Replacement

Front Hub, Axle And Swivel Components:

REMOVE STUB AXLE, AXLE SHAFT AND CONSTANT VELOCITY JOINT
1. Remove front hub assembly, refer to Transmission and Drivetrain
2. Drain swivel pin housing and install plug.





3. Remove six bolts retaining stub axle to swivel housing.
4. Remove mud shield.
5. Remove stub axle and joint washer.





6. Pull out axle shaft and constant velocity joint from axle casing.

REMOVE CONSTANT VELOCITY JOINT FROM AXLE SHAFT
7. Hold axle shaft firmly in a soft jawed vice.





8. Using a soft mallet drive constant velocity joint from shaft.
9. Remove circlip and collar from axle shaft.

CONSTANT VELOCITY JOINT





10. Mark positions of constant velocity joint, inner and outer race and cage for reassembly.
11. Swivel cage and inner race to remove balls.
12. Examine all components in particular inner and outer track, cage balls and bearing surfaces for damage and excessive wear.
13. Maximum acceptable end-float on assembled joint 0.64 mm.
- Renew if worn or damaged.
- Lubricate with a recommended oil during assembly.

INSTALL CONSTANT VELOCITY JOINT TO AXLE
14. Install collar and a new circlip.





15. Engage constant velocity joint on axle shaft splines and using a soft mallet, drive joint in fully.

RENEW STUB AXLE,THRUST RING, OIL SEAL AND BEARING
16. Drill and chisel off thrust ring taking care to avoid damaging stub axle.





17. Remove bearing and oil seal using special tool LRT-37-004 and slide hammer LRT-99-004.
- Ensure lip of tool locates behind bearing to to drive it out.
18. Repeat instruction for removal of oil seal.





19. Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using special tool LRT-54-004.





20. Using special tool LRT-54-005, install bearing with its part number visible when installed, and flush with end face of stub axle.
21. Press install a new thrust ring onto stub axle.

SWIVEL PIN HOUSING ASSEMBLY
22. Remove brake disc shield bracket.
23. Disconnect track-rod end ball joint from housing.
24. Disconnect drag-link ball joint.
25. Disconnect jump hoses from brake jump hose bracket.
26. Remove ABS brake sensor.
27. Remove six bolts securing oil seal and retaining plate to swivel pin housing.
- Pry seal from swivel pin housing.

NOTE: Oil seal and retaining plate cannot be removed until swivel pin bearing housing is removed.

28. Remove two screws securing brake damper/shield bracket, and lower swivel pin to housing.
29. Withdraw lower swivel pin and joint washer by tapping protruding lug.
30. Remove top swivel pin retaining bolts complete with brake jump hose bracket.
31. Remove top swivel pin and shims.
32. Remove swivel pin housing while retrieving lower taper bearing.

SWIVEL PIN BEARING HOUSING
33. Remove seven bolts securing swivel pin bearing housing to axle case.
34. Remove and discard oil seal and joint washer.
35. Remove lower swivel pin bearing race.
36. Remove top swivel pin bush housing assembly.
- Discard two thrust washers and bearing.
37. If worn, pitted or damaged, renew swivel pin bearing housing.
38. Install a new lower swivel pin bearing race.





39. Install a new bush and bush housing.
- Ensure relieved lip of bush housing faces towards rear, as shown.
40. With seal lips trailing press axle shaft oil seal flush into rear of housing.
- Grease lips.
41. Install new thrust washers and bearing into top swivel pin bush.
42. Hang swivel pin bearing housing oil seal and retainer plate over back of housing.
- Ensure they are in correct assembly order.
43. Install a new joint washer and secure swivel pin bearing housing to axle.
- Starting with top fixing dowel bolt.
- Tighten to 72 Nm.

INSTALL SWIVEL PIN HOUSING
44. Grease and install lower swivel pin bearing to bearing housing.
45. Place swivel pin housing in position over swivel pin bearing housing.
46. Using a new joint washer, install lower swivel pin with lip outboard.
- Do not secure with screws at this stage.
47. Install a new sensor bush and new oil seal, lip side leading to top swivel pin.
48. Lubricate with a recommended oil and install top swivel pin with existing shims.
49. Coat threads of top swivel pin bolts with Loctite 542.
- Install bolts and jump hose bracket (do not tighten).
50. Coat threads of lower swivel pin screws with Loctite 270 and install, together with damper and shield bracket.
- Tighten to 25 Nm.
51. Tighten top swivel pin and brake jump hose bracket securing bolts to 65 Nm.

CHECK AND ADJUST PRELOAD ON BEARINGS





52. The preload on bearings to be 0.25 to 0.30 mm, without swivel housing oil seal and axle installed, and reading from center of swivel pin.
- The torque required to turn swivel assembly from lock to lock to be 2.0 to 2.8 Nm.
- Adjust by removing or adding shims as necessary.
53. To take a reading use special tool LRT-57-024 torque test adaptor, with a torque wrench and extension as shown.
54. Apply a recommended- grease between lips of swivel housing oil seal.
55. Secure oil seal with retaining plate and securing bolts.
- Tighten to 11 Nm.
56. Install track-rod and drag link and secure with new cotter pins.
57. Loosely install lock stop bolt for later adjustment.
58. Install brake disc shield.

INSTALL DRIVESHAFT AND STUB AXLE
59. Insert axle shaft, and when differential splines are engaged, push assembly in fully.

CAUTION: Take care not to damage axle shaft oil seals.

60. Place a new joint washer in position on swivel pin housing to stub axle mating face.
- Coat threads of stub axle bolts with Loctite 270.
61. Install stub axle with flat at 12 o'clock position.

CAUTION: Ensure that constant velocity joint bearing journal is butted against thrust ring on stub axle, before stub axle is secured.

62. Place mud shield in position and secure stub axle to swivel pin housing with six bolts and tighten evenly to 65 Nm.
63. Install brake jump hoses to brake jump hose bracket.
64. Install front hub complete assembly.
65. Check swivel pin housing oil drain plug is installed.
66. Fill swivel assembly to correct level, with 0.35 liters (0.75 US pint) of new API GL5 or MIL-L-2105 90W EP gear oil.
67. Set steering lock stop bolts to provide a clearance of 20 mm, refer to Suspension and Steering
68. Install ABS brake sensor, refer to Brakes and Traction Control.