Propeller shaft

and Axle
GENERAL
MECHANICAL SPECIFICATIONS . . . . . . . . PA - 2

PROPELLER SHAFT
FRONT PROPELLER SHAFT
REAR PROPELLER SHAFT

FRONT AXLE
WHEEL HUB

AXLE AND KNUCKLE

WHEEL ALIGNMENT

REAR AXLE
WHEEL HUB
AXLE HOUSING

DIFFERENTIAL CARRIER ASSEMBLY

PA -2

PROPELLER SHAFT AND AXLE

GENERAL
MECHANICAL SPECIFICATIONS

SPECIFICATION

EADD7969

PROPELLER SHAFT
Item

Pipe
Universal Joint

Needle roller Bearing

Slip Joint
Center Bearing

Specification
P2

P3

Outer Diameter
Thickness

63.52.6

76.22.6

Spider Outer Diameter

18.3

22.73

Bearing Cap Outer

Diameter

30

34.92

Outer Diameter

2.5

2.65

Length

12.8

19.7

Amount

26

30

Spline Diameter

38.7

38.7

Inner Diameter Outer

Diameter

3572

4080

Unit : mm
FRONT AXLE
Item
Front axle
Kingpin

Content
Type

Reverse Elliot, "I" beam

O.Dx length

28180mm, 30180mm
1705mm

Tread
Wheel alignment

Turning angle
Lubricant

Toe-in

0~6mm

Camber

1 30

Caster

1 30

Kingpin inclination

8 10

Inner

40.8~42.8

Outer

30.8~32.8

Wheel bearing grease(LIG)

480~500cc

GENERAL

PA -3

REAR AXLE
Model

Item

Standard

Rear Axle Type

Standard / Long

Full flting type

Differential

Hub grease(each left

and right)

Model

D2H(D4AF)

D2H-II (D4AE, D4AD)

D3H (D4DA, D4DB)

Reduction
ratio

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)

Quantity

4.5 0.25 (Fill the reservoir to the plug hole)

Type

N.L.G.I - 2

Quantity

300 30cc

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

SERVICE STANDARD
PROPELLER SHAFT
Nominal value
(Basic diameter in [ ])

Limit

0.1 or less

0.4

0.1 or less

0.4 or less

Turning
direction

0.01~0.09

0.3

Diametric
direction

0.02~0.16

0.3

Front

5g/3000rpm

Adjust
Balance

Rear

10g/3000rpm

weight

0.01~0.06

Replace as a
spider kit

Adijust with
snap ring;
4 types
available(1.5,
1.55, 1.6, 1.6)

Descripiton
Propeller Shaft Runout

At center
At slip joint

Spline play

Propeller Shaft imbalnce

Spider to needle roller bearing clearance

Snap ring(at spider) play in axial direction

Unit : mm

0.06 or less

Correction
and remarks
Correct or
replace
(correction to
be made at
pipe)
Replace

PA -4

PROPELLER SHAFT AND AXLE

FRONT AXLE
Descripiton

Nominal value
(Basic diameter in [ ])

Limit

A=130.8

[30] 29.947~29.98

29.9

[30] 30~30.033

0.020~0.086

0.15

Replace bushing

0.02~0.1

0.2

Adjust with
shims(four types
0.10, 0.15, 0.20,
0.30)

46~71

Correction and
remarks

Front axle center bend in vertical direc

Fine string

To go through center
of center hole.

Correct or replace

Weight

ECOPA5001A

Kingpin O.D.
Bushing I.D. (after press fitting)
Kingpin to bushing clearance
Knuckle vertical clearance
Front wheel hub starting torque(kgf.cm)

Replace

Adjust

REAR AXLE
Descripiton
Rear Axle Shaft Ben

At shaft center
At flange

Rear axle shaft and differential gear splin

play in turning direction

Nominal value
(Basic diameter in [ ])

Limit

2 or less

0.03 or less

0.05

0.18 ~0.23

0.5

0.2 ~ 0.28

0.05 or less

0.05

D2H,D3H

98~195(10~20)

D033H

200~300(20~30)

Rear wheel hub starting torque N cm(kgf.cm)

195~390(20~40)

Runout of final drive gear back surfaec

Final drive pinion starting torque
N cm(kgf.cm)

Correct or replce.
Replace

0.05~0.15

Backlash between diferential gear and

differential pinion

Backlash between final drive gear and final

drive pinion

Correction and
remarks

Adjust with differenti

gear spacer(replace
as differential gear
set in case of poor
tooth contact).
Adjust
Replace as carrier
assembly.
Adjust (do not install
oil seal).
Adjust(do not install
outer oil seal and
rear axle shaft)

GENERAL

PA -5
Nominal value
(Basic diameter in [ ])

Descripiton

Limit

Rear axle housing bend

AA
B1 or B2 V-block

Correction and
remarks

0.5 or less

Correct or
replace(correction
by hydraulically
pressing spring
seat).

B1 - B2

1.0 or less

Replace

ECOPA5002A

TIGHTENING TORQUE
PROPELLER SHAFT
Part to be tightened

Tightening torque
Nm

kgf.m

lb-ft

Flange yoke to
propeller shaft flan
clmp mounting
self-locking nut

P2

60~70

6.0~7.0

43.3~50.6

P3

100~120

10~12

72.3~86.7

Companion flange
clamp nut

P2

205~255

20.5~25.5

148~184

P3

300~400

30~40

217~289

20~30

2.03.0

14.4~21.6

Center bearing attahing bolt(P2 / P3)

FRONT AXLE
Part to be tightened

Tightening Torque
Nm

kgf.m

lb-ft

200~300

20~30

145~217

28~38

2.9~3.9

20.9~28.2

Tightening torque

88 or more

9 or more

65 or more

Loosening torque

135 or more

14 or more

101 or more

69~115

7~12

50.6~86.7

80

57.8

Brake backing plate attaching nut

98~135

10~14

72.3~101

Hub bolt attaching nut

305~380

31~39

224~282

98~125

10~13

72.3~94

59

43.3

Knuckle arm attaching nut

Kingpin lock pin clamping nut
Shock absorber
mounting stud bolt

Tie-rod end to knuckle arm clamping nut

Tie-rod end clamping bolt

Wheel hub lock nut

tightening

Primary torque
Secondary torque
after full loosening
Backing out angle

Approx. 45 (1 /8 turn)

PA -6

PROPELLER SHAFT AND AXLE

REAR AXLE
Part to be tightened

Tightening Torque
Nm

kgf.m

lb-ft

Flange yole to
propeller shaft flange

P2

60~70

6.0~7.0

43.3~50.6

Clamp mounting
self-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 case

attaching 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

Differential carrier assembly attaching nut

Rear brake assembly attaching bolt

34~44

3.5~45

25.3~32.5

98~135

10~14

72.3~101

Rear wheel hub to rear brake drum attaching

nut (after tightening, lock using triangular
or quadrangular pyramid punch)

350~380

31~39

224~282

Wheel bearing lock

nut tightening (Wheel
bearing preload
adjustmen)

Primary tightening

98~125

10~13

72.3~94

Secondary tightenin
tightening after
complete loosening

27~36

3~4

21.6~28.9

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
Vibration
atPropeller Shaft

High Speed

Low Speed

AbnormalNoise
atPropeller Shaft

Remedy

Causes

At start

Running
withRegular
speed

The yoke direction is wrong.

Rearrange the align mark.

The universal joint needle roller

bearing is defective.

Replace with the spider kit.

The propeller shaft is bent

Replace the propeller shaft.

The dynamic balance of the propeller

shaft is incorrect.

Adjust the dynamic balance.

The flange linking bolt is loosened.

Tighten with specified torque.

The ball bearing is worn out

or adhered.

Replace the ball bearing.

The transmission is too fast.

Move the shift bar of the transmission

to proper position.

The axial clearance of the universal

joint spider is too large.

Adjust the clearance by Shim.

The clearance of the slip joint

spline is too large.

Replace the yoke sleeve or

propeller shaft.

The flange linking blot is loosened.

Tighten with specified torque.

The tightening bolt for center

bearing is loosened.

Tighten with specified torque.

The center bearing is weakened

or deformed.

Replace the rubber

The universal joint needle roller

bearing is worn.

Replace with the spider kit.

The clearance of the slip joint

spline is too large.

Replace the yoke sleeve or

propeller shaft.

The axial clearance of the universal

joint spider is too large.

Adjust the clearance by Shim.

The universal joint needle roller

bearing is worn.

Replace with the spider kit.

The ball bearing is worn out

or adhered.

Replace the ball bearing.

The lubricant between the bearing

and the spline is defective.

Lubricate.

PA -8

PROPELLER SHAFT AND AXLE

FRONT AXLE
Symptom
Vibration at Steering Wheel

Remedy

Causes
Kingpin wear.

Replace.

The clearance of kingpin and bushing

is 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 arm

and the tie rod arm are loosened.

Tighten with the specified torque.

The tightening nut for tie rod ball stud

is loosened.

Tighten with the specified torque.

The tightening nut for suspension U-bolt

is loosened.

Tighten with the specified torque.

The vertical clearance between the knuckle

and the front axle is too large.

Adjust the kingpin thrust washer.

The clearance between the kingpin and the

kingpin bushing is too large.

Replace the kingpin bushing.

The strut ball bearing is adhered, worn

or 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.

The grease is deficiency in kingpin.

Oil the grease.

Steering wheel does not

return properly.

The front axle parts are too tightened.

Tighten with the specified torque.

The wheel alignment is defective.

Adjust.

Steering wheel can not

be turned.

The rotating angle adjustment is defective.

Adjust the rotating angle.

The tie rod is bent.

Replace.

Vehicle is drawn to one side.

The sizes of the left and right tires are different.

Replace with the same size.

The outer diameters of the left and right

tires 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.

The front spring is damaged or its

tension is defective.

Replace.

The wheel alignment is defective.

Adjust.

The sizes or types of the left and right

tires are different.

Replace with the same size and type.

The tire is not managed properly.

Replace the tire position.

Hard to control the

steering wheel

Front tire is worn irregularly

or too early.

GENERAL

PA -9

Damage

Adhesion

During running, tire is drawn.

During curving, noise is made.

During running, irregular noise

is made.

During running, noise is made

continually.

Noise at start or changing shift bar.

Propeller shaft is rotating but the

vehicle does not move

Moving force is not transmitted properly.

Oil leakage at rear axle shaft

Causes

Oil leakage at differential carrier and

vrear axle housing

Trouble
Symptom

Oil leakage at companion flange

REAR AXLE

Wheel Hub The tightening bolt for rear axle shaft is loosened.
and Axle
The rear axle housing is bent.
Housing
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.
Reduction
and
Differential

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 assy
is loosened.
The tightening nut for differential carrier assembly
is loosened.
EMTPA5001AA

PA -10

PROPELLER SHAFT AND AXLE

GENERAL INFORMATION

EMTPA5002AA

GENERAL
GENERALS

PA -11
E22909E5

2
1

1. Front Propeller Shaft

2. Rear Propeller Shaft
3. Rear Axle

EMTPA5003A

The propeller shaft installing between the transmission

and the rear axle transmits the engine force changed by
the transmission to the final gear of the rear axle. The propeller shaft comprises of the front and the rear propeller
shafts. Two or more parts are linked and supported by
wheel base. The propeller shaft having two or more parts
includes a center bearing at the center portion supported
by the frame.

The relative position of the transmission to the rear axle is

varying in accordance with the condition of the road surface, the vibration during running of the vehicle and the
amount of the load. To compensate the varying of the position, the propeller shaft includes the universal joint and
the slip joint.
Moving Direction of the Universal Joint
Horizontal Movement

Moving Direction of the Slip Joint

Vertical Movement
Movement along
with the axis

EMTPA5005A

EMTPA5004A

PA -12

PROPELLER SHAFT AND AXLE

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 or

makes an abnormal noise. If there is any problem,
replace the propeller shaft.
A

KMTPA101A

3.
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 or

makes 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 portion

of 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

If the run-out of the propeller shaft excesses the specifications, replace the propeller shaft.

GENERAL

PA -13

GREASING AT ASSEMBLY
Apply wheel bearing grease
to race way
Pack wheel bearing grease

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 grease

between lips

ECOPA5005A

LUBRICATION AFTER INSTALLATION

1.

Pouring Hypoid Gear Oil

Quantity of oil (lit.)

4.5 0.25 (D2H, D3H)
2.

After parts have been installed, bleed the brake system.

For bleeding procedures, see GROUP BR.

Oil filter plug

59 to 78 Nm(6 to 8kgf.m)

ECOPA5006A

PA -14

PROPELLER SHAFT AND AXLE

PROPELLER SHAFT
COMPONENTS

E30B815A

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)

P3 : 100~120 (10~12, 72.3~86.7)

P2 : 60~70 (6~7, 43.3~50.6)

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

1.
2.
3.
4.
5.

Transmission
Front Axle
Rear Propeller Shaft Support
Rear Propeller Shaft
Rear Axle

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

ECOPA5007A

PROPELLER SHAFT
REMOVAL
1.

PA -15
3.

E337574F

Making an align mark (C) to the flange yoke (A) of the

front propeller shaft and the parking brake drum (B),
remove the tightening nut (D) of the propeller shaft.

Making an align mark (C) to the rear axle companion

flange (A) and the flange yoke (B) of the rear propeller
shaft, remove the tightening bolt (D) of the propeller
shaft.

A
B

C
KMTPA113A
KMTPA111A

2.

Remove the tightening bolt (A) of the center bearing

bracket.
NOTE
For the short wheel base, the center bearing is one,
while for the long wheel base, the center bearings are
two.

INSPECTION
1.

E8AF06AD

After checking the clearance between the spider and

the needle roller bearing, if it excesses the specifications, replace the spider kit.

Clearance between the Spider and the Needle

Roller: 0.01~0.06mm

Needle Roller
Bearing

Spider

Dial Gauge

EMTPA5007A

KMTPA112A

PA -16
2.

PROPELLER SHAFT AND AXLE

Measuring the bending at the 50mm around the welding center portion of the propeller shaft, if it excesses
the specification, replace the propeller shaft.

Limit value : 0.4mm or less

[ Measure at center portion ]

EMTPA5008A

PROPELLER SHAFT

PA -17

FRONT PROPELLER SHAFT

DISASSEMBLY

E6265D13

7
8
5
6

10

Wear

Gap to the Axis

Reference: 0.06 or less

Gap
Reference : 0.02~0.05
Limit : 0.1

9 Deterioration or Deformation
12

2 Rotating State 1
Crack or Damage 4

11 Rotating State
13

Disassembling Sequence
1 . Snap Ring
2 . Needle Roller Bearing
3. Flange Yoke
4. Universal Joint Spider
5. Self Locking Nut
6. Companion Package
7. Holder

8. Hanger
9. Cushion
10. Oil Seal Kit
(Housing and Oil Seal)
11. Packing
12. Ball Bearing
13. Front Propeller Shaft

* For disassembly for the

number, refer to the corresponding contents.

ECOPA5008A

PA -18
1.

PROPELLER SHAFT AND AXLE

INSPECTION

Remove the snap ring

1.

CAUTION
Replace the snap ring with new ones after removal.

EF281D65

Check the clearance between the spider and the needle roller bearing.
CAUTION
When replace the spider or needle roller bearing, replace them with the spider kit.

Needle Roller
Bearing
Screw Driver
Spider

Dial Gauge

EMTPA5010A

2.

Remove the needle roller bearing.

EMTPA5007A

Universal Tool Set

2.

Yoke Assembly
Push Rod

Check the clearance of snap ring along to the axis

direction
1. Measure the clearance
2. Adjust the clearance
CAUTION
Replace the snap ring with new ones after removal.
Use the snap rings having the same thickness
at the both sides.

Guide

Guide

EMTPA5011A

3.

Remove the ball bearing

Gear Puller

KMTAX5009A

EMTPA5012A

PROPELLER SHAFT

PA -19

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 the

propeller shaft.
[ Measure at center portion ]

EMTPA5008A

PA -20

PROPELLER SHAFT AND AXLE

REASSEMBLY

E6EE691F

20~29
(2~3, 14~22)
6
Apply an adhesive to the upper split

7
8
9

Align the arrows of housing

12

11

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

* 10

1
3
13

Apply grease to the center bearing

Fill with the wheel bearing grease

25~30g

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

Reassembly Sequence
4
13

12

11

3
10

1
9

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.

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

ECOPA5009A

PROPELLER SHAFT
1.

PA -21

Insert the needle roller bearing by pressing-in.

Housing Installer

Universal Joint Tool Set

Housing
Installer A

Align Arrow
of Housing

Yoke Assembly
Push Rod

Housing
Installer B
Guide
Gap

Bolt
Guide

EMTPA5015A

2.

Front Side

Install the snap ring.

EMTPA5017A

4.

Axis

Using a thickness gauge, measure the gap between

the snap ring and the groove of the snap ring.

Reference : 0~0.15mm
Limit : 0.3mm or less

CAUTION
If the gap excesses the limit value, replace the
snap ring.
EMTPA5016A

3.

Assemble the center bearing.

Setting the arrow mark to upward, insert the center
bearing into cushion, and apply adhesion into the gap.
Install the housing tightening bolt with setting its head
to upward.

EMTPA5030A

5.

Apply the grease enough to the grease nipple of the

universal joint.

Recommended Grease: SELL ALVANIA EP #2

PA -22

PROPELLER SHAFT AND AXLE

REAR PROPELLER SHAFT

DISASSEMBLY

E9A9F492

Clearance along to the axis

Reference : 0.06mm or less

Unit: mm

Clearance
Reference: 0.01~0.06
Limit: 0.1

8
2

Crack, 3
Damage

Rotating
State
1

Value

Bending
Item

At Center
At Slip joint

Normal Value

Limit

0.1 or less

0.4 or less

Plug
Clearance of Spline
Item

Value
Normal Value

Limit

Rotational Direction
Diameter Direction
Disassembly Sequence
1. Snap Ring
2. Needle Roller Bearing
3. Front Yoke
4. Universal Joint Spider
5. Packing Retainer
6. Shield Packing
7. Rear Propeller Shaft
8. Sleeve Yoke

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

Service Kit
Spider Kit

Unit: mm
ECOPA5010A

PROPELLER SHAFT
1.

PA -23
INSPECTION

Remove the snap ring.

1.

CAUTION
Do not reuse the snap ring.

E3D02E4E

Check the clearance between the spider needle roller

bearings.
CAUTION
When replace the spider or needle roller bearing, replace them with the spider kit.

Needle Roller
Bearing
Screw Driver
Spider

Dial Gauge

EMTPA5010A

2.

Remove the needle roller bearing.

Universal Tool Set

EMTPA5007A

Yoke Assembly

2.

Push Rod

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 removal.
Use the snap rings having the same thickness
at the both sides.

Guide

Guide

EMTPA5011A

KMTAX5009A

PA -24

PROPELLER SHAFT AND AXLE

Snap Ring

4.

Thickness(mm)

Color Code

1.5

No Color

1.55

Yellow

1.6

Blue

1.65

Purple

Check the clearance of spline

[ Measure at rotational direction ]

Clearance
Adjust with Snap Ring

EMTPA5020A

Insert the snap ring

[ Measure at diameter direction ]

EMTPA5013A

3.

Check the bending of the propeller shaft.

[ Measure at center portion ]

EMTPA5021A

EMTPA5008A

[ Measure at slip joint ]

EMTPA5019A

PROPELLER SHAFT
REASSEMBLY

PA -25

E82A209C

2
3

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

7

4
8

Snap Ring
2. Needle Roller Bearing
3. Flange Yoke
4. Universal Joint Spider
5. Packing Retainer
6. Sheild Packing
7. Rear Propeller Shaft
8. Sleeve Yoke

For assembly for the

number, refer to the corresponding contents.

Reassembly Sequence
4
75683

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

ECOPA5011A

PA -26
1.

PROPELLER SHAFT AND AXLE

Insert the needle roller bearing by pressing-in.

Universal Tool Set

Yoke Assembly

Push Rod

D
Guide

Guide

EMTPA5011A

2.

Install the snap ring.

KMTPA113A

2.

Install the tightening bolt (A) of the center bearing

bracket.

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

Axis

EMTPA5016A

INSTALLATION
1.

E29551BE

Setting the aligning mark (C) of the rear axle companion flange (A) to that of the flange yoke (B) of the
rear propeller shaft, tighten the bolt (D) of the propeller
shaft.
A

Tightening Torque :
98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft) : P3
59~69 Nm (6~7 kgf.m, 43.3~5.6 lb-ft) : P2

KMTPA112A

NOTE
For narrow version, the center bearing is one, while
for the wide version, the center bearings are two.

PROPELLER SHAFT
3.

PA -27

Setting the aligning mark (C) of the flange yoke (A) of

the front propeller shaft to that of the parking brake
drum (B), tighten the bolt (D) of the propeller shaft.

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

KMTPA111A

4.

After filling up the recommended grease to the grease

nipple (A) until it leaks out from the oil seal, wipe out
the leaked grease completely.

Recommended Grease: ALVANIA EP #2

KMTPA114A

PA -28

PROPELLER SHAFT AND AXLE

FRONT AXLE
WHEEL HUB
DISASSEMBLY

E3DC854A

Wear, Rotation, Scratch

Wear, Corrosion

Wear

Check the Rotation State

Check the Rotation State

Disassembly Sequence
1. Hub Cap
2. Split Pin
3. Lock Nut
4. Washer
5. Wheel Hub and Brake Drum
6. Hub Bolt
7. Front Brake Drum
8. Front Wheel Hub

9. Outer Bearing Inner Race

10. Spacer
11. Oil Seal
12. Inner Bearing Inner Race
13. Inner Bearing Outer Race
14. Outer Bearing Outer Race
15. Dust Cover
16. Front Brake Assembly
EMTPA5023A

FRONT AXLE
1.

PA -29

Place the wooden block (A) at the front and rear side
of the rear wheel.

3.

After removing the wheel nut (A), remove the wheel

and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (D) is not damaged.

A
KCOWT5004A

2.

Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (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 that
the washer and the outer bearing does not fall
down to the ground.

C
A
B
KCOWT5005A

C
B

KMTPA204A

PA -30
5.

PROPELLER SHAFT AND AXLE

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

7.

Tapping evenly the three notch parts on the other side

hub inner surface with a brass bar, removing the outer
bearing race (A).

C
D

B
A

KMTPA205A

6.

Tapping evenly the three notch parts on the hub inner

surface with a brass bar, removing the oil seal (A), the
inner bearing (B) and the inner bearing race (C).

KMTPA207A

8.

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

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

A
B

C
B
KMTPA208A

KMTPA206A

FRONT AXLE

PA -31

[DISK BRAKE]
7
Wear,
Rotation,
Scratch
8

Wear, Corrosion
10
5

17

16
Wear 12
13

14

Check the Rotation State

15 11
Check the Rotation State

Disassembling Sequence
1. Hub Cap
2. Split Pin
3. Lock Nut
4. Washer
5. Disk Brake Assembly
6. Wheel Hub and Rotor
7. Bolt
8. Rotor
9. Front Wheel Hub

10. Hub Bolt

11. Outer Bearing Inner Race
12. Oil Seal
13. Inner Bearing Inner Race
14. Inner Bearing Outer Race
15. Outer Bearing Outer Race
16. Adaptor
17. Dust Cover

EMTPA5024A

PA -32
1.

PROPELLER SHAFT AND AXLE

Place the wooden block (A) at the front and rear sides
of the rear wheel.

3.

After removing the wheel nut (A), remove the wheel

and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire, be careful that
the hub bolt is not damaged.

A
KCOWT5004A

2.

Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (C).

KCOWT5006A

4.

After removing the grease cap (A), remove the split

pin (B) and the lock nut (C).

C
A

B
B
KCOWT5005A

C
A
KMTPS5990A

5.

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

6.

After taking off the disk tightening bolt, remove the

disk assembly from the wheel hub (B).

7.

Remove the hub from the knuckle.

FRONT AXLE
INSPECTION

PA -33
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), tighten

the hub nut (A).

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

KMTPA209A

3.
CAUTION
After tightening the hub nut (A), at least 4 portions
of the groove parts of the stud should be calked.

Install the inner bearing (B) and the oil seal (C) at the
wheel hub (A).
CAUTION
The bearing should be a set with the bearing
race.
Use a new oil seal (C) always.

A
B

B
C
KMTPA208A

2.

By tapping evenly, install the inner bearing race (B)

and the outer bearing race (C) at the wheel hub (A).

KMTPA210A

PA -34
4.

PROPELLER SHAFT AND AXLE

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

b
a

5.

Install the washer (A), the outer bearing (B) and the
hub assembly (C) at the knuckle (D).
CAUTION
The bearing should be a set with the bearing
race.

B
A

KMTPA211A

7.

C
D

Just before the wheel hub (A) is moving, measure the

tangential force using a spring gauge (B). Calculate
the moving torque by multiplying the tangential force
to the radius.

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

KMTPA205A

6.

Install the lock nut (A).

A

1)

With rotating the hub assembly (B), tighten

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

2)

Again with rotating the hub assembly (B), tighten

the lock nut (A) with the force of 5~9 Nm (6
kgfm, 43.3 lb-ft) and then loosen the nut at
45 (1/8 turns).

KMTPA212A

FRONT AXLE
8.

PA -35

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

10. After removing the garage jack (B) supporting the axle
and the safety stand (C) supporting the frame, tighten
the wheel nut (A) with the specified torque.
Tightening Torque :
539~588 Nm (55~60 kgfm, 397.8~433.9 lb-ft)

C
A
B

9.

KMTPA213A

KCOWT5005A

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

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

C
A
KCOWT5006A

KCOWT5004A

PA -36

PROPELLER SHAFT AND AXLE

[DISK BRAKE]
1.

5.

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 kgfm, 42~44 lb-ft)
A

Recommended Grease:
RETINAX 0434 of Hankook Shell Co., Ltd.
RETINAX 0419 of Hankook Shell Co., Ltd.
KO-GW02 of Cheonmi Mineral Oil Co., Ltd
6.

Fill the recommended grease in the wheel hub (A)

with specified amount.

Install the washer, the outer bearing and the hub assembly at the knuckle.
CAUTION
The bearing should be a set with the bearing
race.

7.

KISE220E

2.

Tighten the hub nut to the hub assembly.

Install the lock nut (A).

1. With rotating the hub assembly (B), tighten
the lock nut (A) fully with the force of 98~117
Nm(10~13 kgfm, 72.3~86.7 lb-ft) After that,
loosen the nut fully.
2. Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 59 Nm (6 kgfm,
3.31 lb-ft) and then loosen the nut at 45 (1/8
turns).

CAUTION
After tightening the hub nut, at least 4 portions of
the 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 the
wheel hub (D).
CAUTION
The bearing should be a set with the bearing
race.
Replace the oil seal(C) with new one after removal.
E

C
B
A
KISE210E

B
A
KMTPA5002A

FRONT AXLE
8.

PA -37

Just before the wheel hub (A) is moving, measure the

tangential force using a spring gauge (B). Calculate
the moving torque by multiplying the tangential force
to the radius.

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

Starting Torque : 0.98~3.4 Nm (0.10~0.35

kgfm, 0.72~2.5 lb-ft)

KCOWT5006A

11. After removing the garage jack (B) supporting the axle
and the safety stand (C) supporting the frame, tighten
the wheel nut (A) with the specified torque.
Tightening Torque : 539~588 Nm (55~60
kgfm, 397.8~433.9 lb-ft)

KMTPA212A

9.

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

A
A
B

KCOWT5005A

KMTPS5991A

PA -38

PROPELLER SHAFT AND AXLE

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

A
KCOWT5004A

FRONT AXLE

PA -39

AXLE AND KNUCKLE

COMPONENTS

E8D4AD71

4
5

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

11

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

7

1. Hub Cap
2. Front Wheel Hub
3. Knuckle
4. Dust Cap
5. Kingpin Shim
6. Kingpin

10

7. Thrust Bearing
8. Drag Link
9. Knuckle Arm
10. Tie Rod
11. Front Axle

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

ECOPA5012A

PA -40

PROPELLER SHAFT AND AXLE

DISASSEMBLY

4.

E1B9F4BA

[DRUM TYPE]
1.

Remove the wheel hub. (Refer to the Wheel Hub

Disassembly )

2.

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

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

NOTE
Tie the brake assembly (B) around the relating parts
with a wire.

A
B
C

KMTPA303A

5.
A

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

B
KMTPA301A

3.

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

KMTPA304A

B
A

KMTPA302A

FRONT AXLE
6.

PA -41

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

[DISK TYPE]
1.

Remove the wheel hub. (Refer to the Wheel Hub

Disassembly )

2.

After holding the brake hose with a vise pliers, loosen

the brake hose tightening bolt (A). Remove the brake
hose.

A
KMTPA305A
KMTBR5536A

7.

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

3.

After taking off the tightening bolt(A) of the brake

caliper, remove the caliper(B).
A

B
A

KMTPA306A

KMTBR5538A

4.

After taking off the tightening bolt of the dust cover,

remove the dust cover from the knuckle.

PA -42
5.

PROPELLER SHAFT AND AXLE

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

7.

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

C
C

B
A
A

KMTPA302A

6.

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

KMTPA304A

8.

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

A
B
C

KMTPA303A

KMTPA305A

FRONT AXLE
9.

PA -43

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

2.

Install the king pin (B) and then, install the dust cap
(A).
CAUTION
The groove portion of the king pin (B) should face
to inside.

B
B
A

KMTPA306A

REASSEMBLY

E2E655C2

[DRUM TYPE]
1.

KMTPA305A

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

3.

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

Tightening Torque :
28~38 Nm (2.9~3.9 kgfm, 21~28 lb-ft)
A

B
B
A

KMTPA306A

KMTPA304A

PA -44
4.

PROPELLER SHAFT AND AXLE

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

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

6.

After install the brake assembly (B) to the knuckle (C),

install the tightening bolt (A) for the brake assembly.

Tightening Torque :
98~137 Nm (10~14 kgfm, 72~101 lb-ft)

A
B
C

KMTPA303A

5.

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

KMTPA301A

7.

Install the wheel hub. (Refer to the Wheel Hub Assembly )

[DISK TYPE]

Tightening Torque :
147~186 Nm (15~19 kgfm, 108~137 lb-ft)

1.

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

C
A

B
A
B
A

KMTPA302A

KMTPA306A

FRONT AXLE
2.

PA -45

Install the king pin (B) and then, install the dust cap
(A).
CAUTION
The groove portion of the king pin (B) should face
to inside.

4.

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

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

A
B
C

KMTPA303A
KMTPA305A

3.

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

5.

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

Tightening Torque :
147~186 Nm (15~19 kgfm, 108~137 lb-ft)

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

C
C

B
A
A

KMTPA304A

KMTPA302A

PA -46
6.

PROPELLER SHAFT AND AXLE

After install the brake caliper (B), install the caliper

tightening bolt (A).

Tightening Torque : 98~127 Nm (10~13

kgfm, 72~94 lb-ft)

B
KMTBR5538A

7.

After installing the dust cover (B) to the knuckle (C),

install the tightening bolt (A) of the dust cover.

Tightening Torque : 98~137 Nm (10~14

kgfm, 72~101 lb-ft)
8.

After installing the brake assembly (B) to the knuckle

(C), install the tightening bolt (A) of the brake assembly.

Tightening Torque : 125~139 Nm (12.7~14.2

kgfm, 92~103 lb-ft)
9.

Install the wheel hub. (Refer to the Wheel Hub Assembly )

FRONT AXLE

PA -47

WHEEL ALIGNMENT
DESCRIPTION

4.

ED7D3163

When wheel alignment and steering angle are measured,

check that the vehicle has no load or every parts of the
front axle are properly assembled.

Moving the vehicle to forward so that the marking

point moves backward. Setting the marking point to
the height of the toe-in gauge (i.e. turn 180 ), at the
rear side, measure the distance (B) between the two
wheels.
B

CAUTION
Before 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 loosened.
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.

KMTAX5020A

5.

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. (The

marking point is the middle position of the width and
height of the wheel)

3.

Setting the needle height of the toe-in gauge to the

marking point of the left and right tire, measure the
toe-in value. Measure the distance (A) between the
two wheels.

The difference between the measured value of rear

side (B) and the measured value of front side (A) is
the toe-in value.

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

A

Forward

KHHA850A

KMTAX5019A

PA -48
6.

PROPELLER SHAFT AND AXLE

If the measured toe-in value excesses the specified

value, adjust it by loosening the clamp bolts (B) of the
left and right tie rods (A) and turning the tie rod (A)
with a pipe wrench (C).

5.

Measure the camber value(B) of the gauge (A). The

center line of the bubble is the camber value.

Specified Value : 1 30

Tightening Torque of the Clamp Bolt (B):

20~29 Nm (2~3 kgfm, 14~22 lb-ft)

Tie Rod End

2.0~3.0 kgf.m
A

EMTPA5026A

CAMBER

KMTPA363A

1.

Set the front wheel along with the straight direction.

2.

Remove the wheel hub cap (A).

6.

By the same method, measure the camber value of

the opposite wheel.

KINGPIN INCLINATION ANGLE AND CASTER

1.

To maintain the vehicle in horizontal position, place a

plate (B) having the same height with the turn table
(A) under the rear tire (C).

KCOPA5007A

3.

4.

Wipe out the grease at the end of the spindle. Install

the self centering plunger of the camber, the caster
and the king pin gauge (A) to the wheel hub by setting
them to the center hole of the spindle.
Set the gauge (A) in horizontal plane. To do that, set
the bubble (in longitudinal direction) of the level gauge
to the zero point.

B
C

A
KCOPA5008A

FRONT AXLE
2.

PA -49

Positioning the two front tires of the vehicle to the center of the turn table, pull (set up) the parking brake.

6.

Wipe out the grease at the end of the spindle. Install

the self centering plunger of the camber, the caster
and the king pin gauge (A) to the wheel hub by setting
them to the center hole of the spindle.

If it is hard to move the vehicle, lift up the vehicle

with a jack and place the turn table and the plate
under the front and rear tire.

7.

Set the gauge (A) in horizontal plane. To do that, set

the bubble (in longitudinal direction) of the level gauge
to the zero point.

3.

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

8.

4.

Turn the tire to be measured to the outward until the

scale of the turn table is positioned 20 (A).

By turning the zero setting screws of the caster (A)

under the gauge and the kingpin tilting angle, set the
bubble to 0.

CAUTION

CAUTION
For left side wheel, use the left scale as the kingpin tilting angle scale. For right side wheel, use
the right scale as the kingpin tilting angle scale.
9.

Turn the wheel 20 again so as to set the scale of the

turn table to 0 . Then the center line of the bubble
indicates the kingpin tilting angle value. Measure the
center line value of the bubble.

Specified Value : 8 10
10. By turning the tire to inward, set the scale of the turn
table to 20 .
A

11. Set the gauge (A) in horizontal plane. To do that, set

the bubble (in longitudinal direction) of the level gauge
to the zero point.
KMTPA363A

5.

Remove the wheel hub cap (A).

12. From the caster scale, read the each pointing scale of
the casters.
Specified Value: 1 30
13. By the same method, measure the caster and the
kingpin tilting angle values of the opposite wheel.

KCOPA5009A

PA -50

PROPELLER SHAFT AND AXLE

STEERING ANGLE

6.

Before inspecting the steering angle, complete the inspection of the wheel alignment.
1.

To maintain the vehicle in horizontal position, place a

plate (B) having the same height with the turn table
(A) under the rear tire (C).

If the measured value excesses the specified value,

tighten or loosen the knuckle stopper bolt (A) at both
sides (LH/RH) to adjust the steering angle.

B
C

KMTPA382A
KCOPA5008A

2.

Positioning the two front tires of the vehicle to the center of the turn table, pull (set up) the parking brake.
CAUTION

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 Kgfm, 28.9~39.8 lb-ft)

If it is hard to move the vehicle, lift up the vehicle

with a jack and place the turn table and the plate
under the front and rear tire.
A

3.

Set the scales of the both turn table to 0 .

4.

Turn the tire to inward. Measure the scale of the turn

table.

Specified Value( ) : 40.8~42.8

5.

Turn the tire to outward. Measure the scale of the turn

table.

Specified Value( ) : 30.8~32.8

KMTPA383A

FRONT AXLE
SIDE SLIP
Before checking the side slip, complete the inspection of
the wheel alignment.
1.

Set the front wheel along with the straight direction.

2.

Maintaining the position of the front wheel to the

straight direction, drive the vehicle on the slip tester
slowly.
CAUTION
With maintaining the position of the front wheel to
the straight direction, pass through the side slip
tester thoroughly. Do not turn the wheel or do not
fall off from the tester.

3.

The value indicated on the tester is the side slip. If

the side slip excesses the specified value, the wheel
alignment should be adjusted.

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

PA -51

PA -52

PROPELLER SHAFT AND AXLE

REAR AXLE
WHEEL HUB
COMPONENTS

EC1D3DFC

19

1
18

5
9
8

304~082 14
(31~39, 224~282)

10
11

13
15

6
7~11 (0.7~1.1, 5~8)

98~117
(10~12, 72~87)
2

17
16

12

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

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

EMTPA5027A

REAR AXLE
REMOVAL
1.

PA -53
3.

E01EC3FB

Place the wooden block (A) at the front and rear sides
of the front wheel.

After taking off the wheel nut (A), remove the wheel
and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (D) is not damaged.

A
KCOWT5007A

2.

Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand (B).

A
B

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 hub
bolts (A) into the removing screw holes (C) evenly.

A
KCOWT5008A

B
C
A

KMTPA404A

PA -54
5.

PROPELLER SHAFT AND AXLE

Remove the oil seal (A).

7.

Using the special tool (09527-47000), remove the lock

nut (A).

A
A

KMTPA405A

6.

Loosening the tightening bolt (A) for the lock nut, remove the lock washer (B).

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 not
drop down to the ground.

A
B

KMTPA406A

KMTPA408A

REAR AXLE
DISASSEMBLY
1.

PA -55
2.

E582AF4B

Tapping evenly the three notch parts on the hub inner

surface with a brass bar, removing the oil seal (A), the
inner bearing (B) and the inner bearing race (C).

Tapping evenly the three notch parts on the other side

hub inner surface with a brass bar, removing the outer
bearing race (A).

C
A
B
A
KMTPA410A

KMTPA409A

3.

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

NOTE
When using a brass bar, do not tap except the notch
parts (A) located inside of the hub.

C
B

KMTPA411A

KMTPA420A

PA -56

PROPELLER SHAFT AND AXLE

INSPECTION
1.

E55267A1

Check that the rotation state is proper after installing

the bearing(B) to the bearing race(C). If it has been
adhered, worn or defective in rotation, replace the
bearing and the bearing race (C) in a set.

C
B

C
KMTPA411A

2.
A

By tapping evenly, install the inner bearing race (B)

and the outer bearing race (C) at the wheel hub (A).

KMTPA409A

2.

If the hub bolt is worn or corroded, remove the hub

bolt from the wheel hub and replace it.

REASSEMBLY
1.

E2E5EAF5

Installing the drum (C) to the wheel hub (B), tighten

the hub nut (A).

CAUTION
After tightening the hub nut (A), at least 4 portions
of the groove parts of the stud should be calked.
Tightening Torque : 304~382 Nm (31~39
Kgfm, 224~282 lb-ft)

KMTPA412A

REAR AXLE
3.

PA -57

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

5.

CAUTION

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

The bearing should be a set with the bearing

race.
Replace the oil seal (C) with new ones after
removal.

The bearing should be a set with the bearing race.

A
B

B
C
KMTPA408A

6.
KMTPA413A

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

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 kgfm, 72~94 lb-ft). After that, loosen the
nut fully.
b. Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 29~39 Nm (3~4
kgfm, 22~29 lb-ft).

b
a

B
A

KMTPA211A

PA -58
7.

PROPELLER SHAFT AND AXLE

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)

9.

Install the oil seal (A).

CAUTION
Use a new oil seal (C) always.

B
A

KMTPA415A

8.

Just before the wheel hub (A) is moving, measure the

tangential force using a spring gauge (B). Calculate
the starting torque by multiplying the tangential force
to the radius.

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

KMTPA405A

10. After installing the axle shaft (B), tighten the hub bolt
(A) with specified torque.
Tightening Torque : 98~117 Nm (10~12
Kgf.m, 72~87 lb-ft)

B
A

KMTPA212A

KMTPA416A

REAR AXLE

PA -59

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

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

C
A
KCOWT5007A

A
B

KMTPA403A

12. After removing the garage jack (A) supporting the axle
and the safety stand (B) supporting the frame, tighten
the wheel nut with the specified torque.
Tightening Torque : 539~588 Nm (55~60
Kgf.m, 398~434 lb-ft)

A
KCOWT5008A

PA -60

PROPELLER SHAFT AND AXLE

AXLE HOUSING
COMPONENTS

E116ADC2

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

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

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

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

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

1. Drain Plug
2. Oiling Plug
3. Nut
4. Bolt

5. Reduction and Differential Assembly

6. Nut
7. Rear Axle Housing

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

EMTPA5028A

REAR AXLE
DISASSEMBLY
1.

PA -61
3.

ECFFC067

Place the wooden block (A) at the front and rear sides
of the front wheel.

After taking off the wheel nut (A), remove the wheel
and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (D) is not damaged.

A
KCOWT5007A

2.

Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand (B).

A
B

KMTPA403A

4.

As the same method with the 2~3 steps, remove the

opposite side wheel and tire.

5.

Support the both hub with a jack (A).

A
KCOWT5008A

KMTPA501A

PA -62
6.

PROPELLER SHAFT AND AXLE

Making an align mark (C) to the rear axle companion

flange (A) and the flange yoke (B) of the rear propeller
shaft, remove the tightening bolt (D) of the propeller
shaft.

8.

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

KCOPA5012A

9.

After taking off the tightening nut (A) of the U-bolt,

remove the U-bolt (B).
B

KMTPA113A

7.

After removing the brake line (A), remove the brake

hose clip (B).
NOTE
If the brake line is rubber hose, remove it after
biting it with vise pliers.
If the brake line is steel pipe, remove the line with
pressing the brake pedal.
A
A

KCOPA5013A

KCOPA5011A

REAR AXLE

PA -63

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

2.

Setting the center bolt (A) of the leaf spring to the

center hole (B) of the axle housing, lift up the axle
housing (C) completely.

B
A

A
C
A

KCOPA5014A

3.

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

KMTPA505A

REASSEMBLY
1.

Tightening Torque : 226~255 Nm (23~26

kgfm, 166~188 lb-ft)

E7E5E580

After positioning the axle housing (B) at the rear side

of the vehicle, lift up the jack (A) supporting the both
hubs slowly.

A
KCOPA5013A

KMTPA505A

PA -64
4.

PROPELLER SHAFT AND AXLE

After installing the shock absorber (A), tighten the

shock absorber tightening bolt (A) with the specified
torque.

Tightening Torque : 26~33 Nm (2.7~3.4

kgfm, 20~25 lb-ft)

6.

Setting the align marks (C) of the rear axle companion

flange (A) to the flange yoke (B) of the rear propeller
shaft, install the tightening bolt (D) of the propeller
shaft.

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

KCOPA5012A

5.

After installing the brake hose clip (B), install the brake
line (A).
KMTPA113A

NOTE
If the brake line is rubber hose, remove the vise
pliers after installing the line.
If the brake line is steel pipe, release the brake
pedal after installing the line.

7.

Remove the jack (A) supporting the both hub.

Tightening Torque : 25~29 Nm (2.5~3.0

kgfm, 18~22 lb-ft)

KCOPA5010A

KCOPA5011A

REAR AXLE
8.

PA -65

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

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

C
A
KCOWT5007A

11. Bleed the brake system. (Refer to the "Air Bleeding

of BR Group")

KMTPA403A

9.

After removing the garage jack (A) supporting the axle

and the safety stand (B) supporting the frame, tighten
the wheel nut with the specified torque.

Tightening Torque : 539~588 Nm (55~60

kgfm, 398~434 lb-ft)

A
KCOWT5008A

PA -66

PROPELLER SHAFT AND AXLE

DIFFERENTIAL CARRIER
ASSEMBLY
COMPONENTS

EB41F3DE

25

32
29

30

B
33

26

31

27

36
69~78
(7~8, 51~58)

35
34
28 20~26.4 (2~2.7, 14~20)
24

16

23
21
20

14
3 4

15

11

12

13

17

18

19

10

2
9
1
373~471
(38~48, 275~347)

22

A, B : ONLY D3H, DO33H

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

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

EMTPA5029A

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL
1.

PA -67
4.

E81090E0

After removing the drain plug(A), drain out the gear

oil.

Making an align mark (C) to the rear axle companion

flange (A) and the flange yoke (B) of the rear propeller
shaft, remove the tightening bolt (D) of the propeller
shaft.

KMTPA113A

KMTPA610A

2.

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

5.

Disassemble the contacting surface between the rear

axle companion flange (A) and the flange yoke (B) of
the rear propeller shaft.

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

CAUTION
As this part is very heavy, be careful the precautions. Before the working, be sure that it is supported by jack.

A
B

KMTPA611A

3.

Remove the axle shaft at the opposite side also.

KMTPA613A

PA -68
6.

PROPELLER SHAFT AND AXLE

After taking off the differential carrier tightening bolt

and nut (A), remove the differential carrier assembly
(B) from the axle housing (C).

2.

Setting the aligning mark (C) of the rear axle companion flange (A) to that of the flange yoke (B) of the
rear propeller shaft, tighten the bolt (D) of the propeller
shaft.

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

B
A

KMTPA614A

INSTALLATION
1.

E01F0B5B

After installing the differential carrier assembly (B) to

the axle housing (C), tighten the differential carrier
tightening bolt (A) with the specified torque.

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

KMTPA113A

3.

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

Tightening Torque :
98~118 Nm (10~12 kgfm, 72~87 lb-ft)

B
A

KMTPA614A

KMTPA611A

DIFFERENTIAL CARRIER ASSEMBLY

PA -69

4.

Install the rear axle shaft of the opposite side.

5.

Fill in the recommended oil.

Recommended Oil: API GL-5, SAE 80W/90

API GL-5, SAE 140W/For tropical region
Oil Amount: 4.50.25

ECOPA5014A

3.

Runout on the Back of the Final Drive Gear

Measure at the maximum diameter position.

KCOPA5031A

INSPECTION
1.

E2605DE5

Backlash between the Differential Gear and Differential Pinion

ECOPA5015A

4.

Final Drive Gear Tooth Contact

Apply a light coat of red lead to three or four teeth, turn
the gear several turns and check tooth contact using
paper
C

ECOPA5013A

2.

Backlash between the Final Drive Gear and Final

Drive Pinion
Measure on the final drive gear circumference at
about three points.

ECOPA5016A

PA -70
5.

PROPELLER SHAFT AND AXLE

Rear Axle Shaft and Differential Gear Spline Play in

Turning Direction.

DISASSEMBLY
1.

E8436EF3

Fix the differential carrier (A) at the vise or the working

base.

Rear axle shaft

A
Play

ECOPA5017A

6.

Rear Axle Housing Bend

Support horizontally the housing spindle at the inner
bearing engagement section at both ends by Blocks.
For measurement of A, apply a dial gauge to the outer
bearing engagement section and turn through 360 degrees.
For measurement of B1 and B2, use a square to position the housing squarely and measure B1. Then,
turn through 180 degrees and measure B2.
Replace if the measured value exceeds the limit. In
the case of bend of the spindle section (measurement
of A), however, the spring seat of the housing may be
corrected by a hydraulic press.

KMTPA701A

2.

Remove the differential carrier bearing cap bolt (A).

KMTPA702A

B1 or B2

V-block

3.

After removing the bearing cap(A), remove the side

bearing nut (B).

Square

A
Measuring point
ECOPA5018A

KMTPA703A

DIFFERENTIAL CARRIER ASSEMBLY

4.

PA -71

Remove the differential carrier assembly (A) and the

side bearing race (B) from the differential carrier collar
(C).

8.

Remove the self locking nut (A) and the companion

flange (B).

A
B

B
C

A
KMTPA708A
KMTPA704A

5.

After removing the side bearing (A), remove the differential case bolts (B).

9.

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

A
B

B
A

KMTPA709A
KMTPA705A

6.

After removing the differential case, remove the differential pinion, the differential pinion washer, the differential gear, the differential gear washer and the differential spider, sequentially.

7.

After taking off the tightening bolt of the drive gear,

disassemble the differential case and the driver gear.

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

B
A

KMTPA710A

PA -72

PROPELLER SHAFT AND AXLE

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

3.

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

B
A

B
A
C

KMTPA709A

KMTPA711A

4.

REASSEMBLY
1.

E3C241A6

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

Install the companion flange and the self locking nut

(A).

Tightening Torque : 373~471 Nm (38~48

kgfm, 275~347 lb-ft)

B
A

C
B
A
KMTPA711A
KMTPA708A

2.

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

5.

After assembling the differential case and the drive

gear, install the drive gear tightening bolt.

Tightening Torque : 226~265 Nm (23~27

kgfm, 166~195 lb-ft)
6.
B
A

KMTPA710A

After installing the differential pinion, the differential

pinion washer, the differential gear, the differential
gear washer and the differential spider, install the differential case.

DIFFERENTIAL CARRIER ASSEMBLY

7.

PA -73

After installing the differential case bolt (A), install the

side bearing.

9.

After installing the side bearing nuts (B), install the

bearing cap (A).

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

A
B

KMTPA705A

8.

Install the differential carrier assembly (A) and the

side bearing race (B) at the differential carrier collar
(C).

A
B

KMTPA704A

KMTPA703A

PA -74

PROPELLER SHAFT AND AXLE

ADJUSTMENT
1.

TYPES OF REAR BEARING SHIMS

EDD76B0F

Thickness(mm)

Setting of Starting Torque

0.30
NOTE

1.38

Do not mount front and rear bearing shims, pinion

spacer and oil seal.

1.41
1.44

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

1.47
1.50

Pinion gage

Measurement of
starting torque

1.53
1.56
1.59
1.62

Temporarily installed parts

Rear bearing inner race
Rear bearing outer race
Oil stopper
Front bearing outer race
Front bearing inner race
Propeller shaft joint
Lock nut

1.65

Cylinder gage

ECOPA5019A

2.

Pinion Height Adjustment

With the parts as assembled for setting of the starting
torque, measure clearance A (see illustration) with a
thickness gauge.

Shim thickness A tolerance when assembled : 0.05mm

ECOPA5020A

According to the measured clearance A, select the

rear bearing shim.
Thickness of rear bearing shim = A - 0.3

3.

Adjustment of Starting Torque

Mount the selected rear bearing shim with pinion
spacer and front bearing shim and tighten the lock
nut to specified torque. Find the pinion spacer and
front bearing shim that give the nominal starting
torque when so tightened.
Select such pinion spacer that reduces the required
number 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 that
the 0.3 mm thick shim is installed on the bearing
end.
Oil seal must not be installed.
Types of pinion spacers Yellow paint applied.

DIFFERENTIAL CARRIER ASSEMBLY

PA -75

TYPES OF FRONT BEARING SHIMS

Thickness(mm)
0.30

Differential gear spacer

2.33
2.30
2.27
2.24
2.21
2.18
2.15
ECOPA5022A

2.12
5.

2.09
2.06
2.03
2.00

Measurement of starting torque

Rear bearing shim

(selected one)
Front bearing shim
Pinion spacer
Pinion gauge

Adjustment of Backlash between Final Drive Gear and

Final Drive Pinion
Install the differential assembly in the carrier and partially tighten by the bearing cap. Adjust the side bearing nut for nominal backlash.
After adjustment, further tighten the side bearing nut
to the extent that the backlash does not exceed the
nominal value in order to preload the side bearing. At
this time, keep the sum of additional tightening of the
right and left side bearing nuts to within one notch of
lock plate hole.
After adjustment, line up with the bearing cap alignment mark and tighten to specified torque.
NOTE
When the side bearing nut on one side is loosened,
be sure to tighten the side bearing nut on the other
side by the same amount.

Lock nut
380 to 480 Nm (38 to 48 kgf.m)

ECOPA5021A

4.

Adjustment of Backlash between Differential Gear

and Differ-ential Pinion
NOTE
Use spacers of same thickness on both sides.

TYPES OF DIFFERENTIAL GEAR SPACER

Thickness(mm)

Differential side
bearing adjustment tool

1.4
1.5
1.6

ECOPA5023A

PA -76

PROPELLER SHAFT AND AXLE

7.

Tooth Contact Adjustment of Final Drive Gear

Apply light coat of red lead to three or four teeth and
turn several times to check tooth contact.
If tooth contact is very poor, increase or decrease the
rear bearing shim(s) and backlash to adjust to correct
tooth contact.
In case the gear is to be replaced due to excessive
tooth wear, be sure to replace the final drive gear and
final drive pinion as a gear set.
C

ECOPA5014A

6.

Runout on Back of final Drive Gear

Measure at the maximum diameter position.

ECOPA5016A

ECOPA5015A

ABNORMAL FINAL DRIVE GEAR TOOTH CONTACT AND ITS CAUSE

Correct tooth contact

Cause

Face contact
Backlash too large,
worn gear

Flank contact

Toe contact

Heel contact

Backlash too small

Incorrect pinion
height

Incorrect pinion
height

ECOPA5024A