleshootingTrouble Large shock when shifting "N" -+ "D" Car will not run, slip, or acceleration is very poor in "D", "2", or "1". (Car runs in "R".) Car will not run, slip, or acceleration is very poor in "R". (Car runs in "D", "2", and" 1".) Car will not run in any range. Slip is felt when starting in FWD D range. (Car runs in "1" range.) Slip is felt when starting in 4WD mode. (Car runs in FWD mode.) Car runs even in "N". Low maximum speed, or poor acceleration. Car is braked if lever is set in "R". J H,L,G L K,M,J,X K,L,M,J G,J L,K,G,M,J L,G,J L,G,M,J L,G,M,J L,G,M,J J L,J K,G,M,J K,L,J K,G,J K,G,J K,M,J G,K,J On the car check item G,J G,J j j, r Off the car check item

G,J G,J G,J

n,k,r q, r, v r, t e

j, km,n,h j,m, v m,r k,r r m,r m k,m m,r k,r n,k,t m k,m, r m, t r r m,r k, r

No shift from 1st to 2nd. No shift from 2nd to 3rd. Shift points too high from 1-2 and 2-3. Shift occurs from 1 to 3. Large shock when shifting 1-2. Large shock when shifting 2-3. No shock when shifting 1-2, or slip occurs. No shock when shifting 2-3, or slip occurs. Engine races. Car is braked when shifting 12. Car is braked when shifting 2-3. No shift from 3rd to 2nd. No shift from 2nd to 1st, or from 3rd to lst. Large shock is felt when car speed decreases when accelerator pedal released. 3-2 shift point or 2-1 shift point is too high. No kickdown occurs when accelerator pedal is depressed from 3rd. (Within kickdown limit speed.) Kick down occurs or engine overruns when accelerator pedal is depressed from 3rd. (Above kickdown limit.) Engine races when gear is changed from 3rd to 2nd and accelerator pedal is depressed. Gear remains in 3rd and is not changed to 2nd even when lever is set to "2". No shock is felt, or engine races when shifted from" 1" to "2".

L,G,M,J L,G,M,J L,N,M,J

k,m, r m,r m

7-29


Trouble Gear remains in 3rd and is not changed to 2nd even when lever is set to "1". No engine brake is applied in 1st gear. Gear shift 1-2 or 2-3 occurs in "1". Gear shift 2-1 does not occur in "1". Car begins to move even when lever is set to "P", or parking gear remains engaged even when lever is moved from "P". Transmission overheats. Fluid spouts out while running. Car exhaust emits white smoke while running. Unusual smell from oil supply pipe. Large noise in "P" or "N" . Large noise in "2", "1", or "R". Differential gear oil is contaminated with automatic transmission fluid. Automatic transmission fluid is contaminated with differential gear oil. Large noise when running in FWD 3rd gear. Large noise when running in 4WD 3rd gear.

On the car check item L,K,G,J G,J J K,L,J

Off the car check item k,m, r n, r r n, r v

G,H,L H,G,W N

k, m, n, h,j k, m, n, h,j j, k, m, n q q, t, 1Z,

r, g

z,g w,x l'

4. Inspection Items1) Inspection Items with Automatic Transmission Mounted on VehicleG Oil pressure check H Stall speed J Control valve K Governor valve L Brake band adjustment M Servo pipe N Inspection of fluid by draining W Vacuum diaphragm X Nylon gear

l' m n q r

Transfer gear Brake band and band support Low & reverse brake Oil pump Leak from hydraulic circuit Power train one-way clutch v Parking linkage w Hypoid gear x Reduction gear Z Stator shaft and reduction drive gear oil seals and O-rings, and governor shaft oil seal

running a distance of 5 to 10 km (3 to 6 miles)].

NOTE:

The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking oil level. A change in the ATF level by oil temperature is shown in the following figure.b. Ensure the vehicle is level and set the selector lever in "P" range. Measure fluid level with the engine idling.

2 ON-CAR SERVICE1. Method of Inspection and Adjustment1) Fluid Level Check and Fluid Replacement1) Automatic transmission fluid (ATF)

2) I nspection Item with Automatic Transmission Detached from Vehiclee Transfer valve, transfer pipe, rear drive shaft seal ring f Transfer clutch g Drive pinion rear oil seal h Torque converter one-way clutch j Forward clutch k Reverse clutch Planetary gear

NOTE:

After running, idle the engine for one or two minutes before measurementc. If the fluid level is below the lower limit mark, add the recommended ATF until the fluid level is found within the specified range (within upper and lower limit marks). When the transmission is hot, the level should be above the center of upper and lower marks, and when it is

1) Checking fluid level a. Raise the ATF temperature to 60 to 80C (140 to 176F). [This temperature may be attained by

7-30

-,AUTOMATIC TRANSMISSION AND DIFFERENTIALcold, the level should be found below the center of these two marks.Fluid temperature range / " for fluid level check . . mm Upper IImlt marrk

NOTE:

~

(1.5i~

r

)

a. Use care not to exceed the upper limit level shown in item 2) below. b. Check the ATF level when deliver ing a car to a customer.2) ATF level a. ATF level varies with temperature as shown in figure. Remember that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of fluid.

30 (1.18 )

8,~Qj::J

E -c

>

M_

co ~

E'-

20 (0.79 )P""

~~

~

~

-

~

~

up" range Idling (Engine rpm: 800 - 850 rpm)

i

3

Lower limit mark

1

IO.3~

)

0

30 (86)

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100C (212WF)

Automatic transmission fluid temperatureA13-435

Fig. 7-39 Automatic transmission fluid level (4WD A T)

b. Fluid temperature rising speed, By idling the engine / Time for rising temperature to 60C (140F) with atmospheric temperature of OC (32F): More than 25 minutes (Reference) Time for temperature rise to 30C (86F) with atmospheric temperature of OC (32F): Approx. 8 minutes By running the vehicle Time for temperature rise to 60C (140F) with atmospheric temperature of OC (32F): More than 10 minutes c. Method for checking fluid level upon delivery or at periodic inspection. Check fluid level after a warm-up run of approx. 10 minutes. During this warmup period, the automatic transmission functions can also be checked. 3) Inspection and replacement intervals

4) Replacement of ATF a. After allowing the engine to cool for 3 to 4 hours, remove the fluid pan drain plug, and drain oil thoroughly.

until the oil level can be found within the specified range.

NOTE:

NOTE:

a. The fluid will be discharged to the front as the drain plug is removed. To avoid the stream of fluid, the worker should stand under the oil pan toward the front of the car performing this procedure. b. The amount of fluid that can be drained is approx. 4Q (4.2 US qt, 3.5 Imp qt) of the total capacity of 6.0 to 6.4 Q (6.3 to 6.8 US qt, 5.3 to 5.6 Imp qt) for 4WD and 5.6 to 6.0 Q (5.9 to 6.3 US qt, 4.9 to 5.3 Imp qt) for non-4WD. Some fluid will remain in the torque converter, oil passage, or in the valve body.b. Tighten the drain plug. [Tightening torque: 25 N'm (2.5 kgm, 18 ftlb )].

a. If the drained fluid is black or thick, it indicates that some com ponents in the transmission are faulty. Disassemble and check the transmission. b. Be sure to use recommended ATF when changing the transmission fluid.2) Differential gear oil Checking oil level 1) Ensure the vehicle is level.

NOTE:

Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level.2) Check whether the oil level is between the upper and lower marks. If it is below the lower limit mark, add oil until the level reaches the upper mark. The difference in level between upper and lower marks corresponds to 0.4Q (0.8 US pt, 0.7 Imp pt). Oil to be used Recommended gear oil

NOTE:At delivery, after initial 1,600 km (l,000 miles) and every 24,000 km (lS,OOO miles) or 15 months Every 48,000 km (30,000 miles) or 30 months

Be sure to replace the gasket with a new one.c. Pour 4Q (4.2 US qt, 3.5 Imp qt) of recommend~d ATF into the case through the oil supply pipe. d. Run the vehicle until the fluid temperature rises to 60 to 80C (140 to 176F), and then add fluid

Inspection

API classificationSAE viscosity No.

GL575W80

Replacement

7-31

AUTOMATIC TRANSMISSION AND DIFFERENTIAL Inspection and replacement interval Every 12,000 km (7,500 miles) or 7.5 months Every 48,000 km (30,000 miles) or 30 months Governor test plug Air breather 4) Automatic transmission case Idling rpm for automatic transmission cars (N or Prange)

800 100 rpm

Inspection

Replacement

Replacement of oil Remove the drain plug located on the left side of the final reduction case, and drain the oil completely. Tighten the plug to a torque of 25 Nm (2.5 kg-m, 18 ft-lb), and remove the oil gauge, and pour new oil into the case through the opening until the oil level reaches the upper level mark [total quantity of oil: 1.2Q (1.3 US qt, 1.1 Imp qt).

Mating surface of oil pan and transmission case O-ring on the outer diameter of servo piston cover Test plug (Servo connecting side and servo release side) Oil supply pipe connections ATF pipe connector Vacuum diaphragm location Downshift solenoid location O-ring on the outer diameter of servo adjusting screw Oil pan drain plug Governor pressure and line pressure checking blind plugs (steel ball) 5) Intermediate case

4) Checking and Adjusting the Kickdown Switch and Downshift SolenoidSet the ignition switch to ON, and fully depress the accelerator pedal to see whether the solenoid functions or not. If no kickdown occurs, or if the shift point occurs with the throttle half open, check the kickdown switch, downshift solenoid and associated wires. If kickdown failure occurs infrequently, it may be due to malfunction of the solenoid contaminated with dirt. Wash the inside of solenoid while moving the push rod. After washing, carefully check the operation of the solenoid.

2) Oil Leakage Check PointsIt is difficult to accurately determine

the precise position of a oil leak, since the surrounding area also becomes wet with oil. The places where oil seals and gaskets are used are as follows:1) Jointing portion of the case

Test plugs (two plugs for line pressure, and plugs on forward clutch, reverse clutch, and transfer clutch) Blind plug (steel ball)

NOTE:

6) Extension Rear drive shaft oil seal Transfer solenoid location Thermoswitch location The points listed above should be checked for fluid leak. Checking method is as follows: Place the vehicle in the pit, and check whether the leaking oil is ATF or not. The ATF is wine red in color, and can be discriminated easily from engine oil and gear oil. Wipe clean the leaking oil and dust from a suspectable area, using a noninflammable organic solvent such as carbon tetrachloride. Run the engine to raise the fluid temperature, and set the selector lever to "D" in order to increase the fluid pressure and quickly detect a leaking point.3) Checking the Engine Idling

Before removing or installing the solenoid, drain approx. 2 Q (2.1 US qt, 1.8 Imp qt) of ATF.

Transmission case and final reduction case jointing portion Final reduction case and converter housing jointing portion Transmission case and transmission. cover (or intermediate case) jointing portion Intermediate case and extension case jointing portion2)

5) Checking Negative Intake Pressure Check whether pressure is over -60.0 kPa (-450mmHg, -17.72inHg) at idling speed of engine, and whether pressure decreases in proportion to increase of engine speed when accelerator pedal is depressed.

Converter housing

6) Checking CreepingCheck whether car exhibits a certain amount of creeping when it is brought to a temporary stop with selector lever in "D", "2", "1" or "R" position.

Engine crankshaft oil seal Torque converter impeller sleeve oil seal ATF pipe connector 3) Final reduction case

Final reduction case and governor cover Axle shaft oil seal O-ring on the outside diameter of axle shaft oil seal holder Differential oil fIller port Differential oil drain plug Speedometer cable mounting portion

7) Checking and Adjusting the Manual Linkage Adjustment of the manual linkage, like the inspection of fluid level, is an important operation in the automatic transmission service. Remember that improper adjustment may lead to a damaged transmission.

rpmExcessively low engine idling rpm will lead to rough engine operation and excessively high idling rpm will lead to a sudden shift shock or creeping when shifting from N to D or R.

7-32

AUTOMATIC TRANSMISSION AND DIFFERENTIALRPush button Selector lever Indicator Slide plate Inhibitor switch

N

0

Operation indicated by solid arrow mark .. must be done while pressing the push button. :J Operation indicated by white arrow mark may be done without pressing the button.

Rod

check the vacuum hose for cracks or check the vacuum hose joint. Excessively large shift shocks and the emission of white exhaust smoke while running may indicate a broken vacuum diaphragm. If such symptoms occur, loosen the two bolts securing the vacuum pipe (at governor cover and at the engine and transmission jointing), and turn the vacuum pipe upward around the bracket of the diaphragm joint until the bracket comes free from the bolts. Pull the vacuum hose and vacuum pipe out toward you and drain approx. 2Q (2.1 US qt, 1.8 Imp qt) of ATF. Remove the vacuum diaphragm by rotating by hand.

Fig. 7-40 Selector system

A13-436

1) Inspection 1) While pressing the release button, move the selector lever from the "P" to "1" range; a click will be heard in each position. This clicking sound is caused by a detent of the manual valve in the transmission, and it indicates the correct selector lever position. Check to see that the indicator needle is aligned to this position, and also see that it is aligned with the groove of the guide plate when the release button and selector lever are released. 2) Confirm that the selector lever cannot be moved into "R" from "N" when pushed lightly, without first pressing the release button. 3) Confirm that the engine can only be started in "P" and "N" ranges. 4) Confirm that the backup lamp will light only when the selector lever is moved to the "R" range. 5) Place the vehicle on a slope, and set the selector lever to "P" and check whether the vehicle is locked properly. 2) AdjustmentIf the manual valve detent position is not aligned with the guide plate groove position, perform the adjustment as follows. 1) Set the selector lever to "N". 2) Loosen the adjusting nut of the linkage rod.

3) Set the detent position so the selector arm is aligned with the "N" locating mark of the transmission case [within the range of a 6 mm (0.24 in) dia. boss].

NOTE: a. Be sure to remove the vacuum diaphragm when the transmission is cold. (To avoid a burn.) b. Also take out the diaphragm rod.9) Checking, Correcting, Disassembling, and Reassembling the Governor ValveIf automatic shifting is not performed normally while running in the D range, or if acceleration is possible only up to 50 to 60 km/h (31 to 37 MPH) in the D range, it is often attributable to malfunctioning of the governor valve. Such malfunctioning may be caused by sticking of the valve due to clogged dirt, burrs or nicks on the valve body, etc.

A13-437

Fig. 7-41 Adjusting rod

4) Adjust the rod so that the "N" mark of the guide plate is aligned correctly with this detent position. 5) If the indicator needle is not aligned with the guide plate marking, remove the console box, loosen the four indicator mounting screws and adjust the position of the indicator ASSY.

A13-438

Fig. 7-42 Component of governor valve

8) Checking the Vacuum Diaphragm and Vacuum

1) Disassembly 1) Remove the three governor cover mounting bolts from the right side of the final reduction case, and remove the governor cover by turning it slightly in order to avoid interference from the vacuum pipe bracket.

HoseA loose or disconnected vacuum hose will result in rough engine idling and an abrupt shifting shock even with light acceleration. In such a case,

7-33

AUTOMATIC TRANSMISSION AND DIFFERENTIAL2) Pull the governor valve out while carefully turning clockwise. 3) Remove the Eclip snap ring @ then remove the valve @, spring and other parts from the body . 4) Remove two bolts securing the shaft CD and body and disassemble them. 2) Burrs and nicks at the edge of the valve body groove should be removed by using a small standard screwdriver. 3) Clean the repaired parts in clean lamp oil or white gasoline. Fit the governor valve and governor valve 2 into the valve body, and check for smooth sliding of these parts by lightly pressing them to the inside of the valve body while rotating.Check these areas.

2) Confirm that there is no foreign matter in the oil passage of the governor shaft, and tighten the shaft to the governor body after washing. Tightening torque

9 - 11 Nm (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb)

NOTE:

Be sure to perform the steps 3) and 4) after pulling the governor valve out from the final reduction case.2) Checking Check the governor valve and body visually and by feeling with a finger for burrs and dents, and repair as necessary. If the sliding surface of the body or valve is defective, replace the governor body ASSY with a new one. 3) Correcting 1) To correct the governor valve and governor valve 2, lightly apply a fme grained oil stone to the burred edge as shown in the figure, and rotate the valve one or two turns. Check whether or not the burrs have been removed by feeling with a finger. Repeat this operation until the burrs are no longer felt.

NOTE:

When tightening, fix the flange of the shaft, and be careful not to damage the nylon gear of the shaft.3) When assembling the governorvalve to the final reduction case, it is unnecessary to dry out the governor valve. However, the governor valve should be assembled after confirming that the seal ring is normal.

A13440

Fig. 744 Checking the edge of the governor body groove

NOTE:

NOTE:

If the governor valve checks out to operate normally, the seal ring of governor sleeve must be checked.4)Reassembling

When assembling, use special care not to damage the seal ring, and the lip of the oil seal installed inside the case.4) Before assembling the governor cover, replace the gasket (governor cover) and confirm that the washer is included. Tightening torque

14 - 17 Nm(1.4 - 1.7 kg-m, 1O-12ft-lb)

O@[email protected]

NOTE:

a. Note that the finishing of the end face is not chamferring, but it is light deburring. A sharp edge having no burrs is desirable. b. Replace the valve ASSY if flaws and dents are noted on the sliding surface.

Fig. 745 Reassembling the governor valve

10) Adjusting the Brake BandIf the following abnormal shifting conditions are noted in a road test, the brake band must be adjusted. 1) Shift state and adjustment 1) The 2nd gear state can be achieved but: the engine rpm increase excessively shifting up from 2 to 3. a shift delay (over O. 7 sec) accompanies at kickdown from 3 to 2. If any of these problems occurs, it is attributable to excessive clearance between the reverse clutch drum and brake band: Tighten the adjust screw by turning it clockwise. 2) The 2nd gear state can be achieved, but: the shifting shock is too small at shifting up from 1 to 2. a braking phenomenon is noted when shifting up from 2 to 3.

1) Reassemble the governor valve components by referring to the figure shown above. Pay attention to the orientation of the weight.

Keep oil stone fixed.

Turn Wi:Jh - -+U---+fingers

'----

....

Correct these areas.A13-439

Fig. 743 Correcting valve

-1,,---1

.

,'*

I

~,I,II

tj

I"

,.~

-j",.,,41.~~_-_.w..""""~o.,.

CD /

\f\~l1,,]

Inner bush Inner arm 9 Shock absorber 10 Helper

@-----Q:!';;!

"',.

i~~:::~T1:

Fig.:

nt parts of rear suspension (Except 4WD)

l.

Tightening torque Nm (kg-m, ft-Ib) ~ -93 (7.5 - 9.5, 54 - 69), T2: 88-118 (9 -12,65 - 87) T3: 88 - 127 (9 - 13, 65 "- 94) T4: 118 - 147(12 -15, 87 - 108) T5: 31 - 39 (3.2 - 4.0, 23 -29)

;;:."",.

-14'

Cr()~cp

".

2

Rear:bailrli>

,4 Torsion bar 6 7 8 9 10~ OuHftlmsh ,,~,

3 Front bush'".L:, ,:.'1

1"

~ ~"",

f

11t'

12 .13 14

,*er, . Inner bush Inner arm Sbock absorber Center arm Center arm bolt Helper Castle nut Pm

, Fig. 9-4 Component parts of rear suspension' (4WD)

i "

SUSPENSION, WHEELS AND AXLES

9-2. Front Suspension1. Removal1) Disconnect ground cable from battery. 2) Apply parking brake. 3) Loosen fron t wheel nu ts. 4) Jack up vehicle, support it with safety stands (rigid racks) and remove front tires & wheels. 5) Release parking brake. 6) Remove parking brake cable bracket from transverse link. 7) Disconnect parking brake cable from brake caliper. 8) Disconnect brake hose from brake pipe at apron bracket.

3. Installation1) Install strut mount to body. 29 - 39 Nm Torque

(3.0 - 4.0 kg-m,22 - 29 ft-lb)

A15-011

Fig.9-7 Inserting D.O.J. to drive shaft

NOTE: a. Fit air bleeder cap onto brake pipe to prevent brake fluid from pouring. b. When removing or installing flare nut, use flare nut wrench without fail.9)Drive out spring pin of D.O.1. at inner end by using a steel rod of 6 mm diameter. 10) Disconnect front end of stabilizer from leading rod. 11) Remove leading rod from rear crossmember. 12) Disconnect transverse link bush from front crossmember. 13) Take out transverse link along with leading rod. 14) Remove castle nut and ball stud of tie-rod end. 15) Loosen nuts connecting strut mount to body, then pull D.O.1. out of differential spindle, and remove front suspension assembly from body.

A15-076

Fig. 9-5

3) Install leading rod to rear crossmember according to the following procedure. (1) Install a bushing to leading rod. (2) Install leading rod to rear crossmember, besides install a bushing, a plate and a self-locking nut. (3) Tighten self-locking nut.

36 - 42 Nm

NOTE: Take care of the installing direction of strut mount.

Torque

(3.7 - 4.3 kg-m,27 - 31 ft-Ib)

) Station Wagon, 4WD vehicle and vehicle with power ( steering

(HatchbaCk, Sedan) and Hardtop

Fig. 9-8

A15-146

Fig.9-6 Installing direction of strut mount

2. InspectionCheck the removed parts for any wear, damage and crack, and correct or replace if defective. 2) Align the spring pin holes of D.0.1. and differential spindle, and insert D.0.1. to differential spindle.

NOTE: a. Self-locking nuts should be replaced with new one whenever it is removed. b. Before installing the bushing to the leading rod, soak the bushing to the soap solution for easy installing the bushing to correct position.

,- .....

~. ~ ....'"

.

9-8$2

1SUSPENSION, WHEELS AND AXLES

c. In case that the creaking noise breaks out during the self-locking nut fully tightening, there is possibility that the rubber bushing is pinched between the pipe and the washer. Then, loosen the selflocking nut at once and retighten the nut after centering the leading rod.4) Connect D.O.J. and differential spindle by driving spring pin in.

NOTE: After tightening the nut to the specified torque, adjust groove on the nut and hole on the ball joint by retightening the nut from 0 to 60 degrees.

Torque (Hand brake cable bracket installing bolt)

6.4 - 9.3 Nm (0.65 - 0.95 kg-m, 4.7 - 6.9 ft-lb)

NOTE: a. Make sure that the holes are aligned before driving the spring pin in.b. When driving the spring pin in,

always use new one.A15-078 A15-069

Fig.9-11

Installing tie rod end Fig.9-13 Installing hand brake cable bracket

7) After then, install new cotter pin into the hole, and bend it firmly. 8) Connect stabilizer front end through bracket to leading rod. 18-3INm (1.8 - 3.2 kg-m, 13 - 23 ft-lb)

TorqueA15-015

II) Install hand brake outer cable by attaching outer cable clip to brake caliper. Install the hand brake cable end to the caliper lever.

Fig_ 9-9 Driving spring pin in

5) Install transverse link temporarily to crossmember by using bolt and self-locking nut.

A15-070

..';

Fig. 9-141 2 3 Bracket Leading rod Stabilizer

A15-073

12) Install wheels. 78 - 98 Nm (8 - 10 kg-m, 58 - 72 ft-lb)

Fig. 9-12A15-077

Torque (wheel nut) 9) Attach brake hose to apron bracket by using clip, and then connect brake hose to brake pipe. l2-l8Nm (1.2 - 1.8 kg-m 9 - 13 ft-lb)

Fig. 9-10 Installing transverse link

6) Install tie rod end ball joint to housing knuckle ann. Torque Torque (Castle nut) 25 - 29 Nm (2.5 - 3.0 kg-m, 18 - 22 ft-lb)

13) Bleed air from brake system. 14) Lower vehicle and tighten selflocking nut which installs transverse link to crossmember. Torque ( self-locking nut) 59 - 69 Nm (6.0 - 7.0 kg-m, 43 - 51 ft-Ib)

10) Install hand brake cable bracket to transverse link.

9-9

(SUSPENSION, WHEELS AND AXLES

4. AdjustmentMake sure to measure wheel alignment when removing and reinstalling the suspension. Wheel alignment should be adjusted or checked to the specified values.

s.

Inspection and Adjustmentfor individual parts, refer to the applicable instructions set forth in this manual.

The following chart outlines the basic inspection and adjustment procedures for the entire front suspension system. Regarding specific procedures

Item to be checked Vehicle posture

Description

Remarks

Park the vehicle on a level, solid surface, and check for lateral inclination of the vehicle.

Visual inspection

Coil spring

NOTE: a. Make sure that all tires are inflated to the specified pressure. b. If any noticeable lateral vehicle inclination is detected visually, determine whether it is due to permanent' deformation of coil spring (s), improper body alignment, or other factors. c. If vehicle inclination (to either side) is due to permanent deformation of coil spring, remove the coil spring and measure its free length. If the free length is not within the specification, replace the coil spring.Specified free length: 319 mm (12.56 in)

d. Replace the coil spring if it is cracked, broken or damaged.Damping Force/Noise Rock the left side of the vehicle up and down, and then rock the right side, to check for noise or variances in vehicle posture. Visual and tactile inspection

NOTE: If the up-and-down movement (when hands have been released) continues longer than usual or if any abnormal noise is detected, check the condition of the strut itself. Refer to instructions for inspection procedures.Damper strut Oil leakage Check for oil leaks at or around the lower portion of the strut and oil seal assembly.

NOTE: It is normal for a trace of oil to be oozing at the oil seal assembly.Cracks, Damage or Deformity Check the strut housing for any cracks, damage or deformity. Replace the dust cover if it is damaged.

9-10

SUSPENSION, WHEELS AND AXLESItem to be checked Preliminary Inspection Before checking/adjusting front wheel alignment, be sure to make a prior inspection of the following points and repair/replace the damaged portions/parts as necessary. Tire pressure Wear or damage of tires Wheel balance Looseness on suspension Looseness and smooth operation on axle linkage and connection Looseness and smooth operation on steering linkage and connection Shock absorber operation and oil leakage Damage, deformation etc. on body attaching portion of suspension, axle and steering linkage and connection Vehicle height [It is recommended that the difference of vehicle height between the front and rear ends, or the left and right sides is less than 10 mm (0.39 in) in the unloaded condition.] Stain, rust, grease leakage etc. on front end parts Toe-in Adjustment Wheel alignment Loosen both the left and right lock nuts CD. If toe-in is not within the specified value, turn the left and right tie rods equal amounts until the toe-in is within the specified range. Toe-in gauge Description Remarks

1 Lock nut2 Tie rod

Fig. 9-15

78 - 88 Nm

Torque (lock nut)

(8 - 9 kg-ru, 58 - 65 ft-lb)

NOTE: a. If the tie rod and the tie rod end have been disassembled, assemble these parts in advance so that the toe-in is near the specified range_ b. Both the left and right tie rods are right-hand threaded. To increase toe-in, turn both tie rods counterclockwise equal amounts (as viewed from the outside of the vehicle). c_ If the side slip is not within the specified range but although the toe-in within the specified value, check the steering gear box, ball joints, and wheel bearings for plav, and repair or replace the part(s) if defective_ d. Alwavs a"ust the toe-in after steering angle adjustment. e. Refer to the Specifications for the specified toe-in.

9-11


Item to be checked Camber and Caster

Description

Remarks

Neither camber nor caster can be adjusted. To measure camber and caster, place the wheel to be measured on the turning radius gauges CD, and make sure the vehicle is level. Set Adapter Assembly @ (925621000 for steel wheel) into the center of the wheel, and then install the alignment gauge @. Wheel alignment (continued)

Fig. 9-16

@

A15-147

NOTE: a. Refer to the Specifications for the camber and caster values. b. If the camber or caster measurement is not within the specified range, check for body alignment, deformed transverse link or faulty parts. Repair or replace the parts, if necessary.Looseness Check each mounting portion of the following for looseness and inspect the castle nuts for missing cotter pins. (1) Strut mount to car body (8) Transverse link to (2) Damper strut piston rod to strut crossmember (front) (9) Crossmember to body mount (3) Damper strut to housing (10) Stabilizer to leading rod (4) Housing to ball joint (11) Stabilizer to (5) Ball joint to transverse link crossmember (rear) (6) Transverse link to leading rod (7) Leading rod to crossmember (rear) General Cracks, Damage or Deformity Check the following parts for cracks., damage or deformity. (5) Transverse link (2) Damper strut (6) Leading rod (3) Housing (7) Stabilizer (4) Ball joint Visual inspection

(1) Crossmembers (front and rear)

Rubber Parts Check the following parts for deterioration, cracks or damage. (1) Strut mount (4) Transverse link bushing (2) Damper strut dust cover (5) Leading rod bushing (3) Ball joint boot (6) Stabilizer bushing Visual inspection

\.'~,....-;=."....------...,.-----------------~--------------....

9-12

----...J


9-3. Front Suspension Damper Strut1. Removal and Disassembly1) Disconnect ground cable from battery. 2) Apply parking brake. 3) Loosen front wheel nuts. 4) Jack up vehicle, support it with safety stands (rigid racks) and remove front tires & wheels. 5) Release parking brake. 6) Disconnect parking brake hose from brake pipe at apron bracket. 12) Hold damper strut assembly in a horizontal state. Carefully turn in the thread of Puller and compress spring until the strut upper seat surface is separated from spring. 13) Loosen self-locking nut connecting rod of damper to strut mount by using Wrench [included in Puller & Wrench (925651000)] and 17 mm box wrench.

c. Start the job after cleaning around the oil seal assembly.20) Pull out piston rod a little, and remove packing.Packing--(II4'l"'-"'" (O-ring)

NOTE:

a. Fit air bleeder cap onto brake pipe to prevent brake fluid from pour ing. b. Whenever removing or installing flare nut, use flare nut wrench without fail.7) Disconnect brake hose from caliper body, and detach brake hose. 8) Remove two damper strut installing bolts. 9) Pull strut out of housing gradually and carefully with housing assembly placed downward.A15084

A15-086

Fig. 9-19

21) Pull out piston rod and rod guide.

NOTE:Fig. 9-18

Don't pull out piston rod quickly or along with inner cylinder to prevent oil spillage.22) Remove inner cylinder slowly. 23) Pour oil out completely by turning outer shell upside down. 24) After cleaning disassembled parts with thinner or kerosene, blow off any dust, sludge etc., by compressed air.

~

1 I

14) Pull strut mount out of rod. 15) Remove thrust washer with oil seal and washer (thrust bearing).

I

NOTE:

NOTE:

If strut i~ rusted, apply sufficient "CRC" on housing and strut before pulling strut out.10) Remove nuts clamping strut mount to body. 11) Set damper strut assembly on Puller [included in Puller & Wrench (925651000)] . Fit the hook of Puller to the upper end of coil spring.

Take care not to drop them.16) Remove spring retainer (upper). 17) Carefully return coil spring unscrewing Puller to the original position and remove Puller after spring is completely extended. 18) Remove coil spring.

NOTE:

Don't use thinner or kerosene for non metalic parts. Clean them by using compressed air only.

2. InspectionCheck the disassembled parts for crack, damage and wear, and replace with new parts if defective.

NOTE: 00 not strike rod of damper.19) Remove oil seal assembly by using special tool (Wrench 925390000).

1) Damper strut1) Insert inner cylinder and piston rod into outer shell, and check if they move smoothly. 2) If not, check the following. a. Oil seal assembly If oil leakage is found around oil seal assembly while piston rod and inner cylinder are normal, replace oil seal as seal kit.

NOTE:

A15018

Fig. 9-17

a. Compress damper strut to its minimum length to prevent piston rod from damage. b. When vising the damper strut at its connecting portion to housing, vise it through something like wooden block to prevent it from damage.9-13

-----------------~)


NOTE: Oozing out of oil is normal, and there is no necessity for replacing oil seal.b. Piston rod Replace it with new damper strut if defective.

(3) Check piston rod-to-outer shell total clearance as shown.

Bend limit

0.2mm (0.008 in) 0.1 mm (0.004 in) "TOKICO" 30.05 - 30.15 mm (U831 - 1.1870 in) "KYB" 30.20 - 30.28 mm (1.1890 - 1.1921 in) "SHOW A" 30.0 - 30.052 mm (1.1811 - 1.1831 in)

(1) If leaked oil spreads to near springseat, check piston rod carefully for damage, uneven wear and bend.

(2 kg,41b)

~~~~t :1g~;:::310 mm 10.39 in)A15091

Wear limit

Specified inner diameter

NOTE: Since slight scratch can cause oil leak, check piston rod as carefully as possible.(2) Measure bend and wear as shown.

Fig. 9-21 Measuring clearance

Clamp outer shell, and pull out piston rod to its maximum stroke. Set dial gauge, and apply 20 N (2 kg, 41b) of force upwards and downwards at its free end through spring balance, and read dial gauge. Indication of dial gauge

0.8 mm or less (0.031 in)

d. Outer shell Replace it with new damper strut if defective.

(I) Distortion, crack and damage. (2) Oil leakage around welded portion at its lower end.

1 Dial gauge Bend Measuring 2 Piston rod 3 V-block

c. Inner cylinder Replace it with new damper strut if defective.

2) Strut mount1) Check rubber part for creep, crack and deterioration, and replace it with new one if defective. 2) If distortion is found on its connecting surface to body, replace it with new one.

(1) Check for wear and damage oninner surface and for bend. (2) Measure wear and bend as shown.

3) Thrust washer1) Check for wear, distortion, damage etc., and replace it with new one if defective. 2) If any scratch is found on sliding surface, replace it along with washer with new pair.1 Dial gauge 2 Inner cylinderA15092

Wear Measuring 1 Piston rod 2 Micro meter

A15090

Fig. 9-20 Measuring piston rod0.05 mm (0.0020 in) 0.02mm (0.0008 in) "TOKICO" 19.94 - 19.98 mm (0.7850 - 0.7866 in) "KYB" 19.935 - 19.981 mm (0.7848 - 0.7867 in) "SHOWA" 19.98 - 20.01 mm (0.7866 - 0.7878 in)

4) Oil sealCheck the lip of oil seal for wear, damage and deterioration, and replace it with new one if defective.

Bend limit

Fig. 9-22 Measuring of bend

5) Dust coverIf any crack or damage is found, replace it with new one.

Wear limit

Specified outer diameter

6) . Coil springOne having permanent strain should be replaced with new one. When vehicle posture is uneven although there is not considerable reasons like tyre puncture, uneven loading etc., check coil springs for its free length, crack etc., with referring to specifications.

1 Cylinder gauge 2 CylinderA15093

Fig.9-23 Measuring bore of cylinder

9-14


1NOTE:

3. Assembly Damper Strut1) Insert piston rod into inner cylinder gradually.

NOTE:

a. Since all parts are made with accuracy, be careful not to drop it or to damage by using plier etc. b. Be careful not to use glove or cloth to prevent it from getting dust. c. When inserting piston rod into inner cylinder, compress piston ring slowly into cylinder by fingers not to damage it.2) Insert inner cylinder with piston rod into outer shell slowly. 3) Pour oil into outer shell by using measuring cylinder.All models exeept 4WD 205 em' (205 ee, 12.51 eu in) Oil quantity 4WD 220 em' (220 ee, 13.42 eu in)

Piston rod Packing Rod guideA15095

a. Tighten oil seal assembly with piston rod being stretched to its maximum stroke. b. Use something like wooden block to clamp outer shell not to damage it. c. Be careful not to damage piston rod.8) Set damper strut on Puller [included in Puller & Wrench (925651000)] , and fit coil spring to spring seat correctly as shown.

Fig.9-25 Installing rod guide

6) Install oil seal assembly to piston rod with fitting Installer (925380000) on thread portion of piston rod.

CD

spring

1 Installer (925380000) 2 Oil seal assemblyA15-096

Fig. 9-28 Fitting coil spring

Fig.9-26 Installing oil seal assembly

9) Fit hook of Puller near upper end of coil spring, and turn thread of Puller to compress spring enough.

NOTE: NOTE:

NOTE:

a. Use always new oil, which is available as genuine parts "seal kit". b. Measure oil with accuracy by using measuring cylinder.

a. Apply grease to lip of oil seal. b. Use genuine grease contained in "seal kit" for respective make of damper strut. c. When installing oil seal, use special tool (lnsta"er 925380000) without fail to prevent oil seal lip from being damaged.7) Tighten oil seal assembly by using special tool (Wrench: 925390000)

Be careful not to slip off spring.

All5-0153

Torque

98 - 118 Nm (10.0 - 12.0 kg-m, n - 87 ft-lb)

Fig. 9-29 Compressing coil spring

10) Stretch piston rod to its maximum stroke, and install dust cover, upper spring seat and thrust washer.

Fig.9-24 Pouring oil

4) Attach packing to rod guide as rod guide assembly. 5) Install rod guide assembly to inner cylinder fIrmly with care of not damaging it by thread of piston rod.

NOTE:

a. Be careful not to spill oil. b. After installing, make sure that packing does not rise from rod guide.

A15097

1 Wrench (925390000) 2 Wood block

Fig. 9-27 Tightening oil seal assembly

Fig. 9-30

A 16-163

9-15

(r--

SUSPENSION, WHEELS AND AXLES11) Install washer into oil seal with facing grinded surface of washer to lip side of oil seal.

4. Installation1) Set strut assembly in position, and temporarily tighten nuts clamping strut mount to body.

5) Clamp brake hose with clip on damper strut. 6) Connect brake hose to caliper body.

NOTE: Apply grease on oil seal lip and sliding surface of washer.

NOTE: Take care of installing direction of strut mount2) Push and set stru t into housing gradually and carefully. 3) Tighten two damper strut installing bolts. Torque

Torque (Union bolt)

15 - 20 Nm (1.5 - 2.0 kg-m, 11-14ft-lb)

NOTE: Always be sure to use flare nut wrench.

1 2 3 4 5

Washer Oil seal Thrust washer Piston rod Upper spring seat

A15-100

Bol t installing damper strut bracket to housing Bolt clamping damper strut to housing

29 - 39 Nm (3.0 - 4.0 kg-m, 22 - 29 ft-lb) 29 - 39 Nm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)

Fig. 9-31

Installing oil seal etc.

Fig. 9-35

A15082

12) Install oil seal and washer assembly on to thrust washer.

7) Connect brake hose to brake pipe at apron bracket. 12-18Nm (1.2 - 1.8 kg-m, 9 - 13 ft-lb)

NOTE: Be sure to position oil seal lip to face to coil spring.13) Install strut mount to piston rod, and tighten self-locking nut temporarily.

Torque

NOTE: Never use removed self-locking nut, and replace it with new one.14) Loosen Puller (included in Puller & Wrench (925651000)] gradually, and remove it. 15) Tighten self-locking nut by using Wrench (included in Puller & Wrench (925651000)] . 59 -74 Nm (6.0 - 7.5 kg-m, 43 - 54 ft-lb)A15083

Fig. 9-33

o

}

'

4) Securely tighten nuts clamping strut mount to body.Fig. 9-36A15072

f II

Torque

Torque

29-39Nm (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

8) Install another side damper strut in the same manner. 9) Install tires and wheels, and tighten wheel nuts temporarily. 10) Apply parking brake, and lower vehicle after taking ou t rigid racks. 11) Tighten wheel nuts. 78 - 98 Nm (8.0 - 10.0 kg-m, 58 - 72 ft-lb)

Torque (Wheel nut)

A1S-076 A15-Q84

Fig. 9-32

Fig. 9-34

12) Bleed air from brake system. 13) Connect ground cable to negative terminal of battery.

9-16


9-4. Stabilizer2. InspectionCheck and replace if defective.

1) BushingCracks, deterioration or sticking.

I II

2) StabilizerCracks at curved portions.

~-11~ 1'1 .4--I\' II " \ 11 \11

@

\\" "

"

3. InstallationReverse the removal procedure.

\

1 2 3 4 5 6

Stabilizer Leading rod Stabilizer front bracket Stabilizer front bushing Stabilizer rear bracket Stabilizer rear bushingA15-160

NOTE: a. Stabilizer rear bushing on rear crossmember should be installed by aligning the bushing inner end with the marking on the stabilizer. b. Each bushing must be fitted firmly and fixed with tires on the ground and with no load on the car.Torque Bolt at front bracket

Fig.9-37 Stabilizer

1. Removal1) Jack up body at the front. 2) Remove bolt at stabilizer front bracket.

3) Remove nuts at stabilizer rear bracket. 4) Remove brackets and bushings from stabilizer. 5) Remove stabilizer.

18 - 31 Nm (1.8 - 3.2 kg-m, 13 - 23 ft-Ib) 18-31 Nm (1.8 - 3.2 kg-m 13 - 23 ftlb)

Nut at rear bracket

9-5. Front Crossmember1. Removal1) Disconnect ground cable from battery. 2) Apply parking brake, and remove spare tire and wheel. 3) Loosen front wheel nuts. 4) Jack up vehicle, support it with safety stands (rigid racks), and remove front tires and wheels. 5) Release parking brake. 6) Remove air cleaner assembly and pitching stopper rod.

NOTE: Fit a cap onto carburetor to prevent inside of bore from dust.7) Remove parking brake cable bracket from transverse link. 8) Remove cotter pin and castle nut of ball stud on tie-rod end, and detach tie-rod from knuckle arm. 9) Remove front exhaust pipe. 10) Remove transverse link from front crossmember.9-17

11) Remove cushion rubber from crossmember. 12) Disconnect steering torque rod from pinion shaft. 13) Lift engine assembly by approx. 10 mm by using chain block. 14) Remove crossmember installing nuts with crossmember supported by jack, and remove crossmember downward gradually along with steering gear box.


2. InstallationI) Set crossmember along with steering gear box in position and carefully support them with a jack.

4) Tighten nuts attaching engine mount cushion rubber to crossmember.

6) Install front exhaust pipe. 7) Connect tie-rod end to knuckle arm of housing. 25 - 49 Nm (2.5- 5.0 kg-m, 18 - 36 ft-lb)

NOTE: Check crossmember for cracks and/or damage, and replace it if necessary.2) Lower engine assembly by operating chain block. 3) Tighten self-locking nuts connecting steering torque rod and pinion shaft.----_._ ...

(2.0 -- 3.3 kg-m, 14 -- 24 ft-Ib)-----~

20-32N.n~J---~--.--

Torque (Castle nut)

8) Connect parking brake cable bracket to transverse link. 9) Attach air cleaner assembly and pitching stopper rod.

Torque

14 -- 20 Nm (1.4 - 2.0 kg-m, 10 -- 14 ft-Ib) .

_---]

10) Install front tires and wheels. 11) Apply parking brake and lower vehicle to the ground. 12) Tighten nut connecting transverse link to crossmember to the specified torque.Fig. 9-39A15103

5) Connect transverse link to crossmember by temporarily tightening nuts for transverse link bushing.

[ :---1Torque-'-

59 - 69 Nm (6.0 - 7.0 kg-m, 43 - 51 ft-Ib) -_._-------

~J

13) Connect ground cable to negative terminal of battery.

Fig. 9-38

A15-104

Fig. 9-40

A15-077

96. Ball Joint2) Remove cotter pin, castle nut and bolt to remove ball joint.

b. The ban joint and boot that have been removed must be checked for wear, damage or crack, and any defective part must be replaced.2) Connect ball joint to transverse link. Torque (Castle nut) 39 Nm (4.0 kg-m, 29 ft-lb)

2. Installation1)

Install ball joint onto housing. 29 - 39 Nm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)

A15-161

Fig. 941

Torque (Bolt)

1. Removal1) Jack up body at the front to remove wheels.

NOTE: a. Pay attention not to stick grease to tapered portion of ban stud.9-18

3) Retighten castle nut further until a slot in castle nut is aligned with the hole in ball stud end, then insert new cotter pin and bend it around castle nut.4) Install front wheels, and lower vehicle.

~..'O:.;;.4.-'~_"''''''+;

,I

.1.....'.,b".........................- -.......- -_ _ _ _ _ _ _I

_ _ _ _ _ _-

. . . . ._ _ _ _ _ _ _- -_ _ _ _. . ._ _ _

.....1

-,.-.iSUSPENSION, WHEELS AND AXLES

97. Rear Suspension1. Removal and Disassembly1) Remove the two bolts attaching shock absorber upper end to body.

NOTE:

NOTE:

When pulling off outer arm from crossmember, as inner end of torsion bar engages with serration of crossmember, pay attention not to bend or twist torsion bar.13) Remove torsion bar from outer arm. 14) Remove bolt and nut connecting inner arm and crossmember.

a. At this time, vehicle should be in the unloaded condition. b. loosen bolts with extension bar supported by tire outer surface, and job will be easy.Fig. 9-42

A4124

2) Apply parking brake. 3) Loosen rear wheel nuts. 4) Jack up vehicle, support it with safety stands (rigid racks) and remove rear wheels and tires. 5) (4WD only) Remove following parts and detach rear drive system. a. Spring pins at both ends of drive shaft.

NOTE:

Using a steel bar of 6 mm (0.24 in) diameter, gradually drive out spring pins.b. Rear axle shafts on both sides - - - Remove outer D.O.J. of drive shaft from rear axle spindle by pushing inside D.O.J. of drive shaft fully toward rear differential and pushing brake drum downward. Then remove inner end of drive shaft. c. Four bolts connecting propeller shaft to rear differential.

e. Support rear differential with jack. f. Self-locking nuts connecting rear differential mounting member to body g. Rear differential - - Remove 4 nuts installing rear differential at its front end to rear crossmember, and carefully dismount rear differential. 6) Remove exhaust pipe (front and rear). 7) Remove brake hose from brake pipe at inner arm side bracket (on both sides).

2. InspectionInspect disassembled parts for followings. a. Wear, damage, distorsion, crack etc. b. All thread for damage or distorsion. c. Oil leakage at lower portion or oil sealing portion of shock absorber.

NOTE:

If any damages or cracks are not found in visual check, perform color flaw check (dye penetrant investigation) on peeled or corroded portion.

NOTE:

a. Insert air bleeder cap to brake hose end to prevent brake fluid from pouring. b. Whenever removing or installing flare nut, use suitable flare nut wrench only.8) Support rear crossmember at its center with a jack, and remove four bolts holding rear crossmember. 9) Lower jack gradually and draw out from beneath vehicle body with rear suspension assembly on it.

3. Assembly1) Engage outer serration of torsion bar with outer arm temporarily.

NOTE:

Since transmission oil will flow out when propeller shaft is pulled out from transmission, prepare appropriate cap and oil catcher in advance of above job.

NOTE:

Put dismounted rear suspension assembly on soft material like rag, corrugated paper, tire etc. to prevent brake backplate and/or brake drum from being damaged.10) Remove floating bush (except 4WD). 11) Remove shock absorber. 12) Remove outer arm along with torsion bar.

1 Outer bush 2 Torsion bar 3 Outer arm

A15121

Fig. 9-43 Installing torsion bar to outer arm

d. Propeller shaft - - Set oil catcher at rear end of transmission, and pull out propeller shaft slowly. To prevent oil flowing out, insert appropriate cap immediately.

2) Install outer arm along with torsion bar with adjusting engagement of serrations of torsion bar with crossmember and outer arm, so that outer arm comes to appropriate position.

9-19

SUSPENSION, WHEELS AND AXLES3) Temporarily lock outer bush with lock bolt.

6) Install shock absorber to inner arm at lower end of shock absorber.

Torque

88-118Nm (9.0 - 12.0 kg-m, 65 -- 87 ft-lb)

A15126

Fig. 9-49 Aligning holesA15162

Fig. 9-44 Temporarily locking outer bush

2) Tighten the four bolts holding rear crossrnember at both ends.

4)

Install inner arm to crossmember.A15119

Torque

L -_ _ _ _ _ _ _ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

74 - 93 Nm (7.5- 9.5 kg-m, 54 - 69 ft-lb)

TorqueFig.9-47 Installing shock absorber

118 -147 Nm (12 - 15 kg-m, 87 - 108 ft-lb)

4. Installation1) Support rear crossmember at its center with a jack, and set it in position.Fig.9-45 Installing inner arm Fig. 9-50

A16-117

5) Connect inner arm and outer arm.

3) Connect brake hose and brake pipe on both sides.

Torque

118 - 147 Nm (12.0 - 15.0 kg-m, 87 -108 ft-lb)

Torque

12 - 18 Nm (1.2 - 1.8 kg-m, 9 - 13 ft-lb)

/ CDA16-116

NOTE: Use suitable flare nut wrench.

Fig.9-48 Supporting rear crossmember

1 2 3 4

Connecting bolts Outer arm Inner arm Crossmember

A15-163

Fig. 9-46 Connecting inner arm and outer arm

NOTE: When setting crossmember to vehicle body, insert 13 mm (0.51 in) diameter of bar into holes on crossmember bracket and body frame to facilitate the job by aligning the holes.9-20

Fig. 9-51

SUSPENSION, WHEELS AND AXLES4) Install exhaust pipe (rear) and muffler in position. a. Al1 models except 4WD: Tighten bolts connecting exhaust pipe (rear) along with muffler and exhaust pipe (front), and then connect with three cushions. 42 - 52 Nm (4.3 - 5.3 kg-m, 31-38ft-Ib) b. Connect rear differential mounting member to body. Torque (Self-locking nut) 69 -78 Nm (7.0 - 8.0 kg-m, 51-58ft-Ib)

f. Drive spring pins in at both ends ofdrive shaft gradual1y by using 6 mm (0.24 in) dia. steel bar.

Torque

A15-l08

Fig. 9-57

A15-ll0

Fig. 9-541 Connecting bolt 2 Cushion

Fig. 9-52

A15-ll2

c. Insert propeller shaft carefully in to rear end of transmission. d. Instal1 propel1er shaft onto rear differential. 18-25Nm (I.8 - 2.5 kg-m, 13 - 18 ft-Ib)

6) Install front tires and wheels by temporarily tightening wheel nuts. 7) Lower vehicle after taking out safety stands (rigid racks). 8) Tighten wheel nut firmly. 78-98Nm (8.0- 10.0 kg-m, 58 -72 ft-Ib)

b. 4WD: Tighten bolts connecting exhaust pipe (rear) and exhaust pipe (front), and exhaust pipe (rear) and muffler. Then connect with three cushions. 42 - 52 Nm (4.3 - 5.3 kg-m, 31 - 38 ft-Ib)

Torque Torque

9) Connect shock absorber upper end to body on each side with vehicle unloaded. 88 - 127 Nm (9.0 - 13.0 kg-m, 65 - 94 ft-Ib)

Torque

Torque

5) (4WD only) Install rear differential as follows. a. Set rear differential in position with a jack, and tighten the four nuts.Fig. 9-55A4-123

Torque

69 -78 Nm (7.0 - 8.0 kg-m, 51-58ft-lb)

e. Insert rear drive shafts on both sides onto rear axle spindle and rear differential.A15-l07

Fig. 9-58

10) Tighten outer bushing lock bolts with vehicle unloaded. 31-39Nm (3.2 - 4.0 kg-m, 23 - 29 ft-Ib)

TorqueA1S-lll

Fig. 9-53

Fig. 9-56

A15-l09

9-21

SUSPENSION, WHEELS AND AXLES11) Always be sure to check and

3) Installation

1) Removal

adjust the following:a. Air bleeding of brake system b. Rear vehicle height c. Rear wheel alignment

1) Set inner arm on the press bedthrough base of installer and supporter as shown so that axis of bore of inner arm becomes vertical.

1) To remove torsion bar, removeouter arm along with torsion bar from dismounted rear suspension assembly.

NOTE:

S. Inner Bush1) RemovalRemove inner bush using Bush installer (921390000) as follows. 1) Set inner arm boss end on base 2) Fit shank CD to outer tube of inner bush. 3) Remove bush by using a press.1 Shank 2 Inner bush

When disengagement of torsion bar from inner serration of crossmember is difficult, tap outer end of opposite torsion bar with wooden hammer, and the torsion bar and outer arm can be removed.2) For 4WD model Center arm can be taken out of crossmember, after two torsion bars in both sides of crossmember are removed.

cv.

2) Inspection3 Base4 Inner armA15-132

Fig. 9-60 Setting inner arm on press

Check removed torsion bars and center arm for crack at its peeled and/ or corroded portion by means of visual check and color flaw check. 1) If any flaw is found, replace it with new one. 2) If no defect is found, touch up it with black paint after rasping.

2)

Set inner bush and shank to bore

3) Installation1) Apply grease to inner serration and outer serration of torsion bar. 2) For 4WD models, insert center arm into crossmember. 3) Insert torsion bar engaged with outer arm into crossmember, and engage it with inner serration of crossmember or center arm.

of inner arm. 3) Press bush into bore until end surface of outer tube of inner bush corresponds to upper end of boss of inner arm.1 ShankA15129

2 Base3 Inner arm

Fig. 9-59 Removing inner bush

NOTE:

6. Torsion Bar and Center Arm2) InspectionCheck for crack and damage, and replace if defective.

NOTE:

Center arm is adopted on 4WD models only.

Do not confuse a torsion bar with another one. Confusion between R.H. one and L.H. one will result early breakage of them. When installing torsion bars, confirm color of paint (R.H. - yellow, L.H. green) on outer end of torsion bar.

9-22"-.~~~~I,"","'TJ.,-;-r;..~-~_......_ _ _ _......_ _ _ _ _ _ _ _ _ _ _ _ _ _ _....._

. . ._ _ _ _ _ _ _ _ _ _ _ _~-_-_..J

lSUSPENSION, WHEELS AND AXLES

9-8. Adjustment of Posture (4WD Models Only)Ground clearances of front and rear suspensions of 4WD vehicles can be adjusted according to the following procedure.

ture, check air pressure of the all tires and adiust to the specified pressure if necessary. b. Place the vehicle under unloaded condition on the flat ground.

NOTE: a. Before adjusting the vehicle pos-

1. Front Posture AdjustmentVehicles Specified ground clearance "h" STD 2-door Hatchback 4WD--265 - 290 mm (I0.43 - 11.42 in)

2) If "h" dimension is out of the specified range in the above table, adjust "h" dimension according to following method. 3) Front posture is adjusted by turning four (4) adjusting nuts on the both sides of the struts.

Maximum adjustable height

NOTE: a. When turning the adjusting nuts, turn the both nuts on one side of the strut by the same times.

f----- - - - - - - - - - - - - - - - - -.

GL

270 ~ 295 mm (10.63 ~ 11.61 in)---

mI I I

mII

DL Station Wagon 4WD & Brat GL'------------

265 - 290 mm (10.43- 11.42 in)--------

only upward 25 mm (0.98 in)

270 - 295 mm (

1983 Subaru EA81

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