Removal

FRONT SUSPENSION: FRONT SUSPENSION MEMBER: REMOVAL

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. SECURE STEERING WHEEL Removal

3. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

4. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

5. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

6. REMOVE FRONT WHEELS

7. REMOVE NO. 1 ENGINE UNDER COVER

8. REMOVE FRONT NO. 3 ENGINE UNDER COVER

9. REMOVE REAR ENGINE UNDER COVER LH

10. REMOVE REAR ENGINE UNDER COVER RH

11. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

(a) Remove the nut and separate the front stabilizer link assembly LH from the front stabilizer bar.





HINT
If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt.

12. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

13. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

14. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

15. SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH Removal

16. SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

17. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

(a) Remove the 4 bolts and rear side rail reinforcement sub-assembly LH.





18. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

19. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY

(a) Using a transmission jack and wooden blocks, support the engine assembly with transaxle.





Text in Illustration





(b) Remove the 2 bolts and separate the front cross member sub-assembly from the front engine mounting insulator.





(c) Remove the 4 bolts and front cross member sub-assembly.





20. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

(a) Remove the 3 bolts, clip and front suspension member rear brace LH.





21. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

HINT
Perform the same procedure as for the LH side.

22. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the 2 bolts and 2 nuts, and separate the front suspension crossmember sub-assembly from the rear No. 1 engine mounting insulator.





(b) Using a transmission jack, support the front suspension crossmember sub-assembly.





(c) Remove the 2 bolts and front suspension crossmember sub-assembly.





23. REMOVE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH

(a) Remove the 2 bolts, nut and front No. 1 lower suspension arm sub-assembly LH from the front suspension crossmember.





NOTICE:
Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

24. REMOVE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

25. REMOVE FRONT SUSPENSION MEMBER FRONT BRACE Removal

26. REMOVE FRONT STABILIZER BAR

(a) Remove the front stabilizer bar with front stabilizer bar bushings from the front suspension crossmember sub-assembly.





27. REMOVE STEERING LINK ASSEMBLY Removal

28. REMOVE CAB REAR MOUNTING LOWER SPACER

(a) Remove the 4 cab rear mounting lower spacers from the front suspension crossmember sub-assembly.

29. REMOVE CAB REAR MOUNTING CUSHION

(a) Remove the 4 cab rear mounting cushions from the front suspension crossmember sub-assembly.

30. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER

(a) Remove the front suspension member body mounting front stopper from the front suspension crossmember sub-assembly.





31. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER

(a) Remove the front suspension member body mounting rear stopper from the front suspension member rear brace.





32. REMOVE FRONT UPPER BODY MOUNTING CUSHION

(a) Using a chisel and hammer, bend the flange of the front upper body mounting cushion as shown in the illustration.





(b) Apply lubricant to the contact surface of the front upper body mounting cushion.

(c) Using SST, slightly lower the front upper body mounting cushion.

SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00300





(d) Apply lubricant to the contact surfaces between the front upper body mounting cushion and front suspension crossmember sub-assembly.

(e) Repeat the above 2 steps and remove the front upper body mounting cushion.

NOTICE:
* Be careful when removing the cushion because it may unexpectedly pop out.
* Do not reuse the front suspension member body mounting front cushion.

33. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION

(a) Apply lubricant to the contact surface of the front suspension member body mounting rear cushion.

(b) Position and firmly secure SST as shown in the illustration.

SST : 09710-28031

09711-02030

09711-02040

94622-51200

SST : 09950-40011

09951-04020

09952-04010

09954-04010

09955-04031

SST : 09950-60010

09951-00320





(c) Using SST, slightly lower the front suspension member body mounting rear cushion.

(d) Apply lubricant to the contact surface between the front suspension member body mounting rear cushion and front suspension crossmember sub-assembly.

(e) Repeat the above 2 steps and remove the front suspension member body mounting rear cushion.

NOTICE:
* Be careful when removing the cushion because it may unexpectedly pop out.
* Do not reuse the front suspension member body mounting rear cushion.