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FRONT AXLE GENERAL FA - SPECIFICATION FA - SERVICE STANDARDS FA - TIGHTENING TORQUE FA - SPECIAL TOOL FA - TROUBLESHOOTING FA - SERVICE PROCEDURE FA - INSPECTION AND ADJUSTMENT FA-19 FA-2 FRONT AXLE GENERAL The front axle supports and transmits the weight of the front portion of vehicle to the tires and also serves as a part of the steering system and brake system The front axle also has proper wheel alignment for stabilizing the vehicle as it is driven Wheel alignment Kingpin inclination and camber Caster Toe-in(B-A) Front of vehicle Camber Caster Kingpin inclination Front of vehicle Facilitates steering Ensures stable traveling direction and faciliates steer- Minimizes tire skidding and wear ing CYFA001A SPECIFICATION FA-3 SPECIFICATION Full air type A O H type Brake type Drive system 4X2 Vehicle type Cargo, dump 6X4 6X4 9.5ton Cargo, (Low deck) dump Full cargo C/TRT X 4, 10 X 18ton cargo TRT, 23ton Dump, mixer Front 1st Front 2nd Front 1st Front 2nd 1°30´ ± 30´ ← ← ← 1°30´ ± 30´ ← ← 2° ± 30´ ← Camber angle 1° ± 30´ ← ← ← 1° ± 30´ ← ← ← ← Kingpin angle 7° ± 10´ ← ← ← 7° ± 10´ ← ← ← ← Toe-in ~ 3mm ← ← ← ~ 3mm ← ← ← ← Caster angle Steering angle Inner 47° -2 50° -20 ← ← 47° -20 49° -20 36° -20 49°-20 36° -2 Outer 38° -2 40° -20 ← ← 35° -20 39° -20 29°-20 39°-20 29° -2 650g ← ← ← 650g ← ← 120g ← ← ← 120g ← ← Wheel bearing Wheel hub grease Hub cap (on-wheel) A.O.H type : Air over hydraulic brake type SERVICE STANDARDS Maintenance item Front axle 7° ± 10´ Kingpin angle Bend Nominal value (Basic diameter in [ ] ) Limit 7° ± 30´ Correct or replace Vertical or less Horizontal or less Knuckle to front axle clearance in thrust direction 0.2 or less Replace Adjust with thrust washer O.D [50]-0.002-0.015 49.9 Bushing I.D (after installation) [50]+0.045+0.018 - Kingpin to bushing clearance 0.02 to 0.06 0.15 Wheel bearing starting torque (standard wheel hub) 245 to 540 N·cm (25 to 55 kgf·cm) - Kingpin Remedy and remarks Replace bushing Replace bushing Adjust by tangential force on wheel O.D Standard wheel hub [8 studs] 18 to 38N {1.8 to 3.9 kgf} Hub bolt (P.C.D 285)[10 studs] 15 to 32N {1.5 to 3.3 kgf} Hub bolt (P.C.D 335) FA-4 FRONT AXLE TIGHTENING TORQUE Thread size O.D x pitch (mm) Tightening torque N·m(kgf·m) Kingpin set bolt tightening nut M10 x 1.25 29(3) Knuckle arm attaching bolt tightening nut M24 x 1.5 390 to 635 (40 to 65) Tie rod arm attaching bolt tightening nut M24 x 1.5 390 to 635 (40 to 65) Front brake assembly to knuckle attaching bolt tightening nut M16 x 1.5 215 (22) Location tightened Wheel hub to brake drum tightening nut Standard wheel hub [8 studs] M22 x 1.5 320 (32.8) Standard wheel hub [10 studs] M24 x 1.5 420 (43.0) Hub bearing lock nut tightening (standard wheel hub) Primary tightening M45 x 1.5 195 (20) Primary back off M45 x 1.5 Loosen fully until clearance is formed Secondary tightening M45 x 1.5 195 (20) Secondary back off M45 x 1.5 Back off 22.5°(1/16 tum) M6 x 1.0 6.9 to 11 (0.7 to 1.1) Chamber bracket to knuckle Vehicle with air brake attaching bolt M12 x 1.25 96 (9.8) Tie rod end tightening nut M12 x 1.25 78(8) Tie rod to tie rod arm attaching ball stud tightening nut M24 X 1.5 270 (27.6) Wheel cover bolt M10 x 1.25 19 to 27 (1.9 to 2.8) Lower cover (lower part of kingpin) M27 x 1.5 105 to 165 (11 to 17) Knuckle stopper bolt M14 x 1.5 59 to 83 (6 to 8.5) Hub bearing lock nut locking lock bolt(Standard wheel hub) SPECIAL TOOL FA-5 SPECIAL TOOL Tool (Number and name) Illustration Use 09231-93100 Installation of the bearing outer race and bearing Bar (use with 09517-7D000 and 09517-8A000) D2319310A 09517-7D000 Installation of the inner bearing outer race Oil seal installer (use with 09231-93100) D177D00A 09517-8A000 Oil seal installer Installation of the inner bearing outer race (use with 09231-93100) D178A00A 09517-8A100 Bearing installer Installation of the inner bearing (8ton) D178A10A Installation of the inner bearing 09517-7D100 Bearing installer D177D10A 09431-83100 Removal of the bearing Puller set D31810A FA-6 FRONT AXLE TROUBLESHOOTING Symptom Steering wheel vibrates Steering wheel movement is hard Probable cause Remedy Worn kingpin Replace Clearance between kingpin and bushing to large Replace kingpin bushing Seized, worn or poorly turning wheel hub bearing Replace Wheel misalignment Adjust Excessively worn tie rod end ball stud Replace tie rod end assembly Uneven tire inflation pressure Adjust Loose knuckle arm and tie rod arm tightening castle nut Tighten to Specified torque Loose tie rod ball stud tightening nut Tighten to Specified torque Loose front suspension U-bolt tightening nut Tighten to Specified torque Vertical clearance between knuckle and front axle too large Adjust with kingpin thrust washer Clearance between kingpin and bushing too large Replace kingpin bushing Seized, worn or poorly turning thrust bearing Replace thrust ball bearing Insufficient tire inflation pressure Adjust the tire inflation pressure Wheel misalignment Adjust Insufficient grease on kingpin Apply grease Steering wheel does Front axle parts overtightened not return properly Wheel misalignment Retighten to specified torque Steering wheel cannot be turned Turning angle poorly adjusted Adjust turning angle Bent tie rod Replace Vehicle pulls to one Different tire sizes at right and left side Different tire O.D.s at right and left Uneven or premature wear in front tires Adjust Use tires of the same size Use tires of the same O.D Uneven tire pressure Adjust Bent front axle Replace One of the front springs losing tension or broken Replace Improper wheel alignment Adjust Different tire sizes and types at left and right Use tire of the same size and type Use tires of the same size and type Adjust Improper tire handing Tire rotation SERVICE PROCEDURE FA-7 SERVICE PROCEDURE REMOVAL AND INSTALLATION Brake hose 19 to 25 N·m (1.9 to 2.6 kgf·m) Knuckle arm 21 to 31 N·m (2.1 to 3.2 kgf·m) 39 to 44 N·m (4.0 to 4.5 kgf·m) 200 to 340 N·m (20.7 to 34.5 kgf·m) Tire (8 studs wheel) 400 to 440 N·m (41 to 45 kgf·m) (10 studs wheel) 625 to 735 N·m (64 to 75 kgf·m) U-bolt Shock absorber U-bolt 440 to 540 N·m (45 to 55 kgf·m) 195 to 265 N·m (20 to 27 kgf·m) 245 to 335 N·m (25 to 34 kgf·m) NOTE Remove the brake hose from the frame end first and install it to the wheel brake end first During the procedure,make also sure that the hoses are not twisted Plug the ends of the brake hose removed to prevent entry of dust and dirt On vehicles with air over hydraulic brake, bleed the brake system after the brake hose has been connected K0619A FA-8 FRONT AXLE WHEEL HUB AND BRAKE DRUM Disassembly and Inspection Standard Wheel Hub Brake chamber 12 14 Rotation 13 Wear, damage by rotation 11 Stack adjuster 10 Front brake assembly Rotation Wear Wear, corrosion Disassembly sequence Front wheel hub cover Hub cover gasket Lock bolt Lock plate Lock nut Lock washer Outer bearing 10 11 12 13 14 Oil seal Hub bolt Front wheel hub Front brake drum Front brake assembly Inner bearing Knuckle retainer For disassembly of parts with an encircled number, see procedure given in the following NOTE For vehicles with air brake, all procedures are same as those for vehicles with air over hydraulic brake except that the connection between slack adjuster and brake chamber should be discnected at the front brake assembly K0588A SERVICE PROCEDURE FA-9 Disassembly Procedure Removal of lock nut Socket wrench BS51-08B Removal of wheel hub and brake drum Wheel Hub Puller BS51-08C Removal of inner bearing inner race and knuckle retainer Lever Knuckle retainer Inner bearing inner race BS51-08D Install the claws of the special tool (09431-83100) in the knuckle retainer and remove Knuckle retainer Gear Puller (09431-83100) BS51-08E Removal of inner and outer bearing outer races Using a rod, strike with a hammer to force the outer race evenly out from the inside notched portion Rod Notch Outer race BS51-09A FA-10 FRONT AXLE Reassembly Wheel speed sence Face the lip inward and apply wheel bearing grease A “Z” Sleeve Brake assembly Section B-B (Vehicle with ABS) 22kgf·m 75±3kgf·m C 52.5±12.5kgf·m Hub Fulse ring Bushing 10 Properly assemble the shim to become the gap 0.1 mm or less Spindle 37±0.45kgf·m 0.7±1.1kgf·m Pack 120g of wheel bearing grease B B Pack 650g of wheel bearing grease 8±1.6kgf·m 14±3kgf·m 13 A 14 12 Section A-A Dust cover “B” 11 1±0.1mm Detail drawing of “Z” View “C” Reassembly sequence 14 → 13 → 12 ↑ → 7→6→5→4→3→2→1 10 → 11 → → For reassembly of parts with an encircled number, see procedure given in the following NOTE When installing the brake drum to the knuckle, use care not to damage the oil seal in the wheel hub Make sure that the brake assembly lining surfaces are free of oil or grease For vehicles with air brake, all procedures are the same as those for vehicles with air over hydrualic brake except that the slack adjuster and brake chamber at the front brake assembly should be connected FPV51-006 RA-44 REAR AXLE Starting torque Tangential force Starting torque 70 to 98 N 245 to 345 N·cm (7.1 to kgf) (25 to 35 kgf·cm) Type of shim Part name Thickness Shim B 0.2 mm Shim C 0.1 mm NOTE When the current parts removed are reassembled, the starting torque need not necessarily be the correct starting torque provided that it is over 80% of the correct starting torque since the bearing has been seated 19 Measurement of inter-differential gear backlash (Rear 1st axle) Set the outer washer, outer gear, pinion washer, pinion and spider in the outer case and hold down the spider form above Inter-differential gear backlash NV 0.19 to 0.25 mm L 0.6 mm Set the bushing, washer, inner gear, pinion washer, pinion and spider in the inner case and hold down the spider from above 20 Check of companion flange vertical play (Rear 1st axle) If the service limit has been exceeded, adjust and check the following again • Drive helical gear starting torque (Adjust with shims) • Inter-differential inner gear to bushing clearance NV Nominal Value L Limit J0498A Companion flange vertical play L 1.0 mm • Drive helical gear to inter-differential inner gear spline clearance in rotary direction • Ball bearing radial play J0129A 21 Overall staring torque (Rear 1st axle) Measure with the drive helical gear and differential lock clutch in mesh and the reduction gear properly installed Tangential froce 135 to 175 N Starting torque Application model 1080 to 1370 N·cm P12 (14.1 to 17.9 kgf) (110 to 140 kgf·cm) Spider 120 to 150 N #1710 (12.2 to 15.6 kgf) #1810 J0103A PROPELLER SHAFT GENERAL PS - SPECIFICATIONS PS - SERVICE STANDARD PS - TIGHTENING TORQUE PS - TROUBLESHOOTING PS - SERVICE PROCEDURE PS - PS-2 PROPELLER SHAFT GENERAL The propeller shaft, installed between the transmission and rear axle, transmits the engine power (rotation) changed by the transmission to the final gear of the rear axle The propeller shaft consists of two sections; the front and rear pro- Axial displacement peller shafts Two or more sections are coupled together depending on the wheel base A propeller shaft consisting of two or more H0072B sections has a center bearing at the center, supported by the frame The positional relationship between the transmission and rear axle varies with road surface irregularities, vibration during operation Horizontal displacement and load changes To cope with the variations, the propeller shaft has a universal joint and slip joint that absorb such variations Vertical displacement H0071B SPECIFICATIONS Unit : mm Model Item 15ton P/Cargo 25ton Cargo P/Cargo 6x4, 8x4 6x4, 8x4 8/8.5ton 8/8.5/9.5ton 11-16ton Cargo 23ton Dump 11-16ton Cargo (D6AC, 15ton Dump 100ton-TRT 15ton Dump (D6CA) (D6DA) (D6AB) D6CA) (D6AC) (D6CA) (D6AC) Propeller shaft Type P12 S1810 UJ250 S1810 101.6 x 114.3 x 120 x 6.6 114.3 x - 3.564 3.5 3.5 3.5 3.5 25.5 24.8 25.8 24 25.8 25.8 25.8 30.5 36.25 32.98 36.98 32.98 32.98 32.98 46 52 49.2 57 49.2 49.2 49.2 54 60.325 63.3 78 76.2 63.5 78 P10 Pipe(O·D x thickness) 101.6 x S1710 S1760 101.6 x 101.6 x Needle roller bearing O·D Length Universal joint Spider O·D Bearing cap O·D Slip joint york Spline O·D NOTE O·D : Outer Diameter SERVICE STANDARD PS-3 SERVICE STANDARD Unit : mm Maintenance item Nominal value (Basic diameter in [ ]) Limit Properller shaft bend P8, P10, P12 - 0.6 (measured at center) Spicer #1710, #1810 - 0.1 Spider to needle roller P8 [28.56]0.02 to 0.08 0.2 bearing clearance P10 [30.494]0.03 to 0.08 P12 [36.25] 0.03 to 0.08 Spicer #1710, #1810 [32.9]0.02 to 0.06 P8, P10,P12 to 0.15 Spider axial play - Remedy and remarks Correct or replace Replace Adjust with shim or snapring Spline clearance in rotating P8,P10 0.07 to 0.18 direction P12 0.01 to 0.17 (Rear propeller shaft) Spicer #1710, #1810 0.3 Replace TIGHTENING TORQUE Location tightened Unit : mm Screw size O.D x pitch (mm) Tightening torque N·m (kgf·m) Companion flange nut P8, P10,P12 M33 x 1.5 540 to 735 (55 to 75) (Front propeller shaft) Spicer #1710 1-1/4-18UNS 880 to 1080 (90 to 110) Needle roller bearing P8, P10 M8 x 1.25 18 to 26 (1.8 to 2.7) tightening bolt P12 M10 x 1.25 35 to 53 (3.6 to 5.4) Bearing assembly mounting bolt Spicer #1710, #1810 3/8-24UNF 44 to 54 (4.5 to 5.5) Center bearing bracket P8, P10 M12 x 1.25 43 to 65 (4.4 to 6.6) attaching bolt Spicer #1710 M14 x 1.5 77 to 115 (7.9 to 11.9) Flange yoke connection P8 M12 x 1.25 69 to 100 (7 to 10) tightening bolt and nut Spicer #1710 (6 bolts), #1810 P10 M14 x 1.5 115 to 175 (12 to 18) P12 M16 x 1.5 170 to 260(917.6 to 25.4) Spicer #1710 (8 bolts) M10 x 1.5 42 to 64(4.3 to 6.5) (Front propeller shaft) PS-4 PROPELLER SHAFT TROUBLESHOOTING Symptom Probable cause Remedy Propeller At high Yoke installed in wrong direction shaft speed Worm universal joint as needle roller bearing Replace as a spider kit vibrates Realign the match marks Bent propeller shaft Replace the propeller shaft Propeller shaft out of dynamic balance Adjust the dynamic balance Flange coupling bolts left loose Retighten to specification Seized, worn, or binding ball bearing Replace the ball bearing At low Transmission in the high speed range Shift to the proper gear speed Excessive axial play in the spider of univer- Adjust the clearance with anap ring or shim sal joint Excessive play in the slip joint splines Replace the yoke sleeve or propeller shaft Propeller Flange coupling bolts left loose Retighten to specification shaft develops vehicle is Center bearing mounting bolts left loose Retighten to specification unusual started or Center bearing cushion deteriorated or Replace the cushion noise coasting deformed When the Worn universal joint needle roller bearing Replace as a spider kit Excessive play in the slip joint splines Rrplace the yoke sleeve or propeller shaft At curising Excessive axial play in the spider of Adjust the clearance with snap ring or shim speeds universal joint Worn universal joint needle roller bearing Replace as a spider kit Seized, worn, or binding ball bearing Replace the ball bearing Bearing and splines improperly lubricated Lubricate SERVICE PROCEDURE PS-5 SERVICE PROCEDURE COMPONENT B A Inter propeller shaft A C Center propeller shaft Transmission Rear propeller shaft Front propeller shaft D 179-186N·m (17.9-18.6 kgf·m) A : 176 - 264 N·m (17.6 - 26.4 kgf·m) B : 130 - 180 N·m (13 - 18 kgf·m) C : 45 - 60 N·m (4.5 - kgf·m) D : 178 - 264 N·m (17.8 - 26.4 kgf·m) NOTE Make alignment marks on parts before disassembly Flange may be 90° out of phase on some models They must be reinstalled in the same way FNT49-001 PS-6 PROPELLER SHAFT FRONT PROPELLER SHAFT Disassembly and Inspection T : 398 to 542 (55 to 75) 17 16 Rotating condition 11 Deformation 10 12 13 T : 13 to 19 (1.8 to 2.7) Rotating condition 14 Axial play clearance 15 Wear, damage 19 18 Deflection Cracks, damage Disassembly sequence Lock plate Retainer Shim Needle roller bearing Flange yoke Oil seal Grease nipple Spider Center bearing bracket 10 11 12 13 14 15 16 17 18 19 Cushion Castle nut Plain washer Companion flange Center bearing case Oil seal Snap ring Ball bearing Front and center propeller shaft Seal guard NOTE Make alignment marks on parts before disassembly Align matching marks put at time of disassembly After greasing, wipe off any excessive grease completely TORQUE : lb·ft (kgf·m) AMDPS01A SERVICE PROCEDURE PS-7 11 18 16 14 15 17 18 Clearance BD 32.98 NV 0.03-0.09 L 0.2 17 10 11 12 13 BD Basic Diameter ND Norminal value L Limit Crack, damage Unit : mm Grease valve Needle roller Oil seal Spider Bearing case Bolt Tube yoke Flange yoke Tube 10 11 12 13 14 15 16 17 18 End shaft Dust cover Bearing rubber Center bearing bracket Rubber retainer Retainer bearing Ball bearing Yoke end Castle nut KEGPS02B PS-8 PROPELLER SHAFT DISASSEMBLY After removing flange rock strap bolts, tap the yoke shoulder with a brass hammer and remove the bearing case assembly NOTE Make alignment marks on the yoke and bearing case FNT49-003 Remove the dust seal and grease nipple from the spider CAUTION Do not reuse the grease nipple FNT49-004 Remove the yoke bearing cap bolt and, then disassemble the 1st coupling drive shaft and the 2nd coupling drive shaft while removing the coupling drive shaft NOTE Make the matchmarks on the both yokes FNT49-005 Fix the coupling drive shaft with a vise and remove the yoke NOTE Make the matchmarks on the spline Remove the center bearing bracket and the bracket retainer FNT49-006 Using a gear puller, remove the center bearing assembly CAUTION Be careful not to damage the seal Gear puller JMS49-015 SERVICE PROCEDURE PS-9 INSPECTION Propeller shaft bend Standard value Limit 0.4mm 0.6mm JMS49-020 Rotating end play of spline Standard value Limit 0.01 - 0.17mm 0.2mm Spline yoke Spline End plug FNT49-010 Clearance between the spider and the journal Standard value Limit 0.01 - 0.17mm 0.2mm FNT49-011 Measurement of clearance between the spider and the needle roller bearing (P10, P12) or bearing assembly Item Standard value P10, P12 - 0.15mm SPIDER 0.03 - 0.09mm Limit 0.2mm Move Bearing assembly Spider H0215B PS-10 PROPELLER SHAFT REASSEMBLY 18 to 26 N·m (1.8 to 2.7 kgf·m) 35 to 53 N·m (3.6 to 5.4 kgf·m) Balance piece Balance piece Grease used : Wheel bearing grease [Multipurpose grease (NLGI No.2) Li soap] 17 13 540 to 735 N·m (55 to 75 kgf·m) 10 11 Apply grease 14 Pack grease 15 Grease nipple (pack grease until it overflows out of the spider dust seal) 12 Relief valve 16 Pack grease Reassembly sequence 6→7→ 8→ 4→5→3→ 2→ ↓ 7→ 4→ 3→ 2→ →12→11→10 13→15→16→15→14→9 ↑ For parts with an encircled number, refer to Disassembly and inspection Procedure that follows NOTE Align matching marks put at time of disassembly After greasing, wipe off any excessive grease completely H0372G FRONT PROPELLER SHAFT PS-11 10 947-1009 N·m (96.6-103 kgf·m) 11 Grease nipple (Pack grease until it overlows out of the spider dust seal) Apply grease Reassembly sequence 8→ 9→ 10 → 11 → 7→ → 5→ → → 2→ 1 Castle nut End yoke/ Companion flange Dust cover Cushion rubber Bearing Dust cover 10 11 Tube Universal joint Lock plate Flange yoke Tube yoke KEGPS01A Install the needle roller bearing Install the Dust seal and grease nipple to the spider Grease neeple 45° NOTE Install the grease nipple to the spider at 45° vertically Dust seal SPPS-003 PS-12 Insert the spider to the flange yoke and install the bearing NOTE PROPELLER SHAFT Needle roller bearing Fully fill the flange yoke with ALVANIA Ep #2 grease Spider assembly rest B Spider assembly rest A JMS49-023 Connect the flange yoke with the spider installed to the propeller shaft and then install the bearing and lock strap FNT49-005 Install the center bearing and apply grease Apply grease Recommended grease : ALVANIA EP#2 Bearing case Install the center bearing assembly to the coupling shaft Oil seal JMS49-025 Fit the coupling drive shaft on a vise, put the yoke and tighten the lock nut NOTE Align the matchmarks on the yoke spline and the coupling drive shaft spline FNT49-017 FRONT PROPELLER SHAFT PS-13 Reassembly of slip joint 1) Install the dust cap over the spline shaft of the rear propeller shaft Then, carefully open the retainer, fit it over the splines, and bring it back again Rear Propeller shaft Apply grease 2) Coat the inner surface of the cork seal with grease Facing its rounded side to the splines, install the dust seal in the same way as the retainer 3) Compressing the cork seal to 2mm, press the dust cap Rounded portion Dust cap Cork Retainer Spline seal against the yoke sleeve and stake the claws H03292D Stake here NOTE Never reuse the dust cap, retainer and cork seal Adjustment When replacing the propeller shaft assembly, yoke, universal joint, other parts, measure and adjust the balance using a balancing tool Dynamic blance is adjusted by the Naziko spicer Dynamic balance may be adjusted either by the polar coordinate method or 90° force decomposition method Allowable imbalance amount On pipe periphery Remark 90g·cm/ 2000rpm 114.3 x 6.6 mm NOTE If the imbalance amount is large, use the 90° decomposition method as it requires less balance pieces than the polar coordinate method Yoke sleeve Dust cap Retainer Cork seal H03295B PS-14 PROPELLER SHAFT Use the polar coordinate method 1) Balance piece installation position Balance piece mounting position Matchmark 30 mm Match marks Welding section 30 mm Balance piece Matchmarks Welding section Matchmarks FNT49-027 2) The measure and type of balance piece Type Weight(g) A(mm) B(mm) Thickness(mm) F 10 12.0 35 3.2 G 15 17.6 35 3.2 H 21 24.4 35 3.2 I 27 18.0 43 4.5 J 39 26 43 4.5 K 53 35 43 4.5 3) 90° force decomposition method R T Weight mark FNT49-028 Balance piece Lock plate NOTE • The maximum tolerance on balance pieces installed • in a single place should be limited to 120g The number of balance pieces to be combined • should be limited to a minimum If the imbalance amount before correction is large, use the 90° decomposition FNT49-029 ... 6X4 6X4 9.5ton Cargo, (Low deck) dump Full cargo C/TRT X 4, 10 X 18ton cargo TRT, 23ton Dump, mixer Front 1st Front 2nd Front 1st Front 2nd 1°30´ ± 30´ ← ← ← 1°30´ ± 30´ ← ← 2° ± 30´ ← Camber

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