Table of contents: Hardtop Models and a station wagon…↓ Utility (Van) and Mini Truck Models…↓
Hardtop Models and a station wagon (Station Wagon)
Removal
1. Loosen the front wheel nuts.
2. Jack up the front of the car and place it on supports placed under the frame elements. Remove the front wheels.
3. Unscrew the drain plug and drain the oil from the front axle housing.
4. Mark the position of the front propeller shaft relative to the pinion flange and the front drive flange of the transfer case. Disconnect the propeller shaft and remove it from under the vehicle.
5. Loosen the clamp and disconnect the ventilation hose from the front axle housing.
6. Disconnect the brake pipe from the flexible brake hose, release the retaining clamp and release the hose from the support bracket. Plug the open ends of the pipe and hose to prevent dirt from entering the hydraulic brake system.
7. Remove the cotter pin and unscrew the crown nut securing the ball joint of the pendulum arm of the transverse steering rod to the steering knuckle. Release the pin of the ball joint from the steering knuckle by pressing the striker of a hammer to the back side of the ear of the connecting rod mount, and using a second hammer, strike from the opposite side. Using a piece of wire, tie the pendulum arm of the transverse steering rod to the left side member of the chassis.
8. Loosen the mounting nuts, remove the washers and disconnect the lower shock absorber mounts from the front axle housing.
9. Loosen the nut, remove the washer, then, using a lever, separate the transverse reaction rod from the axle housing. Tie the rod to the front suspension element using a piece of wire.
10. Remove the front coil springs.
11. Using two stands or jacks, support the bridge in a horizontal position.
12. Loosen the nuts and remove the bolts securing the axle housing to the trailing arms, then, with the help of an assistant, remove the axle from under the vehicle.
Installation
Installation is carried out in reverse order.
1. Place the front axle assembly in the installation position, then insert the trailing arm mounting bolts, but do not tighten the nuts at this stage.
2. Reinstall the coil springs, cross-bar and shock absorbers, but do not tighten the mounting nuts at this stage.
3. Connect the tie rod swing arm and tighten the castle nut to 46÷54 Nm. Insert a new cotter pin.
4. Install the driveshaft (sliding joint to the front axle). Make sure that the mounting marks applied during dismantling are correctly aligned. Tighten the fastening nuts and bolts with a force of 78÷88 Nm.
5. Connect the ventilation hose and brake pipe, bleed the hydraulic system.
6. Pour the required amount of oil of the required grade into the bridge housing.
7. Lower the vehicle to the ground and tighten to the required torque (see size and adjustment tables at the end of the Manual) by the force of the nuts securing the longitudinal levers, shock absorbers and transverse reaction rod.
Utility (Van) and Mini Truck Models (Cab Chassis)
Removal
1. Loosen the front wheel nuts.
2. Jack up the front of the car and place it on supports placed under the frame elements. Remove the front wheels.
3. Unscrew the drain plug and drain the oil from the front axle housing.
4. Mark the position of the front propeller shaft relative to the pinion flange and the front drive flange of the transfer case. Disconnect the propeller shaft and remove it from under the vehicle.
5. Loosen the clamps and disconnect the ventilation hose from the front axle housing.
6. Disconnect the brake pipe from the flexible brake hose, release the retaining clamp and release the hose from the support bracket. Plug the open ends of the pipe and hose to prevent dirt from entering the hydraulic brake system.
7. Loosen the mounting nuts, remove the washers and disconnect the lower shock absorber supports from the spring support plates.
8. Loosen the nuts and disconnect the struts from the anti-roll bar.
9. Remove the cotter pin and unscrew the crown nut securing the ball joint of the longitudinal steering rod to the connecting rod. Release the pin of the ball joint from the connecting rod by pressing the striker of a hammer to the back side of the connecting rod fastening ear and striking it with a second hammer from the opposite side. Using a piece of wire, tie the longitudinal rod to the left chassis side member.
10. Loosen the U-bolt nuts on the spring U-bolts and remove the support plates. Lower the front ends of the springs to the ground.
11. Support the front axle horizontally using two stands or jacks.
12. Loosen the fastening nuts and, supporting the springs, remove the plates and shackle pins from their front ends.
13. With the help of an assistant, remove the axle assembly from under the vehicle.
Installation
Installation is carried out in reverse order.
1. Ensure that the axle housing is correctly positioned on the central spring bolts.
2. Install the spring pins, bushings and shackle plates, but do not tighten the mounting nuts at this stage.
3. Install the U-bolts and spring U-bolt support plates, tighten the fastening nuts to 108÷147 Nm.
4. Install the anti-roll bar struts and tighten the mounting nuts to 20÷23 Nm.
5. Connect the longitudinal steering rod to the connecting rod, tighten the nut with a force of 88÷113 Nm and install a new cotter pin.
6. Connect the shock absorbers, but do not tighten the nuts at this stage.
7. Install the driveshaft (sliding joint to the front axle). Make sure that the mounting marks applied during dismantling are correctly aligned. Tighten the fastening nuts and bolts with a force of 78÷88 Nm.
8. Connect the ventilation hose and brake pipe, bleed the hydraulic system.
9. Fill the bridge housing with the required amount of oil of the required grade.
10. Lower the vehicle to the ground and tighten to the required torque (see size and adjustment tables at the end of the Manual) by tightening the nuts that secure the spring and shock absorber earrings pins.