Propeller shaft and Axle.pdf

Propeller shaftand Axle

GENERALMECHANICAL SPECIFICATIONS . . . . . . . . PA - 2

PROPELLER SHAFTFRONT PROPELLER SHAFTREAR PROPELLER SHAFT

FRONT AXLEWHEEL HUB

AXLE AND KNUCKLEWHEEL ALIGNMENT

REAR AXLEWHEEL HUBAXLE HOUSING

DIFFERENTIAL CARRIER ASSEMBLY

PA -2 PROPELLER SHAFT AND AXLE

GENERAL

MECHANICAL SPECIFICATIONS

SPECIFICATION EADD7969

PROPELLER SHAFT

Item Specification

P2 P3

PipeOuter Diameter ×

Thickness63.5×2.6 76.2×2.6

Spider Outer Diameter 18.3 22.73Universal Joint

Bearing Cap OuterDiameter

30 34.92

Outer Diameter 2.5 2.65

Length 12.8 19.7

Needle roller Bearing

Amount 26 30

Slip Joint Spline Diameter 38.7 38.7

Center BearingInner Diameter × Outer

Diameter35×72 40×80

Unit : mm

FRONT AXLE

Item Content

Front axle Type Reverse Elliot, "I" beam

Kingpin O.Dx length 28×180mm, 30×180mm

Tread 1705mm

Toe-in 0~6mm

Camber 1 ±30′

Caster 1 ±30′

Wheel alignment

Kingpin inclination 8 ±10′

Inner 40.8~42.8Turning angle

Outer 30.8~32.8

Lubricant Wheel bearing grease(LIG) 480~500cc

GENERAL PA -3

REAR AXLE

ModelItem

Standard Standard / Long

Rear Axle Type Full flting type

Model D2H(D4AF) D2H-II (D4AE, D4AD)D3H (D4DA, D4DB)

Reductionratio

6.333(D2H)6.142(D2H)5.375(D3H), 6.333(D2H)

Shape Hypoid gear

Gear tooth shape Straight bevel gear

Gear oil Hypoid gear oil

Oil grade API GL-5 SAE 80W 90 (SAE 140 : tropical)

Differential

Quantity 4.5ℓ ± 0.25ℓ (Fill the reservoir to the plug hole)

Type N.L.G.I - 2Hub grease(each leftand right) Quantity 300 ± 30cc

SERVICE STANDARD

PROPELLER SHAFT

DescripitonNominal value

(Basic diameter in [ ])Limit Correction

and remarks

At center0.1 or less 0.4

Correct orreplace

Propeller Shaft Runout

At slip joint0.1 or less 0.4 or less

(correction tobe made atpipe)

Turningdirection

0.01~0.09 0.3 ReplaceSpline play

Diametricdirection

0.02~0.16 0.3

Front 5g/3000rpm -AdjustBalance

Propeller Shaft imbalnce

Rear 10g/3000rpm - weight

Spider to needle roller bearing clearance 0.01~0.06 -Replace as aspider kit

Snap ring(at spider) play in axial direction 0.06 or less -

Adijust withsnap ring;4 typesavailable(1.5,1.55, 1.6, 1.6)

Unit : mm


FRONT AXLE


(Basic diameter in [ ])Limit Correction and

remarks

Front axle center bend in vertical direcFine string

Weight

To go through centerof center hole.

ECOPA5001A

A=130.8 ±1 Correct or replace

Kingpin O.D. [30] 29.947~29.98 29.9 Replace

Bushing I.D. (after press fitting) [30] 30~30.033 -

Kingpin to bushing clearance 0.020~0.086 0.15 Replace bushing

Knuckle vertical clearance 0.02~0.1 0.2

Adjust withshims(four types0.10, 0.15, 0.20,0.30)

Front wheel hub starting torque(kgf.cm) 46~71 - Adjust

REAR AXLE



remarks

At shaft center 2 or less 4Rear Axle Shaft Ben

At flange 0.03 or less 0.05

Correct or replce.

Rear axle shaft and differential gear splinplay in turning direction

0.05~0.15Replace

Backlash between diferential gear anddifferential pinion

0.18 ~0.23 0.5

Adjust with differentigear spacer(replaceas differential gearset in case of poortooth contact).

Backlash between final drive gear and finaldrive pinion

0.2 ~ 0.28 - Adjust

Runout of final drive gear back surfaec 0.05 or less 0.05Replace as carrierassembly.

D2H,D3H 98~195(10~20)Final drive pinion starting torqueN cm(kgf.cm) D033H 200~300(20~30)

- Adjust (do not installoil seal).

Rear wheel hub starting torque N cm(kgf.cm) 195~390(20~40)-

Adjust(do not installouter oil seal andrear axle shaft)

GENERAL PA -5



remarks

A 0.5 or less 1

Correct orreplace(correctionby hydraulicallypressing springseat).

Rear axle housing bendAAB1 or B2 V-block

ECOPA5002A

B1 - B2 1.0 or less 5 Replace

TIGHTENING TORQUE

PROPELLER SHAFT

Tightening torquePart to be tightened

Nm kgf.m lb-ft

P2 60~70 6.0~7.0 43.3~50.6Flange yoke topropeller shaft flanclmp mountingself-locking nut

P3 100~120 10~12 72.3~86.7

P2 205~255 20.5~25.5 148~184Companion flangeclamp nut P3 300~400 30~40 217~289

Center bearing attahing bolt(P2 / P3) 20~30 2.0‘3.0 14.4~21.6

FRONT AXLE

Tightening TorquePart to be tightened

Nm kgf.m lb-ft

Knuckle arm attaching nut 200~300 20~30 145~217

Kingpin lock pin clamping nut 28~38 2.9~3.9 20.9~28.2

Tightening torque 88 or more 9 or more 65 or moreShock absorbermounting stud bolt Loosening torque 135 or more 14 or more 101 or more

Tie-rod end to knuckle arm clamping nut 69~115 7~12 50.6~86.7

Tie-rod end clamping bolt 80 8 57.8

Brake backing plate attaching nut 98~135 10~14 72.3~101

Hub bolt attaching nut 305~380 31~39 224~282

Primary torque 98~125 10~13 72.3~94

Secondary torqueafter full loosening

59 6 43.3

Wheel hub lock nuttightening

Backing out angle Approx. 45 (1 /8 turn)


REAR AXLE

Tightening TorquePart to be tightened

Nm kgf.m lb-ft

Flange yole topropeller shaft flange

P2 60~70 6.0~7.0 43.3~50.6

Clamp mountingself-locking nut

P3 100~120 10~12 72.3~86.7

Propeller shaft joint assembly attaching nut 370~470 38~48 274~347

Final drive gear to differentil caseattaching bolt

225~265 23~27 166~195

Bearing cap tightening bolt 69~78 7~8 50.6~57.8

Side bearing nut fixing lockplate attaching bolt 20~26 2.0~2.7 14.4~19.5

34~44 3.5~45 25.3~32.5Differential carrier assembly attaching nutRear brake assembly attaching bolt 98~135 10~14 72.3~101

350~380 31~39 224~282Rear wheel hub to rear brake drum attachingnut (after tightening, lock using triangularor quadrangular pyramid punch)

Primary tightening 98~125 10~13 72.3~94

27~36 3~4 21.6~28.9

Wheel bearing locknut tightening (Wheelbearing preloadadjustmen)

Secondary tightenintightening aftercomplete loosening

Rear axle shaft attaching bolt 98~115 10~12 72.3~86.7

Lubrication plug 59~78 6~8 43.3~57.8

Drain plug 59~78 6~8 43.3~57.8

GENERAL PA -7

TROUBLESHOOTING E336437B

PROPELLER SHAFT

Symptom Causes Remedy

The yoke direction is wrong. Rearrange the align mark.

The universal joint needle rollerbearing is defective.

Replace with the spider kit.

The propeller shaft is bent Replace the propeller shaft.

The dynamic balance of the propellershaft is incorrect.

Adjust the dynamic balance.

The flange linking bolt is loosened. Tighten with specified torque.

High Speed

The ball bearing is worn outor adhered.

Replace the ball bearing.

The transmission is too fast.Move the shift bar of the transmissionto proper position.

The axial clearance of the universaljoint spider is too large.

Adjust the clearance by Shim.

VibrationatPropeller Shaft

Low Speed

The clearance of the slip jointspline is too large.

Replace the yoke sleeve orpropeller shaft.

The flange linking blot is loosened. Tighten with specified torque.

The tightening bolt for centerbearing is loosened.

Tighten with specified torque.

The center bearing is weakenedor deformed.

Replace the rubber

The universal joint needle rollerbearing is worn.


At start

The clearance of the slip jointspline is too large.

Replace the yoke sleeve orpropeller shaft.

The axial clearance of the universaljoint spider is too large.

Adjust the clearance by Shim.

The universal joint needle rollerbearing is worn.


The ball bearing is worn outor adhered.

Replace the ball bearing.

AbnormalNoiseatPropeller Shaft

RunningwithRegular

speed

The lubricant between the bearingand the spline is defective.

Lubricate.


FRONT AXLE

Symptom Causes Remedy

Kingpin wear. Replace.

The clearance of kingpin and bushingis too large.

Replace the kingpin bushing.

The front wheel hub bearing is adhered,worn or defective in rotation.

Replace.

The wheel alignment is defective. Adjust

The tie rod end ball stud is too worn out. Replace the tie rod end assembly.

The air pressures of the tires are uneven. Adjust.

The tightening castle nuts for the knuckle armand the tie rod arm are loosened.

Tighten with the specified torque.

The tightening nut for tie rod ball studis loosened.


The tightening nut for suspension U-boltis loosened.


Vibration at Steering Wheel

The vertical clearance between the knuckleand the front axle is too large.

Adjust the kingpin thrust washer.

The clearance between the kingpin and thekingpin bushing is too large.

Replace the kingpin bushing.

The strut ball bearing is adhered, wornor defective in rotation.

Replace the thrust ball bearing.

The tire air pressure is too low. Adjust the air pressure.

The wheel alignment is defective. Adjust.

Hard to control thesteering wheel

The grease is deficiency in kingpin. Oil the grease.

The front axle parts are too tightened. Tighten with the specified torque.Steering wheel does notreturn properly. The wheel alignment is defective. Adjust.

The rotating angle adjustment is defective. Adjust the rotating angle.Steering wheel can notbe turned. The tie rod is bent. Replace.

The sizes of the left and right tires are different. Replace with the same size.

The outer diameters of the left and righttires are different.

Replace with the same size.

The air pressures of the tires are different. Apply the same air pressure.

The front axle is bent. Replace.

Vehicle is drawn to one side.

The front spring is damaged or itstension is defective.

Replace.

The wheel alignment is defective. Adjust.

The sizes or types of the left and righttires are different.

Replace with the same size and type.

Front tire is worn irregularlyor too early.

The tire is not managed properly. Replace the tire position.

GENERAL PA -9

REAR AXLE

TroubleSymptom

Causes

Moving force is not transmitted properly.

Wheel Hub and Axle Housing

Reductionand Differential

The tightening bolt for rear axle shaft is loosened.

The rear axle housing is bent.

The rear axle shaft is bent.

The rear axle shaft is broken.

The rear axle shaft is slept out.

The oil seal is defective.

The air breather is cracked, damaged or clogged.

The wheel hub bearing is adhered.

The wheel hub bearing is worn out.

The wheel hub bearing is defective in rotation.

The wheel hub bearing is damaged.

The gear oil is too much.

The gear oil is deficiency.

The oil seal is defective.

The sealant is improper.

The side bearing is adhered.

The side bearing is worn out.

The side bearing is defective in rotation.

The side bearing is damaged.

The operating torque of the side bearing is too high.

The operating torque of the side bearing is too low.

The tightening bolt for reduction and differential assyis loosened.

The tightening nut for differential carrier assemblyis loosened.

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EMTPA5001AA


GENERAL INFORMATION

EMTPA5002AA

GENERAL PA -11

GENERALS E22909E5

1

2

3

1. Front Propeller Shaft2. Rear Propeller Shaft3. Rear Axle

EMTPA5003A

The propeller shaft installing between the transmissionand the rear axle transmits the engine force changed bythe transmission to the final gear of the rear axle. The pro-peller shaft comprises of the front and the rear propellershafts. Two or more parts are linked and supported bywheel base. The propeller shaft having two or more partsincludes a center bearing at the center portion supportedby the frame.

Moving Direction of the Slip Joint

Movement along with the axis

EMTPA5004A

The relative position of the transmission to the rear axle isvarying in accordance with the condition of the road sur-face, the vibration during running of the vehicle and theamount of the load. To compensate the varying of the po-sition, the propeller shaft includes the universal joint andthe slip joint.

Moving Direction of the Universal Joint

Horizontal Movement

Vertical Movement

EMTPA5005A


ADJUSTMENT E154E995

UNIVERSAL JOINT AND BOOT

1. Set the transmission to the neutral position or the N.

2. Lift up the vehicle.

3. Check that the center bearing moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.

A

KMTPA5003A

4. Check that the universal joint boot is torn or shocked.If there is any problem, replace the propeller shaft.

5. Check that the universal joint moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.

PROPELLER SHAFT RUN-OUT

1. Install a dial gauge at the body of the center portionof the front propeller shaft.

2. With rotating the front shaft slowly, check the run-out.And then, check the other side propeller shaft also.

Item Run-out Spec.(mm)

Front Propeller Shaft 0.4 or less

Center Propeller Shaft(Long wheel base)

0.4 or less

Rear Propeller Shaft 0.4 or less

A

KMTPA101A

3. If the run-out of the propeller shaft excesses the spec-ifications, replace the propeller shaft.

GENERAL PA -13

GREASING AT ASSEMBLY

Pack wheel bearing grease

Apply wheel bearing grease to race way

Pack wheel bearing grease

Press-fit flush with hub end face

Apply light coat of wheel bearing grease to lip

Pack wheel bearing grease(300 – 30CC)

Pack wheel bearing greasebetween lips

ECOPA5005A

LUBRICATION AFTER INSTALLATION

1. Pouring Hypoid Gear Oil

Quantity of oil (lit.)4.5ℓ ± 0.25ℓ (D2H, D3H)

2. After parts have been installed, bleed the brake sys-tem.For bleeding procedures, see GROUP BR.

Oil filter plug59 to 78 Nm(6 to 8kgf.m)

ECOPA5006A


PROPELLER SHAFT

COMPONENTS E30B815A

Tightening Torque : Nm (kgf.m, Ib-ft)

540~608(55~62, 398~448)

P2 : 59~69 : P2(6~7, 43.3~50.6)P3 : 98~117 : P3

(10~12, 72.3~86.7)

20~30(2~3, 50.6~61.5)

P2 : 60~70 (6~7, 43.3~50.6)P3 : 100~120 (10~12, 72.3~86.7)

1. Transmission2. Front Axle3. Rear Propeller Shaft Support4. Rear Propeller Shaft5. Rear Axle

ECOPA5007A

PROPELLER SHAFT PA -15

REMOVAL E337574F

1. Making an align mark (C) to the flange yoke (A) of thefront propeller shaft and the parking brake drum (B),remove the tightening nut (D) of the propeller shaft.

B A

C

D

KMTPA111A

2. Remove the tightening bolt (A) of the center bearingbracket.

NOTEFor the short wheel base, the center bearing is one,while for the long wheel base, the center bearings aretwo.

A

KMTPA112A

3. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rear propellershaft, remove the tightening bolt (D) of the propellershaft.

D

B

C

A

KMTPA113A

INSPECTION E8AF06AD

1. After checking the clearance between the spider andthe needle roller bearing, if it excesses the specifica-tions, replace the spider kit.

Clearance between the Spider and the NeedleRoller: 0.01~0.06mm

Needle Roller Bearing

Spider Dial Gauge

EMTPA5007A


2. Measuring the bending at the 50mm around the weld-ing center portion of the propeller shaft, if it excessesthe specification, replace the propeller shaft.

Limit value : 0.4mm or less

[ Measure at center portion ]

EMTPA5008A


FRONT PROPELLER SHAFT

DISASSEMBLY E6265D13

* For disassembly for the number, refer to the corresponding contents.

GapReference : 0.02~0.05Limit : 0.1

12

3

4

5

6

7

8

9

10

11

12

13

Gap to the AxisReference: 0.06 or less

Wear

Rotating State�Rotating State�

Crack or Damage

Deterioration or Deformation

Disassembling Sequence1 . Snap Ring�� 8. Hanger2 . Needle Roller Bearing�� 9. Cushion3. Flange Yoke�� 10. Oil Seal Kit4. Universal Joint Spider�� (Housing and Oil Seal)5. Self Locking Nut�� 11. Packing6. Companion Package�� 12. Ball Bearing7. Holder�� 13. Front Propeller Shaft

ECOPA5008A


1. Remove the snap ring

CAUTION• Replace the snap ring with new ones after re-

moval.

Screw Driver

EMTPA5010A

2. Remove the needle roller bearing.

Universal Tool Set

Yoke Assembly

Push Rod

Guide

Guide

EMTPA5011A

3. Remove the ball bearing

Gear Puller

EMTPA5012A

INSPECTION EF281D65

1. Check the clearance between the spider and the nee-dle roller bearing.

CAUTION• When replace the spider or needle roller bear-

ing, replace them with the spider kit.


Spider Dial Gauge

EMTPA5007A

2. Check the clearance of snap ring along to the axisdirection1. Measure the clearance2. Adjust the clearance

CAUTION• Replace the snap ring with new ones after re-

moval.• Use the snap rings having the same thickness

at the both sides.

KMTAX5009A


Snap Ring

Thickness Color Code

1.5 No Color

1.55 Yellow

1.6 Blue

1.66 Purple

Adjust with Snap Ring

Insert the snap ring

EMTPA5013A

3. Measure the bending at the bent center portion of thepropeller shaft.


EMTPA5008A


REASSEMBLY E6EE691F

Reassembly Sequence

134 2

3 6 5 71

12 11 10 9 8

For assembly for the number, refer to the corresponding contents.

[Caution] The center bearing should be check at every 50,000km

running. If the grease is leaked out, fill the grease. When assembling the center bearing, align the aligning

mark (arrow) and then fill the center bearing grease with specification amount.

1. Fill the grease enough between the bearing inner side and the outer race.2. Fill the grease between the main of the oil seal and the dust rip.3. Fill the grease into the cylindrical container of the housing.4. The total amount of the grease is 25~30g.


54~64 (5.5~6.5, 40~47)

25~30g

20~29(2~3, 14~22)

4

3

2

1

13

1112

9

8

7

6 5

10*

Apply an adhesive to the upper split

Align the arrows of housing

Fill with the wheel bearing grease

Apply grease to the center bearing

P2 : 201~250 (20.5~25.5, 148~184)P3 : 294~392 (30~40, 217~289)

ECOPA5009A


1. Insert the needle roller bearing by pressing-in.

Universal Joint Tool Set

Yoke Assembly

Push Rod

Guide

Guide

EMTPA5015A

2. Install the snap ring.

A

Axis

EMTPA5016A

3. Assemble the center bearing.Setting the arrow mark to upward, insert the centerbearing into cushion, and apply adhesion into the gap.Install the housing tightening bolt with setting it’s headto upward.

Housing Installer

Align Arrow of Housing

Housing Installer A

Housing Installer B

Bolt� Gap

Front Side

EMTPA5017A

4. Using a thickness gauge, measure the gap betweenthe snap ring and the groove of the snap ring.

Reference : 0~0.15mmLimit : 0.3mm or less

CAUTION

• If the gap excesses the limit value, replace thesnap ring.

A

B

C

EMTPA5030A

5. Apply the grease enough to the grease nipple of theuniversal joint.

Recommended Grease: SELL ALVANIA EP #2


REAR PROPELLER SHAFT

DISASSEMBLY E9A9F492

Unit: mm

0.1 or less 0.4 or less

1

86

5

7

34

2

Clearance along to the axisReference : 0.06mm or less

ClearanceReference: 0.01~0.06Limit: 0.1 Rotating

State

Crack,Damage

Item Normal Value Limit

Item Normal Value Limit

Value

Value

At Center

At Slip joint

Clearance of Spline

Rotational Direction

Diameter Direction

Bending

Plug

Disassembly Sequence1. Snap Ring2. Needle Roller Bearing3. Front Yoke4. Universal Joint Spider5. Packing Retainer6. Shield Packing7. Rear Propeller Shaft8. Sleeve Yoke

For disassembly for the ¡� number, refer to the corresponding contents.

Service Kit Spider Kit

Unit: mm

ECOPA5010A


1. Remove the snap ring.

CAUTION• Do not reuse the snap ring.

Screw Driver

EMTPA5010A

2. Remove the needle roller bearing.

Universal Tool Set

Yoke Assembly

Push Rod

Guide

Guide

EMTPA5011A

INSPECTION E3D02E4E

1. Check the clearance between the spider needle rollerbearings.

CAUTION• When replace the spider or needle roller bear-

ing, replace them with the spider kit.


Spider Dial Gauge

EMTPA5007A

2. Check the clearance of snap ring along to the axis.1. Measure the clearance.2. Adjust the clearance.

CAUTION

• Replace the snap ring with new ones after re-moval.

• Use the snap rings having the same thicknessat the both sides.

KMTAX5009A


Snap Ring

Thickness(mm) Color Code

1.5 No Color

1.55 Yellow

1.6 Blue

1.65 Purple

Adjust with Snap Ring

Insert the snap ring

EMTPA5013A

3. Check the bending of the propeller shaft.


EMTPA5008A

[ Measure at slip joint ]

EMTPA5019A

4. Check the clearance of spline

[ Measure at rotational direction ]

Clearance

EMTPA5020A

[ Measure at diameter direction ]

EMTPA5021A


REASSEMBLY E82A209C

Reassembly Sequence

4→

7→5→6→8→3→

For assembly for the number, refer to the corresponding contents.


Snap Ring2. Needle Roller Bearing�3. Flange Yoke4. Universal Joint Spider5. Packing Retainer6. Sheild Packing7. Rear Propeller Shaft8. Sleeve Yoke

1

8

65

7

34

2

54~64 (5.5~6.5, 40~47)

ECOPA5011A


1. Insert the needle roller bearing by pressing-in.

Universal Tool Set

Yoke Assembly

Push Rod

Guide

Guide

EMTPA5011A

2. Install the snap ring.

A

Axis

EMTPA5016A

INSTALLATION E29551BE

1. Setting the aligning mark (C) of the rear axle com-panion flange (A) to that of the flange yoke (B) of therear propeller shaft, tighten the bolt (D) of the propellershaft.

Tightening Torque :98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft) : P359~69 Nm (6~7 kgf.m, 43.3~5.6 lb-ft) : P2

D

B

C

A

KMTPA113A

2. Install the tightening bolt (A) of the center bearingbracket.

Tightening Torque :69~93 Nm (7~9.5 kgf.m, 50.6~68.7 lb-ft)

A

KMTPA112A

NOTEFor narrow version, the center bearing is one, whilefor the wide version, the center bearings are two.


3. Setting the aligning mark (C) of the flange yoke (A) ofthe front propeller shaft to that of the parking brakedrum (B), tighten the bolt (D) of the propeller shaft.

Tightening Torque :98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft)

B A

C

D

KMTPA111A

4. After filling up the recommended grease to the greasenipple (A) until it leaks out from the oil seal, wipe outthe leaked grease completely.

Recommended Grease: ALVANIA EP #2

A

KMTPA114A


FRONT AXLE

WHEEL HUB

DISASSEMBLY E3DC854A

Wear, Rotation, Scratch

Wear, Corrosion

Check the Rotation State


Disassembly Sequence1. Hub Cap2. Split Pin3. Lock Nut4. Washer5. Wheel Hub and Brake Drum6. Hub Bolt7. Front Brake Drum8. Front Wheel Hub

Wear

9. Outer Bearing Inner Race10. Spacer11. Oil Seal12. Inner Bearing Inner Race13. Inner Bearing Outer Race14. Outer Bearing Outer Race15. Dust Cover16. Front Brake Assembly

EMTPA5023A

FRONT AXLE PA -29

1. Place the wooden block (A) at the front and rear sideof the rear wheel.

A

KCOWT5004A

2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).

A

B

C

KCOWT5005A

3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTION

When removing the wheel and tire (B), be carefulthat the hub bolt (D) is not damaged.

A

B

C

KCOWT5006A

4. After removing the wheel cap(A), remove the split pin(B) and the lock nut (C).

CAUTION

When removing the lock nut (C), be careful thatthe washer and the outer bearing does not falldown to the ground.

CB

A

KMTPA204A


5. Remove the washer (A), the outer bearing (B) and thehub assembly (C) from the knuckle (D).

DC

B

A

KMTPA205A

6. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A), theinner bearing (B) and the inner bearing race (C).

NOTE

When using the brass bar, do not tap except the notchparts (A) located inside of the hub.

C

B

A

KMTPA206A

7. Tapping evenly the three notch parts on the other sidehub inner surface with a brass bar, removing the outerbearing race (A).

A

KMTPA207A

8. After removing the hub nut (A), remove the drum (C)from the wheel hub (B).

C

A

B

KMTPA208A

FRONT AXLE PA -31

[DISK BRAKE]

517

16

7

8

9

6

13

12

14

10

15 11

43 2

1

Wear, Rotation, Scratch

Wear, Corrosion



Wear

Disassembling Sequence 1. Hub Cap2. Split Pin3. Lock Nut4. Washer5. Disk Brake Assembly6. Wheel Hub and Rotor7. Bolt8. Rotor9. Front Wheel Hub

10. Hub Bolt11. Outer Bearing Inner Race12. Oil Seal13. Inner Bearing Inner Race14. Inner Bearing Outer Race15. Outer Bearing Outer Race16. Adaptor17. Dust Cover

EMTPA5024A


1. Place the wooden block (A) at the front and rear sidesof the rear wheel.

A

KCOWT5004A

2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).

A

B

C

KCOWT5005A

3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTION

When removing the wheel and tire, be careful thatthe hub bolt is not damaged.

A

B

C

KCOWT5006A

4. After removing the grease cap (A), remove the splitpin (B) and the lock nut (C).

A

B

C

KMTPS5990A

5. Remove the washer (D), the outer bearing (E) and thehub assembly (F) from the knuckle (G).

6. After taking off the disk tightening bolt, remove thedisk assembly from the wheel hub (B).

7. Remove the hub from the knuckle.

FRONT AXLE PA -33

INSPECTION E4EAD549

1. Check the cracks and wear on the hub.

2. Check the scratch and damage on the brake disk.

3. Check for the cracks.

4. Check the assembling state of the bearing.

REASSEMBLY ED458FDE

[DRUM BRAKE]

1. Installing the drum (C) at the wheel hub (B), tightenthe hub nut (A).

Tightening Torque:304~382 Nm (31~39 kgf·m, 224~282 lb-ft)

CAUTION

After tightening the hub nut (A), at least 4 portionsof the groove parts of the stud should be calked.

C

A

B

KMTPA208A

2. By tapping evenly, install the inner bearing race (B)and the outer bearing race (C) at the wheel hub (A).

B

A

C

KMTPA209A

3. Install the inner bearing (B) and the oil seal (C) at thewheel hub (A).

CAUTION

• The bearing should be a set with the bearingrace.

• Use a new oil seal (C) always.

A

B

C

KMTPA210A


4. Fill the recommended grease in the wheel hub (A)with specified amount.

Recommended Grease:RETINAX 0434 of Hankook Shell Co., Ltd.RETINAX 0419 of Hankook Shell Co., Ltd.KO-GW02 of Cheonmi Mineral Oil Co., Ltd

5. Install the washer (A), the outer bearing (B) and thehub assembly (C) at the knuckle (D).

CAUTION• The bearing should be a set with the bearing

race.

DC

B

A

KMTPA205A

6. Install the lock nut (A).

1) With rotating the hub assembly (B), tightenthe lock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.

2) Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 5~9 Nm (6kgf·m, 43.3 lb-ft) and then loosen the nut at45 (1/8 turns).

b

a

B

A

KMTPA211A

7. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.

Moving Torque:0.98~3.4 Nm (0.10~0.35 kgf·m, 0.72~2.51 lb-ft)

B

A

KMTPA212A

FRONT AXLE PA -35

8. After installing the split pin (B), install the wheel cap(A).

BA

KMTPA213A

9. After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).

A

B

C

KCOWT5006A

10. After removing the garage jack (B) supporting the axleand the safety stand (C) supporting the frame, tightenthe wheel nut (A) with the specified torque.

Tightening Torque :539~588 Nm (55~60 kgf·m, 397.8~433.9 lb-ft)

A

B

C

KCOWT5005A

11. Remove the wooden block (A) from the front and rearsides of the rear wheel.

A

KCOWT5004A


[DISK BRAKE]

1. Installing the disk assembly (A) to the wheel hub (B),tighten the disk tightening bolt (C).

Tightening Torque:57~60 Nm (5.8~6.1 kgf·m, 42~44 lb-ft)

A

C

B

KISE220E

2. Tighten the hub nut to the hub assembly.

CAUTION

After tightening the hub nut, at least 4 portions ofthe groove parts of the stud should be calked.

3. By tapping evenly, install the inner bearing race (C)and the outer bearing race (E) at the wheel hub (D).

4. Install the inner bearing (B) and the oil seal (A) at thewheel hub (D).


race.• Replace the oil seal(C) with new one after re-

moval.

E

D

C

B

A

KISE210E



6. Install the washer, the outer bearing and the hub as-sembly at the knuckle.


race.

7. Install the lock nut (A).1. With rotating the hub assembly (B), tighten

the lock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.

2. Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 59 Nm (6 kgf·m,3.31 lb-ft) and then loosen the nut at 45 (1/8turns).

B

A

KMTPA5002A

FRONT AXLE PA -37

8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.

Starting Torque : 0.98~3.4 Nm (0.10~0.35kgf·m, 0.72~2.5 lb-ft)

B

A

KMTPA212A

9. After installing the split pin (A), install the wheel cap.

A

KMTPS5991A


A

B

C

KCOWT5006A

11. After removing the garage jack (B) supporting the axleand the safety stand (C) supporting the frame, tightenthe wheel nut (A) with the specified torque.

Tightening Torque : 539~588 Nm (55~60kgf·m, 397.8~433.9 lb-ft)

A

B

C

KCOWT5005A


12. Remove the wooden block (A) from the front and rearsides of the rear wheel.

A

KCOWT5004A

FRONT AXLE PA -39

AXLE AND KNUCKLE

COMPONENTS E8D4AD71

8. Drag Link

4. Dust Cap

5. Kingpin Shim

6. Kingpin

1. Hub Cap

2. Front Wheel Hub

3. Knuckle

7. Thrust Bearing

11. Front Axle

9. Knuckle Arm

10. Tie Rod


196~294 (20~30, 145~217)

196~294 (20~30, 145~217)

1 2

3

7

4

5

6

8

11

9

10

ECOPA5012A


DISASSEMBLY E1B9F4BA

[DRUM TYPE]

1. Remove the wheel hub. (Refer to the “ Wheel HubDisassembly” )

2. After taking off the tightening bolt (A) for brake assem-bly, remove the brake assembly (B) from the knuckle(C).

NOTETie the brake assembly (B) around the relating partswith a wire.

C B

A

KMTPA301A

3. After taking off the split pin (A) of the drag link tight-ening bolt and lock nut (B), remove the drag link (C).

C

A

B

KMTPA302A

4. After taking off the split pin (A) of the tie rod tighteningbolt and the lock nut (B), remove the tie rod (C).

C

A

B

KMTPA303A

5. After taking off the lock pin nut (A) and the washer (B),remove the lock pin (C).

C

A

B

KMTPA304A

FRONT AXLE PA -41

6. After taking off the dust cap (A), remove the king pin(B).

A

B

KMTPA305A

7. Remove the king pin shim (A) and the dust seal (B).

A

B

A

KMTPA306A

[DISK TYPE]

1. Remove the wheel hub. (Refer to the “ Wheel HubDisassembly” )

2. After holding the brake hose with a vise pliers, loosenthe brake hose tightening bolt (A). Remove the brakehose.

A

KMTBR5536A

3. After taking off the tightening bolt(A) of the brakecaliper, remove the caliper(B).

A

B

KMTBR5538A

4. After taking off the tightening bolt of the dust cover,remove the dust cover from the knuckle.


5. After taking off the split pin (A) of the drag link tighten-ing bolt and the lock nut (B), remove the drag link (C).

C

A

B

KMTPA302A

6. After taking off the split pin (A) of the tie rod tighteningbolt and the lock nut (B), remove the tie rod (C).

C

A

B

KMTPA303A

7. After taking off the lock pin nut (A) and the washer (B),remove the lock pin (C).

C

A

B

KMTPA304A

8. After removing the dust cap (A), remove the king pin(B).

A

B

KMTPA305A

FRONT AXLE PA -43

9. Remove the king pin bushing (A) and the dust seal(B).

A

B

A

KMTPA306A

REASSEMBLY E2E655C2

[DRUM TYPE]

1. Install the king pin bushing (A) and the dust seal (B).

A

B

A

KMTPA306A

2. Install the king pin (B) and then, install the dust cap(A).

CAUTION

The groove portion of the king pin (B) should faceto inside.

A

B

KMTPA305A

3. After installing the lock pin (C), install the lock pinwasher (B) and nut (A).

Tightening Torque :28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)

C

A

B

KMTPA304A


4. After installing the tie rod (C), install the lock nut (B)and split pin (A).

Tightening Torque :69~118 Nm (7~12 kgf·m, 51~87 lb-ft)

C

A

B

KMTPA303A

5. After installing the drag link (C), install the lock nut (B)and split pin (A).


C

A

B

KMTPA302A

6. After install the brake assembly (B) to the knuckle (C),install the tightening bolt (A) for the brake assembly.


C B

A

KMTPA301A

7. Install the wheel hub. (Refer to the “ Wheel Hub As-sembly” )

[DISK TYPE]

1. Install the king pin bushing (A) and the dust seal (B).

A

B

A

KMTPA306A

FRONT AXLE PA -45

2. Install the king pin (B) and then, install the dust cap(A).

CAUTION

The groove portion of the king pin (B) should faceto inside.

A

B

KMTPA305A

3. After installing the lock pin (C), install the lock pinwasher (B) and nut (A).

Tightening Torque :28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)

C

A

B

KMTPA304A

4. After installing the tie rod (C), install the lock nut (B)and split pin (A).


C

A

B

KMTPA303A

5. After installing the drag link (C), install the lock nut (B)and split pin (A).


C

A

B

KMTPA302A


6. After install the brake caliper (B), install the calipertightening bolt (A).

Tightening Torque : 98~127 Nm (10~13kgf·m, 72~94 lb-ft)

A

B

KMTBR5538A

7. After installing the dust cover (B) to the knuckle (C),install the tightening bolt (A) of the dust cover.


8. After installing the brake assembly (B) to the knuckle(C), install the tightening bolt (A) of the brake assem-bly.

Tightening Torque : 125~139 Nm (12.7~14.2kgf·m, 92~103 lb-ft)

9. Install the wheel hub. (Refer to the “ Wheel Hub As-sembly” )

FRONT AXLE PA -47

WHEEL ALIGNMENT

DESCRIPTION ED7D3163

When wheel alignment and steering angle are measured,check that the vehicle has no load or every parts of thefront axle are properly assembled.

CAUTIONBefore the adjustment, check again followings.1. The front wheel is loosened.2. The knuckle is loosened.3. The linkage between the knuckle flange and

knuckle arm is loosened.4. The bolts, the screws or the nuts are loos-

ened.5. The leaf spring is damaged or weakened.6. The tire air pressure is too high or low.7. The adjusted backlash of the steering gear is

proper.

INSPECTION E7697420

TOE-IN

1. Set the front wheel along with the straight direction.

2. Make a mark at the front end of the front wheel. (Themarking point is the middle position of the width andheight of the wheel)

3. Setting the needle height of the toe-in gauge to themarking point of the left and right tire, measure thetoe-in value. Measure the distance (A) between thetwo wheels.

A

KMTAX5019A

4. Moving the vehicle to forward so that the markingpoint moves backward. Setting the marking point tothe height of the toe-in gauge (i.e. turn 180 ), at therear side, measure the distance (B) between the twowheels.

B

KMTAX5020A

5. The difference between the measured value of rearside (B) and the measured value of front side (A) isthe toe-in value.

Specified Value (B-A): 0~6mm

α

A

B

β

Forward

KHHA850A


6. If the measured toe-in value excesses the specifiedvalue, adjust it by loosening the clamp bolts (B) of theleft and right tie rods (A) and turning the tie rod (A)with a pipe wrench (C).

Tightening Torque of the Clamp Bolt (B):20~29 Nm (2~3 kgf·m, 14~22 lb-ft)

2.0~3.0 kgf.m

A

BC

Tie Rod End

EMTPA5026A

CAMBER


2. Remove the wheel hub cap (A).

A

KCOPA5007A

3. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub by settingthem to the center hole of the spindle.

4. Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the level gaugeto the zero point.

5. Measure the camber value(B) of the gauge (A). Thecenter line of the bubble is the camber value.

Specified Value : 1 ±30′

A

KMTPA363A

6. By the same method, measure the camber value ofthe opposite wheel.

KINGPIN INCLINATION ANGLE AND CASTER

1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).

A

BC

KCOPA5008A

FRONT AXLE PA -49

2. Positioning the two front tires of the vehicle to the cen-ter of the turn table, pull (set up) the parking brake.

CAUTIONIf it is hard to move the vehicle, lift up the vehiclewith a jack and place the turn table and the plateunder the front and rear tire.

3. Set the scales of the both turn table to zero point.

4. Turn the tire to be measured to the outward until thescale of the turn table is positioned 20 (A).

A

KMTPA363A

5. Remove the wheel hub cap (A).

A

KCOPA5009A

6. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub by settingthem to the center hole of the spindle.


8. By turning the zero setting screws of the caster (A)under the gauge and the kingpin tilting angle, set thebubble to 0.

CAUTIONFor left side wheel, use the left scale as the king-pin tilting angle scale. For right side wheel, usethe right scale as the kingpin tilting angle scale.

9. Turn the wheel 20 again so as to set the scale of theturn table to 0 . Then the center line of the bubbleindicates the kingpin tilting angle value. Measure thecenter line value of the bubble.

Specified Value : 8 ±10′

10. By turning the tire to inward, set the scale of the turntable to 20 .


12. From the caster scale, read the each pointing scale ofthe casters.

Specified Value: 1 ±30′

13. By the same method, measure the caster and thekingpin tilting angle values of the opposite wheel.


STEERING ANGLE

Before inspecting the steering angle, complete the inspec-tion of the wheel alignment.

1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).

A

BC

KCOPA5008A

2. Positioning the two front tires of the vehicle to the cen-ter of the turn table, pull (set up) the parking brake.

CAUTION

If it is hard to move the vehicle, lift up the vehiclewith a jack and place the turn table and the plateunder the front and rear tire.

3. Set the scales of the both turn table to 0 .

4. Turn the tire to inward. Measure the scale of the turntable.

Specified Value( ) : 40.8~42.8

5. Turn the tire to outward. Measure the scale of the turntable.

Specified Value( ) : 30.8~32.8

6. If the measured value excesses the specified value,tighten or loosen the knuckle stopper bolt (A) at bothsides (LH/RH) to adjust the steering angle.

A

KMTPA382A

7. After adjusting the steering angle, tighten the nut (A)of the stopper bolt with specified torque.

Tightening Torque :39.2~53.9 Nm (4.0~5.5 Kgf·m, 28.9~39.8 lb-ft)

A

KMTPA383A

FRONT AXLE PA -51

SIDE SLIP

Before checking the side slip, complete the inspection ofthe wheel alignment.


2. Maintaining the position of the front wheel to thestraight direction, drive the vehicle on the slip testerslowly.

CAUTION

With maintaining the position of the front wheel tothe straight direction, pass through the side sliptester thoroughly. Do not turn the wheel or do notfall off from the tester.

3. The value indicated on the tester is the side slip. Ifthe side slip excesses the specified value, the wheelalignment should be adjusted.

Specified Value: 3mm/(when going straight per 1m)


REAR AXLE

WHEEL HUB

COMPONENTS EC1D3DFC

19

5

14

18

1

10

9

87

4

6

3

2

1113

17

1612

15

304~082(31~39, 224~282)

7~11 (0.7~1.1, 5~8)

98~117(10~12, 72~87)

[Caution] Be careful that the brake lining and the brake drum inner surface are not contaminated by the oil or grease.


EMTPA5027A

REAR AXLE PA -53

REMOVAL E01EC3FB

1. Place the wooden block (A) at the front and rear sidesof the front wheel.

A

KCOWT5007A

2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand (B).

A

B

KCOWT5008A

3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTION


D

C

B

A

KMTPA403A

4. After taking off the hub bolt (A), remove the axle shaft(B).

NOTE

When it is hard to remove the axle shaft (B), insert hubbolts (A) into the removing screw holes (C) evenly.

BC

A

KMTPA404A


5. Remove the oil seal (A).

A

KMTPA405A

6. Loosening the tightening bolt (A) for the lock nut, re-move the lock washer (B).

B

A

KMTPA406A

7. Using the special tool (09527-47000), remove the locknut (A).

A

KMTPA407A

8. Remove the rear wheel hub (B) with the outer bearing(C) from the axle housing (A).

CAUTION

Be careful that the outer hub bearing (C) do notdrop down to the ground.

A

B

C

KMTPA408A

REAR AXLE PA -55

DISASSEMBLY E582AF4B

1. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A), theinner bearing (B) and the inner bearing race (C).

C

B

A

KMTPA409A

NOTEWhen using a brass bar, do not tap except the notchparts (A) located inside of the hub.

A

KMTPA420A

2. Tapping evenly the three notch parts on the other sidehub inner surface with a brass bar, removing the outerbearing race (A).

A

KMTPA410A

3. After taking off the hub nut (A), remove the drum (C)from the wheel hub (B).

C

A

B

KMTPA411A


INSPECTION E55267A1

1. Check that the rotation state is proper after installingthe bearing(B) to the bearing race(C). If it has beenadhered, worn or defective in rotation, replace thebearing and the bearing race (C) in a set.

C

B

A

KMTPA409A

2. If the hub bolt is worn or corroded, remove the hubbolt from the wheel hub and replace it.

REASSEMBLY E2E5EAF5

1. Installing the drum (C) to the wheel hub (B), tightenthe hub nut (A).

CAUTIONAfter tightening the hub nut (A), at least 4 portionsof the groove parts of the stud should be calked.

Tightening Torque : 304~382 Nm (31~39Kgf·m, 224~282 lb-ft)

C

A

B

KMTPA411A

2. By tapping evenly, install the inner bearing race (B)and the outer bearing race (C) at the wheel hub (A).

B

C

A

KMTPA412A

REAR AXLE PA -57

3. Install the inner bearing (B) and the oil seal (C) at thewheel hub (A).

CAUTION

• The bearing should be a set with the bearingrace.

• Replace the oil seal (C) with new ones afterremoval.

A

B

C

KMTPA413A



5. Install the rear wheel hub (B) and the outer bearing(C) to the axle housing (A).

CAUTIONThe bearing should be a set with the bearing race.

A

B

C

KMTPA408A

6. Install the lock nut (A).a. With rotating the hub assembly (B), tighten the

lock nut (A) fully with the force of 98~127 Nm(10~13 kgf·m, 72~94 lb-ft). After that, loosen thenut fully.

b. Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 29~39 Nm (3~4kgf·m, 22~29 lb-ft).

b

a

B

A

KMTPA211A


7. Setting the lock washer (A) to the spindle groove (B)of the housing, tighten the lock nut tightening bolt (C).

Tightening Torque : 7~11 Nm (0.7~1.1 Kgf.m, 5~8 lb-ft)

A

C

B

KMTPA415A

8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe starting torque by multiplying the tangential forceto the radius.

Starting Torque : 2~4 Nm (0.2~0.4 Kgf.m, 1~3 lb-ft)

B

A

KMTPA212A

9. Install the oil seal (A).

CAUTIONUse a new oil seal (C) always.

A

KMTPA405A

10. After installing the axle shaft (B), tighten the hub bolt(A) with specified torque.

Tightening Torque : 98~117 Nm (10~12Kgf.m, 72~87 lb-ft)

B

A

KMTPA416A

REAR AXLE PA -59


D

C

B

A

KMTPA403A

12. After removing the garage jack (A) supporting the axleand the safety stand (B) supporting the frame, tightenthe wheel nut with the specified torque.

Tightening Torque : 539~588 Nm (55~60Kgf.m, 398~434 lb-ft)

A

B

KCOWT5008A

13. Remove the wooden block (A) from the front and rearsides of the front wheel.

A

KCOWT5007A


AXLE HOUSING

COMPONENTS E116ADC2

49~59 (5~6, 36~43)

59~69 (6~7, 43~51)

59~78 (6~8, 43~58)

59~78 (6~8, 43~58)

245~255 (25~26, 181~188)

1. Drain Plug 5. Reduction and Differential Assembly2. Oiling Plug 6. Nut3. Nut 7. Rear Axle Housing4. Bolt


EMTPA5028A

REAR AXLE PA -61

DISASSEMBLY ECFFC067

1. Place the wooden block (A) at the front and rear sidesof the front wheel.

A

KCOWT5007A

2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand (B).

A

B

KCOWT5008A

3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTION


D

C

B

A

KMTPA403A

4. As the same method with the 2~3 steps, remove theopposite side wheel and tire.

5. Support the both hub with a jack (A).

A

KMTPA501A



D

B

C

A

KMTPA113A

7. After removing the brake line (A), remove the brakehose clip (B).

NOTE

• If the brake line is rubber hose, remove it afterbiting it with vise pliers.

• If the brake line is steel pipe, remove the line withpressing the brake pedal.

A

B

KCOPA5011A

8. After taking off the tightening nut(A) of the shock ab-sorber, remove the shock absorber (B).

KCOPA5012A

9. After taking off the tightening nut (A) of the U-bolt,remove the U-bolt (B).

B

A

KCOPA5013A

REAR AXLE PA -63

10. After getting down the jack (A) supporting the bothhub, remove the axle housing (B).

B

A

A

KMTPA505A

REASSEMBLY E7E5E580

1. After positioning the axle housing (B) at the rear sideof the vehicle, lift up the jack (A) supporting the bothhubs slowly.

B

A

A

KMTPA505A

2. Setting the center bolt (A) of the leaf spring to thecenter hole (B) of the axle housing, lift up the axlehousing (C) completely.

A

B

C

KCOPA5014A

3. After installing the U-bolt (B), tighten the U-bolt tight-ening nut (A) with the specified torque.


B

A

KCOPA5013A


4. After installing the shock absorber (A), tighten theshock absorber tightening bolt (A) with the specifiedtorque.


KCOPA5012A

5. After installing the brake hose clip (B), install the brakeline (A).

NOTE

• If the brake line is rubber hose, remove the visepliers after installing the line.

• If the brake line is steel pipe, release the brakepedal after installing the line.


A

B

KCOPA5011A

6. Setting the align marks (C) of the rear axle companionflange (A) to the flange yoke (B) of the rear propellershaft, install the tightening bolt (D) of the propellershaft.

Tightening Torque : 59~69 Nm (6~7 kgf·m, 43~51 lb-ft)

D

B

C

A

KMTPA113A

7. Remove the jack (A) supporting the both hub.

A

KCOPA5010A

REAR AXLE PA -65

8. Install the wheel and tire (B) to the hub (C). Tightenthe wheel nut (A).

D

C

B

A

KMTPA403A

9. After removing the garage jack (A) supporting the axleand the safety stand (B) supporting the frame, tightenthe wheel nut with the specified torque.


A

B

KCOWT5008A

10. Remove the wooden block (A) from the front and rearsides of the front wheel.

A

KCOWT5007A

11. Bleed the brake system. (Refer to the "Air Bleedingof BR Group")


DIFFERENTIAL CARRIERASSEMBLY

COMPONENTS EB41F3DE

3

1

2

45

67

8

9

10

22

21

1317

3435

31

3669~78 (7~8, 51~58)

20~26.4 (2~2.7, 14~20)

373~471(38~48, 275~347)

33

1819

11 12

16

1415

20

23

24

2726

25

28

29

32

30

[Caution] The bearing cap and the differential carrier should be replaced as a set.


A

B

A, B : ONLY D3H, DO33H

EMTPA5029A

DIFFERENTIAL CARRIER ASSEMBLY PA -67

REMOVAL E81090E0

1. After removing the drain plug(A), drain out the gearoil.

A

KMTPA610A

2. After taking off the hub bolt (A), remove the axle shaft(B).

NOTE

When it is hard to remove the axle shaft (B), inserthub bolts (A) into the removing screw holes evenly.

BA

KMTPA611A

3. Remove the axle shaft at the opposite side also.


D

B

C

A

KMTPA113A

5. Disassemble the contacting surface between the rearaxle companion flange (A) and the flange yoke (B) ofthe rear propeller shaft.

CAUTION

As this part is very heavy, be careful the precau-tions. Before the working, be sure that it is sup-ported by jack.

A

B

KMTPA613A


6. After taking off the differential carrier tightening boltand nut (A), remove the differential carrier assembly(B) from the axle housing (C).

B

A

C

KMTPA614A

INSTALLATION E01F0B5B

1. After installing the differential carrier assembly (B) tothe axle housing (C), tighten the differential carriertightening bolt (A) with the specified torque.

Tightening Torque :34.3~44.1 Nm (3.5~4.5 kgf·m, 25.3~32.5 lb-ft)

B

A

C

KMTPA614A

2. Setting the aligning mark (C) of the rear axle com-panion flange (A) to that of the flange yoke (B) of therear propeller shaft, tighten the bolt (D) of the propellershaft.


D

B

C

A

KMTPA113A

3. After installing the axle shaft (B), tighten the hub bolt(A) with the specified torque.


BA

KMTPA611A


4. Install the rear axle shaft of the opposite side.

5. Fill in the recommended oil.

Recommended Oil: API GL-5, SAE 80W/90API GL-5, SAE 140W/For tropical regionOil Amount: 4.5±0.25ℓ

KCOPA5031A

INSPECTION E2605DE5

1. Backlash between the Differential Gear and Differen-tial Pinion

ECOPA5013A

2. Backlash between the Final Drive Gear and FinalDrive PinionMeasure on the final drive gear circumference atabout three points.

ECOPA5014A

3. Runout on the Back of the Final Drive GearMeasure at the maximum diameter position.

ECOPA5015A

4. Final Drive Gear Tooth ContactApply a light coat of red lead to three or four teeth, turnthe gear several turns and check tooth contact usingpaper

C

ECOPA5016A


5. Rear Axle Shaft and Differential Gear Spline Play inTurning Direction.

Rear axle shaft

Play

ECOPA5017A

6. Rear Axle Housing BendSupport horizontally the housing spindle at the innerbearing engagement section at both ends by Blocks.For measurement of A, apply a dial gauge to the outerbearing engagement section and turn through 360 de-grees.For measurement of B1 and B2, use a square to po-sition the housing squarely and measure B1. Then,turn through 180 degrees and measure B2.Replace if the measured value exceeds the limit. Inthe case of bend of the spindle section (measurementof A), however, the spring seat of the housing may becorrected by a hydraulic press.

A A

B1 or B2V-block

Square

Measuring point

ECOPA5018A

DISASSEMBLY E8436EF3

1. Fix the differential carrier (A) at the vise or the workingbase.

A

KMTPA701A

2. Remove the differential carrier bearing cap bolt (A).

A

KMTPA702A

3. After removing the bearing cap(A), remove the sidebearing nut (B).

A

B

KMTPA703A


4. Remove the differential carrier assembly (A) and theside bearing race (B) from the differential carrier collar(C).

A

B

C

KMTPA704A

5. After removing the side bearing (A), remove the dif-ferential case bolts (B).

A

B

KMTPA705A

6. After removing the differential case, remove the differ-ential pinion, the differential pinion washer, the differ-ential gear, the differential gear washer and the differ-ential spider, sequentially.

7. After taking off the tightening bolt of the drive gear,disassemble the differential case and the driver gear.

8. Remove the self locking nut (A) and the companionflange (B).

A

B

KMTPA708A

9. Remove the pinion drive (A), the inner bearing (B), thespace (C) and the shim (D).

A

B

CD

KMTPA709A

10. Remove the oil seal (A) and the outer bearing (B).

A

B

KMTPA710A


11. Remove the bearing race (A), the oil stopper (B) andthe outer bearing race (C) from the differential collar.

A

C

B

KMTPA711A

REASSEMBLY E3C241A6

1. Install the outer bearing race (C), the oil stopper (B)and the bearing race (A) into the differential collar.

A

C

B

KMTPA711A

2. Install the outer bearing (B) and a new oil seal (A).

A

B

KMTPA710A

3. Install the shim (D), the space (C), the inner bearing(B) and the pinion drive (A).

A

B

CD

KMTPA709A

4. Install the companion flange and the self locking nut(A).


A

B

KMTPA708A

5. After assembling the differential case and the drivegear, install the drive gear tightening bolt.


6. After installing the differential pinion, the differentialpinion washer, the differential gear, the differentialgear washer and the differential spider, install the dif-ferential case.


7. After installing the differential case bolt (A), install theside bearing.

A

B

KMTPA705A

8. Install the differential carrier assembly (A) and theside bearing race (B) at the differential carrier collar(C).

A

B

C

KMTPA704A

9. After installing the side bearing nuts (B), install thebearing cap (A).

Tightening Torque : 69~78 Nm (7~8 kgf·m, 51~58 lb-ft)

A

B

KMTPA703A


ADJUSTMENT EDD76B0F

1. Setting of Starting Torque

NOTEDo not mount front and rear bearing shims, pinionspacer and oil seal.

Starting torque : 98 - 195N.cm (10 - 20 kgf.cm)

Temporarily installed partsRear bearing inner raceRear bearing outer raceOil stopperFront bearing outer raceFront bearing inner racePropeller shaft joint Lock nut

Measurement of starting torquePinion gage

ECOPA5019A

2. Pinion Height AdjustmentWith the parts as assembled for setting of the startingtorque, measure clearance A (see illustration) with athickness gauge.

Shim thickness A tolerance when assem-bled : ± 0.05mm

According to the measured clearance A, select therear bearing shim.

Thickness of rear bearing shim = A - 0.3

TYPES OF REAR BEARING SHIMS

Thickness(mm)

0.30

1.38

1.41

1.44

1.47

1.50

1.53

1.56

1.59

1.62

1.65

Cylinder gage

A

ECOPA5020A

3. Adjustment of Starting TorqueMount the selected rear bearing shim with pinionspacer and front bearing shim and tighten the locknut to specified torque. Find the pinion spacer andfront bearing shim that give the nominal startingtorque when so tightened.Select such pinion spacer that reduces the requirednumber of front bearing shims to minimum.

NOTE• If the 0.3 mm thick shim is used in combination

with others into the rear bearing, make sure thatthe 0.3 mm thick shim is installed on the bearingend.

• Oil seal must not be installed.

Types of pinion spacers Yellow paint applied.


TYPES OF FRONT BEARING SHIMS

Thickness(mm)

0.30

2.33

2.30

2.27

2.24

2.21

2.18

2.15

2.12

2.09

2.06

2.03

2.00

Measurement of starting torque

Rear bearing shim (selected one)

Front bearing shimPinion spacer

Pinion gauge

Lock nut380 to 480 Nm (38 to 48 kgf.m)

ECOPA5021A

4. Adjustment of Backlash between Differential Gearand Differ-ential Pinion

NOTE

Use spacers of same thickness on both sides.

TYPES OF DIFFERENTIAL GEAR SPACER

Thickness(mm)

1.4

1.5

1.6

Differential gear spacer

ECOPA5022A

5. Adjustment of Backlash between Final Drive Gear andFinal Drive PinionInstall the differential assembly in the carrier and par-tially tighten by the bearing cap. Adjust the side bear-ing nut for nominal backlash.After adjustment, further tighten the side bearing nutto the extent that the backlash does not exceed thenominal value in order to preload the side bearing. Atthis time, keep the sum of additional tightening of theright and left side bearing nuts to within one notch oflock plate hole.After adjustment, line up with the bearing cap align-ment mark and tighten to specified torque.

NOTEWhen the side bearing nut on one side is loosened,be sure to tighten the side bearing nut on the otherside by the same amount.

Differential side bearing adjustment tool

ECOPA5023A


ECOPA5014A

6. Runout on Back of final Drive GearMeasure at the maximum diameter position.

ECOPA5015A

7. Tooth Contact Adjustment of Final Drive GearApply light coat of red lead to three or four teeth andturn several times to check tooth contact.If tooth contact is very poor, increase or decrease therear bearing shim(s) and backlash to adjust to correcttooth contact.In case the gear is to be replaced due to excessivetooth wear, be sure to replace the final drive gear andfinal drive pinion as a gear set.

C

ECOPA5016A

ABNORMAL FINAL DRIVE GEAR TOOTH CONTACT AND ITS CAUSE

Correct tooth contact Face contact Flank contact Toe contact Heel contact

Cause Backlash too large,worn gear

Backlash too small Incorrect pinion height

Incorrect pinion height

ECOPA5024A

Propeller shaft and Axle.pdf

Documents

Transcript of Propeller shaft and Axle.pdf