FRONT & REAR AXLE GI

SECTION AX MA

EM

LC

EC

CONTENTS FE

FRONT AXLE ..................................................................2 DISASSEMBLY ........................................................18

CL
Precautions ..................................................................2 INSPECTION ...........................................................19
PRECAUTIONS .........................................................2 ASSEMBLY .............................................................20
MT
Preparation ..................................................................2 INSTALLATION........................................................22
SPECIAL SERVICE TOOLS ........................................2 Service Data and Specifications (SDS).....................22
COMMERCIAL SERVICE TOOLS ................................3 WHEEL BEARING (FRONT) .....................................22 AT
Noise, Vibration and Harshness (NVH) DRIVE SHAFT (4WD MODELS) ................................23
Troubleshooting ...........................................................4 REAR AXLE...................................................................25
NVH TROUBLESHOOTING CHART ............................4 Precautions ................................................................25 TF
On-vehicle Service.......................................................4 PRECAUTIONS .......................................................25
FRONT AXLE PARTS ................................................4 Preparation ................................................................25
FRONT WHEEL BEARING .........................................5 SPECIAL SERVICE TOOLS ......................................25 PD
DRIVE SHAFT ...........................................................7 COMMERCIAL SERVICE TOOLS ..............................25
Components.................................................................8 Noise, Vibration and Harshness (NVH)
Auto-lock Free-running Hub ......................................10 Troubleshooting .........................................................27
DESCRIPTION ........................................................10 On-vehicle Service.....................................................27
REMOVAL AND INSTALLATION ...............................10 REAR AXLE PARTS.................................................27
REAR WHEEL BEARING .........................................28
SU
INSPECTION ...........................................................11
TROUBLE DIAGNOSIS FOR NOISE .........................11 Components...............................................................29
Wheel Hub and Rotor Disc........................................12 Removal.....................................................................30 BR
REMOVAL AND INSTALLATION ...............................12 Inspection...................................................................33
DISASSEMBLY ........................................................13 AXLE SHAFT...........................................................33
INSPECTION ...........................................................13 WHEEL BEARING ...................................................33 ST
ASSEMBLY .............................................................13 AXLE CASE ............................................................33
Knuckle Spindle .........................................................14 Installation..................................................................34
REMOVAL ...............................................................14 2WD MODELS.........................................................34 RS
INSPECTION ...........................................................15 4WD MODELS.........................................................36
INSTALLATION........................................................16 Service Data and Specifications (SDS).....................38
Drive Shaft .................................................................16 WHEEL BEARING (REAR) .......................................38 BT
COMPONENTS .......................................................16
REMOVAL ...............................................................17
HA

SC

EL

IDX
 FRONT AXLE
Precautions

Precautions
PRECAUTIONS NEAX0001
쐌 When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
쐌 Use flare nut wrench when removing and installing brake
tubes.
쐌 After installing removed suspension parts, check wheel
alignment and adjust if necessary.
SBR686C
쐌 Always torque brake lines when installing.
CAUTION:
쐌 The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
쐌 Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.

Preparation
SPECIAL SERVICE TOOLS NEAX0002
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

ST29020001 Removing ball joint for knuckle spindle

(J24319-01) a: 34 mm (1.34 in)
Gear arm puller b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)

NT694

HT72520000 Removing tie-rod outer end

(J25730-B) a: 33 mm (1.30 in)
Ball joint remover b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)

NT546

KV401021S0 Installing wheel bearing outer race

( — )
Bearing race drift

NT153

AX-2
 FRONT AXLE
Preparation (Cont’d)

Tool number
(Kent-Moore No.) Description
Tool name GI
KV40105400 Removing and installing wheel bearing lock nut
(J36001) (4WD models only) MA
Wheel bearing lock nut
wrench
EM
NT154

COMMERCIAL SERVICE TOOLS NEAX0003 LC

Tool name Description

1 Flare nut crowfoot Removing and installing each brake piping EC

2 Torque wrench a: 10 mm (0.39 in)

FE

NT360 CL

MT

AT

TF

PD

SU

BR

ST

RS

BT

HA

SC

EL

IDX
AX-3
 FRONT AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH)

Troubleshooting =NEAX0004
NVH TROUBLESHOOTING CHART NEAX0004S01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

Refer to DRIVE SHAFT

Refer to NVH, BR-8

Refer to NVH, PD-4

Refer to NVH, PD-4

Refer to NVH, SU-3

Refer to NVH, SU-3

Refer to NVH, SU-3

Refer to NVH, ST-5

Refer to AXLE
in this chart.

in this chart.
AX-8, 29

AX-5, 28
AX-19
—

—
Reference page

Improper installation, looseness

Wheel bearing damage

Joint sliding resistance

PROPELLER SHAFT
Excessive joint angle

Parts interference
Possible cause and SUSPECTED PARTS

DIFFERENTIAL

ROAD WHEEL
DRIVE SHAFT

SUSPENSION

STEERING
Imbalance

BRAKES
TIRES
AXLE
Noise, Vibration × × × × × × × × × ×
DRIVE SHAFT
Shake × × × × × × × × ×

Noise × × × × × × × × × ×

Shake × × × × × × × × ×
Symptom Vibration × × × × × × ×
AXLE Shimmy × × × × × × ×

Judder × × × × × ×

Poor quality ride

× × × × × ×
or handling

×: Applicable

On-vehicle Service
FRONT AXLE PARTS NEAX0005
Check front axle parts for excessive play, cracks, wear and other
damage.
쐌 Shake each front wheel to check for excessive play.
If looseness is noted, adjust wheel bearing end play, then
check ball joint end play.
쐌 Make sure that the cotter pin is inserted.
쐌 Retighten all nuts and bolts to the specified torque.
SMA525A
: Refer to SU-20, “FRONT SUSPENSION”.

AX-4
 FRONT AXLE
On-vehicle Service (Cont’d)
FRONT WHEEL BEARING NEAX0006
쐌 Check that wheel bearings operate smoothly.
쐌 Check axial end play. GI
Axial end play: 0 mm (0 in)
쐌 Adjust wheel bearing preload if there is any axial end play or MA
wheel bearing does not turn smoothly.

EM

SMA571A LC
Preload Adjustment (2WD models) NEAX0006S01
Adjust wheel bearing preload after wheel bearing has been EC
replaced or front axle has been reassembled.
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry. FE
2. Apply multi-purpose grease sparingly to the following parts:
쐌 Threaded area of spindle
쐌 Contact surface between lock washer and outer wheel bearing CL
쐌 Hub cap (as shown at left) 18 - 22 g (0.63 - 0.78 oz)
쐌 Grease seal lip MT
SFA847BA

3. Tighten wheel bearing lock nut to the specified torque.

: 34 - 39 N·m (3.5 - 4.0 kg-m, 25 - 29 ft-lb) AT
4. Turn wheel hub several times in both directions to seat wheel
bearing correctly.
5. Again tighten wheel bearing lock nut to the specified torque. TF
: 34 - 39 N·m (3.5 - 4.0 kg-m, 25 - 29 ft-lb)
PD

SFA890

6. Turn wheel bearing lock nut back 45 degrees.

7. Fit adjusting cap and new cotter pin. Align cotter pin slot by
SU
loosening nut 15 degrees or less.
BR

ST

RS
SFA452B

8. Measure wheel bearing preload and axial end play. BT

Axial end play: 0 mm (0 in)
Wheel bearing preload
(As measured at wheel hub bolt): HA
New grease seal
9.8 - 28.4 N (1.0 - 2.9 kg, 2.2 - 6.4 lb) SC
Used grease seal
9.8 - 23.5 N (1.0 - 2.4 kg, 2.2 - 5.3 lb)
Repeat above procedures until correct bearing preload is obtained.
EL
SMA574A
IDX
AX-5
 FRONT AXLE
On-vehicle Service (Cont’d)
9. Spread cotter pin.
10. Install hub cap.
Preload Adjustment (4WD models) NEAX0006S02
Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
Adjust wheel bearing preload as follows:
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry.

SRA417

2. Apply multi-purpose grease sparingly to the following parts:

쐌 Threaded portion of spindle
쐌 Contact surface between wheel bearing washer and outer
wheel bearing
쐌 Grease seal lip
쐌 Wheel hub (as shown at left) 18 - 23 g (0.63 - 0.81 oz)

SFA891-C

3. Tighten wheel bearing lock nut with Tool.

: 78 - 98 N·m (8 - 10 kg-m, 58 - 72 ft-lb)
4. Turn wheel hub several times in both directions.
5. Loosen wheel bearing lock nut so that torque becomes 0 N·m
(0 kg-m, 0 ft-lb).
6. Retighten wheel bearing lock nut with Tool.
: 0.5 - 1.5 N·m (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb)

AFA148

7. Turn wheel hub several times in both directions.

8. Retighten wheel bearing lock nut with Tool.
: 0.5 - 1.5 N·m (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb)
9. Measure wheel bearing axial end play.
Axial end play: 0 mm (0 in)

SFA845B

10. Measure starting force “A” at wheel hub bolt.

SMA580A

AX-6
 FRONT AXLE
On-vehicle Service (Cont’d)
11. Install lock washer by tightening the lock nut within 15 to 30
degrees to align screw holes.
12. Turn wheel hub several times in both directions to seat wheel GI
bearing correctly.
13. Measure starting force “B” at wheel hub bolt. Refer to step 10.
14. Wheel bearing preload “C” can be calculated as shown below. MA
C=B−A
Wheel bearing preload “C”: EM
7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 lb)
15. If wheel bearing preload “C” is outside specifications, remove
SFA830
lock washer. Tighten or loosen lock nut within ±15 degrees LC
(Refer to step 11 above). Install lock washer, then repeat steps
12, 13 and 14.
16. Repeat above procedures until correct axial end play and EC
wheel bearing preload are obtained.
17. Tighten screws. FE
: 1.2 - 1.8 N·m (0.12 - 0.18 kg-m, 10.4 - 15.6 in-lb)
18. Install free-running hub.
19. Tighten bolts. CL
: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
MT
DRIVE SHAFT NEAX0007
쐌 Check for grease leakage and damage. AT
CAUTION:
쐌 The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is TF
made of plastic.
쐌 Do not disassemble the joint assembly with the plastic PD
boot. If the boot or joint is damaged, replace the drive
shaft assembly.

SFA901

SU

BR

ST

RS

BT

HA

SC

EL

IDX
AX-7
 FRONT AXLE
Components

Components NEAX0008

WAX019

AX-8
FRONT AXLE
Components (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

SU

BR

ST

RS

BT

HA

SC
WAX018
EL

IDX
AX-9
 FRONT AXLE
Auto-lock Free-running Hub

Auto-lock Free-running Hub

DESCRIPTION NEAX0041
Auto-lock free-running hubs are locked by placing the transfer case
into the 4WD mode and moving the vehicle. They are unlocked by
placing the transfer case into 2WD mode and moving the vehicle
in reverse gear in a straight line for at least 2–3 meters (7–10
feet).
In most cases, the “ratcheting” noise sometimes heard in auto-lock
free-running hubs occurs when one hub is locked and the opposite
hub is unlocked. The noise is heard in the side opposite to the
locked hub. For example, if the noise is heard at the left front wheel,
the right front hub is still locked and is not unlocking. This condi-
tion may be caused by a mechanical condition in one of the hubs
or by incorrect operation on the part of the vehicle driver, for
example by not backing up in a straight line to unlock the hubs, by
not backing up enough, or by shifting into 4WD at too high a vehicle
speed, etc.
The ratcheting noise does not necessarily cause damage to the
good hub. If the noise is caused by incorrect operation, counsel the
driver of the vehicle. If replacement is necessary, replace only the
defective parts. It is not necessary to replace auto-lock free-running
hubs in pairs.
Use the trouble diagnosis chart to isolate the cause of the noise.
Refer to “TROUBLE DIAGNOSIS FOR NOISE”, AX-11.
REMOVAL AND INSTALLATION NEAX0011

AAX008

1. Remove auto-lock free-running hub assembly.

SFA828B

AX-10
 FRONT AXLE
Auto-lock Free-running Hub (Cont’d)
2. Remove snap ring.
3. Remove spindle washer and fixed cam assembly.
4. Install fixed cam assembly. GI
Be sure to align the tabs of the fixed cam assembly to the
notches of the knuckle.
5. Place the spindle washer and then the snap ring over the axle MA
shaft positioning them between the 2 locking grooves.
6. While supporting the axle shaft behind the knuckle, use an EM
appropriate sized deep socket to securely seat the snap ring
into the inner locking groove.
AFA143 CAUTION: LC
Visually verify that the snap ring is fully seated into the lock-
ing groove.
7. After installing auto-lock free-running hub, check operation. EC
During installation, apply recommended grease to the parts
shown in the above illustration.
FE
INSPECTION NEAX0042
1. Check axle axial end play. Refer to “INSTALLATION”, AX-22.
2. Inspect fixed cam (thrust washer) assembly. If this part shows
CL
evidence of galling or heat damage—usually caused by too
little axle axial end play—replace as necessary. Check axle MT
axial end play if this part is replaced. Refer to
“INSTALLATION”, AX-22.
3. Inspect hub assembly. Hold inner splines on a finger and spin AT
the outer body. If the hub shows signs of damage, or if there
is excessive metallic clicking when the hub is spun, replace
with a new one. TF
NOTE:
New hubs are greased during manufacture. No additional grease
is required. PD
New hubs are supplied with fixed cam assemblies
CAUTION:
Any hub, the original or a new one, should go onto the axle
freely by hand and fit flush against its seat. If it does not fit
flush, do not pull the hub into place by tightening the bolts. SU
The hub is possibly misaligned inside and tightening the bolts
will cause damage. Remove the hub and turn to align correctly
before continuing. BR
4. Once repair is complete, test drive to check for correct opera-
tion and the absence of noise.
TROUBLE DIAGNOSIS FOR NOISE ST
NEAX0043

Symptom Possible cause Repair order

RS
Ratchet noise in hub after shifting the transfer 1. Shifting into 4WD at higher 1. Stop the vehicle or decrease speed to
case into 4WD at speeds higher than 40 km/h speeds is difficult and may less than 40 km/h (25 mph). Return
(25 mph). cause damage to transfer case the transfer case lever to the 2H posi- BT
tion once, then re-shift to the 4H posi-
tion. Move forward until the hubs lock.

Ratchet noise in hub after shifting or attempting 1. Transfer case was not fully 1. Make sure the 4WD lamp on the dash HA
to shift the transfer case into 4WD at speeds engaged or shifting was stopped is ″ON″ when shifting into 4WD. Slow
less than 40 km/h (25 mph). halfway so that only one hub or stop the vehicle. Shift into 2H, then
locked back to 4H. Move forward until the SC
hubs lock.

Ratchet noise in hub after shifting the transfer 1. If the rear wheels slip during the 1. Reduce engine speed and drive for-
case into 4WD on snowy or muddy roads or on hub locking operation, noise can ward slowly. The hubs will lock evenly
EL
slopes. occur in the hubs and the noise will stop.

IDX
AX-11
 FRONT AXLE
Auto-lock Free-running Hub (Cont’d)

Symptom Possible cause Repair order

Ratchet noise in hub after shifting the transfer 1. The hubs may not be fully 1. Stop the vehicle, make sure the trans-
case into 2WD and backing up to unlock the released fer case lever is fully in the 2H
hubs. position, then back up slowly in a
straight line at least 2-3 meters (7-10
feet).

Ratchet noise in hub when driving in extremely 1. The viscosity of differential oil 1. Shift the transfer case into 4H and
cold weather. grows higher in extreme cold, drive the vehicle for 10 minutes or
increasing the possibility that more to warm the differential oil. Then
one hub may lock. A lower vis- shift to 2WD and back up in a straight
cosity differential fluid may be line for at least 2-3 meters (7-10 feet)
required for extreme cold tem- to disengage the hubs.
peratures. See owner’s manual

Continual ratchet noise in one wheel when mov- 1. A hub may be mechanically 1. Remove hubs and inspect. Refer to
ing forward. locked either by damage or “INSPECTION”, AX-11. Pay special
misinstallation attention to the hub opposite the noisy
side. The ratcheting does not neces-
sarily cause damage to the good hub.

Wheel Hub and Rotor Disc

REMOVAL AND INSTALLATION NEAX0012
CAUTION:
If equipped with ABS, disconnect the ABS wheel sensor from
the assembly before removing the front axle assembly. Then
move it away from the front axle assembly area. Failure to do
so may result in damage to the sensor wires and the sensor
becoming inoperative.

1. Remove free-running hub assembly (4WD models).

Refer to “Auto-lock Free-running Hub”, AX-10.
2. Remove brake caliper assembly without disconnecting hydrau-
lic line.
Brake hose need not be disconnected from brake caliper. In
this case, suspend caliper assembly with wire so as not to
stretch brake hose.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.

SFA825B

3. Remove lock washer (4WD models).

SFA364BB

AX-12
 FRONT AXLE
Wheel Hub and Rotor Disc (Cont’d)
4. Remove wheel bearing lock nut.
2WD: With suitable tool
4WD: With Tool GI

MA

EM

AFA141 LC
5. Remove wheel hub and wheel bearings.
Be careful not to drop outer bearing. EC
6. After installing wheel hub and wheel bearings, adjust wheel
bearing preload.
Refer to “Preload Adjustment (2WD models)” and “Preload FE
Adjustment (4WD models)”, AX-5, 6.

CL

SFA827B
MT
DISASSEMBLY NEAX0013
쐌 Remove grease seal and bearing races with suitable brass bar. AT

TF

PD

FA858

INSPECTION
Thoroughly clean wheel bearings and wheel hub.
NEAX0014 SU
Wheel Bearings
쐌
NEAX0014S01
Make sure wheel bearings roll freely and are free from noise, BR
cracks, pitting and wear.
Wheel Hub NEAX0014S02
ST
쐌 Check wheel hub for cracks by using a magnetic exploration
or dyeing test.
RS

ASSEMBLY NEAX0015
BT
1. Install bearing races with Tool until it is fully seated in hub.

HA

SC

EL
AFA156
IDX
AX-13
 FRONT AXLE
Wheel Hub and Rotor Disc (Cont’d)
2. Install the sensor rotor using suitable drift and press.
Always replace sensor rotor with new one.
Pay attention to the direction of front sensor rotor as shown in
figure.

SBR400DA

3. Pack multi-purpose grease in wheel hub and hub cap (2WD

models).

AFA122

4. Apply multi-purpose grease to each bearing cone.

5. Pack grease seal lip with multi-purpose grease, then install it
into wheel hub with suitable drift.

SFA459B

Knuckle Spindle
REMOVAL NEAX0016
1. Remove free-running hub assembly (4WD models).
Refer to “Auto-lock Free-running Hub”, AX-10.
2. Remove wheel hub and rotor disc.
Refer to “Wheel Hub and Rotor Disc”, AX-12.

SFA828B

3. Separate drive shaft from knuckle spindle by slightly tapping

drive shaft end (4WD models).

SFA844-A

AX-14
 FRONT AXLE
Knuckle Spindle (Cont’d)
4. Separate tie-rod from knuckle spindle with Tool.
Install stud nut conversely on stud bolt so as not to damage
stud bolt. GI

MA

EM

AFA139 LC
5. Separate knuckle spindle from ball joints.
a. Loosen (do not remove) upper and lower ball joint tightening
nuts.
EC

FE

CL

SFA829B
MT
b. Separate knuckle spindle from upper and lower ball joint studs
with Tool. AT
During above operation, never remove ball joint nuts
which are loosened in step (a) above.
Tool: TF
2WD
ST29020001 (J24319-01)
PD
4WD
HT72520000 (J25730-B)

SFA079

c. Remove ball joint tightening nuts.

Support lower link with jack. SU
d. Remove knuckle spindle from upper and lower links.
INSPECTION NEAX0017
BR
Knuckle Spindle NEAX0017S01
쐌 Check knuckle spindle for deformation, cracks and other dam- ST
age by using a magnetic exploration or dyeing test.

RS
SFA830B

Bearing Spacer (2WD models) NEAX0017S02

BT
쐌 Check bearing spacer for damage.
Needle Bearing (4WD models) NEAX0017S03 HA
쐌 Check needle bearing for wear, scratches, pitting, flaking and
burn marks.
SC

EL

IDX
AX-15
 FRONT AXLE
Knuckle Spindle (Cont’d)
INSTALLATION NEAX0018
1. Install needle bearing into knuckle spindle (4WD models).
Make sure that needle bearing is facing in the proper direction.
Apply multi-purpose grease.

SFA962-C

2. Install knuckle spindle to upper and lower ball joints with lower
link jacked up.
CAUTION:
Make sure that oil and grease do not come into contact with
tapered areas of ball joint, knuckle spindle and threads of ball
joint.
3. Connect tie-rod to knuckle spindle.
4. Install wheel hub and rotor disc. Refer to “Wheel Hub and
Rotor Disc”, AX-12.

SFA831B

5. After installing knuckle spindle, adjust wheel bearing preload.

Refer to “Preload Adjustment (2WD models)” and “Preload
Adjustment (4WD models)”, AX-5, 6.
6. After installing drive shaft, check drive shaft axial end play.
Do not reuse snap ring once it has been removed.
Refer to “Drive Shaft”, AX-16.
7. Install free-running hub assembly (4WD models). Refer to
“Auto-lock Free-running Hub”, AX-10.

SFA369BC

Drive Shaft
COMPONENTS NEAX0019
CAUTION:
쐌 The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic.
쐌 Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.

AX-16
 FRONT AXLE
Drive Shaft (Cont’d)

GI

MA

EM

LC

EC

FE

SFA874-B CL

MT
REMOVAL NEAX0020
1. Remove free-running hub or drive flange and snap ring. Refer AT
to “Auto-lock Free-running Hub”, AX-10.
2. Remove torsion bar spring. Refer to SU-14, “Torsion Bar
Spring”. TF
3. Remove shock absorber lower bolt.
4. Remove lower link bolts. PD
Support lower link with jack.

SFA832B

5. Remove drive shaft to final drive bolts.

SU

BR

ST

RS
SFA236

6. Separate drive shaft from knuckle spindle by slightly tapping BT

end of drive shaft.

HA

SC

EL
SFA833B
IDX
AX-17
 FRONT AXLE
Drive Shaft (Cont’d)
DISASSEMBLY NEAX0021
Final Drive Side (TS82F) NEAX0021S01
1. Remove plug seal from slide joint housing by lightly tapping
around slide joint housing.
2. Remove boot bands.

SFA880

3. Move boot and slide joint housing toward wheel side, and
apply matching marks.

SFA963

4. Remove snap ring.

SFA964

5. Detach spider assembly with press.

SFA392

6. Draw out boot.

Cover drive shaft serration with tape to prevent damaging the
boot.

SFA799

AX-18
 FRONT AXLE
Drive Shaft (Cont’d)

GI

MA

EM

LC
Wheel Side (ZF100) NEAX0021S02
CAUTION: EC
쐌 The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
made of plastic. FE
쐌 Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly. CL
The procedures for the joint with the rubber boot are as follows:
쐌 Before separating joint assembly, put matching marks on drive
SFA455 shaft and joint assembly. MT
쐌 Separate joint assembly with suitable tool.
Be careful not to damage threads on drive shaft. AT
쐌 Remove boot bands.

TF

PD

INSPECTION NEAX0022
Thoroughly clean all parts in cleaning solvent, and dry with com-
SU
pressed air. Check parts for evidence of deformation and other
damage. BR
Drive Shaft NEAX0022S01
Replace drive shaft if it is twisted, cracked or bent.
ST
Boot NEAX0022S02
Check boot for fatigue, cracks and wear. Replace boot and boot
bands with new. RS
Joint Assembly (Final drive side) NEAX0022S03
쐌 Replace any parts of double offset joint which show signs of BT
scorching, rust, wear or excessive play.
쐌 Check serration for deformation. Replace if necessary.
쐌 Check slide joint housing for any damage. Replace if neces-
HA
sary.
Joint Assembly (Wheel side) SC
NEAX0022S04
CAUTION:
쐌 The ZF100 type (wheel side) joint assembly has two types
of boot material; one is made of rubber and the other is
EL
made of plastic.
IDX
AX-19
 FRONT AXLE
Drive Shaft (Cont’d)
쐌 Do not disassemble the joint assembly with the plastic
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
Replace joint assembly if it is deformed or damaged.
ASSEMBLY NEAX0023
쐌 After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
쐌 Use NISSAN Genuine Grease or equivalent after every
overhaul.

Final Drive Side (TS82F) NEAX0023S01

1. Install new small boot band, boot and side joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damaging
boot during installation.

SFA800

2. Install spider assembly securely, making sure marks are prop-

erly aligned.
쐌 Press-fit with spider assembly serration chamfer facing
shaft.
3. Install new snap ring.

SFA397

4. Pack with grease.

Specified amount of grease:
95 - 105 g (3.35 - 3.70 oz)
5. Make sure that the boot is properly installed on the drive shaft
groove. Set the boot so that it does not swell or deform when
its length is “L1”.
Length “L1”: 95 - 97 mm (3.74 - 3.82 in)

SFA460BA

6. Lock new large boot band securely with a suitable tool, then
lock new small boot band.
7. Install new plug seal to slide joint housing by lightly tapping it.
Apply suitable sealant to mating surface of plug seal.

SFA443B

AX-20
 FRONT AXLE
Drive Shaft (Cont’d)

Wheel Side (ZF100) NEAX0023S02

CAUTION:
쐌 The ZF100 type (wheel side) joint assembly has two types GI
of boot material; one is made of rubber and the other is
made of plastic.
쐌 Do not disassemble the joint assembly with the plastic MA
boot. If the boot or joint is damaged, replace the drive
shaft assembly.
EM
The procedures for the joint with the rubber boot are as follows:

LC
1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape to prevent damaging EC
boot during installation.

FE

CL

SFA800
MT
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring that marks which were AT
made during disassembly are properly aligned.

TF

PD

SFA884

3. Pack drive shaft with specified amount of grease.

Specified amount of grease:
SU
115 - 125 g (4.06 - 4.41 oz)
4. Make sure that the boot is properly installed on the drive shaft BR
groove. Set the boot so that it does not swell or deform when
its length is “L2”.
Length “L2”: 96 - 98 mm (3.78 - 3.86 in) ST

RS
SFA473BA

5. Lock new large boot band securely with a suitable tool, then BT
lock new small boot band.

HA

SC

EL
SFA443B
IDX
AX-21
 FRONT AXLE
Drive Shaft (Cont’d)
INSTALLATION NEAX0024
1. Apply multi-purpose grease.

SFA887

2. Install bearing spacer onto drive shaft.

Make sure that the bearing spacer is facing in the proper direc-
tion.
3. After installing wheel hub and wheel bearing, adjust wheel
bearing preload. Refer to “FRONT WHEEL BEARING”, AX-5,
6.

SFA846

4. When installing drive shaft, adjust drive shaft axial end play by
selecting a suitable snap ring.
a. Temporarily install new snap ring on drive shaft in the same
thickness as the one that was removed.

SFA940

b. Set dial gauge on drive shaft end.

c. Measure axial end play of drive shaft.
Axial end play:
0.45 mm (0.0177 in) or less
d. If axial end play is not within the specified limit, select another
snap ring.
1.1 mm (0.043 in) 1.9 mm (0.075 in)
1.3 mm (0.051 in) 2.1 mm (0.083 in)
1.5 mm (0.059 in) 2.3 mm (0.091 in)
1.7 mm (0.067 in)
SFA847

Service Data and Specifications (SDS)

WHEEL BEARING (FRONT) NEAX0025
2WD Models NEAX0025S01

Wheel bearing axial end play mm (in) 0 (0)

Tightening torque N·m (kg-m, ft-lb) 34 - 39 (3.5 - 4.0, 25 - 29)

Wheel bearing lock nut
Return angle degree 45° - 60°

AX-22
 FRONT AXLE
Service Data and Specifications (SDS) (Cont’d)

At wheel hub bolt

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4)
With new grease seal N (kg, lb)
Wheel bearing starting torque
GI
With used grease seal N (kg, lb) 9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

4WD Models NEAX0025S02 MA

Tightening torque N·m (kg-m, ft-lb) 78 - 98 (8 - 10, 58 - 72)

Retightening torque after loosening wheel bear-

0.5 - 1.5 (0.05 - 0.15, 0.4 - 1.1)
EM
ing lock nut N·m (kg-m, ft-lb)

Axial end play mm (in) 0 (0)

Wheel bearing lock nut
LC
Starting force at wheel hub bolt N (kg, lb) A

Turning angle degree 15° - 30°

EC
Starting force at wheel hub bolt N (kg, lb) B

Wheel bearing preload at wheel hub bolt

N (kg, lb)
B−A 7.06 - 20.99 (0.72 - 2.14, 1.59 - 4.72) FE
DRIVE SHAFT (4WD MODELS) NEAX0026
CL
Final drive side TS82F

Drive shaft joint type Wheel side ZF100*

MT
Fixed joint axial end play limit mm (in) 1 (0.04)

Diameter mm (in) Wheel side (D1) 29.0 (1.142)

AT
Nissan genuine grease or equiva-
Quality
lent
Grease
Final drive side 95 - 105 (3.35 - 3.70)
TF
Capacity g (oz)
Wheel side 115 - 125 (4.06 - 4.41)

Final drive side (L1) 95 - 97 (3.74 - 3.82)

PD
Boot length mm (in)
Wheel side (L2) 96 - 98 (3.78 - 3.86)

SU

BR

ST

RS
SFA877A
BT
*: The ZF100 type (wheel side) joint assembly has two types of boot material; one is made of rubber and the other is made of plastic.
Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.
HA
Drive Shaft Axial End Play NEAX0026S01

Drive shaft axial end play mm (in) 0.45 (0.0177) or less SC

Drive shaft end snap ring NEAX0026S02

Thickness mm (in) Part No.*

EL

IDX
AX-23
 FRONT AXLE
Service Data and Specifications (SDS) (Cont’d)

1.1 (0.043) 39253-88G10

1.3 (0.051) 39253-88G11
1.5 (0.059) 39253-88G12
1.7 (0.067) 39253-88G13
1.9 (0.075) 39253-88G14
2.1 (0.083) 39253-88G15
2.3 (0.091) 39253-88G16

*: Always check with the Parts Department for the latest parts information.

AX-24
 REAR AXLE
Precautions

Precautions
PRECAUTIONS
쐌 When installing rubber parts, final tightening must be car-
NEAX0027
GI
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, MA
hand tools and mats in designated positions.
쐌 Use flare nut wrench when removing and installing brake
tubes. EM
쐌 After installing removed suspension parts, check wheel
alignment and adjust if necessary.
SBR686C
쐌 Always torque brake lines when installing. LC
Preparation
SPECIAL SERVICE TOOLS NEAX0028
EC
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
FE
Tool name

KV40101000 Removing rear axle shaft CL

(J25604-01)
Axle stand
MT

NT159
AT
ST36230000 Removing rear axle shaft
(J25840-A)
Sliding hammer
TF

NT126
PD
(J45073) Removing wheel bearing, oil seal, wheel bearing
Rear axle bearing lock nut, and ABS sensor rotor
removal kit

SU

BR
LAX034

ST37840000 Installing rear axle shaft

ST
( — )
Rear axle shaft guide
RS

NT162
BT
COMMERCIAL SERVICE TOOLS NEAX0029

Tool name Description HA

1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.39 in)
SC

EL
NT360

IDX
AX-25
 REAR AXLE
Preparation (Cont’d)

Tool name Description

Bearing cage oil seal Installing oil seal

drift a: 74 mm (2.91 in) dia.
b: 68 mm (2.68 in) dia.

NT115

Rear axle oil seal drift Installing oil seal

a: 54.5 mm (2.15 in.)
b: 34.5 mm (1.36 in.)

NT115

AX-26
 REAR AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH)

Troubleshooting =NEAX0030
Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”,
GI
“FRONT AXLE”, AX-4.
MA

EM

LC
On-vehicle Service
REAR AXLE PARTS NEAX0031
EC
Check rear axle parts for excessive play, wear and damage.
쐌 Shake each rear wheel to check for excessive play.
FE

CL

SMA525A
MT
쐌 Retighten all nuts and bolts to the specified torque.
: Refer to SU-28, “Removal and Installation”. AT

TF

PD

SRA839

SU

BR

ST

RS

BT

HA

SC

EL

IDX
AX-27
 REAR AXLE
On-vehicle Service (Cont’d)
쐌 Check shock absorber for oil leakage and other damage.
쐌 Check shock absorber bushing for excessive wear and other
damage.

SRA734

REAR WHEEL BEARING NEAX0032

쐌 Check that wheel bearings operate smoothly.
쐌 Check axial end play.
Axial end play:
Refer to “WHEEL BEARING (REAR)”, AX-38.

SRA006-A

AX-28
 REAR AXLE
Components

Components NEAX0033

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

SU

WAX021 BR

ST

RS

BT

HA

SC

EL

IDX
AX-29
 REAR AXLE
Components (Cont’d)

WAX020

Removal NEAX0034
쐌 Before removing the rear axle, disconnect the ABS wheel
sensor from the assembly. Then move it away from the
axle. Failure to do so may result in damage to the sensor
wires and the sensor becoming inoperative.
쐌 Wheel bearing does not require maintenance.
쐌 If growling noise is emitted from wheel bearing during
operation, replace wheel bearing assembly.
쐌 If the wheel bearing assembly is removed, it must be replaced.
The old assembly must not be re-used.

1. Disconnect parking brake cable and brake tube.

2. Remove nuts securing wheel bearing cage with baffle plate.

SRA002

3. Draw out axle shaft with Tool.

When drawing out axle shaft, be careful not to damage oil seal.
4. Remove case shim and case seal (2WD models).
5. Remove O-ring (4WD models).
6. Remove the oil seal.
Do not reuse oil seal once it is removed.
Always install a new oil seal.
7. Remove ABS sensor rotor with Tool (4WD models).

ARA096

AX-30
 REAR AXLE
Removal (Cont’d)
a. Slide the sleeve over the extension tube.

GI

MA

EM

LAX035 LC
b. Slide the extension tube with sleeve over the axle shaft.
EC

FE

CL

LAX036
MT
c. Install the two halves of the collet around the ABS sensor rotor
making sure the lower lip of each collet is slid under the ABS AT
sensor rotor edge.

TF

PD

LAX037

d. Slide the sleeve over the collet.

SU

BR

ST

RS
LAX038

e. Tighten the forcing screw in the extension tube until the ABS BT
sensor rotor is removed.
CAUTION:
Do not use an impact wrench to tighten the forcing screw. HA
f. Remove the Tool and ABS sensor rotor from the axle shaft.
SC

EL
LAX039
IDX
AX-31
 REAR AXLE
Removal (Cont’d)
8. Unbend the lock washer tabs with a suitable tool.

SRA104

9. Remove the wheel bearing lock nut with Tool.

10. Remove wheel bearing together with bearing cage and baffle
plate from axle shaft with Tool.

LAX040

a. Slide the extension tube with sleeve over the axle shaft.

LAX036

b. Install the two halves of the bearing puller jaw over the baffle
plate studs.

LAX041

c. Slide the sleeve down over the bearing puller jaw halves.

LAX042

AX-32
 REAR AXLE
Removal (Cont’d)
d. Install a nut on each baffle plate stud.

GI

MA

EM

LAX043 LC
e. Tighten the forcing screw in the extension tube until the baffle
plate, cage and bearing are pulled free.
11. Remove grease seal in bearing cage with suitable bar.
EC

FE

CL

LAX044
MT
12. Remove wheel bearing outer race with a brass drift (2WD
models). AT

TF

PD

SRA106

13. Remove wheel bearing assembly from bearing cage (4WD

models). SU

BR

ST

RS
ARA094

Inspection NEAX0035
BT
AXLE SHAFT NEAX0035S01
쐌 Check axle shaft for straightness, cracks, damage, wear and HA
distortion. Replace if necessary.
WHEEL BEARING
쐌
NEAX0035S02
Make sure wheel bearing rolls freely and is free from noise, SC
cracks, pitting and wear.
AXLE CASE NEAX0035S03
EL
쐌 Check axle case for yield, deformation and cracks. Replace if
necessary.
IDX
AX-33
 REAR AXLE
Installation

Installation NEAX0036
2WD MODELS NEAX0036S03
1. Install wheel bearing outer race with a brass drift.
2. Install a new grease seal in bearing cage.
After installing new grease seal, coat sealing lip with multi-
purpose grease.

SRA010

3. Install bearing spacer with chamfer side facing axle shaft

flange.

SRA510

4. Install wheel bearing inner race with a brass drift.

5. Coat each bearing cone with multi-purpose grease.
Specified amount of grease:
8 - 12 g (0.28 - 0.42 oz)

SRA011

6. Install plain washer and a new wheel bearing lock washer.

SRA730

7. Tighten wheel bearing lock nut to specified torque.

: 147 - 196 N·m (15 - 20 kg-m, 108 - 145 ft-lb)
Fit wheel bearing lock washer lip in wheel bearing lock nut
groove correctly by tightening lock nut. Be sure to bend
it up.
CAUTION:
When tightening the wheel bearing lock nut, the lock nut
wrench is installed on the torque wrench at a 90° degree angle
as shown.

LAX045

AX-34
 REAR AXLE
Installation (Cont’d)
8. Install a new oil seal with suitable tool.
After installing new oil seal, coat sealing lip with multi-
purpose grease. GI

MA

EM

SRA731 LC
9. Apply recess of axle case end with multi-purpose grease.
10. Apply gear oil to the spline of axle shaft. Coat seal surface of
axle shaft with multi-purpose grease (as shown left).
EC

FE

CL

SRA652A
MT
11. Adjust axial end play.
a. Select end shims. AT
Standard thickness including seal: 1.5 mm (0.059 in)
Axle case end shim: Refer to “WHEEL BEARING
(REAR)”, AX-38. TF
Do not insert end shims between case seal and bearing
cage. PD

SRA653A

b. Insert axle shaft with Tool as a guide.

When inserting axle shaft, be careful not to damage oil SU
seal.
c. Measure end play of axle shaft.
Axial end play:
BR
Servicing only one side of axle shaft
0.02 - 0.15 mm (0.0008 - 0.0059 in) ST
Servicing both side axle shafts
On first axle shaft (right or left) adjust axial end play
0.30 - 0.90 mm (0.0118 - 0.0354 in)
RS
ARA088
After servicing second axle shaft, total end play
0.02 - 0.15 mm (0.0008 - 0.0059 in) BT

HA

SC

EL

IDX
AX-35
 REAR AXLE
Installation (Cont’d)
d. If axial end play is not within the specified limit, reselect axle
case end shims.
While adjusting axial end play, be careful not to damage
oil seal.

SRA006-A

4WD MODELS NEAX0036S04

1. Press new wheel bearing until it bottoms end face of bearing
cage.
Maximum load P:
78 kN (8 ton, 8.8 US ton, 7.9 Imp ton)
Always press outer race of wheel bearing during installation.

SRA288A

2. Press new grease seal until it bottoms end face of bearing

cage.
After installing new grease seal, coat sealing lip with multi-
purpose grease.

SRA289A

3. Press axle shaft into inner race of wheel bearing.

Maximum load P:
47.1 kN (4.8 ton, 5.3 US ton, 4.72 Imp ton)
Be careful not to damage or deform grease seal.

SRA761A

4. Install plain washer and a new wheel bearing lock washer.

SRA762A

AX-36
 REAR AXLE
Installation (Cont’d)
5. Tighten wheel bearing lock nut to specified torque.
: 147 - 196 N·m (15 - 20 kg-m, 108 - 145 ft-lb)
Fit wheel bearing lock washer lip in wheel bearing lock nut GI
groove correctly by tightening lock nut. Be sure to bend
it up.
CAUTION:
MA
When tightening the wheel bearing lock nut, the lock nut
wrench is installed on the torque wrench at a 90° degree angle EM
as shown.

LAX045 LC
6. Check wheel bearing preload.
a. Turn bearing cage (with respect to axle shaft) two or three
times. It must turn smoothly.
EC
b. Attach spring gauge to bearing cage bolt (as shown at left) and
pull it at a speed of 10 rpm to measure preload. FE
Spring gauge indication:
6.9 - 48.1 N (0.7 - 4.9 kg, 1.5 - 10.8 lb)
CL

SRA763A
MT
7. Install new oil seal to rear axle housing using a suitable tool.
After installing new oil seal, coat sealing lip with multi-pur- AT
pose grease.
8. Install new O-ring to rear axle housing.
TF

PD

SRA803A

9. Press ABS sensor rotor onto axle shaft until it contacts wheel
bearing lock nut. SU

BR

ST

RS
SRA802A

10. Position axle shafts in rear axle housing with Tool as a guide. BT
Be careful not to damage oil seal.

HA

SC

EL
ARA088
IDX
AX-37
 REAR AXLE
Installation (Cont’d)
11. Check axial end play.
a. Check that wheel bearings operate smoothly.
b. Check axial end play.
Axial end play:
0 mm (0 in)

SRA006-A

Service Data and Specifications (SDS)

WHEEL BEARING (REAR) NEAX0037
2WD Models NEAX0037S03

Total end play mm (in) 0.02 - 0.15 (0.0008 - 0.0059)

Thickness
Part number*
mm (in)

0.05 (0.0020) 43086-P0110

0.07 (0.0028) 43087-P0110
Available rear axle case end shims
0.10 (0.0039) 43088-P0110
0.15 (0.0059) 43086-B9500
0.20 (0.0079) 43089-P0110
0.50 (0.0197) 43090-P0110
1.00 (0.0394) 43036-01G00

*: Always check with the Parts Department for the latest parts information.

4WD Models NEAX0037S04

Total end play mm (in) 0 (0)

Wheel bearing preload at bearing cage bolt N (kg, lb) 6.9 - 48.1 (0.7 - 4.9, 1.5 - 10.8)

AX-38