92Rocky-FS-Front_Axle_and_Suspension-Part1
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PART 1 - PART 2 - PART 3 - PART 4 - PART 5 - PART 6 - PART 7 - PART 8 - PART 9 - PART 10 - PART 11
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DAIHATSU Ro c ky
FRONT AXLE & SUSPENSION
OUTLINE OF FRONT AXLE &
SUSPENSION FS- 2 WHEELS & TIRES FS- 17 FRONT WHEEL ALIGNMENT FS- 21 _ FRONT SUSPENSION COMPONENTS FS- 28 FRONT AXLE HUB FS- 29 STABILIZER BAR FS- 55 TORSION BAR SPRINGS FS- 60 FRONT SHOCK ABSORBERS FS- 68 UPPER ARMS FS- 72 STEERING KNUCKLES FS- 79 DRIVE SHAFTS FS- 88 LOWER ARMS FS- 97 UPPER & LOWER BALL JOINTS FS-102
WRU90-FS001
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FRONT AXLE & SUSPENSION
OUTLINE OF FRONT AXLE & SUSPENSION
FRONT AXLE
0 The driving force from the engine is transmitted to the drive shafts at the right and left sides vias the transmission, transfer, front propeller shaft and front differential, finally reaching the front hub nneshed with the spline provided at the forward end of each drive shaft. Consequently, the tires are driven. ¢ The drive shaft employs a full floating type in which the vehicle weight is sustained by means of two tapered roller bearings located between the front axle hub and the steering knuckle. Hence, no vehicle weight is applied to the drive shaft. ~ The forward section of the front axle hub adopts two types, depending upon the vehicle type: the rigid
type and the locking hub type. Furthermore, the locking hub comes in two kinds: the manual locking hub mechanism and the automatic locking hub mechanism. This mechanism makes it possible to reduce a mechanical loss which will be generated when the power
from the front wheel drives the front differential and transfer during two wheel drive.
WRUQO-FSO02
Table of front axle hubs
e) I Manual locking hub | Automatic locking hub
Disc
Front axle hub
Rigid TYPE
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Disc
Front axle hub
1 1 1
1 Manual locking hub-equipped vehicle
Free wheel hub assembly
Free Wheel hub cover subassembly
Disc
Front axle hub ,
Automatic locking hub assembly
Automatic locking hub cover subassembly
Automatic locking hub-equipped vehicle
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FRONT AXLE & SUSPENSION
1. MANUAL LOCKING HUB ' The manual locking hub is a mechanism whereby the switching of power flow is made so that the driving force from the front drive shaft can be transmitted to the front wheel or the torque from the front wheei can not be transmitted to the front drive shaft, etc. and this switching is performed through the operation of the handle provided at the front Wheel hub.
WRUQO-FSOO5
How to operate o When the transfer shift lever is shifted tothe position, set the locking hub handie to the [FREE] position at both the right and ieft Wheels. When the transfer shift lever is shifted to the [4H] or
position, set the looking hub hanolie to the [LOCK] position at both the right and left wheels. CAUTION: FREE / 1. Do not move the vehicle if the handle (A mark) is not aligned exactly with the V mark at the “Free” or “Lock” position on the cover. 2. Do not operate the vehicle in 4L or 4H when the hub
handle is set at the “Free” position. 3. Make save to set the handle (A mark on the both the
right and left wheels at the same position.
WRUQO-F8006
Construction ~ The manual looking hub (manual free wheel hub assembly) consists of the free wheel hub body, free wheel hub inner, free Wheel hub rlng sub assembly, free Wheel hub clutch, free wheel hub handle, follower and so forth. V o The tree Wheel hub inner is spline-connected to the drive shaft. On the other hand, the free Wh-eel hub body is mounted on the front wheel hub. Furthermore, its inside is spline-connected to the free wheel hub clutch. The free wheel hub clutch is attached to the free wheel hub handle by means of the follower and two
springS
Front Wheel hub Free wheei hub body
,ul Z free wheel hub clutch V
Free wheel hub ring subassembly
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FRONT AXLE & SUSPENSION
Operation LOCKING HUB HANDLE (FREE WHEEL HUB HANDLE) WHEN SET TO [FREE] POSITION When the free wheel hub handle is set to the [FREE] position, the free wheel hub clutch comes at the outermost position on the spline of the free vvheel hub body (at the extremely right position in the figure below), where no driving force from the drive shaft is transmitted to the front wheel hub.
o LOCKING HUB HANDLE (FREE WHEEL HUB HANDLE) WHEN SET TO [LOCK] POSITION When the free wheel hub handle is turned from the [FREE] position to the [LOCK] position, the iollower moves toward the inside (toward the left side in this figure) along the diagonal groove provided inside the free wheel hub handle. As a result, the free wheel hub clutch which is attached to the follower by means of springs will move toward the inside along the spline of the free wheel hub body. This operation causes the free wheel hub clutch to mesh with the spline ot the free wheel hub inner. Consequently, the driving force from the drive shaft is transmitted to the front wheel hub.
Free wheel hub clutch
Foilower
Free wheel hub inner
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FRONT AXLE & SUSPENSION
2. AUTOMATIC LOCKING HUB The automatic locking hub is a mechanism whereby the switching of power flow is made automatically so that the driving force from the front drive shaft can be transmitted to the front wheel or no driving force can not be transmitted to the front wheel when the transfer lever is shifted from the position to the [4H] position or the position and the vehicle is run.
WRU90~FSO10
How to operate 1. [FREE] STATE TO [LOCK] STATE
(1) With the vehicle in a stationary state, shift the transfer shift lever from the [ZH] position to the [4H] position or the position. (2) With the steering wheel set to a straight-ahead position,
siowiy move off the vehicle and run it approximately ` more than 3 meters. Then, the vehicle is put automat- M J ieaiiy under the [LOCK] eondmon. _:J
NOTE: o When the vehicle runs in a direction opposite to the former direction before stopping (forward movement <->
backward movement) after the vehicle has been run with / L the transfer shift lever placed in the or [4L] position 1| and with the automatic locking hub set to the [LOCK] 1] ' state and the vehicle has been stopped, the automatic /0
locking hub will be switched from the [LOCK] state to the i
locking hub will be switched from the [LOCK] state to the £1/ * [FREE] state and will become the [LOCK] state again.
Run vehicle about 3 meters.
2. [LOCK] STATE TO [FREE] STATE
(1) With the vehicle in a stationary state, shift the transfer
shift lever from the [4H] or [4L] position to the < position. (2) With the steering wheel set to a straight-ahead position,
slowly move oft the vehicle in a direction opposite to the , former direction before the switching to [ZH] position former direction before the switching to [ZH] position I Q9 I Q and run the vehicle approximately more than 3 meters. Then, the vehicle is put automatically under the [FREE] condition.
WRU90-FS013
NOTE: o If the vehicle is moved off in the same direction as the former direction before the switching to the [ZH] position in the operation described in Step (2) above, the vehicle I / / will run under the [LOCK] lock state continually. U
N
Run vehicle approximately 3 meters in a direction opposite to former direction before switching to
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FRONT AXLE & SUSPENSION
Han_dlir_|g Instructions on Automatic Locking Hub Appmation of
Avoidance of Ratcheting Phenomenon i pam
. _ _ i (8 mm cha.) The ratcheting phenomenon means a gear clashing noise _-,;,\-_.........= which occurs when the automatic locking hub clutch (D _ meshes with the automatic locking hub body if there exists Automatic
When such phenomenon occurs, first stop the vehicle. WHYWWJ Subassemmy
off the vehicle straight. Then, proceed to drive the vehicle C: wRU9o-Fsaoo Prohibition of shifting operation of transfer during running If the transfer should be shifted from the 2WD to the 4WD during the running, the aforesaid ratcheting phenomenon would occur. Hence, do not shift the transfer during the running.
Observance ot driving straight immediately after transfer shifting When the automatic locking hub is shifted from the Free position to the Lock position, first stop the vehicle. Then, be certain to move off the vehicle with the steering wheel held in a straight-ahead state and run the vehicle at least 3 meters under this state. If the steering wheel should be turned before the vehicle has been run at least 3 meters, one hub of the automatic locking hubs at the right and left sides may be locked and the other hub may become free, thereby causing the ratcheting phenomenon to occur.
Avoidance of sudden moving off If the vehicle should be moved off suddenly after the transfer has been shifted from the 2WD to the 4WD, the ratcheting phenomenon might occur. Hence, make sure to avoid moving the vehicle suddenly.
Shifting of transfer during running on muddy terrain if you want to get the vehicle out from a muddy terrain or on snowy roads or the like by shifting the transfer from the 2WD to the 4WD while the rear wheels are slipping on these roads, perform the locking slowly, using the half clutch so as to prevent the occurrence of ratcheting phenomenon.
Observance of driving vehicle under 4WD mode during extremely cold climate [below - 15°C If the vehicle should be run under the 2WD mode with the automatic locking hub in the free state, the vehicle may assume the 4WD mode owing to high viscosity of the transfer oil. Consequently, the ratcheting phenomenon may occur. Therefore, during extremely cold climate, drive the vehicle under the 4WD mode until the warming-up is completed.
WRUQO-F8401 Handiing during extremely cold climate [below - 15°C There are many instances where the automatic locking hub fails to become free when the automatic locking hub is in the locked state and you try to unlock it by shifting the transfer shift lever to the 2WD position and by driving the vehicle reversely. This is because the viscosity of the transfer oil is too high. Hence, be certain to drive the vehicle under the 4WD mode until the warming-up is completed. ln this case, after completion of the warming-up operation, shift the transfer from the 4WD to the 2WD.
Do not s.oiI or wipe off the grease that has been applied to the automatic locking hub brake subassembiy. Failure to observe this caution makes it impossible to reuse the brake subassembly.
WRUQO-FS402
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FRONT AXLE & SUSPENSION
Construction i The automatic locking hub assembly consists of the automatic locking hub lock nut, automatic locking hub brake drum. automatic locking hub brake subassembly, outer cam, inner cam, automatic locking hub body, clutch and so forth. - The inside ofthe automatic locking hub inner is spline- connected to the front drive shaft. On its outside are mounted the clutch and so forth. On the other hand, the automatic locking hub body is mounted on the front wheel hub. Furthermore, the inside of the automatic locking hub body is provided with spline so that it may connected with the clutch. 0 On the clutch are attached the toilovver, two springs, inner cam and outer cam. ~ The automatic locking hub brake drum is attached to the hub lock nut with screws.
:imununnnnnnL g 'i/Automatic locking hub inflef
Z Preset spring 12 Clutch
Jac
Follower '
Automatic locking hub brake subassembly
Automatic locking hub lock nut Automatic locking hub brake drum
Clutch /
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FRONT AXLE & SUSPENSION
Operation o AUTOMATIC LOCKING HUB [FREE] STATE TO [LOCK] STATE When the drive shaft turns after the transfer shift lever has been shifted to the [4H] or [4L] position and the vehicle has been moved off, the automatic locking hub inner and follower which are connected with each other through spline will turn as an integral unit. (The follower is connected by means of the outer spline of the automatic locking hub inner.) On the other hand, the inner and outer cams tend to remain in their position because of the operation of the automatic locking hub brake subassembly. As a result, thefollower moves toward the outside while turning along withthe diagonal surface of the inner cam. (The follower moves toward the right side in the figure below.) Refer to Reference 1 in the following pages. When the follower moves toward the outside, the clutch, too, which is pushed by the spring tension, will move toward the outside. Thus, the clutch meshes with the inner spline of the automatic locking hub body, thereby transmitting the driving force from the drive shaft to the front tire via the front wheel hub. Moreover, the point where the automatic locking hub is locked corresponds to the point where the rotation of the follower is prevented by means of the outer cam (i.e. a point where the movement toward the outside is completed). Refer to Reference 2 in the following pages.
[Reference] When the locking of the automatic locking hub is completed, the outer cam rotates in the automatic locking hub brake drum, while sliding together with the automatic locking hub brake subassembly.
Inner cam Inner Cam I
Follower
Clutch
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FRONT AXLE & SUSPENSION
[Reference 1]
G) The inner and cuter cams have a pawl, respectively. Also, the automatic locking hub brake has an
involute- shaped pawl.
In the beginning of the [LOCK] phase, both the inner and inner cams are turning. Thus, their respective
expands because of its involute shape. Consequently, the friction relative to the automatic locking hub brake drum is on the increase. finallv stoooino the rotation of the i
rake drum is on the increase, finally stopping the rotation of the inner and outer cams.
The outer cam has two pawls; One pawl which functions relative to the automatic locking hub brake and
the other pawl which is located at the opposite side. When the follower makes contact with the latter pawl, the rotation of the follower is stopped.
