SMCA520E01
SMCA520E01
SMCA520E01
MODEL
Pub.No. SMCA520E02
QUICK REFERENCE INDEX
GENERAL GE
TRUCK(Chassis) MAINTENANCE MA
SERVICE MANUAL TROUBLE DIAGNOSIS TD
CLUTCH SYSTEM CL
TRANSMISSION TM
PROPELLER SYSTEM PS
FOREWORD
This manual describes the service, by system, of DIFFERENTIAL DF
the chassis of medium duty trucks MK, LK, PK, CDA
and CWA series.
REAR AXLE AND SUSPENSION RA
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be performed
properly. Also, overhaul and repair should be effected FRONT AXLE AND SUSPENSION FA
in accordance with prescribed service standards.
This manual should be kept readily available in the
workshop as a helpful reference for those engaged in TIRE AND WHEEL TW
servicing vehicles. Nissan diesel Motor Co., Ltd.
reserves the right to make changes for improvement
at any time without notice. STEEERING SYSTEM ST
This manual is based on vehicles that were manu-
factured on or before March 1, 1998. Revisions, if
any, will be introduced in the Technical Bulletin. BRAKE SYSTEM BR
ELECTRICAL SYSTEM EL
CAB BODY CB
HEATER HE
AIR CONDITIONER AC
COUPLER CP
X A QUICK REFERENCE INDEX is provided on the first page: Refer to this index along with the index
of the particular section you wish to consult.
X The first page of each section lists the contents and gives the page numbers for the respective top-
ics.
X A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are
designed to assist you in performing repair safely, accurately and quickly.
X Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major compo-
nents, items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]
-1-
X Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part
name, and the number is determined according to the operation sequence.
No. 1, 2, 3 Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks “+” and “,” affixed to the part name number indicate that the key points of operation (pre-
cautions, technique, use of special tools, and other maintenance information) are explained in the text.
+Key points of disassembly
,Key points of reassembly
The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the
illustration.
NOTE
z Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.
-2-
X Removal and installation, disassembly and reassembly:
Explanation of removal and installation, disassembly and reassembly is limited to the parts indi-
cated by the star marks “+”and “,” affixed to the sequence number in the exploded illustration.
NOTE
z If there are no “+” and “,” marks affixed to the parts, general explanation is given for those
parts.
Abbreviations
MK series: MKA·B·C·D210 series and VAC brake: Vacuum servo brake
MKB212 AOH brake: Air over hydraulic brake
LK series: LKA·C·D210 series, LKB212 Air brake: Full air brake
and LKC212 O.D.: Outside diameter
PK series: PKA·B·C·F210, PKC310 I.D.: Inside diameter
series, PKB212 and PKC212 Dia.: Diameter
CDA series: CDA310 series S.T.D.: Standard
LH, RH: Left-Hand, Right-Hand O.S.: Oversize
R.H.D. model: Right-hand drive model U.S.: Undersize
L.H.D. model: Left-hand drive model Ass'y: Assembly
X Position:
X Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
X Specific terms related to the maintenance standard
z Maintenance standard
-3-
“Maintenance standard” indicates the standard clearance when parts are assembled or the standard
performances of assembly parts.
z Service limit
“Service limit” indicates the limit value where adjustment, correction or parts replacement must be
done.
X The captions WARNING and CAUTION warn you about procedures that must be followed to pre-
vent personal injury and/or damage to some parts of the vehicle.
-4-
- MEMO -
-5-
GE
GENERAL
CONTENTS
SPECIFICATIONS .............................. GE-1-1 GENERAL PRECAUTIONS ON
CHASSIS........................................GE-1-1 SERVICING ........................................ GE-5-1
IDENTIFICATION ............................... GE-2-1 TIGHTENING TORQUE OF
LIFTING POINTS................................ GE-3-1 STANDARD BOLTS ........................... GE-6-1
TOWING ............................................. GE-4-1 LUBRICATION ................................... GE-7-1
SPECIFICATIONS
SPECIFICATIONS
CHASSIS
Vehicle model
MKA210 MKB210
Item
Model FE6T FE6A FE6B FE6B FE6T FE6T
Engine Max. gross output (JIS) 135 118 119 132 135 151
kW {PS}/rpm {183}/3,000 {160}/3,000 {162}/3,000 {180}/3,000 {183}/3,000 {205}/2,800
CL207
CL130 CL130
(MHS60A)
(MHS50T) (MHS50T)
Unit name CL710 CL207 CL207 CL710 CL740
CL205 CL205
(MLS61A)
(MHS60A) (MHS60A)
(MLS62A)
Operated by: Air servo VAC servo Air servo Air servo
325 (12.80):
300 (11.81): CL130 CL207
Disc O.D. mm (in) 350 (13.78) 325 (12.80) 350 (13.78)
325 (12.80): CL205 350 (13.78):
CL710
MHS60A
Manual transmis- MHS50T MLS61A MLS61A
MLS61A MHS60A
sion MHS60A MLS62A NEW MLS62A
Unit name NEW MLS62A
Transmission
Automatic trans-
— — — —
mission
Operation Floor-shift Floor-shift
P/S - D/F PS860 PS860
Propeller shaft Unit name
D/F - D/F — —
Tire & wheel Tire size Refer to the “Tire and wheel size table” section.
Gear box Ball-nut type
Type Integral, power steering
Steering system
R.H.D. model — PMU-1487
Unit name
L.H.D. model PSI-Y85-7 PMU-1488
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-1
SPECIFICATIONS
Vehicle model
MKB210 MKB212 MKC210 MKD210
Item
Model FE6TA FE6TA FE6T FE6T FE6A FE6B
Engine Max. gross output (JIS) 173 157 135 151 118 132
kW {PS}/rpm {235}/2,800 {213}/2,800 {183}/3,000 {205}/2,800 {160}/3,000 {180}/3,000
CL130
(MHS50T)
Unit name CL740 CL710 CL740 CL207
CL205
(MHS60A)
Type Coil spring type single disc, dry Diaphragm type single disc, dry
Clutch
Operated by: Air servo VAC or Air servo Air servo
300 (11.81):
CL130
Disc O.D. mm (in) 350 (13.78) 325 (12.80)
325 (12.80):
CL205
Manual transmis- MLS61B MHS50T
MLS62A MHS60A
sion MLS62B MHS60A
Unit name
Transmission Automatic trans-
— — —
mission
Operation Floor-shift
P/S - D/F PS860
Propeller shaft Unit name
D/F - D/F —
Vacuum servo
brake (VAC. B) or Air over hydraulic
Type Air over hydraulic brake (AOH. B)
Air over hydraulic brake (AOH. B)
brake (AOH. B)
Front BHS32
Wheel brake
Rear BLT32
Type Piston type
Air pressure Pressure regulat- VAC: None
governor ing range 706 - 834
Brake system AOH: 706 - 834
{7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi} {7.2 - 8.5, 102 - 121}
Mechanical, drive
line parking brake
Parking brake Spring-activated
type or Spring- Mechanical, drive line parking brake type or Spring-activated rear wheel parking
Type rear wheel parking
activated rear brake type
brake type
wheel parking
brake type
Auxiliary brake Exhaust brake
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-2
SPECIFICATIONS
Vehicle model
MKD210 LKB212 LKC210
Item
Steer angle (Inner x Outer) 44º x 35º 44º x 35º 44º x 35º
Tire & wheel Tire size Refer to the “Tire and wheel size table” section.
Gear box Ball-nut type
Type Integral, power steering
Steering system
R.H.D. model PMU-1487 — PMU-1487
Unit name
L.H.D. model — PMU-1488 PSI-Y85-7 PMU-1488
Type Air over hydraulic brake (AOH. B)
Front BHS32 BHS37 FB52
Wheel brake
Rear BLT32 BLT37 RB52
Type Piston type Piston type Piston type
Air pressure gover- Pressure regulat- 706 - 834
nor ing range 706 - 834 706 - 834
Brake system {7.2 - 8.5,
{7.2 - 8.5, 102 - 121} {7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi} 102 - 121}
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-3
SPECIFICATIONS
Vehicle model
LKC210 LKC212 LKD210
Item
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-4
SPECIFICATIONS
Vehicle model
PKB210 PKB212
Item
Model FE6B FE6T FE6TA FE6TA
Engine Max. gross output (JIS) 132 151 173 157
kW {PS}/rpm {180}/3,000 {205}/2,800 {235}/2,800 {213}/2,800
MLS61A
MLS61A MLS61B
Manual transmission MLS62A
Unit name NEW MLS62A MLS62B
NEW MLS62A
Transmission
Automatic transmission — — — —
Operation Floor-shift
Tire & wheel Tire size Refer to the “Tire and wheel size table” section.
Gear box Ball-nut type
Type Integral, power steering
Steering system
R.H.D. model 446-02580 446-02580
Unit name
L.H.D. model PSI-Y100-46 —
Type Air over hydraulic brake (AOH. B)
Front FB37
Wheel brake
Rear BLT40
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-5
SPECIFICATIONS
Vehicle model
PKC210 PKC212 PKF210
Item
Model FE6T FE6T FE6TA FE6TA FE6T
Engine Max. gross output (JIS) 151 162 173 157 162
kW {PS}/rpm {205}/2,800 {220}/2,800 {235}/2,800 {213}/2,800 {220}/2,800
GE-1-6
SPECIFICATIONS
Vehicle model
PKC310 PKC310BT tractor
Item
Model NE6 NE6T NE6TA NE6T NE6TA
Engine Max. gross output (JIS) 129 157 184 157 184
kW {PS}/rpm {175}/2,800 {213}/2,800 {250}/2,800 {213}/2,800 {250}/2,800
Front
Suspension Type Axle, semi-elliptical, leaf-spring (shackle)
Rear
GE-1-7
SPECIFICATIONS
Vehicle model
CDA310 CWA310
Item
Unit name RD90 (Rear front), RD80 (Rear rear) RW1A + RW1A
Rear axle
Type Inboard type Inboard type Outboard type
Unit name FA50 FA50
GE-1-8
IDENTIFICATION
IDENTIFICATION
CHASSIS SERIAL NUMBER
VIN PLATE
GE-2-1
IDENTIFICATION
Front axle
GE-2-2
IDENTIFICATION
Rear axle
Differential carrier
GE-2-3
LIFTING POINTS
LIFTING POINTS
HYDRAULIC JACK
WARNING
WARNING
z Never get under the vehicle while it is supported only by
the jack. Always use safety stands to support frame
when you have to get under the vehicle.
z Place wheel chocks at both front and back of the
wheel diagonally opposite the jack position.
Lifting point
Lifting point
Safety stand
GE-3-1
LIFTING POINTS
GE-3-2
TOWING
TOWING
TOWING THE VEHICLE
Observe the following when towing the vehicle.
z Unload the vehicle.
z Turn the key switch to “OFF”.
z Check with the nearest towing service. Use of an improper lifting or towing device may damage
the vehicle.
z Observe all state and local regulations when towing the vehicle.
GE-4-1
GENERAL PRECAUTIONS ON SERVICING
GE-5-1
GENERAL PRECAUTIONS ON SERVICING
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
z If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages, to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.
PROTECTION AGAINST CORROSION
After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to
prevent corrosion.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should
be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the
specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the service limit should sometimes be replaced before they exceed the limit from
preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,
the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
Abnormalities
z Uneven wear z Loose fit
z Graded wear z Unusual noise (for bearings)
z Scratches z Discoloration or jamming
z Cracks z Rust formation
z Deformity z Deterioration (for brake linings,
z Fatigue or weakness (for springs) etc.)
z Bends
GE-5-2
GENERAL PRECAUTIONS ON SERVICING
IMPORTANT
Your vehicle may utilize parts which have either metric and/or inch unit dimensions.
Any fasteners, like bolts and nuts used to replace old ones, must have the same dimensions and strength as
those removed.
Numbers on the heads of metric bolts and on the surfaces of metric nuts indicate their strength. Inch bolts use
radial lines for this identification, while most inch nuts do not have strength markings.
Potential thread mismatch condition may occur with certain metric thread-inch thread fastener combinations
involving incompatible fastener systems. Mismatched or incorrect thread fasteners combinations can result in
stripped threads and/or assembly weakness leading to vehicle damage, malfunction or possible personal
injury.
The following combinations of metric and inch bolts and nuts (or tapped holes) must not be utilized in service.
GE-5-3
TIGHTENING TORQUE OF STANDARD BOLTS
NOTE
z Special parts are excluded.
z This standard is applicable to bolts having the following marks embossed on the bolt head.
Material code Mark
4T 4 or 40
7T 7 or 70
9T 9 or 90
GE-6-1
LUBRICATION
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant/Fluid Specifications Remarks
Natural aspirated engine API CC or CD
Engine oil
With turbocharged engine API CD
Refer to the recommended SAE vis-
Manual transmission cosity chart.
API GL-4
Gear oil (Except Eaton transmission)
Differential API GL-5
Power steering system fluid Type DEXRON® II GM ATF type
Apply grease NLGI No. 1
Lithium soap base
Grease Lubricate with a grease gun NLGI No. 2 or No. 3
Grease* NLGI No. 000 or equivalent Calcium soap base
Brake and clutch fluid DOT 3 US FMVSS No. 116
Antifreeze — Ethylene glycol base
2-D Diesel fuel or equivalent
Above -7ºC (20ºF) Check with the service establishment
blended diesel fuel
Fuel to be sure you get the properly
1-D Diesel fuel or equivalent blended fuel.
Below -7ºC (20ºF)
blended diesel fuel
NOTE
z It is recommended that API CD class multi-grade oil be
used as engine oil for turbocharged engines.
z *: Apply grease to door hinge pin bushings.
z For Eaton transmissions, refer to the respective recom-
mendations.
Eaton® Recommendations
<Lubrication change and inspection>
HIGHWAY USE
First 5,000 to 8,000 km
Change transmission oil on new units.
(3,000 to 5,000 miles)
Every 16,000 km*1
Inspect oil level. Check for leaks.
(10,000 miles)
Every 80,000 km*2
Change transmission oil.
(50,000 miles)
GE-7-1
LUBRICATION
<Recommended lubricants>
Use only recommended lubricants to ensure smooth running.
Type Grade Temperature Range
Mild EP Gear Oil to
Specifications:
MIL-L-2105 or From -26ºC to 21ºC
SAE80W
API-GL-4 (-15ºF to 70ºF)
MIL-L-2105 or From -12ºC to 37ºC
SAE90W
API-GL-4 (11ºF to 100ºF)
Heavy Duty Engine Oil
to Specifications:
MIL-L-2104C or
MIL-L-46152 SAE30 Below -12ºC (11ºF)
API-SF/CD
Heavy Duty Gear Oil to
Specification:
API-GL-4 SAE80W/90 Below -12ºC (11ºF)
CAUTION:
z DO NOT use oil additives, friction modifiers or synthetic lubricants.
GE-7-2
LUBRICATION
CAPACITIES (APPROXIMATELY)
Item Liter Imp measure
FE6A, FE6B, FE6T, FE6TA 12 2-5/8 gal
Engine oil pan (H-level) FE6TA* 14 3-1/8 gal
NE6 series 15 3-1/4 gal
Engine oil FE6A, FE6B, FE6T, FE6TA 15 3-1/4 gal
System total FE6TA* 17 3-3/4 gal
NE6 series 18 4 gal
Oil filter 2 1-3/4 qt
MK and LK series 3 2-5/8 qt
Power steering system fluid
PK, CDA and CWA series 5.5 4-7/8 qt
Without P.T.O. 5.0 4-3/8 qt
MHS50 With P.T.O. 5.2 4-5/8 qt
With high power P.T.O. 5.5 4-7/8 qt
Without P.T.O. 4.5 4 qt
MHS60 With P.T.O. 4.7 4-1/8 qt
With high power P.T.O. 5.0 4-3/8 qt
Without P.T.O. 6.4 5-5/8 qt
MLS61A and MLS62A With P.T.O. 6.5 5-3/4 qt
Manual transmission With high power P.T.O. 6.8 6 qt
Without P.T.O. 6.2 5-1/2 qt
MLS61B With P.T.O. 6.4 5-5/8 qt
With high power P.T.O. 6.7 5-7/8 qt
Without P.T.O. 7.5 6-5/8 qt
MPS50W
With P.T.O. 8.0 7 qt
Without P.T.O. 7.0 6-1/8 qt
MPS62
With P.T.O. 7.7 6-3/4 qt
Eaton 6109 8.5 7-1/2 qt
MK series 7 6-1/8 qt
LKB and LKC series 9 7-7/8 qt
Differential LKD, PK and CDA series 13 11-1/2 qt
Rear front 12 10-5/8 qt
CWA series
Rear rear 12 10-5/8 qt
MK, LK and PK210 series 22 19-3/8 qt
Cooling system
PK310, CDA and CWA310 series 26 22-7/8 qt
NOTE
z Capacities shown are for reference only. When filling, observe the specified level.
z * Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).
GE-7-3
MA
MAINTENANCE
CONTENTS
MAINTENANCE SCHEDULE .......... MA-1-1 STEERING SYSTEM ................... MA-2-1
LUBRICATION AND FILTER BRAKE SYSTEM ......................... MA-2-8
REPLACEMENT INTERVALS ...... MA-1-2 AXLE AND WHEEL .................... MA-2-21
MAINTENANCE INTERVALS ....... MA-1-3 SUSPENSION ............................ MA-2-31
PERIODIC PARTS CLUTCH ..................................... MA-2-32
REPLACEMENT ............................. MA-1-7 TRANSMISSION ........................ MA-2-35
LUBRICATION POINT AND PROPELLER SHAFT ................. MA-2-36
INTERVALS .................................. MA-1-8 ELECTRICAL SYSTEM ............. MA-2-37
MAINTENANCE PROCEDURE ....... MA-2-1 OTHERS .................................... MA-2-40
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Abbreviations:
I : Inspect. Correct, adjust or replace if necessary.
A : Adjust R : Replace C : Cleaning
RB : Rebuilding T : Tighten to specified torque
L : Lubricate : Initial maintenance
NOTE
z The maintenance or lubrication service shown below are to be performed at the indicated inter-
vals (km, miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be con-
tinued at the same intervals as before except the initial maintenance.
z Under the following severe operating conditions, more frequent servicing will be required.
— Operation in heavy dust conditions
— Extended high-speed operation with vehicle fully-loaded to its GVW
— Extended low-speed operation
— Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine Nis-
san Diesel parts.
MA-1-1
MAINTENANCE SCHEDULE
Maintenance intervals
Kilometers x
1 5 10 15 20 25 30 35 40 45 50 55 60
Items 1,000 Remarks
Daily
Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months - 1 2 3 4 5 6 7 8 9 10 11 12
ENGINE
CHASSIS
Remarks:(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the scheduled replacement.
(2) If the warning light comes on even before the scheduled replacement, clean or replace element.
(3) Service every 6 months. (4) Service every 12 months.
(5) VAC and AOH brake vehicles. Replace every year. (6) Replace every year.
MA-1-2
MAINTENANCE SCHEDULE
MAINTENANCE INTERVALS
Maintenance intervals
Kilometers x
1 5 10 15 20 25 30 35 40 45 50 55 60 Re-
Items 1,000
Daily marks
Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months — 1 2 3 4 5 6 7 8 9 10 11 12
ENGINE
Condition of exhaust I I I I I I I I I I I I I
Air cleaner element I/C I/C I/C I/C I/C I/C (1)
Valve clearance I I
Oil leakage I I I I I I I I I I I I I I
Fuel leakage I I I I I I I I I I I I I I
I I I I I I/C
Fuel strainer
Drain Drain Drain Drain Drain Drain
I I I I I I I I I I I I
Primary fuel filter
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Nozzle (injection pressure and pat-
I
tern)
Injection timing I
V-belt I I I I I I I I I I I I I
Coolant level I I I I I I I I I I I I I
Coolant leakage I I I I I I
Radiator cap I
Thermostat I
Turbocharger I (2)
Fan clutch I
Remarks:(1) If the warning light comes on even before the scheduled replacement, clean or replace element.
(2) With turbocharger engine equipped vehicle only.
MA-1-3
MAINTENANCE SCHEDULE
Maintenance intervals
Kilometers x
1 5 10 15 20 25 30 35 40 45 50 55 60 Re-
Items 1,000
Daily marks
Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months — 1 2 3 4 5 6 7 8 9 10 11 12
STEERING
Steering wheel free play I I I I I I
Steering wheel operation I I I I I
Steering system fluid leakage I I I I I I I I I I I I I I
BRAKE SYSTEM
Brake pedal play I I I I I I I I I I I I I I
Braking effectiveness I I I I I I I I I I I I I
(1)
Brake fluid level I I I I I I I I I I I I I
(2)
Hose and pipe for fluid and/or air
I I I I I I I I I I I I I
leakage
I I I I I I I I I I I I I
Draining air reservoir
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Brake valve and other valves I
Brake lining clearance I I I I I I I I I I I I (4)
Brake chamber push rod stroke I I I I I I I I I I I I (3)
Brake lining I I I I I I I I I I I I
Brake drum I
Back plate I
(1)
Brake booster air cleaner clogging I I I I
(2)
Brake booster for fluid and air tight- (1)
I
ness (2)
Brake booster's check valve and (1)
I
relay valve (2)
Remarks:(1) VAC brake vehicles. (2) AOH brake vehicles. (3) Air brake vehicles.
(4) VAC and AOH brake vehicles.
MA-1-4
MAINTENANCE SCHEDULE
Maintenance intervals
Kilometers x
1 5 10 15 20 25 30 35 40 45 50 55 60 Re-
Items 1,000
Daily marks
Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months — 1 2 3 4 5 6 7 8 9 10 11 12
BRAKE SYSTEM
Wheel cylinder for proper function- (1)
I
ing (2)
Brake chamber I (3)
Brake camshaft I (3)
Parking brake lining clearance I I I I I (4)
Parking brake lever stroke I I I I I I I I I I I I I (4)
Parking brake effectiveness I I I I I I I I I I I I
Parking brake wire I I I I I (4)
Parking brake drum T T T T/I (4)
Parking brake lining I (4)
Air dryer I I I I
Air compressor and air pressure
I
governor
L.S.P.V. for wiring or rod I (5)
Exhaust brake I I I I I I I I I I I I I
SUSPENSION
Leaf spring I I I I I
Spring bracket I
Shock absorber I I I
Stabilizer I I I I I
Remarks:(1) VAC brake vehicles. (2) AOH brake vehicles. (3) Air brake vehicles.
(4) Mechanically-actuated type. (5) If so equipped.
MA-1-5
MAINTENANCE SCHEDULE
Maintenance intervals
Kilometers x
1 5 10 15 20 25 30 35 40 45 50 55 60 Re-
Items 1,000
Daily marks
Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months — 1 2 3 4 5 6 7 8 9 10 11 12
CLUTCH
Clutch pedal play I I I I I I I I I I I I I I
TRANSMISSION
Transmission gear oil leakage I I I I I I I I I I I I I I
Transmission control mechanism I
PROPELLER SHAFT
Shaft joint T T T T T
Propeller shaft deflection I
Sliding shaft and universal joint I
Center bearing I
ELECTRICAL SYSTEM
Charging function of generator I I I I I I I I I I I I
Battery electrolyte level I I I I I I I I I I I I
Specific gravity of battery electrolyte I I I I I
Battery terminals I I I I I
Wiring connections I I I I I I I I I I I I
OTHERS
Lights I I I I I I I I I I I I I
Horn, wiper, windshield washer and
I I I I I
defroster
Meters and gauges I I I I I
Exhaust tubing and muffler I I I I I
Door locks I I I I I I
MA-1-6
MAINTENANCE SCHEDULE
ENGINE
Fuel hose (engine side) R R R R R
Fuel hose (fuel tank side) R R
Air compressor rubber hose R R R R R (2) (3)
STEERING
Power steering rubber hose R R R R R
Power steering rubber parts R R R R R
BRAKE
Brake rubber hose R R R R R R R R R R (1) (2)
Vacuum hose R R R R R (1)
Brake fluid reservoir hose R R R R R (1) (2)
Brake booster rubber parts R R R R R R R R R R (1) (2)
Brake booster piston packing and hydraulic piston assembly R R R R R (1) (2)
Safety cylinder rubber parts R R R R R R R R R R (1)
Wheel cylinder cup, dust seal, etc. R R R R R R R R R R (1) (2)
Wheel parking brake chamber diaphragm R R R R R R R R R R (4)
Brake valve rubber parts R R R R R R R R R R (2) (3)
Relay valve rubber parts R R R R R R R R R R (3)
Quick release valve rubber parts R R R R R R R R R R (3) (4)
Wheel parking brake valve rubber parts R R R R R R R R R R (4)
Spring brake valve rubber parts R R R R R R R R R R (3)
Brake chamber rubber parts R R R R R R R R R R (3)
Trailer brake valve rubber parts R R R R R R R R R R (6)
L.S.P.V. rubber parts R R R R R R R R R R
Air dryer parts (desiccant, filter, rubber parts) R R R R R R R R R R (5)
OTHERS
Jumper hoses R R R R R (6)
Remarks:(1) VAC brake vehicles. (2) AOH brake vehicles. (3) Air brake vehicles.
(4) Air-actuated type parking brake equipped vehicles. (5) Replace every year. (6) Semi-trailer trucks.
MA-1-7
MAINTENANCE SCHEDULE
NOTE:
: Lubricate with a grease gun : Apply grease x 2: No. of grease nipples or points
RL: Lubrication points on left and right sides of vehicle +: Refer to enlarged view.
MA-1-8
MAINTENANCE SCHEDULE
MA-1-9
MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
NOTE
z Described here are maintenance procedures for chassis
related parts. For maintenance procedures for engine
related parts, refer to the Engine Service Manual.
z For maintenance standard values, refer to the data given
in each section.
STEERING SYSTEM
STEERING WHEEL FREE PLAY
1. Idle the engine.
2. Position the front wheels in the straight-forward direction.
Slowly turn the steering wheel to the left and right to check
for free play. A small amount of free play may be due to a
small amount of steering gear backlash; excessive free play
may be due to excessive steering gear backlash or worn
parts. Disassemble the gear box and steering linkage to
check and correct the cause of the problem.
Unit: mm (in)
Vehicle model Maintenance standard
MK and LKB, C series 10 - 40 (0.39 - 1.57)
LKD, PK, CDA and CWA series 30 - 50 (1.18 - 1.97)
MA-2-1
MAINTENANCE PROCEDURE
CAUTION
z Do not allow dirt or debris to enter the fluid reservoir
when open. Always clean the fluid reservoir and cap
before removing the cap.
z Check for proper oil level before engine start.
MA-2-2
MAINTENANCE PROCEDURE
3. Drain fluid from the gear case by turning the steering wheel
fully to the right and left several times.
MA-2-3
MAINTENANCE PROCEDURE
3. Fill the fluid reservoir up to the filler port with new power
steering fluid and then crank the engine using the starting
motor, but shut off fuel and do not run the motor longer than
1 or 2 seconds to prevent the engine from starting.
4. Repeat the operation in item 3 while adding fluid to keep the
fluid reservoir filled.
5. When fluid drained becomes clean, connect the return hose
to the reservoir to restore the piping to its normal condition.
MA-2-4
MAINTENANCE PROCEDURE
STEERING LINKAGE
Move the drag link and tie rod back and forth and then to the left
and right by hand to check for free play at the fastening section. If
free play is present, the ball joint may be worn.
MA-2-5
MAINTENANCE PROCEDURE
MA-2-6
MAINTENANCE PROCEDURE
KNUCKLE JOINT
1. Jack up the front axle, and check if the kingpin rattles by
axially shaking each wheel by hand.
When the wheel bearing is loose, let a helper depress the
brake pedal to check the kingpin for looseness.
2. When the kingpin is loose, disassemble and measure each
related part. Replace worn parts.
WHEEL ALIGNMENT
Before checking wheel alignment (camber, caster, toe-in and king-
pin inclination) and the steering angle of the wheels, park the vehi-
cle on a flat surface and check and correct the following, as
necessary:
z Tire pressure
z Front wheel bearing play
z Condition of the steering gear box and steering linkage
z Operation of the shock absorber
z Vehicle is under no-load condition.
NOTE
z Ensure that engine oil and cooling water are filled to their
specified levels when the vehicle is unloaded.
MA-2-7
MAINTENANCE PROCEDURE
BRAKE SYSTEM
BRAKE PEDAL PLAY
Check the brake pedal for a proper play by depressing it with a light
force.
Unit: mm (in)
Item Maintenance standard Service limit
Vacuum brake 8 - 15 (0.31 - 0.59) —
R.H.D. model 12 - 18 (0.47 - 0.71) —
AOH and air brake
L.H.D. model 5 - 13 (0.20 - 0.51) —
BRAKING EFFECTIVENESS
Road test to check for overall braking performance, including
unequal braking action, noises, braking distance, braking dragging,
wheel locking condition, etc. by observing the trail of the wheels.
NOTE
z Braking effectiveness is influenced by the condition of
the road surface. Test the brakes on a dry paved road
free of water and oil.
MA-2-8
MAINTENANCE PROCEDURE
CAUTION
z Remove any dirt accumulation from the brake fluid reser-
voir cap and surrounding area before removing the res-
ervoir cap. Do not allow dirt, debris, water or other
foreign materials to enter the reservoir while it is open.
z To avoid fire hazard, do not allow brake fluid to contact
the hot parts of the exhaust system.
z Use only DOT 3 brake fluid from a sealed container.
z Do not add brake fluid above the HIGH mark.
z Do not allow brake fluid to contact the painted surfaces
of your vehicle. Brake fluid contact may result in paint
damage.
z Remove the reservoir strainer and clean any foreign mat-
ter from it.
If the reservoir contains sediment, inspect and clean the
reservoir.
MA-2-9
MAINTENANCE PROCEDURE
CAUTION
z Do not use brake fluid of a different brand. If it is neces-
sary to do so, completely replace the old brake fluid with
the new fluid, otherwise, the physical properties of the
brake fluid will change, resulting in a decrease in boiling
point or rust formation.
z Take extreme care when handling brake fluid because
brake fluid readily absorbs moisture. When adding or
storing brake fluid, do not allow water/moisture to enter.
Use of brake fluid containing water/moisture decreases
the boiling point, resulting in “vapor lock” in the brake
system. This is very dangerous.
z Do not allow mineral oil (such as light oil, gasoline, etc.)
to get into the brake fluid; otherwise, rubber parts will
become swollen or poor braking performance may result.
MA-2-10
MAINTENANCE PROCEDURE
Unit: mm (in)
Item Maintenance standard Service limit
Lining clearance 0.2 - 0.3 (0.008 - 0.012) —
MA-2-11
MAINTENANCE PROCEDURE
Unit: mm (in)
Item Maintenance standard Service limit
Front
Lining clearance 0.3 - 0.4 (0.012 - 0.016) —
Rear
MA-2-12
MAINTENANCE PROCEDURE
2. After the lining has come into contact with the drum, back
off the adjusting screw until the brake chamber push rod
stroke equals the maintenance standard. Then, turn the
adjusting screw to the nearest lock position. Turn the drum
to ensure that the gap is uniform.
Unit: mm (in)
Item Maintenance standard Service limit
Front 30 (1.18) —
PKC210,
30 (1.18) —
Rear 310 series
CWA310 24 (0.94) —
NOTE
z Adjusting screw lock grooves are provided at six places
on the screw shaft at 60º intervals.
MA-2-13
MAINTENANCE PROCEDURE
BRAKE LINING
(FRONT AND REAR)
Remove the access hole lid and check the brake lining for wear. If it
is worn down to the graded section, replace the brake lining.
Checks for wear should be performed at two inspection holes per
wheel.
BRAKE DRUM
(FRONT AND REAR)
Remove the brake drum and check for cracks or wear. If graded or
unusual wear on the inner wall of the drum is noticed, grind the wall
or replace the brake drum as necessary. If the inside diameter of
the drum exceeds wear limit, it should be replaced.
Refer to the “BR” section for removal and installation procedures.
BACK PLATE
Check the back plate for deformation or damage.
BRAKE BOOSTER
Air cleaner clogging
Check the air cleaner for contamination, clogging or other damage.
<Hydromaster>
1. Check the vacuum pressure to make sure it is held within
the specified range. If it is lower, start the engine to increase
it to the specified range. Then stop the engine.
MA-2-14
MAINTENANCE PROCEDURE
<Brake booster>
1. Check the air pressure to make sure it is held within the
specified range. If it is lower, start the engine to increase the
air pressure to the specified range. Then stop the engine.
MA-2-15
MAINTENANCE PROCEDURE
BRAKE CHAMBER
1. Completely depress the brake pedal to check if air leaks
from the brake chamber. Tires should be inflated to the
standard pressure.
2. Disassemble the brake chamber and check the condition of
component parts. Replace parts which should be changed
at regular intervals.
BRAKE CAMSHAFT
1. Remove the camshaft and check for scratches, wear or
damage.
2. Measure the inside diameter of the camshaft bushing and
check the bushing-to-camshaft clearance.
PARKING BRAKE
<WITH MECHANICAL DRIVELINE PARKING BRAKE>
Lining clearance
1. Chock the front wheels and push the parking brake lever
down to release the parking brake. Jack up the rear wheels.
2. Remove the rubber plug from the inspection hole for the
parking brake drum.
MA-2-16
MAINTENANCE PROCEDURE
MA-2-17
MAINTENANCE PROCEDURE
<MK series>
Manual release procedure
1. Block the wheels to prevent the vehicle from moving.
2. Loosen the lock nuts.
3. Turn the turnbuckle to extend the push rod until the brake
shoes are released from the drum.
Reset procedure
1. Reset the turnbuckle to the dimension shown in the follow-
ing figure.
2. Torque the lock nuts to 34 to 45 N·m {3.5 to 4.6 kgf·m, 25 to
33 ft·lbf}.
MA-2-18
MAINTENANCE PROCEDURE
Reset procedure
1. Reset the release nut to the dimension shown in the follow-
ing figure.
MA-2-19
MAINTENANCE PROCEDURE
Reset procedure
1. Unscrew and remove the release stud and nut.
2. Reinstall the release stud and nut in the carrying pocket.
Install the access plug in the housing opening.
AIR DRYER
Visually check to be sure that water drains from the drain port of the
air dryer. Water will drain when the air pressure governor stops
pressurization. The governor stops pressurization when the air
pressure in the reservoir reaches the upper level of the normal
operating pressure range. When the sound of air supplied to the
reservoir can no longer be heard, or when the sound of the engine
changes, this condition has been reached.
If no water drains from the air dryer, drain the water from the
air reservoir. If a large amount of water is drained, have the
air dryer repaired. (Refer to the “BR” section for disassembly
and reassembly procedures.) If the drained liquid contains a
large amount of oil, additionally have the air compressor
checked.
If air pressure does not increase within the specified length of time,
the air pressure system or the compressor may be faulty. Check
and repair as required.
MA-2-20
MAINTENANCE PROCEDURE
EXHAUST BRAKE
1. Be sure that no pressure is applied to both the accelerator
pedal and the clutch pedal.
2. Make sure that the exhaust brake operates normally with
the indicator light turned on when the exhaust brake switch
is operated.
MA-2-21
MAINTENANCE PROCEDURE
3. Fill the differential with fresh oil. Check the oil level. Add oil
until the level reaches the bottom of the filler plug hole.
4. Reinstall and tighten the filler plug using a new gasket.
: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
MA-2-22
MAINTENANCE PROCEDURE
3. Pour oil into the case through the level plug hole until oil
flows out of the level plug hole; this will require approxi-
mately 11 liters (9-5/8 Imp qt). Next, pour oil through the
filler plug hole until oil flows out of the level plug hole; this
will require approximately 1 liter (7/8 Imp qt).
4. Reinstall and tighten the filler plug and level plug using a
new gasket.
: Filler plug: 88 - 118 N·m {9 - 12 kgf·m, 65 - 87 ft·lbf}
Level plug: 88 - 118 N·m {9 - 12 kgf·m, 65 - 87 ft·lbf}
AXLE SHAFT
1. Remove the rear axle shaft, and check for bends, cracks
and oil leakage.
2. Check to see if the rear axle shaft oil seal is damaged, and
if the differential breather is clogged or leaking oil.
MA-2-23
MAINTENANCE PROCEDURE
MA-2-24
MAINTENANCE PROCEDURE
8.25-20-14PR z
9.00-20-12PR z
9.00-20-14PR z
10.00-20-14PR z
10.00-20-16PR(Dual) z
(Single) z
11.00-20-14PR z
215/75R17.5 124/123 z
225/90R 17.5-14PR z
8.25R 16-14PR z
8.25R 20-14PR z
9.00R 20 141/138L z
9R 22.5-14PR z
10.00R 20-14PR z
10.00R 20-16PR z
10R 22.5-14PR z
11.00R 20-14PR z
11.00R 20-16PR z
11R 22.5-14PR z
11R 22.5-16PR z
TIRE
Cracks or damage
Check tires for cracks, abnormal wear or damage. Also check for
foreign material (metal chips, pebbles, etc.) caught in tire treads; if
left unheeded, such foreign matter progressively intrudes into the
tire, causing punctures, and shortening tire life.
MA-2-25
MAINTENANCE PROCEDURE
WARNING
WARNING
z If foreign matter is hard to remove, raise the wheel with a
jack, deflate the tire and remove foreign matter; other-
wise, foreign matter may be ejected by air pressure, pos-
sibly resulting in injury.
Check tires for the amount of remaining tread. If tread depth is less
than 16 mm (0.063 in), replace the tire.
The tire is provided with six wear indicators. If any of the wear indi-
cators appears on the tire surface, replace the tire.
Check the tire side walls and treads carefully for scratches, cuts,
internal cracks, or damage. Do not use a tire which has any of the
following defects.
1. Scratches reaching tire cords or rubber cracks
2. Cord breakage or dragging
3. Separation
4. Damaged beads
5. Air leakage or defects irreparable
MA-2-26
MAINTENANCE PROCEDURE
WHEEL NUT
Tighten the wheel nuts for conventional tires, tighten the wheel nuts
to the specified torque. If the rear wheels use double tires (standard
type), proceed as follows:
NOTE
z The following figures show an example of tightening the
right-hand tire (standard type).
MA-2-27
MAINTENANCE PROCEDURE
MA-2-28
MAINTENANCE PROCEDURE
[Preload measurement]
1. Remove the wheel.
2. Wrap a string around the hub bolt.
3. Pull the string horizontally with a spring scale until the hub
rotates at least 90º. Read the scale indication (average
value).
Unit: N {kgf, lbf}
Unit Service
Vehicle model Maintenance standard
name limit
MKA/B series FA30 22.6 - 46.1 {2.3 - 4.7, 5.1 - 10.4} —
MKC, D and LK
FA35 22.6 - 46.1 {2.3 - 4.7, 5.1 - 10.4} —
series
PKB210 FA40 24.5 - 49.0 {2.5 - 5.0, 5.5 - 11.0} —
PKC, PKF, CDA
FA50 19.6 - 53.9 {2.0 - 5.5, 4.4 - 12.1} —
and CWA series
[Preload measurement]
1. Raise the rear axle with a jack.
2. Remove the wheel.
3. Wrap a string around the hub bolt.
4. Pull the string horizontally with a spring scale until the hub
rotates at least 90º. Read the scale indication (average
value).
Unit: N {kgf, lbf}
Unit Service
Vehicle model Maintenance standard
name limit
MKA/B/D RS55 38.2 - 61.8 {3.9 - 6.3, 8.6 - 13.9} —
MKC210,
RS65 38.2 - 61.8 {3.9 - 6.3, 8.6 - 13.9} —
LKB212
LKC, LKD series RS75 38.2 - 61.8 {3.9 - 6.3, 8.6 - 13.9} —
PKB, PKF series RS90 29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3} —
PKC210.310.310-T RS1A 29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3} —
CDA310 RD90/80 29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3} —
CWA310 RW1A 29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3} —
MA-2-29
MAINTENANCE PROCEDURE
Rear
Disassemble the rear axle hub. Remove the old grease and charge
new grease as shown below.
Unit: g (oz)
Unit Amount of grease
Vehicle model
name (Approximately)
MKA/B/D210 RS55 530 (18.69)
MKC210, LKB212 RS65 530 (18.69)
LKC/D series RS75 530 (18.69)
PKB, PKF series RS90 1,620 (57.14)
PKC series RS1A 1,620 (57.14)
RD90
(Drive)
CDA310 1,620 (57.14)
RD80
(Dead)
CWA310 RW1A 1,620 (57.14)
MA-2-30
MAINTENANCE PROCEDURE
SUSPENSION
LEAF SPRING
Check the leaf spring for damage, displacement of leaves or loose-
ness. If loose, tighten bolts and nuts to the specified torque. For
tightening torque, refer to the “SU” section.
SPRING BRACKET
Inspect rivets on the spring bracket for looseness by tapping with a
hammer. Also, visually inspect the bracket for cracks and damage.
MA-2-31
MAINTENANCE PROCEDURE
SHOCK ABSORBER
Check the shock absorber for proper installation, damage or leak-
age. If leakage is present, replace the shock absorber.
STABILIZER
Check the stabilizer for proper installation or damage.
CLUTCH
CLUTCH PEDAL PLAY
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17) —
Depress the clutch pedal by hand until resistance is felt. While hold-
ing the clutch pedal in this position, measure the stroke length of
pedal play. If it is outside the specified range, adjust as follows:
Pedal play adjustment
<Clutch master cylinder>
1. Loosen the lock nut on the push rod.
2. Turn the push rod until it touches the piston and there is no play.
Under this condition, return the push rod 4/5 turn and make
sure the free play is approximately 1 mm (0.04 in).
3. Tighten the lock nut while holding the push rod stationary
with a wrench.
MA-2-32
MAINTENANCE PROCEDURE
NOTE
z Before checking wear on the clutch disc, ensure that
clutch pedal free play is adjusted to within the specified
range.
MA-2-33
MAINTENANCE PROCEDURE
MA-2-34
MAINTENANCE PROCEDURE
TRANSMISSION
GEAR OIL LEAKAGE
Check the transmission for oil leakage. If leakage is present, cor-
rect the cause and check the level of gear oil and add as necessary.
3. Fill the transmission with fresh oil through the filler plug hole
located on the side of the transmission to the specified
level.
4. Visually check the oil level and add oil, if necessary, until it
reaches the bottom of the filler plug hole.
CAUTION
z To prevent dirt and debris from entering the transmis-
sion, clean the filler plug, transmission housing, and sur-
rounding area before checking.
z If the transmission oil level is low, the transmission will
not operate normally and could malfunction. Check to
determine the cause of low oil level. Correct the condi-
tion before operating the vehicle.
5. After checking the oil level, replace the filler plug gasket
with a new one.
6. Reinstall and tighten the filler plug using a new gasket.
: 98 - 127 N·m {10 - 13 kgf·m, 72 - 94 ft·lbf}
MA-2-35
MAINTENANCE PROCEDURE
PROPELLER SHAFT
SHAFT JOINT
Inspect that the fitting bolts, etc. of the yoke flange, joint yoke, bear-
ing cover and center bearing case are tight.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
MK and LKB/C series 88 - 108 {9 - 11, 65 - 80}
Propeller shaft
mounting bolt LKD, PK, CDA and 211 - 240
CWA series {21.5 - 24.5, 156 - 177}
Center bearing MK and LKB/C series 59 {6, 43}
retainer mount- LKD, PK, CDA and
ing bolt 98 {10, 72}
CWA series
3. Move the yoke of the universal joint up, down, left and right
by hand to check for free play. If free play is present, disas-
semble the joint and replace the needle bearing and/or jour-
nal as required.
4. Reinstall the propeller shaft.
MK and LKB/C series:
: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
LKD, PK, CDA and CWA series:
: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}
MA-2-36
MAINTENANCE PROCEDURE
CENTER BEARING
Check the center bearing for free play and grease leakage and
replace it if faulty.
ELECTRICAL SYSTEM
CHARGING FUNCTION OF GENERATOR
Check charging condition by observing warning light indication.
BATTERY
Observe the following when handling battery electrolyte.
WARNING
WARNING
z The battery produces hydrogen gas, which is harmful to
the human body. Never place the battery close to a fire or
allow it to spark.
z Be careful not to spill battery electrolyte on any part of
your body, clothes or finished surfaces of parts. Wear
goggles when handling it. Do not touch or rub your eyes
with your hands. After handling electrolyte, wash your
hands thoroughly under running water.
If electrolyte should come into contact with your eyes,
rinse the eyes for at least fifteen seconds and immedi-
ately see doctor.
CAUTION
z When the battery is replaced, perform maintenance in
accordance with the battery manufacturer's instructions.
MA-2-37
MAINTENANCE PROCEDURE
<Maintenance-free type>
The battery electrolyte should be maintained between the upper
and lower levels on the case. If low, add distilled water to the speci-
fied level and charge the battery for at least 30 minutes.
MA-2-38
MAINTENANCE PROCEDURE
Battery terminal
Check the battery terminals for corrosion and dirt. Clean as neces-
sary. If corroded and accompanied by white powder, pour lukewarm
water on the terminals and wipe clean; if excessively corroded, dis-
connect the battery cables and clean using a wire brush or sandpa-
per. After cleaning, apply a small amount of grease to the terminals.
CAUTION
z Always disconnect the ground cable first and then the
positive cable. When connecting, connect the positive
cable first and then the ground cable.
NOTE
z Tighten (do not overtighten) the battery cables firmly.
MA-2-39
MAINTENANCE PROCEDURE
WIRING CONNECTIONS
1. Check the battery cables and wiring harness for damage,
and the clamps for tightness.
2. Check the terminal block (socket) connections for loose
parts.
OTHERS
LIGHTS
Check if the light comes on when the switch of each light is turned
to the ON position. This inspection can be performed more easily
by two people.
1. End outline marker lights
2. Top marker lights
3. Fog light
4. Headlight
5. Front turn signal light
6. Side clearance light and cornering light
7. Side turn signal light
8. Side turn signal light [PK series: with overfender]
9. Back-up light
10. License plate light
11. Rear turn signal light
12. Rear combination light (tail and stop light)
SEAT BELT
Tighten loose seat belts or replace damaged belts.
TILT LOCK
Operate the cab tilt lock device to examine the function and dam-
age.
COUPLER
1. Operate the lever to check for bent plunger, free play and
lubricating condition.
2. Check the mounting section of the coupler for looseness,
the pitching shaft and bearing locations for wear or damage.
Also check the pin hole in the jaw for wear or damage.
3. Check the upper surface of the coupler base for wear, lubri-
cating condition, etc.
MA-2-41
TD
TROUBLE DIAGNOSIS
CONTENTS
FOREWORD .................................... TD-1-1 PROBABLE CAUSE AND
WARNING LIGHTS .......................... TD-2-1 REMEDY ........................................... TD-4-1
TROUBLE SYMPTOMS CLUTCH ........................................ TD-4-1
AND FAULTY UNIT .......................... TD-3-1 TRANSMISSION ........................... TD-4-3
WHEN STARTING ENGINE ......... TD-3-1 PROPELLER SHAFT .................... TD-4-5
AFTER STARTING ENGINE ........ TD-3-1 REAR AXLE AND DIFFERENTIAL
WHEN STARTING TO MOVE CARRIER ...................................... TD-4-6
VEHICLE ...................................... TD-3-1 BRAKE .......................................... TD-4-7
WHEN VEHICLE IS RUNNING .... TD-3-2 STEERING SYSTEM AND FRONT
AXLE ........................................... TD-4-12
FOREWORD
FOREWORD
In an automobile, a unit is composed of many component parts. Units such as the engine, clutch, transmission,
and rear axle are combined to operate in conjunction with each other. In order to effectively conduct automo-
tive troubleshooting, therefore, we must fully understand the structure and function of each automotive part
and the interrelationship of the various parts.
In performing troubleshooting, the first thing to do is to try to understand the nature of the problem. To do this,
you must obtain from the user exact information concerning the symptoms of the trouble, including the parts
affected the conditions of use, and the date the symptoms arose.
An automotive problem, in most cases, is due to many causes; though in some cases it will be due to a single
cause. Accordingly, troubleshooting requires a systematic way of thinking and an ability to approach a problem
step-by-step. For example, take the case where the steering wheel does not turning smoothly. The pitman arm
linkage should be removed first, instead of hastily disassembling the steering gear box; an examination should
then be conducted and a determination made as to whether the cause of the problem is on the gear box side
or on the linkage side.
In disassembling any component in an attempt to locate the cause of a problem, work should be performed
systematically and efficiently, starting with easy tasks first. Troubleshooting procedures used and the results
thereof must be theoretically supported or explained.
TD-1-1
WARNING LIGHTS
WARNING LIGHTS
The following lists the warning functions when warning lights come
on.
TD-2-1
WARNING LIGHTS
5 — Not applicable —
6 — Not applicable —
OVERHEATING AND COOL- If the coolant drops below a specified level, or its temper-
ANT LEVEL warning light ature rises above 103ºC (217ºF), the warning light comes
7 on and a warning buzzer sounds.
TILT LOCK warning light If the tilt lock of the cab is incomplete, the warning light
will come on and the warning buzzer will sound.
8
AIR CLEANER warning light If the air cleaner element becomes clogged, the warning
light will come on or flicker intermittently.
9
OIL FILTER ELEMENT warning This warning light will illuminate when the oil filter element
light is clogged.
10
11 — Not applicable —
OIL PRESSURE warning light The warning light will come on if the oil pressure drops
below 49 kPa {0.5 kgf/cm2, 7 psi} while the engine is run-
12 ning.
TD-2-2
WARNING LIGHTS
ENGINE CONTROL warning The warning light comes on when a problem occurs in the
light engine control system.
14 When this occurs, white smoke and engine power loss
may be noticed.
15 — Not applicable —
16 — Not applicable —
ANTI-LOCK BRAKE warning This light illuminates when the key switch is turned “ON”
light and goes out when the vehicle reaches a speed of 7 km/h
17 (4 MPH) after starting.
If the anti-lock brake system becomes inoperative during
operation, the warning light will illuminate.
18 — Not applicable —
ENGINE OVERRUN warning When the engine speed increases over the specified rev-
light olutions, the warning light will illuminate. At the same
19 time, the warning buzzer will sound.
TD-2-3
TROUBLE SYMPTOMS AND FAULTY UNIT
Faulty starting
No sound
system
Listen to sound as
ENGINE FAILS TO Engine does
the starting motor Faulty engine
START not run
pinion pops out Sound is heard Depress clutch pedal
Faulty
Engine runs
transmission
Faulty clutch
Faulty transmission
UNUSUAL NOISE Faulty propeller shaft
Faulty rear axle
Slippage of engine drive belt(s)
Faulty engine
Parking brake dragging
VEHICLE DOES Foot brake dragging
NOT MOVE
SMOOTHLY Faulty clutch
Vehicle jerks or stutters Excessive play in power train
Engine rubber mounting fatigued
TD-3-1
TROUBLE SYMPTOMS AND FAULTY UNIT
Clutch slippage
Foot brake dragging
POOR ACCELERATION
Parking brake dragging
Faulty engine fuel system
TD-3-2
TROUBLE SYMPTOMS AND FAULTY UNIT
TD-3-3
PROBABLE CAUSE AND REMEDY
TD-4-1
PROBABLE CAUSE AND REMEDY
CLUTCH SLIPPAGE
When the clutch begins to slip, pedal play decreases and many
things begin to occur simultaneously. It should be kept in mind that
a short time after the start of clutch slippage, the clutch disc will
completely wear out, frequently causing damage to the pressure
plate and the flywheel.
Set the hand brake, disengage the clutch, and slowly shift into high
gear, if the engine does not stop, you can determine the problem to
be clutch slippage.
TD-4-2
PROBABLE CAUSE AND REMEDY
TRANSMISSION
UNUSUAL NOISE
Unusual noise emanating from the transmission must be examined
to determine whether it is present during driving or is heard only
while shifting gears. This is a factor to consider while troubleshoot-
ing. In addition, it should be determined whether the usual noise is
being emitted from the gears or from the bearings.
TD-4-3
PROBABLE CAUSE AND REMEDY
TD-4-4
PROBABLE CAUSE AND REMEDY
PROPELLER SHAFT
When there is something wrong with the propeller shaft, it fre-
quently causes vibration while the vehicle is in motion, or unusual
noise when the vehicle is started or being driven. This vibration or
unusual noise is closely related to vehicle speed because it is
transmitted to the vehicle body by centrifugal force generated by
the rotating propeller shaft. Generally, however, this vibration or
unusual noise often acts in concert with vibration associated with
undercarriage parts, such as the rear axle, and is emitted at a par-
ticular rotating speed of the propeller shaft.
Often overlooked in troubleshooting is propeller shaft vibration
caused by its improper installation on the companion flange of the
differential. On occasion, a check must be made not only on the
bending of the propeller shaft but also on the companion flange to
which the shaft is connected.
TD-4-5
PROBABLE CAUSE AND REMEDY
UNUSUAL NOISE
Symptom Probable cause Remedy
UNUSUAL NOISE WHEN VEHICLE STARTS TO MOVE
z Excessive backlash in differential gear z Adjust backlash.
z Excessive backlash between ring gear and drive pin- z Adjust backlash.
ion
z Loose connection between companion flange and pro- z Tighten to specified torque.
peller shaft
z Low pinion bearing preload z Adjust preload.
z Loose drive pinion retaining nut z Tighten to specified torque.
WHEN ROUNDING A CURVE
z Side gear, pinion, spider, thrust washer, side bearing, z Correct or replace faulty parts.
etc. worn or damaged
z Low oil level z Replenish oil.
WHEN DRIVING
z Excessive backlash between ring gear and drive pin- z Adjust backlash.
ion
z Worn or damaged bearing z Replace bearing.
z Worn or damaged gear z Correct or replace.
z Low oil level z Replenish oil.
WHEN RUNNING BY INERTIA
z Insufficient backlash between ring gear and drive pin- z Adjust backlash.
ion
z Worn or damaged bearing z Replace bearing.
z Improper gear contact pattern z Correct or replace faulty gear(s).
z Low oil level z Replenish oil.
TD-4-6
PROBABLE CAUSE AND REMEDY
OIL LEAKAGE
Symptom Probable cause Remedy
Oil leakage z Oil seal worn, loose or damaged z Replace oil seal.
z Differential carrier retaining nuts loose or gasket dam- z Replace gasket and tighten nuts to specified
aged torque.
z Scratches on mating surface of differential carrier z Correct or, if necessary, replace differential car-
rier.
z Loose drain plug or damaged gasket z Replace gasket and tighten loose plug to speci-
fied torque.
z Breather plugged or damaged z Clean or replace breather.
z Cracked axle housing z Correct or replace axle housing.
z Companion flange seal surface scratched or deformed z Correct or replace companion flange.
z Companion flange runout due to faulty drive pinion z Replace bearing.
bearing
z Deformed axle housing due to overload z Correct or replace axle housing.
BRAKE
Trouble symptoms of the brake system include insufficient braking,
dragging, braking or only one side, and unusual noise. The usual
causes of insufficient braking action are worn-out braking linings
and excessive clearance between the brake lining and the drum. If
nothing can be found wrong with the brake system, the conditions
of use of the brakes should be considered. When the brake drags,
examination should be made to determine whether all the wheels or
only one particular wheel is affected. When only one wheel drags,
the brake body may be malfunctioning. When all the wheels are
affected, the problem may be in the operating mechanism. In the
case of braking action on only one side, not only the brake body but
also the tires should be taken into account.
Unusual noise produced when the brakes are applied is usually
attributable to “brake squeak”. In most cases, the cause is a deteri-
orated lining surface.
TD-4-7
PROBABLE CAUSE AND REMEDY
UNUSUAL NOISE
Symptom Probable cause Remedy
Unusual noise is z Exposed rivets or bolts due to worn linings z Replace linings.
emitted when brake z Hardened linings z Replace linings.
pedal is depressed.
z Deteriorated linings z Replace linings.
z Improper contact of brake shoe and linings z Drive rivets or tighten bolts.
z Uneven wear on inner surface of drum or loose instal- z Correct or re-tighten drum.
lation
z Loose brake shoe anchor pin z Adjust brake shoe clearance and tighten anchor
pin lock nut.
z Worn wheel bearing z Replace wheel bearing.
z Deformed brake drum z Correct or replace drum.
TD-4-8
PROBABLE CAUSE AND REMEDY
TD-4-9
PROBABLE CAUSE AND REMEDY
UNUSUAL NOISE
Refer to the “VACUUM SERVO HYDRAULIC BRAKE” section.
TD-4-10
PROBABLE CAUSE AND REMEDY
[AIR BRAKE]
INSUFFICIENT BRAKING FORCE
Symptom Probable cause Remedy
Brakes do not apply CORRECT AIR PRESSURE
completely or at all. z Short brake valve stroke z Check and, if necessary, replace brake valve.
z Camshaft inoperative (Lack of lubrication to bushing) z Check camshaft for operation and, if necessary,
replace.
z Brake chamber push rod stroke improperly adjusted z Adjust stroke.
z Improper sliding contact of relay valve z Disassemble and repair.
z Overheated or deteriorated brake lining z Replace lining.
z Improper contact of brake lining z Correct lining contact.
z Oil on lining or drum z Clean oil off with appropriate cleaner and
replace lining.
z Water entry into brake drum z Allow drum to dry by lightly depressing brake
pedal while car is in operation.
LOW AIR PRESSURE
z Air leakage in air line z Repair leaking point.
z Air compressor inoperative z Disassemble and repair air compressor.
z Air pressure governor maladjusted or inoperative due z Adjust or clean governor.
to entry of foreign matter
z Air leakage at brake valve z Disassemble and repair brake valve.
UNUSUAL NOISE
Refer to the “VACUUM SERVO HYDRAULIC BRAKE” section.
TD-4-11
PROBABLE CAUSE AND REMEDY
TD-4-12
PROBABLE CAUSE AND REMEDY
TD-4-13
PROBABLE CAUSE AND REMEDY
TD-4-14
ENGINE REMOVAL & INSTALLATION
ER
CONTENTS
SERVICE DATA ................................ ER-1-1 CONSTRUCTION ........................ ER-2-1
TIGHTENING TORQUE ............... ER-1-1 ENGINE INSTALLATION .................. ER-3-1
ENGINE REMOVAL ......................... ER-2-1
SERVICE DATA
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Bracket 29 {3.0, 22}
Front engine mounting bolt and nut
Cushion 49 {5.0, 36}
Front cushion mounting bolt 49 {5.0, 36}
Engine 49 {5.0, 36}
Rear cushion mounting bolt
Member 127 {13.0, 94}
ER-1-1
ENGINE REMOVAL
ENGINE REMOVAL
CONSTRUCTION
NOTE
z Numbers before part names do not indicate the disassembly sequence.
ER-2-1
ENGINE REMOVAL
WARNING
WARNING
z Cool the engine before removing parts. Otherwise, you
may be burned or fuel may ignite.
ER-2-2
ENGINE REMOVAL
ER-2-3
ENGINE INSTALLATION
ENGINE INSTALLATION
1. Install both the front and rear engine mounting insulators on
the engine.
ER-3-1
CLUTCH SYSTEM
CL
CLUTCH
CLUTCH UNIT (VAC SERVO TYPE)
CLUTCH UNIT (AIR SERVO TYPE)
CLUTCH
CONTENTS
SERVICE DATA...................................CL-1-1 INSTALLATION ...............................CL-3-9
SPECIFICATIONS.......................... CL-1-1 ADJUSTMENT ..................................CL-3-12
SERVICE DATA.............................. CL-1-2
TIGHTENING TORQUE ................. CL-1-6 = UNIT NAME CL710, 740, 750, 810 =
TOOLS.................................................CL-2-1 CONSTRUCTION................................CL-4-1
DISASSEMBLY ...................................CL-4-2
= UNIT NAME CL130, 205, 207 = REMOVAL .......................................CL-4-2
CONSTRUCTION ................................CL-3-1 DISASSEMBLY ...............................CL-4-5
DISASSEMBLY ...................................CL-3-2 INSPECTION.......................................CL-4-9
REMOVAL ...................................... CL-3-2 REASSEMBLY ..................................CL-4-14
DISASSEMBLY .............................. CL-3-4 REASSEMBLY ..............................CL-4-14
INSPECTION .......................................CL-3-6 INSTALLATION .............................CL-4-16
REASSEMBLY ....................................CL-3-9 ADJUSTMENT ..................................CL-4-18
REASSEMBLY ............................... CL-3-9
SERVICE DATA CLUTCH PROPER
SERVICE DATA
SPECIFICATIONS
UNIT NAME CL130, 205, 207
Unit name CL130 CL205 CL207
Type Diaphragm type single disc, dry
Facing dimensions 300 x 190 x 4 325 x 210 x 4
Clutch disc
UNIT NAME
CL 1 30
CL-1-1
SERVICE DATA CLUTCH PROPER
SERVICE DATA
UNIT NAME CL130, 205, 207
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Less than
Runout 1.3 (0.051)
1.0 (0.039)
Clutch disc Facing thickness (one side) — 0.2 (0.008) Above rivet head
Less than
Play in radial direction of spline 0.3 (0.012)
0.22 (0.0087)
Less than
CL130 0.2 (0.008)
Flatness of contact 0.05 (0.0020)
surface CL205 0.10 - 0.15
—
Clutch pressure CL207 (0.0039 - 0.0059)
plate 32.58 - 32.68
CL130 32.13 (1.2650)
Thickness of contact (1.2827 - 1.2866)
surface CL205 36.66 - 36.76
36.21 (1.4256)
CL207 (1.4433 - 1.4472)
44-46
CL130 —
Diaphragm spring (1.73 -1.81)
Clutch cover height CL205 56-58
—
assembly CL207 (2.20 -2.28)
Less than
Diaphragm spring height difference —
1.0 (0.039)
Less than
CL130 0.18 (0.0071)
Flatness of contact 0.15 (0.0059)
surface CL205 Less than
Flywheel 0.20 (0.0079)
CL207 0.05 (0.0020)
Thickness of contact Type I 20.5 (0.807) 18.5 (0.728)
surface Type II 21.5 (0.846) 19.5 (0.768)
CL205
Width of lever plate 4.0 (0.157) 3.6 (0.142)
CL207
24.96 - 24.98
Release shaft OD —
Clutch release (0.9827 - 0.9835)
mechanism 6.0 -7.0
VAC —
(0.236 - 0.276)
Clutch outer lever play
4.0 - 5.0
AOH —
(0.157 - 0.197)
CL-1-2
SERVICE DATA CLUTCH PROPER
CL-1-3
SERVICE DATA CLUTCH PROPER
Unit: mm (in)
Item Maintenance standard Service limit Remarks
FE6B Less than
0.2 (0.008)
FE6T 0.05 (0.0020)
CL710
Less than
NE6 0.2 (0.008)
0.12 (0.0047)
Flatness of FE6T
CL740
con-tact sur- FE6TA
face Less than
CL750 FE6T 0.2 (0.008)
0.05 (0.0020)
FE6T
FE6TA
CL810
NE6T Less than
0.2 (0.008)
NE6TA 0.12 (0.0047)
Thickness
23.0 (0.906) 21.0 (0.827)
FE6B (A)
FE6T Height
43.0 (1.693) 45.0 (1.772)
(H)
CL710
Thickness
26.0 (1.024) 24.0 (0.945)
(A)
NE6
Flywheel Height 42.9 - 43.1
45.0 (1.772)
(H) (1.689 - 1.697)
Thickness
23.0 (0.906) 21.0 (0.827)
FE6T (A)
CL740
FE6TA Height
Decrease in 43.0 (1.693) 45.0 (1.772)
(H)
thickness of
contact surface Thickness
23.0 (0.906) 21.0 (0.827)
(A)
CL750 FE6T
Height
43.0 (1.693) 45.0 (1.772)
(H)
Thickness
23.0 (0.906) 21.0 (0.827)
FE6T (A)
FE6TA Height
48.0 (1.890) 50.0 (1.969)
(H)
CL810
Thickness
21.0 (0.827) 19.0 (0.748)
NE6T (A)
NE6TA Height 47.9 - 48.1
50.0 (1.969)
(H) (1.886 - 1.894)
CL-1-4
SERVICE DATA CLUTCH PROPER
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Measure
after bushing
Release lever bushing ID — 10.2 (0.402) has been
pressed into
release lever
Lever pin and support pin OD — 9.8 (0.386)
Support ID — 10.2 (0.402)
MLS61A 24.96 - 24.98
—
MLS62A (0.9827 - 0.9835)
CL710
MPS50W 29.99 - 30.01
—
Release shaft MPS62T (1.1807 - 1.1815)
OD 24.96 - 24.98
CL740 —
(0.9827 - 0.9835)
CL750 29.99 - 30.01
—
CL810 (1.1807 - 1.1815)
Width of lever plate 7.0 (0.276) 6.3 (0.248)
Clutch release
mechanism CL710
77.5 - 78.5
CL740 —
(3.051 - 3.091)
CL750
Height of lever With
82.5 - 83.5
plate or lever —
(3.248 - 3.287)
release lever plate
CL810
Without
76.5 - 77.5
lever —
(3.012 - 3.051)
plate
Clearance between release lever
0.5 (0.020) —
and lever plate
5.0 -6.0
CL710 —
(0.197 -0.236)
Clutch outer 5.5 -6.5
CL740 —
lever play (0.217 -0.256)
CL750 6.0 -7.5
—
CL810 (0.236 -0.295)
CL-1-5
SERVICE DATA CLUTCH PROPER
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
CL130, 205, 207 30 - 41 {3.1 - 4.2, 22 - 30}
Clutch cover mounting bolt
CL710, 740, 750, 810 39 - 49 {4.0 - 5.0, 29 - 36}
CL130 20 - 25 {2.0 - 2.5, 14 - 18}
CL205 32 - 52 {3.3 - 5.3, 24 - 38}
Strap setting bolt
CL207 39 - 59 {4.0 - 6.0, 29 - 43}
CL710, 740, 750, 810 39 - 49 {4.0 - 5.0, 29 - 36}
Lock plate mounting bolt CL710, 740, 750, 810 10 - 15 {1.0 - 1.5, 7 - 11}
CL130 57 - 76 {5.8 - 7.7, 42 - 56}
CL205, 207 77 - 98 {7.9 - 10.0, 57 - 72}
MLS61A
89 - 118 {9.1 - 12.0, 66 - 87}
MLS62A
CL710
MPS50W
Clutch housing and transmission 137 - 186 {14.0 - 19.0, 101 - 137}
MPS62T
assembling bolt
CL740 127 - 157 {13.0 - 16.0, 94 - 116}
CL750 186 - 235 {19.0 - 24.0, 137 - 174}
MPS62T 137 - 186 {14.0 - 19.0, 101 - 137}
CL810 EATON
70 - 78 {7.1 - 8.0, 51 - 58}
6109
CL130 19 - 25 {1.9 - 2.5, 14 - 18}
CL205, 207 25 - 31 {2.5 - 3.2, 18 - 23}
FE6 25 - 31 {2.5 - 3.2, 18 - 23}
Clutch housing and flywheel housing CL710
NE6 40 - 54 {4.1 - 5.5, 30 - 40}
assembling bolt and nut
CL740, 750 25 - 31 {2.5 - 3.2, 18 - 23}
FE6 25 - 31 {2.5 - 3.2, 18 - 23}
CL810
NE6 40 - 54 {4.1 - 5.5, 30 - 40}
CL-1-6
TOOLS CLUTCH PROPER
TOOLS
Application
Tool name and number Description Shape CL CL CL CL CL CL CL
130 205 207 710 740 750 810
99797 Z5004 O
O O
99797 Z5011
*1 *2
Used to center clutch O O
99797 Z5012 disc and to inspect *2 *2
and adjust the height
O
99797 Z5009 of release levers (dia- O
Setting shaft *3
phragm spring). The
setting shaft is used O O
99797 Z5013
with the setting *4 *6
sleeve. O
99797 Z5010
*7
O O
99797 Z0010
*5 *8
NOTE
z *1 Without engine rear P.T.O.
z *2 With engine rear P.T.O.
z *3 FE6 engine for MLS series transmission
z *4 FE6 engine for MPS series transmission
z *5 NE6 engine
z *6 NE6 engine for EATON 6109 transmission
z *7 FE6 engine
z *8 NE6 engine for MPS series transmission
CL-2-1
CONSTRUCTION CL130, 205, 207
CL-3-1
DISASSEMBLY CL130, 205, 207
DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the clutch assembly, turn the key switch to
the “OFF” position and chock the wheels.
2. Be sure to remove the clutch booster and bracket as a unit
from the transmission, and fasten to the frame with twine.
NOTE
Setting sleeve
z CL205 and 207:
Use the basic line on 99798 Z5003 for CL210
CL-3-2
DISASSEMBLY CL130, 205, 207
z Even when the clutch disc setting tool is not available, mea-
sure and record distance between the release lever and the
end face of the flywheel bearing shown in the figure below.
NOTE
z If dimension “L” is over, replace the clutch disc.
Unit: mm (in)
Dimension
Unit name
“L”
CL130 74 (2.91)
CL205 Type I 88 (3.46)
CL207 Type II 89 (3.50)
CL-3-3
DISASSEMBLY CL130, 205, 207
DISASSEMBLY
CLUTCH COVER
CL-3-4
DISASSEMBLY CL130, 205, 207
CLUTCH HOUSING
CL-3-5
INSPECTION CL130, 205, 207
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has exceeded, repair or replace faulty parts.
CLUTCH DISC
Runout
Unit: mm (in)
Maintenance standard Service limit
Less than 1.0 (0.039) 1.3 (0.051)
CL-3-6
INSPECTION CL130, 205, 207
FLYWHEEL
Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
Less than
CL130 0.18 (0.0071)
0.15 (0.0059)
Less than
CL205, 207 0.20 (0.0079)
0.05 (0.0020)
CL-3-7
INSPECTION CL130, 205, 207
CL-3-8
REASSEMBLY CL130, 205, 207
REASSEMBLY
REASSEMBLY
CLUTCH COVER
Key point of reassembly
Before assembling, apply a coat of molybdenum disulfide grease to
all frictional surfaces.
z Sliding surfaces of wire ring and diaphragm spring
z Sliding surfaces of pressure plate and diaphragm spring
z Sliding surfaces of transmission main drive shaft and clutch
disc
2 Pressure plate
Place the clutch cover onto the pressure plate while matching the
matching marks made at the time of disassembly.
CLUTCH HOUSING
Key point of reassembly
18 Clutch housing
When installing the clutch housing onto the transmission case,
install shims on the bearing at the tip of the counter shaft.
NOTE
z Install shims by combining them so that they project by
0.2 to 0.3 mm (0.008 to 0.012 in) from the transmission
case end surface.
Shim thickness: 0.1, 0.2, 0.3 mm (0.004, 0.008, 0.012 in)
16 Release yoke
Start to tighten the lock nut only after the setscrew touches ( ) the
groove in the release shaft.
INSTALLATION
1. A small hole is drilled next to the knock pin hole in the clutch
cover to identify the knock pin hole. Be sure not to mistake
other mounting bolt holes for the knock pin hole when
mounting.
CL-3-9
REASSEMBLY CL130, 205, 207
CL-3-10
REASSEMBLY CL130, 205, 207
NOTE
z For the basic line of the setting shaft and setting sleeve
to be used, refer to page CL-3-2.
CL-3-11
ADJUSTMENT CL130, 205, 207
ADJUSTMENT
CLUTCH PEDAL PLAY
Depress the clutch pedal by hand until resistance is felt. While hold-
ing the clutch pedal in this position, measure the stroke length of
pedal play. If it is outside the specified range, adjust as follows:
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17) —
Fully depress the clutch pedal several times, then check to be sure
the end of the pointer is at the “SET” position.
CL-3-12
CONSTRUCTION CL710, 740, 750, 810
CL-4-1
DISASSEMBLY CL710, 740, 750, 810
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the clutch assembly, turn the key switch to
the “OFF” position and chock the wheels.
2. Be sure to remove the clutch booster and bracket as a unit
from the transmission, and fasten to the frame with twine.
NOTE
Steering sleeve
z CL740, 750 and CL810 (FE engine and NE engine with
EATON T/M):
Use the basic line on 99798 Z5003 for CL710
Setting shaft
z CL710 (FE engine with MPS T/M):
Use the basic line on 99797 Z5013 for CL810
CL-4-2
DISASSEMBLY CL710, 740, 750, 810
z CL740:
Use the basic line on 99797 Z5009 for CL710
CL-4-3
DISASSEMBLY CL710, 740, 750, 810
Even when the clutch disc setting tool is not available, measure and
record distance between the release lever and the end face of the
flywheel bearing shown in the figure below.
NOTE
z If dimension “L” is over, replace the clutch disc.
Unit: mm (in)
Unit name Dimension “L”
CL710 FE6B
CL740 FE6T 116.5 (4.59)
CL750 FE6TA
CL710 NE6 119.0 (4.69)
CL810 FE6T 115.5 (4.55)
CL810 FE6TA 120.5 (4.74)
NE6T
CL810 119.0 (4.69)
NE6TA
z Loosen the bolts which hold the clutch cover, and remove
the clutch cover assembly and clutch disc.
NOTE
z Be sure to loosen the bolts equally in a crisscross fash-
ion.
WARNING
WARNING
z Before removing the clutch cover assembly, support it
with lifting wires to prevent it from dropping.
CL-4-4
DISASSEMBLY CL710, 740, 750, 810
DISASSEMBLY
CLUTCH COVER
CL-4-5
DISASSEMBLY CL710, 740, 750, 810
CL-4-6
DISASSEMBLY CL710, 740, 750, 810
CLUTCH HOUSING
Transmission models MLS61A, MLS61B and MLS62A
CL-4-7
DISASSEMBLY CL710, 740, 750, 810
CL-4-8
INSPECTION CL710, 740, 750, 810
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has exceeded, repair or replace faulty parts.
CLUTCH DISC
Runout
Unit: mm (in)
Unit name Maintenance standard Service limit
CL710
CL740 Less than 0.7 (0.028) 1.0 (0.039)
CL750
CL810 Less than 1.0 (0.039) 1.4 (0.055)
CL-4-9
INSPECTION CL710, 740, 750, 810
CL810 FE6TA
NE6T 86.9 (3.421) 84.2 (3.315)
NE6TA
Tension
Unit: N {kgf, lbf}
Unit name Maintenance standard Service limit Remarks
799.3 - 883.6
757.1
CL710 {81.5 - 90.1,
{77.2, 170.2}
179.7 - 198.7}
When com-
947.4 - 1,047.4
897.3 pressed to
CL740 {96.6 - 106.8,
{91.5, 201.8} 54.8 mm
213.0 - 235.5}
(2.157 in)
1,062.1 - 1,173.9
1,006.2
CL750 {108.3 - 119.7,
{102.6, 226.2}
238.8 - 263.9}
1,323.9 1,258.2
FE6T
{135.0, 297.7} {128.3, 282.9} When com-
pressed to
CL810 FE6TA 1,026.8 - 1,134.7
972.9 59.6 mm
NE6T {104.7 - 115.7,
{99.2, 218.7} (2.346 in)
NE6TA 230.9 - 255.1}
CL-4-10
INSPECTION CL710, 740, 750, 810
Tilt
Unit: mm (in)
Unit name Maintenance standard Service limit Remarks
CL710 Less than 3.5 (0.138) 5.3 (0.209)
CL740 Less than 3.0 (0.118) 4.5 (0.177)
Measure at
CL750 Less than 2.8 (0.110) 4.2 (0.165)
free length
FE6T Less than 3.3 (0.130) —
CL810
NE6TA Less than 3.0 (0.118) 4.0 (0.157)
FLYWHEEL
Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
FE6B
Less than 0.05 (0.0020) 0.2 (0.008)
CL710 FE6T
NE6 Less than 0.12 (0.0047) 0.2 (0.008)
FE6T
CL740
FE6TA
CL750 FE6T Less than 0.05 (0.0020) 0.2 (0.008)
FE6T
FE6TA
CL810
NE6T
Less than 0.12 (0.0047) 0.2 (0.008)
NE6TA
Thickness
Unit: mm (in)
Unit name Maintenance standard Service limit
CL710 FE6B (A) 23.0 (0.906) 21.0 (0.827)
CL740 FE6T
CL750 FE6TA (H) 43.0 (1.693) 45.0 (1.772)
CL-4-11
INSPECTION CL710, 740, 750, 810
CL-4-12
INSPECTION CL710, 740, 750, 810
CL-4-13
REASSEMBLY CL710, 740, 750, 810
REASSEMBLY
REASSEMBLY
CLUTCH COVER
Key point of reassembly
Before assembling, apply a coat of molybdenum disulfide grease to
all frictional surfaces.
z Sliding surfaces of release lever and support pin
z Sliding surfaces of release lever and lever pin
z Sliding surfaces of transmission main drive shaft and clutch
disc
24 Lever support
z When installing the support, be sure the flat surface of the
support faces the outer side of the pressure plate.
z Use a new cotter pin.
18 Release lever
Attach the release lever assembly to the pressure plate using a
lever pin and cotter pin.
NOTE
z Use a new cotter pin.
14 Spring seat
13 Pressure spring
12 Spring
} CL810 (FE engine with
EATON transmission) model only
When installing the pressure spring, install it in the position marked
with O in the illustration.
NOTE
z Do not install the pressure spring in the position marked
with z in the illustration.
11 Clutch cover
Place the clutch cover onto the pressure plate while matching the
alignment marks made at the time of disassembly.
Using guide bolts or a press, firmly attach the clutch cover to the
pressure plate.
NOTE
z Using a round rod, correct the position of the pressure
spring.
CL-4-14
REASSEMBLY CL710, 740, 750, 810
2 Lever plate
Position the lever plate on the release lever and then install the
return spring.
NOTE
z Make sure that all of the release levers are the same
height when installing the return springs.
CLUTCH HOUSING
Key point of reassembly
<Transmission models MLS61A, MLS61B and MLS62A>
16 Release yoke
Secure the release shaft to the release yoke with a setscrew via the
lock nut.
NOTE
z Start to tighten the lock nut only after the setscrew
touches ( ) the groove in the release shaft.
CL-4-15
REASSEMBLY CL710, 740, 750, 810
INSTALLATION
Key point of installation
1. After assembling the clutch cover, install the clutch disc and
clutch cover to the flywheel housing using a setting tools.
NOTE
z Be sure to align the knock pins when installing the clutch
cover assembly.
z Remove the guide bolts after the clutch cover has been
installed on the flywheel.
z Tighten the clutch cover mounting bolts symmetrically
and equally.
z Evenly tighten the clutch cover mounting bolts in the
order indicated in the figure at right.
z Four bolts (painted red for identification) which are used
for suspending the pressure plate, are installed on the
clutch cover assembly as service parts. Be sure to
remove the bolts after tightening the clutch cover assem-
bly bolts.
CL-4-16
REASSEMBLY CL710, 740, 750, 810
NOTE
z For the basic line of the setting shaft and setting sleeve
to be used, refer to page CL-4-2.
3. After tightening the lock plate, remove the clutch disc set-
ting tool and tap on the lever plate several times with a
wooden mallet. Then insert the clutch disc setting tool again
and make sure that the reference line is aligned with posi-
tion “N”.
NOTE
z When reusing the clutch disc after it has been removed,
use the reference line which is verified during removal.
z If alignment is not made, readjust.
CL-4-17
ADJUSTMENT CL710, 740, 750, 810
ADJUSTMENT
CLUTCH PEDAL PLAY
Depress the clutch pedal by hand until resistance is felt. While hold-
ing the clutch pedal in this position, measure the stroke length of
pedal play. If it is outside the specified range, adjust as follows:
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17)
CL-4-18
ADJUSTMENT CL710, 740, 750, 810
NOTE
z Before checking wear on the clutch disc, ensure that
clutch pedal free play is adjusted to within the specified
range.
CL-4-19
CLUTCH UNIT
(VAC SERVO TYPE)
CONTENTS
SERVICE DATA ................................ CL-1- 1 REASSEMBLY ............................. CL-3- 5
SPECIFICATIONS ........................ CL-1- 1 ADJUSTMENT ............................. CL-3- 7
SERVICE DATA ............................ CL-1- 1 PERFORMANCE TEST ............... CL-3- 7
TIGHTENING TORQUE ............... CL-1- 2 CLUTCH MASTER CYLINDER ....... CL-4- 1
SYSTEM DIAGRAM ..................... CL-1- 2 CONSTRUCTION ........................ CL-4- 1
TOOLS ............................................. CL-2- 1 DISASSEMBLY ............................ CL-4- 2
CLUTCH BOOSTER ........................ CL-3- 1 INSPECTION ............................... CL-4- 3
CONSTRUCTION ........................ CL-3- 1 REASSEMBLY ............................. CL-4- 4
DISASSEMBLY ............................ CL-3- 2 ADJUSTMENT ............................. CL-4- 4
INSPECTION ............................... CL-3- 4
SERVICE DATA CLUTCH UNIT (VAC)
SERVICE DATA
SPECIFICATIONS
CLUTCH BOOSTER
Unit: mm (in)
Item Vacuum servo
Power piston diaphragm effective dia. 152.4 (6.00)
Hydraulic cylinder ID 19.05 (0.7500)
Relay piston OD 9.5 (0.374)
Relay valve diaphragm effective dia. 48.6 (1.913)
Push rod (power piston) OD 8 (0.31)
Power piston stroke 38 (1.50)
Hydraulic piston stroke 38 (1.50)
SERVICE DATA
CLUTCH BOOSTER
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Clearance between hydraulic piston and
— 0.08 (0.0031)
hydraulic cylinder
Clearance between relay piston and valve body — 0.13 (0.0051)
Bend of push rod — 0.15 (0.0059)
Free length 197 (7.76) —
Piston return spring When compressed to
Tension N {kgf, lbf} — 41.2 {4.2, 9.3}
77 mm (3.03 in)
Free length 47.7 (1.878) —
Relay valve spring When compressed to
Tension N {kgf, lbf} — 10.8 {1.1, 2.4}
28.6 mm (1.126 in)
Free length 22.8 (0.898) —
Poppet spring When compressed to
Tension N {kgf, lbf} — 2.9 {0.3, 0.7}
13.1 mm (0.516 in)
CL-1-1
SERVICE DATA CLUTCH UNIT (VAC)
TIGHTENING TORQUE
CLUTCH BOOSTER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Diaphragm retainer (power piston) mounting nut 19.6 - 29.4 {2.0 - 3.0, 14 - 22}
Tube connector 14.7 - 39.2 {1.5 - 4.0, 11 - 29}
Valve body mounting screw 1.0 - 2.0 {0.1 - 0.2, 0.7 - 1.4}
Rear shell mounting nut 9.8 - 15.7 {1.0 - 1.6, 7 - 12}
Plug (air bleeder) 4.9 - 7.8 {0.5 - 0.8, 3.6 - 5.8}
MASTER CYLINDER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Stopper bolt 1.5 - 2.9 {0.15 - 0.30, 1.1 - 2.2}
Nipple 25 - 34 {2.5 - 3.5, 18 - 25}
SYSTEM DIAGRAM
CL-1-2
TOOLS CLUTCH UNIT (VAC)
TOOLS
Tool name and number Description Shape
Used to secure the front shell
Bracket
1340-0017
Plate
910-22061
Lever
910-22100
Bolt
11000-0123
Nut
11000-0132
CL-2-1
TOOLS CLUTCH UNIT (VAC)
Cup guide
910-23284
Cup guide
910-23285
Guide pin
910-20061
NOTE
z Parts Nos. are adopted by Jidosha Kiki.
CL-2-2
CLUTCH BOOSTER CLUTCH UNIT (VAC)
CLUTCH BOOSTER
CONSTRUCTION
CL-3-1
CLUTCH BOOSTER CLUTCH UNIT (VAC)
DISASSEMBLY
CL-3-2
CLUTCH BOOSTER CLUTCH UNIT (VAC)
22 Rear shell
Attach the special tool (plate: 910-22061, lever: 910-22100, bolt:
1100-0123, nut: 1100-0132) to the rear shell stud. Turn the rear
shell counterclockwise until the stopper comes off. Then, remove
the rear shell, power piston assembly and return spring.
NOTE
z Be careful because the rear shell may jump up by the
return spring force when the stopper is released.
CL-3-3
CLUTCH BOOSTER CLUTCH UNIT (VAC)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between hydraulic piston and hydraulic cyl-
inder
Unit: mm (in)
Maintenance standard Service limit
— 0.08 (0.0031)
CL-3-4
CLUTCH BOOSTER CLUTCH UNIT (VAC)
REASSEMBLY
Key point of reassembly
33 35 Cup packings
Using the cup guide (fluid pressure side: 910-23286, atmospheric
pressure side: 910-23287), install the cup packings on the hydraulic
piston. The two cup packings are not the same. Be careful of the
mounting position and direction.
NOTE
z Apply a coat of brake fluid to the cup packing before
installation. After installation, apply a coat of rubber
grease to its periphery.
34 Hydraulic piston
NOTE
z Pay attention to the direction of the hydraulic piston.
z Always face the ends of the retaining ring in a horizontal
direction.
23 Nut
Punch the nut at two places to lock it.
22 Rear shell
To install the rear shell, use the special tool (plate: 910-22061,
lever: 910-22100, bolt: 1100-0123, nut: 1100-0132). Perform as fol-
lows:
Align the rear shell and front shell as shown in the figure. Push the
former against the latter. With the two shells held in that position,
turn the rear shell's stud bolt until the cut-out portion contacts the
stopper. Next, secure the two shells.
CL-3-5
CLUTCH BOOSTER CLUTCH UNIT (VAC)
17 19 Cup packings
z Apply a coat of brake fluid to the cup packing before instal-
lation.
8 Poppet valve
Install the poppet valve to the valve body as follows:
Insert the vacuum valve into the valve body on the diaphragm side,
and the atmospheric valve on the other side.
Fasten the screw which is on the atmospheric valve into the vac-
uum valve so the seating surface of the vacuum valve is 1.6 to 2.4
mm (0.063 to 0.094 in) (L) away from the mounting surface of the
valve body.
NOTE
z Apply Three Bond #1324 or equivalent to the threaded
portion of the poppet valve. Then, tighten it and peen the
thread.
CL-3-6
CLUTCH BOOSTER CLUTCH UNIT (VAC)
ADJUSTMENT
Air bleeding the fluid line. For this procedure, refer to the “MA” section.
PERFORMANCE TEST
TEST USING A TESTER
Item to test Description
Air tightness for fluid pressure When a vacuum pressure of 80.0 kPa {600 mmHg, 23.62 inHg} is held within the line
for 15 seconds, a pressure drop should not exceed 0.3 kPa {2 mmHg, 0.08 inHg}.
Air tightness under no load When a vacuum pressure of 66.7 kPa {500 mmHg, 19.69 inHg} is held within the line for
15 seconds, a pressure drop should not exceed 0.33 kPa {2.5 mmHg, 0.098 inHg}.
Air tightness under full load A vacuum pressure drop should not exceed 0.33 kPa {2.5 mmHg, 0.098 inHg}
when a vacuum pressure of 66.7 kPa {500 mmHg, 19.69 inHg}, a clutch master
fluid pressure of 3,432 kPa {35 kgf/cm2, 498 psi} and an output of 1,893±147 N
{193±15 kgf, 426±33 lbf} are held for 15 seconds.
Air tightness under high pressure When a clutch master fluid pressure of 9,807 kPa {100 kgf/cm2, 1,422 psi} is held
for 15 seconds, a pressure drop should not exceed 981 kPa {10 kgf/cm2, 142 psi}.
Boosting performance under light load Output should be within the 608 to 804 N {62 to 82 kgf, 137 to 181 lbf} range
when a vacuum pressure of 66.7 kPa {500 mmHg, 19.69 inHg} and a clutch
master fluid pressure of 1,177 kPa {12 kgf/cm2, 171 psi} are held.
Boosting performance under full load Output should be within the 1,746 to 2,040 N {178 to 208 kgf, 392 to 459 lbf}
range when a vacuum pressure of 66.7 kPa {500 mmHg, 19.69 inHg} and a
clutch master's fluid pressure of 3,432 kPa {35 kgf/cm2, 498 psi} are held.
CL-3-7
CLUTCH BOOSTER CLUTCH UNIT (VAC)
CL-3-8
CLUTCH MASTER CYLINDER CLUTCH UNIT (VAC)
CL-4-1
CLUTCH MASTER CYLINDER CLUTCH UNIT (VAC)
DISASSEMBLY
REMOVAL
1. Pedal bracket assembly 6. Clutch master cylinder assembly 10. Pedal bushing
2. Switch bracket 7. Pedal shaft 11. Pedal bushing
3. P.T.O. switch assembly 8. Clutch pedal assembly 12. Stopper
4. Switch push-plate 9. Return spring 13. Stopper
5. Exhaust brake switch assembly
NOTE
z Numbers before part names do not indicate the disas-
sembly sequence.
CL-4-2
CLUTCH MASTER CYLINDER CLUTCH UNIT (VAC)
DISASSEMBLY
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between pedal shaft and bushing
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
CL-4-3
CLUTCH MASTER CYLINDER CLUTCH UNIT (VAC)
REASSEMBLY
REASSEMBLY
Key point of reassembly
09 Piston assembly
1. Apply a coat of rubber grease to the cup, cylinder and the
frictional surface of the piston.
2. Ensure the cup is installed with lip facing the valve.
INSTALLATION
Key point of installation
1. Apply grease to the shaft bushing and spring when installing
the clutch pedal assembly onto the pedal bracket assembly.
2. If the clutch pedal has no free play when the clutch master cyl-
inder is installed onto the pedal assembly, loosen the lock nut
and turn the push rod clockwise to adjust the free play.
ADJUSTMENT
Air bleeding the fluid line. For this procedure, refer to the “MA” sec-
tion.
CL-4-4
CLUTCH UNIT
(AIR SERVO TYPE)
CONTENTS
SERVICE DATA ................................ CL-1- 1 INSPECTION ............................... CL-3- 3
SPECIFICATIONS ........................ CL-1- 1 REASSEMBLY ............................. CL-3- 5
SERVICE DATA ............................ CL-1- 1 PERFORMANCE TEST ............... CL-3- 5
TIGHTENING TORQUE ............... CL-1- 2 CLUTCH MASTER CYLINDER ....... CL-4- 1
SYSTEM DIAGRAM ..................... CL-1- 3 CONSTRUCTION ........................ CL-4- 1
TOOLS ............................................. CL-2- 1 DISASSEMBLY ............................ CL-4- 2
CLUTCH BOOSTER ........................ CL-3- 1 INSPECTION ............................... CL-4- 3
CONSTRUCTION ........................ CL-3- 1 REASSEMBLY ............................. CL-4- 4
DISASSEMBLY ............................ CL-3- 2 ADJUSTMENT ............................. CL-4- 4
SERVICE DATA CLUTCH UNIT (AIR)
SERVICE DATA
SPECIFICATIONS
CLUTCH BOOSTER
Unit: mm (in)
*Unit name 04554
04017 04021 04022 04351 04547
Item 04581
Power cylinder ID 70 (2.76) 70 (2.76) 90 (3.54)
Hydraulic cylinder ID 22.2 (0.874) 19.05 (0.7500) 22.2 (0.874) 22.2 (0.874)
Liquid pres-
16.0 (0.630) 12.7 (0.500) 16.0 (0.630) 12.7 (0.500) 12.7 (0.500) 16.0 (0.630)
Relay piston sure side
OD Atmospheric
27.0 (1.063) 27.0 (1.063) 27.0 (1.063)
side
Push rod OD 8.0 (0.315) 8.0 (0.315)
Power cylinder stroke 35.8 (1.409) 35.8 (1.409)
Relay piston stroke 3.6 (0.142) 3.6 (0.142)
* Identification of the clutch booster unit
The unit can be clearly identified by the number stamped on the power cylinder name plate.
Ex. 642-04017 (Refer to type 04017.)
SERVICE DATA
CLUTCH BOOSTER
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Clearance between power piston and cylinder shell — 1.5 (0.059)
Clearance between hydraulic piston and hydraulic cylinder — 0.08 (0.0031)
Clearance between relay piston Liquid pressure side — 0.11 (0.043)
and body Atmospheric side — 0.3 (0.012)
Bend of push rod — 0.15 (0.0059)
Free length 90.2 (3.551) —
Piston return When compressed
spring Tension N {kgf, lbf} — 66.69 {6.80, 14.99} to 59.9 mm
(2.358 in)
Free length 28.2 (1.110) —
Relay piston When compressed
return spring Tension N {kgf, lbf} — 10.40 {1.06, 2.34} to 13.1 mm
(0.516 in)
Free length 22.1 (0.870) —
CL-1-1
SERVICE DATA CLUTCH UNIT (AIR)
TIGHTENING TORQUE
CLUTCH BOOSTER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
For power cylinder ID 70 14.7 - 19.6 {1.5 - 2.0, 11 - 14}
Body and cylinder shell assembling bolt
For power cylinder ID 90 19.6 - 29.4 {2.0 - 3.0, 14 - 22}
Upper valve body mounting bolt 3.9 - 5.9 {0.4 - 0.6, 2.9 - 4.3}
Connector 19.6 - 29.4 {2.0 - 3.0, 14 - 22}
Power piston mounting nut 19.6 - 29.4 {2.0 - 3.0, 14 - 22}
Air bleeder screw 6.9 - 12.7 {0.7 - 1.3, 5.1 - 9.4}
Breather 14.7 - 19.6 {1.5 - 2.0, 11 - 14}
MASTER CYLINDER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Stopper bolt 1.5 - 2.9 {0.15 - 0.30, 1.1 - 2.2}
Nipple 25 - 34 {2.5 - 3.5, 18 - 25}
CL-1-2
SERVICE DATA CLUTCH UNIT (AIR)
SYSTEM DIAGRAM
CL-1-3
TOOLS CLUTCH UNIT (AIR)
TOOLS
CLUTCH BOOSTER
* Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and number Application
Liquid Atmo- Description Shape 04554
pres- spheric 04017 04021 04022 04351 04547
04581
sure side side
CL-2-1
CLUTCH BOOSTER CLUTCH UNIT (AIR)
CLUTCH BOOSTER
CONSTRUCTION
CL-3-1
CLUTCH BOOSTER CLUTCH UNIT (AIR)
DISASSEMBLY
CL-3-2
CLUTCH BOOSTER CLUTCH UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
CL-3-3
CLUTCH BOOSTER CLUTCH UNIT (AIR)
Free length
Unit: mm (in)
Item Maintenance standard Service limit
Piston return spring 90.2 (3.551) —
Relay piston return
28.2 (1.110) —
spring
Poppet spring 22.1 (0.870) —
Tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
Piston return 66.69 When compressed to
—
spring {6.80, 14.99} 59.9 mm (2.358 in)
Relay piston 10.40 When compressed to
—
return spring {1.06, 2.34} 13.1 mm (0.516 in)
2.26 When compressed to
Poppet spring —
{0.23, 0.51} 13.0 mm (0.512 in)
CL-3-4
CLUTCH BOOSTER CLUTCH UNIT (AIR)
REASSEMBLY
Key point of reassembly
26, 27 Cup packing
Using the cup packing inserting guide, install the cup packings to
the hydraulic piston.
Pay attention to the installation position and direction as two cup
packings are not the same.
Cup packing inserting guide
Unit name
Liquid pressure side Atmospheric side
04017
04351
Cup diameter
04547 910-23280 910-23281
22.2 mm (0.874 in)
04554
04581
04021 Cup diameter
910-23284 910-23285
04022 19.05 mm (0.7500 in)
12 Cup packing
Using the cup packing inserting guide, install the cup packing to the
relay piston assembly.
Cup packing inserting guide
Unit name
Liquid pressure side Atmospheric side
04017
04022 Cup diameter16.0
910-24902 910-24905
04554 mm (0.630 in)
04581
04021
Cup diameter12.7
04351 910-24900 910-24903
mm (0.500 in)
04547
PERFORMANCE TEST
AIR TIGHTNESS TEST
With the clutch booster attached to the vehicle, raise the air pres-
sure to 588 kPa {6 kgf/cm<sup>2<reset>, 85 psi} or more, then
loosen the plugs on the clutch booster exhaust pipe and cylinder
shell bottom to determine whether any compressed air leaks.
CL-3-5
CLUTCH BOOSTER CLUTCH UNIT (AIR)
OPERATION TEST
Depress the clutch pedal repeatedly and then check the movement
of the clutch booster push rod by listening to the noise of com-
pressed air being discharged from the exhaust pipe. The push rod
must move smoothly without any delay.
CL-3-6
CLUTCH BOOSTER CLUTCH UNIT (AIR)
CL-3-7
CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)
CL-4-1
CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)
DISASSEMBLY
REMOVAL
1. Pedal bracket assembly 6. Clutch master cylinder assembly 10. Pedal bushing
2. Switch bracket 7. Pedal shaft 11. Pedal bushing
3. P.T.O. switch assembly 8. Clutch pedal assembly 12. Stopper
4. Switch push-plate 9. Return spring 13. Stopper
5. Exhaust brake switch assembly
NOTE
z Numbers before part names do not indicate the disas-
sembly sequence.
CL-4-2
CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)
DISASSEMBLY
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between pedal shaft and bushing
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
CL-4-3
CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)
REASSEMBLY
REASSEMBLY
Key point of reassembly
9 Piston assembly
1. Apply a coat of rubber grease to the cup, cylinder and the
frictional surface of the piston.
2. Ensure the cup is installed with lip facing the valve.
INSTALLATION
Key point of installation
1. Apply grease to the shaft bushing and spring when install-
ing the clutch pedal assembly onto the pedal bracket
assembly.
2. If the clutch pedal has no free play when the clutch master
cylinder is installed onto the pedal assembly, loosen the
lock nut and turn the push rod clockwise to adjust the free
play.
ADJUSTMENT
Air bleeding the fluid line. For this procedure, refer to the “MA” sec-
tion.
CL-4-4
TRANSMISSION SYSTEM
TM
TRANSMISSION PROPER
TRANSMISSION PTO
TRANSMISSION LINKAGE
TRANSMISSION PROPER
CONTENTS
SERVICE DATA ................................ TM-1-1 REASSEMBLY ........................... TM-5-17
SPECIFICATIONS ........................ TM-1-1 INSTALLATION .......................... TM-5-21
SERVICE DATA ............................ TM-1-3
TIGHTENING TORQUE ............. TM-1-15 = UNIT NAME MLS62 =
TOOLS .............................................. TM-2-1
CONSTRUCTION ............................. TM-6-1
= UNIT NAME MHS50 = DISASSEMBLY ................................ TM-6-4
REMOVAL .................................... TM-6-4
CONSTRUCTION ............................. TM-3-1 DISASSEMBLY ............................ TM-6-5
DISASSEMBLY ................................ TM-3-3 INSPECTION .................................. TM-6-19
REMOVAL .................................... TM-3-3 REASSEMBLY ............................... TM-6-23
DISASSEMBLY ............................ TM-3-4 REASSEMBLY ........................... TM-6-23
INSPECTION .................................. TM-3-12 INSTALLATION .......................... TM-6-32
REASSEMBLY ............................... TM-3-16
REASSEMBLY ........................... TM-3-16 = UNIT NAME MPS50 =
INSTALLATION ........................... TM-3-21
CONSTRUCTION ............................. TM-7-1
= UNIT NAME MHS60 = DISASSEMBLY ................................ TM-7-3
REMOVAL .................................... TM-7-3
CONSTRUCTION ............................. TM-4-1 DISASSEMBLY ............................ TM-7-4
DISASSEMBLY ................................ TM-4-3 INSPECTION .................................. TM-7-15
REMOVAL .................................... TM-4-3 REASSEMBLY ............................... TM-7-20
DISASSEMBLY ............................ TM-4-4 REASSEMBLY ........................... TM-7-20
INSPECTION .................................. TM-4-13 INSTALLATION .......................... TM-7-27
REASSEMBLY ............................... TM-4-17
REASSEMBLY ........................... TM-4-17 = UNIT NAME MPS62 =
INSTALLATION ........................... TM-4-22
CONSTRUCTION ............................. TM-8-1
= UNIT NAME MLS61 = DISASSEMBLY ................................ TM-8-4
REMOVAL .................................... TM-8-4
CONSTRUCTION ............................. TM-5-1 DISASSEMBLY ............................ TM-8-5
DISASSEMBLY ................................ TM-5-3 INSPECTION .................................. TM-8-19
REMOVAL .................................... TM-5-3 REASSEMBLY ............................... TM-8-23
DISASSEMBLY ............................ TM-5-4 REASSEMBLY ........................... TM-8-23
INSPECTION .................................. TM-5-13 INSTALLATION .......................... TM-8-32
REASSEMBLY ............................... TM-5-17
SERVICE DATA T/M PROPER
SERVICE DATA
SPECIFICATIONS
Unit name MHS50T MHS60A MLS61A MLS61B MLS62A MPS50W MPS62B MPS62T
6 speeds forward, 1
speed reverse
(Synchro-
5 speeds 6 speeds 5 speeds mesh
6 speeds
forward, 1 forward, 1 forward, 1 type: 1-6
forward, 1
speed speed speed speeds
speed
reverse reverse reverse Constant (Synchro-
6 speeds forward, 1 reverse
(Synchro- (Synchro- (Synchro- mesh mesh
speed reverse (Synchro-
mesh mesh mesh type: type: 2-6
(Synchromesh type: 2-6 mesh
Transmission system type: 2-5 type: 2-6 type: 2-5 reverse) or speeds
speeds type: 1-6
speeds speeds speeds (Synchro- Constant
Constant mesh type: 1 speeds
Constant Constant Constant mesh mesh
speed and reverse) Constant
mesh mesh mesh type: 2-6 type: 1
mesh
type: 1 type: 1 type: 1 speeds speed and
type:
speed and speed and speed and Constant reverse)
reverse)
reverse) reverse) reverse) mesh
type: 1
speed and
reverse)
Operating system Remote control
TM-1-1
SERVICE DATA T/M PROPER
No. of modifications
No. of gearshift stages
(5: 5 speed)
(6: 6 speed)
Main transmission
(S: With synchromesh)
Distance between main
shaft and counter shaft
Transmission type
M: Manual
TM-1-2
SERVICE DATA T/M PROPER
SERVICE DATA
UNIT NAME: MHS50, MHS60, MLS61 AND MLS62
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
Clearance between shift lever 0.1 - 0.4 0.8
O O O O
and select lever assembly (0.004 - 0.016) (0.031)
0.05 - 0.11
Radial play between inner 0.5
(0.0020 - O O O O
shaft and shift lever splines (0.020)
0.0043)
0.1 - 0.4 0.8
O — O —
(0.004 - 0.016) (0.031)
Clearance between shift lever 0.7 - 1.0 1.4
— O — —
and shifters (0.028 - 0.039) (0.055)
0.4 - 0.7 0.8
— — — O
(0.016 - 0.028) (0.031)
Clearance between transmis- 0.1 - 0.2 0.8
O O O O
sion cover and fork shaft (0.004 - 0.008) (0.031)
0.04 - 0.07
(0.0016 - O — — —
Clearance between transmis- 0.0028) 0.1
sion cover and select lever 0.03 - 0.08 (0.004)
(0.0012 - — O O O
Transmis- 0.0031)
sion cover
When com-
Fork shaft locking spring force 80.71 pressed to
— O O O O
N {kgf, lbf} {8.23, 18.15} 26 mm
(1.02 in)
When com-
73.6 pressed to
— O O O —
{7.5, 16.5} 35 mm
(1.38 in)
Left side
When com-
39.2 pressed to
— — — — O
Resist pin {4.0, 8.8} 15.5 mm
locking spring (0.610 in)
force When com-
N {kgf, lbf} 27.56 pressed to
— — O O —
{2.81, 6.20} 19 mm
(0.75 in)
Right side
When com-
25.5 pressed to
— — — — O
{2.6, 5.7} 15.2 mm
(0.598 in)
TM-1-3
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
When com-
50.80 pressed to
O — — —
{5.18, 11.42} 35 mm
(1.38 in)
When com-
27.36 pressed to
Left side — — O O —
{2.79, 6.15} 38.5 mm
(1.516 in)
When com-
Resist spring 29.42 pressed to
force — — — O
{3.0, 6.62} 36 mm
Transmis- N {kgf, lbf} (1.42 in)
sion cover
40.80 When com- — O — —
{4.16, 9.17} pressed to
38.54 37 mm
(1.46 in) — — O —
{3.93, 8.67}
Right side —
When com-
29.42 pressed to
— — — O
{3.0, 6.62} 36 mm
(1.42 in)
0.10 - 0.29
Clearance between shift fork 1.0
(0.0039 - O O O O
and sleeve groove (0.039)
0.0114)
TM-1-4
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
0.35
0.10 - 0.20 O — — —
Each main gear and counter (0.0138)
(0.0039 -
gear backlash 0.50
0.0079) — O O O
(0.0197)
0.28 - 0.69
(0.0110 - O — — —
0.0272)
0.28 - 0.70
0.9
1st-2nd gear (0.0110 - — O O —
(0.035)
0.0276)
0.28 - 0.42
(0.0110 - — — — O
0.0165)
0.46 - 0.91
1.1
(0.0181 - O — — —
(0.043)
0.0358)
0.26 - 0.70
3rd-4th gear (0.0102 - — O — —
0.0276) 0.9
0.20 - 0.70 (0.035)
(0.0079 - — — — —
Transmis-
0.0276)
sion proper
0.20 - 0.80
Each main
(0.0079 - — — O —
gear end play
0.0315) 0.9
3rd gear
0.34 - 0.56 (0.035)
(0.0134 - — — — O
0.0220)
0.20 - 0.74
(0.0079 - — — O —
0.0291) 0.9
4th gear
0.06 - 0.54 (0.035)
(0.0024 - — — — O
0.0213)
0.26 - 0.70
(0.0102 - — O — —
0.0276)
0.20 - 0.70
0.9
6th gear (0.0079 - — — O —
(0.035)
0.0276)
0.26 - 0.44
(0.0102 - — — — O
0.0173)
TM-1-5
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
0.46 - 0.64
0.9
(0.0181 - O — — —
(0.035)
0.0252)
0.21 - 0.64
0.8
(0.0083 - — O — —
(0.031)
Each main 0.0252)
Reverse gear
gear end play 0.20 - 0.50
(0.0079 - — — O —
0.0197) 0.7
0.26 - 0.44 (0.028)
(0.0102 - — — — O
0.0173)
0.24 - 0.46
(0.0094 - O — — —
0.0181)
0.28 - 0.42
0.7
Reverse idler gear end play (0.0110 - — O — —
(0.028)
0.0165)
0.34 - 0.56
(0.0134 - — — O O
0.0220)
0.20 - 0.30
Transmis- 0.5
(0.0079 - O — — —
sion proper (0.020)
0.0118)
0.98 - 1.08
1.3
1st gear (0.0386 - — O — —
(0.051)
0.0425)
0.40 - 0.50
0.7
(0.0157 - — — O O
(0.028)
0.0197)
0.20 - 0.30
Radial play 0.5
(0.0079 - O — O O
between (0.020)
0.0118)
sleeves and 2nd gear
clutch gear 0.69 - 0.79
1.0
splines (0.0272 - — O — —
(0.039)
0.0311)
0.20 - 0.30
0.5
(0.0079 - O — — O
(0.020)
0.0118)
0.39 - 0.49
3rd gear (0.0154 - — O — —
0.0193) 0.7
0.40 - 0.50 (0.028)
(0.0157 - — — O —
0.0197)
TM-1-6
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
0.20 - 0.30
0.5
(0.0079 - O — — O
(0.020)
0.0118)
0.39 - 0.49
4th gear (0.0154 - — O — —
0.0193) 0.7
0.40 - 0.50 (0.028)
(0.0157 - — — O —
0.0197)
0.67 - 0.77
1.0
(0.0264 - — O — —
(0.039)
0.0303)
6th gear
0.20 - 0.30
0.5
(0.0079 - — — O O
(0.020)
0.0118)
Radial play
between 0.20 - 0.30
Transmis- 0.5
sleeves and (0.0079 - O — — —
sion proper (0.020)
clutch gear 0.0118)
splines
0.39 - 0.49
Reverse gear (0.0154 - — O — —
0.0193) 0.7
0.40 - 0.50 (0.028)
(0.0157 - — — O O
0.0197)
0.20 - 0.30
0.5
(0.0079 - O — O —
(0.020)
0.0118)
0.67 - 0.77
Main drive 1.0
(0.0264 - — O — —
gear (0.039)
0.0303)
0.40 - 0.50
0.7
(0.0157 - — — — O
(0.028)
0.0197)
TM-1-7
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
0.10 - 0.20
1st-reverse 0.3
(0.0039 -
gear (0.012)
0.0079)
0.22 - 0.29
0.5
2nd-3rd gear (0.0087 - O — — —
(0.020)
0.0114)
0.10 - 0.20
4th-main 0.3
(0.0039 -
drive gear (0.012)
0.0079)
Reverse gear
Radial play 1st-2nd gear 0.20 - 0.30
between hub 0.5
3rd-4th gear (0.0079 - — O — O
Transmis- and sleeve (0.020)
0.0118)
sion proper splines 6th-main
drive gear
Reverse gear 0.20 - 0.30
0.5
(0.0079 - — — O —
1st-2nd gear (0.020)
0.0118)
0.20 - 0.30
3rd-4th gear (0.0079 -
0.0118) 0.5
— — O —
0.20 - 0.30 (0.020)
6th-main
(0.0079 -
drive gear
0.0118)
0.5
Ball bearing axial play — O O O O
(0.020)
Determine
average
Synchro- value by
Level of 2nd synchronizer ring 0 - 0.5 1.0
nizer sys- measuring — O O —
and disc (0 - 0.020) (0.039)
tem two points
that are
180º apart.
TM-1-8
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
standard limit MHS50T MHS60A MLS62A
MLS61B
2nd-3rd 1.9 - 2.1 0.5
O — — —
4th-5th (0.075 - 0.083) (0.020)
Clearance
between syn- 1.35 - 1.55
chronizer ring 3rd-4th (0.0531 -
and each 0.0610) 0.5
— O O —
gear 1.30 - 1.70 (0.020)
5th-6th (0.0512 -
0.0669)
4.90 - 5.25
2nd-3rd (0.1929 - —
0.2067)
O — — —
Synchro- 4.20 - 4.55
nizer sys- 4th-5th (0.1654 - —
tem 0.1791)
Radial clear-
3.59 - 3.95
ance between
3rd-4th (0.1413 - —
strut and syn-
0.1555)
chronizer ring — O — —
3.39 - 3.75
5th-6th (0.1335 - —
0.1476)
3rd-4th 3.50 - 3.85
(0.1378 - — — — O —
5th-6th 0.1516)
0.04 - 0.19
Clearance between synchro-
(0.0016 - — O O O —
nizer hub and strut
0.0075)
TM-1-9
SERVICE DATA T/M PROPER
TM-1-10
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance
Item Service limit Remarks MPS62A
standard MPS50W
MPS62T
0.1 - 0.2
O —
Main gear and counter gear back- (0.004 - 0.008)
0.5 (0.020)
lash 0.09 - 0.19
— O
(0.0035 - 0.0075)
0.3 - 0.5
0.7 (0.028) O —
(0.012 - 0.020)
End play of main gears
0.2 - 0.4
0.6 (0.024) — O
(0.008 - 0.016)
0.3 - 0.6
O —
(0.012 - 0.024)
End play of reverse idler gear 1.0 (0.039)
Transmission 0.3 - 0.8
proper — O
(0.012 - 0.031)
Radial play 0.2 - 0.3 O —
between hub (0.008 - 0.012)
Except 5th & 6th — O
(incl. main shaft) 0.5 (0.020)
and sleeve 0.07 - 0.34
5th & 6th only — O
splines (0.0028 - 0.0134)
TM-1-11
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MPS62A
standard limit MPS50W
MPS62T
-0.2 to 0.4 Minus (-) sym-
Alignment of synchronizer rings with
Pin type (-0.008 to — bol: Protrusion O —
their discs
0.016) from the disc
1.6 - 2.5
— O —
(0.063 - 0.098)
Clearance
between Outer ring- 1.7 - 2.3
Double — Measure as a — O
synchro- inner ring (0.067 - 0.091)
cone type set including
nizer ring Cone-inner 0.8 - 1.2
(2nd-3rd) — three parts. — O
and their ring (0.031 - 0.047)
cone
Single cone type 1.5 - 2.5
— — O
(4th-6th) (0.059 - 0.098)
Tangential clearance between synchro- 5.3 - 5.7
— O —
Synchro- nizer ring and synchronizer hub (0.209 - 0.224)
nizer Radial The wear limit
system Locking Double cone type 6.4 - 6.8 1.0
clearance is specified as — O
plunger (2nd-3rd) (0.252 - 0.268) (0.039)
between a single ring.
type
synchro-
6.9 - 7.3
nizer ring Single cone 4th The wear limit — O
(0.272 - 0.287) 1.0
and syn- type is specified as
chronizer 4.9 - 5.3 (0.039)
(4th-6th) 5th-6th a single ring. — O
hub (0.193 - 0.209)
Radial 0.05 - 0.35
clearance (0.0020 - — O —
between 0.0138)
synchro-
nizer hub 0.1 - 0.3
and syn- 2nd-6th (0.004 - — — O
chronizer 0.012)
detent
TM-1-12
SERVICE DATA T/M PROPER
Unit: mm (in)
Application
Maintenance Service
Item Remarks MPS62A
standard limit MPS50W
MPS62T
Free length 15 (0.59) — O —
When com-
Type I 5.9 - 9.8
Tension 3.9 pressed to
{0.6 - 1.0, O —
N {kgf, lbf} {0.4, 0.9} 12.5 mm
1.3 - 2.2}
(0.492 in)
Free A 15 (0.59) — O
—
length B 13.5 (0.531) — (Set)
21.6 - 26.5
18.6
*1 {2.2 - 2.7,
{1.9, 4.2} When com-
4.9 - 6.0}
A pressed to 12
29.4 - 35.3 mm (0.47 in)
24.5
Type II *2 {3.0 - 3.6,
{2.5, 5.5}
Locking Tension 6.6 - 7.9} O
Detent —
plunger N {kgf, lbf} 6.4 - 7.8 (Set)
spring
type *1 {0.65 - 0.8,
Synchro- 1.4 - 1.8} When com-
4.9
nizer sys- B pressed to 12
5.9 - 7.4 {0.5, 1.1}
tem mm (0.47 in)
*3 {0.6 - 0.75,
1.3 - 1.7}
Free A 15 (0.59) — O
—
length B 13.5 (0.531) — (Set)
40.31 - 44.62
40.31
Type III A *2 {4.11 - 4.55,
{4.11, 9.06} When com-
Tension 9.06 - 10.03} pressed to O
—
N {kgf, lbf} 10.30 - 11.47 10.30 11.07 mm (Set)
B *3 {1.05 - 1.17, {1.05, (0.4358 in)
2.32 - 2.58} 2.32}
Free length 31.3 (1.232) — — O
Key Synchronizer When com-
37.36 - 41.29
type spring (2nd-6th) Tension 35.3 pressed to
{3.81 - 4.21, — O
N {kgf, lbf} {3.6, 7.9} 18.53 mm
8.40 - 9.28}
(0.7295 in)
NOTE
z Identification paint
*1: Without *2: Blue *3: White
TM-1-13
SERVICE DATA T/M PROPER
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Item No. 16* 18.1 (0.713) —
Free length Item No. 21* 15.0 (0.591) —
Item No. 26* 21.0 (0.827) —
40.2 - 52.0 When com-
Item No. 16* 47.1 {4.8, 10.6} {4.1 - 5.3, pressed to 13.0
Power shift 9.0 - 11.7} mm (0.512 in)
Power shift spring
15.7 - 20.6 When com-
(JKC make) Tension
Item No. 21* 18.6 {1.9, 4.2} {1.6 - 2.1, pressed to 13.0
N {kgf, lbf}
3.5 - 4.6} mm (0.512 in)
10.8 - 13.7 When com-
Item No. 26* 12.7 {1.3, 2.9} {1.1 - 1.4, pressed to 10.0
2.4 - 3.1} mm (0.394 in)
0.15 (0.0059),
Valve seal dent depth —
max.
Power shift Power shift Valve assembly 14.1 (0.555) 13.0 (0.512)
Free length
(SANWA make) spring Rod assembly 16.3 (0.642) 15.5 (0.610)
NOTE
z Item Nos. indicate the disassembly sequence in the illustration.
TM-1-14
SERVICE DATA T/M PROPER
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
MLS61A MPS62B
Item Tightening torque MHS50T MHS60A MLS62A MPS50W
MLS61B MPS62T
57 - 76 {5.8 - 7.7, 42 - 56} O O — — — —
89 - 118 {9.1 - 12.0, 66 - 87} — — O O — —
Clutch housing mounting bolt 186 - 235 {19 - 24, 137 - 174} — — — — O —
142 - 186
— — — — — O
{14.5 - 19.0, 105 - 137}
Housing cover mounting bolt 4 - 6 {0.4 - 0.6, 2.9 - 4.3} O O O O — —
32 - 42 {3.3 - 4.3, 24 - 31} — — — O — —
Control cover mounting bolt
19 - 25 {1.9 - 2.6, 14 - 19} — — — — O O
Transmission cover mounting
32 - 42 {3.3 - 4.3, 24 - 31} O O O O O O
bolt or nut
9 - 13 {0.9 - 1.3, 6.5 - 9.4} O — — — — —
Guide plate mounting bolt
19 - 25 {1.9 - 2.6, 14 - 19} — O — — — —
Shift fork and shifter setscrew 16 - 21 {1.6 - 2.1, 12 - 15} O O O — — —
Shift fork and shifter mounting
16 - 21 {1.6 - 2.1, 12 - 15} — — — O — —
bolt
Locking lever shaft mounting
89 - 118 {9.1 - 12.0, 66 - 87} — — — — O —
nut
Shift guide bolt 34 - 45 {3.5 - 4.6, 25 - 33} — — — — O —
Reverse switch 16 - 21 {1.6 - 2.1, 12 - 15} O O O O — —
19 - 25 {1.9 - 2.6, 14 - 19} O O O — — —
Plug
89 - 118 {9.1 - 12.0, 66 - 87} — — — — — O
Screw plug 34 - 45 {3.5 - 4.6, 25 - 33} — — — — — O
16 - 21 {1.6 - 2.1, 12 - 15} O O O — — —
Neutral switch
19 - 25 {1.9 - 2.6, 14 - 19} — — — O — —
Backup light & neutral switch 34 - 39 {3.5 - 4.0, 25 - 29} — — — — O O
Stopper bolt 16 - 21 {1.6 - 2.1, 12 - 15} O O O — — —
Guide bolt mounting bolts 34 - 44 {3.5 - 4.5, 25 - 33} O O O — — —
Location lever mounting bolt 91 - 122 {9.3 - 12.4, 67 - 90} O O O O — —
Drain plug and level plug 98 - 127 {10 - 13, 72 - 94} O O O O — —
34 - 45 {3.5 - 4.6, 25 - 33} O O O O — —
Side cover mounting bolt
19 - 25 {1.9 - 2.6, 14 - 19} — — — — O O
57 - 76 {5.8 - 7.7, 42 - 56} O O O — — —
PTO gear box mounting bolt
32 - 42 {3.3 - 4.3, 24 - 31} — — — — O —
Counter shaft rear cover
57 - 76 {5.8 - 7.7, 42 - 56} — — — — O —
mounting bolt
32 - 42 {3.3 - 4.3, 24 - 31} O O — — — —
Bearing retainer mounting
57 - 76 {5.8 - 7.7, 42 - 56} — — O O O O
bolt or nut
89 - 118 {9.1 - 12.0, 66 - 87} — — — — O —
Reverse idler shaft lock plate
19 - 25 {1.9 - 2.6, 14 - 19} O O O O — —
mounting bolt
Parking brake wire bracket
34 - 45 {3.5 - 4.6, 25 - 33} O O O O — —
mounting bolt
89 - 118 {9.1 - 12.0, 66 - 87} O O — O — —
Parking brake mounting bolt
196 - 265 {20 - 27, 145 - 195} — — O — — —
Speedometer sleeve set bolt 9 - 13 {0.9 - 1.3, 6.5 - 9.4} O O O O — —
392 - 500 {40 - 51, 289 - 369} O O — — — —
Companion flange mounting 598 - 745 {61 - 76, 441 - 550} — — O O O —
castellated nut or pinion nut 686 - 981
— — — — — O
{70 - 100, 506 - 723}
Transmission assembly
19 - 25 {1.9 - 2.5, 14 - 18} O O O O — —
mounting bolts and nuts
Main drive gear bearing cap
32 - 42 {3.3 - 4.3, 24 - 31} — — — — O O
mounting bolt
TM-1-15
SERVICE DATA T/M PROPER
mounting bolt
Power shift cylinder 78 - 98 {8 - 10, 58 - 72} — — — — — O
Power shift cylinder screw 2.0 - 3.4 {0.2 - 0.35, 1.4 - 2.5} — — — — — O
Power shift striker nut 29 - 39 {3 - 4, 22 - 29} — — — — — O
Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7} — — — — — O
Power shift cylinder nut 59 - 69 {6 - 7, 43 - 51} — — — — — O
Power shift slider mount-
13 - 16 {1.3 - 1.6, 9 - 12} — — — O — —
ing bolt
Power shift rod input
23 - 25 {2.3 - 2.6, 17 - 19} — — — O — —
SANWA make
mounting nut
Power shift lifter lock nut 6.4 - 7.4 {0.65 - 0.75, 4.7 - 5.4} — — — O — —
Power shift lifter lock bolt 8 - 10 {0.8 - 1.0, 5.8 - 7.2} — — — O — —
Power shift body assembly
15 - 18 {1.5 - 1.8, 11 - 13} — — — O — —
mounting bolt
Power shift cover mount-
8 - 10 {0.8 - 1.0, 5.8 - 7.2} — — — O — —
ing bolt
TM-1-16
TOOLS T/M PROPER
TOOLS
Application
Tool name and number Description Shape
MHS50 MHS60 MLS61 MLS62 MPS50 MPS62
Sliding hammer
O O O O O O
99547 Z0000
Adapter
O O — — — —
99808 Z5000
Used to remove/install
main shaft companion
Socket wrench
flange. O O — — — —
99535 Z0011
Width across flats = 46
mm (1.81 in)
Used to remove/install
main shaft companion
Socket wrench
flange. — — O O O —
99535 Z0003
Width across flats = 50
mm (1.97 in)
Used to remove/install
main shaft companion
Socket wrench
flange. — — — — — O
99535 Z0074
Width across flats = 58
mm (2.28 in)
TM-2-1
CONSTRUCTION MHS50
TM-3-1
CONSTRUCTION MHS50
TM-3-2
DISASSEMBLY MHS50
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-3-3
DISASSEMBLY MHS50
DISASSEMBLY
TRANSMISSION ASSEMBLY
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-3-4
DISASSEMBLY MHS50
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-3-5
DISASSEMBLY MHS50
TM-3-6
DISASSEMBLY MHS50
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-3-7
DISASSEMBLY MHS50
TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
7 Castellated nut
When loosening the castellated nut, support the transmission case
securely so that it does not move.
14 Bearing retainer
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
TM-3-8
DISASSEMBLY MHS50
TM-3-9
DISASSEMBLY MHS50
NOTE
z Attach a tag to the synchronizer ring for identification.
TM-3-10
DISASSEMBLY MHS50
TM-3-11
INSPECTION MHS50
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever assem-
bly
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-3-12
INSPECTION MHS50
TM-3-13
INSPECTION MHS50
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.35 (0.0138)
SYNCHROMESH SYSTEM
Clearance between synchronizer ring and each gear
NOTE
z Determine the average value by measuring two points
that are 180º apart.
Unit: mm (in)
Item Maintenance standard Service limit
2nd-3rd
1.9 - 2.1 (0.075 - 0.083) 0.5 (0.020)
4th-5th
TM-3-14
INSPECTION MHS50
TM-3-15
REASSEMBLY MHS50
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
3, 4 Plug
The plug and cap must be securely caulked by tapping them at the
center.
TRANSMISSION ASSEMBLY
Key point of reassembly
25 Lock plate
Make sure the lock plate groove on the reverse idler shaft faces
upward.
1. Reverse idler shaft 4. Transmission case
2. Reverse idler gear 5. O-ring
3. Needle bearing
TM-3-16
REASSEMBLY MHS50
2 Retaining ring
Select the retaining ring so that the hub's axial direction play is at
the minimum limit.
The thicknesses of the retaining rings are 2.00 and 2.15 mm
(0.0787 and 0.0846 in).
TM-3-17
REASSEMBLY MHS50
NOTE
z When driving the 2nd-3rd synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
TM-3-18
REASSEMBLY MHS50
NOTE
z When driving the 4th-5th synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
z The oil groove side of the hub must be facing the 4th
gear.
1 Thrust washer
Install the thrust washer so that the oil groove side is facing the
gear.
TM-3-19
REASSEMBLY MHS50
TRANSMISSION ASSEMBLY
Key point of reassembly
19 Main drive gear
Press fit the roller bearing onto the main drive gear, and install the
main drive gear at the front of the case.
NOTE
z Select the retaining ring so that the hub's axial play is at
the minimum limit.
The thicknesses of the retaining rings are 1.82 and 1.90
mm (0.0717 and 0.0748 in).
z Be sure the cutout section of the synchronizer cone
faces downward.
17 Side cover
Apply a coat of Three Bond No. 1215 to the mating surface of the
case and side cover.
7 Castellated nut
If the castellated nut pin hole will not line up, loosen it up just
enough to the nearest position which will line it up.
5 Shim
Select the shims and install them so that they protrude beyond the
transmission case end surface by 0.2 to 0.3 mm (0.008 to 0.012 in).
The thicknesses of the shims are 0.1, 0.2 and 0.3 mm (0.004, 0.008
and 0.012 in).
TM-3-20
REASSEMBLY MHS50
29 Transmission case
4 Gasket
Coat the transmission case with liquid gasket (Three Bond 1104 or
1215). Place a sheet gasket on it and apply liquid gasket on the
clutch housing side of the sheet gasket as shown in the illustration.
The diameter of the bead should be 3 mm (0.12 in).
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-3-21
CONSTRUCTION MHS60
TM-4-1
CONSTRUCTION MHS60
TM-4-2
DISASSEMBLY MHS60
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and transmission gear oil from the
transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-4-3
DISASSEMBLY MHS60
DISASSEMBLY
TRANSMISSION ASSEMBLY
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-4-4
DISASSEMBLY MHS60
TM-4-5
DISASSEMBLY MHS60
TM-4-6
DISASSEMBLY MHS60
TM-4-7
DISASSEMBLY MHS60
TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
7 Castellated nut
When loosening the castellated nut, support the transmission case
securely so that it does not move.
13 Bearing retainer
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
TM-4-8
DISASSEMBLY MHS60
TM-4-9
DISASSEMBLY MHS60
NOTE
z Attach tags to the synchronizer ring for later identifica-
tion.
NOTE
z Attach a tag to the synchronizer ring for identification.
TM-4-10
DISASSEMBLY MHS60
NOTE
z Attach a tag to the synchronizer ring for identification.
30 Steel ball
Be careful not to lose the steel ball.
3, 5, 6 Counter gear
Remove each gear assembly together with a key by using a
hydraulic press, etc.
NOTE
z Be careful not to drop the counter shaft.
TM-4-11
DISASSEMBLY MHS60
TM-4-12
INSPECTION MHS60
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever assembly
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-4-13
INSPECTION MHS60
TM-4-14
INSPECTION MHS60
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)
TM-4-15
INSPECTION MHS60
SYNCHROMESH SYSTEM
Clearance between synchronizer ring and each gear
NOTE
z Determine the average value by measuring two points
that are 180º apart.
Unit: mm (in)
Item Maintenance standard Service limit
1.35 - 1.55
3rd-4th
(0.0531 - 0.0610)
0.5 (0.020)
1.30 - 1.70
5th-6th
(0.0512 - 0.0669)
TM-4-16
REASSEMBLY MHS60
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
TM-4-17
REASSEMBLY MHS60
2 Retaining ring
Select the retaining ring so that the hub's axial play is at the mini-
mum limit.
The thicknesses of the retaining rings are 2.00 and 2.15 mm
(0.0787 and 0.0846 in).
27 Thrust washer
Install the thrust washer so that its chamfered side on the inside
diameter side faces the 2nd gear.
TM-4-18
REASSEMBLY MHS60
NOTE
z When driving the 3rd-4th synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
17 Thrust washer
Install the thrust washer so that the oil groove side faces the 4th
gear.
TM-4-19
REASSEMBLY MHS60
NOTE
z When driving the 5th-6th synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
5 Reverse hub
Always install the reverse hub with the groove facing the 1st gear.
TRANSMISSION ASSEMBLY
Key point of reassembly
25 Counter shaft assembly
TM-4-20
REASSEMBLY MHS60
18 Lock plate
Make sure the lock plate groove in the reverse idler shaft faces
upward.
1. Reverse idler shaft 4. Transmission case
2. Reverse idler gear 5. O-ring
3. Needle bearing
7 Castellated nut
If the castellated nut pin hole will not line up, loosen it up just
enough to the nearest position which will line it up.
5 Shim
Select shims and install so that they protrude beyond the transmis-
sion case end surface by 0.2 to 0.3 mm (0.008 to 0.012 in). The
thicknesses of the shims are 0.1, 0.2 and 0.3 mm (0.004, 0.008 and
0.012 in).
TM-4-21
REASSEMBLY MHS60
26 Transmission case
4 Gasket
Coat the transmission case with liquid gasket (Three Bond 1104 or
1215). Place a sheet gasket on it and apply liquid gasket on the
clutch housing side of the sheet gasket as shown in the illustration.
The diameter of the bead should be 3 mm (0.12 in).
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-4-22
CONSTRUCTION MLS61
TM-5-1
CONSTRUCTION MLS61
TM-5-2
DISASSEMBLY MLS61
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-5-3
DISASSEMBLY MLS61
DISASSEMBLY
TRANSMISSION ASSEMBLY
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-5-4
DISASSEMBLY MLS61
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-5-5
DISASSEMBLY MLS61
TM-5-6
DISASSEMBLY MLS61
TM-5-7
DISASSEMBLY MLS61
TRANSMISSION ASSEMBLY0
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
6 Pinion nut
When loosening the pinion nut, support the transmission case
securely so that it does not move.
NOTE
z Do not re-use the pinion nut after removal.
10 Bearing retainer
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
TM-5-8
DISASSEMBLY MLS61
21 Synchronizer ring
Attach tags to the synchronizer cone and synchronizer ring for later
identification.
TM-5-9
DISASSEMBLY MLS61
NOTE
z Attach tags to the synchronizer ring for later identifica-
tion, and main shaft so that they can be reinstalled in
their original positions.
TM-5-10
DISASSEMBLY MLS61
32 Steel ball
Be careful not to lose the steel ball.
2 Retaining ring
The figure at right shows the roller bearing inner race to which the
puller is attached, after removal of the retaining ring.
TM-5-11
DISASSEMBLY MLS61
3, 4, 5 Counter gear
Remove each gear assembly together with a key by using a
hydraulic press, etc.
NOTE
z Be careful not to drop the counter shaft.
TM-5-12
INSPECTION MLS61
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever assem-
bly
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-5-13
INSPECTION MLS61
TM-5-14
INSPECTION MLS61
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)
TM-5-15
INSPECTION MLS61
SYNCHROMESH SYSTEM
Clearance between synchronizer ring and each gear
NOTE
z Determine the average value by measuring two points
that are 180º apart.
Unit: mm (in)
Item Maintenance standard Service limit
3rd-4th 1.35 - 1.55 (0.0531 - 0.0610)
0.5 (0.020)
5th-6th 1.30 - 1.70 (0.0512 - 0.0669)
TM-5-16
REASSEMBLY MLS61
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
TM-5-17
REASSEMBLY MLS61
2 Retaining ring
Select a retaining ring that minimizes the hub's axial play. The thick-
nesses of the available retaining rings are 2.00, 2.20 and 2.40 mm
(0.0787, 0.0866 and 0.0945 in).
TM-5-18
REASSEMBLY MLS61
NOTE
z When driving the 3rd-4th synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
17 Thrust washer
Install the thrust washer with the oil groove side facing the gear.
NOTE
z When driving the 5th-6th synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
27, 24, 20, 16, 10, 4 Retaining ring
Use a retaining ring thick enough to remove axial free play. The
thicknesses of the available retaining rings are as follows:
Unit: mm (in)
Item Retaining ring
2.50 (0.0984)
27 2nd gear 2.65 (0.1043)
2.80 (0.1102)
24 3rd gear 2.80 (0.1102)
2.50 (0.0984)
20 4th gear 2.65 (0.1043)
2.80 (0.1102)
2.50 (0.0984)
16 3rd-4th synchronizer assembly 2.65 (0.1043)
2.80 (0.1102)
2.50 (0.0984)
10 5th-6th synchronizer assembly 2.65 (0.1043)
2.80 (0.1102)
2.50 (0.0984)
4 Reverse hub 2.65 (0.1043)
2.80 (0.1102)
TM-5-19
REASSEMBLY MLS61
TRANSMISSION ASSEMBLY
Key point of reassembly
26 Counter shaft assembly
Select a space that minimizes the hub's axial play. The thicknesses
of the available spacers are 3.0, 3.1, 3.2 and 3.3 mm (0.118, 0.122,
0.126 and 0.130 in).
15 Lock plate
Align the lock plate with the groove in the reverse idler shaft and
install.
TM-5-20
REASSEMBLY MLS61
6 Pinion nut
1. When tightening the pinion nut, support the transmission
case securely so that it does not move.
: 598 - 745 N·m {61 - 76 kgf·m, 441 - 550 ft·lbf}
2. Lock the pinion nut so that two clinched points contact each
other.
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-5-21
CONSTRUCTION MLS62
TM-6-1
CONSTRUCTION MLS62
TM-6-2
CONSTRUCTION MLS62
TM-6-3
DISASSEMBLY MLS62
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-6-4
DISASSEMBLY MLS62
DISASSEMBLY
TRANSMISSION ASSEMBLY
TM-6-5
DISASSEMBLY MLS62
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-6-6
DISASSEMBLY MLS62
TM-6-7
DISASSEMBLY MLS62
TM-6-8
DISASSEMBLY MLS62
TM-6-9
DISASSEMBLY MLS62
TM-6-10
DISASSEMBLY MLS62
TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
6 Pinion nut
When loosening the pinion nut, support the transmission case
securely so that it does not move.
NOTE
z Do not re-use the pinion nut after removal.
10 Bearing retainer
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
TM-6-11
DISASSEMBLY MLS62
21 Synchronizer ring
Attach tags to the synchronizer cone and synchronizer ring for later
identification.
TM-6-12
DISASSEMBLY MLS62
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification and main shaft so that they
can be reinstalled in their original positions.
TM-6-13
DISASSEMBLY MLS62
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification and main shaft so that they
can be reinstalled in their original positions.
43 Steel ball
Be careful not to lose the steel ball.
3, 4, 5 Counter gear
Remove each gear assembly together with a key by using a
hydraulic press, etc.
NOTE
z Be careful not to drop the counter shaft.
TM-6-14
DISASSEMBLY MLS62
2, 4, 27 Steel ball
The steel ball used to lock the fork shaft will tend to fly out when
removing the fork shaft. Use a rag, etc. to prevent the steel ball
from flying out.
13 Welch plug
Do not remove the cap plug unless necessary.
TM-6-15
DISASSEMBLY MLS62
15 Shift shaft
Be sure to align the alignment marks placed on the shift lever and
shift shaft during disassembly.
TM-6-16
DISASSEMBLY MLS62
8. Remove the two retaining rings and then remove the valve
assembly.
NOTE
z Be careful not to damage the valve seal surface.
9. Remove the screw and then remove the lifter, pivot and O-
ring.
TM-6-17
DISASSEMBLY MLS62
10. Push the rod assembly out toward the rear side. Remove
the retaining ring, piston half, X-ring and O-ring. Then
remove the rod assembly.
12. Remove the retaining ring from inside the rod. Using a mag-
net, remove the pin and then pull out the rod assembly.
13. Remove the guide and drive out the pin. Then, disassemble
the rod assembly.
NOTE
z It is not necessary to remove the E-ring unless the rod is
worn excessively.
z Be careful not to damage the sliding portion of the rod
when driving out the pin.
14. Drive the spring pin out, and remove the cover, joint and
bushing.
NOTE
z It is not necessary to remove the bushing if there is no
excessive wear.
TM-6-18
INSPECTION MLS62
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TRANSMISSION COVER
Clearance between shift lever and select lever assem-
bly
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-6-19
INSPECTION MLS62
TM-6-20
INSPECTION MLS62
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)
TM-6-21
INSPECTION MLS62
TM-6-22
REASSEMBLY MLS62
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
13 Welch plug
Be sure to drive the cap plug while aligning it with the end face of
boss on the control cover.
TM-6-23
REASSEMBLY MLS62
2. Install the rod assembly (inner) and then drive the pin into
the end face of the rod.
NOTE
z Be careful not to damage the sliding portion of the rod
when driving the rod in.
4. Insert the guide into the rod, and install the retaining ring.
NOTE
z Install the retaining ring with the sharp edge facing out-
ward.
6. Install the plate and packing onto the rod assembly. Insert
them into the cylinder and push them out rearward.
NOTE
z Install the plate so that the tapered portion of the outer
periphery is on the joint side.
TM-6-24
REASSEMBLY MLS62
8. Push the rod assembly toward the front. Secure the packing
and plate with the retaining ring.
Install the stopper and pin onto the input rod, and secure
them with a nut.
9. Install the O-ring on the body and place the pivot in the cen-
ter of the body. Insert the lifter and tighten them with a
screw.
NOTE
z Apply sealant (Three Bond No. 1343N or equivalent) to
the screw.
z Be careful not to damage the lifter tip and valve seat.
10. Install the valve assembly on the body and secure it with the
retaining ring.
NOTE
z Install the retaining ring with the sharp edge facing out-
ward.
11. Install the O-ring onto the body assembly and then install
them onto the cylinder assembly.
: 15 - 18 N·m {1.5 - 1.8 kgf·m, 11 - 13 ft·lbf}
TM-6-25
REASSEMBLY MLS62
12. Insert the plate and packing into the rod assembly and
install the retaining ring.
NOTE
z Install the plate so that the tapered portion of the outer
periphery is on the outside.
13. Install the roller and bracket assembly onto the lever
assembly.
TM-6-26
REASSEMBLY MLS62
6 Welch plug
Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.
TM-6-27
REASSEMBLY MLS62
2 Retaining ring
Select a retaining ring that minimizes the hub's axial play. The thick-
nesses of the available retaining rings are 2.00, 2.20 and 2.40 mm
(0.0787, 0.0866 and 0.0945 in).
TM-6-28
REASSEMBLY MLS62
TM-6-29
REASSEMBLY MLS62
TM-6-30
REASSEMBLY MLS62
TRANSMISSION ASSEMBLY
Key point of reassembly
26 Counter shaft assembly
Select a space that minimizes the hub's axial play. The thicknesses
of the available spacers are 3.0, 3.1, 3.2 and 3.3 mm (0.118, 0.122,
0.126 and 0.130 in).
15 Lock plate
Make sure the lock plate groove in the reverse idler shaft faces
upward.
1. Reverse idler shaft 4. Transmission case
2. Reverse idler gear 5. O-ring
3. Needle bearing
TM-6-31
REASSEMBLY MLS62
6 Pinion nut
1. When tightening the pinion nut, support the transmission
case securely so that it does not move.
2. Lock the pinion nut so that two clinched points contact each
other.
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-6-32
CONSTRUCTION MPS50
TM-7-1
CONSTRUCTION MPS50
TM-7-2
DISASSEMBLY MPS50
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-7-3
DISASSEMBLY MPS50
DISASSEMBLY
TRANSMISSION ASSEMBLY
TM-7-4
DISASSEMBLY MPS50
TM-7-5
DISASSEMBLY MPS50
TM-7-6
DISASSEMBLY MPS50
Marks “+” and “,” indicate that the key points of operation are explained in the text.
TM-7-7
DISASSEMBLY MPS50
TM-7-8
DISASSEMBLY MPS50
TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
4 Bearing cap
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.
6 Pinion nut
When loosening the pinion nut, support the transmission case
securely so that it does not move.
NOTE
z Do not re-use the pinion nut after removal.
TM-7-9
DISASSEMBLY MPS50
9 Bearing retainer
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.
TM-7-10
DISASSEMBLY MPS50
2. Remove the pilot bearing, lock nut, lock washer and spacer
with a bearing puller.
NOTE
z Tighten the lock nut until the bearing puller is properly
positioned.
TM-7-11
DISASSEMBLY MPS50
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification.
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification.
TM-7-12
DISASSEMBLY MPS50
3, 6, 7 Counter gear
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the countershaft on the
floor.
5, 8 Steel ball
Do not confuse the large steel ball with the small one. The small
steel ball is installed on the backup light side while the large steel
ball is on the neutral switch side.
TM-7-13
DISASSEMBLY MPS50
9, 10 Welch plug
Make sure that the welch plug is driven out together with the shift
fork shaft.
16 Inner shaft
Place an alignment mark on the shift lever and inner shaft before
removal.
18 Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
TM-7-14
INSPECTION MPS50
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TM-7-15
INSPECTION MPS50
TRANSMISSION ASSEMBLY
Main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.2 (0.004 - 0.008) 0.5 (0.020)
TM-7-16
INSPECTION MPS50
TM-7-17
INSPECTION MPS50
SYNCHRONIZER SYSTEM
<Pin type>
Alignment of synchronizer rings with their discs
NOTE
z Measure the value on the opposite side (180º apart) and
determine the mean value.
Unit: mm (in)
Maintenance standard Service limit Remarks
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc
TM-7-18
INSPECTION MPS50
Detent spring
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
5.9 - 9.8
Type I
When compressed to
Tension {0.6 - 1.0, 0.3 {0.4, 0.9}
12.5 mm (0.492 in)
1.3 - 2.2}
21.6 - 26.5
*1 {2.2 - 2.7, 18.6 {1.9, 4.2}
4.9 - 6.0}
A
29.4 - 35.3
*2 {3.0 - 3.6, 24.5 {2.5, 5.5}
Tension
Type II
NOTE
z Identification paint
*1: Without *2: Blue *3: White
TM-7-19
REASSEMBLY MPS50
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
TRANSMISSION CONTROL COVER ASSEMBLY
Key point of reassembly
21, 23 Return spring
Do not confuse the left and right return springs.
Paint color:
Red: Right spring
Blue: Left spring
16 Inner shaft
Be sure to align the marks placed on the shift lever and inner shaft
during disassembly.
2, 11 Lock plate
Bend the lock plate to lock the plug.
TM-7-20
REASSEMBLY MPS50
9, 10 Welch plug
Be careful not to damage the plug.
TM-7-21
REASSEMBLY MPS50
1 Retaining ring
Make sure the retaining ring is fitted into the groove properly.
31 Reverse gear
Insert the reverse gear with the clutch gear section facing down-
ward.
TM-7-22
REASSEMBLY MPS50
30 Thrust washer
Face the large chamfered I.D. of the thrust washer toward the
reverse gear, and install the washer by aligning it with the dowel
pin.
19 Thrust washer
Face the large chamfered side I.D. of the thrust washer toward the
3rd gear, and install the thrust washer by aligning it with the dowel
pin.
TM-7-23
REASSEMBLY MPS50
7 Lock washer
Install the lock washer in the groove of the main shaft with the pawl
facing down.
6 Lock nut
Tighten the lock nut with the socket wrench (99535 Z0014).
4 Retaining ring
1. Ensure that the retaining ring is fitted in the groove.
2. The retaining ring should be turned after it has been
installed.
TM-7-24
REASSEMBLY MPS50
1 Thrust washer
Drive the thrust washer into place with the large chamfered side
facing the rear of the main shaft assembly.
TRANSMISSION ASSEMBLY
Key point of reassembly
26 Counter shaft assembly
Face the letter side of the outer race outward.
25 Ball bearing
Be sure to drive the ball bearing until it reaches the “butt-up” point.
24 Spacer
Select a spacer so that the clearance between the spacer and
retaining ring is less than 0.15 mm (0.0059 in). Spacers are avail-
able in four different thicknesses between 3.0 and 3.3 mm (0.118
and 0.130 in) at intervals of 0.1 mm (0.004 in).
TM-7-25
REASSEMBLY MPS50
14 Ball bearing
Drive the ball bearing until it reaches the “butt-up” point.
6 Pinion nut
1. Secure the transmission case to prevent it from turning
when tightening the pinion nut.
TM-7-26
REASSEMBLY MPS50
2. Lock the pinion nut so that two clinched points contact each
other.
4 Bearing cap
Align the oil hole in the transmission case with the oil groove in the
bearing cap and face the marked side upward when installing.
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-7-27
CONSTRUCTION MPS62
TM-8-1
CONSTRUCTION MPS62
TM-8-2
CONSTRUCTION MPS62
TM-8-3
DISASSEMBLY MPS62
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.
TM-8-4
DISASSEMBLY MPS62
DISASSEMBLY
TRANSMISSION ASSEMBLY
TM-8-5
DISASSEMBLY MPS62
TM-8-6
DISASSEMBLY MPS62
TM-8-7
DISASSEMBLY MPS62
TM-8-8
DISASSEMBLY MPS62
TM-8-9
DISASSEMBLY MPS62
TM-8-10
DISASSEMBLY MPS62
TM-8-11
DISASSEMBLY MPS62
TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
3 Bearing cap
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.
5 Pinion nut
When loosening the pinion nut, support the transmission case
securely so that it does not move.
NOTE
z Do not re-use the pinion nut after removal.
TM-8-12
DISASSEMBLY MPS62
9 Bearing retainer
Remove the oil seal only when leakage is noticed. Discard the old
oil seal and install a new one.
TM-8-13
DISASSEMBLY MPS62
25 Roller bearing
Drive the roller bearing out of the front of the counter shaft using
counter shaft bearing puller (99802 Z0000).
NOTE
z Do not remove the counter plug unless necessary. If the
counter shaft bearing puller is not available, remove the
plug first.
Do not re-use the plug after removal.
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification and main shaft so that they
can be reinstalled in their original positions.
14 Inner race
Attach a puller to the 3rd gear, and drive inner races out.
NOTE
z Hold the inner race to prevent it from slipping off the
inner race.
z Make sure that the workbench is securely fixed in place.
TM-8-14
DISASSEMBLY MPS62
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification and main shaft so that they
can be reinstalled in their original positions.
33 Inner race
Attach a puller to the 3rd gear, and drive inner races out.
NOTE
z Hold the puller firmly to prevent it from slipping off the
inner race.
TM-8-15
DISASSEMBLY MPS62
3, 5, 6 Counter gear
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the counter shaft on the
floor.
9, 10 Welch plug
Make sure that the welch plug is driven out together with the shift
fork shaft.
TM-8-16
DISASSEMBLY MPS62
13, 17 Type I
21, 23 Type II } Resist spring
Tag the left and right resist springs for identification.
18 Type I
29 Type II } Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal, and install a new one.
TM-8-17
DISASSEMBLY MPS62
36 Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.
TM-8-18
INSPECTION MPS62
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TM-8-19
INSPECTION MPS62
TRANSMISSION ASSEMBLY
Main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.09 - 0.19 (0.0035 - 0.0075) 0.5 (0.020)
TM-8-20
INSPECTION MPS62
TM-8-21
INSPECTION MPS62
Synchronizer spring
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
When com-
37.36 - 41.29
35.3 pressed to
2nd-6th Tension {3.81 - 4.21,
{3.6, 7.9} 18.53 mm
8.40 - 9.28}
(0.7295 in)
POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
18.1
Item No. 16 —
(0.713)
15.0
Free length Item No. 21 —
(0.591)
21.0
Item No. 26 —
(0.827)
When com-
40.2 - 52.0
47.1 pressed to
Item No. 16 {4.1 - 5.3,
{4.8, 10.6} 13.0 mm
9.0 - 11.7}
(0.512 in)
When com-
15.7 - 20.6
Tension 18.6 pressed to
Item No. 21 {1.6 - 2.1,
N {kgf, lbf} {1.9, 4.2} 13.0 mm
3.5 - 4.6}
(0.512 in)
When com-
10.8 - 13.7
12.7 pressed to
Item No. 26 {1.1 - 1.4,
{1.3, 2.9} 10.0 mm
2.4 - 3.1}
(0.394 in)
NOTE
z Item Nos. indicate the disassembly sequence.
TM-8-22
REASSEMBLY MPS62
REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.
33 Housing setscrew
Install the housing setscrew and clinch in two locations.
NOTE
z Be sure to install the springs in the correct sequence.
TM-8-23
REASSEMBLY MPS62
12 Tube ring
Using the insert tool (910-26500 JKC No.) install the tube ring.
45 Rod pipe
Using the guide (910-24800 JKC No.) install the valve assembly.
NOTE
z Apply a coat of silicone grease to inner side of the rod
pipe. Be careful not to damage the seals.
1 Boot
Install the boot.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.
TM-8-24
REASSEMBLY MPS62
13, 17 Type I
}
21, 23 Type II Resist spring
Do not confuse the left and right resist springs.
Paint color:
z Red: Right spring
z Blue: Left spring
10 Type I
17 Type II
}Cap plug
Be sure to drive the cap plug while aligning it with the end face of
the boss on the control cover.
NOTE
z Do not attempt to rotate the shaft if the interlock pin is
already installed.
11, 13, 17, 18, 22, 23, 27 Shift fork & shifter
Install and tighten the setscrew on each shift fork and shifter. Make
sure that the setscrew is properly fitted into the groove on the shaft,
then firmly lock the setscrew at three points.
NOTE
z Ensure that the screw thread portions are properly
clinched.
TM-8-25
REASSEMBLY MPS62
9, 10 Welch plug
Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.
4, 7 Key
When installing a key, make sure that its large chamfered side is on
the side gear installation side.
TM-8-26
REASSEMBLY MPS62
2 Retaining ring
Make sure that the retaining ring is fitted into the groove.
NOTE
z Make sure that the synchronizer assembly is installed
with the non-splined side of the hub and the splined side
of the sleeve (shown by “C” in the figure) facing the 3rd
gear.
TM-8-27
REASSEMBLY MPS62
NOTE
z Make sure that synchronizer assembly is installed with
the oil groove side facing the 5th gear.
21 Pilot bearing
Install the pilot bearing with the chamfered bore side toward the
lock nut.
20 Retaining ring
Make sure that the retaining ring is fitted into the groove.
TM-8-28
REASSEMBLY MPS62
18 Reverse sleeve
Make sure that reverse sleeve is installed with side “B” (shown in
the figure) facing the reverse gear.
NOTE
z Make sure that the synchronizer assembly is installed
with the non-splined side of the hub and the splined side
of the sleeve (shown by “A” in the figure) toward the 2nd
gear.
1 Thrust washer
Make sure that the oil groove side of the thrust washer faces the
5th gear.
TM-8-29
REASSEMBLY MPS62
TRANSMISSION ASSEMBLY
Key point of reassembly
26 Counter plug
Make sure that the peripheral rubber part of the counter plug is free
of breakage before installation.
Wipe excess gear oil off the counter plug after installation.
25 Roller bearing
Ensure that the final position of the front roller bearing outer race is
4.5 to 5.0 mm (0.177 to 0.197 in) inside the front end surface of the
transmission case.
23 Roller bearing
Make sure that the roller bearing completely bottoms.
TM-8-30
REASSEMBLY MPS62
22 Spacer
Select a suitable spacer so that the spacer to retaining ring clear-
ance is less than 0.15 mm (0.0059 in). Spacers are available in four
different thicknesses ranging from 3.0 to 3.3 mm (0.118 to 0.130 in)
at intervals of 0.1 mm (0.004 in).
3 Bearing cap
Align the oil groove on the bearing cap with the oil return “through”
hole, and install bearing cap using a gasket.
NOTE
z Align the 11 mm (0.43 in) dia. hole in the gasket with the
oil return hole.
z Make sure the bearing cap is installed with the market
side facing upward.
TM-8-31
REASSEMBLY MPS62
INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.
TM-8-32
TRANSMISSION PTO
CONTENTS
SERVICE DATA ................................ TM-1-1 REMOVAL .................................... TM-3-1
SPECIFICATIONS ........................ TM-1-1 DISASSEMBLY ............................ TM-3-2
SERVICE DATA ............................ TM-1-2 INSPECTION .................................... TM-4-1
TIGHTENING TORQUE ............... TM-1-4 REASSEMBLY ................................. TM-5-1
SYSTEM DIAGRAM ..................... TM-1-5 REASSEMBLY ............................. TM-5-1
CONSTRUCTION ............................. TM-2-1 INSTALLATION ............................ TM-5-5
DISASSEMBLY ................................ TM-3-1
SERVICE DATA PTO
SERVICE DATA
SPECIFICATIONS
PTO output torque/Engine Number of gear teeth
Type PTO ratio Transmission model
speed N·m {kgf·m, ft·lbf}/rpm a b c d d' e
1.615 22 42 MHS60A
13 23
1.825 19 41 MHS50T
I 147 {15, 108)/1,000 — 11
1.753 23 44 MLS61A, MLS62A
12 25
1.642 24 43 MLS61B
II 294 {30, 217}/1,000 1.672 18 43 20 28 — 14 MPS50W
1.170 22 42 27 MHS60A
III-a 245 {25, 181}/1,000 37 25 21
1.175 19 41 24 MHS50T
1.170 22 42 27 MHS60A
25 21
Air shift 1.175 19 41 24 MHS50T
III-b 245 {25, 181}/1,000 37
1.658 22 42 27 MHS60A
21 25
1.666 19 41 24 MHS50T
IV-a 1.141 24 44 47 23 22 28 MPS62B
294 {30, 217}/1,000
IV-b 1.034 20 47 42 22 25 21 MPS62T
1.518 23 44 MLS61A, MLS62A
25 21
V-a 1.003 24 43 MLS61B
343 {35, 253}/1,000 36 24
V-b 1.071 23 44 MLS61A, MLS62A
21 25
1.421 24 43 MLS61B
1.615 22 42 13 23 MHS60A
I 147 {15, 108}/1,000 1.753 23 44 12 25 — 11 MLS61A, MLS62A
1.825 19 41 13 23 MHS50T
1.170 22 42 27 MHS60A
Vacuum 25 21
1.175 19 41 24 MHS50T
shift II 245 {25, 181}/1,000 37
1.658 22 42 27 MHS60A
21 25
1.666 19 41 24 MHS50T
1.518 25 21 MLS61A
III 343 {35, 253}/1,000 23 44 36 24
1.071 21 25 MLS61A
PTO IN OPERATION
TM-1-1
SERVICE DATA PTO
SERVICE DATA
Unit: mm (in)
Application
Maintenance Service Air shift Vacuum shift
Item Remarks
standard limit Type Type Type Type Type Type Type Type
I II III IV V I II III
0.1 - 0.2 0.35
O O
Idler gear - PTO (0.004 - 0.008) (0.0138)
gear 0.15 - 0.25 0.5
O
(0.0059 - 0.0098) (0.020)
Gear backlash
Counter shaft 4th
gear - idler gear 0.1 - 0.2 0.35
O O O O O
Idler gear - PTO (0.004 - 0.008) (0.0138)
gear
0.25 - 0.79 1.1
PTO gear end play O O
(0.0098 - 0.0311) (0.043)
0.25 - 0.52 0.8
O O O
(0.0098 - 0.0205) (0.031)
Idler gear end play
0.23 - 0.47 0.7
O O
(0.0091 - 0.0185) (0.028)
0.03 - 0.12
— O O O O
(0.0012 - 0.0047)
Clearance between cylinder and piston
0.08 - 0.15 0.2
O
(0.0031 - 0.0059) (0.008)
0 - 0.07
Clearance between case and cylinder — O O O O
(0 - 0.0028)
0.03 - 0.09 0.11
Clearance between case and shift fork O O O
(0.0012 - 0.0035) (0.0043)
Clearance between shift fork and 0.05 - 0.95 1.4
O O O O O O O
sleeve (0.0020 - 0.0374) (0.055)
0.45 - 0.54 0.7
O
(0.0177 - 0.0213) (0.028)
0.07 - 0.14 0.3
O
Radial play between PTO shaft and (0.0028 - 0.0055) (0.012)
PTO gear spline 0.40 - 0.50 0.7
O O O
(0.0157 - 0.0197) (0.028)
0.40 - 0.48 0.7
O O O
(0.0157 - 0.0189) (0.028)
0.45 - 0.54 0.7
O
(0.0177 - 0.0213) (0.028)
Radial play between PTO shaft and 0.20 - 0.30 0.7
O O O
sleeve spline (0.0079 - 0.0118) (0.028)
0.40 - 0.48 0.7
O O O
(0.0157 - 0.0189) (0.028)
Clearance between PTO case and shift 0.02 - 0.07 0.2
O
shaft (0.0008 - 0.0028) (0.008)
Clearance between shift fork and shift 0 - 0.05 0.2
O
shaft (0 - 0.0020) (0.008)
Clearance between shift fork and PTO 0.1 - 0.3 1.0
O
gear (0.004 - 0.012) (0.039)
TM-1-2
SERVICE DATA PTO
Application
Maintenance Service Air shift Vacuum shift
Item Remarks
standard limit Type Type Type Type Type Type Type Type
I II III IV V I II III
50 (1.97) — O O O O
Free length 80 (3.15) O
60 (2.36) — O O O
When com-
35.70 - 45.50
pressed to
{3.64 - 4.64, — O O O O
32.75 mm
8.03 - 10.23}
(1.2894 in)
When com-
54.53 - 64.33
pressed to
{5.56 - 6.56, — O O O O
24.75 mm
Return spring 12.26 - 14.46}
(0.9744 in)
Tension
186.3 - 225.6 When com-
N {kgf, lbf} 147.1
{19 - 23, pressed to 39 O
{15, 33.1}
41.9 - 50.7} mm (1.54 in)
38.44 - 48.25 When com-
{3.92 - 4.92, — pressed to 38 O O O
8.64 - 10.85} mm (1.50 in)
53.94 - 63.75 When com-
{5.50 - 6.50, — pressed to 30 O O O
12.13 - 14.33} mm (1.18 in)
0.5
Ball bearing axial direction play — One side O O O O O O O O
(0.020)
TM-1-3
SERVICE DATA PTO
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Tightening torque
Air shift type Vacuum shift type
PTO output torque
Item
147 294 245 294 343 147 245 343
{15, 108} {30, 217} {25, 181} {30, 217} {35, 253} {15, 108} {25, 181} {35, 253}
Type I Type II Type III Type IV Type V Type I Type II Type III
57 - 76 46 - 62 57 - 76 57 - 76 57 - 76 57 - 76 57 - 76 57 - 76
PTO gear box mount-
{5.8 - 7.7, {4.7 - 6.3, {5.8 - 7.7, {5.8 - 7.7, {5.8 - 7.7, {5.8 - 7.7, {5.8 - 7.7, {5.8 - 7.7,
ing bolt
42 - 56} 34 - 46} 42 - 56} 42 - 56} 42 - 56} 42 - 56} 42 - 56} 42 - 56}
57 - 76 98 - 147 118 - 157 98 - 147 118 - 157 57 - 76 118 - 157 118 - 157
Companion flange
{5.8 - 7.7, {10 - 15, {12 - 16, {10 - 15, {12 - 16, {5.8 - 7.7, {12 - 16, {12 - 16,
mounting nut
42 - 56} 72 - 108} 87 - 116} 72 - 108} 87 - 116} 42 - 56} 87 - 116} 87 - 116}
Plate and diaphragm 2.9 - 5.9 2.9 - 5.9 2.9 - 5.9
mounting castellated — — {0.3 - 0.6, {0.3 - 0.6, {0.3 - 0.6,
nut 2.2 - 4.3} 2.2 - 4.3} 2.2 - 4.3}
16 - 21 16 - 21 16 - 21 16 - 21 16 - 21 16 - 21 16 - 21
Front bearing cover {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1,
12 - 15} 12 - 15} 12 - 15} 12 - 15} 12 - 15} 12 - 15} 12 - 15}
16 - 21 16 - 21 32 - 42 30 - 41 16 - 21 16 - 21 30 - 41
Rear bearing cover {1.6 - 2.1, {1.6 - 2.1, {3.3 - 4.3, {3.1 - 4.2, {1.6 - 2.1, {1.6 - 2.1, {3.1 - 4.2,
12 - 15} 12 - 15} 24 - 31} 22 - 30} 12 - 15} 12 - 15} 22 - 30}
16 - 21 16 - 21 16 - 21
Diaphragm mounting
— — {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1,
nut
12 - 15} 12 - 15} 12 - 15}
16 - 21 3.9 - 5.9 16 - 21 16 - 21 16 - 21
Air cylinder mounting
{1.6 - 2.1, {0.4 - 0.6, {1.6 - 2.1, {1.6 - 2.1, {1.6 - 2.1, — — —
bolt
12 - 15} 2.9 - 4.3} 12 - 15} 12 - 15} 12 - 15}
57 - 76
Shift fork setscrew — {5.8 - 7.7, — — — — — —
42 - 56}
29 - 49
Drain plug — — — {3.0 - 5.0, — — — —
22 - 36}
TM-1-4
SERVICE DATA PTO
SYSTEM DIAGRAM
AIR SHIFT TYPE
TM-1-5
CONSTRUCTION PTO
CONSTRUCTION
AIR SHIFT TYPE
Type I
Type II
TM-2-1
CONSTRUCTION PTO
Type IV-a
TM-2-2
CONSTRUCTION PTO
Type IV-b
TM-2-3
CONSTRUCTION PTO
TM-2-4
DISASSEMBLY PTO
DISASSEMBLY
REMOVAL
Key point of removal
z Measure and record the backlash of the reverse idler gear
and PTO gear. (Air shift types I, II and vacuum shift type I)
TM-3-1
DISASSEMBLY PTO
DISASSEMBLY
AIR SHIFT TYPE
Type I
TM-3-2
DISASSEMBLY PTO
Type II
TM-3-3
DISASSEMBLY PTO
Type IV
TM-3-4
DISASSEMBLY PTO
TM-3-5
DISASSEMBLY PTO
TM-3-6
DISASSEMBLY PTO
TM-3-7
DISASSEMBLY PTO
6 (Type I)
10 (Type II) } Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
18 (Type I)
16 (Type II) }PTO shaft
Remove the PTO shaft assembly, and then press the PTO shaft
assembly out from the front side.
19 (Type I)
24 (Type II) }Shift fork
Disengage the shift fork from the groove in the gear and remove the
PTO shaft assembly through the rear bearing hole.
TM-3-8
DISASSEMBLY PTO
7 Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
16 PTO shaft
Remove the retaining ring and drive the PTO shaft out of the front of
the case.
25 Shift fork
Disengage the shift fork from the groove in the gear and remove the
PTO shaft assembly through the rear bearing hole.
TM-3-9
DISASSEMBLY PTO
7 Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.
22 PTO shaft
Remove the retaining ring and drive the PTO shaft out of the front of
the case.
TM-3-10
INSPECTION PTO
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
TM-4-1
INSPECTION PTO
TM-4-2
INSPECTION PTO
TM-4-3
INSPECTION PTO
TM-4-4
INSPECTION PTO
TM-4-5
REASSEMBLY PTO
REASSEMBLY
REASSEMBLY
AIR SHIFT TYPE (TYPES I AND II)
Key point of reassembly
18 (Type I)
16 (Type II) }
PTO shaft
Insert the PTO shaft assembly into the PTO case via the rear bear-
ing hole and engage the shift fork and the groove in the sleeve.
TM-5-1
REASSEMBLY PTO
20 Plain washer
Make sure the outer edge of the plain washer is facing away from
the diaphragm.
TM-5-2
REASSEMBLY PTO
16 PTO shaft
Insert the PTO shaft assembly into the PTO case via the rear bear-
ing hole and engage the shift fork and the groove in the sleeve.
14 Retaining ring
Install the PTO gear and retaining ring on the PTO shaft, and press
the rear ball bearing onto the shaft.
NOTE
z Be careful not to expand the retaining ring excessively.
After installation, ensure that the retaining ring is prop-
erly fitted in the groove.
z Be careful not to bend the retaining ring during bearing
installation.
9 O-ring
Make sure the outer edge of the diaphragm fits in the groove in the
PTO case.
NOTE
z Be sure to prevent the O-ring from being caught by the
cover.
TM-5-3
REASSEMBLY PTO
22 PTO shaft
Insert the PTO shaft into the front of the case and the gear, and
install the retaining ring.
NOTE
z Be careful not to expand the retaining any more than nec-
essary.
9 O-ring
Make sure the outer edge of the diaphragm fits in the groove in the
PTO case.
NOTE
z Be sure to prevent the O-ring from being caught by the
cover.
TM-5-4
REASSEMBLY PTO
INSTALLATION
Key point of installation
z Measure and record the backlash of the reverse idler gear
and PTO gear. (Air shift types I, II and vacuum shift type I)
Unit: mm (in)
Maintenance
Application Service limit
standard
0.1 - 0.2
Type I 0.35 (0.0138)
(0.004 - 0.008)
Air shift type
0.15 - 0.25
Type II 0.5 (0.020)
(0.0059 - 0.0098)
0.1 - 0.2
Vacuum shift type Type I 0.35 (0.0138)
(0.004 - 0.008)
TM-5-5
TRANSMISSION CONTROL LINKAGE
CONTENTS
CONSTRUCTION.............................. TM-1-1 REASSEMBLY ................................. TM-2-1
CONSTRUCTION ......................... TM-1-1 INSTALLATION ............................. TM-2-1
CONSTRUCTION
CONSTRUCTION
CONSTRUCTION
TRANSMISSION CONTROL LINKAGE
UNIT NAME MHS AND MLS SERIES
TM-1-1
CONSTRUCTION
TM-1-2
CONSTRUCTION
TM-1-3
CONSTRUCTION
TM-1-4
REASSEMBLY
REASSEMBLY
INSTALLATION
DIMENSION OF CONTROL CABLE AND CONTROL ROD
Unit: mm (in)
Unit name Control rod Control cable
Shift rod Select rod Shift cable Select cable
Trans- Trans- Remarks
Transmission Engine With Without With Without Cab side: Cab side:
mission mission
P.T.O. P.T.O. P.T.O. P.T.O. A A
side: B side: B
425 343 230
MHS50T FE6A
(16.73) (13.50) (9.06)
FE6A
423 341
MHS60A FE6B
(16.65) (13.43)
FE6T
FE6A
MLS61A FE6B 479 414.5 — —
MLS61B FE6T (18.86) (16.32)
FE6TA
Manual 479 414.5
FE6T
shift (18.86) (16.32)
MLS62A
Power 470.5 406
FE6T
shift (18.52) (15.98)
385.5 320.5 225
FE6B (8.86)
487.5 487.5 (15.18) (12.62)
MPS50W
(19.19) (19.19) 487 159.5
NE6
(19.17) (6.28)
FE6B 416 351 231 243 231
(9.09) (9.57) (9.09)
Manual FE6T (16.38) (13.82)
shift 159.5 367 367
FE6TA for HKG
MPS62T (6.28) (14.45) (14.45)
MPS62B 262.5 198
FE6T for TWN
Power 159.5 (10.33) (7.80)
shift (6.28) 211
FE6TA — — for TWN
(8.31)
517.5 463
NE6 (20.37) (18.23)
159.5 240
NE6T
(6.28) 522 467 (9.45)
NE6TA for tractor
(20.55) (18.39)
427 395 231
FE6T — —
(16.81) (15.55) (9.09)
544 499.5
EATON 6109
NE6T (21.42) (19.67) 395 395 240
NE6TA 560 506 (15.55) (15.55) (9.45)
for tractor
(22.05) (19.92)
TM-2-1
REASSEMBLY
2. Do not handle the boot with your bare hand, or strike the
boot on any adjacent parts during installation.
TM-2-2
REASSEMBLY
6. When the control rod is removed, install the cross shift and
shift lever in the positions shown in the figure.
TM-2-3
REASSEMBLY
TM-2-4
REASSEMBLY
3. If the ball joint does not align with the select lever hole,
loosen the lock nut located at the tip of the cable.Turn the
ball joint for alignment.
NOTE
z If it is not possible to adjust location due to a faulty
cable, replace the control cable with a new one.
TM-2-5
REASSEMBLY
TM-2-6
PROPELLER SHAFT
CONTENTS PS
SERVICE DATA ................................ PS-1-1 REASSEMBLY .............................. PS-2-6
SPECIFICATIONS ........................ PS-1-1 INSTALLATION ............................. PS-2-9
TABLE OF PROPELLER SHAFT
SHAPE AND COMBINATION ....... PS-1-3 = UNIT NAME PS410, 420, 430, 520 =
SERVICE DATA ............................ PS-1-5 CONSTRUCTION .............................. PS-3-1
TIGHTENING TORQUE ............... PS-1-5 DISASSEMBLY ................................. PS-3-3
REMOVAL ..................................... PS-3-3
= UNIT NAME PS860 = DISASSEMBLY ............................. PS-3-3
CONSTRUCTION ............................. PS-2-1 INSPECTION ..................................... PS-3-6
DISASSEMBLY ................................ PS-2-2 REASSEMBLY .................................. PS-3-7
REMOVAL .................................... PS-2-2 REASSEMBLY .............................. PS-3-7
DISASSEMBLY ............................ PS-2-2 INSTALLATION ........................... PS-3-10
INSPECTION .................................... PS-2-5
REASSEMBLY ................................. PS-2-6
SERVICE DATA PROPELLER SHAFT
SERVICE DATA
SPECIFICATIONS
UNIT NAME PS860
Unit: mm (in)
Propeller shaft tube O.D. 90 (3.54)
Universal joint journal
A 112 (4.41)
B 24 (0.94)
C 17.5 (0.689)
D 22.3 (0.878)
E 3.5 (0.138)
F 22 (0.87)
G 35.5 (1.398)
I 56 (2.20)
J 35.5 (1.398)
K 40º
Type SAE
Involute spline Number of teeth 16
Diameter 45 (1.77)
PS-1-1
SERVICE DATA PROPELLER SHAFT
E 43 (1.69) 55 (2.17)
G 25 (0.98) 26 (1.02)
*1 Differential to differential
PS-1-2
SERVICE DATA PROPELLER SHAFT
PS-1-3
SERVICE DATA PROPELLER SHAFT
*1 PS410
PS-1-4
SERVICE DATA PROPELLER SHAFT
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Less than
PS860 0.5 (0.020)
0.3 (0.012)
Propeller shaft runout
PS410, PS420, Less than
0.9 (0.035)
PS430, PS520 0.7 (0.028)
0.20 - 0.33
PS860 0.5 (0.020)
(0.0079 - 0.0130)
Spline rotational direction play
PS410, PS420, 0.11 - 0.20
0.5 (0.020)
PS430, PS520 (0.0043 - 0.0079)
PS860, PS410,
Journal-to-journal bearing 0.03 - 0.07
PS420, PS430, 0.25 (0.0098)
clearance (0.0012 - 0.0028)
PS520
0.01 - 0.05
Bearing end play PS860 0.25 (0.0098) Adjust with retaining ring
(0.0004 - 0.0020)
PS410, PS420,
End play of journal and bearing 0 (0) —
PS430, PS520
1.0 - 2.3
PS420, PS430 — Adjust with side plate
Swing torque of journal {0.10 - 0.23, 0.7 - 1.7}
N·m {kgf·m, ft·lbf} 1.0 - 3.6
PS520 —
{0.10 - 0.37, 0.7 - 2.7}
0.18 - 0.25
PS860 0.25 (0.0098)
(0.0071 - 0.0098)
Center ball bearing axial play
PS420, PS430, 0.18 - 0.24
0.25 (0.0098)
PS520 (0.0071 - 0.0094)
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
PS860 88 - 108 {9 - 11, 65 - 80}
Companion flange bolts and nuts PS420, PS430,
211 - 240 {21.5 - 24.5, 156 - 177}
PS520
PS860 520 - 628 {53 - 64, 383 - 463}
Companion flange mounting nuts PS420, PS430,
343 - 402 {35 - 41, 253 - 297}
PS520
PS410, PS420,
Side plate mounting bolts 25 - 31 {2.5 - 3.2, 18 - 23}
PS430, PS520
PS860 59 {6, 43}
Center bearing retainer mounting bolts and
nuts PS420, PS430,
98 {10, 72}
PS520
PS-1-5
CONSTRUCTION PS860
PS-2-1
DISASSEMBLY PS860
DISASSEMBLY
REMOVAL
Key point of removal
1. Always chock both the front and rear wheels.
2. Engage gear (1st or reverse) to lock the propeller shaft.
3. Place a stand under the propeller shaft or support the shaft
with a lifting cable to prevent it from dropping when
removed.
4. Ensure that the splined yoke and shaft have alignment
marks. If they do not, scribe an alignment mark.
DISASSEMBLY
PS-2-2
DISASSEMBLY PS860
8 Center bearing
1. Propeller shaft
2. Slinger
3. Center bearing assembly
1. Do not attempt to disassemble the center bearing assem-
bly. (Cannot be disassembled)
2. Be careful not to damage the dust seal and slinger.
3. Do not remove the slinger unless it is to be replaced with a
new one.
PS-2-3
DISASSEMBLY PS860
13 Splined yoke
Put an alignment mark on splined shaft and yoke.
PS-2-4
INSPECTION PS860
INSPECTION
z Clean all disassembled parts in cleaning solvent. Carefully
check for scratches, deformity or damage. Replace faulty
parts.
z If measurement indicates that parts exceed the specified
service limit, repair or replace faulty parts.
PS-2-5
REASSEMBLY PS860
REASSEMBLY
REASSEMBLY
Key point of reassembly
10 Dust cap
Fit the dust cap onto the splined yoke fully and caulk at 3 points at
120-degree intervals with a center punch, on the scribed line on the
outside periphery of the dust cap.
8 Center bearing
1. Charge the center bearing case with grease.
2. Do not strike the dust seal.
7 Companion flange
Ensure that the alignment marks (to indicate “phase”) are aligned.
CAUTION
z When tightening the nut ensure that the propeller shaft is
secured in the vise.
PS-2-6
REASSEMBLY PS860
5 Flange yoke
Before installing, align the matching marks.
4 Grease nipple
Ensure that the grease nipple is at a 45º angle to the axis of the
journal arm.
3 Journal
Apply grease to the needle rollers. While guiding the journal, use a
press with a press-fitting tool in place to press-fit the needle roller
bearing assembly into the yoke. Be careful not to drop the needle
rollers.
NOTE
z In assembling, note the relative position of grease nipple
and yoke.
z Use an insertion tool having an outside diameter of 32 to
35 mm (1.26 to 1.38 in), and a shape such that it does not
touch the center of the head of the bearing cap.
z Do not strike the head of the bearing cap directly with a
hammer.
PS-2-7
REASSEMBLY PS860
1 Retaining ring
1. Install a 1.46 mm (0.0575 in) retaining ring (new) which is
used for taking measurements in the groove at the top and
bottom of the yoke.
2. Next, push the bearing cap and retaining ring to one side
and insert a feeler gauge between the retaining ring and
bearing cap to measure the end play.
NOTE
z There must be no gap between the bottom retaining ring
and bearing cap, and top and bottom bearing caps and
journal during measurement.
Unit: mm (in)
Retaining ring table
Thickness
Thickness dimension Identification
designation
1.46 (0.0575) 1.44 - 1.48 (0.0567 - 0.0583) Unpainted
1.50 (0.0591) 1.48 - 1.52 (0.0583 - 0.0598) Yellow
1.54 (0.0606) 1.52 - 1.56 (0.0598 - 0.0614) Green
1.58 (0.0622) 1.56 - 1.60 (0.0614 - 0.0630) White
1.62 (0.0638) 1.60 - 1.64 (0.0630 - 0.0646) Blue
1.66 (0.0654) 1.64 - 1.68 (0.0646 - 0.0661) Brown
NOTE
z Retaining rings are available in six sizes by increments
of 0.04 mm (0.0016 in). An identification coating is
located on the periphery of each snap ring.
z The difference in thickness between the snap rings
installed in a single yoke must be less than 0.06 mm
(0.0024 in).
4. After verifying the end play, tap the yoke shoulder with a
hammer until the bearing cap comes into contact with the
retaining ring.
PS-2-8
REASSEMBLY PS860
INSTALLATION
PS-2-9
CONSTRUCTION PS410, 420, 430, 520
PS-3-1
CONSTRUCTION PS410, 420, 430, 520
PS-3-2
DISASSEMBLY PS410, 420, 430, 520
DISASSEMBLY
REMOVAL
Key point of removal
1. Always chock both the front and rear wheels.
2. Engage gear (1st or reverse) to lock the propeller shaft.
3. Place a stand under the propeller shaft or support the shaft
with a lifting cable to prevent it from dropping when removed.
4. Ensure that the splined yoke and shaft have alignment
marks. If they do not, scribe an alignment mark.
DISASSEMBLY
UNIT NAME PS420, 430, 520
Marks “+” and “,” indicate that the key points of operation are explained in the text.
PS-3-3
DISASSEMBLY PS410, 420, 430, 520
PS-3-4
DISASSEMBLY PS410, 420, 430, 520
PS-3-5
INSPECTION PS410, 420, 430, 520
INSPECTION
z Clean all disassembled parts in cleaning solvent. Carefully
check for scratches, deformity or damage. Replace faulty
parts.
z If measurement indicates that parts exceed the specified
service limit, repair or replace faulty parts.
Propeller shaft runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.7 (0.028) 0.9 (0.035)
NOTE
z The center bearing is a non-greasing type. If the service
limit has been exceeded, replace the center bearing as
an assembly.
z Make sure there is no damage or cracking on the cushion
rubber. Replace if damage or cracking is found.
PS-3-6
REASSEMBLY PS410, 420, 430, 520
REASSEMBLY
REASSEMBLY
Key point of reassembly
19 Dust cap (Except PS410)
Fit the dust cap onto the splined yoke fully and caulk at 3 points at
120-degree intervals with a center punch, on the scribed line on the
outside periphery of the dust cap.
PS-3-7
REASSEMBLY PS410, 420, 430, 520
7 PS410
8 PS420, 430, 520
} Journal
1. Apply grease to the section between the needle roller and
sealing lip.
2. Ensure that the groove to lock the needle roller bearing is
aligned with the bolt hole in the yoke.
3. Ensure that the journal with the grease nipple is on the pro-
peller shaft side.
4 PS410
5 PS420, 430, 520,
} Thrust washer
Ensure that the thrust washer is installed in the bottom of the bear-
ing.
2 PS410
3 PS420, 430, 520
} Side plate
1. Install a side plate (size A) on one side of the propeller shaft
yoke and apply pressure to the other end to remove any
free play. Then, measure the end play of the bearing.
Unit: mm (in)
Maintenance standard Service limit
Bearing end play
0 (0) —
PS-3-8
REASSEMBLY PS410, 420, 430, 520
3. Measure the swing torque of the journal (on the flange yoke
and propeller shaft yoke sides). If it is outside maintenance
standards, replace the side plates and readjust.
Unit: N·m {kgf·m, ft·lbf}
Model Maintenance standard Service limit
1.0 - 2.3
Swing torque of PS420, 430 —
{0.10 - 0.23, 0.7 - 1.7}
journal
1.0 - 3.6
PS520 —
{0.10 - 0.37, 0.7 - 2.7}
PS-3-9
REASSEMBLY PS410, 420, 430, 520
INSTALLATION
PS-3-10
DIFFERENTIAL
CONTENTS
SERVICE DATA ................................ TM-1-1 DISASSEMBLY ................................. DF-4-2
SPECIFICATIONS ........................ DF-1-1 REMOVAL ..................................... DF-4-2 DF
SERVICE DATA ............................ DF-1-3 DISASSEMBLY ............................. DF-4-4
TIGHTENING TORQUE ............... DF-1-6 INSPECTION ..................................... DF-4-8
TOOLS ............................................. DF-2-1 REASSEMBLY .................................. DF-4-9
REASSEMBLY .............................. DF-4-9
= UNIT NAME SRHF-3, SRHH-2 = INSTALLATION ........................... DF-4-15
SERVICE DATA
SPECIFICATIONS
Type Single reduction
Unit name SRHF-3 SRHH-2 SRHL-1 SRHL
Type of reduction gear Hypoid gear
Gear ratio
Refer to the table below.
Number of teeth
Ring gear diameter mm (in) 340 (13.39)* 344 (13.54) 378 (14.88) 428 (16.85)
Pinion offset mm (in) 27 (1.06) 31.75 (1.25) 35 (1.38)
Type and number of differential gears Straight bevel gear: Large 2, Small 4
Gear oil capacity liter (Imp qt) 7 (6-1/8) 9 (7-7/8) 13 (11-1/2) 12 (10-5/8)
NOTE
*: Gear ratio 4.111 only
SRHH-2 z z z z
Unit
SRHL-1 z z z z z z z z z
name
SRHL z z z z
ITHL z z z z
UNIT NAME
SR H F -3
DF-1-1
SERVICE DATA DIFFERENTIAL
DF-1-2
SERVICE DATA DIFFERENTIAL
SERVICE DATA
UNIT NAMES SRHF-3, SRHH-2, SRHL AND SRHL-1
Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.20 - 0.30
SRHF-3 0.5 (0.020)
(0.0079 - 0.0118)
0.25 - 0.35
Drive gear backlash SRHH-2 0.55 (0.0217)
(0.0098 - 0.0138)
SRHL 0.30 - 0.40
0.6 (0.024)
SRHL-1 (0.0118 - 0.0157)
0.18 - 0.23
SRHF-3 0.4 (0.016)
(0.0071 - 0.0091)
Side gear and differential pinion gear 0.20 - 0.28
SRHH-2
backlash (0.0079 - 0.0110)
0.5 (0.020)
SRHL 0.20 - 0.35
SRHL-1 (0.0079 - 0.0138)
19.6 - 29.4
SRHF-3 —
{2.0 - 3.0, 4.4 - 6.6}
24.5 - 34.3 With new
SRHH-2 —
{2.5 - 3.5, 5.5 - 7.7} bearing
SRHL 19.6 - 39.2
— Starting
Drive pinion bearing preload SRHL-1 {2.0 - 4.0, 4.4 - 8.8}
preload
N {kgf, lbf} 12.7 - 19.6
SRHF-3 — (w/oil seal)
{1.3 - 2.0, 2.9 - 4.4}
15.7 - 22.6 With reused
SRHH-2 —
{1.6 - 2.3, 3.5 - 5.1} bearing
SRHL 12.7 - 25.5
—
SRHL-1 {1.3 - 2.6, 2.9 - 5.7}
19.6 - 44.1
SRHF-3 —
{2.0 - 4.5, 4.4 - 9.9} With new bearing
19.6 - 34.3 (Reference value)
SRHH-2 —
{2.0 - 3.5, 4.4 - 7.7}
SRHL 46.1 - 61.8
Differential side bearing preload — With new bearing
SRHL-1 {4.7 - 6.3, 10.4 - 13.9}
N {kgf, lbf}
19.6 - 44.1
SRHF-3 — With reused bearing
{2.0 - 4.5, 4.4 - 9.9}
(Reference value)
SRHH-2 — —
SRHL 30.4 - 39.2
— With new bearing
SRHL-1 {3.1 - 4.0, 6.8 - 8.8}
DF-1-3
SERVICE DATA DIFFERENTIAL
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pinion
gear
SRHF-3
Pinion
shaft
Pinion
Clearance between differential gear 0.10 - 0.14
SRHH-2 0.25 (0.0098)
pinion gear and pinion shaft Pinion (0.0039 - 0.0055)
shaft
Pinion
gear SRHL
Pinion SRHL-1
shaft
SRHF-3
Clearance between side gear boss and SRHH-2 0.21 - 0.31
0.5 (0.020)
differential case SRHL (0.0083 - 0.0122)
SRHL-1
DF-1-4
SERVICE DATA DIFFERENTIAL
DF-1-5
SERVICE DATA DIFFERENTIAL
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
A 88 - 118 {9 - 12, 65 - 87}
Drain plug B 127 - 147 {13 - 15, 94 - 108}
ITHL C 127 - 147 {13 - 15, 94 - 108}
Drain and filler plug
Filler plug 88 - 118 {9 - 12, 65 - 87}
Level plug 88 - 118 {9 - 12, 65 - 87}
Except ITHL 127 - 147 {13 - 15, 94 - 108}
SRHF-3 255 - 294 {26 - 30, 188 - 217}
Ring gear bolt SRHH-2 373 - 412 {38 - 42, 275 - 304}
SRHL, SRHL-1, ITHL 588 - 686 {60 - 70, 434 - 506}
SRHF-3 98 - 137 {10 - 14, 72 - 101}
Differential case bolt SRHH-2 137 - 167 {14 - 17, 101 - 123}
SRHL, SRHL-1, ITHL 216 - 275 {22 - 28, 159 - 203}
SRHF-3 177 - 216 {18 - 22, 130 - 159}
Bearing cap bolt SRHH-2 275 - 304 {28 - 31, 203 - 224}
SRHL, SRHL-1, ITHL 441 - 490 {45 - 50, 325 - 362}
SRHF-3, SRHH-2 10 - 15 {1.0 - 1.5, 7 - 11}
Lock plate bolt
SRHL, SRHL-1, ITHL 19 - 21 {1.9 - 2.1, 14 - 15}
SRHF-3 59 - 78 {6 - 8, 43 - 58}
Bearing retainer bolt
SRHH-2, SRHL
(drive pinion) 118 - 137 {12 - 14, 87 - 101}
SRHL-1, ITHL
Bearing retainer bolt
ITHL 78 - 88 {8 - 9, 58 - 65}
(divider gear)
Pilot bearing mounting nut SRHF-3 20 - 23 {2.0 - 2.3, 14 - 17}
Pilot bearing mounting bolt SRHH-2 39 - 49 {4 - 5, 29 - 36}
SRHF-3 343 - 490 {35 - 50, 253 - 362}
Companion flange nut SRHH-2 392 - 490 {40 - 50, 289 - 362}
SRHL, SRHL-1 392 - 539 {40 - 55, 289 - 398}
Companion flange bolt ITHL 118 - 137 {12 - 14, 87 - 101}
Differential carrier mounting bolt SRHF-3, SRHH-2 M12 78 - 98 {8 - 10, 58 - 72}
and nut SRHL, SRHL-1, ITHL M14 127 - 147 {13 - 15, 94 - 108}
SRHF-3, SRHH-2 137 - 157 {14 - 16, 101 - 116}
Rear axle shaft bolt SRHL-1 147 - 167 {15 - 17, 108 - 123}
SRHL, ITHL 137 - 177 {14 - 18, 101 - 130}
SRHF-3
Type PS860 88 - 108 {9 - 11, 65 - 80}
SRHH-2
Propeller shaft bolt and nut SRHL Type PS420,
SRHL-1 PS430, 211 - 240 {21.5 - 24.5, 156 - 177}
ITHL PS520
DF-1-6
TOOLS DIFFERENTIAL
TOOLS
Tool name and number Description Shape
99823 Z0005
[SRHF-3]
Use when disassembling and reassembling the
Attachment differential carrier. The attachment is used by
installing it on the engine stand.
99823 Z0004
[SRHL]
[SRHL-1]
99826 Z5001
[SRHF-3]
99826 Z0000
Diff. wrench [SRHH-2] Used for turning adjusting nut
[SRHL]
[SRHL-1]
[ITHL]
99535 Z0011
[SRHF-3]
Wrench 99535 Z0003 Used for turning the companion flange nut
socket [SRHH-2]
[SRHL]
[SRHL-1]
DF-2-1
TOOLS DIFFERENTIAL
DF-2-2
CONSTRUCTION SRHF-3, SRHH-2
DF-3-1
CONSTRUCTION SRHF-3, SRHH-2
DF-3-2
DISASSEMBLY SRHF-3, SRHH-2
DISASSEMBLY
z Chock the wheels.
REMOVAL
Key point of removal
z Remove the breather and check for clogging and damage.
If there is clogging or damage, clean or replace the
breather.
1. Remove the drain plug and drain the gear oil completely.
WARNING
WARNING
z Never attempt to service the unit or drain oil immediately
after stopping the engine. Wait until the oil temperature
drops below 50ºC (122ºF) to prevent scalding.
NOTE
z Drain the oil into a container having a capacity of at least
7 liters (6-1/8 Imp qt) for the SRHF-3 or at least 9 liters (7-
7/8 Imp qt) for the SRHH-2.
z The drain plug has a built-in magnet. Remove metal fill-
ings from the drain plug when reinstalling.
DF-3-3
DISASSEMBLY SRHF-3, SRHH-2
z SRHH-2
Install the differential carrier on the differential stand (99823
Z0003).
DF-3-4
DISASSEMBLY SRHF-3, SRHH-2
DISASSEMBLY
UNIT NAME SRHF-3
DF-3-5
DISASSEMBLY SRHF-3, SRHH-2
DF-3-6
DISASSEMBLY SRHF-3, SRHH-2
2. Place the aligning marks on the side bearing cap and car-
rier case.
4 SRHF-3
5 SRHH-2 }Differential case assembly
Remove the differential case assembly using a bar.
NOTE
z Do not allow the side bearing outer race to drop into the
case assembly.
DF-3-7
DISASSEMBLY SRHF-3, SRHH-2
5 SRHF-3
6 SRHH-2 } Drive pinion assembly
Before disassembling the drive pinion assembly, measure and
record the preload.
NOTE
z Record the thickness of the removed shim(s).
12 SRHF-3
13 SRHH-2 }Pinion gear
Measure the backlash of differential pinion gear, and record the
results.
NOTE
z Always measure the backlash while holding the pinion
shaft in position.
19 SRHF-3
20 SRHH-2 } Companion flange nut
Secure the drive pinion assembly in a vise and using the wrench
socket (99535 Z0011), remove the companion flange nut.
NOTE
z Before loosening the companion flange nut, take the
staked portions (2 places) out from the grooves.
z Discard the old nuts: replace with new ones.
21 SRHF-3
22 SRHH-2 }
Dust shield
NOTE
z Do not remove the dust shield unless it is faulty.
DF-3-8
INSPECTION SRHF-3, SRHH-2
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)
DF-3-9
REASSEMBLY SRHF-3, SRHH-2
REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.
REASSEMBLY
Key point of reassembly
29 31 SRHF-3
30 32 SRHH-2 }Taper roller bearing (inner and outer)
Press the bearing outer races in.
30 SRHF-3
31 SRHH-2 } Oil seal
After adjusting the preload of the drive pinion bearing, remove the
oil seal again and apply RTV (Room Temperature Vulcanizing) liq-
uid gasket (THREE BOND # 1215 or equivalent). Then, reinstall the
oil seal.
27 SRHF-3
28 SRHH-2 } Retaining ring
Drive the pilot bearing in and secure it with the retaining ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.
DF-3-10
REASSEMBLY SRHF-3, SRHH-2
25 SRHF-3
}
27 SRHH-2 Adjusting washer
Measure the preload of the drive pinion bearing.
If the preload is not within the specified range, add or remove
adjusting washer(s) until it is.
Unit: N {kgf, lbf}
Item Maintenance standard
SRHF-3 19.6 - 29.4 {2.0 - 3.0, 4.4 - 6.6}
Preload of New (*)
SRHH-2 24.5 - 34.3 {2.5 - 3.5, 5.5 - 7.7}
drive pinion
bearing SRHF-3 12.7 - 19.6 {1.3 - 2.0, 2.9 - 4.4}
Old (*)
SRHH-2 15.7 - 22.6 {1.6 - 2.3, 3.5 - 5.1}
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 41 washers in 0.0125 mm (0.0005 in) incre-
ments in the 2.1000 to 2.6000 mm (0.0827 to 0.1024 in)
range.
· · · SRHF-3
z There are 29 washers in 0.0125 mm (0.0005 in) incre-
ments in the 2.2500 to 2.6000 mm (0.0886 to 0.1024 in)
range.
· · · SRHH-2
21 SRHF-3 Dust shield
Press-fit a new dust shield (if the old shield is removed) to the com-
panion flange. Driving tool (99828 Z5002)
19 SRHF-3
20 SRHH-2 }
Companion flange nut
After adjusting preload, stake the companion flange nut and drive
pinion with the staking tool.
: SRHF-3 · · · 343 - 490 N·m
{35 - 50 kgf·m, 253 - 362 ft·1lbf}
SRHH-2 · · · 392 - 490 N·m
{40 - 50 kgf·m, 289 - 362 ft·1lbf}
NOTE
z Securely stake the nut so that the staked portions come
into contact with the grooves (2 places).
z No breakages should exist in the staked portions.
DF-3-11
REASSEMBLY SRHF-3, SRHH-2
16 SRHF-3
}
17 SRHH-2 Differential case (LH)
Install the left differential case on the drive gear.
Hold it with a pressing tool and tighten ring gear bolts to the speci-
fied torque.
: SRHF-3 · · · 255 - 294 N·m
{26 - 30 kgf·m, 188 - 217 ft·1lbf}
SRHH-2 · · · 373 - 412 N·m
{38 - 42 kgf·m, 275 - 304 ft·1lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the drive gear side when installing.
12 SRHF-3
13 SRHH-2 } Pinion gear
Make sure that the backlash of the differential gear is within the
maintenance standard.
If the backlash is not within the specified range, change the side
gear thrust washer with one that is of the proper thickness in order
to adjust it properly.
Unit: mm (in)
Maintenance standard Service limit
0.18 - 0.23
SRHF-3 0.4 (0.016)
(0.0071 - 0.0091)
0.20 - 0.28
SRHH-2 0.5 (0.020)
(0.0079 - 0.0110)
Thrust washers
}
1.60 - 1.65 mm (0.0630 - 0.0650 in)
1.65 - 1.70 mm (0.0650 - 0.0669 in)
1.70 - 1.75 mm (0.0669 - 0.0689 in) SRHF-3
1.75 - 1.80 mm (0.0689 - 0.0709 in)
1.60 - 1.70 mm (0.0630 - 0.0669 in)
1.70 - 1.80 mm (0.0669 - 0.0709 in) } SRHH-2
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential carrier.
DF-3-12
REASSEMBLY SRHF-3, SRHH-2
8 SRHF-3
9 SRHH-2 } Differential case (RH)
Align the marks on the left and right differential cases, and tempo-
rarily tighten with bolts. Then, hold the cases with a pressing tool
and retighten the bolts to the specified torque.
: SRHF-3 ... 98 - 137 N·m {10 - 14 kgf·m, 72 - 101 ft·lbf}
SRHH-2 ... 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}
5 SRHF-3
6 SRHH-2 } Drive pinion assembly
Install the drive pinion assembly using adjusting shim(s).
NOTE
z Be sure to install the O-ring in the proper order. Also, be
careful not to twist the O-ring during installation.
z Install the one-piece-type shim on the O-ring side.
4 SRHF-3
5 SRHH-2 }Differential case assembly
1. Measure the side bearing preload using the increase in the
fit-in diameter of the bearing cap. Before installing the differ-
ential case, tighten the side bearing cap to the specified
torque. Measure the fit-in diameter, making sure it is within
the maintenance standard shown below. Record the fit-in
diameter.
: SRHF-3 ... 177 - 216 N·m {18 - 22 kgf·m, 130 - 159 ft·lbf}
SRHH-2 ... 275 - 304 N·m {28 - 31 kgf·m, 203 - 224 ft·lbf}
Unit: mm (in)
Item Maintenance standard
Side bearing cap SRHF-3 φ320.59 - 320.79 (12.622 - 12.630)
fit-in diameter SRHH-2 φ361.70 - 361.80 (14.240 - 14.244)
DF-3-13
REASSEMBLY SRHF-3, SRHH-2
DF-3-14
REASSEMBLY SRHF-3, SRHH-2
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
DF-3-15
REASSEMBLY SRHF-3, SRHH-2
NOTE
z When removing or adding split shims, loosen the bolt
and slide the sleeve approximately 10 mm (0.39 in) from
the sleeve assembly (just enough to insert the shim).
Sliding the sleeve too far out of the sleeve assembly may
damage the O-ring.
z Insert the split shim into the gap between the sleeve and
one-piece type shim.
Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
Split type 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)
DF-3-16
REASSEMBLY SRHF-3, SRHH-2
Decrease backlash by
Tooth contact pattern is
loosening the right adjust-
3. toward the “heel” of the
ing nut and tightening the
tooth.
left one.
NOTE
z If the contact patterns on both surfaces of the tooth are extremely different, the drive gear and
drive pinion should be replaced as a unit.
z After adjusting gear contact, be sure to recheck the backlash.
DF-3-17
REASSEMBLY SRHF-3, SRHH-2
INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.
DF-3-18
REASSEMBLY SRHF-3, SRHH-2
DF-3-19
REASSEMBLY SRHF-3, SRHH-2
6. Remove the level plug, and then pour gear oil into the plug
holes. The amount of oil required is approximately 7 liters
(6-1/8 Imp qt) for the SRHF-3 or approximately 9 liters (7-7/
8 Imp qt) for the SRHH-2.
: Filler plug 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
NOTE
z It is advisable to replenish gear oil two hours after the
differential carrier has been assembled.
z Be careful not to allow dust or dirt to get into the carrier
when replenishing oil.
z After installing the filler plug, clean the surrounding area.
DF-3-20
CONSTRUCTION SRHL, SRHL-1
DF-4-1
DISASSEMBLY SRHL, SRHL-1
DISASSEMBLY
z Chock the wheels.
REMOVAL
Key point of removal
z Remove the breather and check for clogging and damage.
If there is clogging or damage, clean or replace the
breather.
1. Remove the drain plug and drain the gear oil completely.
WARNING
WARNING
z Never attempt to service the unit or drain oil immediately
after stopping the engine. Wait until the oil temperature
drops below 50ºC (122ºF) to prevent scalding.
NOTE
z Drain the oil into a container having a capacity of at least
12 liters (10-5/8 Imp qt) ... SRHL, 13 liters (11-1/2 Imp qt) ...
SRHL-1.
z The drain plug has a built-in magnet. Remove metal fill-
ings from the drain plug when reinstalling.
DF-4-2
DISASSEMBLY SRHL, SRHL-1
DF-4-3
DISASSEMBLY SRHL, SRHL-1
DISASSEMBLY
DF-4-4
DISASSEMBLY SRHL, SRHL-1
2. Place the aligning marks on the side bearing cap and car-
rier case.
DF-4-5
DISASSEMBLY SRHL, SRHL-1
10 Pinion gear
Measure the backlash of differential pinion gear, and record the
results.
NOTE
z Always measure the backlash while holding the pinion
shaft in position.
DF-4-6
DISASSEMBLY SRHL, SRHL-1
22 Dust shield
NOTE
z Do not remove the dust shield unless it is faulty.
DF-4-7
INSPECTION SRHL, SRHL-1
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
DF-4-8
REASSEMBLY SRHL, SRHL-1
REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.
REASSEMBLY
Key point of reassembly
30 32 Taper roller bearing (inner and outer)
Press the bearing outer races in.
28 Retaining ring
Drive the pilot bearing assembly and secure it with the retaining
ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.
26 Adjusting washer
Measure the preload of the drive pinion bearing.
If the preload is not within the specified range, add or remove
adjusting washer(s) until it is.
Unit: N {kgf, lbf}
Item Maintenance standard
Preload of New (*) 19.6 - 39.2 {2.0 - 4.0, 4.4 - 8.8}
drive pinion
bearing Old (*) 12.7 - 25.5 {1.3 - 2.6, 2.9 - 5.7}
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 29 washers in 0.0125 mm (0.0005 in) incre-
ments in the 2.2500 to 2.6000 mm (0.0886 to 0.1024 in)
range.
DF-4-9
REASSEMBLY SRHL, SRHL-1
10 Pinion gear
Make sure that the backlash of the differential gear is within the
maintenance standard.
If the backlash is not within the specified range, change the side
gear thrust washer with one that is of the proper thickness in order
to adjust it properly.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)
DF-4-10
REASSEMBLY SRHL, SRHL-1
Thrust washers
1.60 mm (0.0630 in)
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.
DF-4-11
REASSEMBLY SRHL, SRHL-1
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
DF-4-12
REASSEMBLY SRHL, SRHL-1
NOTE
z When removing or adding split shims, loosen the bolt
and slide the sleeve approximately 10 mm (0.39 in) from
the sleeve assembly (just enough to insert the shim).
Sliding the sleeve too far out of the sleeve assembly may
damage the O-ring.
z Insert the split shim into the gap between the sleeve and
one-piece type shim.
Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
Split type 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)
DF-4-13
REASSEMBLY SRHL, SRHL-1
Decrease backlash by
Tooth contact pattern is
loosening the right adjust-
3. toward the “heel” of the
ing nut and tightening the
tooth.
left one.
NOTE
z If the contact patterns on both surfaces of the tooth are extremely different, the drive gear and
drive pinion should be replaced as a unit.
z After adjusting gear contact, be sure to recheck the backlash.
DF-4-14
REASSEMBLY SRHL, SRHL-1
INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.
DF-4-15
REASSEMBLY SRHL, SRHL-1
DF-4-16
REASSEMBLY SRHL, SRHL-1
6. Remove the level plug, and then pour gear oil into the plug
holes. The amount of oil required is approximately 12 liters
(10-5/8 Imp qt) (Type SRHL), 13 liters (11-1/2 Imp qt) (Type
SRHL-1).
: Filler plug 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
NOTE
z It is advisable to replenish gear oil two hours after the
differential carrier has been assembled.
z Be careful not to allow dust or dirt to get into the carrier
when replenishing oil.
z After installing the filler plug, clean the surrounding area.
DF-4-17
REASSEMBLY SRHL, SRHL-1
- MEMO -
DF-4-18
CONSTRUCTION ITHL
DF-5-1
DISASSEMBLY ITHL
DISASSEMBLY
z Chock the wheels.
REMOVAL
Key point of removal
1. Remove the drain plugs (A, B and C) and drain the gear oil
completely.
WARNING
WARNING
z Never attempt to service the unit or drain oil immediately
after stopping the engine. Wait until the oil temperature
drops below 50ºC (122ºF) to prevent scalding.
NOTE
z Drain the oil into a container having a capacity of at least
12 liters (10-5/8 Imp qt).
z The drain plug has a built-in magnet. Remove metal fill-
ings from the drain plug when reinstalling.
2. Remove the axle shaft.
NOTE
z Be careful not to scratch the oil seal when removing the
axle shaft.
DF-5-2
DISASSEMBLY ITHL
DISASSEMBLY
DF-5-3
DISASSEMBLY ITHL
DF-5-4
DISASSEMBLY ITHL
48 Bearing retainer
Utilizing the puller bolt hole.
54 Adjusting nut
1. Measure and record the drive gear backlash before remov-
ing the adjusting nut.
DF-5-5
DISASSEMBLY ITHL
2. Place the aligning marks on the side bearing cap and car-
rier case.
DF-5-6
DISASSEMBLY ITHL
62 Pinion gear
Measure the backlash of differential pinion gear, and record the
results.
NOTE
z Always measure the backlash while holding the pinion
shaft in position.
82 Oil catcher
Confirm the number stamped on the removed shims and the num-
ber of shims, and record them.
DF-5-7
INSPECTION ITHL
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
DF-5-8
INSPECTION ITHL
Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.6 (0.024)
DF-5-9
INSPECTION ITHL
DF-5-10
REASSEMBLY ITHL
REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.
REASSEMBLY
Key point of reassembly
82 Oil catcher
Confirm the number stamped on the removed shims and the num-
ber of shims.
77 Retaining ring
Drive the pilot bearing in and secure it with the retaining ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.
DF-5-11
REASSEMBLY ITHL
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 32 washers in 0.0125 mm (0.0005 in) incre-
ments in the 1.9125 to 2.3000 mm (0.0753 to 0.0906 in)
range.
z If the holes in the castellated nut groove and drive pinion
are not aligned properly, tighten (do not loosen) the nut
until they are aligned.
62 Pinion gear
Make sure that the backlash of the differential gear is within the
maintenance standard.
If the backlash is not within the specified range, change the side
gear thrust washer with one that is of the proper thickness in order
to adjust it properly.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.60 (0.0236)
DF-5-12
REASSEMBLY ITHL
Thrust washers
1.60 mm (0.0630 in)
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.
DF-5-13
REASSEMBLY ITHL
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
DF-5-14
REASSEMBLY ITHL
z Insert the split shim into the gap between the sleeve and
one-piece type shim.
Adjusting shims thickness
Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)
Split type
(RH, LH)
Small backlash
Drive gear too close to the
2. (Loosen left adjusting nut
drive pinion
and tighten the right one.)
Large backlash
Drive gear too far from
3. (Loosen right adjusting nut
drive pinion
and tighten the left one.)
NOTE
z If the contact patterns on both sides of the drive gear tooth are extremely different, replace the
drive gear and drive pinion as a unit.
z After the gear contact pattern has been checked and adjusted, also be sure to inspect the back-
lash.
DF-5-15
REASSEMBLY ITHL
50 Divider gear
1. Install the bearing retainer and shim(s), and then tighten the
three bolts to their specified torque. Turn the divider gear
box to break the bearing in properly and then measure the
preload to make sure it is 0 kg. If not, adjust it by adding
shim(s). Place a dial gauge on the divider gear and turn the
gear counterclockwise until the dial gauge reading is at its
minimum. Pry the divider gear with a lever that has been
inserted through the inspection window to check whether
the gear play is within the specified range. If it is not, add or
remove the shim(s) until the specified play is obtained.
: 78 - 88 N·m {8 - 9 kgf·m, 58 - 65 ft·lbf}
Axial direction play 0.10 - 0.17 mm (0.0039 - 0.0067 in)
43 Idler gear
1. Face the idler shaft cutout to the lock plate mounting bolt
hole in the carrier cover.
DF-5-16
REASSEMBLY ITHL
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 25 adjusting washers in 0.025 mm (0.0010 in)
increments in the 1.600 to 2.200 mm (0.0630 to 0.0866 in)
range.
4. Lock the castellated nut with a cotter pin.
NOTE
z If the groove in the nut is not aligned with the hole in the
idler shaft, tighten (do not loosen) the nut until they are.
DF-5-17
REASSEMBLY ITHL
Proceed carefully when placing the cylinder over the piston to avoid
turning the felt oilers up.
DF-5-18
REASSEMBLY ITHL
13 Pinion gear
Measure the backlash of the differential gear and make sure the
measured value is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.45 (0.0177)
NOTE
z Always measure the backlash while holding the spider
shaft in position.
6 Oil seal
Using the driving tool (99828 Z0016), drive the oil seal into the oil
seal retainer.
z Apply rubber grease between the oil seal lips.
DF-5-19
REASSEMBLY ITHL
INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.
DF-5-20
REASSEMBLY ITHL
DF-5-21
REASSEMBLY ITHL
6. Remove the filler plug and level plug, and then pour gear oil
into the plug holes.
: 88 - 118 N·m {9 - 12 kgf·m, 65 - 87 ft·lbf}
NOTE
z Be sure to fill the carrier case with approx. 11 liters (9-5/8
Imp qt) of gear oil and the intermediate axle differential
with approx. 1 liter (7/8 Imp qt) of oil.
DF-5-22
REAR AXLE AND SUSPENSION
CONTENTS
SERVICE DATA ................................ RA-1-1 DISASSEMBLY ............................ RA-5-2
SPECIFICATIONS ........................ RA-1-1 INSPECTION ............................... RA-5-6
SERVICE DATA ............................ RA-1-5 REPAIR AND REPLACEMENT .... RA-5-7
TIGHTENING TORQUE ............... RA-1-7 REASSEMBLY ............................ RA-5-11 RA
TOOLS ............................................. RA-2-1 SUSPENSION ................................... RA-6-1
CONSTRUCTION ........................ RA-6-1
= UNIT NAME RS55, RS65, RS70, RS75 = DISASSEMBLY ............................ RA-6-2
INSPECTION ............................... RA-6-5
REAR AXLE ..................................... RA-3-1 REPAIR AND REPLACEMENT .... RA-6-6
CONSTRUCTION ........................ RA-3-1 REASSEMBLY ............................. RA-6-7
DISASSEMBLY ............................ RA-3-3
INSPECTION ............................... RA-3-6 = UNIT NAME RD90, RD80, RW1A =
REPAIR AND REPLACEMENT .... RA-3-6
REASSEMBLY ............................. RA-3-8 REAR AXLE ...................................... RA-7-1
SUSPENSION .................................. RA-4-1 CONSTRUCTION ........................ RA-7-1
CONSTRUCTION ........................ RA-4-1 DISASSEMBLY ............................ RA-7-4
DISASSEMBLY ............................ RA-4-2 INSPECTION ............................. RA-7-10
INSPECTION ............................... RA-4-5 REPAIR AND REPLACEMENT ... RA-7-11
REPAIR AND REPLACEMENT .... RA-4-6 REASSEMBLY ........................... RA-7-14
REASSEMBLY ............................. RA-4-7 SUSPENSION ................................... RA-8-1
CONSTRUCTION ........................ RA-8-1
= UNIT NAME RS90, RS1A = DISASSEMBLY ............................ RA-8-3
INSPECTION ............................... RA-8-8
REAR AXLE ..................................... RA-5-1 REPAIR AND REPLACEMENT .... RA-8-9
CONSTRUCTION ........................ RA-5-1 REASSEMBLY ............................ RA-8-11
SERVICE DATA REAR AXLE & SUSPENSION
SERVICE DATA
SPECIFICATIONS
REAR AXLE
Unit name RS55 RS65 RS70 RS75
Type of rear axle Full-floating, axle tube type
Type of axle housing Pressed, banjo type
Axle shaft diameter mm (in) 42 (1.65) 44 (1.73) 44 (1.73) 48 (1.89)
Type of brake drum
Inboard type
installation
Oil capacity liter (Imp qt) 7 (6-1/8) 7 (6-1/8) 9 (7-7/8)
Hub bolt number 6 6, 8 6 8
RA-1-1
SERVICE DATA REAR AXLE & SUSPENSION
Unit name
R S 55
NOMINAL WEIGHT ON
AXLE(S)
UNIT CLASSIFICATION APPLICABLE MODEL
55 5.5 ton
R REAR AXLE REAR SINGLE
S SHAFT TRUCK 65 6.5 ton
REAR 1-axle 70 7.0 ton
D
DOUBLE drive 75 7.5 ton
SHAFT 2-axle
W TRUCK 90 9.0 ton
drive
1A 10.0 ton
SUSPENSION
Item RS55 RS65 RS70 RS75
Type of suspension Rigid axle type
Type of spring Semi-elliptic, leaf spring (shackle type)
Type of shock absorber
Cylindrical double-action
(if so equipped)
RA-1-2
SERVICE DATA REAR AXLE & SUSPENSION
SPRING SPECIFICATIONS
Unit: mm (in)
Axle model Vehicle model Length x width x thickness - Number of leaves
Main: 1,300 x 70 x 11 - 6 (51.18 x 2.76 x 0.43 - 6)
MKA210
Helper: 980 x 70 x { 10 - 1
12 - 4
(38.58 x 2.76 x { 0.39 - 1
0.47 - 4
)
RS70 LKD210
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
{ {
PKB210
13 - 2 0.51 - 2
Main: 1,600 x 80 x 14 - 4 (62.99 x 3.15 x 0.55 - 4 )
RS90 13 - 2 0.51 - 2
Helper: 1,100 x 80 x 12 - 6 (43.31 x 3.15 x 0.47 - 6)
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
PKB212
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 6 (43.31 x 3.15 x 0.47 - 6)
RA-1-3
SERVICE DATA REAR AXLE & SUSPENSION
Unit: mm (in)
Axle model Vehicle model Length x width x thickness - Number of leaves
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
PKC210
Main: 1,600 x 80 x
{ 13 - 2
14 - 5 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 5 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 8 (43.31 x 3.15 x 0.47 - 8)
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 6 (43.31 x 3.15 x 0.47 - 6)
PKC212
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Main: 1,600 x 80 x
{ 13 - 2
14 - 5 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 5 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 8 (43.31 x 3.15 x 0.47 - 8)
Main: 1,600 x 80 x
{ 13 - 2
14 - 4 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 4 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
PKC310
Main: 1,600 x 80 x
{ 13 - 2
14 - 5 (62.99 x 3.15 x
13 - 2 { 0.51 - 2
0.55 - 5 )
0.51 - 2
Helper: 1,100 x 80 x 12 - 8 (43.31 x 3.15 x 0.47 - 8)
PKC310BT
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
RA-1-4
SERVICE DATA REAR AXLE & SUSPENSION
SERVICE DATA
REAR AXLE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
RS55
RS65 Measure the runout at 157 mm
RS70 (6.18 in) dia. point of flange surface.
Axle shaft flange sur- RS75
0.1 (0.004) max. 0.5 (0.020)
face runout
RS90
Measure the runout at 205 mm
RS1A
(8.07 in) dia. point of flange surface.
RW1A
Hub bolt 38.2 - 61.8
number 6 {3.9 - 6.3, 8.6 - 13.9}
RS55
Hub bolt 29.4 - 48.1
—
number 8 {3.0 - 4.9, 6.6 - 10.8}
38.2 - 61.8
RS65
{3.9 - 6.3, 8.6 - 13.9}
Hub bearing preload Measure the preload at hub bolt
N {kgf, lbf} RS70 29.4 - 48.1
— location.
RS75 {3.0 - 4.9, 6.6 - 10.8}
RS90
RS1A
29.4 - 63.7
RD80 —
{3.0 - 6.5, 6.6 - 14.3}
RD90
RW1A
RA-1-5
SERVICE DATA REAR AXLE & SUSPENSION
SUSPENSION
Unit: mm (in)
Item Maintenance standard Service limit
RS55
RS65
28.0 (1.102) 27.5 (1.083)
RS70
Spring pin and shackle pin O.D. RS75
RS90
30.0 (1.181) 29.5 (1.161)
RS1A
RS55
RS65
28.0 (1.102) 28.8 (1.134)
Spring pin and shackle pin RS70
bushing I.D. RS75
RS90
30.0 (1.181) 31.0 (1.220)
RS1A
RS55
RS65
0.07 - 0.12 (0.0028 - 0.0047) 1.0 (0.039)
Clearance between spring (shackle) RS70
pin and bushing RS75
RS90
0.02 - 0.14 (0.0008 - 0.0055) 1.0 (0.039)
RS1A
RD80
99.93 - 99.98 (3.9342 - 3.9362)
Trunnion shaft O.D. RD90 99.4 (3.913)
RW1A 99.95 - 99.99 (3.9350 - 3.9366)
RD80
Trunnion shaft bushing I.D. RD90 100.17 - 100.22 (3.9437 - 3.9457) 100.60 (3.9606)
RW1A
RD80
Clearance between trunnion shaft 0.19 - 0.29 (0.0075 - 0.0114)
RD90 1.0 (0.039)
and bushing
RW1A 0.18 - 0.27 (0.0071 - 0.0106)
RD80
Thrust washer thickness RD90 4.95 - 5.05 (0.1949 - 0.1988) 4.70 (0.1850)
RW1A
Leaf wear — 15% of nominal thickness
RA-1-6
SERVICE DATA REAR AXLE & SUSPENSION
TIGHTENING TORQUE
REAR AXLE
Unit: N·m {kgf·m, ft·lbf}
Models
Item Tightening torque
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
137 - 157 {14 - 16, 101 - 116} O O O O — — — — —
Axle shaft bolt
147 - 167 {15 - 17, 108 - 123} — — — — O O — O O
Hub cap mounting bolt 59 - 69 {6 - 7, 43 - 51} — — — — — — O — —
294 - 343 {30 - 35, 217 - 253} O O O O — — — — —
Hub bolts and nuts
294 - 412 {30 - 42, 217 - 304} — — — — O O O O O
Drain and filler plug 127 - 147 {13 - 15, 94 - 108} O O O O O O — O O
SAE 363 - 422 {37 - 43, 268 - 311} O O O O — — — — —
Wheel nut type 412 - 481 {42 - 49, 304 - 354} — — — — O O O O O
(both inner
and outer) ISO
588 - 637 {60 - 65, 434 - 470} — — — — — O — — O
type
BLT32 127 - 147 {13 - 15, 94 - 108} O O — — — — — — —
RB52 147 - 167 {15 - 17, 108 - 123} — — O O — — — — —
RA-1-7
SERVICE DATA REAR AXLE & SUSPENSION
SUSPENSION
Unit: N·m {kgf·m, ft·lbf}
Models
Item Tightening torque RS70/ RD80/
RS55 RS65 RS90 RS1A RW1A
RS75 RD90
108 - 127 {11 - 13, 80 - 94} O O O O O — —
Spring center bolt
167 - 196 {17 - 20, 123 - 145} — — — — — O O
265 - 324 {27 - 33, 195 - 239} O O O — — — —
U-bolt nut 490 - 539 {50 - 55, 362 - 398} — — — O O — —
716 - 843 {73 - 86, 528 - 622} — — — — — O O
8 - 13 {0.8 - 1.3, 5.8 - 9.4} O O O O O — —
Clip bolt
49 - 59 {5.0 - 6.0, 36 - 43} — — — — — O O
Spring pin lock bolt and nut 64 - 78 {6.5 - 8.0, 47 - 58} O O O O O — —
Spring helper bolt and nut 77 - 98 {7.9 - 10.0, 57 - 72} O O O — — — —
Trunnion bracket mounting bolt 216 - 275 {22 - 28, 159 - 203} — — — — — O O
Torque rod mounting bolt and nut 196 - 265 {20 - 27, 145 - 195} — — — — — O O
Trunnion shaft side plate mount-
216 - 235 {22 - 24, 159 - 174} — — — — — O O
ing bolt
Trunnion shaft spring seat mount-
157 - 245 {16 - 25, 116 - 181} — — — — — O O
ing bolt
Trunnion shaft cover mounting
23 - 30 {2.3 - 3.1, 17 - 22} — — — — — O O
bolt
255 - 343
Trunnion shaft bolt and nut {26 - 35, 188 - 253} (bolt) — — — — — O O
333 - 441 {34 - 45, 246 - 325}
RA-1-8
TOOLS REAR AXLE & SUSPENSION
TOOLS
REAR AXLE
Models
Part name and number Description Shape
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
99820 Z5001
1 99829 Z5000 O O O O — — — — —
2 99540 Z0000
99820 Z0009
1 99829 Z0008 — — — — O O O O O
2 99540 Z0000
99840 Z5003 O O O O — — — — —
Used to remove
the hub
99840 Z0010 — — — — — — — — —
Used to remove
Rear 99840 Z0000
the hub
1 99848 Z0000
hub
2 99849 Z0000
1 Puller body — — — — O O — — —
puller 2 Puller seat
3 99532 Z0000
3 Puller bolt
Used to remove
99840 Z0012
the hub
1 99848 Z0011
1 Puller body
2 99849 Z0003
2 Puller seat
— — — — — — O O O
3 99532 Z0010
3 Puller bolt
4 99531 Z0003
4 Bolt (M16 x 1.5)
RA-2-1
TOOLS REAR AXLE & SUSPENSION
Models
Part name and number Description Shape
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
Oil seal
replacer
99828 Z0005 — — — — — — — — —
99828 Z0000 — — — — — — — O O
Hub
bearing
replacer
99827 Z0062 — — — — O O O O O
Used to install the
inner hub bearing
inner races
O O O O — — — — —
99827 Z0063
O O O O — — — — —
Used to install the
outer hub bearing
inner races
99827 Z0062 — — — — O O O O O
RA-2-2
TOOLS REAR AXLE & SUSPENSION
Models
Part name and number Description Shape
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
99843 Z5005 — — — — — — — — —
O O O O — — — — —
Hub
bearing 99843 Z5003
replacer
— — — — — — — — —
99843 Z5005 — — — — O O O O O
99827 Z0009 O O O — — — — — —
99827 Z0061 — — — — O O O O O
RA-2-3
TOOLS REAR AXLE & SUSPENSION
SUSPENSION
Models
Part name and number Description Shape
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
Used together
Exten- with the socket
sion bar
99535 Z0012
wrench to remove O O O O O O O O O
the U-bolt nut
99535 Z0000 — — — — — — O O O
99535 Z0008 O O O O O O — — —
99888 Z0002 O O O O — — — — —
Used when
Bush-
replacing the
ing
spring (shackle)
replacer
pin bushing
99888 Z0003 — — — — O O — — —
Used when
T-type
socket
99535 Z0005 removing the O O O O O O O O O
spring clip bolt
RA-2-4
TOOLS REAR AXLE & SUSPENSION
Models
Part name and number Description Shape
RS55 RS65 RS70 RS75 RS90 RS1A RD80 RD90 RW1A
Used to remove
Replac- and install the
ing tool
99888 Z0065
torque rod bush- — — — — — — O O O
ing
Used to replace
the spring seat
99883 Z0006
Bush- (trunnion shaft)
1 99888 Z0060
ing
2 99894 Z0001
bushing — — — — — — O O O
replacer 1 Replacer
3 81-14055-1A
2 Attachment
3 Bolt
RA-2-5
TOOLS REAR AXLE & SUSPENSION
- MEMO -
RA-2-6
REAR AXLE RS55, RS65, RS70, RS75
RA-3-1
REAR AXLE RS55, RS65, RS70, RS75
RA-3-2
REAR AXLE RS55, RS65, RS70, RS75
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the front wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads.
3. The left-hand wheel nuts are marked with an “L”.
4. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
5. Place a jack under the rear axle housing and raise the rear
of the vehicle. For safety's sake, place a safety stand under
each side of the rear of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
RA-3-3
REAR AXLE RS55, RS65, RS70, RS75
DISASSEMBLY
RA-3-4
REAR AXLE RS55, RS65, RS70, RS75
6 Oil seal
When removing the oil seal, pinch the protrusion with pliers.
Do not pry the oil seal with a screwdriver or other tool.
8 Adjusting nut
Remove the adjusting nut with the adjusting nut wrench (99820
Z5001).
12 Hub
Remove the hub assembly with the rear hub puller (99840 Z5003).
WARNING
WARNING
z The hub (w/brake drum) is heavy. Use a rope and hoist to
remove the hub. Use a helper when doing this work. Be
careful not to drop the hub onto your foot.
NOTE
z Disassemble the hub and drum as required. Refer to the
“REPAIR AND REPLACEMENT” section for procedures.
z When necessary, use a suitable tool to drive the outer
race from the inner/outer hub bearing.
RA-3-5
REAR AXLE RS55, RS65, RS70, RS75
19 Brake assembly
For removal procedure of the brake assembly, refer to the “BR” sec-
tion.
21 Axle housing
Carefully lower the jack and extract the axle housing.
CAUTION
z Be careful not to drop the axle housing.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
2. Align the flanged section of the hub bolt with the hub groove
to install the hub bolt. Install the hub nut from the inner side
of the brake drum and tighten the hub together with the
brake drum.
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
NOTE
z Use the hub bolt with an “L” on it on the left hub and that
with no mark on the right hub. Face the short side (the
distance from the flanged section to the end of the bolt)
toward the outer side of the truck.
RA-3-6
REAR AXLE RS55, RS65, RS70, RS75
3. Clinch the heads of the hub bolts (on the nut sides) at three
places.
HUB BEARING
1. Remove the oil seal and the outer races of the inner and
outer bearings from the hub.
NOTE
z When removing the outer race of the outer bearing, use a
puller and other appropriate tools for the notches in the
grease collector and then remove.
z When changing the hub bearing, the inner and outer
races are changed as a set. Better results will also be
obtained if the inner and outer bearings are changed as a
set.
z Dispose of the oil seal after removal.
2. Push the outer races of the inner and outer bearings onto
the hub.
NOTE
z Use a hub bearing replacer.
[as a set including the brace rod (99844 Z5000)].
Unit: mm (in)
Tool number Bearing outside diameter Remarks
99843 Z5002 120 (4.72) Inner bearing
99843 Z5003 130 (5.12) Outer bearing
OIL SEAL
1. Put a new oil seal onto the hub.
2. Drive in the oil seal using an oil seal replacer (99828
Z0006).
NOTE
z Before putting on the new oil seal, apply grease to the lip
section.
RA-3-7
REAR AXLE RS55, RS65, RS70, RS75
GREASE
All markedly soiled deposits of grease should be removed from the
inner hub and bearings and replaced with new grease.
Amount of grease:530 g (18.69 oz)
REASSEMBLY
REASSEMBLY
Key point of reassembly
21 Axle housing
Install the axle housing. Install the upper pad above the leaf spring.
Tighten the pad with U-bolts.
CAUTION
z Support the axle housing with a jack and proceed very
carefully with work.
U-bolt nut
: 265 - 324 N·m {27 - 33 kgf·m, 195 - 239 ft·lbf}
19 Brake assembly
For installation procedure of the brake assembly, refer to the “BR”
section.
NOTE
z Do not allow grease to come into contact with the brake
lining.
Unit: N·m {kgf·m, ft·lbf}
Model Type Tightening torque
RS55 BLT32 127 - 147 {13 - 15, 94 - 108}
RS65 BLT32 127 - 147 {13 - 15, 94 - 108}
RS70
RB52 147 - 167 {15 - 17, 108 - 123}
RS75
RA-3-8
REAR AXLE RS55, RS65, RS70, RS75
12 Hub
Insert the hub assembly into the axle housing and drive the outer
bearing inner race into the hub assembly with the hub bearing
replacer (99827 Z0063).
WARNING
WARNING
z Use a lifting cable and hoist to install the hub equipped
with the brake drum. Use a helper when doing this work.
Be careful not to drop the hub.
RA-3-9
REAR AXLE RS55, RS65, RS70, RS75
8 Adjusting nut
1. Attach lock washer and adjusting nut and tighten with
adjusting nut wrench (99820 Z5001).
2. Adjust the preload for the bearing.
z With the adjusting nut secure, turn the hub two or three
times and check that it does not wobble.
z Loosen the adjusting nut and adjust so that the preload is
within the specified value.
NOTE
z The return angle for the adjusting nut should be 60º or
less.
z Use a spring scale for measuring preload and carry it out
at the hub bolt position.
z The brake lining and drum should not be touching each
other when measuring the preload.
Unit: N {kgf, lbf}
Service
Maintenance standard (At hub bolt location)
limit
RS55 (Hub bolt number 6)
38.2 - 61.8 {3.9 - 6.3, 8.6 - 13.9} —
RS65
RS55 (Hub bolt number 8)
RS70 29.4 - 48.1 {3.0 - 4.9, 6,6 - 10.8} —
RS75
3. Align the groove position for the axle housing tube and the
screw hole position for the adjusting nut and attach the lock
plate.
NOTE
z When the holes for the lock plate and the adjusting nut
are not aligned with each other, return the adjusting nut
10º or less and attach the lock plate.
: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
5 Axle shaft
1. Insert the axle shaft.
WARNING
WARNING
z Be careful not to pinch your fingers.
CAUTION
z Be careful not to damage the oil seal.
RA-3-10
REAR AXLE RS55, RS65, RS70, RS75
INSTALLATION
Key point of installation
Connect brake hose, brake tube and connector parts.
CAUTION
z Apply a coat of Three Bond 1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.
NOTE
z Make certain that the brake hose is not twisted when con-
necting.
NOTE
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
RA-3-11
REAR AXLE RS55, RS65, RS70, RS75
RA-3-12
SUSPENSION RS55, RS65, RS70, RS75
SUSPENSION
CONSTRUCTION
RA-4-1
SUSPENSION RS55, RS65, RS70, RS75
DISASSEMBLY
REMOVAL
Key point of removal
Chock the front wheels and remove mud and grease from the sus-
pension system before dismounting.
1. Jack up the rear axle and place a safety stand under the
frame at the rear of the spring. The stand should be such
that the rear wheels are 10 to 20 mm (0.39 to 0.79 in) off the
ground when the spring is free.
WARNING
WARNING
z In order to prevent a serious injury or accident, never get
under the vehicle while jacking it up.
RA-4-2
SUSPENSION RS55, RS65, RS70, RS75
DISASSEMBLY
RA-4-3
SUSPENSION RS55, RS65, RS70, RS75
RA-4-4
SUSPENSION RS55, RS65, RS70, RS75
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
RA-4-5
SUSPENSION RS55, RS65, RS70, RS75
6. Clamp the spring leaves together with the center bolt and
nut.
: 108 - 127 N·m {11 - 13 kgf·m, 80 - 94 ft·lbf}
7. Remove the C-clamp from the spring assembly.
8. Install the clip bolt together with the spring assembly.
9. After tightening the clip bolt, stake the threaded end of the
clip bolt with the punch so that it is locked.
: 8 - 13 N·m {0.8 - 1.3 kgf·m, 5.8 - 9.4 ft·lbf}
Bushing
1. Remove the bushing using bushing replacer (99888
Z0002).
RA-4-6
SUSPENSION RS55, RS65, RS70, RS75
REASSEMBLY
Key point of reassembly
26 Shackle pin
1. Align the cutout section for the shackle pin lock bolt with the
bracket before installing the shackle pin.
2. Align the cutout section for the spring pin lock bolt with the
shackle before driving the spring pin into place.
RA-4-7
SUSPENSION RS55, RS65, RS70, RS75
8 U-bolt nut
Install the spring on the rear axle with the upper and lower spring
pads in place.
: 265 - 324 N·m {27 - 33 kgf·m, 195 - 239 ft·lbf}
NOTE
z When securing the spring, jack up the axle until it con-
tacts the spring.
z Face the arrow of the lower spring pad toward the front
of the vehicle. (RS70 only)
RA-4-8
REAR AXLE RS90, RS1A
RA-5-1
REAR AXLE RS90, RS1A
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the front wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
6. Place a jack under the rear axle housing and raise the rear
of the vehicle. For safety's sake, place a safety stand under
each side of the rear of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
10. When removing brake hose and tube, have a tray on hand
for the parts to be removed.
RA-5-2
REAR AXLE RS90, RS1A
DISASSEMBLY
RS90 and RS1A models
RA-5-3
REAR AXLE RS90, RS1A
6 Oil seal
When removing the oil seal, pinch the protrusion with pliers. Do not
pry the oil seal with a screwdriver or other tool. (RS90, RS1A)
8 Adjusting nut
Remove the adjusting nut with the adjusting nut wrench.
Models Adjusting nut wrench
RS90
99820 Z0009
RS1A
RA-5-4
REAR AXLE RS90, RS1A
12 Hub
Remove the inner race of the outer hub bearing and the hub (with
the brake drum attached) with the rear hub puller.
Models Rear hub puller
RS90
99840 Z0000
RS1A
WARNING
WARNING
z The hub (w/brake drum) is heavy. Use a rope and hoist to
remove the hub. Use a helper when doing this work. Be
careful not to drop the hub onto our foot.
NOTE
z Disassemble the hub and drum as required. Refer to the
“REPAIR AND REPLACEMENT” section for procedures.
z When necessary, use a suitable tool to drive the outer
race from the inner/outer hub bearing.
18 Brake assembly
19 Brake bracket
For disassembly procedure of the brake assembly, refer to the “BR”
section.
RA-5-5
REAR AXLE RS90, RS1A
23 Axle housing
Carefully lower the jack and extract the axle housing.
CAUTION
z Be careful not to drop the axle housing.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
RA-5-6
REAR AXLE RS90, RS1A
NOTE
z Use the hub bolt with an “L” on it on the left hub and that
with no mark on the right hub. Face the short side (the
distance from the flanged section to the end of the bolt)
toward the outer side of the truck.
3. Clinch the heads of the hub bolts (on the nut sides) at three
places.
<ISO type>
NOTE
z Do not attempt to press hub bolts into place by tighten-
ing nuts. Doing so causes serrations to rotate and the
hub will not lock properly.
z Use hub bolts stamped “L” for the left-hand hub and
those without any stamp for the right-hand hub.
RA-5-7
REAR AXLE RS90, RS1A
NOTE
z Be careful not to scratch the hub, brake drum and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.
2. Press bolts into the hub.
RA-5-8
REAR AXLE RS90, RS1A
NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.
2. Press new hub bolts into the hub.
RA-5-9
REAR AXLE RS90, RS1A
NOTE
z Be careful not to scratch the hub or brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure hub bolts are flush and pressed properly.
z Wipe off oil seepage.
HUB BEARING
1. Remove the oil seal and the outer races of the inner and
outer bearings from the hub.
NOTE
z When removing the outer race of the outer bearing, use a
puller and other appropriate tools for the notches in the
grease collector and then remove.
z When changing the hub bearing, the inner and outer races
are changed as a set. Better results will also be obtained if
the inner and outer bearings are changed as a set.
z Dispose of the oil seal after removal.
2. Push the outer races of the inner and outer bearings onto
the hub.
NOTE
z Use a hub bearing replacer.
[as a set including the brace rod (99844 Z5000)].
RS90
99843 Z5005 Bearing outside diameter 150 mm (5.91 in)
RS1A
RS90
99843 Z5006 Bearing outside diameter 160 mm (6.30 in)
RS1A
OIL SEAL
Hub portion oil seal (RS90 and RS1A)
1. Put a new oil seal onto the hub with the oil seal replacer
(99828 Z0006).
NOTE
z Before putting on the new oil seal, apply grease to the lip
section.
GREASE
All markedly soiled deposits of grease should be removed from the
inner hub and bearings and replaced with new grease.
Unit: g (oz)
Models Amount of grease
RS90
1,620 (57.14)
RS1A
RA-5-10
REAR AXLE RS90, RS1A
REASSEMBLY
REASSEMBLY
Key point of reassembly
23 Axle housing
Install the axle housing. Install the upper pad above the leaf spring.
Tighten the pad with U-bolts.
CAUTION
z Support the axle housing with a jack and proceed very
carefully with work.
z Face the lower pad with the arrow mark down and point
the arrow toward the front.
U-bolt nut
: 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}
19 Brake bracket
18 Brake assembly
For installation procedure of the brake assembly, refer to the “BR”
section.
14 Oil seal retainer
Drive the oil seal retainer into the axle housing tube with the oil seal
retainer replacer.
Models Oil seal retainer replacer
RS90
99827 Z0061
RS1A
NOTE
z Remove all excess grease from the perimeter of the bear-
ing.
RA-5-11
REAR AXLE RS90, RS1A
12 Hub
Insert the hub assembly into the axle housing and drive the outer
bearing inner race into the hub assembly with the hub bearing
replacer.
Models Hub bearing replacer
RS90
99827 Z0062
RS1A
WARNING
WARNING
z Use a lifting cable and hoist to install the hub equipped
with the brake drum. Use a helper when doing this work.
Be careful not to drop the hub.
8 Adjusting nut
1. Attach adjusting nut and tighten with adjusting nut wrench.
Models Adjusting nut wrench
RS90
99820 Z0009
RS1A
RA-5-12
REAR AXLE RS90, RS1A
Preload
Unit: N {kgf, lbf}
Maintenance standard
Models
(At hub bolt location)
RS90
29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3}
RS1A
3. Align the groove position for the axle housing tube and the
screw hole position for the adjusting nut and attach the lock
plate.
: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
5 Axle shaft
1. Insert a new gasket and insert it on the axle shaft.
WARNING
WARNING
z Be careful not to pinch your fingers.
CAUTION
z Be careful not to damage the oil seal.
RA-5-13
REAR AXLE RS90, RS1A
INSTALLATION
Key point of installation
For AOH.B
1. Do not twist the brake air hose.
2. Clean the area around the connector to prevent foreign
matter from getting into the port.
CAUTION
z Apply a coat of Three Bond 1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.
For AIR.B
Connect the brake air hose.
NOTE
z Do not twist the brake air hose.
CAUTION
z Apply a coat of Three Bond 1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.
RA-5-14
REAR AXLE RS90, RS1A
NOTE
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
washers (the tapered portion). Wipe away any excess
with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.
RA-5-15
REAR AXLE RS90, RS1A
- MEMO -
RA-5-16
SUSPENSION RS90, RS1A
SUSPENSION
CONSTRUCTION
RA-6-1
SUSPENSION RS90, RS1A
DISASSEMBLY
REMOVAL
Key point of removal
Chock the front wheels and remove mud and grease from the sus-
pension system before dismounting.
1. Jack up the rear axle and place a safety stand under the
frame at the rear of the spring. The stand should be such
that the rear wheels are 10 to 20 mm (0.39 to 0.79 in) off the
ground when the spring is free.
WARNING
WARNING
z In order to prevent a serious injury or accident, never get
under the vehicle while jacking it up.
RA-6-2
SUSPENSION RS90, RS1A
DISASSEMBLY
RA-6-3
SUSPENSION RS90, RS1A
RA-6-4
SUSPENSION RS90, RS1A
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
RA-6-5
SUSPENSION RS90, RS1A
Bushing
1. Remove the bushing using bushing replacer (99888
Z0003).
RA-6-6
SUSPENSION RS90, RS1A
REASSEMBLY
Key point of reassembly
25 Shackle pin
1. Align the cutout section for the shackle pin lock bolt with the
bracket before installing the shackle pin.
3. Align the cutout section for the spring pin lock bolt with the
shackle before driving the spring pin into place.
RA-6-7
SUSPENSION RS90, RS1A
8 U-bolt nut
Install the spring on the rear axle with the upper and lower spring
pads in place.
: 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}
NOTE
z When securing the spring, jack up the axle until it con-
tacts the spring.
z Face the arrow of the lower spring pad toward the front
of the vehicle.
RA-6-8
REAR AXLE RD90, RD80, RW1A
RA-7-1
REAR AXLE RD90, RD80, RW1A
RD80 model
RA-7-2
REAR AXLE RD90, RD80, RW1A
RW1A model
RA-7-3
REAR AXLE RD90, RD80, RW1A
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the front wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
6. Place a jack under the rear axle housing and raise the rear
of the vehicle. For safety's sake, place a safety stand under
each side of the rear of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
10. When removing brake hose and tube, have a tray on hand
for the parts to be removed.
RA-7-4
REAR AXLE RD90, RD80, RW1A
DISASSEMBLY
RD90 and RD80 models
RA-7-5
REAR AXLE RD90, RD80, RW1A
RA-7-6
REAR AXLE RD90, RD80, RW1A
RW1A MODEL
RA-7-7
REAR AXLE RD90, RD80, RW1A
8 Adjusting nut
Use an adjusting nut wrench to remove the adjusting nut (99820
Z0009).
RA-7-8
REAR AXLE RD90, RD80, RW1A
11 Hub
1. Use a rear hub puller to remove the hub assembly.
2. When removing the hub assembly, be careful not to drop
the bearing assembly, as it comes off with the oil seal
(99840 Z0012).
WARNING
WARNING
z The hub (with brake drum) is heavy. Use a rope and hoist
to remove the hub. Use a helper when doing this work.
Be careful not to drop the hub onto your foot.
18 Brake assembly
For disassembly procedure of the brake assembly, refer to the “BR”
section.
23 RD90
33 RW1A
}Axle housing, 19-1 Axle tube (RD80 only)
1. Remove the axle housing.
CAUTION
z Be careful not to drop the axle housing.
RA-7-9
REAR AXLE RD90, RD80, RW1A
NOTE
z Secure the spring assembly to prevent it from turning.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
RA-7-10
REAR AXLE RD90, RD80, RW1A
NOTE
z Ensure that the hub bolt marked “L” is installed on the
hub on the left side of the vehicle.
z Ensure that the shorter hub bolt thread faces the outside
of the vehicle.
2. After tightening the hub bolt, clinch the thread end at three
places.
RA-7-11
REAR AXLE RD90, RD80, RW1A
HUB BEARING
Use a hub bearing replacer.
[as a set including the brace rod (99844 Z5000)].
Unit: mm (in)
Tool number Bearing outside diameter
99843 Z5005 150 (5.91)
99843 Z5006 160 (6.30)
OIL SEAL
Drive in the oil seal using an oil seal replacer (99828 Z0006).
NOTE
z Apply grease to the lip.
Use an oil seal replacer (99828 Z0000) to install the oil seal (Except
RD80 model).
RA-7-12
REAR AXLE RD90, RD80, RW1A
GREASE
All markedly soiled deposits of grease should be removed from the
inner hub and bearings and replaced with new grease.
Rear hub greasing procedure
<Drive axle type>
RA-7-13
REAR AXLE RD90, RD80, RW1A
REASSEMBLY
REASSEMBLY
Key point of reassembly
23 RD90
33 RW1A } Axle housing, 19-1 Axle tube (RD80 only)
1. Connect the axle housing (Rear front axle) with the torque
rod; and then remove the wire used to suspend the axle
housing or axle tube (RD80 only) (Rear rear axle).
: 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
NOTE
z Free the spring assembly so that it can rotate.
2. Install the axle housing. Install the spring pad above the leaf
spring. Tighten the pad with U-bolts.
CAUTION
z Support the axle housing with a jack and proceed very
carefully with work.
U-bolt nut
: *716 - 843 N·m {73 - 86 kgf·m, 528 - 622 ft·lbf}
*: Apply engine oil or grease (wet) to the nut thread, nut seat,
U-bolt thread and spring seat and tighten the nut.
18 Brake assembly
For installation procedure of the brake assembly, refer to the “BR”
section.
RA-7-14
REAR AXLE RD90, RD80, RW1A
8 Adjusting nut
1. Install the washer and adjusting nut, and adjust the preload.
2. Tighten the adjusting nut while turning the brake drum.
NOTE
z Use an adjusting nut wrench to adjust the adjusting nut.
(99820 Z0009)
Back off the adjusting nut approximately 60º.
z Turn the brake drum more than 90º and read the average
valve.
z If the preload is not within maintenance standards, adjust
using the adjusting nut.
z Install the lock plate after aligning its screw hole with the
one in the adjusting nut.
: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
NOTE
z When the holes for the lock plate and the adjusting nut
are not aligned with each other, always align the holes so
that movement of the adjusting nut is kept to a minimum.
RA-7-15
REAR AXLE RD90, RD80, RW1A
5 Axle shaft
1. Install the axle shaft.
WARNING
WARNING
z Be careful not to pinch your fingers.
CAUTION
z Be careful not to damage the oil seal.
INSTALLATION
Key point of installation
Connect the brake hose with the connector on the axle housing.
CAUTION
z Apply a coat of Three Bond 1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.
NOTE
z Be careful not to twist the air hose.
NOTE
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
RA-7-16
REAR AXLE RD90, RD80, RW1A
RA-7-17
SUSPENSION RD90, RD80, RW1A
SUSPENSION
CONSTRUCTION
TYPE I
[Rear 1-axle drive model]
RA-8-1
SUSPENSION RD90, RD80, RW1A
TYPE II
[Rear 2-axle drive model]
RA-8-2
SUSPENSION RD90, RD80, RW1A
DISASSEMBLY
REMOVAL
Key point of removal
Chock the front wheels and remove mud and grease from the sus-
pension system before dismounting.
1. Jack up the rear axle and place a safety stand under the
frame at the rear of the spring. The stand should be such
that the rear wheels are 10 to 20 mm (0.39 to 0.79 in) off the
ground when the spring is free.
WARNING
WARNING
z In order to prevent a serious injury or accident, never get
under the vehicle while jacking it up.
RA-8-3
SUSPENSION RD90, RD80, RW1A
DISASSEMBLY
TYPE I
[Rear 1-axle drive model]
RA-8-4
SUSPENSION RD90, RD80, RW1A
RA-8-5
SUSPENSION RD90, RD80, RW1A
TYPE II
[Rear 2-axle drive model]
RA-8-6
SUSPENSION RD90, RD80, RW1A
3 Spring assembly
When removing the spring assembly, fix it to a suitable device to
prevent it from dropping.
RA-8-7
SUSPENSION RD90, RD80, RW1A
31 Trunnion bracket
Place a jack under the trunnion shaft when removing the trunnion
bracket.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
RA-8-8
SUSPENSION RD90, RD80, RW1A
RA-8-9
SUSPENSION RD90, RD80, RW1A
2. Align the line at the eye-end of the torque rod and the scribe
lines at the outside periphery of the bushing, set the replace
tool and press fit the bushing until the bushing and torque
rod top surface are matched at the torque rod.
RA-8-10
SUSPENSION RD90, RD80, RW1A
REASSEMBLY
Key point of reassembly
31 Trunnion bracket
1. Align the lock bolt hole at the trunnion shaft and the trunnion
bracket, then install the trunnion shaft with knock bolt and
nut.
: Knock bolt
255 - 343 N·m {26 - 35 kgf·m, 188 - 253 ft·lbf}
Lock nut
333 - 441 N·m {34 - 45 kgf·m, 246 - 325 ft·lbf}
2. When installing the trunnion shaft and bracket assembly to
the frame, support the trunnion shaft and bracket with
garage jacks securely.
: 216 - 275 N·m {22 - 28 kgf·m, 159 - 203 ft·lbf}
NOTE
z Be sure to install the trunnion shaft with its oil groove
facing the vehicle front.
18 Thrust washer
Drive the dowel pin into the trunnion bracket and install the oil seal
and thrust washer (without oil groove).
RA-8-11
SUSPENSION RD90, RD80, RW1A
9 Shim
1. Measure dimension L shown in the figure at right, rounding
off results to 0.1 mm (0.004 in) increments.
2. Select shim(s) which is(are) 0.1 to 0.2 mm (0.004 to 0.008
in) thicker than dimension L.
Unit: mm (in)
Dimension L Shim thickness
0.6 (0.024) 0.6 + 0.2 (0.024 + 0.008)
0.5 (0.020) 0.6 (0.024)
0.4 (0.016) 0.6 (0.024)
0.3 (0.012) 0.2 + 0.2 (0.008 + 0.008)
0.2 (0.008) 0.2 + 0.2 (0.008 + 0.008)
0.1 (0.004) 0.2 (0.008)
0 (0) 0.2 (0.008)
-0.1 (-0.004) No shims required
RA-8-12
FRONT AXLE AND SUSPENSION
CONTENTS
SERVICE DATA ................................. FA-1-1 = UNIT NAME FA40, FA50 =
SPECIFICATIONS ......................... FA-1-1
SERVICE DATA ............................. FA-1-4 FRONT AXLE (FA40) ........................ FA-5-1
TIGHTENING TORQUE ................ FA-1-5 CONSTRUCTION ......................... FA-5-1
TOOLS .............................................. FA-2-1 DISASSEMBLY ............................. FA-5-2
FRONT AXLE ................................ FA-2-1 INSPECTION ................................ FA-5-6
SUSPENSION ............................... FA-2-5 REPAIR AND REPLACEMENT ..... FA-5-9 FA
REASSEMBLY ............................ FA-5-16
= UNIT NAME FA30, 35 = FRONT WHEEL ALIGNMENT .... FA-5-24
FRONT AXLE (FA50) ........................ FA-6-1
FRONT AXLE .................................... FA-3-1 CONSTRUCTION ......................... FA-6-1
CONSTRUCTION ......................... FA-3-1 DISASSEMBLY ............................. FA-6-2
DISASSEMBLY ............................. FA-3-2 INSPECTION ................................ FA-6-8
INSPECTION ................................ FA-3-7 REPAIR AND REPLACEMENT ... FA-6-10
REPAIR AND REPLACEMENT ..... FA-3-9 REASSEMBLY ............................ FA-6-19
REASSEMBLY ............................ FA-3-12 FRONT WHEEL ALIGNMENT .... FA-6-28
FRONT WHEEL ALIGNMENT .... FA-3-21 SUSPENSION ................................... FA-7-1
SUSPENSION ................................... FA-4-1 CONSTRUCTION ......................... FA-7-1
CONSTRUCTION ......................... FA-4-1 DISASSEMBLY ............................. FA-7-2
DISASSEMBLY ............................. FA-4-2 INSPECTION ................................ FA-7-7
INSPECTION ................................ FA-4-6 REPAIR AND REPLACEMENT ..... FA-7-8
REPAIR AND REPLACEMENT ..... FA-4-7 REASSEMBLY .............................. FA-7-9
REASSEMBLY .............................. FA-4-8
SERVICE DATA FRONT AXLE & SUSPENSION
SERVICE DATA
SPECIFICATIONS
FRONT AXLE
Item FA30 FA35 FA40 FA50
Type of front axle Drop forged steel I cross section beam
Type of steering knuckle Reverse-Elliot
Kingpin O.D. mm (in) 35 (1.38) 40 (1.57) 47 (1.85)
Toe-in mm (in) 1 (0.04) 0 - 2 (0 - 0.08)
1º00´
Camber 1º30´ [Front axle tread 1,760 mm 1º00´
Wheel alignment (69.3 in)]
Caster 3º20´
Kingpin inclination angle 7º00´
Maximum turning angle (Inside) x (Outside) 53º x 39º 36º x 30º* 44º x 35º 50º x 38º 45º x 36º 47º x 36º
Type of brake drum installation Inboard Outboard Inboard
NOTE
z *: Only vehicles equipped with 9.00 x 20 size
UNIT NAME
F A 30
FA-1-1
SERVICE DATA FRONT AXLE & SUSPENSION
SUSPENSION
Item FA30, FA35 FA40, FA50
Type of suspension Rigid axle type
Type of spring Semi-elliptic, leaf spring (shackle type)
Type of shock absorber Cylindrical double-action or single-action
Type of stabilizer (if so equipped) Torsion bar
SPRING SPECIFICATIONS
Unit: mm (in)
Axle model Vehicle model L.H.D. R.H.D. Length x width x thickness - Number of leaves
MKA210
z
—
1,300 x 70 x { 14 - 1
18 - 2
(51.18 x 2.76 x { 0.55 - 1
0.71 - 2
)
{ {
MKB212 — 14 - 1 0.55 - 1
1,300 x 70 x 18 - 2 (51.18 x 2.76 x 0.71 - 2 )
FA30
13 - 1 0.51 - 1
MKB210 z z 1,300 x 70 x 11 - 6 (51.18 x 2.76 x 0.43 - 6)
MKB212 — z 1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
MKB210 — z 1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
MKC210 z — 1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
LKC212 — z 1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
LKC210 z z 1,300 x 70 x 11 - 6 (51.18 x 2.76 x 0.43 - 6)
MKD210 z z 1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
LKC210 z z 1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
FA35 LKC210 — z 1,300 x 70 x 11 - 9 (51.18 x 2.76 x 0.43 - 9)
LKB212
LKC210
z
z
—
—
1,300 x 70 x { 16 - 1
18 - 2
(51.18 x 2.76 x { 0.63 - 1
0.71 - 2
)
{ {
16 - 1 0.63 - 1
LKC212 z — 1,300 x 70 x 18 - 2 (51.18 x 2.76 x 0.71 - 2 )
14 - 4 0.55 - 4
FA-1-2
SERVICE DATA FRONT AXLE & SUSPENSION
Unit: mm (in)
Axle model Vehicle model L.H.D. R.H.D. Length x width x thickness - Number of leaves
1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
{ {
LKD210 z z
12 - 7 0.47 - 7
1,400 x 80 x (55.12 x 3.15 x )
11 - 1 0.43 - 1
FA40 1,400 x 80 x { 12 - 5
11 - 2
(55.12 x 3.15 x { 0.47 - 5
0.43 - 2
)
PKB210
PKB212
z
—
z
z 1,400 x 80 x { 12 - 7
11 - 1
(55.12 x 3.15 x { 0.47 - 7
0.43 - 1
)
1,400 x 80 x { 12 - 5
11 - 3
(55.12 x 3.15 x { 0.47 - 5
0.43 - 3
)
FA50
CDA310
CWA310
—
—
z
z
1,400 x 80 x { 12 - 8
14 - 1
(55.12 x 3.15 x { 0.47 - 8
0.55 - 1
)
FA-1-3
SERVICE DATA FRONT AXLE & SUSPENSION
SERVICE DATA
FRONT AXLE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
FA30 34.98 - 35.00
34.90 (1.3740)
FA35 (1.3772 - 1.3780)
39.96 - 39.98
Kingpin O.D. FA40 39.9 (1.571)
(1.5732 - 1.5740)
46.98 - 47.00
FA50 46.9 (1.846)
(1.8496 - 1.8504)
FA30 0.02 - 0.07
0.15 (0.0059)
FA35 (0.0008 - 0.0028)
Clearance between kingpin and 0.03 - 0.07
FA40 0.2 (0.008)
bushing (0.0012 - 0.0028)
0.01 - 0.10
FA50 0.2 (0.008)
(0.0004 - 0.0039)
FA30 0 - 0.04
0.1 (0.004)
Clearance between front axle hole FA35 (0 - 0.0016)
and kingpin FA40 0 - 0.04
0.15 (0.0059)
FA50 (0 - 0.0016)
FA30 22.6 - 46.1
—
FA35 {2.3 - 4.7, 5.1 - 10.4}
Preload of front hub 24.5 - 49.0
FA40 —
N {kgf, lbf} {2.5 - 5.0, 5.5 - 11.0}
19.6 - 53.9
FA50 —
{2.0 - 5.5, 4.4 - 12.1}
Starting force of steering knuckle Spring balance reading taken at
Less than 9.8 {1.0, 2.2} —
N {kgf, lbf} end knuckle
Clearance between steering knuckle and axle Less than 0.1 (0.004) — Measure with shims in place.
Kingpin angle 7º±10´ —
SUSPENSION
Unit: mm (in)
Item Maintenance standard Service limit
FA30
28.0 (1.102) 27.5 (1.083)
FA35
Spring pin and shackle pin OD
FA40
30.0 (1.181) 29.5 (1.161)
FA50
FA30
28.0 (1.102) 28.8 (1.134)
Spring pin and shackle pin bushing FA35
ID FA40
30.0 (1.181) 31.0 (1.220)
FA50
FA30 0 - 0.1
1.0 (0.039)
Clearance between spring (shackle) FA35 (0 - 0.004)
pin and bushing FA40 0.02 - 0.14
1.0 (0.039)
FA50 (0.0008 - 0.0055)
Leaf wear — 15% of nominal thickness
FA-1-4
SERVICE DATA FRONT AXLE & SUSPENSION
TIGHTENING TORQUE
FRONT AXLE
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
FA30 FA35 FA40 FA50
235 - 275 {24 - 28, 174 - 203} O O — —
U-bolt nut
490 - 539 {50 - 55, 362 - 398} — — O O
370 - 420 {37 - 43, 273 - 309} O O — —
SAE type
Wheel nut 540 - 590 {55 - 60, 398 - 435} — — O O
ISO type 590 - 630 {60 - 65, 435 - 465} — — — O
196 - 265 {20 - 27, 145 - 195} O O — —
Steering arm mounting nut 284 - 373 {29 - 38, 210 - 275} — — O —
490 - 588 {50 - 60, 362 - 434} — — — O
29 - 34 {3.0 - 3.5, 22 - 25} O O O —
Lock pin nut of kingpin
25 - 39 {2.5 - 4.0, 18 - 29} — — — O
57 - 76 {5.8 - 7.7, 42 - 56} O O O —
Stopper bolt lock nut
137 - 167 {14 - 17, 101 - 123} — — — O
167 - 294 {17 - 30, 123 - 217} O O — —
Connecting for tie-rod arm and tie-rod ball
196 - 255 {20 - 26, 145 - 188} — — O —
stud
245 - 304 {25 - 31, 181 - 224} — — — O
88 - 113 {9.0 - 11.5, 65 - 83} O O — —
Tie-rod clamp bolt, nut
59 - 78 {6.0 - 8.0, 43 - 58} — — O O
294 - 343 {30 - 35, 217 - 253} O O — —
Hub bolt nut
294 - 412 {30 - 42, 217 - 304} — — — O
Hub cap mounting bolt 11 - 18 {1.1 - 1.8, 8 - 13} —*O*1 —*O*1 O O
Brake chamber bracket mounting bolt 69 - 88 {7.0 - 9.0, 51 - 65} — — — O
Kingpin cap bolt 15 - 18 {1.5 - 1.8, 11 - 13} O O O —
Kingpin plug 59 - 78 {6.0 - 8.0, 43 - 58} — — — O
167 - 226 {17 - 23, 123 - 166} O O — —
Connecting nut for steering arm (knuckle
196 - 255 {20 - 26, 145 - 188} — — O —
arm) and drag link ball stud
167 {17, 123} — — — O
Brake assembly BHS32 127 - 147 {13 - 15, 94 - 108} O O — —
mounting bolt FB52, BHS37 147 - 167 {15 - 17, 108 - 123} — O — —
Upper side 216 - 294 {22 - 30, 159 - 217} — — — O
Tie-rod arm Lower side (Tighten
mounting bolt together with tie-rod 490 - 588 {50 - 60, 362 - 434} — — — O
arm mounting nut)
196 - 265 {20 - 27, 145 - 195} O O — —
Tie-rod arm mounting nut 284 - 373 {29 - 38, 210 - 275} — — O —
490 - 588 {50 - 60, 362 - 434} — — — O
Lock plate bolt 7 - 9 {0.7 - 0.9, 5.1 - 6.5} O O O O
NOTE
z *: Hub cap type 1
z *1: Hub cap type 2
FA-1-5
SERVICE DATA FRONT AXLE & SUSPENSION
SUSPENSION
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
FA30 FA35 FA40 FA50
47 - 72 {4.8 - 7.3, 35 - 53} O O — —
Spring center bolt
108 - 127 {11 - 13, 80 - 94} — — O O
235 - 275 {24 - 28, 174 - 203} O O — —
U-bolt nut
490 - 539 {50 - 55, 362 - 398} — — O O
Clip bolt 8 - 13 {0.8 - 1.3, 5.8 - 9.4} O O O O
Link rod 54 {5.5, 40} O O O —
Stabilizer
Bushing pin 373 {38, 275} O O O —
FA-1-6
TOOLS FRONT AXLE & SUSPENSION
TOOLS
FRONT AXLE
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
Used to
Lock plate
remove and
bolt wrench 99545 Z0003 — — O O
install the lock
socket
plate bolt
99535 Z0100 O O O —
Used to
tighten and
Adjusting
remove the nut
nut wrench
fastening front
hub bearing
99820 Z0002 — — O O
FA-2-1
TOOLS FRONT AXLE & SUSPENSION
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
99840 Z0016 O O — —
Used to
Front hub
remove the
puller
hub
99840 Z0009 — — O O
99532 Z0017 O O O —
Used to
remove the
Puller bolt inner race
from the inner
hub bearing
99532 Z0061 — — — O
FA-2-2
TOOLS FRONT AXLE & SUSPENSION
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
99831 Z5001 O O — —
Used to
remove and
install the king-
pin bushing
99831 Z0001 — — O —
Kingpin
bushing tool
FA-2-3
TOOLS FRONT AXLE & SUSPENSION
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
99843 Z5001 O O — —
Used to install the
inner hub bear-
ing outer race
99843 Z5003 — — O —
{Used with brace
rod (99844 1 Bearing race replacer:Bearing OD for 120 mm (4.72 in)
Z5000) as a set} 2 Bearing race replacer:Bearing OD for 140 mm (5.51 in)
99843 Z5004 3 Brace rod — — — O
99827 Z5000 O O — —
Hub bearing Used to install the
replacer hub bearing inner
race, hub bearing
outer race and oil
seal retainer
99827 Z5001 — — O —
FA-2-4
TOOLS FRONT AXLE & SUSPENSION
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
FA-2-5
TOOLS FRONT AXLE & SUSPENSION
SUSPENSION
Application
Tool name and number Description Shape
FA30 FA35 FA40 FA50
99888 Z0003 — — O O
Used when
Bushing replacing the
replacer spring (shackle)
pin bushing.
99888 Z0002 O O — —
Used when
T-type
99535 Z0005 removing the O O O O
socket
spring clip bolt.
Used together
with the socket
Extension
99535 Z0012 wrench to O O O O
bar
remove the U-
bolt nut.
FA-2-6
FRONT AXLE FA30, FA35
FA-3-1
FRONT AXLE FA30, FA35
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads.
3. The left-hand wheel nuts are marked with an “L”.
4. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
5. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
FA-3-2
FRONT AXLE FA30, FA35
DISASSEMBLY
FA-3-3
FRONT AXLE FA30, FA35
5 Adjusting nut
Using the adjusting nut socket (99535 Z0100), remove the adjust-
ing nut.
FA-3-4
FRONT AXLE FA30, FA35
12 Stopper bolt
Remove the plug and stopper bolt from the back of the knuckle, and
insert the puller bolts (99532 Z0017) into those holes. Turn the
puller bolts alternately to remove the inner hub bearing inner race
and oil seal retainer.
17 Castellated nut
1. If the ball stud and tie-rod are hard to remove, use a puller.
Do not tap with a hammer.
2. Only the dust cover of the tie-rod assembly can be singly
replaced. For replacement procedures, refer to the instruc-
tions under the “REPAIR AND REPLACEMENT” section.
FA-3-5
FRONT AXLE FA30, FA35
28 Steering arm
Do not tap the ball stud of the drag link with a hammer. Use a puller
if necessary.
40 Front axle
Place a jack under the front axle and remove the nuts from the U-
bolts.
WARNING
WARNING
z Be sure to perform this operation with a jack placed
under the front axle.
FA-3-6
FRONT AXLE FA30, FA35
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
FA-3-7
FRONT AXLE FA30, FA35
FA-3-8
FRONT AXLE FA30, FA35
FA-3-9
FRONT AXLE FA30, FA35
NOTE
z After properly tightening the hub bolt, clinch it at three
points.
HUB BEARING
1. Remove the outer hub bearing outer race by striking with a
hammer and a suitable bar. When removing the inner hub
bearing outer race, insert a suitable bar into the notch on
the grease sump and strike the bar.
NOTE
z The oil seal is also removed when the outer race is
removed. The oil seal must not be reused. Always
replace it with a new one.
FA-3-10
FRONT AXLE FA30, FA35
TIE-ROD ASSEMBLY
Inspection
1. Check the dust cover for grease leaks or damage. If the
dust cover is damaged, remove it and check areas sur-
rounding the ball stud.
z If grease is contaminated with mud, replace the tie-rod
assembly.
z If dirt is only on the grease surface, wipe areas around the
ball stud, and replace the dust cover with a new one
charged with grease.
NOTE
z Discard the old dust cover. Replace with a new one.
2. Check the lip of the dust cover for wear. If it is worn, replace
the dust cover with a new one.
FA-3-11
FRONT AXLE FA30, FA35
REASSEMBLY
REASSEMBLY
Key point of reassembly
40 Front axle
1. Put the front axle under the leaf spring, with the knuckle
stopper side facing the rear of the vehicle.
FA-3-12
FRONT AXLE FA30, FA35
2. Insert a caster shim and shim between the front axle and
leaf spring, with the center bolt holes aligned.
For details, refer to the “SUSPENSION” section.
CAUTION
z Insert the caster shim with the thick side facing the rear
of the vehicle.
39 Steering knuckle
1. After selecting the shim, extract the kingpin, being careful
not to damage the dust seal. Then remove the temporarily
installed steering knuckle.
WARNING
WARNING
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during installation.
NOTE
z Do not drop the thrust bearing during installation.
FA-3-13
FRONT AXLE FA30, FA35
CAUTION
z When installing the shim and bearing, do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
NOTE
z Do not drop the thrust bearing during removal and instal-
lation.
z Apply antirust lubricant NOX-RUST·X-110 (made by
DAUBERT CHEMICAL COMPANY, INC.) or equivalent to
the shim.
37 Thrust bearing
Install the thrust bearing on the lower part of the front axle. Using
the kingpin or a similar bar, temporarily install the steering knuckle.
NOTE
z Before installing the thrust bearing, apply bearing grease
to it until grease oozes out.
z When the thrust bearing is an O-ring type, face the O-ring
upward when installing.
36 Shim
Measure the clearance between the steering knuckle and front
axle. Select the shim so that clearance corresponds to the mainte-
nance standard.
CAUTION
z When installing the shim and bearing do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
Type of shim
7 types from 2.1 to 2.7 mm (0.083 to 0.106 in) at inter-
vals of 0.1 mm (0.004 in)
33 Lock pin
1. Align the groove in the kingpin with the lock pin bore in the
front axle, and drive in the kingpin.
2. Insert the lock pin from the rear of the front axle with the cut
surface facing the kingpin.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
FA-3-14
FRONT AXLE FA30, FA35
NOTE
z Discard the old packing and use a new one.
28 Steering arm
Install the steering arm on the steering knuckle. Install and tighten
the new clinch nut and lock it securely.
: 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
FA-3-15
FRONT AXLE FA30, FA35
3. Secure the brake hose from the wheel cylinder with a lock
nut, and connect it with the flare nut of the tube on the
frame side.
CAUTION
z After installing the brake assembly, be sure to bleed air
from the brake system. Refer to the “MA” section for
instructions.
21 Tie-rod end
1. Apply a thin coat of grease to the threaded portions of the
left and right ends of the tie-rod.
Equally screw in both ends of the tie-rod. The left end of the
tie-rod is left-hand threaded and the right end is right-hand
threaded.
FA-3-16
FRONT AXLE FA30, FA35
CAUTION
z To properly align the cotter pin holes in the nut and bolt,
tighten the nut to 167 N·m {17 kgf·m, 123 ft·lbf} and then
align them. If they are not aligned there, slowly tighten
(do not loosen) the nut until its slot is aligned with the
nearest hole in the bolt.
FA-3-17
FRONT AXLE FA30, FA35
12 Stopper bolt
Screw the plug into the front of the kingpin and temporarily tighten
the stopper and lock nut on the rear of the kingpin.
The stopper bolt should be tightened to the specified torque after
installing the wheel and adjusting the steering angle.
Refer to the “WHEEL ALIGNMENT” section for instructions.
Knuckle stopper bolt lock nut
: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
7 Hub
1. Charge the grease sump of the hub with bearing grease so
that grease properly lubricates the hub bearing.
NOTE
z For details, refer to “Front hub greasing procedure” on
page FA-3-11.
WARNING
WARNING
z Because the hub (with the brake drum attached) is heavy,
use a lifting cable and hoist to install it. To assure safety,
this operation should be performed by more than two
people. Be careful not to drop the hub and drum onto
your feet.
FA-3-18
FRONT AXLE FA30, FA35
FA-3-19
FRONT AXLE FA30, FA35
INSTALLATION
Key point of installation
1. Align the tire so that the hub bolts are in the middle of the
disc wheel bolt holes, and tighten the wheel nuts tempo-
rarily.
CAUTION
z If the wheel mounting section is dirty, the wheel nuts may
loosen. Clean with a wire brush and rag.
NOTE
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
2. Position a garage jack under the front axle and raise the
front of vehicle. Remove the right and left trestles from the
front of the frame, and slowly lower the vehicle.
WARNING
WARNING
z Apply the jack at the jacking-up point accurately.
FA-3-20
FRONT AXLE FA30, FA35
Measure procedure
1. Orient the front tires so that they face straight ahead.
2. On the front of the left and right tires, place a mark at the
center height (the same height as the center of the knuckle
spindle shaft) and center position of the tire tread.
3. Place the toe-in gauge in front of the tires and parallel to the
axle. Align the gauge needle with the marks. Next, read the
distance between the marks. Assume this dimension to be
“A”.
5. Place the toe-in gauge behind the axle. Following the same
procedure as in step 3, read the distance between the
marks. Assume this dimension to be “B”.
FA-3-21
FRONT AXLE FA30, FA35
Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the front, and clamp it.
z When clamping, eliminate any mutual angular disparity
between the left and right ends.
2. After confirming that the values meet the prescribed stan-
dard, tighten the tie-rod end clamp bolt to the prescribed
torque.
: 88 - 113 N•m {9.0 - 11.5 kgf•m, 65 - 83 ft•lbf}
MEASURING CAMBER
A : Camber
B : Kingpin inclination
Use a flat area to measure camber. If a flat area is not available,
select a place that is as flat as possible.
1. Place the rear wheels on stands that are the same height as
the turning radius gauge.
2. Raise the front wheels with jacks and point them straighta-
head.
3. Slowly lower the jacks, making sure that the center of the
turning radius gauge is aligned with the center contacting
surface of the tire. At this point, set the gauge to zero.
4. Carefully attach the camber-caster-kingpin inclination
gauge horizontally to the hub.
5. Camber is determined by reading the center of the air bub-
ble in the camber scale.
6. If the measured value is in excess of specifications, check
the kingpin and bushing for wear, hub bearing for play, and
front axle for bending. Correct faulty part(s) as required.
1º00´
Camber
1º30´ [Front axle tread 1,760 mm (69.3 in)]
Kingpin inclination angle 7º00´
FA-3-22
FRONT AXLE FA30, FA35
2. After the wheel is turned 20º, align the centers of both the
caster and kingpin inclination scales with the centers of the
air bubbles.
1. Place the left and right front road wheels in the center of a
turntable equipped with a turning radius gauge, and set the
steering wheel at the straight forward position.
FA-3-23
FRONT AXLE FA30, FA35
2. Turn the steering wheel fully to the right, and adjust the right
wheel (inner wheel) angle to the specified range with the
knuckle screw located on the steering knuckle.
Item Maximum turning angle Remarks
Inside 53º
FA30
Outside 39º
Inside 36º Only vehicles equipped with
Outside 30º 9.00 x 20 size tires
FA35
Inside 44º
Outside 35º
NOTE
z Keep the power steering oil pump operating.
OVERALL INSPECTION
Wheel alignment (including that of the rear wheels) is interrelated.
An error at one point means an error at another point. After comple-
tion of adjustment, ascertain whether or not alignment is correct by
using a side slip tester; first check toe-in. If toe-in appears correct,
the error lies elsewhere. Factors in addition to camber and caster
include bending of the frame, incorrect mounting of the rear axle
(rear axle not parallel to front axle), shock absorber trouble and
excessive steering gear play.
FA-3-24
SUSPENSION FA30, FA35
SUSPENSION
CONSTRUCTION
SUSPENSION
STABILIZER
FA-4-1
SUSPENSION FA30, FA35
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads.
3. The left-hand wheel nuts are marked with an “L”.
4. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
5. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
FA-4-2
SUSPENSION FA30, FA35
DISASSEMBLY
FA-4-3
SUSPENSION FA30, FA35
FA-4-4
SUSPENSION FA30, FA35
STABILIZER
SUSPENSION
Key point of disassembly
11 U-bolt nut
Using the extension bar (99535 Z0012) and wrench socket (99535
Z0008), loosen the U-bolt nut and remove the U-bolt. Also remove
the pad and rubber bumper.
FA-4-5
SUSPENSION FA30, FA35
24 Spring pin
Remove the cotter pin and castellated nut and remove the spring
pin.
NOTE
z Use a copper rod when removing the spring pin.
27 Spring pin
Remove the lock bolt and spring pin.
NOTE
z Use a copper rod when removing the spring pin.
32 Shackle pin
Remove the cotter pin and castellated nut and remove the shackle
pin and shackle.
NOTE
z Use a copper rod when removing the shackle pin.
INSPECTION
<SUSPENTION>
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
Spring pin and shackle pin outside diameter
Unit: mm (in)
Maintenance standard Service limit
28.0 (1.102) 27.5 (1.083)
FA-4-6
SUSPENSION FA30, FA35
FA-4-7
SUSPENSION FA30, FA35
Bushing
1. Remove the bushing with the bushing replacer (99888
Z0002).
REASSEMBLY
<SUSPENSION>
Apply a coat of bearing grease to the sliding sections of the various
parts before installation.
NOTE
z Always face the thinner side of the caster shim towards
the front of the vehicle.
FA-4-8
SUSPENSION FA30, FA35
26 Lock bolt
Be sure to insert the bolt from the front.
: 64 - 78 N·m {6.5 - 8.0 kgf·m, 47 - 58 ft·lbf}
25 Grease nipple
The “L” grease nipple for the front spring pin should face the front.
Vehicle model MKA210 MKB210 MKB212 MKC210 MKD210 MKD210 LKB212 LKC210 LKC212 LKD210
Steering wheel L.H.D. L.H.D. R.H.D. L.H.D. R.H.D. L.H.D. L.H.D. R.H.D. R.H.D. L.H.D. L.H.D. R.H.D. L.H.D. R.H.D. L.H.D. R.H.D.
Mounting
LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH
position
Shim x 2 15 15 15 15 15 15 15 15 15
Shim 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16
Caster shim 17 17 17 17 17 17
Caster shim 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18
Center pin 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19
Center pin 20 20 20 20 20 20
FA-4-9
SUSPENSION FA30, FA35
11 U-bolt nut
Place a caster shim between the front axle and spring and secure
the spring to the front axle with U-bolts.
: 235 - 275 N·m {24 - 28 kgf·m, 174 - 203 ft·lbf}
Face the thin side of the caster shim toward the front of the vehicle.
When securing the spring, jack up the vehicle until the front axle
contacts the spring.
<STABILIZER>
Key point of reassembly
z Apply a coat of bearing grease to the sliding sections of the
various parts before installation.
13 Stabilizer bushing
Temporarily install the stabilizer bar on the stabilizer holder using
the bushing and clamp.
NOTE
z Be sure to install the bushing with the protruded portion
facing the direction shown in the figure right.
FA-4-10
SUSPENSION FA30, FA35
12 Link rod
Install the stabilizer rod link on the stabilizer holder.
: 54 N·m {5.5 kgf·m, 40 ft·lbf}
NOTE
z Pay attention to the direction of the rod link during instal-
lation.
2 Sub-stabilizer lever
Install the left and right sub-stabilizer levers.
NOTE
z Be sure to install the sub-stabilizer lever with a large pin
hole toward the inner side and that with a small pin hole
toward the outer side.
1 Bushing pin
Install the stabilizer bar.
: 373 N·m {38 kgf·m, 275 ft·lbf}
FA-4-11
SUSPENSION FA30, FA35
- MEMO -
FA-4-12
FRONT AXLE (FA40) FA40
FA-5-1
FRONT AXLE (FA40) FA40
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads.
3. The left-hand wheel nuts are marked with an “L”.
4. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
5. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
8. Remove the flare nut and lock nut on the frame side of the
brake hose out of the bracket. The connector on the wheel
cylinder side need not be disconnected.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
9. Remove the castellated nut on the drag link side, and sepa-
rate the drag link from the steering arm.
NOTE
z Do not tap the ball stud of the drag link with a hammer.
Use a puller if necessary.
FA-5-2
FRONT AXLE (FA40) FA40
DISASSEMBLY
FA-5-3
FRONT AXLE (FA40) FA40
8 Brake drum
Remove the screws, and then remove the brake drum.
WARNING
WARNING
z Because the brake drum is heavy, use a lifting cable and
hoist to move it. To assure safety, this operation should
be performed by more than two men. Be careful not to
drop the drum onto your feet.
9 Hub
Using the front hub puller (99840 Z0009), remove the hub (with the
outer hub bearing and inner hub bearing outer race attached).
WARNING
WARNING
z Because the hub is heavy, use a lifting cable and hoist to
move it. To assure safety, this operation should be per-
formed by more than two men. Be careful not to drop the
hub and drum onto your feet.
FA-5-4
FRONT AXLE (FA40) FA40
13 Stopper bolt
Remove the plug and stopper bolt from the back of the knuckle, and
insert the puller bolts (99532 Z0017) into those holes. Turn the
puller bolts alternately to remove the inner hub bearing inner race
and oil seal retainer.
18 Castellated nut
1. If the ball stud and tie-rod are hard to remove, use a puller.
Do not tap with a hammer.
2. Only the dust cover of the tie-rod assembly can be singly
replaced. For replacement procedures, refer to the instruc-
tions under the “REPAIR AND REPLACEMENT” section.
32 Steering arm
Do not tap the ball stud of the drag link with a hammer. Use a puller
if necessary.
FA-5-5
FRONT AXLE (FA40) FA40
44 Front axle
Place a jack under the front axle and remove the nuts from the U-
bolts.
WARNING
WARNING
z Be sure to perform this operation with a jack placed
under the front axle.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
FA-5-6
FRONT AXLE (FA40) FA40
FA-5-7
FRONT AXLE (FA40) FA40
2. Remove dirt and dust from the bore of the knuckle kingpin
hole and apply a coat of oil to the bore.
3. Using the kingpin bushing tool, press the bushing into place
with the clinched portion set at 45º toward the inner front
side of the vehicle.
CAUTION
z The upper bushing is shorter than the lower bushing.
Place the bushing with the oil groove extending to the
end facing upward.
FA-5-9
FRONT AXLE (FA40) FA40
FA-5-10
FRONT AXLE (FA40) FA40
NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.
2. Press new hub bolts into the hub.
FA-5-11
FRONT AXLE (FA40) FA40
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.
HUB BEARING
1. Remove the outer hub bearing outer race by striking with a
hammer and a suitable bar. When removing the inner hub
bearing outer race, insert a suitable bar into the notch on
the grease sump and strike the bar.
NOTE
z The oil seal is also removed when the outer race is
removed. The oil seal must not be reused. Always
replace it with a new one.
FA-5-12
FRONT AXLE (FA40) FA40
FA-5-13
FRONT AXLE (FA40) FA40
FA-5-14
FRONT AXLE (FA40) FA40
TIE-ROD ASSEMBLY
Inspection
1. Check the dust cover for grease leaks or damage. If the
dust cover is damaged, remove it and check areas sur-
rounding the ball stud.
z If grease is contaminated with mud, replace the tie-rod
assembly.
z If dirt is only on the grease surface, wipe areas around the
ball stud, and replace the dust cover with a new one
charged with grease.
NOTE
z Discard the old dust cover. Replace with a new one.
2. Check the lip of the dust cover for wear. If it is worn, replace
the dust cover with a new one.
FA-5-15
FRONT AXLE (FA40) FA40
REASSEMBLY
REASSEMBLY
Key point of reassembly
44 Front axle
1. Put the front axle under the leaf spring, with the knuckle
stopper side facing the rear of the vehicle.
2. Insert a caster shim, spacer and shim between the front
axle and leaf spring, with the center bolt holes aligned.
The shim is used only on the left side of left-hand drive vehi-
cles.
CAUTION
z Insert the caster shim with the thick side facing the rear
of the vehicle.
43 Steering knuckle
1. After selecting the shim, extract the kingpin, being careful
not to damage the dust seal. Then remove the temporarily
installed steering knuckle.
WARNING
WARNING
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during installation.
NOTE
z Do not drop the thrust bearing during installation.
FA-5-16
FRONT AXLE (FA40) FA40
CAUTION
z When installing the shim and bearing, do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
NOTE
z Do not drop the thrust bearing during removal and instal-
lation.
z Apply antirust lubricant NOX-RUST·X-110 (made by
DAUBERT CHEMICAL COMPANY, INC.) or equivalent to
the shim.
41 Thrust bearing
Install the thrust bearing on the lower part of the front axle. Using
the kingpin or a similar bar, temporarily install the steering knuckle.
NOTE
z Before installing the thrust bearing, apply bearing grease
to it until grease oozes out.
z When the thrust bearing is an O-ring type, face the O-ring
upward when installing.
FA-5-17
FRONT AXLE (FA40) FA40
40 Shim
Measure the clearance between the steering knuckle and front
axle. Select the shim so that clearance corresponds to the mainte-
nance standard.
CAUTION
z When installing the shim and bearing do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
Type of shim
9 types from 2.0 to 2.8 mm (0.079 to 0.110 in) at intervals of
0.1 mm (0.004 in)
37 Lock pin
1. Align the groove in the kingpin with the lock pin bore in the
front axle, and drive in the kingpin.
2. Insert the lock pin from the rear of the front axle with the cut
surface facing the kingpin.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
Hang a spring balance from the steering knuckle spindle, as shown
in the figure at right. Measure the starting force of the steering
knuckle.
CAUTION
z Hang the spring balance from the cotter pin hole in the
spindle.
z Measurements should be taken with the steering arm and
tie rod arm removed.
FA-5-18
FRONT AXLE (FA40) FA40
NOTE
z Discard the old packing and use a new one.
2. Insert the bolt via the lower lock plate and install the tie-rod
arm on the opposite side of the knuckle and temporarily
tighten with the castellated nut.
CAUTION
z Ensure that the lower and upper lock plates prevent the
bolt from turning.
NOTE
z Do not allow grease to come in contact with the brake lining.
3. Tighten the castellated nut to 284 N·m {29 kgf·m, 210 ft·lbf}.
If the slot in the nut are not aligned with the cotter pin hole in
the stud bolt, align by tightening the nut further.
: 284 - 373 N·m {29 - 38 kgf·m, 210 - 275 ft·lbf}
4. Install the drag link to the steering arm and tighten with the
castellated nut. Insert the cotter pin, and bend the legs of
the pin to fasten securely.
: 196 - 255 N·m {20 - 26 kgf·m, 145 - 188 ft·lbf}
CAUTION
z If the cotter pin mounting holes are not aligned, loosen
and align to the nearest hole.
FA-5-19
FRONT AXLE (FA40) FA40
28 Brake assembly
Secure the brake hose from the wheel cylinder with a lock nut, and
connect it with the flare nut of the tube on the frame side.
CAUTION
z After installing the brake assembly, be sure to bleed air
from the brake system. Refer to the “MA” section for
instructions.
21 Tie-rod end
1. Apply grease sparingly to the threads on both ends of the
tie-rod. Then turn the tie-rod end assembly the same dis-
tance on each end.
NOTE
z The right-hand tie-rod end has right-hand threads and
the left-hand end left-hand threads.
2. With the tie-rod ends attached, install the tie rod assembly
to the tie-rod arm with the slotted nut and secure with the
cotter pin.
: 196 - 255 N·m {20 - 26 kgf·m, 145 - 188 ft·lbf}
CAUTION
z When linking the tie-rod assembly to the tie-rod arms,
insert the ball stud from below the arm. The grease fitting
on the tie-rod end should face the rear of the vehicle.
z Tighten the castellated nut to 196 N·m {20 kgf·m, 145
ft·lbf}. If the nut slots are not aligned with the cotter pin
hole in the ball stud, tighten the nut further to align.
FA-5-20
FRONT AXLE (FA40) FA40
13 Stopper bolt
Screw the plug into the front of the kingpin and temporarily tighten
the stopper and lock nut on the rear of the kingpin.
The stopper bolt should be tightened to the specified torque after
installing the wheel and adjusting the steering angle. Refer to the
“FRONT WHEEL ALIGNMENT” section for instructions.
Knuckle stopper bolt lock nut
: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
9 Hub
1. Charge the grease sump of the hub with bearing grease so
that grease properly lubricates the hub bearing.
NOTE
z For details, refer to “Front hub greasing procedure” on
page FA-5-14.
FA-5-21
FRONT AXLE (FA40) FA40
NOTE
z Be sure that the screw head does not protrude from the
surface of the brake drum.
4. Drive in the outer hub bearing's inner race into place using
the hub bearing replacers (99827 Z5001 and 99827
Z5005).
NOTE
z If the lock plate hole does not align with the bolt hole,
turn the lock plate inside out or turn the adjusting nut
within the range of the specified preload to locate the
lock plate. If the preload is smaller, turn the adjusting nut
in the tightening direction to locate the lock plate. If the
preload is larger, turn the adjusting nut in the loosening
direction.
FA-5-22
FRONT AXLE (FA40) FA40
2 Hub cap
Install the new gasket and hub cap.
: 11 - 18 N·m {1.1 - 1.8 kgf·m, 8 - 13 ft·lbf}
NOTE
z Before installing the hub cap, pack it with the specified
amount of grease. For details, refer to “Front hub greas-
ing procedure” on page FA-5-14.
INSTALLATION
Key point of installation
1. Align the tire so that the hub bolts are in the middle of the disc
wheel bolt holes, and tighten the wheel nuts temporarily.
CAUTION
z If the wheel mounting section is dirty, the wheel nuts may
loosen. Clean with a wire brush and rag.
FA-5-23
FRONT AXLE (FA40) FA40
Measure procedure
1. Orient the front tires so that they face straight ahead.
2. On the front of the left and right tires, place a mark at the
center height (the same height as the center of the knuckle
spindle shaft) and center position of the tire tread.
3. Place the toe-in gauge in front of the tires and parallel to the
axle. Align the gauge needle with the marks. Next, read the
distance between the marks. Assume this dimension to be
“A”.
5. Place the toe-in gauge behind the axle. Following the same
procedure as in step 3, read the distance between the
marks. Assume this dimension to be “B”.
FA-5-24
FRONT AXLE (FA40) FA40
Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the front, and clamp it.
z When clamping, eliminate any mutual angular disparity
between the left and right ends.
2. After confirming that the values meet the prescribed stan-
dard, tighten the tie-rod end clamp bolt to the prescribed
torque.
: 59 - 78 N•m {6.0 - 8.0 kgf•m, 43 - 58 ft•lbf}
MEASURING CAMBER
A : Camber
B : Kingpin inclination
FA-5-25
FRONT AXLE (FA40) FA40
2. After the wheel is turned 20º, align the centers of both the
caster and kingpin inclination scales with the centers of the
air bubbles.
1. Place the left and right front road wheels in the center of a
turntable equipped with a turning radius gauge, and set the
steering wheel at the straight forward position.
2. Turn the steering wheel fully to the right, and adjust the right
wheel (inner wheel) angle to the specified range with the
knuckle screw located on the steering knuckle.
FA-5-26
FRONT AXLE (FA40) FA40
NOTE
z Keep the power steering oil pump operating.
OVERALL INSPECTION
Wheel alignment (including that of the rear wheels) is interrelated.
An error at one point means an error at another point. After comple-
tion of adjustment, ascertain whether or not alignment is correct by
using a side slip tester; first check toe-in. If toe-in appears correct,
the error lies elsewhere. Factors in addition to camber and caster
include bending of the frame, incorrect mounting of the rear axle
(rear axle not parallel to front axle), shock absorber trouble and
excessive steering gear play.
FA-5-27
FRONT AXLE (FA50) FA50
FA-6-1
FRONT AXLE (FA50) FA50
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
6. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
9. Remove the flare nut and lock nut on the frame side of the
brake hose out of the bracket. The connector on the wheel
cylinder side need not be disconnected.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
FA-6-2
FRONT AXLE (FA50) FA50
10. Remove the castellated nut on the drag link side, and sepa-
rate the drag link from the steering arm.
NOTE
z Do not tap the ball stud of the drag link with a hammer.
Use a puller if necessary.
11. Remove the screws, and then remove the brake drum (Out-
board type only).
WARNING
WARNING
z Because the brake drum is heavy, use a lifting cable and
hoist to move it. To assure safety, this operation should
be performed by more than two men. Be careful not to
drop the drum onto your feet.
FA-6-3
FRONT AXLE (FA50) FA50
DISASSEMBLY
FA-6-4
FRONT AXLE (FA50) FA50
4 Inboard type
5 Outboard type }
Adjust nut
Using the adjusting nut socket (99820 Z0002), remove the adjust-
ing nut.
FA-6-5
FRONT AXLE (FA50) FA50
8 Inboard type
7 Outboard type } Hub
Using the front hub puller (99840 Z0009), remove the hub (with the
outer hub bearing and inner hub bearing outer race attached).
WARNING
WARNING
z Because the hub (with the brake drum attached) is heavy,
use a lifting cable and hoist to move it. To assure safety,
this operation should be performed by more than two
men. Be careful not to drop the hub and drum onto your
feet.
14 Stopper bolt
Remove the plug and stopper bolt from the back of the knuckle, and
insert the puller bolts (99532 Z0061) into those holes. Turn the
puller bolts alternately to remove the inner hub bearing inner race
and oil seal retainer.
19 Castellated nut
1. If the ball stud and tie-rod are hard to remove, use a puller.
Do not tap with a hammer.
2. Only the dust cover of the tie-rod assembly can be singly
replaced. For replacement procedures, refer to the instruc-
tions under the “REPAIR AND REPLACEMENT” section.
FA-6-6
FRONT AXLE (FA50) FA50
30 Steering arm
Do not tap the ball stud of the drag link with a hammer. Use a puller
if necessary.
34 Kingpin plug
The grease seal and kingpin cap should not be reused.
1. Grease nipple 6. Washer
2. Bolt 7. Kingpincap
3. Lock washer 8. Kingpinplug
4. Kingpin cap 9. Grease nipple
5. Gasket
NOTE
z In air brake vehicles, part 4 is the brake chamber bracket.
43 Front axle
Place a jack under the front axle and remove the nuts from the U-
bolts.
WARNING
WARNING
z Be sure to perform this operation with a jack placed
under the front axle.
FA-6-7
FRONT AXLE (FA50) FA50
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
FA-6-8
FRONT AXLE (FA50) FA50
FA-6-9
FRONT AXLE (FA50) FA50
4. After installing the kingpin bushing, drive the oil seal into the
steering knuckle using the oil seal replacer.
NOTE
z Ensure that the oil seal lip faces the opposite side of the
kingpin bushing during installation.
z Apply grease to the oil seal lip after installation.
FA-6-10
FRONT AXLE (FA50) FA50
CAUTION
z The upper bushing is shorter than the lower bushing.
Install the upper bushing with its oil groove facing
upward.
z When installing the bushings, press-fit with the clinch
faced 45º inward to the front of the vehicle.
2. Install the hub bolts with the bolt flanges fitted in the
grooves on the hub. Put the hub and brake drum together
and tighten with the hub nuts on the inside of the drum.
: 294 - 412 N·m {30 - 42 kgf·m, 217 - 304 ft·lbf}
NOTE
z Use hub bolts stamped “L” for the left-hand hub and
those without any stamp for the right-hand hub. The hub
bolts must be installed with the shorter flange portion
facing outward.
FA-6-11
FRONT AXLE (FA50) FA50
FA-6-12
FRONT AXLE (FA50) FA50
NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.
2. Press new hub bolts into the hub.
FA-6-13
FRONT AXLE (FA50) FA50
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.
FA-6-14
FRONT AXLE (FA50) FA50
HUB BEARING
1. Remove the outer hub bearing outer race by striking with a
hammer and a suitable bar. When removing the inner hub
bearing outer race, insert a suitable bar into the notch on
the grease sump and strike the bar.
NOTE
z The oil seal is also removed when the outer race is
removed. The oil seal must not be reused. Always
replace it with a new one.
FA-6-15
FRONT AXLE (FA50) FA50
FA-6-16
FRONT AXLE (FA50) FA50
Type 2
z PKC210 (for AUSTRALIA) and PKC310 (for AUSTRALIA, NEW ZEALAND) only
FA-6-17
FRONT AXLE (FA50) FA50
TIE-ROD ASSEMBLY
Inspection
1. Check the dust cover for grease leaks or damage. If the
dust cover is damaged, remove it and check areas sur-
rounding the ball stud.
z If grease is contaminated with mud, replace the tie-rod
assembly.
z If dirt is only on the grease surface, wipe areas around the
ball stud, and replace the dust cover with a new one
charged with grease.
NOTE
z Discard the old dust cover. Replace with a new one.
2. Check the lip of the dust cover for wear. If it is worn, replace
the dust cover with a new one.
FA-6-18
FRONT AXLE (FA50) FA50
REASSEMBLY
REASSEMBLY
Key point of reassembly
43 Front axle
1. Put the front axle under the leaf spring, with the knuckle
stopper side facing the rear of the vehicle.
2. Insert a caster shim between the front axle and leaf spring,
with the center bolt holes aligned.
CAUTION
z Insert the caster shim with the thick side facing the rear
of the vehicle.
FA-6-19
FRONT AXLE (FA50) FA50
42 Steering knuckle
1. After selecting the shim, extract the kingpin, being careful
not to damage the dust seal. Then remove the temporarily
installed steering knuckle.
WARNING
WARNING
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during installation.
NOTE
z Do not drop the thrust bearing during installation.
CAUTION
z When installing the shim and bearing, do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
NOTE
z Do not drop the thrust bearing during removal and instal-
lation.
z Apply antirust lubricant NOX-RUST·X-110 (made by
DAUBERT CHEMICAL COMPANY, INC.) or equivalent to
the shim.
FA-6-20
FRONT AXLE (FA50) FA50
39 Thrust bearing
Install the thrust bearing on the lower part of the front axle. Using
the kingpin or a similar bar, temporarily install the steering knuckle.
NOTE
z Before installing the thrust bearing, apply bearing grease
to it until grease oozes out.
z When the thrust bearing is an O-ring type, face the O-ring
upward when installing.
38 Shim
Measure the clearance between the steering knuckle and front
axle. Select the shim so that clearance corresponds to the mainte-
nance standard.
CAUTION
z When installing the shim and bearing do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.
Type of shim
8 types from 2.1 to 2.8 mm (0.083 to 0.110 in) at intervals
of 0.1 mm (0.004 in)
36 Lock pin
Align the groove in the kingpin with the lock pin bore in the front
axle, and drive in the kingpin.
Insert the lock pin from the rear of the front axle with the cut surface
facing the kingpin.
: 25 - 39 N·m {2.5 - 4.0 kgf·m, 18 - 29 ft·lbf}
FA-6-21
FRONT AXLE (FA50) FA50
34 Kingpin plug
Install related parts. A grease seal should be attached to the upper
and lower sections of the kingpin.
CAUTION
z Use a new grease seal and kingpin cap. Apply grease to
the lips before installation. (AOH B. only)
z Install the kingpin cap as shown below. (AOH B. only)
Kingpin plug
: 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}
1. Grease nipple 6. Washer
2. Bolt 7. Kingpin cap
3. Lockwasher 8. Kingpin plug
4. Kingpincap 9. Grease nipple
5. Gasket
NOTE
z In air brake vehicles, part 4 is the brake chamber bracket.
30 Steering arm
1. Install the steering arm to the left-hand steering knuckle.
Tighten with the castellated nut, insert the cotter pin, and
bend the legs of the pin to fasten securely.
: 490 - 588 N·m {50 - 60 kgf·m, 362 - 434 ft·lbf}
NOTE
z Tighten the castellated nut to the specified lower-limit
torque. If the slot in the nut is not aligned with a hole in
the bolt, turn the castellated nut in the “tightening” direc-
tion until the slot is aligned with the hole closest to it.
FA-6-22
FRONT AXLE (FA50) FA50
2. Install the drag link to the steering arm and tighten with the
castellated nut. Insert the cotter pin, and bend the legs of
the pin to fasten securely.
: 167 N·m {17 kgf·m, 123 ft·lbf}
CAUTION
z If the cotter pin mounting holes are not aligned, loosen
and align to the nearest hole.
CAUTION
z Install the lower two bolts so that the lock plates prevent
them from turning.
z Tighten the castellated nut on the side of the tie-rod arm
to 343 N·m {35 kgf·m, 253 ft·lbf}. If the slot in the nut are
not aligned with the cotter pin hole in the bolt, tighten the
nut further to align.
NOTE
z Be careful not to wet the brake linings with oil or grease.
2. Secure the brake hose from the wheel cylinder with a lock
nut, and connect it with the flare nut of the tube on the
frame side.
CAUTION
z When the brake piping has been disconnected, be sure
to bleed air out of the brake system after restoring it to its
former condition.
22 Tie-rod end
1. Apply a thin coat of grease to the threaded portions of the
left and right ends of the tie-rod.
Equally screw in both ends of the tie-rod. The left end of the
tie-rod is left-hand threaded and the right end is right-hand
threaded.
FA-6-23
FRONT AXLE (FA50) FA50
CAUTION
z To properly align the cotter pin holes in the nut and bolt,
tighten the nut to 245 N·m {25 kgf·m, 181 ft·lbf} and then
align them. If they are not aligned there, slowly tighten
(do not loosen) the nut until its slot is aligned with the
nearest hole in the bolt.
FA-6-24
FRONT AXLE (FA50) FA50
15 Lock nut
Screw the plug into the front of the kingpin and temporarily tighten
the stopper and lock nut on the rear of the kingpin.
The stopper bolt should be tightened to the specified torque after
installing the wheel and adjusting steer-angle. For adjusting the
steering angle, refer to the “FRONT WHEEL ALIGNMENT” section.
Knuckle stopper bolt lock nut
: 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}
8 Inboard type
7 Outboard type }
Hub
1. Charge the grease sump of the hub with bearing grease so
that grease properly lubricates the hub bearing.
NOTE
z For details, refer to “Front hub greasing procedure” on
page FA-6-16 or FA-6-17.
NOTE
z Ensure that the brake linings are not in contact with the
drum.
Preload
19.6 - 53.9 N {2.0 - 5.5 kgf, 4.4 - 12.1 lbf}
FA-6-25
FRONT AXLE (FA50) FA50
4 Inboard type
5 Outboard type } Adjusting nut
1. Back off the adjusting nut so that the screw hole in it aligns
with that in the lock plate (backing-off angle: within 10º).
2. Turn the hub 2 or 3 turns and then make sure the preload is
correct.
Preload
19.6 - 53.9 N {2.0 - 5.5 kgf, 4.4 - 12.1 lbf}
1 Inboard type
2 Outboard type } Hub cap
Install the new gasket and hub cap.
: 11 - 18 N·m {1.1 - 1.8 kgf·m, 8 - 13 ft·lbf}
NOTE
z Befor installing the hub cap, pack it with the specified
amount of grease. For details, refer to “Front hub greas-
ing procedure” on page FA-6-16 or FA-6-17.
1. Bolt 3. Hub cap
2. Lock washer 4. Gasket
FA-6-26
FRONT AXLE (FA50) FA50
INSTALLATION
Key point of installation
Align the tire so that the hub bolts are in the middle of the disc
wheel bolt holes, and tighten the wheel nuts temporarily.
CAUTION
z If the wheel mounting section is dirty, the wheel nuts may
loosen. Clean with a wire brush and rag.
NOTE
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
washers (the tapered portion).
Wipe away any excess with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.
Position a garage jack under the front axle and raise the front of
vehicle. Remove the right and left trestles from the front of the
frame, and slowly lower the vehicle.
WARNING
WARNING
z Apply the jack at the jacking-up point accurately.
Tighten the wheel nuts so that disc closely contacts the neck of
each bolt.
: 540 - 590 N·m {55 - 60 kgf·m, 398 - 435 ft·lbf}
(SAE type)
: 590 - 630 N·m {60 - 65 kgf·m, 435 - 465 ft·lbf}
(ISO type)
CAUTION
z Tighten the wheel nuts diagonally as shown at right,
tighten to the specified torque in several steps.
FA-6-27
FRONT AXLE (FA50) FA50
Measure procedure
1. Orient the front tires so that they face straight ahead.
FA-6-28
FRONT AXLE (FA50) FA50
2. On the front of the left and right tires, place a mark at the
center height (the same height as the center of the knuckle
spindle shaft) and center position of the tire tread.
3. Place the toe-in gauge in front of the tires and parallel to the
axle. Align the gauge needle with the marks. Next, read the
distance between the marks. Assume this dimension to be
“A”.
4. Slowly move the vehicle straight forward, rotating the front
tires 180 degrees.
CAUTION
z Do not rotate the tires more than 180 degrees. If you
rotate them more than that, repeat the procedure from
step 1.
5. Place the toe-in gauge behind the axle. Following the same
procedure as in step 3, read the distance between the
marks. Assume this dimension to be “B”.
6. The toe-in is determined by subtracting “A” from “B”. Con-
firm that the value meets the prescribed standard. If the pre-
scribed standard is not met, adjust with the tie-rod.
Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
Bias tire 0 - 4 mm (0 - 0.16 in)
Toe-in
Radial tire 0 - 2 mm (0 - 0.08 in)
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the front, and clamp it.
z When clamping, eliminate any mutual angular disparity
between the left and right ends.
2. After confirming that the values meet the prescribed stan-
dard, tighten the tie-rod end clamp bolt to the prescribed
torque.
: 59 - 78 N•m {6.0 - 8.0 kgf•m, 43 - 58 ft•lbf}
FA-6-29
FRONT AXLE (FA50) FA50
MEASURING CAMBER
A: Camber
B: Kingpin inclination
Use a flat area to measure camber. If a flat area is not available,
select a place that is as flat as possible.
1. Place the rear wheels on stands that are the same height
as the turning radius gauge.
2. Raise the front wheels with jacks and point them straighta-
head.
3. Slowly lower the jacks, making sure that the center of the
turning radius gauge is aligned with the center contacting
surface of the tire. At this point, set the gauge to zero.
4. Carefully attach the camber-caster-kingpin inclination
gauge horizontally to the hub.
5. Camber is determined by reading the center of the air bub-
ble in the camber scale.
6. If the measured value is in excess of specifications, check
the kingpin and bushing for wear, hub bearing for play, and
front axle for bending. Correct faulty part(s) as required.
Camber 1º00´
Kingpin inclination angle 7º00´
2. After the wheel is turned 20º, align the centers of both the
caster and kingpin inclination scales with the centers of the
air bubbles.
FA-6-30
FRONT AXLE (FA50) FA50
1. Place the left and right front road wheels in the center of a
turntable equipped with a turning radius gauge, and set the
steering wheel at the straight forward position.
2. Turn the steering wheel fully to the right, and adjust the right
wheel (inner wheel) angle to the specified range with the
knuckle screw located on the steering knuckle.
Item Maximum turning angle
Inside 47º
Outside 36º
NOTE
z Keep the power steering oil pump operating.
OVERALL INSPECTION
Wheel alignment (including that of the rear wheels) is interrelated.
An error at one point means an error at another point. After comple-
tion of adjustment, ascertain whether or not alignment is correct by
using a side slip tester; first check toe-in. If toe-in appears correct,
the error lies elsewhere. Factors in addition to camber and caster
include bending of the frame, incorrect mounting of the rear axle
(rear axle not parallel to front axle), shock absorber trouble and
excessive steering gear play.
FA-6-31
SUSPENSION FA40, FA50
SUSPENSION
CONSTRUCTION
SUSPENSION
STABILIZER
FA-7-1
SUSPENSION FA40, FA50
DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.
6. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.
FA-7-2
SUSPENSION FA40, FA50
DISASSEMBLY
<SUSPENSION>
FA-7-3
SUSPENSION FA40, FA50
FA-7-4
SUSPENSION FA40, FA50
FA-7-5
SUSPENSION FA40, FA50
<SUSPENSION>
Key point of disassembly
14 U-bolt nut
Using the extension bar (99535 Z0012) and wrench socket (99535
Z0008), loosen the U-bolt nut and remove the U-bolt. Also remove
the pad and rubber bumper.
31 Shackle pin
Remove the bolt (shackle pin lock bolt) and remove the shackle pin,
shackle and shims.
NOTE
z Use a copper rod when removing the shackle pin.
FA-7-6
SUSPENSION FA40, FA50
INSPECTION
<SUSPENSION>
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
Spring pin and shackle pin outside diameter
Unit: mm (in)
Maintenance standard Service limit
30.0 (1.181) 29.5 (1.161)
FA-7-7
SUSPENSION FA40, FA50
Bushing
1. Remove the bushing with the bushing replacer (99888
Z0003).
FA-7-8
SUSPENSION FA40, FA50
REASSEMBLY
<SUSPENSION>
Apply a coat of bearing grease to the sliding sections of the various
parts before installation.
NOTE
z Always face the thinner side of the caster shim towards
the front of the vehicle.
FA-7-9
SUSPENSION FA40, FA50
25 Grease nipple
The “L” grease nipple for the front spring pin should face the front.
14 U-bolt nut
1. Place a caster shim between the front axle and spring and
secure the spring to the front axle with U-bolts.
: 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}
2. Face the thin side of the caster shim toward the front of the
vehicle.
3. When securing the spring, jack up the vehicle until the front
axle contacts the spring.
FA-7-10
SUSPENSION FA40, FA50
<STABILIZER>
(Models equipped with front stabilizer)
Apply a coat of bearing grease to the sliding sections of the various
parts before installation.
8 Bushing
Be sure to install the bushing with the protruded portion facing the
direction shown in the figure below.
FA-7-11
TIRES AND WHEELS
CONTENTS
SERVICE DATA ................................ TW-1-1 DISASSEMBLY ............................ TW-2-3
SPECIFICATIONS ........................ TW-1-1 INSPECTION .................................... TW-3-1
SERVICE DATA ............................ TW-1-3 REASSEMBLY ................................. TW-4-1
TIGHTENING TORQUE ............... TW-1-4 REASSEMBLY ............................. TW-4-1
DISASSEMBLY ................................ TW-2-1 INSTALLATION ............................ TW-4-4
REMOVAL .................................... TW-2-1
TW
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Item Vehicle model
Tire Wheel M M M M M L L L L P P P P P P C C
K K K K K K K K K K K K K K K D W
A B C D B C D C B B C F B C C A A
Size Construction Size Mounting 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 2 0 0 2 2 0 0 0 2 2 0 0 0
8.25-16-14PR B 16 x 6.00GS-135 6 z z z z
20 x 6.00S-135 6 z
8.25-20-14PR B
20 x 6.50T-145 8 z z
9.00-20-12PR B 20 x 7.00T-162 8 z
20 x 6.50T-145 8 z z
9.00-20-14PR B 20 x 6.50T-152 8 z z z
20 x 7.00T-162 8 z z z z z z
8 z z
20 x 7.50V-165
11.00-20-14PR B 10 z z
20 x 7.00T-162 10 z z
8 z z z z z z
20 x 7.00T-162
10 z
10.00-20-14PR B
8 z z z z z z
20 x 7.50V-165
10 z z
8 z z z z
10.00-20-16PR B 20 x 7.50V-165
10 z z
17.5 x 6.00-135 6 z z
215/75R17.5 124/123 S R
17.5 x 6.75-135 6 z
225/90R17.5-14PR S R 17.5 x 6.00-135 6 z
235/75R17.5 130/128 S R 17.5 x 6.75-135 6 z z z
245/70R19.5 133L S R 19.5 x 6.75-136 8 z z z
8 z
275/70R22.5 148/145L S R 22.5 x 8.25-165
10 (ISO) z
8.25R16-14PR R 16 x 6.00GS-135 6 z
20 x 6.00S-135 6 z
8.25R20-14PR R
20 x 6.50T-145 8 z
9.00R20 141/138L R 20 x 7.00T-162 8 z
9R22.5-14PR S R 22.5 x 6.75-152 8 z z
20 x 7.00T-162 8 z z
10.00R20-14PR R
20 x 7.50V-165 8 z z
8 z z z
10.00R20-16PR R 20 x 7.50V-165 10 z z z
10 (ISO) z z z
10R22.5 141/138L R 22.5 x 6.75-152 8 z
10R22.5-14PR S R 22.5 x 6.75-152 8 z z z
8 z z
11.00R20-14PR R 20 x 7.50V-165
10 z z
8 z z
11.00R20-16PR R 20 x 7.50V-165
10 z z
8 z z z z z
22.5 x 7.50L-162
11R22.5-14PR S R 10 z z z z
22.5 x 8.25-162 10 z z z z
8 z z z
22.5 x 7.50L-162
10 z z z z
11R22.5-16PR S R
22.5 x 8.25-162 10 z z z z
22.5 x 8.25-165 10 (ISO) z z z
NOTE
z Tire construction S: Tubeless, B: Bias, R: Radial
z Wheel mounting 6: 6 stud, 8: 8 stud, 10: 10 stud
TW-1-1
SERVICE DATA
Please note that the sizes in the below chart are examples of typi-
cal tire sizes and do not necessarily apply to your vehicle.
11 R 22.5 L (16PR)
Load range
Rim diameter in inches
Indicates radial construction
Nominal section width in inches
7.50 - 20 - F (12PR)
Load range
Rim diameter in inches
Nominal section width in inches
TW-1-2
SERVICE DATA
SERVICE DATA
TIRE SIZES AND TIRE INFLATION PRESSURES
Standard air pressure kPa {kgf/cm2, psi}
Tire size designation 564 588 613 638 662 687 711 725 736 760 785 794 810 825 834 858 875
{5.75, {6.00, {6.25, {6.50, {6.75, {7.00, {7.25, {7.4, {7.50, {7.75, {8.00, {8.10, {8.25, {8.40, {8.50, {8.75, {8.90,
82} 85} 89} 92} 96} 100} 103} 105} 107} 110} 114} 115} 117} 120} 121} 124} 127}
8.25-16-14PR z
8.25-20-14PR z
9.00-20-12PR z
9.00-20-14PR z
10.00-20-14PR z
Dual z
10.00-20-16PR
Single z
11.00-20-14PR z
215/75R17.5-124/123 z
235/75R17.5-130/128 z
225/90R17.5-14PR z
245/70R19.5-14PR z
275/70R22.5148/145 z
8.25R16-14PR z
8.25R20-14PR z
9.00R20-14PR z
9R22.5-14PR z
10.00R20-14PR z
10.00R20-16PR z
10R22.5-14PR z
11.00R20-14PR z
11.00R20-16PR z
11R22.5-14PR z
11R22.5-16PR z
TW-1-3
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance Service
Item
standard limit
NOTE
z Disc wheel sectional area and measuring points differ
between type 1 and type 2. (Refer to the figure.)
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Vehicle model Tightening torque
MK, LK series 370 - 420 {37 - 43, 273 - 309}
Wheel SAE type PK, CD and CW
540 - 590 {55 - 60, 398 - 435}
nut series
ISO type PK and CW series 590 - 630 {60 - 65, 435 - 465}
TW-1-4
DISASSEMBLY
DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Apply the parking brake and chock all tires except the one
to be removed.
ISO type
The left and right wheel nuts have the same right-hand thread
designs.
TW-2-1
DISASSEMBLY
<HYDRAULIC JACK>
WARNING
WARNING
z Never get under the vehicle while it is supported only by
the jack. Always use safety stands to support frame
when you have to get under the vehicle.
z Place wheel chocks at both front and back of the wheel
diagonally opposite the jack position.
NOTE
z Be careful not to damage the threads of the hub bolts
with the bolt holes in the disc wheel when removing
wheel.
TW-2-2
DISASSEMBLY
DISASSEMBLY
Key point of disassembly
Disassembling the type with tube
1. Carefully remove the tire valve core and release all air pres-
sure inside the tire. If the valve is obstructed while discharg-
ing air pressure, use a thin wire to remove the foreign
matter.
WARNING
WARNING
z The valve sometimes freezes because of high air pres-
sure inside the tire. Do not put your face close to the
valve while discharging air pressure. Pieces of ice may
surge out, causing an injury.
NOTE
z While removing the valve core, hold it with your fingers
so that it does not pop out.
2. Drive a bead hammer between the tire bead and rim flange
until the bead and flange separate completely.
3. Spread lubricant or soapy water on the tire bead and rim
flange.
4. Insert the lever into the end gap of the side ring. Push it
down to the point where the lever groove is visible.
5. Push the other lever into the lever groove. Turn the lever
over toward the wheel center by pivoting the lever so that
the side ring end surface is elevated.
TW-2-3
DISASSEMBLY
6. Insert the two levers between the side ring and rim alter-
nately. Gradually pry up the levers to remove the side ring.
NOTE
z When the side ring comes off about half of the circumfer-
ence, hold remaining, yet to be removed portion of the
ring with foot.
7. Install the cap on the valve and press-fit the valve stem into
the valve hole.
8. Raise the tire and gradually and push the wheel center out
using foot.
NOTE
z The wheel may suddenly come out from the tire. Be care-
ful not to allow the wheel to roll out.
9. Insert the lever between the bead and rim near the valve.
Push the rim out and remove the wheel.
NOTE
z The wheel may suddenly come out from the tire. Be care-
ful not to allow the wheel to roll out.
10. Remove the flap and then pull the tube out.
NOTE
z While removing the valve core, hold it with your fingers
so that it does not pop out.
TW-2-4
DISASSEMBLY
2. Drive a bead hammer between the tire bead and rim flange
until the bead and flange separate completely.
CAUTION
z In aluminum wheels, the lever should be used carefully
so as not to damage the wheel. Never use a bead ham-
mer.
5. Hold one lever in position with your foot and lean the sec-
ond lever toward the center of the wheel.
Progressively work the first bead off the rim.
WARNING
WARNING
z Be careful when pulling the lever toward the center of the
wheel. The tip of the lever may slip out from the tire.
NOTE
z Take off about 1/2 the circumference. The rest comes off
easily.
TW-2-5
DISASSEMBLY
7. Push the lever to raise the wheel and insert another lever in
close vicinity to further raise the wheel by providing a rock-
ing or bouncing action to pry the rim out of the assembly.
NOTE
z Take off about 1/3 the circumference. The rest comes off
easily.
TW-2-6
INSPECTION
INSPECTION
TIRE
New tire
There are many types of tire construction, tread patterns and tire
sizes. It is very important to select the best one for the particular
vehicle (including rims) and for the conditions it will be used in.
NOTE
z Never mix the following tires on one vehicle.
z Different kinds of tires (bias, radial, etc.)
z Different sizes
z Normal tires, snow tire, snow tire with spikes
z Mount snow tires on all wheels on snowy or icy roads.
Used tire
Check for abnormalities as instructed in section “MA”. Replace if
faulty.
TW-3-1
INSPECTION
TW-3-2
REASSEMBLY
REASSEMBLY
REASSEMBLY
Key point of reassembly
Reassembling the type with tube
1. To prevent friction between the tire inside and tube, and the
tube and flap, coat each part with talc powder.
2. Blow a small amount of air into the tube and insert the tube
into the tire.
NOTE
z Be sure to blow air with the valve core installed.
3. Insert the valve stem into the valve hole in the flap. Sequen-
tially insert the flap uniformly.
NOTE
z Be careful not to allow the upper and lower ends of the
flap to bend inside the tire.
4. Place the wheel on a level surface and insert the valve stem
into the valve hole.
5. Fit the tire in the wheel by slowly sliding the tire around the
wheel. Then, rotate the wheel so that the valve is located in
the center of the rim hole.
6. Press-fit the side ring into the rim groove.
NOTE
z Locate the end gap of the side ring 90º from the valve so
it is evenly spaced between the disc ornamental holes.
TW-4-1
REASSEMBLY
NOTE
z If the side ring end clearance is not within the above
specifications, remove and check it. If there is any abnor-
mality, replace the side ring with a new one.
TW-4-2
REASSEMBLY
2. Mount the tire to the rim flange using your hands and knees
as much as possible.
3. Insert the lever between the rim flange and the bead, and
pry the bead into the rim flange by forcing the lever down-
ward.
Work the remaining section.
NOTE
z Mount the valve region of the rim last.
7. Apply soapy water to the mating surfaces of the tire and rim
flange and check both sides for signs of leakage.
Also check the valve for leakage, using soapy water.
TW-4-3
REASSEMBLY
INSTALLATION
Key point of installation
Procedures for mounting tires differ between the SAE type and ISO
type. When installing tires, be sure to observe precautions for each
tire.
SAE type
1. Clean the wheel mounting surfaces with a wire brush and
clean waste cloth. Dirty mounting surfaces may cause the
wheel nuts to loosen.
2. Apply a coat of engine or gear oil to the threaded portions of
the hub bolts and wheel nuts only. Do not use molybdenum
grease for this purpose.
3. The wheel nuts on the right side of the vehicle have right-
handed threading; the left side wheel nuts have left-handed
threading.
4. Tighten the wheel nuts in the sequence shown in the figure
little by little to the specified torque. For the tightening
torque, refer to the “SERVICE DATA”.
NOTE
z Do not tighten the wheel nuts excessively.
z After removing only the rear outer wheel, retighten the
inner wheel nuts to the specified torque setting.
ISO type
1. The left and right wheel nuts have the same right-hand
thread designs.
2. Clean the wheel mounting surfaces with a wire brush and a
clean waste cloth. Dirty mounting surfaces may cause the
wheel nuts to loosen.
TW-4-4
REASSEMBLY
4. Apply two drops of engine oil or gear oil to the threaded por-
tions of the wheel nuts and between the nuts and washers
(the tapered portion).
Wipe away any excess with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.
5. Wheel nut tightening sequence and procedures are the
same as those for the SAE type.For the tightening torque,
refer to the “SERVICE DATA”.
NOTE
z Do not tighten the wheel nuts excessively.
TW-4-5
STEERING SYSTEM
ST
STEERING GEAR BOX AND
HYDRAULIC PUMP
CONTENTS
SERVICE DATA..................................ST-1- 1 = STEERING GEAR BOX
SPECIFICATIONS..........................ST-1- 1 (UNIT NAME 446-02580) =
SERVICE DATA..............................ST-1- 3
TIGHTENING TORQUE .................ST-1- 5 CONSTRUCTION................................ST-5-1
TOOLS................................................ST-2- 1 DISASSEMBLY ...................................ST-5-2
REMOVAL .......................................ST-5-2
= STEERING GEAR BOX (UNIT NAMES DISASSEMBLY ...............................ST-5-3
PMU-1487, PMU-1488 AND PSI-Y85-7) = INSPECTION.......................................ST-5-7
REASSEMBLY ....................................ST-5-8
CONSTRUCTION ...............................ST-3- 1 REASSEMBLY ................................ST-5-8
DISASSEMBLY ..................................ST-3- 2 INSTALLATION .............................ST-5-14
REMOVAL ......................................ST-3- 2 PERFORMANCE CHECKS ..............ST-5-15
DISASSEMBLY ..............................ST-3- 3
INSPECTION ......................................ST-3- 6 = HYDRAULIC PUMP =
REASSEMBLY ...................................ST-3- 7
REASSEMBLY ...............................ST-3- 7
INSTALLATION..............................ST-3-11 CONSTRUCTION................................ST-6-1
DISASSEMBLY ...................................ST-6-3
= STEERING GEAR BOX REMOVAL .......................................ST-6-3
(UNIT NAME PSI-Y100-46) = DISASSEMBLY ...............................ST-6-4
INSPECTION.......................................ST-6-8
CONSTRUCTION ................................ST-4-1 REASSEMBLY ....................................ST-6-9
DISASSEMBLY ...................................ST-4-2 REASSEMBLY ................................ST-6-9
REMOVAL .......................................ST-4-2 INSTALLATION .............................ST-6-10
DISASSEMBLY ...............................ST-4-3 INSPECTING RELIEF VALVE
INSPECTION .......................................ST-4-6 PRESSURE................................... ST-6-11
REASSEMBLY ....................................ST-4-7 BLEEDING AIR FROM THE POWER
REASSEMBLY ................................ST-4-7 STEERING SYSTEM.........................ST-6-12
INSTALLATION..............................ST-4-11
SERVICE DATA GEAR BOX AND HYD PUMP
SERVICE DATA
SPECIFICATIONS
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Unit: mm (in)
Item PMU-1487 PMU-1488 PSI-Y85-7 PSI-Y100-46
O.D. of steering wheel 460 (18.11)
Type Integral
Gear ratio 18.5 - 16.5 22.76
Operating angle of sector shaft 2x 45º+2º
0 2 x 48º+2º
0
Center-to-center distance between sector
75 (2.95) 93 (3.66)
shaft and ball screw
Type of sector shaft Gear
Type Straight ball groove
Dia. of piston 85 (3.35) 100 (3.94)
Ball Torsional direction of ball screw Right Left
screw O.D. of ball x number of balls - ball 7.144 x 32 - 30 7.144 x 35 - 35
pitch (0.2813 x 32 - 1.18) (0.2813 x 35 - 1.38)
Lead 14.288 (0.5625)
ST-1-1
SERVICE DATA GEAR BOX AND HYD PUMP
HYDRAULIC PUMP
Made by JIDOSHA KIKI Co., Ltd.
Type I Type II Type III Type IV
Item 470-04420 475-04271, 475-04273 475-04270, 475-04272 475-04233
470-04422 475-04279, 475-04293 475-04278, 475-04292 475-04333
Type Vane type
Drive Gear driven
Operating speed rpm 500 - 5,141 500 - 4,300
Relief set pressure 12,259
12,259 {125, 1,778} 10,297 {105, 1,493}
kPa {kgf/cm2, psi} {125, 1,778}
PMU-1487 z z z z z
R.H.D.
446-02580 z z z z z z z z z z
Steer-
PSI-Y85-7 z z z z
ing gear
box PMU-1488 z z z z z
L.H.D.
PSI-
z z z z z z
Y100-46
470-04420 z z z z z z
Type I
470-04422 z z z z z z z z
475-04271 z
475-04273 z
Type II
475-04279 z z z
Hydrau- 475-04293 z z
lic
pump 475-04270 z
475-04272 z
Type III
475-04278 z z
475-04292 z
475-04233 z z z
Type IV
475-04333 z z z
ST-1-2
SERVICE DATA GEAR BOX AND HYD PUMP
SERVICE DATA
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
<PMU-1487, PMU-1488 and PSI-Y85-7>
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Clearance between gear case and ball screw 0.04 - 0.09
0.15 (0.0059)
assembly (0.0016 - 0.0035)
Wear of worm shaft O.D. 22.00 (0.8661) 21.87 (0.8610)
Axial play of adjusting bolt 0 (0) 0.1 (0.004)
Measure at end of pitman
arm 250 mm (9.84 in) with
gears in Neutral.
Backlash between sector gear and ball screw 0.15 - 0.35
0.5 (0.020) Measure backlash while
assembly (0.0059 - 0.0138)
specified load ±20 N {±2 kgf,
±4 lbf} is applied to pitman
arm
Wear of sector shaft Adjusting bolt side 44.98 - 45.00
44.95 (1.7697)
O.D. Pitman arm side (1.7709 - 1.7717)
Rotating torque of input shaft under no load (as Less than Pump ON and gears set
—
gear assembly unit) N·m {kgf·cm, in·lbf} 1.3 {13, 11} near Neutral (Max. value)
Axial play of piston and worm shaft 0.02 (0.0008) 0.12 (0.0047)
<PSI-Y100-46>
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Clearance between gear case and ball screw 0.03 - 0.095
0.15 (0.0059)
assembly (0.0012 - 0.0037)
Less than
Axial play of ball screw 0.04 (0.0016)
0.02 (0.0008)
Measure at end of pitman
Backlash between sector gear and ball screw 0.06 - 0.30
— arm 300 mm (11.81 in) with
assembly (0.0024 - 0.0118)
gears in Neutral.
Clearance between sleeve and spool — 0.02 (0.0008)
Clearance between groove in sleeve and Less than
0.10 (0.0039)
straight pin 0.035 (0.0014)
Wear of sector shaft Adjusting bolt side 50.00 (1.9685) 49.95 (1.9665)
O.D. Pitman arm side 57.12 (2.2488) 57.07 (2.2468)
Less than
Axial play of adjusting screw —
0.10 (0.0039)
ST-1-3
SERVICE DATA GEAR BOX AND HYD PUMP
HYDRAULIC PUMP
Unit: mm (in)
Item Maintenance standard Service limit Remarks
470-04420
TYPE I
470-04422
475-04271
12,014 - 12,749
475-04273
TYPE II {122.5 - 130, —
475-04279
1,742 - 1,849}
Adjusted pressure 475-04293
kPa {kgf/cm2, psi} 475-04233
TYPE IV
475-04333
475-04270
10,052 - 10,788
475-04272
TYPE III {102.5 - 110, —
475-04278
1,458 - 1,564}
475-04292
Clearance between relief valve outside
— 0.03 (0.0012)
diameter and body inside diameter
ST-1-4
SERVICE DATA GEAR BOX AND HYD PUMP
TIGHTENING TORQUE
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
<PMU-1487, PMU-1488 and PSI-Y85-7>
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Valve housing mounting bolt 108 - 147 {11 - 15, 80 - 108}
Side cover mounting bolt 78 - 103 {8.0 - 10.5, 58 - 76}
Adjusting bolt lock nut 59 - 78 {6 - 8, 43 - 58}
Lock nut at front cover 157 - 196 {16 - 20, 116 - 145}
Ball screw circulator setscrew 4 - 5 {0.4 - 0.5, 2.9 - 3.6}
Gear case mounting bolt 206 - 235 {21 - 24, 152 - 174}
Pitman arm mounting nut 343 - 392 {35 - 40, 253 - 289}
<PSI-Y100-46>
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Valve housing mounting bolt 127 - 157 {13 - 16, 94 - 116}
Side cover mounting bolt 78 - 103 {8.0 - 10.5, 58 - 76}
Tapered plug 29 - 39 {3 - 4, 22 - 29}
Adjusting screw lock nut 59 - 78 {6 - 8, 43 - 58}
Lock nut 177 - 216 {18 - 22, 130 - 159}
Stub shaft rotating torque
Plug
20 - 49 {2 - 5, 14 - 36}
Piston cap 275 - 343 {28 - 35, 203 - 253}
Tube clamp mounting screw 4 - 5 {0.4 - 0.5, 2.9 - 3.6}
Steering gear box mounting bolt and nut 294 - 343 {30 - 35, 217 - 253}
Pitman arm mounting nut 441 - 490 {45 - 50, 325 - 362}
ST-1-5
SERVICE DATA GEAR BOX AND HYD PUMP
HYDRAULIC PUMP
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Pump body mounting bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Type I —
Type II
Pressure plate mounting screw
Type III 5.9 - 8.8 {0.6 - 0.9, 4.3 - 6.5}
Type IV
Plug (relief valve) 49 - 59 {5.0 - 6.0, 36 - 43}
ST-1-6
TOOLS GEAR BOX AND HYD PUMP
TOOLS
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Applicable
Tool name and number Description Shape
steering unit
PMU -1487
Press
Used to press-fit oil seal and bearing -1488
23431-06917
PSI -Y85-7
PMU -1487
Tightening tool
-1488
23431-06912
PSI -Y85-7
Tightening tool
PSI -Y100-46
23431-06901
PMU -1487
Tightening tool -1488
Used to tighten front cover
PSJIG-00183-2 PSI -Y85-7
-Y100-46
ST-2-1
TOOLS GEAR BOX AND HYD PUMP
Applicable
Tool name and number Description Shape
steering unit
PMU -1487
*Remover (push rod)
-1488
EKC-10100201
PSI -Y85-7
PMU -1487
*Remover (flange)
-1488
EKC-10100202
PSI -Y85-7
1. Push rod
2. Flange
3. Mount
PMU -1487
*Remover (mount)
-1488
EKC-10100203
PSI -Y85-7
PMU -1487
Installer
Used to install steering gear box -1488
PSJIG-00252
PSI -Y85-7
ST-2-2
TOOLS GEAR BOX AND HYD PUMP
Applicable
Tool name and number Description Shape
steering unit
PMU -1487
23431-
-1488
06908
PSI -Y85-7
Torque cap
23431- Used to measure torque
06908
PSJIG-
PSI -Y100-46
00184-5
Pin remover
Used to drive out pin PSI -Y100-46
PSJIG-00184-2
ST-2-3
TOOLS GEAR BOX AND HYD PUMP
Applicable
Tool name and number Description Shape
steering unit
Insert tool
Used to press-fit oil seal into plug PSI -Y100-46
PSJIG-00184-4
PMU -1487
** Hydraulic circuit
Used to test performance of hydrau- -1488
measuring tool
lic lines PSI -Y85-7
915-00082
-Y100-46
ST-2-4
TOOLS GEAR BOX AND HYD PUMP
Tool assembly
Used to install the thrust bearing
910-10611
Attachment assembly
Used to secure the valve housing
910-10671
ST-2-5
TOOLS GEAR BOX AND HYD PUMP
Insert
Used to set the Y-packing correctly
910-21704
Press fit
Used to press-fit the adjusting plug
910-20404
ST-2-6
TOOLS GEAR BOX AND HYD PUMP
Squeezer
Used to crimp the adjusting screw
910-21801
ST-2-7
TOOLS GEAR BOX AND HYD PUMP
ST-2-8
CONSTRUCTION PMU-1487, PMU-1488 AND PSI-Y85-7
ST-3-1
DISASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.
ST-3-2
DISASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
DISASSEMBLY
ST-3-3
DISASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
9 Lock nut
Remove the nuts and front cover. (tools: 23431-06912 and PSJIG-
00183-2)
ST-3-4
DISASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
38 Needle bearing
Do not remove the needle bearing unless necessary.
1. Needle bearing 3. Oil seal
2. U-packing
ST-3-5
INSPECTION PMU-1487, PMU-1488 AND PSI-Y85-7
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between gear case and ball screw assembly
Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.09 (0.0016 - 0.0035) 0.15 (0.0059)
ST-3-6
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
REASSEMBLY
REASSEMBLY
Key point of reassembly
40 Dust seal, 39 U-packing and 38 Needle bearing
Install the dust seal, U-packing and needle bearing on the gear
case. (tool: 23431-06917)
1. Needle bearing 3. Dust seal
2. U-packing
NOTE
z Apply a coat of grease to the needle bearing and the seal-
ing lips of the seal.
z The U-packing has a special design and is divided into
two sections. Always install the U-packing, bearing and
oil seal, as shown in the figure below. After installing,
straighten the temporarily bent section.
34 Piston
1. Apply a coat of grease to the inner side of the circulator and
position steel balls in the circulator.
2. Insert the worm shaft into the piston. Set the worm shaft
horizontally, and axially align the grooves in the worm shaft
and the piston.
3. While gradually rotating the worm shaft, position the steel
balls in the circulator one by one until there is no clearance
between balls.
NOTE
z Do not put any steel balls outside the circulator.
z Make sure there are 32 steel balls in all.
4. Install the circulator and circulator holder on the piston.
NOTE
z After assembling the ball screw, ensure that it rotates
smoothly.
CAUTION
z Do not force the ball screw assembly against the stroke
end. It will ride over the incomplete threaded section and
may damage the ball tube, resulting in improper opera-
tion.
ST-3-7
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
27 Rotor assembly
Install the rotor, O-ring and sleeve.
NOTE
z Align the hole in the rotor assembly with the pin.
z Install the O-ring on the sleeve assembly in advance
1. Stub shaft 4. Rotor assembly
2. Pin 5. O-ring
3. Sleeve assembly 6. Worm shaft
25 Sleeve
One O-ring and one teflon ring are installed in each groove on the
sleeve.
1. Sleeve 4. Teflon ring
2. O-ring
23 Valve housing
1. Apply a coat of grease to the needle bearing and the seal-
ing lips of the oil seal.
2. Ensure that the retaining ring is fitted into the groove
1. O-ring 4. Retainingring
2. Needle bearing 5. Valve housing
3. Oil seal
ST-3-8
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
14 Thrust race
Ensure that the thick side of the thrust race faces the worm.
9 Lock nut
Install the O-ring on the front cover together with the nut and tem-
porarily install the nut.
8 Adjuster bolt
Install the lock nut on the adjusting bolt. Tighten the adjusting bolt
all the way and then back it off approximately one turn. Then, lock
the adjusting bolt with the lock nut.
ST-3-9
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
2. Install the sector shaft and side cover assembly on the gear
case and tighten with the bolts.
: 78 - 103 N·m {8.0 - 10.5 kgf·m, 58 - 76 ft·lbf}
NOTE
z Ensure that the center groove of the ball screw's rack
gear is aligned with the center of the hole in the sector
shaft.
3. Install the lock nut on the adjusting bolt. Tighten the adjust-
ing bolt all the way and then back it off approximately one
turn. Then, lock the adjusting bolt with the lock nut.
<Adjusting the preload>
1. Slightly loosen the nuts which have been temporarily tight-
ened on the front cover and measure the “base” torque
[Approximately 0.5 to 1.0 N·m {5 to 10 kgf·cm, 4.3 to 8.7
in·lbf}]. Tighten the nuts by an additional torque of 0.2 to 0.4
N·m {2 to 4 kgf·cm, 1.7 to 3.5 in·lbf}. (tools: PSJIG-00252
and PSJIG-00183-2)
NOTE
z Do not apply preload to the sector gear when tightening
the nuts.
z After torque adjustment, operate the stub shaft over its
entire range several times to check for the starting
torque.
2. Prevent the front cover from turning and tighten the nuts.
(tool: 23431-06901)
: 157 - 196 N·m {16 - 20 kgf·m, 116 - 145 ft·lbf}
3. After tightening the nuts, recheck the starting torque.
ST-3-10
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
2. Tighten the adjusting bolt all the way (backlash = 0). Back
the adjusting bolt off and adjust the backlash with the pit-
man arm at a position of 250 mm (9.84 in) from the center of
the sector shaft. After proper backlash adjustment, lock the
adjusting bolt with the lock nut.
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.35 (0.0059 - 0.0138) 0.5 (0.020)
INSTALLATION
Key point of installation
1. After making sure the vehicle wheels are in the straight-
ahead direction, install the steering gear box.
: 206 - 235 N·m {21 - 24 kgf·m, 152 - 174 ft·lbf}
3. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.
: 343 - 392 N·m {35 - 40 kgf·m, 253 - 289 ft·lbf}
ST-3-11
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
ST-3-12
CONSTRUCTION PSI-Y100-46
ST-4-1
DISASSEMBLY PSI-Y100-46
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.
ST-4-2
DISASSEMBLY PSI-Y100-46
DISASSEMBLY
ST-4-3
DISASSEMBLY PSI-Y100-46
z Align the mark on the sector shaft by turning the stub shaft,
as shown in the figure at right. Gears will now set in neutral.
7 Lock nut
Using the Wrench (PSJIG-00174), remove the lock nut.
ST-4-4
DISASSEMBLY PSI-Y100-46
15 Plug
Place the valve housing in a vise. Using the Plug Tool (PSJIG-
00183-2), remove the plug assembly.
NOTE
z Do not remove the thrust bearing unless it is damaged.
22 Straight pin
While supporting the worm and stub shaft on the “V” block (PSJIG-
00184-1), remove the straight pin which connects the worm shaft to
the torsion bar using the Pin Remover (PSJIG-00184-2).
36 Needle bearing
Do not remove the needle bearing unless it is damaged.
ST-4-5
INSPECTION PSI-Y100-46
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between gear case and ball screw assembly
Unit: mm (in)
Maintenance standard Service limit
0.03 - 0.095 (0.0012 - 0.0037) 0.15 (0.0059)
ST-4-6
REASSEMBLY PSI-Y100-46
REASSEMBLY
REASSEMBLY
Key point of reassembly
39 Oil seal
Using the Tool (PSJIG-00184-3) and a press, press the oil seal into
the gear case.
NOTE
z Be careful not to scratch the inner perimeter of the U-
packing.
38 Tapered plug
When installing the taper plug, wind seal tape around the thread.
: 29 - 39 N·m {3 - 4 kgf·m, 22 - 29 ft·lbf}
24 Sleeve
1. Expand the seal ring to match the outside diameter [61 mm
(2.40 in) dia.] of the sleeve, and fit into the groove. Run-in
the seal ring using a jig whose inner diameter is smoothly
finished to 61 mm (2.40 in) and whose inlet is well cham-
fered.
2. Insert the spool into the sleeve while aligning the pin hole in
the spool with pin groove in the sleeve in the circumferential
direction. Slowly push the spool toward the pin groove in
the sleeve and hold it there. Insert the worm-stub shaft
assembly into the spool, paying attention to the pin location.
Insert the pin into the hole in the spool and assemble the
sleeve to the worm.
NOTE
z Do not allow the sleeve and spool to gouge each other.
ST-4-7
REASSEMBLY PSI-Y100-46
4. Drive the selected new straight pin into the pin hole.
5. Remove the setscrew (M6 x 1.0) used step 1. above.
15 Plug
Using the Plug Tool (PSJIG-00183-2), tighten the plug assembly on
the valve housing completely and back off some amount so that the
worm can be turned by hand. At this point, temporarily tighten the
plug assembly.
13 Oil seal
Using the Tool (PSJIG-00184-4) and a press, press the oil seal into
the plug.
ST-4-8
REASSEMBLY PSI-Y100-46
3. Apply grease to one half of the ball tube and position nine
balls in the tube. Place the other half of the ball tube on the
ball tube which contains the balls.
NOTE
z Be sure to apply a sufficient amount of grease so that all
balls are properly greased.
4. Install the ball tube on the ball nut and secure with the tube
clamp and screw.
: 4 - 5 N·m {0.4 - 0.5 kgf·m, 2.9 - 3.6 ft·lbf}
5. After installing the ball tube, ensure that the worm smoothly
makes six complete turns in both directions.
ST-4-9
REASSEMBLY PSI-Y100-46
7 Lock nut
Using the Lock Nut Tool (PSJIG-00174), tighten the lock nut.
: 177 - 216 N·m {18 - 22 kgf·m, 130 - 159 ft·lbf}
ST-4-10
REASSEMBLY PSI-Y100-46
2. Insert the sector shaft and side cover assembly into the
gear case. Using a plastic hammer, tap the side cover until
it contacts the gear case and tighten with the bolts.
NOTE
z Be careful not to damage the seals.
z Ensure that the ball nut gear and sector shaft gear are
engaged at their centers.
: 78 - 103 N·m {8.0 - 10.5 kgf·m, 58 - 76 ft·lbf}
INSTALLATION
Key point of installation
1. After making sure the vehicle wheels are in the straight-
ahead direction, install the steering gear box.
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
ST-4-11
REASSEMBLY PSI-Y100-46
3. Fill the dust cover with grease and install it onto the sector
shaft (if the dust cover was removed).
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.
4. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.
: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ftvlbf}
ST-4-12
CONSTRUCTION 446-02580
ST-5-1
DISASSEMBLY 446-02580
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.
ST-5-2
DISASSEMBLY 446-02580
DISASSEMBLY
Marks “+” and “,” indicate that the key points of operation are explained in the text.
ST-5-3
DISASSEMBLY 446-02580
z Turn the worm shaft until gears are set in neutral, and place
the steering gear box in a vise.
6 Side cover
Using the Needle (910-21200), remove the O-ring from the perime-
ter of the side cover and the Y-packing and remove the back-up ring
located at the back of the needle bearing.
Do not remove the needle bearing unless it is damaged.
9 Sector shaft
1. Unlock the two clinched portions of the retainer of the sector
shaft assembly.
NOTE
z Do not disassemble the sector shaft unless it is dam-
aged.
z Place the sector shaft in the “soft” jaws of a vise.
ST-5-4
DISASSEMBLY 446-02580
16 Bearing case
Place a plastic container under the shaft assembly as shown and
push the fastening portion of the piston. The side race, steel balls
and bearing cage will then detach one after another into the con-
tainer. Be careful not to lose the steel balls.
No of steel balls used: 18
ST-5-5
DISASSEMBLY 446-02580
20 Seal ring
Remove the rotor from the worm shaft assembly. Using the Needle
(910-21200), remove the seal ring from the rotor.
25 Piston
1. Be careful to prevent damage. Do not insert a screwdriver
or sharp pointed object between the ball tube and piston.
2. Some steel balls may have been left in the ball tube. Be
careful not to lose them.
Total No. of steel balls: 32
ST-5-6
INSPECTION 446-02580
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between gear case and ball screw assembly
Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)
ST-5-7
REASSEMBLY 446-02580
REASSEMBLY
REASSEMBLY
Key point of reassembly
33 Oil seal
Using the Insert Tool Assembly (910-11001), press the oil seal into
the steering body. Be sure to apply grease to the oil seal before
installation.
29 Ball tube
Fill the inner wall of the one-half ball tube with grease. Affix ten or
eleven steel balls to the inner wall side by side. Place the second
half of the ball tube on the first half of the ball tube.
ST-5-8
REASSEMBLY 446-02580
2. Place the rotor between the stub and worm shafts while
aligning the cutout portion with the straight pin.
19 Thrust bearing
1. Attach the Guide (910-23033) to the Tool Assembly (910-
10611). Position the shaft assembly (previously assembled)
into these tools with the input side facing down.
Install one bearing side race, bearing cage and steel balls in
that order. While sliding the Tool Assembly (910-10611)
down, set the steel balls in place.
ST-5-9
REASSEMBLY 446-02580
16 Y-packing
1. Using the Press-Fit Tool (910-20404), install the Y-packing
in the recess on the inner perimeter of the adjusting plug.
NOTE
z When installing the Y-packing, use a hand press.
ST-5-10
REASSEMBLY 446-02580
2. After positioning the steel balls, insert the ball tube into the
piston and secure with the ball tube clip, washer and screw.
: 4.4 - 5.4 N·m {0.45 - 0.55 kgf·m, 3.3 - 4.0 ft·lbf}
NOTE
z Use your hand when inserting the ball tube into the pis-
ton.
5. Align the oil groove in the steering body with that in the
valve housing and tighten with bolts.
: 118 - 127 N·m {12 - 13 kgf·m, 87 - 94 ft·lbf}
ST-5-11
REASSEMBLY 446-02580
9 Sector shaft
1. Fill the adjusting screw hole in the sector shaft with grease
and insert the adjusting screw into the hole. Using the Bar
(910-22811), tighten the retainer.
Tightening the retainer
After completely tightening the retainer, back it off 180°.
Retighten it by 20°. Ensure that the adjusting screw turns
smoothly.
6 Side cover
1. Before installing the Y-packing, fill the groove on the side
cover with a sufficient amount of grease. Ensure that the Y-
packing is installed with the lip facing the needle bearing.
2. It is easy to position the back-up ring while temporarily
bending it like a heart in shape.
ST-5-12
REASSEMBLY 446-02580
4. Put two punch marks 180º apart from each other on the
periphery of the valve housing and adjusting plug contact-
ing area.
ST-5-13
REASSEMBLY 446-02580
INSTALLATION
Key point of installation
1. After making sure the vehicle wheels are in the straight-
ahead direction, install the steering gear box.
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
3. Fill the dust cover with grease and install it onto the sector
shaft (if the dust cover was removed).
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.
4. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.
: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}
ST-5-14
PERFORMANCE CHECKS STEERING GEAR BOX
PERFORMANCE CHECKS
HYDRAULIC PRESSURE
Installing the oil pressure gauge
The oil pressure circuit measuring tool (915-00082) consists of an
oil pressure gauge and a cock. Connect the oil pressure gauge on
the hydraulic pump side and the cock in the line between the power
steering inlet and the oil pump.
WARNING
WARNING
z Do not install the oil pressure gauge and cock while the
temperature of power steering fluid is high; otherwise,
you may be burned.
CAUTION
z Ensure that the cock is fully open.
Installation procedure
Connect the oil pressure gauge, valve and copper tube in advance.
(No. 1 through 9 parts)
1. Disconnect the inlet pipe 13 from the steering gear box.
2. Remove the connector 12 and gasket 11 from the inlet of
the steering gear box and install them to the inlet pipe 13.
3. Connect the connector 10 to the connector 12 with the gas-
ket 11 in place.
4. Connect the copper tube 6 to the connector 10.
5. Connect the connector 15 to the inlet of the steering gear
box with the gasket 14 in place.
6. Connect the copper tube 9 to the connector 15.
ST-5-15
PERFORMANCE CHECKS STEERING GEAR BOX
NOTE
z The connector 5. has a hole to which the oil tube for the
oil pressure gauge is to be connected. Remove the
tapered plug from the hole.
ST-5-16
PERFORMANCE CHECKS STEERING GEAR BOX
ST-5-17
PERFORMANCE CHECKS STEERING GEAR BOX
Judgement
1. Returns to set pressure quickly ... Normal
2. Drops below set pressure and does not return to set pres-
sure quickly ... Faulty
3. Drops below set pressure and does not return to set pres-
sure ... Faulty
If judged to be “faulty”, repair or replace the hydraulic pump.
CHECKING METHOD 1
(W/FRONT WHEELS RAISED)
Procedure
1. Jack up the front wheels.
2. Fully open the cock.
3. Operate the engine at idle. Measure pressure while turning
the steering wheel fully to left and right (until it stops at the
knuckle stopper).
Judgement
Hydraulic pump Type I, Type II and Type IV
1. 12,014 - 12,749 kPa {122.5 - 130 kgf/cm2, 1,742 - 1,849
psi} ... Normal
2. 12,014 kPa {122.5 kgf/cm2, 1,742 psi}, max. ... Faulty
power steering system
Repair or replace faulty parts.
Hydraulic pump Type III
1. 10,052 - 10,788 kPa {102.5 - 110 kgf/cm2, 1,458 - 1,564 psi}
... Normal
2. 10,052 kPa {102.5 kgf/cm2, 1,458 psi}, max. ... Faulty
power steering system
Repair or replace faulty parts.
ST-5-18
PERFORMANCE CHECKS STEERING GEAR BOX
CHECKING METHOD 2
(W/FRONT WHEELS ON GROUND)
Procedure
1. Lower the front wheels.
2. Fully open the cock.
3. Operate the engine at 1,000 to 1,500 rpm. Turn the steering
wheel to the extreme limits of travel until the oil pressure
gauge registers 4,904 kPa {50 kgf/cm2, 711 psi}. Then,
release the steering wheel and record the pressure drop.
Repeat this operation at least five times.
4. Change set pressure to 3,923, 2,942, 1,961, 981 kPa {40,
30, 20, 10 kgf/cm2, 569, 427, 284, 142 psi}, respectively,
and repeat tests as outlined in step 3. above.
Judgement
1. Returns to 490 kPa {5 kgf/cm2, 71 psi} (piping resistance)
quickly ... Normal
2. Same pressure as when steering wheel is turned to its
travel limits ... Faulty power steering system (if steering col-
umn and under-carriage system are in good condition)
3. Returns to pressure higher than 490 kPa {5 kgf/cm2, 71 psi}
(piping resistance) ... Same as 2. above.
Repair or replace faulty parts.
DRIVING TEST
Turn the steering wheel during driving tests to determine which part
is faulty. Repair or replace faulty parts.
ST-5-19
CONSTRUCTION HYDRAULIC PUMP
= HYDRAULIC PUMP =
CONSTRUCTION
Type I*1
NOTE
z *1: 470-04420 and 470-04422
z *2: 475-04271, 475-04273, 475-04279 and 475-04293
z *3: 475-04270, 475-04272, 475-04278 and 475-04292
ST-6-1
CONSTRUCTION HYDRAULIC PUMP
Type IV*4
NOTE
z *4: 475-04233 and 475-04333
ST-6-2
DISASSEMBLY HYDRAULIC PUMP
DISASSEMBLY
REMOVAL
Key point of removal
Be sure to work on a flat floor and chock the front and rear wheels.
1. Disconnect the oil tube, and drain power steering oil from
the hydraulic pump and oil reservoir.
NOTE
z Provide a container to catch oil.
z Plug the disconnected hose to keep out dust.
WARNING
WARNING
z Do not drain oil immediately after stopping the engine to
prevent scalding yourself. Drain when the oil tempera-
ture drops below 50°C (122°F).
ST-6-3
DISASSEMBLY HYDRAULIC PUMP
DISASSEMBLY
Type I
ST-6-4
DISASSEMBLY HYDRAULIC PUMP
ST-6-5
DISASSEMBLY HYDRAULIC PUMP
Type IV
Marks “+” and “,” indicate that the key points of operation are explained in the text.
ST-6-6
DISASSEMBLY HYDRAULIC PUMP
ST-6-7
INSPECTION HYDRAULIC PUMP
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between relief valve outside diameter and
body inside diameter
Unit: mm (in)
Maintenance standard Service limit
— 0.03 (0.0012)
ST-6-8
REASSEMBLY HYDRAULIC PUMP
REASSEMBLY
REASSEMBLY
Key point of reassembly
14 Type I, Type II and Type III
16 Type IV }Shaft assembly
z If the shaft cannot be inserted to its normal position by
hand, tap it with a copper hammer.
z When inserting the shaft, be careful not to damage the oil
seal lip on the splines.
ST-6-9
REASSEMBLY HYDRAULIC PUMP
INSTALLATION
Key point of installation
1. Install the hydraulic pump assembly with three bolts.
2. Connect the inlet and outlet tubes.
3. Refill power steering oil and bleed air from the system.
a. Jack up the front axle and check the rear wheels.
b. Fill the reservoir with oil to the specified level.
c. Idle the engine and turn the steering wheel to both sides
several times. Add oil to the specified level.
d. Repeat the operation in item 3 above until the oil level sta-
bilizes.
e. Turn the steering wheel and check that the right and left
wheels move smoothly.
f. Lower the jack supporting the front axle, and ensure that no
oil leaks from the tubes and connector.
g. Make sure that the reservoir contains the specified amount
of oil.
ST-6-10
REASSEMBLY HYDRAULIC PUMP
NOTE
z If the type I relief valve regulated pressure cannot be
adjusted, replace as a relief valve assembly.
ST-6-11
BLEEDING AIR FROM THE POWER STEERING SYSTEM
ST-6-12
STEERING LINKAGE
CONTENTS
SERVICE DATA................................... ST-1-1 INSPECTION .................................. ST-3-5
SERVICE DATA...............................ST-1-1 REASSEMBLY ................................ ST-3-6
TIGHTENING TORQUE ..................ST-1-1 STEERING LINKAGE ......................... ST-4-1
SYSTEM DIAGRAM........................ST-1-2 DISASSEMBLY ............................... ST-4-1
TOOLS ................................................ ST-2-1 INSPECTION .................................. ST-4-3
STEERING COLUMN.......................... ST-3-1 REPAIR AND REPLACEMENT....... ST-4-4
CONSTRUCTION ...........................ST-3-1 REASSEMBLY ................................ ST-4-6
DISASSEMBLY ...............................ST-3-2
SERVICE DATA ST LINKAGE
SERVICE DATA
SERVICE DATA
STEERING COLUMN
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Axial play of journal locations Less than 0.2 (0.008) —
Free play of ball bearing locations Less than 0.05 (0.0020) —
Free play of steering wheel 30 - 50 (1.18 - 1.97) —
STEERING LINKAGE
Drag link
Item Maintenance standard Service limit Remarks
12 - 22 g
Amount of grease —
(0.42 - 0.78 oz)
Dust cover pressing load 3,923 N {400 kgf, 882 lbf} —
TIGHTENING TORQUE
STEERING COLUMN
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Steering wheel mounting nut 88 {9, 65}
Steering column mounting bolt and nut 20 {2, 14}
Tilt handle mounting bolt 10 {1, 7}
Steering column yoke mounting bolt 51 - 61 {5.2 - 6.2, 38 - 45}
STEERING LINKAGE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
MK series
LK series 343 - 392 {35 - 40, 253 - 289}
(without LKD210)
Pitman arm mounting nut LKD210
PK series
441 - 490 {45 - 50, 325 - 362}
CDA series
CWA series
MK series
LK series 167 - 226 {17 - 23, 123 - 166}
(without LKD210)
LKD210
196 - 255 {20 - 26, 145 - 188}
Drag link mounting nut PKB series
PKC series
PKF series
216 - 343 {22 - 35, 159 - 253}
CDA series
CWA series
ST-1-1
SERVICE DATA ST LINKAGE
SYSTEM DIAGRAM
STEERING SYSTEM
Model MK and LK series (without LKD210 models)
ST-1-2
SERVICE DATA ST LINKAGE
ST-1-3
TOOLS ST LINKAGE
TOOLS
Part name and number Description Shape
Used when removing steering wheel.
ST-2-1
STEERING COLUMN ST LINKAGE
STEERING COLUMN
CONSTRUCTION
ST-3-1
STEERING COLUMN ST LINKAGE
DISASSEMBLY
REMOVAL
Marks “+” and “,” indicate that the key points of operation are explained in the text.
ST-3-2
STEERING COLUMN ST LINKAGE
ST-3-3
STEERING COLUMN ST LINKAGE
DISASSEMBLY
ST-3-4
STEERING COLUMN ST LINKAGE
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
ST-3-5
STEERING COLUMN ST LINKAGE
REASSEMBLY
INSTALLATION
Key point of installation
12 Key switch assembly
Install the key switch assembly onto the steering column with the
lock pin protruding beyond the switch.
z Temporarily tighten the key switch assembly using a new
self-shear type screw.
z Ensure that the key switch locks properly.
z Tighten the self-shear type screw until the head is cut off.
11 Steering column and 10 Clamp assembly
Apply grease to the frictional surfaces of the column assembly and
clutch assembly, and the column assembly and bracket assembly
during reassembly.
9 Rivet and 8 Self-locking nut
Discard the old rivet and self-locking nut and replace with new
ones.
6 Yoke bolt
Install steering gear box to yoke while aligning the alignment mark
scribed during disassembly.
: 51 - 61 N·m {5.2 - 6.2 kgf·m, 38 - 45 ft·lbf}
ST-3-6
STEERING LINKAGE ST LINKAGE
STEERING LINKAGE
DISASSEMBLY
REMOVAL
Model MK and LK series (without LKD210)
ST-4-1
STEERING LINKAGE ST LINKAGE
ST-4-2
STEERING LINKAGE ST LINKAGE
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
DUST COVER
Clean foreign matter off the ball joint and check the following:
1. Dust cover for grease leaks. Replace the dust cover if nec-
essary.
2. Depress the dust cover to ensure that grease does not
come out at any point. If it does, replace the dust cover.
3. Ensure that the dust cover is not lower than the arm. If it is,
replace the dust cover.
ST-4-3
STEERING LINKAGE ST LINKAGE
4. Check the dust lip for wear. If worn, replace the dust cover
with a new one.
ST-4-4
STEERING LINKAGE ST LINKAGE
2. Socket inspection
Check the contact surface of the socket at the dust cover for indica-
tions of rust formation.
NOTE
z Remove rust from the socket using sandpaper.
NOTE
z Apply grease to dust and sealing lips of the dust cover.
z Ensure that the press-fit portion of the dust cover is
clean and free of grease.
z Fill with grease, being careful not to allow air to enter
grease.
z Do not allow grease to come in contact with the dust
cover exterior.
ST-4-5
STEERING LINKAGE ST LINKAGE
PAINTING
NOTE
z Do not paint the dust cover. If the frame at the rubber part
is painted, mask the dust cover in advance. Remove
paint if it comes in contact with the cover.
REASSEMBLY
INSTALLATION
Key point of installation
2 Pitman arm
1. Fill the dust cover with grease and install it onto the sector
shaft (if the dust cover was removed except models MK and
LK series without LKD models).
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.
ST-4-6
STEERING LINKAGE ST LINKAGE
2. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.
: Models MK and LK series (without LKD)
343 - 392 N·m {35 - 40 kgf·m, 253 - 289 ft·lbf}
Models LKD, PK, CDA and CWA series
441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}
1 Drag link
Install the drag link so that the identification mark “FR” is on the pit-
man arm side.
NOTE
z When inserting the cotter pin on the pitman arm side,
insert from above and bend it securely.
: Models MK and LK series (without LKD)
167 - 226 N·m {17 - 23 kgf·m, 123 - 166 ft·lbf}
Models LKD and PKB series
196 - 255 N·m {20 - 26 kgf·m, 145 - 188 ft·lbf}
Models PKC, PKF, CDA and CWA series
216 - 343 N·m {22 - 35 kgf·m, 159 - 253 ft·lbf}
ST-4-7
BRAKE SYSTEM
BRAKE PROPER
BRAKE UNIT: VACUUM (VAC) SERVO BRAKE UNIT
BRAKE UNIT: AIR OVER HYDRAULIC (AOH) BRAKE UNIT
BRAKE UNIT: AIR BRAKE UNIT
PARKING BRAKE
BR
BRAKE PROPER
CONTENTS
SERVICE DATA ..................................... BR-1- 1 CONSTRUCTION ..................................... BR-5- 1
SPECIFICATIONS .................................... BR-1- 1 DISASSEMBLY ......................................... BR-5- 2
SERVICE DATA ........................................ BR-1- 5 REASSEMBLY .......................................... BR-5- 5
TIGHTENING TORQUE ............................ BR-1- 9 REAR BRAKE
TOOLS ................................................... BR-2- 1 (UNIT NAME RB37, BLT40) ................... BR-5- 7
CONSTRUCTION ..................................... BR-5- 7
= BRAKE PROPER (UNIT NAME DISASSEMBLY ......................................... BR-5- 9
BHS32, BLT32, RB50) = REASSEMBLY ......................................... BR-5-14
INSPECTION ......................................... BR-5-18
FRONT BRAKE (UNIT NAME BHS32) .. BR-3- 1 REPAIR AND REPLACEMENT ............. BR-5-21
CONSTRUCTION ...................................... BR-3- 1 ADJUSTMENT ....................................... BR-5-22
DISASSEMBLY ......................................... BR-3- 3
REASSEMBLY .......................................... BR-3- 7 = BRAKE PROPER (UNIT NAME
REAR BRAKE BHL41, BLL41) =
(UNIT NAME BLT32, RB50) .................. BR-3- 9
CONSTRUCTION ...................................... BR-3- 9 FRONT BRAKE (UNIT NAME BHL41) .. BR-6- 1
DISASSEMBLY ........................................ BR-3-12 CONSTRUCTION ..................................... BR-6- 1
REASSEMBLY ......................................... BR-3-20 DISASSEMBLY ......................................... BR-6- 3
INSPECTION ......................................... BR-3-24 REASSEMBLY .......................................... BR-6- 7
REPAIR AND REPLACEMENT ............ BR-3-27 REAR BRAKE (UNIT NAME BLL41) ..... BR-6- 9
ADJUSTMENT ...................................... BR-3-28 CONSTRUCTION ..................................... BR-6- 9
DISASSEMBLY ........................................ BR-6-11
= BRAKE PROPER (UNIT NAME REASSEMBLY ......................................... BR-6-15
FB52, RB52, BHS37, BLT37) = INSPECTION ......................................... BR-6-17
REPAIR AND REPLACEMENT ............. BR-6-20
FRONT BRAKE ADJUSTMENT ....................................... BR-6-21
(UNIT NAME FB52, BHS37) .................. BR-4- 1
CONSTRUCTION ..................................... BR-4- 1 = BRAKE PROPER (UNIT NAME
DISASSEMBLY ......................................... BR-4- 3 BAL41, RB41, BPL41) =
REASSEMBLY .......................................... BR-4- 7
REAR BRAKE FRONT BRAKE (UNIT NAME BAL41) .. BR-7- 1
(UNIT NAME RB52, BLT37) .................. BR-4- 9 CONSTRUCTION ..................................... BR-7- 1
CONSTRUCTION ..................................... BR-4- 9 DISASSEMBLY ......................................... BR-7- 2
DISASSEMBLY ........................................ BR-4-12 REASSEMBLY .......................................... BR-7- 4
REASSEMBLY ......................................... BR-4-19 REAR BRAKE
INSTALLATION .......................................... BR-4-21 (UNIT NAME RB41, BPL41) .................. BR-7- 6
INSPECTION ......................................... BR-4-23 CONSTRUCTION ..................................... BR-7- 6
REPAIR AND REPLACEMENT ............ BR-4-25 DISASSEMBLY ......................................... BR-7- 8
ADJUSTMENT ...................................... BR-4-26 REASSEMBLY ......................................... BR-7-11
INSPECTION ......................................... BR-7-14
= BRAKE PROPER (UNIT NAME REPAIR AND REPLACEMENT ............. BR-7-19
FB37, RB37, BHS40, BLT40) = ADJUSTMENT ....................................... BR-7-22
FRONT BRAKE
(UNIT NAME FB37, BHS40) .................. BR-5- 1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
FRONT WHEEL BRAKE
Unit name *BHS32 *FB52 *BHS37 *FB37 *BHS40
Vacuum
Brake system servo brake Air-over hydraulic brake system
system
Brake shoe type Two-leading shoe type
Brake drum I.D. mm (in) 320 (12.60) 370 (14.57) 400 (15.75)
Width 95 (3.74) 110 (4.33) 100 (3.94) 120 (4.72)
Brake lining mm (in)
Thickness 12.0 (0.472) 12.9 (0.508) 15.0 (0.591)
Wheel cylinder type Hydraulic piston type
Wheel cylinder I.D. mm (in) 34.93 (1.3752) 36.51 (1.4374) 38.10 (1.5000)
NOTE
z Unit names marked with * are those which require type classification because there are differ-
ent types with the same unit name. For details, refer to the “BRAKE TYPE (BR-1-4)”.
BR-1-1
SERVICE DATA
NOTE
z Unit names marked with * are those which require type classification because there are differ-
ent types with the same unit name. For details, refer to the “BRAKE TYPE (BR-1-4)”.
BR-1-2
SERVICE DATA
UNIT NAME
FB 5 2
B H S 32
BR-1-3
SERVICE DATA
BRAKE TYPE
z For unit names BHS32 to BLT40, type classification in the text is based on the table below.
Front wheel brake and rear wheel brake are two different types. Be careful not to confuse them.
Front wheel brake
Item Anti-lock Brake System (ABS) Brake lining clearance adjusting system
Unit name Without With Manual-adjuster Auto-adjuster
Type I O — O —
BHS32 Type II O — — O
Type III — O — O
FB52 Type I O — O —
Type II O — — O
BHS37
Type III — O — O
FB37 Type I O — O —
BHS40 Type I O — O —
BR-1-4
SERVICE DATA
SERVICE DATA
UNIT NAME BHS32, BLT32, RB50, FB52, RB52, BHS37,
BLT37, FB37, RB37, BHS40, BLT40
Unit: mm (in)
Application
Maintenance B B R F R B B F R B B
Item Service limit Remarks H L B B B H L B B H L
standard
S T 50 52 52 S T 37 37 S T
32 32 37 37 40 40
320 (12.60) 322 (12.68) O O O — — — — — — — —
I.D. 370 (14.57) 372 (14.65) — — — O O O O — — — —
400 (15.75) 403 (15.87) — — — — — — — O O O O
Brake
drum Less than 0.08 Difference between max. and O O O — — — — — — — —
0.20 (0.0079)
Out-of- (0.0031) min. drum diameters
roundness 0.04 - 0.05 — — — O O O O O O O O
0.20 (0.0079)
(0.0016 - 0.0020)
BR-1-5
SERVICE DATA
Unit: mm (in)
Application
Maintenance B B R F R B B F R B B
Item Service limit Remarks H L B B B H L B B H L
standard
S T 50 52 52 S T 37 37 S T
32 32 37 37 40 40
Wheel cylinder I.D. — O O — — — — — — — —
36.51 mm (1.4374
36.4 - 37.0 More than in) [Type II (With
(1.433 - 1.457) 0.65 (0.0256) wedge wheel cylin-
der), Type III and
Type IV only]
Wheel cylinder I.D. — — — O — O — — — — —
Wheel Wheel cylinder piston 38.4 - 38.8 More than
36.51 mm (1.4374
cylinder cup O.D. (1.512 - 1.528) 0.65 (0.0256)
in)
Wheel cylinder I.D. — — — — O — O O — O —
39.75 - 40.25 More than
38.10 mm (1.5000
(1.5650 - 1.5846) 0.65 (0.0256)
in)
Wheel cylinder I.D. — — — — — — — — O — O
44.6 - 45.2 More than
42.86 mm (1.6874
(1.756 - 1.780) 0.65 (0.0256)
in)
Free length 180.5 (7.11) — O — — — — — — — — — —
Measure tension
291 - 356
291 when spring is set
Tension N {kgf, lbf} {29.7 - 36.3,
{29.7, 65} at 192.0 mm (7.56
65 - 80}
in) in length
Free length 208.0 (8.19) — — O O — — — — — — — —
Type I Measure tension
353 - 432
Type II Tension 353 when spring is set
{36.0 - 44.0,
N {kgf, lbf} {36.0, 79} at 217.0 mm (8.54
79 - 97}
in) in length
Free
95.5 (3.760) —
length
Small
Measure tension
402 - 470
Tension 402 when spring is set
{41.0 - 47.9,
Type N {kgf, lbf} {41.0, 90.4} at 103.0 mm (4.06
90.4 - 105.6}
III in) in length
Type Free
Brake IV 88.0 (3.465) —
length
shoe
Large
BR-1-6
SERVICE DATA
BR-1-7
SERVICE DATA
Unit: mm (in)
Application
Maintenance B B B R B
Item Service limit Remarks H L A B P
standard
L L L 41 L
41 41 41 41
40.0 (1.575) 39.7 (1.563) — — O — O
Camshaft O.D.
44.0 (1.732) 43.7 (1.720) — — — O —
0.05 - 0.12 — — O — O
Cam- (0.0020 - 0.60 (0.0236)
shaft 0.0047)
Clearance between camshaft
bushing and camshaft 0.37 - 0.44 — — — O —
(0.0146 - 0.60 (0.0236)
0.0173)
Free length 195.9 (7.71) — O — — — —
549 - 637
Measure tension when spring is
Tension N {kgf, lbf} {56.0 - 65.0, —
set at 219.0 mm (8.62 in) in length
123 - 143}
Free length 192.0 (7.56) — — O — — —
Outer 462.4 - 527.1
Tension Measure tension when spring is
{47.15 - 53.75, —
N {kgf, lbf} set at 219.0 mm (8.62 in) in length
104.0 - 118.5}
Free length 243.9 (9.60) —
Inner 178.9 - 208.3 Measure tension when spring is
Tension
{18.24 - 21.24, — set at 257.7 mm (10.15 in) in
N {kgf, lbf}
40.2 - 46.8} length
Free length 195.9 (7.71) — — — O — —
*1 549 - 637
Brake Tension Measure tension when spring is
{56.0 - 65.0, —
shoe N {kgf, lbf} set at 219.0 mm (8.62 in) in length
123 - 143}
return
spring Free length 194.3 (7.65) —
*2 544 - 642
Tension Measure tension when spring is
{55.5 - 65.5, —
N {kgf, lbf} set at 219.0 mm (8.62 in) in length
122 - 144}
Free length 229.8 (9.05) — — — — O —
783.6 Measure tension when spring is
Tension N {kgf, lbf} —
{79.9, 176.2} set at 250.0 mm (9.84 in) in length
Free length 195.9 (7.71) — — — — — O
Outer 549 - 637
Tension Measure tension when spring is
{56.0 - 65.0, —
N {kgf, lbf} set at 219.0 mm (8.62 in) in length
123 - 143}
Free length 242.6 (9.55) —
Inner 198 - 233
Tension Measure tension when spring is
{20.2 - 23.8, —
N {kgf, lbf} set at 252.5 mm (9.94 in) in length
45 - 52}
30 (1.18) 45 (1.77) — — O — O
Brake chamber push rod stroke
24 (0.94) 40 (1.57) — — — O —
BR-1-8
SERVICE DATA
NOTE
z *1 and *2 indicate respectively the inboard type and out-
board type installation methods of the brake drum.
TIGHTENING TORQUE
UNIT NAME BHS32, BLT32, FB52, RB52, BHS37, BLT37, FB37, RB37, BHS40, BLT40
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
BHS32, BLT32, RB50 127 - 147 {13.0 - 15.0, 94 - 108}
FB52, RB52, BHS37, BLT37 147 - 167 {15.0 - 17.0, 108 - 123}
Back plate mounting bolt FB37 (Front axle model: FB40) Castellated nut 275 - 343 {28.0 - 35.0, 203 - 253}
or nut Castellated nut 490 - 588 {50.0 - 60.0, 362 - 434}
BHS40 (Front axle model: FA50)
Bolt 216 - 294 {22.0 - 30.0, 159 - 217}
RB37, BLT40 216 - 284 {22.0 - 29.0, 159 - 210}
7T M10 x 1.5 35 - 53 {3.6 - 5.4, 26 - 39}
BHS32
7T M12 x 1.75 63 - 94 {6.4 - 9.6, 46 - 69}
Type I 7T M12 x 1.75 63 - 94 {6.4 - 9.6, 46 - 69}
BLT32 Type II Without wedge side 7T M12 x 1.75 63 - 94 {6.4 - 9.6, 46 - 69}
Type III
Type IV With wedge side 7T M10 x 1.5 35 - 53 {3.6 - 5.4, 26 - 39}
RB50 7T M10 x 1.5 35 - 53 {3.6 - 5.4, 26 - 39}
7T M10 x 1.25 37 - 49 {3.8 - 5.0, 27 - 36}
FB52, BHS37
7T M14 x 1.5 98 - 132 {10.0 - 13.5, 72 - 98}
7T M12 x 1.25 63 - 84 {6.4 - 8.6, 46 - 62}
Type I
Wheel cylinder mounting RB52 7T M14 x 1.5 98 - 132 {10.0 - 13.5, 72 - 98}
bolt
Type II 7T M12 x 1.25 63 - 84 {6.4 - 8.6, 46 - 62}
Without wedge side
9T M14 x 1.5 123 - 167 {12.5 - 17.0, 90 - 123}
Type III
BLT37 10T M12 x 1.25 103 - 137 {10.5 - 14.0, 76 - 101}
Type IV With wedge side
10T M14 x 1.5 157 - 216 {16.0 - 22.0, 116 - 159}
7T M10 x 1.25 37 - 49 {3.8 - 5.0, 27 - 36}
FB37, BHS40
9T M14 x 1.5 123 - 167 {12.5 - 17.0, 90 - 123}
Type I 9T M14 x 1.5 123 - 167 {12.5 - 17.0, 90 - 123}
RB37, Without wedge side 9T M14 x 1.5 123 - 167 {12.5 - 17.0, 90 - 123}
BLT40 Type II 9T M12 x 1.25 79 - 108 {8.1 - 11.0, 59 - 80}
With wedge side
9T M16 x 1.5 186 - 255 {19.0 - 26.0, 137 - 188}
BR-1-9
SERVICE DATA
BR-1-10
SERVICE DATA
BR-1-11
TOOLS
TOOLS
Application
Part name and B B R F R B B F R B B B B B R B
Description Shape H L B B B H L B B H L H L A B P
number
S T 50 52 52 S T 37 37 S T L L L 41 L
32 32 37 37 40 40 41 41 41 41
Return spring tool Used to
99867 Z0000 remove/install
return spring
NOTE
z For unit
names * *
marked with O O O O O O O O O O O O O O O O
* on the
Application
column,
this tool is
used only
on the outer
side.
Return spring tool Used to
assembly remove/install
99867 Z0001 return spring
1 99868 Z0000 (inner side)
2 99868 Z0001 1 Handle
2 Hanger
— — — — — — — — — — — — O — — —
BR-2-1
TOOLS
Application
Part name and B B R F R B B F R B B B B B R B
Description Shape H L B B B H L B B H L H L A B P
number
S T 50 52 52 S T 37 37 S T L L L 41 L
32 32 37 37 40 40 41 41 41 41
Piston cup guide Use as a
*1 99866 Z0006 guide when
*2 99866 Z0008 installing the
piston cup
into the wheel
cylinder
Cup guide *1 *2
— — — — — — — — — — — — — —
inside diame- O O
ter (D):
*1 50.8 mm
(2.000 in)
*2 55.56 mm
(2.1874 in)
BR-2-2
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
BR-3-1
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
BR-3-2
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels.
(Refer to the “FRONT AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-3-3
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II and Type III
BR-3-4
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
<WHEEL CYLINDER>
Manual adjuster type
BR-3-5
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
BR-3-6
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
REASSEMBLY
REASSEMBLY
<WHEEL BRAKE>
Key point of reassembly
11 Wheel cylinder assembly
Since the shape of the cylinder body of the wheel cylinder compris-
ing the front brake is different, the mounting position is indicated on
the back plate mounting surface of the wheel cylinder. When reas-
sembling and remounting the wheel cylinder, confirm the mounting
position to ensure that it is correct.
Symbol Mounting position
RF or R Front of right front wheel
RR or R Rear of right front wheel
LF or L Front of left front wheel
RF or L Rear of left front wheel
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “FRONT AXLE” section for procedures.)
BR-3-7
FRONT BRAKE (UNIT NAME BHS32) BHS32, BLT32, RB50
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
5. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
BR-3-8
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-9
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
Type II
BR-3-10
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-11
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
DISASSEMBLY
REMOVAL
1. Chock the rear road wheel at the front and rear.
2. Remove the rear road wheel.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-3-12
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
DISASSEMBLY
<WHEEL BRAKE>
Type I and Type II
BR-3-13
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-14
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-15
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
<WHEEL CYLINDER>
Manual adjuster type (Without wedge)
BR-3-16
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-17
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-18
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-19
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
15 Manual adjuster type
11 Auto adjuster type }Tappet (With wedge only)
When installing the tappet on the wheel cylinder body, align the
alignment marks of the tappet and body.
<WHEEL BRAKE>
Key point of reassembly
12 Type I and Type II
}
12 Type III and Type IV Wheel cylinder
Without wedge
Since the shape of the cylinder body of the wheel cylinder compris-
ing the front brake is different, the mounting position is indicated on
the back plate mounting surface of the wheel cylinder. When reas-
sembling and remounting the wheel cylinder, confirm the mounting
position to ensure that it is correct.
Symbol Mounting position
RF or R Front of right rear wheel
RR or R Rear of right rear wheel
LF or L Front of left rear wheel
LR or L Rear of left rear wheel
With wedge
The wheel cylinder which is equipped with a wheel parking brake is
used at the rear of the rear brake. A “LH” or “RH” mark is indicated,
as shown in the table below, on the cylinder body for identification.
Do not confuse one cylinder with the other.
Symbol Mounting position
RH Right hand of rear wheel
LH Left hand of rear wheel
BR-3-20
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
BR-3-21
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “REAR AXLE” section for procedures.)
NOTE
z When adjusting the rod length, lightly pull the wedge in
the spring chamber (actuator) direction by hand to elimi-
nate the free play of the rod.
z Tighten the lock nut.
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
BR-3-22
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
4. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
5. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
6. Install the rear roadwheel.
(Refer to the “REAR AXLE” section for procedures.)
BR-3-23
INSPECTION BHS32, BLT32, RB50
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BHS32
320 (12.60) 322 (12.68)
BLT32
Out-of-roundness
To check, measure the inside diameter of the drum at four places. If
the difference between the maximum and minimum values exceeds
the service limit, machine the inner surface of the drum to correct.
Unit: mm (in)
Unit name Maintenance standard Service limit
BHS32
Less than 0.08 (0.0031) 0.20 (0.0079)
BLT32
BRAKE LINING
Wheel brake assembly outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BHS32
319.0 - 320.0 (12.55 - 12.60) —
BLT32
BR-3-24
INSPECTION BHS32, BLT32, RB50
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
BHS32
0.030 - 0.090 (0.0012 - 0.0035) 0.15 (0.0059)
BLT32
*1 Type I only
*2 Type II and Type III only
*3 Type I and Type II (Without wedge wheel cylinder) only
*4 Type II (With wedge wheel cylinder), Type III and Type IV only
*5 Difference between O.D. of piston cup and I.D. wheel cylinder
BR-3-25
INSPECTION BHS32, BLT32, RB50
Tension
Unit: N {kgf, lbf}
Maintenance Service
Unit name Remarks
standard limit
Measure tension
291 - 356
291 when spring is set
BHS32 {29.7 - 36.3,
{29.7, 65} at 192.0 mm (7.56
65 - 80}
in) in length
Measure tension
353 - 432
Type I 353 when spring is set
{36.0 - 44.0,
Type II {36.0, 79} at 217.0 mm (8.54
79 - 97}
in) in length
Measure tension
402 - 470 402
when spring is set
BLT32 Small {41.0 - 47.9, {41.0,
at 103.0 mm (4.06
90.4 - 105.6} 90.4}
Type III in) in length
Type VI Measure tension
441 - 539 441
when spring is set
Large {45.0 - 55.0, {45.0,
at 106.0 mm (4.17
99.2 - 121.3} 99.2}
in) in length
BR-3-26
REPAIR AND REPLACEMENT BHS32, BLT32, RB50
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-3-27
ADJUSTMENT BHS32, BLT32, RB50
ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
Manual adjuster type
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the rubber plug from the adjusting hole, and turn
the adjuster in the direction of arrow marked on the backing
plate by using a screwdriver until the lining lightly contacts
the drum.
NOTE
z Be sure to adjust at the two adjusting holes.
3. With the lining in contact with the drum, depress the brake
pedal several times. Recheck that the lining contacts the
drum properly.
4. Back off the adjuster 4 to 5 notches.
BR-3-28
ADJUSTMENT BHS32, BLT32, RB50
BR-3-29
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
BR-4-1
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
BR-4-2
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels.
(Refer to the “FRONT AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-4-3
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II and Type III
BR-4-4
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
<WHEEL CYLINDER>
Manual adjuster type
BR-4-5
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
BR-4-6
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
7 Manual adjuster type
12 Auto adjuster type } Back-up ring
Install the back-up ring so that the sides without inside diameter
chamfer are on the side of the piston cup.
<WHEEL BRAKE>
Key point of reassembly
5 Brake shoe assembly
After installing the brake shoe assembly, attach the band or ring
[370 mm (14.57 in) in inside diameter] to the edge of the brake lin-
ing.
BR-4-7
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “FRONT AXLE” section for procedures.)
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
5. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
BR-4-8
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-9
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
Type II
BR-4-10
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-11
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the rear road wheels.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-4-12
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II, Type III and Type IV
BR-4-13
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-14
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
<WHEEL CYLINDER>
Manual adjuster type (Without wedge)
BR-4-15
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-16
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-17
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
BR-4-18
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
13 Manual adjuster type
19 Auto adjuster type } Wedge cover (With wedge only)
Pour rubber grease up to the shaded part shown in the figure, and
install the wedge cover.
: 2.4 - 3.5 N·m {0.24 - 0.36 kgf·m, 1.7 - 2.6 ft·lbf}
NOTE
z Apply a coat of liquid packing (Three Bond 1104 or equiv-
alent) to the mating surface of the cover and body.
}
6 11 Manual adjuster type (Without wedge)
7 21 Manual adjuster type (With wedge)
Back-up ring
12 16 Auto adjuster type (Without wedge)
12 27 Auto adjuster type (With wedge)
Install the back-up ring so that the sides without inside diameter
chamfer are on the side of the piston cup.
BR-4-19
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
<WHEEL BRAKE>
Key point of reassembly
6 Brake shoe assembly
After installing the brake shoe assembly, attach the band or ring
[370 mm (14.57 in) in inside diameter] to the edge of the brake lin-
ing.
BR-4-20
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “REAR AXLE” section for procedures.)
BR-4-21
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
NOTE
z Face the drain hole of the spring chamber (actuator)
downward and align with clamps.
: 88 - 108 N·m {9.0 - 11.0 kgf·m, 65 - 80 ft·lbf}
z Connect the spring chamber (actuator) and lever with a pin
and secure with a cotter pin.
z Supply air 736 kPa {7.5 kgf/cm2, 107 psi} to the spring
chamber (actuator).
z Connect the rod assembly and lever with a pin and secure
with a cotter pin.
z Screw the spring chamber (actuator) side of the rod assem-
bly into the wheel cylinder clevis, and secure the bracket
side to the lever using a pin and cotter pin.
z Loosen the lock nut.
NOTE
z When adjusting the rod length, lightly pull the wedge in
the spring chamber (actuator) direction by hand to elimi-
nate the free play of the rod.
z Tighten the lock nut.
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
z After assembling the brake system, operate the brake sev-
eral times to make sure there is no interference between
parts.
4. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
BR-4-22
INSPECTION FB52, RB52, BHS37, BLT37
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB52, BHS37
370 (14.57) 372 (14.65)
RB52, BLT37
Out-of-roundness
To check, measure the inside diameter of the drum at four places. If
the difference between the maximum and minimum values exceeds
the service limit, machine the inner surface of the drum to correct.
Unit: mm (in)
Unit name Maintenance standard Service limit
FB52, BHS37 0.04 - 0.05
0.20 (0.0079)
RB52, BLT37 (0.0016 - 0.0020)
BRAKE LINING
Wheel brake assembly outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB52, BHS37 369.3 - 369.6
—
RB52, BLT37 (14.54 - 14.55)
BR-4-23
INSPECTION FB52, RB52, BHS37, BLT37
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
FB52, BHS37 0.025 - 0.126
0.20 (0.0079)
RB52, BLT37 (0.0010 - 0.0050)
Tension
Unit: N {kgf, lbf}
Maintenance
Unit name Service limit Remarks
standard
353 - 432 Measure tension when
353
FB52, BHS37 {36.0 - 44.0, spring is set at 224.5 mm
{36.0, 79}
79 - 97} (8.84 in) in length
344.2 - 420.7 Measure tension when
344.2
RB52, BLT37 {35.1 - 42.9, spring is set at 228.4 mm
{35.1, 77.4}
77.4 - 94.6} (8.99 in) in length
BR-4-24
REPAIR AND REPLACEMENT FB52, RB52, BHS37, BLT37
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-4-25
ADJUSTMENT FB52, RB52, BHS37, BLT37
ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
Manual adjuster type
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the rubber plug from the adjusting hole, and turn
the adjuster in the direction of arrow marked on the backing
plate by using a screwdriver until the lining lightly contacts
the drum.
NOTE
z Be sure to adjust at the two adjusting holes.
3. With the lining in contact with the drum, depress the brake
pedal several times. Recheck that the lining contacts the
drum properly.
4. Back off the adjuster 4 to 5 notches.
BR-4-27
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
BR-5-1
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
DISASSEMBLY
REMOVAL
1. Chock the rear road wheel at the front and rear.
2. Remove the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-5-2
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
DISASSEMBLY
<WHEEL BRAKE>
BR-5-3
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
<WHEEL CYLINDER>
BR-5-4
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
7 Back-up ring
Install the back-up ring so that the sides without inside diameter
chamfer are on the side of the piston cup.
<WHEEL BRAKE>
Key point of reassembly
5 Brake shoe assembly
After installing the brake shoe assembly, attach the band or
ring [400 mm (15.75 in) in inside diameter] to the edge of the
brake lining.
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “FRONT AXLE” section for procedures.)
BR-5-5
FRONT BRAKE (UNIT NAME FB37, BHS40) FB37, RB37, BHS40, BLT40
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
5. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
BR-5-6
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
BR-5-7
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
Type II
BR-5-8
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
DISASSEMBLY
REMOVAL
1. Chock the rear road wheel at the front and rear.
2. Remove the rear road wheel.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the rear axle housing
side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
BR-5-9
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
DISASSEMBLY
<WHEEL BRAKE>
Type I and Type II
BR-5-10
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
BR-5-11
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
<WHEEL CYLINDER>
Without wedge
BR-5-12
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
With wedge
BR-5-13
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
13 Wedge cover (With wedge only)
Pour rubber grease up to the shaded part shown in the figure, and
install the wedge cover.
: 2.4 - 3.5 N·m {0.24 - 0.36 kgf·m, 1.7 - 2.6 ft·lbf}
NOTE
z Apply a coat of liquid packing (Three Bond 1104 or equiv-
alent) to the mating surface of the cover and body.
6 11 Without wedge
7 21 With wedge } Back-up ring
Install the back-up ring so that the sides without inside diame-
ter chamfer are on the side of the piston cup.
<WHEEL BRAKE>
Key point of reassembly
6 Brake shoe assembly
After installing the brake shoe assembly, attach the band or
ring [400 mm (15.75 in) in inside diameter] to the edge of the
brake lining.
BR-5-14
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the pre-load.
(Refer to the “REAR AXLE” section for procedures.)
BR-5-15
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
BR-5-16
REAR BRAKE (UNIT NAME RB37, BLT40) FB37, RB37, BHS40, BLT40
NOTE
z When adjusting the rod length, lightly pull the wedge in
the spring chamber (actuator) direction by hand to elimi-
nate the free play of the rod.
z Tighten the lock nut.
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
z After assembling the brake system, operate the brake sev-
eral times to make sure there is no interference between
parts.
4. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
5. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
6. Install the rear road wheel.
(Refer to the “REAR AXLE” section for procedures.)
BR-5-17
INSPECTION FB37, RB37, BHS40, BLT40
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB37, BHS40
400 (15.75) 403 (15.87)
RB37, BLT40
Out-of-roundness
To check, measure the inside diameter of the drum at four places. If
the difference between the maximum and minimum values exceeds
the service limit, machine the inner surface of the drum to correct.
Unit: mm (in)
Unit name Maintenance standard Service limit
FB37, BHS40 0.04 - 0.05
0.20 (0.0079)
RB37, BLT40 (0.0016 - 0.0020)
BRAKE LINING
Wheel brake assembly outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB37, BHS40 399.3 - 399.6
—
RB37, BLT40 (15.72 - 15.73)
BR-5-18
INSPECTION FB37, RB37, BHS40, BLT40
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
FB37, BHS40 0.025 - 0.126
0.20 (0.0079)
RB37, BLT40 (0.0010 - 0.0050)
BR-5-19
INSPECTION FB37, RB37, BHS40, BLT40
Tension
Unit: N {kgf, lbf}
Maintenance
Unit name Service limit Remarks
standard
344.2 - 420.7 Measure tension when
344.2
FB37, BHS40 {35.1 - 42.9, spring is set at 228.4 mm
{35.1, 77.4}
77.4 - 94.6} (8.99 in) in length
423.7 - 517.8 Measure tension when
423.7
RB37, BLT40 {43.2 - 52.8, spring is set at 266.5 mm
{43.2, 95.3}
95.3 - 116.4} (10.49 in) in length
BR-5-20
REPAIR AND REPLACEMENT FB37, RB37, BHS40, BLT40
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-5-21
ADJUSTMENT FB37, RB37, BHS40, BLT40
ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the rubber plug from the adjusting hole, and turn
the adjuster in the direction of arrow marked on the backing
plate by using a screwdriver until the lining lightly contacts
the drum.
NOTE
z Be sure to check at the two adjustment holes.
3. With the lining contacting the drum, depress the brake
pedal several times. Then check that the lining contacts the
drum properly.
4. Back off the adjuster 8 to 10 notches.
BR-5-22
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
BR-6-1
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
<WHEEL CYLINDER>
BR-6-2
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels.
(Refer to the “FRONT AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
BR-6-3
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
DISASSEMBLY
<WHEEL BRAKE>
BR-6-4
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
BR-6-5
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
<WHEEL CYLINDER>
BR-6-6
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
5 Piston cup
Install the piston cup to the piston using piston cup guide (99866
Z0006).
4 Back-up ring
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.
<WHEEL BRAKE>
Key point of reassembly
17 Adjuster cam assembly
Apply bearing grease sparingly when installing.
BR-6-7
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
2 Lock washer
After tightening the bolt to specifications, bend the lock washer
sharply against the flat bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgf·m, 15 - 25 ft·lbf}
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “FRONT AXLE” section for procedures.)
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
5. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
BR-6-8
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
BR-6-9
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
<WHEEL CYLINDER>
BR-6-10
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the rear road wheels.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
BR-6-11
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
DISASSEMBLY
<WHEEL BRAKE>
BR-6-12
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
BR-6-13
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
<WHEEL CYLINDER>
BR-6-14
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
5 Piston cup
Install the piston cup to the piston using piston cup guide (99866
Z0008).
4 Back-up ring
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.
<WHEEL BRAKE>
Key point of reassembly
21 Adjuster cam assembly
Apply bearing grease sparingly when installing.
BR-6-15
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
5 Lock washer
After tightening the bolt to specifications, bend the lock plate
sharply against the flat bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgf·m, 15 - 25 ft·lbf}
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “REAR AXLE” section for procedures.)
3. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.)
5. Install the rear road wheel.
(Refer to the “REAR AXLE” section for procedures.)
BR-6-16
INSPECTION BHL41, BLL41
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BHL41
410 (16.14) 414 (16.30)
BLL41
Out-of-roundness
To check, measure the inside diameter of the drum at four places. If
the difference between the maximum and minimum values exceeds
the service limit, machine the inner surface of the drum to correct.
Unit: mm (in)
Unit name Maintenance standard Service limit
BHL41 Less than
0.20 (0.0079)
BLL41 0.025 (0.0010)
BRAKE LINING
Brake lining thickness
Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
BHL41
16.0 (0.630) 5.0 (0.197) Remaining thickness (H)
BLL41
BR-6-17
INSPECTION BHL41, BLL41
BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BHL41
30.0 (1.181) 29.85 (1.1752)
BLL41
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
0.120 - 0.234
BHL41
(0.0047 - 0.0092)
0.25 (0.0098)
0.128 - 0.248
BLL41
(0.0050 - 0.0098)
BR-6-18
INSPECTION BHL41, BLL41
Tension
Unit: N {kgf, lbf}
Maintenance
Unit name Service limit Remarks
standard
549 - 637 Measure tension when
BHL41 {56.0 - 65.0, — spring is set at 219.0
123 - 143} mm (8.62 in) in length
462.4 - 527.1 Measure tension when
Outer {47.15 - 53.75, — spring is set at 219.0
104.0 - 118.5} mm (8.62 in) in length
BLL41
178.9 - 208.3 Measure tension when
Inner {18.24 - 21.24, — spring is set at 257.7
40.2 - 46.8} mm (10.15 in) in length
BR-6-19
REPAIR AND REPLACEMENT BHL41, BLL41
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-6-20
REPAIR AND REPLACEMENT BHL41, BLL41
ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the back plate grommet, and insert a 0.3 to 0.4 mm
(0.012 to 0.016 in) feeler gauge.
3. Rotate the adjuster cam from the “START” position in the
direction of the arrow, until resistance is felt when pulling
out the feeler gauge.
Unit: mm (in)
Unit name Maintenance standard Service limit
BHL41 0.3 - 0.4
—
BLL41 (0.012 - 0.016)
NOTE
z Rotate the drum to check the clearance all around the
brake drum, and make adjustments where the clearance
is the smallest.
BR-6-21
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
BR-7-1
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels.
(Refer to the “FRONT AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
BR-7-2
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
DISASSEMBLY
BR-7-3
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
REASSEMBLY
REASSEMBLY
Key point of reassembly
20 Brake chamber assembly
Before installing the brake chamber assembly, make sure dimen-
sion “L” is 225 mm (8.86 in).
: 81 - 108 N·m {8.3 - 11.0 kgf·m, 60 - 80 ft·lbf}
(Chamber size #20)
167 - 186 N·m {17.0 - 19.0 kgf·m, 123 - 137 ft·lbf}
(Chamber size #24)
12 Wear indicator
Install the wear indicator by aligning it with the arrow mark on the
camshaft.
7 Roller pin
Pay attention to the direction of the roller pin during installation.
After installation, check the roller for smooth rotation.
NOTE
z Do not apply grease to any part of the roller and roller
pin.
BR-7-4
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
2 Lock washer
After tightening the bolt, bend the lock washer sharply against the
bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgf·m, 15 - 25 ft·lbf}
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “FRONT AXLE” section for procedures.)
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)
BR-7-5
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
BR-7-6
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
BR-7-7
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the rear road wheels.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
BR-7-8
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
DISASSEMBLY
BR-7-9
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
BR-7-10
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
REASSEMBLY
REASSEMBLY
Key point of reassembly
18 Unit name RB41
}
23 Unit name BPL41 Brake chamber bracket
After inserting the camshaft, check that the camshaft can be rotated
smoothly, then tighten the brake chamber bracket.
: RB41
127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 ft·lbf}
BPL41
137 - 157 N·m {14.0 - 16.0 kgf·m, 101 - 116 ft·lbf}
BR-7-11
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
BR-7-12
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “REAR AXLE” section for procedures.)
3. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.
4. Install the rear road wheel.
(Refer to the “REAR AXLE” section for procedures.)
BR-7-13
INSPECTION BAL41, RB41, BPL41
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BAL41
410 (16.14) 414 (16.30)
RB41, BPL41
Out-of-roundness
To check, measure the inside diameter of the drum at four places. If
the difference between the maximum and minimum values exceeds
the service limit, machine the inner surface of the drum to correct.
Unit: mm (in)
Unit name Maintenance standard Service limit
BAL41
Less than 0.025 (0.0010) 0.20 (0.0079)
RB41, BPL41
BRAKE LINING
Brake lining thickness
Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
BAL41, BPL41 16.0 (0.630)
5.0 (0.197) Remaining thickness (H)
RB41 15.0 (0.591)
BR-7-14
INSPECTION BAL41, RB41, BPL41
BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BAL41, BPL41 30.0 (1.181) 29.85 (1.1752)
RB41 32.0 (1.260) 31.80 (1.2520)
BR-7-15
INSPECTION BAL41, RB41, BPL41
CAMSHAFT
Camshaft bushing inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
BAL41, BPL41 40.0 (1.575) 40.3 (1.587)
RB41 44.0 (1.732) 44.3 (1.744)
BR-7-16
INSPECTION BAL41, RB41, BPL41
BR-7-17
INSPECTION BAL41, RB41, BPL41
Tension
Unit: N {kgf, lbf}
Maintenance Service
Remarks
standard limit
549 - 637 Inboard type Measure ten-
{56.0 - 65.0, — sion when spring is set at
123 - 143} 219.0 mm (8.62 in) in length
BAL41
544 - 642 Outboard type Measure ten-
{55.5 - 65.5, — sion when spring is set at
122 - 144} 219.0 mm (8.62 in) in length
Measure tension when spring
783.6
RB41 — is set at 250.0 mm (9.84 in) in
{79.9, 176.2}
length
549 - 637 Measure tension when spring
Outer {56.0 - 65.0, — is set at 219.0 mm (8.62 in) in
123 - 143} length
BPL41
198 - 233 Measure tension when spring
Inner {20.2 - 23.8, — is set at 252.5 mm (9.94 in) in
45 - 52} length
BR-7-18
REPAIR AND REPLACEMENT BAL41, RB41, BPL41
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-7-19
REPAIR AND REPLACEMENT BAL41, RB41, BPL41
NOTE
z Do not coat the shoe bushing with grease or oil.
CAMSHAFT BUSHING
<UNIT NAME BAL41>
1. Remove the oil seal from the brake bracket.
2. Drive out the camshaft bushing from the brake bracket.
3. Remove all dirt and foreign matter from the brake bracket
bushing hole.
4. Press-fit the new bushing and oil seal onto the brake
bracket. After press-fitting the bushing, measure the bush-
ing inside diameter. If it is over 40.00 to 40.03 mm (1.5748
to 1.5760 in), ream the bushing so that the inside diameter
is within the standard value.
NOTE
z When press-fitting the rear side bushing, align the bush-
ing hole with the grease hole in the brake bracket.
BR-7-20
REPAIR AND REPLACEMENT BAL41, RB41, BPL41
BR-7-21
ADJUSTMENT BAL41, RB41, BPL41
ADJUSTMENT
ADJUSTING THE BRAKE CHAMBER PUSH ROD
STROKE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Measure the push rod stroke when the brake pedal is
depressed with normal pressure.
Unit: mm (in)
Unit name Maintenance standard Service limit
BAL41, BPL41 30 (1.18) 45 (1.77)
RB41 24 (0.94) 40 (1.57)
BR-7-22
BRAKE UNIT
VACUUM (VAC) SERVO
BRAKE UNIT
CONTENTS
SERVICE DATA .......................................... BR-1- 1 REASSEMBLY .......................................... BR-4- 5
SPECIFICATIONS .................................... BR-1- 1 FUNCTIONAL CHECK ............................. BR-4- 8
SERVICE DATA ........................................ BR-1- 1 SAFETY CYLINDER .................................. BR-5- 1
TIGHTENING TORQUES ......................... BR-1- 2 CONSTRUCTION ..................................... BR-5- 1
DIAGRAM OF AIR PIPING ........................ BR-1- 2 DISASSEMBLY AND REASSEMBLY ....... BR-5- 2
TOOLS .......................................................... BR-2- 1 INSPECTION ............................................ BR-5- 3
MASTER CYLINDER ................................. BR-3- 1 FUNCTIONAL CHECK ............................. BR-5- 3
CONSTRUCTION ..................................... BR-3- 1 LOAD SENSING
DISASSEMBLY AND REASSEMBLY ....... BR-3- 2 PROPORTION VALVE ............................... BR-6- 1
INSPECTION ............................................ BR-3- 4 CONSTRUCTION ..................................... BR-6- 1
ADJUSTMENT .......................................... BR-3- 4 DISASSEMBLY AND REASSEMBLY ....... BR-6- 2
HYDROMASTER ........................................ BR-4- 1 FUNCTIONAL CHECK ............................. BR-6- 3
CONSTRUCTION ..................................... BR-4- 1 BLEEDING AIR FROM
DISASSEMBLY ......................................... BR-4- 2 THE BRAKE SYSTEM ............................... BR-7- 1
INSPECTION ............................................ BR-4- 5
SERVICE DATA BRAKE UNIT (VAC)
SERVICE DATA
SPECIFICATIONS
Unit: mm (in)
Item Contents
Type Piston type
Master cylinder Cylinder I.D. 38.1 (1.500)
Maximum stroke 35 (1.38)
Type Vacuum servo type
Power piston O.D. 241.3 (9.500)
Power piston stroke 163 (6.42)
Hydromaster Hydraulic piston O.D. 19.05 (0.7500)
Hydraulic piston stroke 159 (6.26)
Relay valve O.D. 25.4 (1.000)
Push rod O.D. 10 (0.39)
Type Dual piston type
Safety cylinder Piston O.D. 30 (1.18)
Effective stroke (while driving) 30 (1.18)
Load sensing proportion valve (LSPV) Type Chain type
SERVICE DATA
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
8 - 15
Brake pedal play —
(0.31 - 0.59)
0.5 - 1.0
Master cylinder push rod play —
(0.020 - 0.039)
0.04 - 0.14 0.25
Clearance between cylinder and piston
(0.0016 - 0.0055) (0.0098)
99.0
Master cylinder Free length —
(3.898)
Piston spring
49.0 When compressed to
Tension N {kgf, lbf} —
{5.0, 11.0} 66.5 mm (2.618 in)
Clearance between hydraulic piston and 0.04 - 0.13 0.15
hydraulic cylinder (0.0016 - 0.0051) (0.0059)
Clearance between relay valve piston and 0.05 - 0.11 0.15
Hydromaster
valve fitting (0.0020 - 0.0043) (0.0059)
Less than
Push rod run-out —
0.6 (0.024)
0.17
Clearance between cylinder and piston —
(0.0067)
Safety cylinder
14.7 When compressed to
Spring tension N {kgf, lbf} —
{1.5, 3.3} 43 mm (1.69 in)
BR-1-1
SERVICE DATA BRAKE UNIT (VAC)
TIGHTENING TORQUES
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Pedal bracket mounting bolt 11 - 14 {1.1 - 1.4, 8 - 10}
Pedal bracket
Pedal shaft nut 20 - 23 {2.0 - 2.3, 14 - 17}
Hydraulic cylinder plug 147 - 245 {15 - 25, 108 - 181}
Hydromaster Hydraulic cylinder lock nut 59 - 98 {6 - 10, 43 - 72}
Valve fitting 44 - 64 {4.5 - 6.5, 33 - 47}
Cylinder cap 24 - 26 {2.4 - 2.7, 17 - 20}
Safety cylinder Valve cap 8 - 10 {0.8 - 1.0, 5.8 - 7.2}
Air bleeder valve 13 - 15 {1.3 - 1.5, 9 - 11}
Socket bolt lock nut 13 - 18 {1.3 - 1.8, 9 - 13}
Load sensing proportion valve (LSPV)
Stem plunger lock nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
4.76 (0.1874) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
Tube O.D. 8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut
Steel brake mm (in) 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
tube joints 12.0 (0.472) 59 - 78 {6.0 - 8.0, 43 - 58}
15.0 (0.591) 69 - 93 {7.0 - 9.5, 51 - 69}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}
BR-1-2
TOOLS BRAKE UNIT (VAC)
TOOLS
HYDROMASTER
z Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and number Description Shape
Stand Used to disassemble and assemble
910-10140 the hydromaster
Retaining ring insertion tool Used to install the check valve retain-
910-22010 ing ring
BR-2-1
TOOLS BRAKE UNIT (VAC)
BR-2-2
MASTER CYLINDER BRAKE UNIT (VAC)
MASTER CYLINDER
CONSTRUCTION
BR-3-1
MASTER CYLINDER BRAKE UNIT (VAC)
NOTE
z Numbers before part names do not indicate the disassembly sequence.
BR-3-2
MASTER CYLINDER BRAKE UNIT (VAC)
BR-3-3
MASTER CYLINDER BRAKE UNIT (VAC)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between cylinder and piston
Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.14 (0.0016 - 0.0055) 0.25 (0.0098)
PISTON SPRING
Free length
Unit: mm (in)
Maintenance standard Service limit
99.0 (3.898) —
Tension
Unit: N {kgf, lbf}
Maintenance standard Service limit Remark
49.0 When compressed to
—
{5.0, 11.0} 66.5 mm (2.618 in)
ADJUSTMENT
ADJUSTMENT OF BRAKE PEDAL PLAY
After properly assembling the brake, bleed air from the brake sys-
tem and adjust the free play of the brake pedal.
(For detailed information on bleeding the air from the brake line,
refer to “BLEEDING AIR FROM THE BRAKE SYSTEM”.)
1. Remove the return spring from the brake pedal.
2. Loosen the lock nut on the push rod, and turn to extend the
push rod until free play is zero.
3. Then, back off the push rod by 1/2 turn. This will provide a
free play of 0.5 to 1.0 mm (0.020 to 0.039 in) at the end.
4. Tighten the lock nut. Use care not to allow the push rod to
rotate at the same time.
BR-3-4
MASTER CYLINDER BRAKE UNIT (VAC)
BR-3-5
HYDROMASTER BRAKE UNIT (VAC)
HYDROMASTER
CONSTRUCTION
BR-4-1
HYDROMASTER BRAKE UNIT (VAC)
DISASSEMBLY
DISASSEMBLY
BR-4-2
HYDROMASTER BRAKE UNIT (VAC)
12 Valve fitting
Loosen the valve fitting using box wrench (910-21981).
26 Hydraulic cylinder
Loosen the nut on the cylinder using the wrench (910-20130).
Then, attach the wrench to the two flats at the upper portion of the
cylinder and remove the cylinder.
BR-4-3
HYDROMASTER BRAKE UNIT (VAC)
30 Hydraulic piston
When compressed air is used.
Since the push rod rises together with the hydraulic piston at its end
when compressed air is sucked in from the control tube, remove
the push rod pin with a piece of wire, etc. and remove the hydraulic
piston.
NOTE
z The compressed air pressure must be under 98 kPa {1
kgf/cm2, 14 psi}
z When compressed air is not used.
To disassemble the hydraulic piston without using compressed air,
remove the end plate and power piston as a unit. Push the end
plate to compress the return spring and extract the push rod pin.
Then, remove the hydraulic piston.
35 End plate
Before disassembly, place an alignment mark on the end plate and
cylinder. Remove the end plate.
38 Nut
Secure the ring assembly (910-11030) in a vise. Align the two flats
on the push rod nut with those on the ring assembly and install the
power piston assembly. After that, remove the nut using the socket
assembly (910-23531).
52 Oil seal
Remove the oil seal using special tool (910-20191).
BR-4-4
HYDROMASTER BRAKE UNIT (VAC)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between hydraulic piston and hydraulic cyl-
inder
Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.13 (0.0016 - 0.0051) 0.15 (0.0059)
REASSEMBLY
REASSEMBLY
Key point of reassembly
52 Oil seal
Using the special tool (910-20191), press-fit the push rod oil seal
onto the end plate.
38 Nut
Secure the ring assembly (910-11030) in a vise. Align the two flats
on the push rod nut with those on the ring assembly and install the
power piston assembly. After that, tighten the nut using the socket
assembly (910-23531).
BR-4-5
HYDROMASTER BRAKE UNIT (VAC)
30 Hydraulic piston
z When compressed air is used.
1. Insert the hook bolt into the guide in the assembly stand
(910-10140).
2. Install the cylinder shell on the stand (910-10140). Install
the power piston assembly by inclining it obliquely.
NOTE
z Apply a coat of silicone grease to the frictional surface of
the piston and the inner wall of the cylinder shell.
3. Position the return spring with the small end facing the pis-
ton and install the end plate by aligning its mark with that on
the cylinder.
BR-4-6
HYDROMASTER BRAKE UNIT (VAC)
5. Insert the power piston into the cylinder shell while tilting it
and keeping it aligned with the alignment mark on the cylin-
der.
NOTE
z Apply a coat of silicone grease paste to the frictional sur-
face of the piston and the inner wall of the cylinder shell.
26 Hydraulic cylinder
Tighten the hydraulic cylinder to the end plate by hand and then
tighten further with a wrench (910-20130) until it contacts the bot-
tom. When the air bleeder screw is on the same plane as the air
bleeder screw of the end plate, tighten the lock nut. When the air
bleeder screws do not meet on the same plane, back off the
hydraulic cylinder until they are on the same plane and then tighten
the lock nut.
: 59 - 98 N·m {6 - 10 kgf·m, 43 - 72 ft·lbf}
16 Piston cup
Using the cup insertion tool (910-20010), insert the piston cup into
the relay valve piston.
12 Valve fitting
Install the relay valve piston assembly onto the valve fitting. Using
the box wrench (910-21981), tighten them to the end plate.
: 44 - 64 N·m {4.5 - 6.5 kgf·m, 33 - 47 ft·lbf}
BR-4-7
HYDROMASTER BRAKE UNIT (VAC)
7 Valve body
Using the guide pin (910-20061 or 910-20064) install the dia-
phragm.
FUNCTIONAL CHECK
TESTING WITH A FIXED TESTER
After assembling the hydromaster, test the following items:
Hydromaster test standards table
Test conditions: negative pressure 66.7 kPa
{500 mmHg, 19.69 inHg}
Air tightness when performing open test
Less than
(drop in vacuum for 15 seconds)
3.3 {25, 0.98}
kPa {mmHg, inHg}
Fluid tightness test (time required for pres-
sure to drop by 981 kPa {10 kgf/cm2, 142 psi}
More than
when the system is blocked after a hydraulic
10 seconds
pressure of 11,768 kPa {120 kgf/cm2, 1,706
psi} is applied)
Operation start pressure (at 66.7 kPa {500
mmHg, 19.69 inHg} negative pressure) 127 - 226
{1.3 - 2.3, 18 - 33}
kPa {kgf/cm2, psi}
Master cylinder fluid pressure 1,569
Full load kPa {kgf/cm2, psi} {16, 228}
operation
test Hydraulic cylinder fluid pressure 10,101 - 11,082
kPa {kgf/cm2, psi} {103 - 113, 1,465 - 1,607}
Full load air tightness test (drop in vacuum More than 3.3
for 15 seconds) kPa {mmHg, inHg} {25, 0.98}
Residual pressure check valve test 78 - 127
kPa {kgf/cm2, psi} {0.8 - 1.3, 11 - 18}
BR-4-8
HYDROMASTER BRAKE UNIT (VAC)
BR-4-9
SAFETY CYLINDER BRAKE UNIT (VAC)
SAFETY CYLINDER
CONSTRUCTION
BR-5-1
SAFETY CYLINDER BRAKE UNIT (VAC)
BR-5-2
SAFETY CYLINDER BRAKE UNIT (VAC)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between cylinder and piston
Unit: mm (in)
Maintenance standard Service limit
— 0.17 (0.0067)
Spring tension
Unit: N {kgf, lbf}
Maintenance standard Service limit Remarks
14.7 When compressed to
—
{1.5, 3.3} 43 mm (1.69 in)
FUNCTIONAL CHECK
Operation test
1. Loosen the air bleeder screw (one side only) of the front
wheel to place in a brake fluid leaking state.
2. Pump the brake pedal quickly two times. If there is pedal
play remaining, the operation of the front safety cylinder is
normal.
3. Test the rear safety cylinder in the same manner.
BR-5-3
LOAD SENSING PROPORTION VALVE BRAKE UNIT (VAC)
BR-6-1
LOAD SENSING PROPORTION VALVE BRAKE UNIT (VAC)
BR-6-2
LOAD SENSING PROPORTION VALVE BRAKE UNIT (VAC)
FUNCTIONAL CHECK
Preparations for function test
1. Connect air pressure gauges 19,614 kPa {200 kgf/cm2,
2,844 psi} in the line between the hydromaster and supply
port and also between the delivery port and wheel cylinder.
2. Completely bleed air from the lines.
BR-6-3
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (VAC)
BR-7-1
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (VAC)
5. After bleeding air from all air bleeder screws, turn the safety
cylinder air bleeding valve fully clockwise.
6. Add brake fluid to the specified level in the brake fluid reser-
voir.
7. After the above operations have been completed, start the
engine and set the vacuum pressure to the specification.
Then, depress the brake pedal strongly to make sure there
is no “spongy” feel due to air contamination.
BR-7-2
BRAKE UNIT
AIR OVER HYDRAULIC (AOH)
BRAKE UNIT
CONTENTS
SERVICE DATA ......................................... BR- 1- 1 AIR PRESSURE GOVERNOR ................ BR- 5- 1
SPECIFICATIONS ................................... BR- 1- 1 CONSTRUCTION .................................... BR- 5- 1
SERVICE DATA ....................................... BR- 1- 2 DISASSEMBLY AND REASSEMBLY ...... BR- 5- 2
TIGHTENING TORQUE ........................... BR- 1- 4 FUNCTIONAL CHECK ............................ BR- 5- 3
DIAGRAM OF PIPING ............................. BR- 1- 7 AIR DRYER ................................................ BR- 6- 1
TOOLS ......................................................... BR- 2- 1 = DR-31 =
BRAKE VALVE ..................................... BR- 3- 1 CONSTRUCTION .................................... BR- 6- 1
CONSTRUCTION .................................... BR- 3- 1 DISASSEMBLY ........................................ BR- 6- 2
DISASSEMBLY ........................................ BR- 3- 6 INSPECTION ........................................... BR- 6- 3
INSPECTION .......................................... BR- 3-14 REASSEMBLY ......................................... BR- 6- 3
REASSEMBLY ........................................ BR- 3-16 INSPECTION AFTER MOUNTING ON
FUNCTIONAL CHECK ........................... BR- 3-19 VEHICLE .................................................. BR- 6- 4
AIR BOOSTER ........................................... BR- 4- 1 = DR-41 AND DR-42 =
= TYPE I AND TYPE II = CONSTRUCTION .................................... BR- 6- 5
CONSTRUCTION .................................... BR- 4- 1 DISASSEMBLY ........................................ BR- 6- 7
DISASSEMBLY ........................................ BR- 4- 1 INSPECTION ........................................... BR- 6- 9
INSPECTION ........................................... BR- 4- 5 REASSEMBLY ......................................... BR- 6- 9
REASSEMBLY ......................................... BR- 4- 6 INSPECTION AFTER MOUNTING ON
FUNCTIONAL CHECK ............................ BR- 4- 8 VEHICLE ................................................. BR- 6-11
= TYPE III AND TYPE IV = PARKING BRAKE VALVE ....................... BR- 7- 1
CONSTRUCTION ................................... BR- 4-10 CONSTRUCTION .................................... BR- 7- 1
DISASSEMBLY ....................................... BR- 4-10 DISASSEMBLY ........................................ BR- 7- 2
INSPECTION .......................................... BR- 4-14 INSPECTION ........................................... BR- 7- 3
REASSEMBLY ........................................ BR- 4-15 REASSEMBLY ......................................... BR- 7- 4
FUNCTIONAL CHECK ........................... BR- 4-17 FUNCTIONAL CHECK ............................ BR- 7- 5
= AOH-31 = LOAD SENSING PROPORTION
CONSTRUCTION ................................... BR- 4-19 VALVE ......................................................... BR- 8- 1
DISASSEMBLY ....................................... BR- 4-20 = CHAIN TYPE =
INSPECTION .......................................... BR- 4-21 CONSTRUCTION .................................... BR- 8- 1
REASSEMBLY ........................................ BR- 4-22 DISASSEMBLY AND REASSEMBLY ...... BR- 8- 2
FUNCTIONAL CHECK ........................... BR- 4-23 FUNCTIONAL CHECK ............................ BR- 8- 3
= AOH-2 = = LEAF SPRING TYPE =
CONSTRUCTION ................................... BR- 4-25 CONSTRUCTION .................................... BR- 8- 4
DISASSEMBLY ....................................... BR- 4-25 DISASSEMBLY ........................................ BR- 8- 5
INSPECTION .......................................... BR- 4-27 INSPECTION ........................................... BR- 8- 6
REASSEMBLY ........................................ BR- 4-29 REASSEMBLY ......................................... BR- 8- 7
FUNCTIONAL CHECK ........................... BR- 4-29 FUNCTIONAL CHECK ............................ BR- 8- 9
QUICK RELEASE VALVE ........................ BR- 9- 1 SPRING BRAKE CHAMBER ................. BR-12- 1
CONSTRUCTION .................................... BR- 9- 1 = TYPE I =
DISASSEMBLY AND REASSEMBLY ...... BR- 9- 1 CONSTRUCTION ................................... BR-12- 1
FUNCTIONAL CHECK ............................ BR- 9- 2 DISASSEMBLY ....................................... BR-12- 1
DOUBLE CHECK VALVE ........................ BR-10- 1 INSPECTION .......................................... BR-12- 3
CONSTRUCTION ................................... BR-10- 1 REASSEMBLY ........................................ BR-12- 3
DISASSEMBLY AND REASSEMBLY ..... BR-10- 2 FUNCTIONAL CHECK ........................... BR-12- 4
FUNCTIONAL CHECK ........................... BR-10- 3 = TYPE II =
PROTECTION VALVE .............................. BR-11- 1 CONSTRUCTION ................................... BR-12- 6
CONSTRUCTION ................................... BR-11- 1 DISASSEMBLY ....................................... BR-12- 7
DISASSEMBLY AND REASSEMBLY ..... BR-11- 2 INSPECTION .......................................... BR-12- 8
FUNCTIONAL CHECK ........................... BR-11- 3 REASSEMBLY ........................................ BR-12- 8
FUNCTIONAL CHECK .......................... BR-12-10
BLEEDING AIR FROM THE BRAKE
SYSTEM ..................................................... BR-13- 1
SERVICE DATA BRAKE UNIT (AOH)
SERVICE DATA
SPECIFICATIONS
Item Contents
Type Dual type
E6-R15
R.H.D. model
Brake valve E6-ER1
Model
E6-RP4
L.H.D. model
E6-ERP1
*Air booster Type Air servo type
Type Piston type
Low 667 {6.8, 97}
Air pressure Pressure adjustment Type I
High 785 {8.0, 114}
governor range
Low 706 {7.2, 102}
kPa {kgf/cm2, psi} Type II
High 834 {8.5, 121}
Type Barrel type
DR-31
Air dryer
Model DR-41
DR-42
Parking brake valve Cam type (with release knob)
Type I Chain type
Load sensing proportion valve (LSPV)
Type II Leaf spring type
Quick release valve Diaphragm type
Type I Multi type
Protection valve
Type II Single type
Type Diaphragm type
Spring brake
Maximum stroke Type I 28 (1.10)
chamber
mm (in) Type II 50 (1.97)
Safety valve opening pressure kPa {kgf/cm2 , psi} 932 - 971 {9.5 - 9.9, 135 - 141}
Check valve opening pressure Supply reservoir fitted Less than 29 {0.3, 4}
2, psi}
kPa {kgf/cm Service reservoir fitted 2.0 - 3.9 {0.02 - 0.04, 0.3 - 0.6}
Light ON pressure 461 - 520 {4.7 - 5.3, 67 - 75}
Air pressure switch kPa {kgf/cm2, psi}
Light OFF pressure 471 - 579 {4.8 - 5.9, 68 - 84}
*Air booster
(Made by JIDOSHA KIKI CO., LTD.)
Type I Type II Type III Type IV
Model
234-06719 234-06720 234-06721 234-06839 234-04116 234-04669
Cylinder shell I.D. 114.3 (4.50) 138.0 (5.43)
mm (in) Stroke 79 (3.11) 188 (7.40) 118 (4.65)
Hydraulic cylinder I.D. 23.8 (0.937) 29.1 (1.146)
mm (in) Stroke 76 (2.99) 185 (7.28) 115 (4.53)
2 78 - 127 {0.8 - 1.3, 11 - 18}
Residual pressure kPa {kgf/cm , psi}
BR-1-1
SERVICE DATA BRAKE UNIT (AOH)
SERVICE DATA
BRAKE VALVE
MODEL E6-R15, E6-RP4, E6-ER1 AND E6-ERP1
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pin hole I.D. 10.0 (0.394) 10.25 (0.4035)
Pin O.D. 10.0 (0.394) 9.85 (0.3878) Except for E6-ER1
I.D. 10.0 (0.394) 10.25 (0.4035)
Roller
O.D. 18.7 (0.736) 17.60 (0.6929)
Mounting plate bushing I.D. 26.5 (1.043) 26.70 (1.0512)
Piston O.D. 48.7 (1.917) 49.6 (1.953) E6-ER1 only
Relay piston O.D. 74.77 (2.9437) 74.67 (2.9398)
Plunger O.D. 26.5 (1.043) 26.20 (1.0315)
Main spring 35.8 (1.409) —
Sub spring 19.1 (0.752) —
Relay piston return spring 24.7 (0.972) —
Piston return spring 78.9 (3.106) —
Spring free length
33.2 (1.307) — Except for E6-ER1
Upper valve spring
32.0 (1.260) — E6-ER1
35.6 (1.402) — Except for E6-ER1
Lower valve spring
34.1 (1.343) — E6-ER1
When compressed to
Main spring 235 {24.0, 52.9} —
34.0 mm (1.339 in)
When compressed to
Sub spring 249.1 {25.4, 56.0} —
15.3 mm (0.602 in)
When compressed to
Relay piston return spring 8.8 {0.9, 2.0} —
Spring tension 16.7 mm (0.657 in)
N {kgf, lbf} When compressed to
Piston return spring 89.2 {9.1, 20.1} —
25.4 mm (1.000 in)
When compressed to
Upper valve spring 44.1 {4.5, 9.9} —
14.4 mm (0.567 in)
When compressed to
Lower valve spring 57.9 {5.9, 13.0} —
13.0 mm (0.512 in)
Pressure difference between primary and Less than
—
secondary outlet kPa {kgf/cm2, psi} 29.4 {0.3, 4.3}
12.0 - 18.0
E6-R15 —
(0.472 - 0.709)
Brake pedal free E6-RP4 5.0 - 13.0
—
play E6-ERP1 (0.197 - 0.512)
6.0 - 15.0
E6-ER1 — At an angel of 3º to 5º
(0.236 - 0.591)
BR-1-2
SERVICE DATA BRAKE UNIT (AOH)
AIR BOOSTER
Made by JIDOSHA KIKI CO., LTD.
<Model Type I, Type II, Type III and Type IV>
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Clearance between cylinder shell and power
— 1.8 (0.071)
piston
Type I
— 0.15 (0.0059)
Type II
Push rod run-out
Type III
— 1.2 (0.047)
Type IV
Clearance between hydraulic cylinder and
— 0.15 (0.0059)
piston
Type I 63.7 When compressed to
—
Type II {6.5, 14.3} 120.0 mm (4.72 in)
Power piston spring tension 103.0 When compressed to
Type III —
N {kgf, lbf} {10.5, 23.2} 245.2 mm (9.65 in)
103.0 When compressed to
Type IV —
{10.5, 23.2} 175.2 mm (6.90 in)
BR-1-3
SERVICE DATA BRAKE UNIT (AOH)
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
E6-R15 Upper piston installation bolt 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
E6-RP4
E6-ERP1 Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Nipple, Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
Brake valve Upper piston installation bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
E6-ER1
Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Nipple, Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
L.H.D. model only Brake pedal mounting bolt 23 - 32 {2.3 - 3.3, 17 - 24}
E6-R15 Brake pedal link mounting bolt 12 - 16 {1.2 - 1.6, 9 - 12}
E6-ER1 Brake valve assembly mounting bolt 23 - 32 {2.3 - 3.3, 17 - 24}
BR-1-4
SERVICE DATA BRAKE UNIT (AOH)
BR-1-5
SERVICE DATA BRAKE UNIT (AOH)
BR-1-6
SERVICE DATA BRAKE UNIT (AOH)
DIAGRAM OF PIPING
MK, LK AND PKB SERIES
BR-1-7
SERVICE DATA BRAKE UNIT (AOH)
BR-1-8
SERVICE DATA BRAKE UNIT (AOH)
BR-1-9
TOOLS BRAKE UNIT (AOH)
TOOLS
AIR BOOSTER
z Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Application
Tool name and
Description Shape Type Type Type Type
number
I II III IV
Stand Used to disassembly/reas-
910-00450 sembly the air booster
O O O O
O O O O
O O — —
O O O O
BR-2-1
TOOLS BRAKE UNIT (AOH)
BR-2-2
BRAKE VALVE BRAKE UNIT (AOH)
BRAKE VALVE
CONSTRUCTION
R.H.D. MODEL
Brake valve
<E6-R15>
BR-3-1
BRAKE VALVE BRAKE UNIT (AOH)
<E6-ER1>
BR-3-2
BRAKE VALVE BRAKE UNIT (AOH)
L.H.D. MODEL
Brake valve link assembly
BR-3-3
BRAKE VALVE BRAKE UNIT (AOH)
Brake valve
<E6-RP4>
BR-3-4
BRAKE VALVE BRAKE UNIT (AOH)
<E6-ERP1>
BR-3-5
BRAKE VALVE BRAKE UNIT (AOH)
DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
WARNING
WARNING
z Be sure to insert the safety pin into the lock hole after tilt-
ing the cab upward.
BR-3-6
BRAKE VALVE BRAKE UNIT (AOH)
DISASSEMBLY
<R.H.D. MODEL>
Brake valve
<E6-R15>
BR-3-7
BRAKE VALVE BRAKE UNIT (AOH)
<E6-ER1>
BR-3-8
BRAKE VALVE BRAKE UNIT (AOH)
<L.H.D. MODEL>
Brake pedal assembly
BR-3-9
BRAKE VALVE BRAKE UNIT (AOH)
Brake valve
<E6-RP4>
BR-3-10
BRAKE VALVE BRAKE UNIT (AOH)
<E6-ERP1>
BR-3-11
BRAKE VALVE BRAKE UNIT (AOH)
}
13 E6-R15
5 E6-RP4
15 E6-ER1 Upper piston assembly
4 E6-ERP1
Remove the upper piston assembly as an assembly and then dis-
assemble.
34 E6-R15
26 E6-RP4 }Lower valve assembly
Remove the lower valve assembly as an assembly and then disas-
semble.
32 E6-ER1
26 E6-ERP1 } Check valve seat
The lower valve assembly can be disassembled by first removing
the check valve seat.
BR-3-12
BRAKE VALVE BRAKE UNIT (AOH)
NOTE
z When securing the piston in a vice, never hold the valve
seat.
50 E6-R15
42 E6-RP4 }Upper valve assembly
Remove the upper valve assembly as an assembly and then disas-
semble.
48 E6-ER1
34 E6-ERP1 } Upper valve assembly
The upper valve assembly can be disassembled by first removing
the retaining ring.
BR-3-13
BRAKE VALVE BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-3-14
BRAKE VALVE BRAKE UNIT (AOH)
BR-3-15
BRAKE VALVE BRAKE UNIT (AOH)
Spring tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
235 When compressed to
Main spring —
{24.0, 52.9} 34.0 mm (1.339 in)
249.1 When compressed to
Sub spring —
{25.4, 56.0} 15.3 mm (0.602 in)
Relay piston 8.8 When compressed to
—
return spring {0.9, 2.0} 16.7 mm (0.657 in)
Piston return 89.2 When compressed to
—
spring {9.1, 20.1} 25.4 mm (1.000 in)
Upper valve 44.1 When compressed to
—
spring {4.5, 9.9} 14.4 mm (0.567 in)
Lower valve 57.9 When compressed to
—
spring {5.9, 13.0} 13.0 mm (0.512 in)
REASSEMBLY
REASSEMBLY
Key point of reassembly
z Apply lithium soap-base grease or equivalent to the sliding
surfaces of the inlet valve, body and relay piston.
z When assembling the O-ring, be sure to apply lithium soap-
base grease or equivalent to the O-ring. Fill the O-ring
groove with this grease.
z Apply molybdenum disulfide grease or equivalent to the
sliding surfaces (10-mm dia. pin and plunger) of pedal.
z After fitting each retaining ring, make sure it is securely
located in its groove.
BR-3-16
BRAKE VALVE BRAKE UNIT (AOH)
48 E6-ER1
34 E6-ERP1 }Upper valve assembly
When assembling the upper valve, pay attention to the direction of
the retainer.
NOTE
z When assembling the upper valve, apply silicone grease
to it.
z When installing the retaining ring, turn it about 30
degrees to make sure it fits securely in the groove.
}
13 E6-R15
5 E6-RP4
15 E6-ER1 Upper piston assembly
4 E6-ERP1
After assembling the upper piston assembly, make sure the spring
seat is located in the center, as shown in the figure.
Except for E6-ER1
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
E6-ER1
: 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
NOTE
z When securing the piston in a vise, never hold the valve
seat.
3 Pin
When installing the pin, lightly tap in with a hammer or similar tool.
Do not apply excessive force or impact.
BR-3-17
BRAKE VALVE BRAKE UNIT (AOH)
INSTALLATION
Key point of installation (L.H.D. model only)
1. Install the brake valve assembly on the brake valve link
assembly. In advance, loosen the link assembly rod nut.
: 23 - 32 N·m {2.3 - 3.3 kgf·m, 17 - 24 ft·lbf}
NOTE
z Apply a coat of molybdenum grease to the plunger rod
butting portion.
z Install on the cab the link assembly with the brake valve
assembly installed.
: 12 - 16 N·m {1.2 - 1.6 kgf·m, 9 - 12 ft·lbf}
BR-3-18
BRAKE VALVE BRAKE UNIT (AOH)
z Turn the link rod so that the rod length (dimension L) is 72.70
mm (2.8622 in). Also measure the pedal play to make sure
that it is in the range of 5.0 to 13.0 mm (0.197 to 0.512 in).
z Tighten the nut.
: 35 - 41 N·m {3.6 - 4.2 kgf·m, 26 - 30 ft·lbf}
5. Turn the key switch to “ON”. If the spot light comes on with-
out operating the pedal, adjust the rod length (dimension L)
again.
z Loosen the nut.
z Turn the pedal and turn it back to the link side until the rod
tip separates from the plunger.
z Repeat step 4.
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Fit an air pressure gauge to the line on the brake valve out-
let side (primary and secondary), as close as possible to the
brake valve.
Use an air pressure gauge which is capable of reading up to
981 kPa {10 kgf/cm2, 142 psi}.
2. Fill the air reservoir to the specified air pressure.
3. Make sure there are no leaks coming from the connections.
If there are leaks, repair them.
BR-3-19
BRAKE VALVE BRAKE UNIT (AOH)
FUNCTION TEST
1. While watching the air pressure gauge, gradually depress
the brake pedal and take note of the initial rise point (A) on
the air pressure gauge.
<Right-hand drive model>
At point (A), the angle of the depressed brake pedal should
be 2.8 to 3.5º. If it is not, adjust the setscrew located at the
lower portion of the brake pedal so that the angle meets the
specification.
<Left-hand drive model>
At point (A), the push rod stroke should be 1.0 to 1.3 mm
(0.039 to 0.051 in). If it is not, adjust the length of the push
rod so that it meets the specification.
2. Next, further depress the brake pedal to check that pres-
sures at the brake rapid-pressure rise points (B and C) cor-
respond to the values shown in the figure. When the last
rapid-rise point (C) is surpassed, the pressure increases
rapidly to equal the air pressure in the reservoir.
Before reaching the full stroke (D), the air reservoir pres-
sure equalize with the brake pressure. There must be some
brake travel remaining at this point.
R.H.D. model
Item Point B Point C
L.H.D. model
Item Point B Point C
6.0 - 7.2
Plunger stroke mm (in) 3.0 (0.118)
(0.236 - 0.283)
BR-3-20
AIR BOOSTER BRAKE UNIT (AOH)
AIR BOOSTER
= TYPE I AND TYPE II =
CONSTRUCTION
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the brake booster, drain the brake fluid
from the air booster to remove dirt and dust.
2. Plug the connections to prevent dirt and dust from entering
the lines and prevent the brake fluid from flowing out.
BR-4-1
AIR BOOSTER BRAKE UNIT (AOH)
DISASSEMBLY
BR-4-2
AIR BOOSTER BRAKE UNIT (AOH)
11 O-ring
Using the needle (910-21200), remove the O-ring from the connec-
tor.
23 Cup packing
Using the needle (910-21200), remove the cup packing from the
power piston assembly.
BR-4-3
AIR BOOSTER BRAKE UNIT (AOH)
25 Retaining ring
Remove the retaining ring and then remove the back-up ring and
push rod together with the hydraulic piston assembly.
29 Cup packing
Using the needle (910-21200), remove the cup packing from the
hydraulic piston assembly.
34 Retainer assembly
Extract the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If extracted from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.
35 O-ring
Using the needle (910-21200), remove the O-ring from the retainer
assembly.
BR-4-4
AIR BOOSTER BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-4-5
AIR BOOSTER BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
34 Retainer assembly
Install the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If installed from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.
29 Cup packing
Install the back-up ring in the hydraulic piston groove. Using the cup
insert guide (910-23289), install the cup packing.
NOTE
z Pay attention to the installation direction of the cup pack-
ing.
BR-4-6
AIR BOOSTER BRAKE UNIT (AOH)
23 Cup packing
Install the power piston, paying attention to the installation direction
of the cup packing.
10 Connector
Immerse the installed pressure retaining valve in brake fluid and
insert it into the cylinder body. After that, push the connector attach-
ing the O-ring in from above and install the retaining ring.
NOTE
z Install the pressure retaining valve so that the rubber
valve face faces inner side.
z Make sure the connector O-ring is not twisted or protrud-
ing.
BR-4-7
AIR BOOSTER BRAKE UNIT (AOH)
FUNCTIONAL CHECK
SIMPLE TEST
1. Prepare an air pressure gauge 785 kPa {8 kgf/cm2, 114
psi}, 2 hydraulic gauges 19,614 kPa {200 kgf/cm2, 2,844
psi}, pipes and joints.
2. Remove the hydraulic cylinder plug air bleeder screw and
install a hydraulic pressure gauge 19,614 kPa {200 kgf/cm2,
2,844 psi}.
3. Install an air pressure gauge 785 kPa {8 kgf/cm2, 114 psi}.
4. Remove the wheel cylinder air bleeder screw and install a
hydraulic pressure gauge 19,614 kPa {200 kgf/cm2, 2,844
psi}.
TEST PROCEDURE
1. Operational test with load.
z Keep air pressure at the specified value.
z When the brake pedal is depressed until the air pressure
gauge shows 686 kPa {7 kgf/cm2, 100 psi}, the hydraulic
gauge on the hydraulic cylinder plug shows above 14,514
to 16,476 kPa {148 to 168 kgf/cm2, 2,105 to 2,389 psi}. If it
shows below 14,514 to 16,476 kPa {148 to 168 kgf/cm2,
2,105 to 2,389 psi}, repair since the brake fluid may leak
from the hydraulic piston (packing cup or valve) or air mixes
in hydraulic system.
z When the brake pedal is depressed slowly, the air pressure
gauge and hydraulic pressure gauge pointers should raise
up in proportion to the pedal force. When the air pressure
reaches the maximum point, release the brake pedal. At
this time, the pressure should be returned quickly.
z If this response is not smooth, inspect by following the test
procedure above.
2. Air-tightness test with load.
Raise the air pressure to the specified value, inspect air
leakage with the brake pedal depressed.
If the air pressure falls, the power piston rubber packing or
control tube is faulty.
3. Hydraulic-tightness test.
Keep the air pressure at the specified value.
Depress the brake pedal, observe the air pressure gauge
and keep the air pressure at 588 kPa {6 kgf/cm2, 85 psi}. At
this time, if the pedal goes ahead, the brake fluid leaks from
the wheel cylinder, hydraulic line or cylinder tube.
BR-4-8
AIR BOOSTER BRAKE UNIT (AOH)
z Performance curve.
BR-4-9
AIR BOOSTER BRAKE UNIT (AOH)
CONSTRUCTION
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the brake booster, drain the brake fluid
from the air booster to remove dirt and dust.
2. Plug the connections to prevent dirt and dust from entering
the lines and prevent the brake fluid from flowing out.
BR-4-10
AIR BOOSTER BRAKE UNIT (AOH)
DISASSEMBLY
BR-4-11
AIR BOOSTER BRAKE UNIT (AOH)
21 Piston
Using the needle (910-21200), remove the O-ring from the piston.
29 O-ring
Using the needle (910-21200), remove the O-ring from the connec-
tor.
41 Cup packing
Using the needle (910-21200), remove the cup packing from the
power piston assembly.
BR-4-12
AIR BOOSTER BRAKE UNIT (AOH)
43 Retaining ring
Remove the retaining ring and then remove the back-up ring and
push rod together with the hydraulic piston assembly.
46 Retainer assembly
Extract the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If extracted from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.
48 O-ring
Using the needle (910-21200), remove the O-ring from the retainer
assembly.
50 Cup packing
Using the needle (910-21200), remove the cup packing from the
hydraulic piston assembly.
BR-4-13
AIR BOOSTER BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-4-14
AIR BOOSTER BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
50 Cup packing
Install the back-up ring in the hydraulic piston groove. Using the cup
insert guide (910-23290), install the cup packing.
NOTE
z Pay attention to the installation direction of the cup pack-
ing.
46 Retainer assembly
Install the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If installed from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.
BR-4-15
AIR BOOSTER BRAKE UNIT (AOH)
41 Cup packing
Install the power piston, paying attention to the installation direction
of the cup packing.
28 Connector
Immerse the installed pressure retaining valve in brake fluid and
insert it into the cylinder body. After that, push the connector attach-
ing the O-ring in from above and install the retaining ring.
NOTE
z Install the pressure retaining valve so that the rubber
valve face faces inner side.
z Make sure the connector O-ring is not twisted or protrud-
ing.
BR-4-16
AIR BOOSTER BRAKE UNIT (AOH)
FUNCTIONAL CHECK
SIMPLE TEST
1. Prepare an air pressure gauge 785 kPa {8 kgf/cm2, 114
psi}, hydraulic pressure gauges 19,614 kPa {200 kgf/cm2,
2,844 psi}, pipes and joints.
2. Remove the hydraulic cylinder plug air bleeder screw and
install a hydraulic pressure gauge 19,614 kPa {200 kgf/cm2,
2,844 psi}.
3. Remove the power cylinder shell oil plug and install an air
pressure gauge 785 kPa {8 kgf/cm2, 114 psi}.
4. Remove the wheel cylinder air bleeder screw and install a
hydraulic pressure gauge 19,614 kPa {200 kgf/cm2, 2,844
psi}.
TEST PROCEDURE
1. Air tightness test without load.
z This test is to check air-tightness from air lines. At first, keep
air pressure at the specified value.
z Coat soapy water around air pipes and connectors and
observe if bubbles appear. If bubbles appear, it shows leak-
age. Repair or replace faulty parts.
z Coat soapy water on the exhaust cover. Any bubble shows
the air tightness imperfection of relay valve inlet valve
(atmosphere side). In this case, replace the inlet valve.
2. Operational test with load.
z Keep air pressure at the specified value.
z When the brake pedal is depressed until the air pressure
gauge shows 588 kPa {6 kgf/cm2, 85 psi}, the hydraulic
gauge on the hydraulic cylinder plug shows above 12,259
to 13,632 kPa {125 to 139 kgf/cm2, 1,778 to 1,977 psi}. If it
shows below 12,259 to 13,632 kPa {125 to 139 kgf/cm2,
1,778 to 1,977 psi}, repair since the brake fluid may leak
from the hydraulic piston (packing cup or ball) or air mixes
in hydraulic system.
z When the brake pedal is depressed slowly, the air pressure
gauge and hydraulic pressure gauge pointers should raise
up in proportion to the pedal stroke. When the air pressure
reaches to maximum point, release the brake pedal. At this
time, the pressure should be returned quickly.
z If this response is not smooth, inspect by following the test
procedure above. If the air booster is not returned to the non-
operating condition, the relay valve does not slide smoothly.
3. Air-tightness test with load.
Raise the air pressure to the specified value, inspect air
leakage with the brake pedal depressed.
If the air pressure falls, the relay valve inlet valve (atmo-
sphere side), piston assembly, power piston leather packing
or control tube is faulty.
4. Hydraulic-tightness test.
Keep the air pressure at the specified value.
Depress the brake pedal, observe the air pressure gauge
and keep the air pressure at 588 kPa {6 kgf/cm2, 85 psi}. At
this time, if the pedal goes ahead, the brake fluid leaks from
the wheel cylinder, hydraulic line or cylinder tube.
BR-4-17
AIR BOOSTER BRAKE UNIT (AOH)
z Performance curve.
BR-4-18
AIR BOOSTER BRAKE UNIT (AOH)
= AOH-31 =
CONSTRUCTION
BR-4-19
AIR BOOSTER BRAKE UNIT (AOH)
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the brake booster, drain the brake fluid
from the air booster to remove dirt and dust.
2. Plug the connections to prevent dirt and dust from entering
the lines and prevent the brake fluid from flowing out.
DISASSEMBLY
BR-4-20
AIR BOOSTER BRAKE UNIT (AOH)
2. Push in the cylinder body cover by hand and then push the
push rod pin out with a round bar or a similar tool.
NOTE
z Use care when disassembling the cylinder body cover as
it is under tension by the piston spring with a spring load
of 118 N {12 kgf, 26 lbf}.
30 Bushing
Extract the bushing while pushing it inward with a spatula or a simi-
lar tool.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-4-21
AIR BOOSTER BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
14 Push rod pin
1. Wind the ring guide around the hydraulic piston groove. Do
not insert the ring guide into the groove.
BR-4-22
AIR BOOSTER BRAKE UNIT (AOH)
FUNCTIONAL CHECK
TEST EQUIPMENT
BR-4-23
AIR BOOSTER BRAKE UNIT (AOH)
PERFORMANCE CURVE
TEST METHOD
Unit: kPa {kgf/cm2, psi}
Test item Test method Rated values
Hydraulic tightness test (Fluid Apply a hydraulic pressure of 11,768 {120, 1,706} to the 10 seconds or more
pressure system) fluid pressure system and measure the time required for the
pressure to drop to 981 {10, 142} after cutting off the pres-
sure.
Air tightness test without load Apply an air pressure of 588 {6, 85} to the air booster and 39 {0.4, 6} or less
(Air pressure system) measure the amount of pressure drop over 15 seconds after
cutting off the compressed air.
Operation start pressure test Pressure in the service line when the cylinder pressure 10 - 25
starts to increase while the brake valve pedal is being {0.10 - 0.26, 1.4 - 3.7}
depressed gradually
Operation test with full load Hydraulic pressure in the wheel cylinder when the service 14,809 - 15,229
line pressure is 686 {7, 100} {151 - 156, 2,147 - 2,218}
Air tightness test with full load Measure the amount of pressure drop over 15 seconds after 59 {0.6, 9} or less
cutting off the service line under full load operating condi-
tions.
Residual pressure test Measure the wheel cylinder hydraulic pressure when the 78 - 127
brake pedal has been released. {0.8 - 1.3, 11 - 18}
Switch assembly operation Loosen the bleeder screw and apply an air pressure of 196 Must operate
test to 294 {2 to 3, 28 to 43} to operate the piston assembly.
Confirm that the switch assembly is operating properly,
using an electric tester.
BR-4-24
AIR BOOSTER BRAKE UNIT (AOH)
= AOH-2 =
CONSTRUCTION
DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the brake booster, drain the brake fluid
from the air booster to remove dirt and dust.
2. Plug the connections to prevent dirt and dust from entering
the lines and prevent the brake fluid from flowing out.
BR-4-25
AIR BOOSTER BRAKE UNIT (AOH)
DISASSEMBLY
BR-4-26
AIR BOOSTER BRAKE UNIT (AOH)
2. Push in the cylinder body cover by hand and then push the
push rod pin out with a round bar or a similar tool.
NOTE
z Use care when disassembling the cylinder body cover as
it is under tension by the piston spring with a spring load
of 177 to 216 N {18.0 to 22.0 kgf, 39.7 to 48.5 lbf}.
43 Cylinder bushing
Extract the bushing while pushing it inward with a spatula or a simi-
lar tool.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-4-27
AIR BOOSTER BRAKE UNIT (AOH)
BR-4-28
AIR BOOSTER BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
28 Push rod pin
1. Wind the ring guide around the hydraulic piston groove. Do
not insert the ring guide into the groove.
FUNCTIONAL CHECK
TEST EQUIPMENT
BR-4-29
AIR BOOSTER BRAKE UNIT (AOH)
PERFORMANCE CURVE
TEST METHOD
Unit: kPa {kgf/cm2, psi}
Test item Test method Rated values
Hydraulic tightness test (Fluid Apply a hydraulic pressure of 11,768 {120, 1,706} to the 10 seconds or more
pressure system) fluid pressure system and measure the time required for the
pressure to drop to 981 {10, 142} after cutting off the pres-
sure.
Air tightness test without load Apply an air pressure of 588 {6, 85} to the air booster and 39 {0.4, 6} or less
(Air pressure system) measure the amount of pressure drop over 15 seconds after
cutting off the compressed air.
Operation start pressure test Pressure in the service line when the cylinder pressure 29 - 49
starts to increase while the brake valve pedal is being {0.3 - 0.5, 4 - 7}
depressed gradually
Operation test with full load Hydraulic pressure in the wheel cylinder when the service 11,768 - 13,141
line pressure is 588 {6, 85} {120 - 134, 1,706 - 1,905}
Air tightness test with full load Measure the amount of pressure drop over 15 seconds after 59 {0.6, 9} or less
cutting off the service line and supply line under full load
operating conditions.
Residual pressure test Measure the wheel cylinder hydraulic pressure when the 78 - 127
brake pedal has been released. {0.8 - 1.3, 11 - 18}
Switch assembly operation Loosen the bleeder screw and apply an air pressure of 196 Must operate
test to 294 {2 to 3, 28 to 43} to operate the piston assembly.
Confirm that the switch assembly is operating properly,
using an electric tester.
BR-4-30
AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)
BR-5-1
AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)
BR-5-2
AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)
REASSEMBLY
Key point of reassembly
z Prior to reassembly, apply a coat of silicone grease to the
inner wall of the body, the outer surface of the piston and
the O-ring groove, O-ring, spring guide and adjusting screw.
6 Piston
Position the O-ring in the groove at the piston stem hole. Install the
valve on the piston with the small spring diameter end facing the
valve, and push the large spring diameter end into the groove in the
piston.
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Disconnect the check valve from the air reservoir and con-
nect a 981 kPa {10 kgf/cm2, 142 psi} pressure gauge to it.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.
FUNCTIONAL TEST
1. Gradually increase air pressure. When the air pressure
increase is stopped, ensure that the air pressure is within
the specified high pressure range.
Next, gradually decrease the air pressure and ensure that it
is within the low pressure range when the “hissing” sound is
heard.
Unit: kPa {kgf/cm2, psi}
Maintenance
Item Service limit
standard
647 - 686
Low range —
{6.6 - 7.0, 94 - 100}
Type I
765 - 814
High range —
{7.8 - 8.3, 111 - 118}
686 - 726
Low range —
{7.0 - 7.4, 100 - 105}
Type II
814 - 863
High range —
{8.3 - 8.8, 118 - 125}
BR-5-3
AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)
BR-5-4
AIR DRYER BRAKE UNIT (AOH)
AIR DRYER
= DR-31 =
CONSTRUCTION
BR-6-1
AIR DRYER BRAKE UNIT (AOH)
DISASSEMBLY
DISASSEMBLY
BR-6-2
AIR DRYER BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
14 Oil filter
Install the oil filter with the bend section of the net facing down.
11 , 7 Filter
Be sure to install the filter with the thick, soft layer side facing up.
10 Desiccant
1. The standard weight of the desiccant to be used is 480 g
(16.93 oz). In the case of desiccant being purchased as a
repair kit, use the full contents of one bag.
BR-6-3
AIR DRYER BRAKE UNIT (AOH)
BR-6-4
AIR DRYER BRAKE UNIT (AOH)
CONSTRUCTION
DR-41
BR-6-5
AIR DRYER BRAKE UNIT (AOH)
DR-42
BR-6-6
AIR DRYER BRAKE UNIT (AOH)
DISASSEMBLY
DISASSEMBLY
DR-41
BR-6-7
AIR DRYER BRAKE UNIT (AOH)
DR-42
BR-6-8
AIR DRYER BRAKE UNIT (AOH)
20 DR-41
23 DR-42 }Piston
While holding the piston using a 10 mm (0.39 in) hex. wrench,
remove the bolts, piston, valve and valve spring.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
19 Exhaust cover
Place a suitable pipe on the flat surface of the exhaust cover, and
lightly tap the end of the pipe using a hammer until the exhaust
cover is properly positioned in the valve body.
9 DR-41
10 DR-42 } Filter
Install the filter with the soft surface side facing upward.
BR-6-9
AIR DRYER BRAKE UNIT (AOH)
8 DR-41
9 DR-42 } Desiccant
Place the specified amount [approximately 200 g (7.05 oz)] of des-
iccant in the filter case. If a bag of desiccant is available in the
repair kit, use the entire contents in the filter case.
NOTE
z Discard the old bag of desiccant, and replace with a new
one designated for the DR-41, DR-42 unit. Note that the
desiccant used in the DR-41 unit differs from those for
DR-2 and DR-3 units.
7 DR-41
8 DR-42 } Filter,
6 DR-41
7 DR-42 } Filter plate
After installing the filter and filter plate on the case, tap the case as
follows:
CAUTION
z Tapping the case is important to increase the density of the
desiccant and maintain performance as a drying agent.
NOTE
z Install the filter with the soft side facing down.
Tapping method
z Using both hands, lift the filter case to a height of 10 cm (3.9
in).
z Repeatedly tap the case against a cloth folded in two or
three, approximately 30 times.
NOTE
z The cloth is necessary to prevent the bottom of the case
from becoming scratched.
z Finish “tapping” after the filter plate is approximately 4 to 6
mm (0.16 to 0.24 in) below the original position.
3 DR-41
4 DR-42 } Check valve
Fit the check valve into the case cover while pushing the expanded
middle portion of the valve.
NOTE
z Apply grease to the protrusion of the check valve in
advance to facilitate installation.
BR-6-10
AIR DRYER BRAKE UNIT (AOH)
BR-6-11
PARKING BRAKE VALVE BRAKE UNIT (AOH)
BR-7-1
PARKING BRAKE VALVE BRAKE UNIT (AOH)
DISASSEMBLY
DISASSEMBLY
BR-7-2
PARKING BRAKE VALVE BRAKE UNIT (AOH)
15 C-ring
Remove the piston assembly C-ring, and remove the feed valve
seat and the O-ring. Also remove the C-ring from the feed valve,
and remove the feed valve. Remove the O-ring from the piston
O.D. section.
NOTE
z When removing the C-ring from the feed valve, pay atten-
tion not to expand it excessively.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Free length
Unit: mm (in)
Item Maintenance standard Service limit
Main spring 31.7 (1.248) 30.7 (1.209)
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)
BR-7-3
PARKING BRAKE VALVE BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
Reassemble after greasing the O-ring groove, pin, shim, and sliding
sections.
22 Cam ring
Apply grease to the cam ring sliding surface, and install the cam
ring into the holder so that the pin is positioned as shown.
BR-7-4
PARKING BRAKE VALVE BRAKE UNIT (AOH)
8 Valve spring
When installing the valve spring, check that the valve spring is cor-
rectly positioned on the feed valve C-ring.
3 Spring
Apply grease to the handle assembly fitting portion of the body.
Rotate the cam holder in a clockwise direction as viewed from the
handle head side until it contacts the stopper, align the cutout por-
tion of the spring seat coated with grease with the body hook hole,
and then fit the hooked end of the spring into the body hook hole.
FUNCTIONAL CHECK
AIR LEAKAGE TEST
With the handle set in the PARK position, apply an air pressure of
785 kPa {8 kgf/cm2, 114 psi} to the inlet port. Apply soapsuds to the
exhaust port to make sure no air is leaking. Rotate the handle to the
RELEASE position. Apply soapsuds to the exhaust port again, and
apply air pressure. Check that the diameters of the air bubbles
formed in 15 seconds are within 15 mm (0.59 in). Also check that
no air is leaking from each joint and tightened portion of the body.
BR-7-5
PARKING BRAKE VALVE BRAKE UNIT (AOH)
FUNCTIONAL TEST
Attach a pressure gauge to the outlet port and also to the second-
ary port. Using an angle gauge, measure the brake handle angle,
and check that the pressure is within the performance levels shown
below. If it is not within the specified range, adjust as follows:
1. To adjust the initial outlet pressure, change the number of
main spring shims. If the pressure is too high, reduce the
number of main spring shims. If the pressure is too low,
increase the number of shims.
2. To the angle at which air discharge starts, change the num-
ber of cam holder shims (cam side). In this case, check the
dimension from the body to exhaust valve seat.
BR-7-6
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
CONSTRUCTION
BR-8-1
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
BR-8-2
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTION TEST
1. Connect air pressure gauges 19,614 kPa {200 kgf/cm2,
2,844 psi} in the line between the hydromaster and supply
port and also between the delivery port and wheel cylinder.
2. Completely bleed air from the lines.
BR-8-3
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
CONSTRUCTION
BR-8-4
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
DISASSEMBLY
DISASSEMBLY
BR-8-5
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
11 , 13 Straight pin
Using the pin (X7237-321), push out the spring pin and remove the
straight pin.
22 Seal retainer
Using the spanner (X7237-322), remove the seal retainer. Then,
remove the plunger and rod assembly.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-8-6
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
REASSEMBLY
REASSEMBLY
Key point of reassembly
32 Steel ball
Put the plug and gasket in the proper position on the work bench.
Install the spring and steel ball in that order. Place the body over the
plug and carefully tighten it.
NOTE
z Make sure the steel ball is properly seated before tight-
ening the cover.
22 Seal retainer
Install the seal retainer assembly onto the body assembly, and
tighten it with the spanner (X7237-322).
: 20 - 39 N·m {2.0 - 4.0 kgf·m, 14 - 29 ft·lbf}
NOTE
z After tightening, stake 2 places with a punch to prevent
the seal retainer assembly from turning.
BR-8-7
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
21 Spring
Install the spring so that the side with a smaller diameter is on the
rod side.
13 Straight pin
Set the clevis in the lever assembly and drive the spring pin in
through the straight pin to secure the lever assembly.
NOTE
z If the spring pin hole does not locate in the correct posi-
tion, adjust by screwing a bolt of M4 x 0.7 into the
threaded hole in the end face of the straight pin.
4 Leaf spring
Install the leaf spring to the lever with a plate in position.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
NOTE
z Install the plate so that the rounded end of the flat sur-
face is on the relief spring side.
INSTALLATION
Key point of installation
Connect the brake tube and install the wire to the rear axle.
NOTE
z When installing the wire, unload the vehicle and lower
the end of the leaf spring from the free position by the
distance “L” (mm) stamped on the name plate. Then
install the wire onto the axle bracket.
BR-8-8
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AOH)
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTION TEST
1. Connect air pressure gauges 19,614 kPa {200 kgf/cm2,
2,844 psi} in the line between the air booster and supply
port and also between the delivery port and wheel cylinder.
2. Completely bleed air from the lines.
3. Measure and record the “free” position at the leaf spring end.
BR-8-9
QUICK RELEASE VALVE BRAKE UNIT (AOH)
BR-9-1
QUICK RELEASE VALVE BRAKE UNIT (AOH)
FUNCTIONAL CHECK
1. Depress the brake valve to supply air pressure of 588 kPa
{6 kgf/cm2, 85 psi} (minimum) to the brake chamber. While
the brake valve is depressed, apply soapy water to the
exhaust port and connections to check for air leakage.
2. Also check that air pressure is quickly routed to the brake
chamber when the brake valve is depressed and that it
quickly discharges from the brake chamber through the
exhaust port when the brake valve is released.
BR-9-2
DOUBLE CHECK VALVE BRAKE UNIT (AOH)
Type II
BR-10-1
DOUBLE CHECK VALVE BRAKE UNIT (AOH)
BR-10-2
DOUBLE CHECK VALVE BRAKE UNIT (AOH)
Type II
FUNCTIONAL CHECK
<TYPE I>
FUNCTIONAL TEST
Block port B (A) and apply air pressure of 49 to 834 kPa {0.5 to 8.5
kgf/cm2, 7 to 121 psi} to port A (B) to ensure that there is airflow to
the outlet.
<TYPE II>
FUNCTIONAL TEST
1. Valve opening pressure: With the outlet side at atmospheric
pressure, apply air to inlet sides (A) and (B) respectively,
confirming that the outlet pressure rises to 569 to 608 kPa
{5.8 to 6.2 kgf/cm2, 82 to 88 psi}. Apply air at a rate such
that pressure rises up to 216 to 412 kPa {2.2 to 4.2 kgf/cm2,
31 to 60 psi} over a period of 8 to 22 seconds.
2. Valve closing pressure: When inlet side (A) or (B) as well as
the outlet side are at a pressure of 686 to 883 kPa {7 to 9
kgf/cm2, 100 to 128 psi}
BR-10-3
DOUBLE CHECK VALVE BRAKE UNIT (AOH)
BR-10-4
PROTECTION VALVE BRAKE UNIT (AOH)
PROTECTION VALVE
CONSTRUCTION
Type I
Type II
BR-11-1
PROTECTION VALVE BRAKE UNIT (AOH)
A , B and C :
Disassemble the remaining three places in a manner similar to
steps 1 from 9 above.
BR-11-2
PROTECTION VALVE BRAKE UNIT (AOH)
Type II
FUNCTIONAL CHECK
<TYPE I>
PREPARATIONS FOR FUNCTION TEST
1. Connect 981 kPa {10 kgf/cm2, 142 psi} pressure gauges to
delivery ports a, b, c, and d, and supply port. Install valves
to the delivery lines enabling them to discharge air to the
atmosphere as required.
2. Maintain the air reservoir pressure at the normal operating
value.
3. Check all line connections to make sure no leakage is
present. If necessary, correct leaking connections.
FUNCTION TEST
1. Open one of the valves, a, b, c or d to allow air leakage for
test purposes. Under this condition, check the pressure in
the remaining lines (in which valves are connected) to
determine if it is equivalent to the lower limit of the guaran-
teed value for the valve opened.
BR-11-3
PROTECTION VALVE BRAKE UNIT (AOH)
2. Next, open the two valves in the “OUT” circuits to allow air
leakage. Under this condition, check the pressure in the
remaining lines to determine if it is equivalent to the lower
limit of the guaranteed pressure value (See “c” for OUT in
the following table).
Unit: kPa {kgf/cm2, psi}
Circuit Guaranteed pressure
OUT. a
559 - 588 {5.7 - 6.0, 81 - 85}
OUT. d
OUT. c
510 - 539 {5.2 - 5.5, 74 - 78}
OUT. b
<TYPE II>
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Connect air pressure gauges to the inlet and outlet of the
protection valve. Each pressure gauge should be capable
of registering more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.
FUNCTIONAL TEST
Maintain both the inlet and outlet of the protection valve at a pres-
sure of 686 kPa {7 kgf/cm2, 100 psi}. Decrease the air pressure at
the outlet for the specified length of time.
The minimum holding pressure at the inlet should be in the range of
422 to 461 kPa {4.3 to 4.7 kgf/cm2, 61 to 67 psi} regardless of
decreases in the outlet air pressure.
(Specified length of time:
Less than 3 seconds required to decrease air pressure
from 392 to 686 kPa {4 to 7 kgf/cm2, 57 to 100 psi})
BR-11-4
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
CONSTRUCTION
DISASSEMBLY
REMOVAL
Key point of removal
Set the parking brake valve to release and charge the spring brake
chamber (actuator).
NOTE
z The air pressure should be equivalent to the upper limit
pressure of the governor.
BR-12-1
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
DISASSEMBLY
BR-12-2
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
13 Non-pressure plate
Install the return spring and other parts onto the non-pressure plate
in sequence, and secure them with a press.
NOTE
z When securing with a press, align the reference mark
(marked when disassembling) on the non-pressure plate
with that on the pressure plate.
BR-12-3
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
6 Clamp band
Gradually compress the pressure plate, diaphragm and non-pres-
sure plate until their flanged sections contact each other. Next,
install the clamp band.
CAUTION
z While pressing, be sure the chamber is not dislocated or
bent in respect to the center of the press.
NOTE
z Before installing the spring, rod, diaphragm and pres-
sure plate, align their centers.
4 Stud bolt
Attach the lock nut and clevis to the stud, and adjust dimension A.
Tighten the lock nut.
A = 224 mm (8.82 in)
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
INSTALLATION
Key point of installation
1. Install the spring brake chamber (actuator) onto the bracket.
: 104 - 157 N·m {10.6 - 16.0 kgf·m, 77 - 116 ft·lbf}
NOTE
z Face the drain hole on the spring brake chamber (actua-
tor) downward and align the position of the clamp.
2. Set the parking brake valve to release and supply air to the
spring brake chamber (actuator).
NOTE
z Be sure the air pressure is the same as the max. gover-
nor pressure.
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Supply air to the inlet at a pressure of 490 to 785 kPa {5 to 8 kgf/
cm2, 71 to 114 psi}. Apply soapy water over the entire pressure
plate, clamp portion, and the area around the chamber case hole.
Ensure that there is no leakage. If leakage exists, disassemble the
spring chamber and determine the cause.
BR-12-4
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
FUNCTIONAL TEST
Supply air to the inlet at a pressure lower than 441 kPa {4.5 kgf/
cm2, 64 psi} to make sure the push rod moves smoothly over its
entire stroke. Discharge air to ensure it returns to the original posi-
tion.
Stroke 28 mm (1.10 in)
BR-12-5
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
= TYPE II =
CONSTRUCTION
BR-12-6
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
DISASSEMBLY
REMOVAL
Set the parking brake valve to release and charge the spring brake
chamber (actuator).
NOTE
z The air pressure should be equivalent to the upper limit
pressure of the governor.
DISASSEMBLY
BR-12-7
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Return spring tension
Unit: N {kgf, lbf}
Maintenance standard Service limit Remarks
7,846 - 8,826 When compressed to
—
{800 - 900, 1,764 - 1,985} 50.0 mm (1.969 in)
REASSEMBLY
REASSEMBLY
Key point of reassembly
12 Non-pressure plate
Install the return spring and other parts onto the non-pressure plate
in sequence, and secure them with a press.
NOTE
z When securing with a press, align the reference mark
(marked when disassembling) on the non-pressure plate
with that on the pressure plate.
BR-12-8
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
4 Clamp band
Gradually compress the pressure plate, diaphragm and chamber
case until their flanged sections contact each other. Next, install the
clamp band.
: 18 - 20 N·m {1.8 - 2.0 kgf·m, 13 - 14 ft·lbf}
CAUTION
z While pressing, be sure the chamber is not dislocated or
bent in respect to the center of the press.
NOTE
z Before installing the spring, rod, diaphragm and pres-
sure plate, align their centers.
1 Nut
Attach the lock nut and clevis to the stud, and adjust dimension A.
Tighten the lock nut.
A = 120 mm (4.72 in)
: 18 - 20 N·m {1.8 - 2.0 kgf·m, 13 - 14 ft·lbf}
INSTALLATION
Key point of installation
1. Install the spring brake chamber (actuator) onto the bracket.
: 104 - 157 N·m {10.6 - 16.0 kgf·m, 77 - 116 ft·lbf}
NOTE
z Face the drain hole on the spring brake chamber (actua-
tor) downward and align the position of the clamp.
2. Set the parking brake valve to release and supply air to the
spring brake chamber (actuator).
NOTE
z Be sure the air pressure is the same as the max. gover-
nor pressure.
BR-12-9
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Supply air to the inlet at a pressure of 490 to 785 kPa {5 to 8 kgf/
cm2, 71 to 114 psi}. Apply soapy water over the entire pressure
plate, clamp portion, and the area around the chamber case hole.
Ensure that there is no leakage. If leakage exists, disassemble the
spring brake chamber (actuator) and determine the cause.
FUNCTIONAL TEST
Supply air to the inlet at a pressure lower than 588 kPa {6 kgf/cm2,
85 psi} to make sure the push rod moves smoothly over its entire
stroke. Discharge air to ensure it returns to the original position.
Stroke
50 mm (1.97 in)
BR-12-10
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (AOH)
BR-13-1
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (AOH)
BR-13-2
BRAKE UNIT
AIR BRAKE UNIT
CONTENTS
SPECIFICATIONS ..................................... BR- 1- 1 INSPECTION ........................................... BR- 5- 3
SERVICE DATA ....................................... BR- 1- 2 REASSEMBLY ......................................... BR- 5- 4
TIGHTENING TORQUE ........................... BR- 1- 5 FUNCTIONAL CHECK ............................ BR- 5- 5
DIAGRAM OF PIPING ............................. BR- 1- 7 TRAILER BRAKE HAND CONTROL
BRAKE VALVE .......................................... BR- 2- 1 VALVE ......................................................... BR- 6- 1
CONSTRUCTION .................................... BR- 2- 1 CONSTRUCTION .................................... BR- 6- 1
DISASSEMBLY ........................................ BR- 2- 6 DISASSEMBLY ........................................ BR- 6- 2
INSPECTION .......................................... BR- 2-13 INSPECTION ........................................... BR- 6- 3
REASSEMBLY ........................................ BR- 2-16 REASSEMBLY ......................................... BR- 6- 3
FUNCTIONAL CHECK ........................... BR- 2-19 FUNCTIONAL CHECK ............................ BR- 6- 4
AIR PRESSURE GOVERNOR ................ BR- 3- 1 QUICK RELEASE VALVE ........................ BR- 7- 1
CONSTRUCTION .................................... BR- 3- 1 CONSTRUCTION .................................... BR- 7- 1
DISASSEMBLY AND REASSEMBLY ...... BR- 3- 2 DISASSEMBLY AND REASSEMBLY ...... BR- 7- 1
FUNCTIONAL CHECK ............................ BR- 3- 3 FUNCTIONAL CHECK ............................ BR- 7- 2
AIR DRYER ................................................ BR- 4- 1 DOUBLE CHECK VALVE ........................ BR- 8- 1
= DR-5 = CONSTRUCTION .................................... BR- 8- 1
CONSTRUCTION .................................... BR- 4- 1 DISASSEMBLY AND REASSEMBLY ...... BR- 8- 1
DISASSEMBLY ........................................ BR- 4- 2 FUNCTIONAL CHECK ............................ BR- 8- 2
INSPECTION ........................................... BR- 4- 3 PROTECTION VALVE .............................. BR- 9- 1
REASSEMBLY ......................................... BR- 4- 3 CONSTRUCTION .................................... BR- 9- 1
INSPECTION AFTER MOUNTING ON DISASSEMBLY AND REASSEMBLY ...... BR- 9- 1
VEHICLE .................................................. BR- 4- 6 FUNCTIONAL CHECK ............................ BR- 9- 2
= DR-31 = AIR BRAKE CHAMBER .......................... BR-10- 1
CONSTRUCTION .................................... BR- 4- 7 = NO. 20B =
DISASSEMBLY ........................................ BR- 4- 8 CONSTRUCTION ................................... BR-10- 1
INSPECTION ........................................... BR- 4- 9 DISASSEMBLY ....................................... BR-10- 1
REASSEMBLY ......................................... BR- 4- 9 INSPECTION .......................................... BR-10- 2
INSPECTION AFTER MOUNTING ON REASSEMBLY ........................................ BR-10- 3
VEHICLE ................................................. BR- 4-10 FUNCTIONAL CHECK ........................... BR-10- 3
= DR-42 = = NO. 24 =
CONSTRUCTION ................................... BR- 4-11 CONSTRUCTION ................................... BR-10- 5
DISASSEMBLY ....................................... BR- 4-12 DISASSEMBLY ....................................... BR-10- 5
INSPECTION .......................................... BR- 4-13 INSPECTION .......................................... BR-10- 6
REASSEMBLY ........................................ BR- 4-13 REASSEMBLY ........................................ BR-10- 6
INSPECTION AFTER MOUNTING ON FUNCTIONAL CHECK ........................... BR-10- 7
VEHICLE ................................................. BR- 4-15 SPRING BRAKE CHAMBER
PARKING BRAKE VALVE ....................... BR- 5- 1 (ANCHORLOK MAKE) ............................. BR-11- 1
CONSTRUCTION .................................... BR- 5- 1 = MODEL 3030 =
DISASSEMBLY ........................................ BR- 5- 2 CONSTRUCTION ................................... BR-11- 1
DISASSEMBLY AND REASSEMBLY ..... BR-11- 2
= MODEL 3030 LC = = JIDOSHA KIKI =
CONSTRUCTION ................................... BR-11- 9 CONSTRUCTION ................................... BR-13- 3
DISASSEMBLY AND REASSEMBLY ..... BR-11- 9 DISASSEMBLY AND REASSEMBLY ..... BR-13- 4
LOAD SENSING FUNCTIONAL CHECK ........................... BR-13- 4
PROPORTION VALVE ............................. BR-12- 1 2-WAY RELAY VALVE ............................. BR-14- 1
CONSTRUCTION ................................... BR-12- 1 CONSTRUCTION ................................... BR-14- 1
DISASSEMBLY ....................................... BR-12- 1 DISASSEMBLY ....................................... BR-14- 2
INSPECTION .......................................... BR-12- 3 INSPECTION .......................................... BR-14- 3
REASSEMBLY ........................................ BR-12- 3 REASSEMBLY ........................................ BR-14- 3
FUNCTIONAL CHECK ........................... BR-12- 3 FUNCTIONAL CHECK ........................... BR-14- 3
RELAY VALVE .......................................... BR-13- 1 SYNCHRO VALVE .................................... BR-15- 1
= NABCO = CONSTRUCTION ................................... BR-15- 1
CONSTRUCTION ................................... BR-13- 1 DISASSEMBLY ....................................... BR-15- 2
DISASSEMBLY AND REASSEMBLY ..... BR-13- 2 INSPECTION .......................................... BR-15- 3
FUNCTIONAL CHECK ........................... BR-13- 2 REASSEMBLY ........................................ BR-15- 3
FUNCTIONAL CHECK ........................... BR-15- 4
NYLON TUBING ....................................... BR-16- 1
SERVICE DATA BRAKE UNIT (AIR)
SERVICE DATA
SPECIFICATIONS
Item Contents
Type Dual type
E6-R15
R.H.D. model
Brake valve E6-ER1
Model
E6-RP4
L.H.D. model
E6-ERP1
Type Piston type
Low 667 {6.8, 97}
Air pressure Pressure adjust- Type I
High 785 {8.0, 114}
governor ment range
Low 706 {7.2, 102}
kPa {kgf/cm2, psi} Type II
High 834 {8.5, 121}
Type Barrel type
DR-5
Air dryer
Model DR-31
DR-42
Parking brake valve Cam type (with release knob)
Trailer brake hand control valve Cam type
Quick release valve Diaphragm type
Protection valve Single type
Type Diaphragm type
No. 20B
Air brake cham- Model
No. 24
ber
No. 20B 58.0 (2.283)
Maximum stroke mm (in)
No. 24 63.0 (2.480)
Type Mechanically-actuated release
Spring brake
Model 3030
chamber
Maximum stroke mm (in) 63.5 (2.500)
Load sensing proportion valve (LSPV) Diaphragm type
Relay valve Coil spring type
2-way relay valve Diaphragm type
Synchro valve Piston type
Safety valve opening pressure kPa {kgf/cm2
, psi} 932 - 971 {9.5 - 9.9, 135 - 141}
Check valve opening pressure Supply reservoir fitted Less than 29 {0.3, 4}
2
kPa {kgf/cm , psi} Service reservoir fitted 2.0 - 3.9 {0.02 - 0.04, 0.3 - 0.6}
Air pressure switch Light ON pressure 490 - 549 {5.0 - 5.6, 71 - 80}
kPa {kgf/cm2 , psi} Light OFF pressure 490 - 598 {5.0 - 6.1, 71 - 87}
BR-1-1
SERVICE DATA BRAKE UNIT (AIR)
SERVICE DATA
BRAKE VALVE
Model E6-R15, E6-RP4, E6-ER1 and E6-ERP1
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pin hole I.D. 10.0 (0.394) 10.25 (0.4035)
Pin O.D. 10.0 (0.394) 9.85 (0.3878)
I.D. 10.0 (0.394) 10.25 (0.4035)
Roller Except for E6-ER1
O.D. 18.7 (0.736) 17.60 (0.6929)
Mounting plate bushing I.D. 26.5 (1.043) 26.70 (1.0512)
Piston O.D. 48.7 (1.917) 49.6 (1.953)
E6-ER1 only
Relay piston O.D. 74.77 (2.9437) 74.67 (2.9398)
Plunger O.D. 26.5 (1.043) 26.20 (1.0315)
Main spring 35.8 (1.409) —
Sub spring 19.1 (0.752) —
Relay piston return spring 24.7 (0.972) —
Piston return spring 78.9 (3.106) —
Spring free length
33.2 (1.307) — Except for E6-ER1
Upper valve spring
32.0 (1.260) — E6-ER1
35.6 (1.402) — Except for E6-ER1
Lower valve spring
34.1 (1.343) — E6-ER1
When compressed to
Main spring 235 {24.0, 52.9} —
34.0 mm (1.339 in)
When compressed to
Sub spring 249.1 {25.4, 56.0} —
15.3 mm (0.602 in)
When compressed to
Relay piston return spring 8.8 {0.9, 2.0} —
Spring tension 16.7 mm (0.657 in)
N {kgf, lbf} When compressed to
Piston return spring 89.2 {9.1, 20.1} —
25.4 mm (1.000 in)
When compressed to
Upper valve spring 44.1 {4.5, 9.9} —
14.4 mm (0.567 in)
When compressed to
Lower valve spring 57.9 {5.9, 13.0} —
13.0 mm (0.512 in)
Pressure difference between primary and Less than
—
secondary outlet kPa {kgf/cm2, psi} 29.4 {0.3, 4.3}
12.0 - 18.0
E6-R15 —
(0.472 - 0.709)
Brake pedal free E6-RP4 5.0 - 13.0
—
play E6-ERP1 (0.197 - 0.512)
6.0 - 15.0
E6-ER1 — At an angle of 3º to 5º
(0.236 - 0.591)
BR-1-2
SERVICE DATA BRAKE UNIT (AIR)
NO. 24
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Return spring free length 160.0 (6.299) —
BR-1-3
SERVICE DATA BRAKE UNIT (AIR)
SYNCHRO VALVE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Clearance between lower valve and valve More than
—
guide 0.28 (0.011)
More than
Clearance between piston and body —
0.28 (0.011)
Leakage amount to delivery
and exhaust ports Less than 30 (1.1) —
Air leakage ml (Imp fl oz)/min
test
Leakage amount from exhaust
Less than 30 (1.1) —
port ml (Imp fl oz)/min
Pressure at which valve opens
314 - 373
and delivery pressure rises —
{3.2 - 3.8, 46 - 54}
kPa {kgf/cm2, psi}
Operating
test Supply and control pressures
when delivery pressure is 0 245 - 304
—
kPa {0 kgf/cm2, 0 psi} {2.5 - 3.1, 36 - 44}
kPa {kgf/cm2, psi}
BR-1-4
SERVICE DATA BRAKE UNIT (AIR)
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
E6-R15 Upper piston installation bolt 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
E6-RP4
E6-ERP1 Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Nipple, Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
Brake valve Upper piston installation bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
E6-ER1
Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Nipple, Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
Brake pedal mounting bolt 23 - 32 {2.3 - 3.3, 17 - 24}
L.H.D. model only Brake pedal link mounting bolt 12 - 16 {1.2 - 1.6, 9 - 12}
Brake valve assembly mounting bolt 23 - 32 {2.3 - 3.3, 17 - 24}
Air pressure governor Lock nut 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Cartridge assembly mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Stopper plate mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Terminal cord mounting screw 1.5 - 2.5 {0.15 - 0.25, 1.1 - 1.8}
DR-5
Heater assembly 20 - 29 {2.0 - 3.0, 14 - 22}
Case cover mounting nut 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Purge chamber bracket mounting nut 5 - 6 {0.5 - 0.6, 3.6 - 4.3}
Purge chamber and body mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
Air dryer
Piston mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
DR-31
Bracket tightening bolt 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Heater 23 - 29 {2.3 - 3.0, 17 - 22}
Oil filter mounting rolling screw 2 - 4 {0.2 - 0.4, 1.4 - 2.9}
Case cover mounting rolling screw 2 - 4 {0.2 - 0.4, 1.4 - 2.9}
DR-42
Valve assembly mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Purge chamber mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
Handle head mounting screw 3.4 - 4.9 {0.35 - 0.50, 2.5 - 3.6}
Parking brake valve
Cover mounting screw 5.4 - 7.4 {0.55 - 0.75, 4.0 - 5.4}
Handle head mounting screw 3.4 - 4.9 {0.35 - 0.50, 2.5 - 3.6}
Trailer brake hand control valve
Cover mounting screw 5.4 - 7.4 {0.55 - 0.75, 4.0 - 5.4}
Double check
Type I only Nipple 34 - 44 {3.5 - 4.5, 25 - 33}
valve
Brake chamber mounting nut 81 - 108 {8.3 - 11.0, 60 - 80}
No. 20B Clamp band mounting nut 15 - 20 {1.5 - 2.0, 11 - 14}
Air brake cham- Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
ber Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
No. 24 Clamp band mounting nut 20 - 25 {2.0 - 2.6, 14 - 19}
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
BR-1-5
SERVICE DATA BRAKE UNIT (AIR)
BR-1-6
SERVICE DATA BRAKE UNIT (AIR)
DIAGRAM OF PIPING
PKC series (Air brake vehicle)
PKC tractor
BR-1-7
SERVICE DATA BRAKE UNIT (AIR)
BR-1-8
BRAKE VALVE BRAKE UNIT (AIR)
BRAKE VALVE
CONSTRUCTION
R.H.D. MODEL
Brake valve
<E6-R15>
BR-2-1
BRAKE VALVE BRAKE UNIT (AIR)
<E6-ER1>
BR-2-2
BRAKE VALVE BRAKE UNIT (AIR)
L.H.D. MODEL
Brake valve link assembly
BR-2-3
BRAKE VALVE BRAKE UNIT (AIR)
Brake valve
<E6-RP4>
BR-2-4
BRAKE VALVE BRAKE UNIT (AIR)
<E6-ERP1>
BR-2-5
BRAKE VALVE BRAKE UNIT (AIR)
DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
BR-2-6
BRAKE VALVE BRAKE UNIT (AIR)
DISASSEMBLY
<R.H.D. MODEL>
Brake valve
<E6-R15>
BR-2-7
BRAKE VALVE BRAKE UNIT (AIR)
<E6-ER1>
BR-2-8
BRAKE VALVE BRAKE UNIT (AIR)
<L.H.D. MODEL>
Brake pedal assembly
BR-2-9
BRAKE VALVE BRAKE UNIT (AIR)
Brake valve
<E6-RP4>
BR-2-10
BRAKE VALVE BRAKE UNIT (AIR)
<E6-ERP1>
BR-2-11
BRAKE VALVE BRAKE UNIT (AIR)
}
13 E6-R15
5 E6-RP4
15 E6-ER1 Upper piston assembly
4 E6-ERP1
Remove the upper piston assembly as an assembly and then dis-
assemble.
34 E6-R15
26 E6-RP4 } Lower valve assembly
Remove the lower valve assembly as an assembly and then disas-
semble.
32 E6-ER1
26 E6-ERP1 } Check valve seat
The lower valve assembly can be disassembled by first removing
the check valve seat.
BR-2-12
BRAKE VALVE BRAKE UNIT (AIR)
NOTE
z When securing the piston in a vise, never hold the valve
seat.
50 E6-R15
42 E6-RP4 }Upper valve assembly
Remove the upper valve assembly as an assembly and then disas-
semble.
48 E6-ER1
34 E6-ERP1 } Upper valve assembly
The upper valve assembly can be disassembled by first removing
the retaining ring.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-2-13
BRAKE VALVE BRAKE UNIT (AIR)
BR-2-14
BRAKE VALVE BRAKE UNIT (AIR)
Spring tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
235 When compressed to
Main spring —
{24.0, 52.9} 34.0 mm (1.339 in)
249.1 When compressed to
Sub spring —
{25.4, 56.0} 15.3 mm (0.602 in)
Relay piston 8.8 When compressed to
—
return spring {0.9, 2.0} 16.7 mm (0.657 in)
Piston return 89.2 When compressed to
—
spring {9.1, 20.1} 25.4 mm (1.000 in)
Upper valve 44.1 When compressed to
—
spring {4.5, 9.9} 14.4 mm (0.567 in)
Lower valve 57.9 When compressed to
—
spring {5.9, 13.0} 13.0 mm (0.512 in)
BR-2-15
BRAKE VALVE BRAKE UNIT (AIR)
REASSEMBLY
REASSEMBLY
Key point of reassembly
z Apply lithium soap-base grease or equivalent to the sliding
surfaces of the inlet valve, body and relay piston.
z When assembling the O-ring, be sure to apply lithium soap-
base grease or equivalent to the O-ring. Fill the O-ring
groove with this grease.
z Apply molybdenum disulfide grease or equivalent to the
sliding surfaces (10 mm dia. pin and plunger) of pedal.
z After fitting each retaining ring, make sure it is securely
located in its groove.
48 E6-ER1
34 E6-ERP1 }Upper valve assembly
When assembling the upper valve, pay attention to the direction of
the retainer.
NOTE
z When assembling the upper valve, apply silicone grease
to it.
z When installing the retaining ring, turn it about 30
degrees to make sure it fits securely in the groove.
}
13 E6-R15
5 E6-RP4
15 E6-ER1 Upper piston assembly
4 E6-EPR1
After assembling the upper piston assembly, make sure the spring
seat is located in the center, as shown in the figure.
Except for E6-ER1
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
E6-ER1
: 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
BR-2-16
BRAKE VALVE BRAKE UNIT (AIR)
NOTE
z When securing the piston in a vise, never hold the valve
seat.
3 Pin
When installing the pin, lightly tap in with a hammer or similar tool.
Do not apply excessive force or impact.
INSTALLATION
Key point of installation (L.H.D. model only)
1. Install the brake valve assembly on the brake valve link
assembly. In advance, loosen the link assembly rod nut.
: 23 - 32 N·m {2.3 - 3.3 kgf·m, 17 - 24 ft·lbf}
NOTE
z Apply a coat of molybdenum grease to the plunger rod
butting portion.
BR-2-17
BRAKE VALVE BRAKE UNIT (AIR)
z Install on the cab the link assembly with the brake valve
assembly installed.
: 12 - 16 N·m {1.2 - 1.6 kgf·m, 9 - 12 ft·lbf}
BR-2-18
BRAKE VALVE BRAKE UNIT (AIR)
5. Turn the key switch to “ON”. If the spot light comes on with-
out operating the pedal, adjust the rod length (dimension L)
again.
z Loosen the nut.
z Turn the pedal and turn it back to the link side until the rod
tip separates from the plunger.
z Repeat step 4.
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Fit an air pressure gauge to the line on the brake valve out-
let side (primary and secondary), as close as possible to the
brake valve.
Use an air pressure gauge which is capable of reading up to
981 kPa {10 kgf/cm2, 142 psi}.
2. Fill the air reservoir to the specified air pressure.
3. Make sure there are no leaks coming from the connections.
If there are leaks, repair them.
FUNCTIONAL TEST
1. While watching the air pressure gauge, gradually depress
the brake pedal and take note of the initial rise point (A) on
the air pressure gauge.
<Right-hand drive model>
At point (A), the angle of the depressed brake pedal should
be 2.8 to 3.5º. If it is not, adjust the setscrew located at the
lower portion of the brake pedal so that the angle meets the
specification.
<Left-hand drive model>
At point (A), the push rod stroke should be 1.0 to 1.3 mm
(0.039 to 0.051 in). If it is not, adjust the length of the push
rod so that it meets the specification.
2. Next, further depress the brake pedal to check that pres-
sures at the brake rapid-pressure rise points (B and C) cor-
respond to the values shown in the figure. When the last
rapid-rise point (C) is surpassed, the pressure increases
rapidly to equal the air pressure in the reservoir.
Before reaching the full stroke (D), the air reservoir pres-
sure equalize with the brake pressure. There must be some
brake travel remaining at this point.
BR-2-19
BRAKE VALVE BRAKE UNIT (AIR)
R.H.D. model
Item Point B Point C
Pedal step E6-R15 7.5º 15º
angle E6-ER1 8º 15.3º - 18.3º
L.H.D. model
Item Point B Point C
6.0 - 7.2
Plunger stroke mm (in) 3.0 (0.118)
(0.236 - 0.283)
BR-2-20
AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)
BR-3-1
AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)
BR-3-2
AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)
REASSEMBLY
Key point of reassembly
z Prior to reassembly, apply a coat of silicone grease to the
inner wall of the body, the outer surface of the piston and
the O-ring groove, O-ring, spring guide and adjusting screw.
6 Piston
Position the O-ring in the groove at the piston stem hole. Install the
valve on the piston with the small spring diameter end facing the
valve, and push the large spring diameter end into the groove in the
piston.
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Disconnect the check valve from the air reservoir and con-
nect a 981 kPa {10 kgf/cm2, 142 psi} pressure gauge to it.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.
FUNCTIONAL TEST
1. Gradually increase air pressure. When the air pressure
increase is stopped, ensure that the air pressure is within
the specified high pressure range.
Next, gradually decrease the air pressure and ensure that it
is within the low pressure range when the “hissing” sound is
heard.
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit
647 - 686
Low range —
{6.6 - 7.0, 94 - 100}
Type I
765 - 814
High range —
{7.8 - 8.3, 111 - 118}
686 - 726
Low range —
{7.0 - 7.4, 100 - 105}
Type II
814 - 863
High range —
{8.3 - 8.8, 118 - 125}
BR-3-3
AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)
BR-3-4
AIR DRYER BRAKE UNIT (AIR)
AIR DRYER
= DR-5 =
CONSTRUCTION
BR-4-1
AIR DRYER BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-4-2
AIR DRYER BRAKE UNIT (AIR)
6 Case cover
Remove the nut while pushing the case cover, and then remove the
case cover.
WARNING
WARNING
z Be sure to hold down the case cover from above while
removing. If this is not done, the case cover will jump out
because of the force of the set spring.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
26 Valve assembly
When inserting the valve assembly into the body, be careful not to
allow the O-ring to get caught in the cutout of the body.
15 Filter plate
Keep pushing the spacer, O-ring and gasket ring into the recess in
the oil filter assembly. At this point, install the filter plate and gasket
ring from the other side and then insert a bolt from the filter plate
side.
BR-4-3
AIR DRYER BRAKE UNIT (AIR)
NOTE
z Install the filter plate with the protruding side in the cen-
ter facing the oil filter assembly side.
13 Filter
With the softer layer of the filter facing upward, insert it all the way
into the case.
12 Desiccant
1. Fill the case with the specified 1,100 g (39 oz) of desiccant.
In the case of desiccant being purchased as a repair kit,
insert the full contents of one bag.
NOTE
z Replace the desiccant with a new one. Be sure to use the
specified DR-5. DR-31 and DR-41 are different from DR-5.
BR-4-4
AIR DRYER BRAKE UNIT (AIR)
11 Filter
With the softer layer of the filter facing downward, insert it into the
case.
7 Check valve
Push the raised portion in the center of the check valve to fit it in the
case cover.
NOTE
z Apply grease to the projecting portion of the check valve
to facilitate easy fitting.
6 Case cover
Place the filter plate and set spring in the case already containing
desiccant. After that, fit the case cover and push on with the special
tool and then secure with a bolt, spring washer and nut.
: 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
WARNING
WARNING
z Be careful when installing as the set spring setting load
is almost 726 N {74 kgf, 163 lbf}.
3 Stopper ring
Lever the stopper ring into the groove by moving a flat-blade screw-
driver outward.
BR-4-5
AIR DRYER BRAKE UNIT (AIR)
BR-4-6
AIR DRYER BRAKE UNIT (AIR)
= DR-31 =
CONSTRUCTION
BR-4-7
AIR DRYER BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-4-8
AIR DRYER BRAKE UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
14 Oil filter
Install the oil filter with the bend section of the net facing down.
11 , 7 Filter
Be sure to install the filter with the thick, soft layer side facing up.
10 Desiccant
1. The standard weight of the desiccant to be used is 480 g
(16.93 oz). In the case of desiccant being purchased as a
repair kit, use the full contents of one bag.
BR-4-9
AIR DRYER BRAKE UNIT (AIR)
BR-4-10
AIR DRYER BRAKE UNIT (AIR)
= DR-42 =
CONSTRUCTION
BR-4-11
AIR DRYER BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-4-12
AIR DRYER BRAKE UNIT (AIR)
23 Piston
While holding the piston using a 10 mm (0.39 in) hex. wrench,
remove the bolts, piston, valve and valve spring.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
19 Exhaust cover
Place a suitable pipe on the flat surface of the exhaust cover, and
lightly tap the end of the pipe using a hammer until the exhaust
cover is properly positioned in the valve body.
10 Filter
Install the filter with the soft surface side facing upward.
BR-4-13
AIR DRYER BRAKE UNIT (AIR)
9 Desiccant
Place the specified amount [approximately 200 g (7.05 oz)] of des-
iccant in the filter case. If a bag of desiccant is available in the
repair kit, use the entire contents in the filter case.
NOTE
z Discard the old bag of desiccant, and replace with a new
one designated for the DR-42 unit. Note that the desic-
cant used in the DR-42 unit differs from those for DR-2
and DR-3 units.
NOTE
z Install the filter with the soft side facing down.
Tapping method
z Using both hands, lift the filter case to a height of 10 cm (3.9
in).
z Repeatedly tap the case against a cloth folded in two or
three, approximately 30 times.
NOTE
z The cloth is necessary to prevent the bottom of the case
from becoming scratched.
z Finish “tapping” after the filter plate is approximately 4 to 6
mm (0.16 to 0.24 in) below the original position.
4 Check valve
Fit the check valve into the case cover while pushing the expanded
middle portion of the valve.
NOTE
z Apply grease to the protrusion of the check valve in
advance to facilitate installation.
BR-4-14
AIR DRYER BRAKE UNIT (AIR)
BR-4-15
PARKING BRAKE VALVE BRAKE UNIT (AIR)
BR-5-1
PARKING BRAKE VALVE BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-5-2
PARKING BRAKE VALVE BRAKE UNIT (AIR)
15 C-ring
Remove the piston assembly C-ring, and remove the feed valve
seat and the O-ring. Also remove the C-ring from the feed valve,
and remove the feed valve. Remove the O-ring from the piston
O.D. section.
NOTE
z When removing the C-ring from the feed valve, pay atten-
tion not to expand it excessively.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Free length
Unit: mm (in)
Item Maintenance standard Service limit
Main spring 31.7 (1.248) 30.7 (1.209)
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)
BR-5-3
PARKING BRAKE VALVE BRAKE UNIT (AIR)
REASSEMBLY
REASSEMBLY
Key point of reassembly
z Reassemble after greasing the O-ring groove, pin, shim,
and sliding sections.
22 Cam ring
Apply grease to the cam ring sliding surface, and install the cam
ring into the holder so that the pin is positioned as shown.
BR-5-4
PARKING BRAKE VALVE BRAKE UNIT (AIR)
8 Valve spring
When installing the valve spring, check that the valve spring is cor-
rectly positioned on the feed valve C-ring.
3 Spring
Apply grease to the handle assembly fitting portion of the body.
Rotate the cam holder in a clockwise direction as viewed from the
handle head side until it contacts the stopper, align the cutout por-
tion of the spring seat coated with grease with the body hook hole,
and then fit the hooked end of the spring into the body hook hole.
FUNCTIONAL CHECK
AIR LEAKAGE TEST
With the handle set in the PARK position, apply an air pressure of
785 kPa {8 kgf/cm2, 114 psi} to the inlet port. Apply soapsuds to the
exhaust port to make sure no air is leaking. Rotate the handle to the
RELEASE position. Apply soapsuds to the exhaust port again, and
apply air pressure. Check that the diameters of the air bubbles
formed in 15 seconds are within 15 mm (0.59 in). Also check that
no air is leaking from each joint and tightened portion of the body.
BR-5-5
PARKING BRAKE VALVE BRAKE UNIT (AIR)
FUNCTIONAL TEST
Attach a pressure gauge to the outlet port and also to the second-
ary port. Using an angle gauge, measure the brake handle angle,
and check that the pressure is within the performance levels shown
below. If it is not within the specified range, adjust as follows:
1. To adjust the initial outlet pressure, change the number of
main spring shims. If the pressure is too high, reduce the
number of main spring shims. If the pressure is too low,
increase the number of shims.
2. To the angle at which air discharge starts, change the num-
ber of cam holder shims (cam side). In this case, check the
dimension from the body to exhaust valve seat.
BR-5-6
TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)
BR-6-1
TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-6-2
TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Free length
Unit: mm (in)
Item Maintenance standard Service limit
Main spring 31.7 (1.248) 30.7 (1.209)
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)
REASSEMBLY
REASSEMBLY
Key point of reassembly
z Reassemble after greasing the O-ring groove, pin, shim and
sliding sections.
20 Cam ring
Apply grease to the cam ring sliding surface, and install the cam
ring so that the pin is positioned as shown.
BR-6-3
TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)
2. Install the cam ring into the body so that its notched portion
aligns with the pin driven into the body. Adjust the thickness
of shim (cam side) so that the dimension (Z) from the body
end face to the exhaust valve seating face is 38.3 to 38.7
mm (1.508 to 1.524 in).
8 Valve spring
Install the valve spring by checking that it is correctly positioned on
the feed valve C-ring.
FUNCTIONAL CHECK
AIR LEAKAGE TEST
With the handle set in the RELEASE position, apply an air pressure
of 785 kPa {8 kgf/cm2, 114 psi} to the inlet port. Apply soapsuds to
the exhaust port to make sure no air is leaking. Rotate the handle to
the brake operating position. Apply soapsuds to the exhaust port
again, and apply air pressure. Check that the diameters of the air
bubbles formed in 15 seconds are within 15 mm (0.59 in). Also
check that no air is leaking from each joint and tightened portion of
the body.
BR-6-4
TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)
FUNCTIONAL TEST
Attach a pressure gauge to the outlet port.
Using an angle gauge, measure the brake handle angle, and check
that the pressure is within the performance levels shown below. If it
is not within the specified range, adjust as follows:
1. To adjust the initial outlet pressure, change the number of
main spring shims. If the pressure is too high, reduce the
number of main spring shims. If the pressure is too low,
increase the number of shims.
2. To the angle at which air discharge begins, change the
number of cam holder shims (cam side). In this case, check
the dimension from the body to the exhaust valve seat.
BR-6-5
QUICK RELEASE VALVE BRAKE UNIT (AIR)
BR-7-1
QUICK RELEASE VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
1. Depress the brake valve to supply air pressure of 588 kPa
{6 kgf/cm2, 85 psi} (minimum) to the brake chamber. While
the brake valve is depressed, apply soapy water to the
exhaust port and connections to check for air leakage.
2. Also check that air pressure is quickly routed to the brake
chamber when the brake valve is depressed and that it
quickly discharges from the brake chamber through the
exhaust port when the brake valve is released.
BR-7-2
DOUBLE CHECK VALVE BRAKE UNIT (AIR)
BR-8-1
DOUBLE CHECK VALVE BRAKE UNIT (AIR)
BR-8-2
PROTECTION VALVE BRAKE UNIT (AIR)
PROTECTION VALVE
CONSTRUCTION
BR-9-1
PROTECTION VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Connect air pressure gauges to the inlet and outlet of the
protection valve. Each pressure gauge should be capable
of registering more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.
FUNCTIONAL TEST
Maintain both the inlet and outlet of the protection valve at a pres-
sure of 686 kPa {7 kgf/cm2, 100 psi}. Decrease the air pressure at
the outlet for the specified length of time.
The minimum holding pressure at the inlet should be in the range of
422 to 461 kPa {4.3 to 4.7 kgf/cm2, 61 to 67 psi} regardless of
decreases in the outlet air pressure.
Specified length of time:
Less than 3 seconds required to decrease air pressure
from 392 to 686 kPa {4 to 7 kgf/cm2, 57 to 100 psi}
BR-9-2
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-10-1
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
1 Clamp band
Compress the return spring. Project the push rod approximately 5
mm (0.20 in) and secure it with a hand clamp.
Remove the clamp bolt and separate the clamp.
6 Non-pressure plate
Place the push rod side downward on the work bench. Hold down
the non-pressure plate and remove the hand clamp.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Return spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Free length 115.1 (4.531) —
Tension When compressed to
137 {14, 31} —
N {kgf, lbf} 70.0 mm (2.756 in)
BR-10-2
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
REASSEMBLY
REASSEMBLY
Key point of reassembly
1 Clamp band
1. Force the non-pressure plate downward until its bottom sur-
face contacts the work bench. Using the hand clamp,
secure the push rod at this position.
z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 225 mm (8.858 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Supply to the inlet air at a pressure of 490 to 785 kPa {5 to 8 kgf/
cm2, 71 to 114 psi}. Apply soapy water over the entire pressure
plate, the clamp portion, and the area around the non-pressure
plate hole. Ensure that there is no leakage. If leakage exists, disas-
semble the brake chamber and determine the cause.
BR-10-3
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
FUNCTIONAL TEST
Confirm that the push rod operates rapidly during the entire stroke
when air of 98 kPa {1 kgf/cm2, 14 psi} is supplied from the inlet port,
and, when air is exhausted, that is returns rapidly to its original
position.
BR-10-4
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
= NO. 24 =
CONSTRUCTION
DISASSEMBLY
DISASSEMBLY
BR-10-5
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
1 Clamp band
The pressure plate is pushed up by the spring force of the return
spring.
Remove the clamp band while pressing the pressure plate against
the spring force.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
3 Diaphragm
Assemble the diaphragm so that it is at the center of the non-pres-
sure plate.
2 Pressure plate
Assemble the pressure plate to the non-pressure plate by aligning
the match marks.
BR-10-6
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
1 Clamp band
Install the clamp band while tapping the outer periphery of the band
with a plastic hammer.
: 20 - 25 N·m {2.0 - 2.6 kgf·m, 14 - 19 ft·lbf}
z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 225 mm (8.858 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Coat the clamp band completely with soapsuds, and apply an air
pressure of 785 kPa {8 kgf/cm2, 114 psi} to the inlet port to check
for air leaks.
BR-10-7
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
CONSTRUCTION
BR-11-1
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
BR-11-2
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
BR-11-3
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
General instructions
If spring brake shows structural damage, do not cage compression
spring. Remove spring brake from vehicle and replace with new
unit.
If vehicle air pressure is used to aid in the caging process, do not
tighten release stud nut more than finger tight. The air pressure
must always be exhausted after the compression spring has been
mechanically caged before any clamps are removed.
Never strike any part of the spring brake with a hammer or any
other heavy object; structural damage may result. When replacing
diaphragms in spring brakes installed on a vehicle, block wheels to
prevent rollaway.
Piloted diaphragms are to be used only with Anchorlok Spring
Brakes and only on the emergency side.
When compression spring is broken do not attempt to mechanically
release (cage) the spring. Remove complete spring brake and
replace with identical size Anchorlok Spring Brake.
Do not drop spring chamber assembly as compression spring may
forcefully release.
BR-11-4
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
DANGER
z The below listed instructions 7, 8 and 9 only apply when
spring brake is not pressurized. If air pressure is used to
compress spring, do not tighten release stud nut more
than finger tight. Torqueing the nut can cause pressure
plate damage resulting in sudden release of the spring
causing death or severe personal injury.
BR-11-5
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
WARNING
WARNING
z If the recommended “X” dimension is not correct for
chamber size and torque value, the spring brake should
be replaced.
BR-11-6
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
BR-11-7
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 60 mm (2.362 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}
INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
INSTRUCTIONS FOR MECHANICAL RELEASE OF
SPRING BRAKE for details.)
z Check the position mark (R or L) on the chamber, which
was applied during dismounting, and install the assem-
bly on the same side it was dismounted from.
z After mounting, uncage compression spring and reas-
semble release tool in side pocket of adapter. Install dust
plug in release tool key hole in center of chamber.
BR-11-8
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
= MODEL 3030 LC =
CONSTRUCTION
BR-11-9
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
BR-11-10
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
General instructions
If spring brake shows structural damage, do not cage compression
spring. Remove spring brake from vehicle and replace with new
unit.
If vehicle air pressure is used to aid in the caging process, do not
tighten release stud nut more than finger tight. The air pressure
must always be exhausted after the compression spring has been
mechanically caged before any clamps are removed.
Never strike any part of the spring brake with a hammer or any
other heavy object; structural damage may result. When replacing
diaphragms in spring brakes installed on a vehicle, block wheels to
prevent rollaway.
When compression spring is broken do not attempt to mechanically
release (cage) the spring. Remove complete spring brake and
replace with identical size Anchorlok Spring Brake.
Do not drop spring chamber assembly as compression spring may
forcefully release.
BR-11-11
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
DANGER
z The below listed instructions 1, 2 and 3 only apply when
spring brake is not pressurized. If air pressure is used to
compress spring, do not tighten release stud nut more
than finger tight. Torqueing the nut can cause pressure
plate damage resulting in sudden release of the spring
causing death or severe personal injury.
BR-11-12
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 60 mm (2.362 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}
BR-11-13
SPRING BRAKE CHAMBER (ANCHORLOK MAKE) BRAKE UNIT (AIR)
INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
INSTRUCTIONS FOR MECHANICAL RELEASE OF
SPRING BRAKE for details.)
z Check the position mark (R or L) on the chamber, which
was applied during dismounting, and install the assem-
bly on the same side it was dismounted from.
z After mounting, uncage compression spring and reas-
semble release tool in side pocket of adapter. Install dust
plug in release tool key hole in center of chamber.
BR-11-14
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)
DISASSEMBLY
REMOVAL
Key point of removal
z Remove any mud or dirt attached to the exteriors before
disassembling.
NOTE
z Before removing the load sensing proportion valve, mea-
sure the installation length of the wire and confirm that
the indicator is aligned with the alignment mark (under
no load conditions).
BR-12-1
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)
DISASSEMBLY
BR-12-2
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
5 Retaining ring
When reassembling the piston assembly, install the valve, valve
spring and spring seat, and secure these parts with a retaining ring.
INSTALLATION
Key point of installation
Install the load sensing proportion valve in the vehicle and set the
wire length as follows:
1. Set the installation length of the wire so that the indicator is
aligned with the alignment mark on the body. Then fix the
wire.
2. Measure the installation length of the wire and make sure it
is equal with the length measured before removal.
NOTE
z The wire length should be set with the vehicle parked on
a level surface under no load conditions.
FUNCTIONAL CHECK
AIR LEAKAGE TEST
1. Close the brake chamber side (delivery port) and supply
pressurized air at 686 kPa {7 kgf/cm2, 100 psi} from the
brake valve side (supply port) to move the operating arm up
and down between MAX and MIN. Coat soapy water
around the body and check for air leakage.
2. Air leakage from the exhaust port must be below 25 mm
(0.98 in) in soapy water bubbles within 5 minutes after fixing
the operating arm in position.
BR-12-3
LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)
BR-12-4
RELAY VALVE BRAKE UNIT (AIR)
RELAY VALVE
= NABCO =
CONSTRUCTION
BR-13-1
RELAY VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
OPERATIONAL CHECK
1. Adjust the air pressure to the specified value.
2. Be sure that the brake operates promptly when the parking
brake valve button is pulled and that the brake is released
promptly when the button is pressed to its original position.
BR-13-2
RELAY VALVE BRAKE UNIT (AIR)
= JIDOSHA KIKI =
CONSTRUCTION
BR-13-3
RELAY VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL TESTS
1. Connect two air pressure gauges: one in the signal line
between the brake and relay valves and another in the
operating pressure line between the relay valve and air
chamber. Each pressure gauge should be capable of mea-
suring more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase the air reservoir pressure to the specified level.
3. Check all line connections to ensure that no leakage is
present. If necessary, correct leaking connections.
FUNCTIONAL TEST
1. Depress the brake pedal to ensure that the pressure differ-
ence between the two gauges is within 29.4 kPa {0.3 kgf/
cm2, 4.3 psi}.
2. Also check to ensure that the readings on the two pressure
gauges follow up proportionally when the brake pedal is
depressed or released.
BR-13-4
2-WAY RELAY VALVE BRAKE UNIT (AIR)
BR-14-1
2-WAY RELAY VALVE BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-14-2
2-WAY RELAY VALVE BRAKE UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Valve spring
Maintenance
Item Service limit Remarks
standard
Free length
46.0 (1.811) —
mm (in)
When com-
Tension
59 {6.05, 13} — pressed to 30.0
N {kgf, lbf}
mm (1.181 in)
REASSEMBLY
REASSEMBLY
Key point of reassembly
8 Diaphragm
When installing the diaphragm, pay attention not to allow dirt and
dust to contact the cover and body surfaces.
: 12 - 15 N·m {1.2 - 1.5 kgf·m, 9 - 11 ft·lbf}
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Allowable air leakage
Part
ml (Imp fl oz)/min Test pressure kPa {kgf/cm2, psi} Remarks
BR-14-3
2-WAY RELAY VALVE BRAKE UNIT (AIR)
BR-14-4
SYNCHRO VALVE BRAKE UNIT (AIR)
SYNCHRO VALVE
CONSTRUCTION
BR-15-1
SYNCHRO VALVE BRAKE UNIT (AIR)
DISASSEMBLY
DISASSEMBLY
BR-15-2
SYNCHRO VALVE BRAKE UNIT (AIR)
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
REASSEMBLY
REASSEMBLY
Key point of reassembly
11 Valve guide
Assemble the lower valve assembly paying attention to the orienta-
tion of the valve guide.
NOTE
z After assembling, check that the retaining ring is
installed correctly.
BR-15-3
SYNCHRO VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
AIR LEAKAGE TEST
1. Verify leakage to the delivery port and exhaust port when air
pressure of 686 kPa {7 kgf/cm2, 100 psi} is supplied to the
supply port section.
Unit: ml (Imp fl oz)/min
Maintenance standard Service limit
Less than 30 (1.1) —
OPERATING TEST
1. Verify the pressure at which the delivery pressure starts ris-
ing when pressure is applied to both the supply and control
ports at the same time. The pressure is gradually increased.
Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit
314 - 373 {3.2 - 3.8, 46 - 54} —
BR-15-4
NYLON TUBING BRAKE UNIT (AIR)
NYLON TUBING
NYLON TUBING
For the most part, in the air brake system, the nylon tubing is
assembled. The fittings used at the ends of nylon tubing are a com-
pression-type as follows:
To assemble tubing ends for use with the compression-type fittings,
the following steps should be followed carefully.
A tube insert will be used in all applications of the nylon tubing in
the air brake system. The insert provides a stiff or rigid area for the
sleeve to be crimped or compressed on the tube and prevents col-
lapsing the tubing when the nut is tightened.
Once the tubing has been connected and tightened, the sleeve has
been crimped on the tubing and insert. Since the sleeve has been
compressed and distortion of the insert may have resulted, the
sleeve and insert should never be used the second time.
1. Loosen and remove nut from connector.
2. Pull tubing from connector.
3. Repeat the same operations at the other end of the tube. If
only one end of the tube needs repair, the other end need
not be disconnected if the tube is long enough to permit
repair.
4. Cut the selected size of the tube to length.
Be sure to make smooth, square cuts. Either a sharp knife
or hack saw may be used.
5. Position the nut on the tube.
6. Position the sleeve on the tube.
7. Insert the tube insert into the tube.
8. Position the tube, insert and sleeve in the connector. Push
the tube into the connector until it bottoms.
9. Install the tighten the nut to secure the sleeve on the tube.
10. Inspect the tube connections for air leakage.
With the tube and associated fittings charged to full system air
pressure, coat tube lines and fittings with soap suds to check
for leakage. No leakage is permissible. Leakage at a tube fit-
ting is sometimes corrected by tightening the nut. If this fails to
correct the leakage, replace the tube fitting, tube or both.
PRECAUTIONS
The originally installed nylon tubing should not be substituted for
any metallic tubing. In addition, the following precautions must be
taken in the use of nylon tubing.
1. Do not use nylon tubing for any application which would
cause it to be exposed to temperatures below -40ºC (-40ºF)
or above 90ºC (194ºF).
2. Do not subject nylon tubing to working pressure in excess
of 981 kPa {10 kgf/cm2, 142 psi}.
3. Do not use nylon tubing for frame-to-axle, tractor-to-trailer or
any similar line where a high degree of flexibility is required.
4. Observe extreme care when welding or drilling near nylon
tubing. Hot slag or sparks will damage the tubing.
5. Protect nylon tubing from battery acid. The service nylon
tubing will be marked with name, number, type, size and
manufacturing code designations. This marking is intended
to positively identify the tubing and prevent substitution of
inferior quality tubing.
BR-16-1
PARKING BRAKE
CONTENTS
SERVICE DATA .......................................... BR-1- 1 DISASSEMBLY ......................................... BR-4- 3
SPECIFICATIONS .................................... BR-1- 1 INSPECTION ............................................... BR-4- 4
SERVICE DATA ........................................ BR-1- 1 REPAIR AND REPLACEMENT ................ BR-4- 5
TIGHTENING TORQUE ............................ BR-1- 2 REPLACING THE BRAKE LINING ........... BR-4- 5
TOOLS .......................................................... BR-2- 1 REASSEMBLY ............................................ BR-4- 6
REASSEMBLY .......................................... BR-4- 6
= UNIT NAME CB52 = INSTALLATION ......................................... BR-4- 7
ADJUSTMENT ............................................ BR-4- 8
CONSTRUCTION ....................................... BR-3- 1
DISASSEMBLY ........................................... BR-3- 2 = UNIT NAME CB31 =
REMOVAL ................................................. BR-3- 2
DISASSEMBLY ......................................... BR-3- 3 CONSTRUCTION ....................................... BR-5- 1
INSPECTION ............................................... BR-3- 4 DISASSEMBLY ........................................... BR-5- 2
REASSEMBLY ............................................ BR-3- 5 REMOVAL ................................................. BR-5- 2
REASSEMBLY .......................................... BR-3- 5 DISASSEMBLY ......................................... BR-5- 3
INSTALLATION ......................................... BR-3- 6 INSPECTION ............................................... BR-5- 4
ADJUSTMENT ............................................ BR-3- 7 REPAIR AND REPLACEMENT ................ BR-5- 5
REPLACING THE BRAKE LINING ........... BR-5- 5
= UNIT NAME CB41 = REASSEMBLY ............................................ BR-5- 6
REASSEMBLY .......................................... BR-5- 6
CONSTRUCTION ....................................... BR-4- 1 INSTALLATION ......................................... BR-5- 7
DISASSEMBLY ........................................... BR-4- 2 ADJUSTMENT ............................................ BR-5- 8
REMOVAL ................................................. BR-4- 2
SERVICE DATA PARKING BRAKE
SERVICE DATA
SPECIFICATIONS
Unit name CB52 CB41 CB31
Type of parking brake Propeller shaft braking, internal expansion type
Type of brake lining Duo-servo type
Operating system Mechanical type
Brake drum I.D. mm (in) 203.2 (8.00) 254 (10.00) 305 (12.00)
Width 35 (1.38) 60 (2.36) 75 (2.95)
Brake lining mm (in)
Thickness 5.0 (0.197) 5.7 (0.224) 6.1 (0.240)
Number of brake linings 1 per brake shoe
UNIT NAME
CB 4 1
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Parking brake lever stroke 3 - 11 notches —
CB52 203.2 (8.00) 204.2 (8.04)
Brake drum I.D. CB41 254 (10.00) 256 (10.08)
CB31 305 (12.00) 307 (12.09)
Difference between maxi-
mum and minimum values
Uneven brake drum wear 0.02 (0.0008) 0.2 (0.008)
measured at 4 points of the
I.D.
CB52 5.0 (0.197) 1.5 (0.059)
Brake lining thickness CB41 5.7 (0.224) 3.1 (0.122) Thickness of remaining lining
CB31 6.1 (0.240) 3.7 (0.146)
0.3 - 0.5 Back up 8 to 10 notches from
CB52 —
(0.012 - 0.020) zero clearance.
Clearance between the 0.2 - 0.3 Back up 8 notches from zero
CB41 —
brake drum and lining (0.008 - 0.012) clearance.
0.2 - 0.3 Back up 8 to 9 notches from
CB31 —
(0.008 - 0.012) zero clearance.
BR-1-1
SERVICE DATA PARKING BRAKE
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
CB52 15 - 20 {1.5 - 2.0, 11 - 14}
Brake lever mounting nut CB41 17 - 23 {1.7 - 2.3, 12 - 17}
CB31 15 - 23 {1.5 - 2.3, 11 - 17}
CB52 98 - 118 {10 - 12, 72 - 87}
Brake assembly mounting CB41 196 - 235 {20 - 24, 145 - 174}
bolt 137 - 157 {14 - 16, 101 - 116} Transmission model: MPS50
CB31
245 - 294 {25 - 30, 181 - 217} Transmission model: MPS62
Transmission model: MHS50, MHS60
*Type I 392 - 500 {40 - 51, 289 - 369}
Width across flats = 46 mm (1.81 in)
CB52
Transmission model: MLS61, MLS62
*Type II 598 - 745 {61 - 76, 441 - 550}
Width across flats = 50 mm (1.97 in)
Transmission model: MLS61, MLS62,
598 - 745 {61 - 76, 441 - 550} MPS50
Width across flats = 50 mm (1.97 in)
Companion flange nut CB41
Transmission model: MPS62
686 - 981 {70 - 100, 506 - 723} Width across flats = 55 mm (2.17 in)
or 58 mm (2.28 in)
Transmission model: MPS50
598 - 745 {61 - 76, 441 - 550}
Width across flats = 50 mm (1.97 in)
CB31
Transmission model: MPS62
686 - 981 {70 - 100, 506 - 723}
Width across flats = 58 mm (2.28 in)
Brake drum mounting bolt CB41 and CB31 118 - 137 {12 - 14, 87 - 101}
PS860 88 - 108 {9 - 11, 65 - 80}
Propeller shaft mounting bolt
PS420, 430, 520 211 - 240 {21.5 - 24.5, 156 - 177}
NOTE
z *: Type I: Castellated nut
Type II: Pinion nut (Clinched type)
BR-1-2
TOOLS PARKING BRAKE
TOOLS
Tool name and number Description Shape
Return spring remover Used to remove the brake shoe return spring
99878 Z0000
Return spring replacer Used to install the brake shoe return spring
99879 Z0000
Socket wrench
99535 Z0011
Width across flats = 46 mm
(1.81 in)
Socket wrench
99535 Z5007
Width across flats = 55 mm
(2.17 in)
Socket wrench
99535 Z0074
Width across flats = 58 mm
(2.28 in)
BR-2-1
CONSTRUCTION CB52
BR-3-1
DISASSEMBLY CB52
DISASSEMBLY
z Chock the wheels so that the vehicle cannot move.
z Shift the gear into first or reverse so as not to turn the pro-
peller shaft.
REMOVAL
Key point of removal
<Type I>
1. Remove the cotter pin.
2. Unlock the castellated nut, and remove the castellated nut
using socket wrench (99535 Z0011). Remove the compan-
ion flange, plain washer and O-ring.
<Type II>
1. Unlock the pinion nut, and remove the pinion nut using
socket wrench (99535 Z0003). Remove the companion
flange and O-ring.
NOTE
z When loosening the pinion nut, support the transmission
case securely so that it does not move.
z Do not re-use the pinion nut after removal.
BR-3-2
DISASSEMBLY CB52
DISASSEMBLY
BR-3-3
INSPECTION CB52
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-3-4
REASSEMBLY CB52
REASSEMBLY
REASSEMBLY
Key point of reassembly
11 Support plate
When reassembling the hand brake, coat each of the following slid-
ing parts with heat resistant grease.
1. Camshaft and brake shoe contact parts
2. Camshaft and plate contact surface
3. Camshaft and support plate contact surface
4. Brake shoe and support plate contact surface
5. Brake shoe and adjuster contact surface
6. Adjusting screw threads and socket
2 Return spring
Install the brake shoe return spring using the return spring replacer
(99879 Z0000).
NOTE
z Make sure that the brake shoe return spring is installed
correctly.
BR-3-5
REASSEMBLY CB52
INSTALLATION
Key point of installation
<Type I>
Install the companion flange, O-ring, plain washer and castellated
nut using the socket wrench (99535 Z0011).
: 392 - 500 N·m {40 - 51 kgf·m, 289 - 369 ft·lbf}
<Type II>
Install the companion flange, O-ring and pinion nut. Tighten the lock
nut using the socket wrench (99535 Z0003).
: 598 - 745 N·m {61 - 76 kgf·m, 441 - 550 ft·lbf}
NOTE
z Lock the pinion nut so that two clinched points contact
each other.
z When tightening the pinion nut, support the transmission
case securely so that it does not move.
BR-3-6
ADJUSTMENT CB52
ADJUSTMENT
BRAKE LINING CLEARANCE
Chock the front wheels and jack up the rear wheel to adjust the
brake lining clearance.
1. Remove the rubber plug attached to the adjusting hole in
the brake drum. Turn the drum by hand so that the adjusting
hole is located at the lower portion (where the adjuster can
be seen).
BR-3-7
CONSTRUCTION CB41
BR-4-1
DISASSEMBLY CB41
DISASSEMBLY
z Chock the wheels so that the vehicle cannot move.
z Shift the gear into first or reverse so as not to turn the pro-
peller shaft.
REMOVAL
Key point of removal
1. Unlock the pinion nut, and remove the pinion nut using
socket wrench. Remove the companion flange and O-ring.
Socket wrench:
99535 Z0003 ... width across flats = 50 mm (1.97 in)
99535 Z5007 ... width across flats = 55 mm (2.17 in)
99535 Z0074 ... width across flats = 58 mm (2.28 in)
NOTE
z When loosening the pinion nut, support the transmission
case securely so that it does not move.
z Do not re-use the pinion nut after removal.
BR-4-2
DISASSEMBLY CB41
DISASSEMBLY
BR-4-3
INSPECTION CB41
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-4-4
REPAIR AND REPLACEMENT CB41
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-4-5
REASSEMBLY CB41
REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate
When reassembling the hand brake, coat each of the following slid-
ing parts with heat resistant grease.
1. Camshaft and brake shoe contact parts
2. Camshaft and plate contact surface
3. Camshaft and support plate contact surface
4. Brake shoe and support plate contact surface
5. Brake shoe and adjuster contact surface
6. Adjusting screw threads and socket
2 Return spring
Install the brake shoe return spring using the return spring replacer
(99879 Z0000).
NOTE
z Make sure that the brake shoe return spring is installed
correctly.
BR-4-6
REASSEMBLY CB41
INSTALLATION
Key point of installation
Install the companion flange, O-ring and pinion nut. Tighten the lock
nut using the socket wrench.
Socket wrench
99535 Z0003 (Width across flats = 50 mm (1.97 in) 99535
Z0074 (Width across flats = 55 mm (2.17 in) or 58 mm (2.28
in)
: 598 - 745 N·m {61 - 76 kgf·m, 441 - 550 ft·lbf}
Pinion nut: Width across flats = 50 mm (1.97 in)
686 - 981 N·m {70 - 100 kgf·m, 506 - 723 ft·lbf}
Pinion nut: Width across flats = 55 mm (2.17 in) or
58 mm (2.28 in)
NOTE
z Lock the pinion nut so that two clinched points contact
each other.
z When tightening the pinion nut, support the transmission
case securely so that it does not move.
BR-4-7
ADJUSTMENT CB41
ADJUSTMENT
BRAKE LINING CLEARANCE
Chock the front wheels and jack up the rear wheel to adjust the
brake lining clearance.
1. Remove the rubber plug attached to the adjusting hole in
the brake drum. Turn the drum by hand so that the adjusting
hole is located at the lower portion (where the adjuster can
be seen).
2. Using a flat-blade screwdriver, turn the adjuster in the direc-
tion which the shoe expands (moving the screwdriver from
the upper to the lower portion) so that the brake shoe
comes into slight contact with the drum (the clearance
between the lining and drum is zero).
3. Turn back the adjuster 8 turns (moving the screwdriver from
the lower to the upper portion). The clearance between the
lining and drum is 0.2 to 0.3 mm (0.008 to 0.012 in).
4. After adjustment, install the rubber plug on the adjusting
hole.
BR-4-8
CONSTRUCTION CB31
BR-5-1
DISASSEMBLY CB31
DISASSEMBLY
z Chock the wheels so that the vehicle cannot move.
z Shift the gear into first or reverse so as not to turn the pro-
peller shaft.
REMOVAL
Key point of removal
1. Unlock the pinion nut, and remove the pinion nut using
socket wrench. Remove the companion flange and O-ring.
Socket wrench:
99535 Z0003 ... Width across flats = 50 mm (1.97 in)
99535 Z0074 ... Width across flats = 58 mm (2.28 in)
NOTE
z When loosening the pinion nut, support the transmission
case securely so that it does not move.
z Do not re-use the pinion nut after removal.
BR-5-2
DISASSEMBLY CB31
DISASSEMBLY
BR-5-3
INSPECTION CB31
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BR-5-4
REPAIR AND REPLACEMENT CB31
2. Align the brake shoe with the lining at rivet holes and place
in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets.
Fasten the brake shoe and lining with rivets, starting in
the middle and alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining
BR-5-5
REASSEMBLY CB31
REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate
When reassembling the hand brake, coat each of the following slid-
ing parts with heat resistant grease.
1. Camshaft and brake shoe contact parts
2. Camshaft and plate contact surface
3. Camshaft and support plate contact surface
4. Brake shoe and support plate contact surface
5. Brake shoe and adjuster contact surface
6. Adjusting screw threads and socket
12 Camshaft lever
Align the match mark on the camshaft lever with that on the cam-
shaft.
2 Return spring
Install the brake shoe return spring using the return spring replacer
(99879 Z0000).
NOTE
z Make sure that the brake shoe return spring is installed
correctly.
BR-5-6
REASSEMBLY CB31
INSTALLATION
Key point of installation
Install the companion flange, O-ring and pinion nut. Tighten the lock
nut using the socket wrench.
Socket wrench
99535 Z0003 [Width across flats = 50 mm (1.97 in)]
99535 Z0074 [Width across flats = 58 mm (2.28 in)]
: 598 - 745 N·m {61 - 76 kgf·m, 441 - 550 ft·lbf}
Pinion nut: width across flats = 50 mm (1.97 in)
686 - 981 N·m {70 - 100 kgf·m, 506 - 723 ft·lbf}
Pinion nut: width across flats = 58 mm (2.28 in)
NOTE
z Lock the pinion nut so that two clinched points contact
each other.
z When tightening the pinion nut, support the transmission
case securely so that it does not move.
BR-5-7
ADJUSTMENT CB31
ADJUSTMENT
BRAKE LINING CLEARANCE
Chock the front wheels and jack up the rear wheel to adjust the
brake lining clearance.
1. Remove the rubber plug attached to the adjusting hole in
the brake drum. Turn the drum by hand so that the adjusting
hole is located at the lower portion (where the adjuster can
be seen).
BR-5-8
ELECTRICAL SYSTEM
CONTENTS
INTRODUCTION .................................... EL- 1- 1 STARTING SYSTEM ............................... EL-13- 5
HOW TO READ WIRING DIAGRAM ........ EL- 1- 1 ENGINE AIR HEATER SYSTEM ............. EL-13- 6
ILLUSTRATION OF CONNECTORS ..... EL- 2- 1 CHARGING SYSTEM .............................. EL-13- 7
CONNECTORS ........................................ EL- 2- 1 TRAILER BRAKE INDICATOR LIGHT ..... EL-13- 8
SMJ ........................................................... EL- 2- 2 FUEL GAUGE .......................................... EL-13- 9
RELAY ...................................................... EL- 2- 3 TACHOMETER ....................................... EL-13-10
BATTERY AND CIRCUIT AIR PRESSURE AND VACUUM
PROTECTOR ......................................... EL- 3- 1 WARNING LIGHT ................................... EL-13-11
BATTERY .................................................. EL- 3- 1 ENGINE COOLANT LEVEL AND
FUSE ........................................................ EL- 3- 4 OVERHEAT WARNING LIGHT ............... EL-13-13
FUSIBLE LINK .......................................... EL- 3- 4 OIL PRESSURE WARNING LIGHT ........ EL-13-14
HARNESS LAYOUT ............................... EL- 4- 1 OIL FILTER WARNING LIGHT ............... EL-13-15
SCHEMATIC DIAGRAM ........................... EL- 4- 1 AIR FILTER WARNING LIGHT ............... EL-13-16
CAB HARNESS ........................................ EL- 4- 2 BRAKE WARNING LIGHT ...................... EL-13-17
MAIN HARNESS ....................................... EL- 4- 4 TILT LOCK WARNING LIGHT ................ EL-13-18
CHASSIS HARNESS AND TAIL WARNING LIGHT BULB CHECK
HARNESS ................................................. EL- 4- 8 SYSTEM ................................................. EL-13-19
CHASSIS HARNESS (FOR TRACTOR) .. EL- 4-12 HEADLIGHT ........................................... EL-13-20
LOCATION OF ELECTRICAL UNIT ...... EL- 5- 1 DAY TIME LIGHT .................................... EL-13-21
SWITCH (CAB SIDE) ................................ EL- 5- 1 FOG LIGHT ............................................. EL-13-23
RELAY (CAB SIDE) .................................. EL- 5- 3 TURN SIGNAL AND HAZARD LIGHT .... EL-13-24
CONTROL UNIT (CAB SIDE) ................... EL- 5- 5 TURN SIGNAL, HAZARD AND
ELECTRICAL UNIT (CHASSIS SIDE) ...... EL- 5- 7 CORNERING LIGHT .............................. EL-13-27
SUPER MULTIPLE JUNCTION (SMJ) ...... EL- 5- 8 TAIL AND STOP LIGHT .......................... EL-13-31
FUSE ........................................................ EL- 5- 8 CLEARANCE LIGHT .............................. EL-13-35
FUSIBLE LINK .......................................... EL- 5- 8 BACK-UP LIGHT .................................... EL-13-36 EL
EARTH POINT ....................................... EL- 6- 1 ROOM LIGHT ......................................... EL-13-37
CHASSIS SIDE ......................................... EL- 6- 1 MARKER LIGHT ..................................... EL-13-39
CAB SIDE ................................................. EL- 6- 3 ILLUMINATION LIGHT CONTROL ......... EL-13-40
STARTING SYSTEM .............................. EL- 7- 1 EXHAUST BRAKE SYSTEM .................. EL-13-41
STARTER CIRCUIT .................................. EL- 7- 1 TRANSMISSION PTO ............................ EL-13-45
METER CLUSTER ................................. EL- 8- 1 THIRD DIFFERENTIAL LOCK SYSTEM EL-13-47
WARNING SYSTEM .............................. EL- 9- 1 WINDSHIELD WIPER ............................. EL-13-48
LIGHTING SYSTEM .............................. EL-10- 1 POWER DOOR LOCK ............................ EL-13-50
HEADLIGHT ............................................ EL-10- 1 POWER WINDOW .................................. EL-13-52
LIGHTING SWITCH HORN ..................................................... EL-13-54
(COMBINATION SWITCH) ...................... EL-10- 3 CIGARETTE LIGHTER ........................... EL-13-55
TAIL, FOG, CLEARANCE AND AIR CONDITIONER ................................ EL-13-56
OTHER LIGHTS ...................................... EL-10- 4 AUDIO ..................................................... EL-13-58
OPERATION SYSTEM .......................... EL-11- 1 SEAT BELT WARNING ........................... EL-13-59
ACCESSORY SYSTEM ........................ EL-12- 1 VNT CONTROL SYSTEM ...................... EL-13-61
WIRING DIAGRAM ............................... EL-13- 1 ABS ......................................................... EL-13-63
POWER SUPPLY .................................... EL-13- 1 SPEED LIMITER SYSTEM ..................... EL-13-65
TACHOGRAPH ....................................... EL-13-66
INTRODUCTION
INTRODUCTION
HOW TO READ WIRING DIAGRAM
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing or repairing electrical parts, be sure the
ground cable and body grounding connection are dis-
connected. The ignition switch should be turned off.
ABBREVIATION
The parts abbreviation indicates the name, location and condition of
each part, such as a switch, meter, or light.
ON Switch on
OFF Switch off
ACC Accessory
ST Start
RH Right hand
LH Left hand
AOH Air over hydraulic brake
TEMP Engine coolant temperature
W/L Warning light
I/L Indicator light
MAIN H. Main harness
CHASSIS H. Chassis harness
ENGINE H. Engine heater harness
TAIL H. Tail harness
FLOOR UPPER H. Floor upper harness
FLOOR H. Floor harness
BODY SIDE H. Body side harness
DOOR H. Door harness
EXH Exhaust
IGN Ignition
M/V Magnetic valve
WAT Water
SW Switch
BATT Battery
SMJ Super multiple junction
EL-1-1
INTRODUCTION
CIRCUIT CONNECTION
A circuit connection is indicated by lines showing the electric wires
connecting the electrical devices.
EL-1-2
INTRODUCTION
EL-1-3
INTRODUCTION
Two types of batteries that are used are as shown in the figure.
Diode check
Check continuity using an ohmmeter.
Diode is functioning properly if test results are as shown in the fig-
ure at left.
Specifications may vary depending on the type of tester.
Before performing this inspection, be sure to refer to the
instruction manual of the tester to be used.
EL-1-4
INTRODUCTION
Indication of switch
The switches are illustrated as in the normal state. The switch which is off in the normal state is called a “nor-
mal open switch”, and that which is on in the normal state is called a “normal close switch”.
NOTE
z The circuit makes when the normal open switch is oper-
ated and it breaks when the normal close switch is oper-
ated.
EL-1-5
INTRODUCTION
Indication of relay
The relays use normal open relays. As shown in the figure, the nor-
mal open relay makes when it is operated. The relay that breaks
when it is operated is called a normal closed relay.
Similar to conventional switches, relays are shown in the “OFF”
state in wiring diagrams.
ILLUSTRATION OF CONNECTORS
Connectors shown in wiring diagrams are represented in accor-
dance with a specified standard. From the connector symbol, the
number, style, type (female or male), etc. of connectors can be
clearly identified to facilitate identification with those in actual vehi-
cles.
Example 1
a. The connector symbol is divided into six sections which
indicates a 6-pole connector.
b. The black rectangular section (Shown at the top of the con-
nector symbol) indicates a “male” connector.
c. Both sides of the connector symbol are rounded to indicate
a “W” type connector.
EL-1-6
INTRODUCTION
Example 2
a. The connector symbol is divided into 8 square sections
which indicates an 8-pole connector.
b. The white rectangular section at the top of the connector
symbol indicates a “female” connector.
c. The four corners of the connector symbol are 90º so the
symbol indicates an “M” type connector.
EL-1-7
INTRODUCTION
EL-1-8
ILLUSTRATION OF CONNECTORS
ILLUSTRATION OF CONNECTORS
CONNECTORS
The symbol of a connector in the wiring diagram indicates the number of poles, type, and male or female
shape of the terminal from which the connector of an electrical device can be checked.
EL-2-1
ILLUSTRATION OF CONNECTORS
SMJ
EL-2-2
ILLUSTRATION OF CONNECTORS
RELAY
EL-2-3
BATTERY AND CIRCUIT PROTECTOR
NOTE
z The type is the nominal designation in accordance with
JASO standards.
z The above battery performance is based on an electro-
lyte specific gravity of 1.280 [20ºC (68ºF)].
CAUTION
PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical units, be sure to discon-
nect the negative (-) cable from the battery to ensure
safety.
z Be sure to turn the key switch to “OFF” before discon-
necting the negative (-) cable from the battery.
z If any of the electrical systems and wiring are changed or
modified arbitrarily, there is the possibility of vehicle
trouble as well as fire due to an overloaded circuit or
short circuit.
Inspection
1. Check the electrolyte level.
The battery electrolyte should be maintained between the
upper and lower levels on the case. If low, add distilled
water to the specified level and charge the battery for at
least 30 minutes.
EL-3-1
BATTERY AND CIRCUIT PROTECTOR
EL-3-2
BATTERY AND CIRCUIT PROTECTOR
NOTE
z Read the indication at the upper end of the electrolyte
surface.
z The measured specific gravity of the electrolyte must be
corrected to the 20ºC (68ºF) standard. S20 = St + 0.0007 (t
- 20)
Where,
S20: Specific gravity of electrolyte at standard
temperature (20ºC)
St: Specific gravity measured at tºC
t: Temperature of measured electrolyte (ºC)
WARNING
WARNING
z Be careful not to spill battery electrolyte on any part of
your body, clothes or finished surfaces of parts.
z Do not touch your eyes with dirty hands. After handling
battery electrolyte, wash your hands thoroughly under
running water.
z If electrolyte should come into contact with your eyes,
rinse the eyes for at least fifteen minutes and immedi-
ately see a doctor.
3. Check that the battery and battery terminals are free from
corrosion and dirt.
EL-3-3
BATTERY AND CIRCUIT PROTECTOR
FUSE
Inspection
1. Visually inspect each fuse.
2. If any fuse is cracked or blown, trace the cause, repair the
trouble, and then replace the fuse.
NOTE
z Always use a fuse of the specified capacity.
FUSIBLE LINK
CARTRIDGE TYPE
Specifications
Color Capacity current
Black 65A
Green 30A
Brown 25A
Inspection
z Visually check each fusible link.
z If any fusible link is burned out, check the cause and repair
it. Replace the fusible link with that of the specified capacity.
EL-3-4
HARNESS LAYOUT
HARNESS LAYOUT
SCHEMATIC DIAGRAM
The schematic diagram illustrates how each harness (main harness, chassis harness, floor harness, floor
upper harness, body side harness, etc.) is wired on the actual vehicle. Depending on the vehicle model, how-
ever, the arrangements of the wires and units may sometimes be different, so the respective schematic dia-
grams must be carefully checked to see if they coincide with the arrangements in the actual vehicle.
EL-4-1
HARNESS LAYOUT
CAB HARNESS
RHD model
EL-4-2
HARNESS LAYOUT
LHD model
EL-4-3
HARNESS LAYOUT
MAIN HARNESS
RHD model
EL-4-4
M-1 Chassis harness (C-1) M-44 Engine overrun buzzer
M-2 Chassis harness (C-2) M-45 Cigarette lighter
M-3 Wiper motor M-46 Radio
M-4 Flasher unit M-47 Heater control (For illumination)
M-5 Intermittent wiper relay M-48 Heater control
M-6 Air heater timer M-49 Air conditioner switch
M-7 Water level and overheat buzzer M-50 Differential lock switch (CWA310)
M-8 DC-DC converter M-51 Floor upper harness (FU-1)
M-9 Checker M-53 Tachograph
M-10 Memory reset (For FE6TA engine) M-54 Speedometer
M-11 Diagnosis switch (For FE6TA engine) M-55 Clutch switch (For exhaust brake)
M-12 DDS-3 (For FE6TA engine) M-57 Cluster meter
M-13 Checker M-58 Cluster meter
M-14 Headlight relay 1 M-59 Cluster meter
M-15 Headlight relay 2 M-60 Cluster meter
M-16 Warning light check relay M-61 Cluster meter
M-17 Blower motor relay M-62 Combination switch
M-18 Condenser relay M-63 Starter switch
M-19 Cooler compressor M-64 Stop light switch
M-20 Transmission PTO relay M-65 Warning buzzer
M-21 Horn relay M-66 Fog light switch
M-23 Diode M-67 Transmission PTO switch
M-24 Door harness (For assistant) (DA-1) M-68 Door harness (For driver) (DD-1)
M-24 Door harness (For assistant) (DA-2) M-69 Door harness (For driver) (DD-3)
EL-4-5
M-25 Cab front harness (CF-1) M-70 Door harness (For assistant) (DD-3)
M-26 Cab front harness (CF-2) M-71 Cab earth
M-27 Cab front harness (CF-5) M-72 Accel switch
HARNESS LAYOUT
M-28 Cab front harness (CF-3) M-73 Body side harness (B-1)
M-31 Tail light relay M-82 DDS-2
M-32 Accessory relay M-83 Rack out
M-33 Ignition relay M-85 Cab front harness (F-22)
M-34 Spot light relay M-86 Diode
M-35 Fuse block M-89 Governor select resistor
M-36 Blower motor M-90 Memory reset
M-37 Resistor M-91 Diagnosis switch
M-38 Thermo switch M-92 DDS-3
M-39 OPT connector (batt) M-93 0 adjusting resistor
M-40 OPT connector (acc) M-94 Transmission high-low relay
M-41 OPT connector (ign) M-95 Idle volume
M-42 OPT connector (earth) M-96 Accel sensor
M-43 Diode M-97 Idle switch
ZEL902B
HARNESS LAYOUT
LHD model
EL-4-6
M-1 Chassis harness (C-1) M-48 Heater control
M-2 Chassis harness (C-2) M-49 Air conditioner switch
M-4 Flasher unit M-51 Floor upper harness (FU-1)
M-5 Intermittent wiper relay M-52 Floor upper harness (FU-2)
M-6 Air heater timer M-53 Tachograph
M-7 Water level and overheat buzzer M-54 Speedometer
M-8 DC-DC converter M-55 Clutch switch (For exhaust brake)
M-9 Checker M-56 Clutch switch (For PTO)
M-10 Memory reset (For FE6TA engine) M-57 Cluster meter
M-11 Diagnosis switch (For FE6TA engine) M-58 Cluster meter
M-12 DDS-3 (For FE6TA engine) M-59 Cluster meter
M-14 Headlight relay 1 M-60 Cluster meter
M-15 Headlight relay 2 M-61 Cluster meter
M-16 Warning light check relay M-62 Combination switch
M-17 Blower motor relay M-63 Starter switch
M-18 Condenser relay M-64 Stop light switch
M-19 Cooler compressor relay M-65 Warning buzzer
M-20 Transmission PTO relay M-66 Fog light switch
M-21 Horn relay M-67 Transmission PTO switch
M-22 Diode M-68 Door harness (For driver) (DD-2)
M-23 Diode M-69 Door harness (For driver) (DD-3)
M-24 Door harness (For assistant) (DA-2) M-70 Door harness (For assistant) (DA-3)
M-25 Cab front harness (CF-1) M-71 Cab earth
M-26 Cab front harness (CF-2) M-73 Body side harness (B-1)
M-29 Cab front harness (CF-6) M-74 ABS diagnosis
M-30 Cab front harness (CF-4) M-75 Seat belt timer
EL-4-7
M-31 Tail light relay M-76 Seat belt buzzer
M-32 Accessory relay M-77 Day time light cut relay
M-33 Ignition relay M-78 Day time light relay 1
M-34 Stop light relay M-79 Day time light relay 2
HARNESS LAYOUT
ZEL903B
HARNESS LAYOUT
EL-4-8
C-1 Main harness (M-1) C-36 3rd differential lock magnetic valve C-66 Back-up light switch
C-2 Main harness (M-2) C-37 Exhaust brake magnetic valve C-67 Transmission PTO magnetic valve (For AOH and full air)
C-3 Unit harness (U-4) C-38 Vacuum switch C-68 Transmission PTO magnetic valve (For vacuum)
C-4 Unit harness (U-5) C-39 Exhaust brake magnetic valve C-69 Tail harness (T-2)
C-7 Cooler condenser motor C-40 Air dryer C-71 Tank unit
C-8 Cooler pressure switch C-41 Air pressure switch C-78 Air dryer
C-9 Speed limiter actuator C-42 Air booster stroke switch No. 2 C-87 Engine speed sensor
C-10 Horn (High) C-43 Air booster stroke switch No. 1 C-88 Boost compensator cut magnetic valve
C-11 Turn signal light LH C-44 Brake fluid level switch C-89 Engine stop solenoid valve
C-14 Speed limiter sensor C-45 Water level switch C-94 Pre-stroke sensor
C-16 Horn (low) C-46 Engine stop motor C-95 Fog light RH
C-18 Turn signal light RH C-47 Fusible link box C-96 Fog light LH
C-19 PCM valve C-48 Sub starter switch C-97 NE sensor
C-20 Oil filter switch C-49 Heater harness C-98 Air filter switch
C-21 Revolution sensor C-50 Heater harness C-99 Starter relay (B)
C-22 N and TDC sensor C-51 Heater harness C-100 Starter relay (C)
C-23 Oil pressure switch C-52 Heater harness C-101 Transmission high-low switch
C-24 Rack sensor C-53 Heater harness C-102 Cab harness (CL-35) (for MD-TICS Engine)
C-25 Alternator C-54 Safety relay C-104 Cab harness (U-34) (for MD-TICS Engine)
C-26 Alternator B C-55 Safety relay C terminal T-2 Chassis harness (C-69)
C-27 Water temperature sensor C-56 Safety relay B terminal T-3 Tank unit
C-28 Water temperature sensor C-57 Engine heater relay T-4 Rear combination light RH
C-29 Overheat switch C-58 Engine heater relay T-5 Rear combination light LH
C-30 Cooler compressor magnetic clutch C-59 Starter motor C terminal T-6 Back buzzer
EL-4-9
C-31 Thermo sender C-60 Starter motor B terminal T-7 Back-up light
C-32 Air pressure switch C-61 Starter motor B terminal T-8 License plate light
C-33 Air pressure switch C-63 Frame earth T-9 Frame earth
HARNESS LAYOUT
ZEL904B
HARNESS LAYOUT
LHD model
EL-4-10
C-1 Main harness (M-1) C-38 Vacuum switch C-69 Tail harness (T-2)
C-2 Main harness (M-2) C-39 Exhaust brake magnetic valve C-70 Tail harness (T-1)
C-3 Unit harness (U-4) C-40 Air dryer C-71 Tank unit
C-5 Unit harness (U-7) C-41 Air pressure switch C-72 Frame earth
C-6 Unit harness (U-6) C-42 Air booster stroke switch No. 2 C-73 ABS actuator
C-7 Cooler condenser motor C-43 Air booster stroke switch No. 1 C-74 ABS actuator
C-8 Cooler pressure switch C-44 Brake fluid level switch C-75 ABS actuator
C-10 Horn (low) C-45 Water level sensor C-76 Speed sensor RR, RH
C-11 Turn signal light LH C-46 Engine stop motor C-77 Speed sensor RR, LH
C-12 Day time light LH C-47 Fusible link box C-78 Air dryer
C-13 Speed sensor FR, LH C-48 Sub starter switch C-88 Boost compensator cut magnetic valve
C-15 Speed sensor FR, RH C-49 Heater harness C-89 Engine stop solenoid valve
C-17 Day time light RH C-50 Heater harness C-90 Cap harness (U-17)
C-18 Turn signal light RH C-51 Heater harness C-91 Cap harness (U-18)
C-19 PCM valve C-52 Heater harness C-92 Cap harness (U-19)
C-20 Oil filter switch C-53 Heater harness C-93 Cap harness (U-20)
C-21 Revolution sensor C-54 Safety relay C-94 Pre-stroke sensor
C-22 N and TDC sensor C-55 Safety relay C terminal C-97 NE sensor
C-23 Oil pressure switch C-56 Safety relay B terminal C-99 Starter relay (B)
C-24 Rack sensor C-57 Engine heater relay C-100 Starter relay (C)
C-25 Alternator C-58 Engine heater relay C-101 Transmission high-low switch
C-26 Alternator B C-59 Starter motor C terminal C-104 Cab harness (U-34) (for MD-TICS Engine)
C-27 Water temperature sensor C-60 Starter motor B terminal C-105 Cab harness (U-34) (for MD-TICS Engine)
C-28 Water temperature sensor C-61 Starter motor B terminal T-1 Chassis harness (C-70)
EL-4-11
C-29 Overheat switch C-62 Frame earth T-2 Chassis harness (C-69)
C-30 Cooler compressor magnetic clutch C-63 Frame earth T-3 Tank unit
C-31 Thermo sender C-64 Frame earth T-4 Rear combination light RH
HARNESS LAYOUT
C-32 Air pressure switch No. 1 C-65 Transmission neutral switch T-5 Rear combination light LH
C-33 Air pressure switch No. 2 C-66 Back-up light switch T-6 Back buzzer
C-34 Air pressure switch No. 3 Transmission PTO magnetic valve (For AOH T-7 Back-up light
C-67
C-35 Air pressure switch No. 4 and full air) T-8 License plate light
C-37 Exhaust brake magnetic valve C-68 Transmission PTO magnetic valve (For vacuum) T-9 Frame earth
ZEL905B
HARNESS LAYOUT
EL-4-12
C-1 Main harness (M-1) C-39 Exhaust brake magnetic valve C-63 Frame earth
C-2 Main harness (M-2) C-41 Air pressure switch C-65 Transmission neutral switch
C-7 Cooler condenser motor C-45 Water level sensor C-66 Back-up light switch
C-8 Cooler pressure switch C-46 Engine stop motor C-67 Transmission PTO magnetic valve (For AOH)
C-10 Horn (low) C-47 Fusible link box C-71 Tank unit
C-11 Turn signal light LH C-48 Sub starter switch C-78 Air dryer
C-18 Turn signal light RH C-49 Heater harness C-79 Trailer brake switch
C-21 Revolution sensor C-54 Safety relay C-80 Jumper cable
C-23 Oil pressure switch C-55 Safety relay C terminal C-81 Rear combination light LH
C-25 Alternator C-56 Safety relay B terminal C-82 License plate light
C-26 Alternator B C-57 Engine heater relay C-83 Frame earth
C-28 Water temperature sensor C-58 Engine heater relay C-84 Back buzzer
C-29 Overheat switch C-59 Starter motor C terminal C-85 Back-up light
C-30 Cooler compressor magnetic clutch C-60 Starter motor B terminal C-86 Rear combination light RH
C-31 Thermo sender C-61 Starter motor B terminal C-101 Transmission high-low switch
EL-4-13
HARNESS LAYOUT
ZEL906B
HARNESS LAYOUT
LHD model
EL-4-14
C-1 Main harness (M-1) C-39 Exhaust brake magnetic valve C-63 Frame earth
C-2 Main harness (M-2) C-41 Air pressure switch C-65 Transmission neutral switch
C-7 Cooler condenser motor C-45 Water level sensor C-66 Back-up light switch
C-8 Cooler pressure switch C-46 Engine stop motor C-67 Transmission PTO magnetic valve (For AOH)
C-10 Horn (low) C-47 Fusible link box C-71 Tank unit
C-11 Turn signal light LH C-48 Sub starter switch C-78 Air dryer
C-18 Turn signal light RH C-49 Heater harness C-79 Trailer brake switch
C-21 Revolution sensor C-54 Safety relay C-80 Jumper cable
C-23 Oil pressure switch C-55 Safety relay C terminal C-81 Rear combination light LH
C-25 Alternator C-56 Safety relay B terminal C-82 License plate light
C-26 Alternator B C-57 Engine heater relay C-83 Frame earth
C-28 Water temperature sensor C-58 Engine heater relay C-84 Back buzzer
C-29 Overheat switch C-59 Starter motor C terminal C-85 Back-up light
C-30 Cooler compressor magnetic clutch C-60 Starter motor B terminal C-86 Rear combination light RH
C-31 Thermo sender C-61 Starter motor B terminal C-101 Transmission high-low switch
EL-4-15
HARNESS LAYOUT
ZEL907B
LOCATION OF ELECTRICAL UNIT
EL-5-1
LOCATION OF ELECTRICAL UNIT
LHD model
EL-5-2
LOCATION OF ELECTRICAL UNIT
EL-5-3
LOCATION OF ELECTRICAL UNIT
LHD model
EL-5-4
LOCATION OF ELECTRICAL UNIT
EL-5-5
LOCATION OF ELECTRICAL UNIT
LHD model
EL-5-6
LOCATION OF ELECTRICAL UNIT
EL-5-7
LOCATION OF ELECTRICAL UNIT
FUSE
FUSIBLE LINK
EL-5-8
LOCATION OF ELECTRICAL UNIT
EL-5-9
EARTH POINT
EARTH POINT
CHASSIS SIDE
ONLY VEHICLES WITH D, E OR F WHEELBASE
EL-6-1
EARTH POINT
EL-6-2
EARTH POINT
CAB SIDE
EL-6-3
STARTING SYSTEM
STARTING SYSTEM
STARTER CIRCUIT
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical units, be sure to turn the
ignition switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.
Auto-preheat specifications
OFF
ACC ON HEAT START
(LOCK)
B O O O O
ACC O O
IGN O O O
H O O
S O
A O O O O O
P1 O
P2 O O O
EL-7-1
STARTING SYSTEM
Inspection
Check the continuity, operation and insulation of the starter safety
relay.
Inspection
Check the continuity, operation and insulation of the air heater
relay.
IGNITION RELAY
Inspection
Check the circuit of the ignition relay. Refer to “ILLUSTRATION OF
CONNECTORS”.
EL-7-2
STARTING SYSTEM
Inspection
Using a tester (in ohm range), measure resistance values across
the sensor terminals at different test temperatures (see the follow-
ing table).
Test temperature Current Resistance
ºC (ºF) mA kΩ
39 - 41 (102 - 106) 1 1.011 - 1.411
59 - 61 (138 - 142) 1 0.505 - 0.805
Inspection
1. Check the continuity and insulation of the sub starter
switch.
2. Check to see that 20 to 39 N {2 to 4 kgf, 4 to 9 lbf} are
required to operate the switch.
ACCESSORY RELAY
Inspection
Check the circuit of the accessory relay. Refer to “ILLUSTRATION
OF CONNECTORS”.
EL-7-3
STARTING SYSTEM
Inspection
1. Check the engine stop motor assembly for insulation resis-
tance and continuity.
2. Check the engine stop motor assembly for operation.
Stroke: 35 mm (1.38 in)
Connection chart
OFF ON
Terminal
1 O
2 O
Inspection
Check the continuity between the terminal and heater body with a
circuit tester (ohm range).
EL-7-4
STARTING SYSTEM
AIR HEATER
Inspection
Conduct continuity tests in air heater circuits.
EL-7-5
STARTING SYSTEM
EL-7-6
METER CLUSTER
METER CLUSTER
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
Before servicing the electrical units, be sure to turn the ignition key to “OFF” and disconnect
the negative (-) cable from the battery to ensure safety.
EL-8-1
METER CLUSTER
Replacement of bulbs
Replacement of bulbs
Installation and removal of the bulbs are the same as those of the
cluster meter.
Inspection of tachograph
Check the tachograph. Replace as an assembly if bent recording
needle or any other faults are noted.
EL-8-2
METER CLUSTER
THERMO SENDER
Specifications
Rated voltage V 12
Indication temperature range ºC (ºF) 50 - 150 (122 - 302)
Inspection
Check temperature versus resistance characteristics.
Temperature
50 (122) 80 (176) 100 (212) 110 (230) 150 (302)
ºC (ºF)
Resistance
105 - 155 43.5 - 53.5 23.7 - 29.7 15 - 25 7
Ω
EL-8-3
METER CLUSTER
TANK UNIT
Inspection
Using a tester (ohm range), make sure that resistance between
each terminal is within the specified value depending on the change
in the float position.
Float position mm (in)
95.5 liters Resistance
100 liters (21 Imp gal) 200 liter Ω
(22 Imp gal) and 134.5 liter (44 Imp gal)
(29-5/8 Imp gal)
239.4 260.0 401.2
A 140 - 160
(9.43) (10.24) (15.80)
Approx. 88
177.0 251.6 316.2 For 100 liter
B
(6.97) (9.91) (12.45) (22 Imp gal)
Approx. 79.6
132.2 130.0 196.1
C 47 - 53
(5.20) (5.12) (7.72)
72.0 56.7 90.0
D Approx. 26
(2.835) (2.232) (3.543)
17.0 0 0
E 0-2
(0.669) (0) (0)
REVOLUTION SENSOR
Specifications
Resistance Ω Note
883 - 1,065 20ºC (68ºF)
Inspection
Using a tester (ohm range), check the resistance between terminals
(1) and (2).
Also check the insulation between terminals (1), (2) and the revolu-
tion sensor body.
EL-8-4
WARNING SYSTEM
WARNING SYSTEM
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical unit, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.
Connection chart
Terminal ON I ON II
a O O
b O
c O
EL-9-1
WARNING SYSTEM
VACUUM SWITCH
Inspection
Using a circuit tester (ohm range), check the switch to see that it
makes (body earth) and breaks the circuit under the specified vac-
uum pressure.
Operating vacuum pressure
-65.3 kPa {-490 mmHg, -19.29 inHg}
EL-9-2
WARNING SYSTEM
OVERHEAT SWITCH
Specifications
Rated voltage 12V
Indication temperature 101 - 105 (214 - 221) SWITCH CLOSED
ºC (ºF) 92.5 - 105.5 (199 - 222) SWITCH OPEN
Inspection
Raise the temperature and check if the overheat switch operates
within the specifications.
EL-9-3
WARNING SYSTEM
Inspection
Raise the pressure and check if the oil filter switch operates within
the specifications.
EL-9-4
WARNING SYSTEM
Inspection
1. Check the continuity between the switch terminals and insu-
lation to the body.
2. Check the switch operation.
3. Check the spring free length and tension.
Item Maintenance standard
Spring free length 53 mm (2.09 in)
24.5 N {2.5 kgf, 5.5 lbf}
Spring tension
[When compressed to 48 mm (1.89 in)]
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
EL-9-5
LIGHTING SYSTEM
LIGHTING SYSTEM
HEADLIGHT
REPLACEMENT
Specifications
Type
24V 75W/70W
Semi-sealed beam (Halogen bulb)
EL-10-1
LIGHTING SYSTEM
EL-10-2
LIGHTING SYSTEM
Inspection
Check the continuity between the respective terminals of the light-
ing switch with a circuit tester (ohm range).
LIGHTING SWITCH DIMMER SWITCH
OFF I II M D P
1 O O
2 O
3 O O
29 O
30 O
4 O
5 O O
6 O
7 O O O
EL-10-3
LIGHTING SYSTEM
HEADLIGHT RELAY
Inspection
Check the circuit of the headlight relay.
Refer to “ILLUSTRATION OF CONNECTORS”.
FOG LIGHT
Specifications
Type 24V/35W
EL-10-4
LIGHTING SYSTEM
INTERIOR LIGHT
Circuit
EL-10-5
LIGHTING SYSTEM
DOOR SWITCH
Inspection
Check the continuity between the respective terminals of the turn
signal switch with a circuit tester (ohm range).
HAZARD
Terminal RH N LH
Terminal OFF ON
8 O O
22 O
9 O
10 O
23 O
31 O O
32 O
24 O
33 O
EL-10-6
LIGHTING SYSTEM
Inspection
Check the continuity, insulation and operation of the buzzer.
EL-10-7
LIGHTING SYSTEM
1. Cover 4. Packing
2. Housing 5. Lens
3. Bulb
BACK-UP LIGHT
Specifications
Type I 24V 25W
Type II 24V 21W
EL-10-8
LIGHTING SYSTEM
BACK BUZZER
Specifications
Rated voltage 24V
Working voltage 18 - 32V
Number of buzzer sounding 60 - 100 times/minute
NOTE
z When installing the switches, be sure to wind sealing
tape around the threads as shown in the figure.
EL-10-9
LIGHTING SYSTEM
EL-10-10
OPERATION SYSTEM
OPERATION SYSTEM
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical units, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
Terminal OFF ON
50 O
51 O
CLUTCH SWITCH
Inspection
Using a circuit tester (ohm range), check the continuity between the
terminals and check the insulation of the switch.
Terminal OFF ON
1 O
2 O
EL-11-1
OPERATION SYSTEM
ACCELERATOR SWITCH
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
Terminal OFF ON
1 O
2 O
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
Terminal OFF ON
1 O
2 O
EL-11-2
OPERATION SYSTEM
PTO RELAY
Inspection
Check the circuit of the PTO relay. Refer to “ILLUSTRATION OF
CONNECTORS”.
EL-11-3
OPERATION SYSTEM
Inspection
Check the continuity between the respective terminals of the wiper
and washer switch with a circuit tester (ohm range).
OFF INT LOW HIGH WASH
11 O
12 O O
13 O O O
14 O
15 O
16 O O O O
WIPER MOTOR
Specifications
SEMI-WIDE CAB EXTRA-WIDE CAB
LOW 35 - 45 rpm 37 - 45 rpm
Speed
HIGH 58 - 72 rpm 56 - 68 rpm
Starting voltage 20V or less 16V or less
31.4 N·m 39.2 N·m
LOW
{320 kgf·cm, 278 in·lbf} {400 kgf·cm, 347 in·lbf}
Torque
23.5 N·m 36.3 N·m
HIGH
{240 kgf·cm, 208 in·lbf} {370 kgf·cm, 321 in·lbf}
EL-11-4
OPERATION SYSTEM
s
Terminal No. OFF LOW HIGH
E O O
P O
L O
H O O
Inspection
1. Using the circuit tester (ohm range), check the continuity
between the respective terminals and inspect the motor.
2. Check the operation of the motor (refer to the specifica-
tions).
Inspection
Using a circuit tester (ohm range), check the continuity between the
respective terminals and check the insulation of the relay.
EL-11-5
OPERATION SYSTEM
WINDOW WASHER
Specifications
Rated voltage 24V
Discharge pressure 78 kPa {0.8 kgf/cm2, 11 psi}
Discharge flow rate 200 mili liter (7.0 Imp fl oz)/10 sec.
Minimum working voltage 16V or less
Inspection
Check the continuity, operation and insulation of the switch.
Installing the window washer reservoir
1. Connect the wiring connector.
2. Install the window washer reservoir.
3. Connect the washer tube connector.
EL-11-6
OPERATION SYSTEM
1 O O DRIVER SWITCH
POWER WINDOW
2 O O O
MOTOR (PASS)
POWER WINDOW
3 O O O
MOTOR (PASS)
4 O O POWER SOURCE
5 O O DRIVER SWITCH
EL-11-7
OPERATION SYSTEM
Inspection
1. Using the circuit tester (ohm range), check the continuity
between the terminals and inspect the motor.
2. Check the operation of the motor (refer to the specifica-
tions).
CIRCUIT BREAKER
Inspection
Rated voltage 24V
Cycle 5 sec. (Action) - 1 sec. (Lock)
EL-11-8
OPERATION SYSTEM
Inspection
Check the continuity between the respective terminals of the power
door lock switch with a circuit tester (ohm range).
EL-11-9
OPERATION SYSTEM
Inspection
1. Using the circuit tester (ohm range), check the continuity
between the terminals and inspect the motor.
2. Check the motor rotation direction by changing the polarity
of terminals (1) and (2).
EL-11-10
ACCESSORY SYSTEM
ACCESSORY SYSTEM
CAUTION
z Before servicing or repairing electrical parts, be sure the
key switch is turned “OFF” and the negative (-) cable is
disconnected from the battery, to ensure safety.
HORN SWITCH
Inspection
Disconnect the horn switch from the main harness and check the
switch for continuity.
ON OFF
28 O
Earth O
HORN
Inspection
Connect a test circuit as shown in the figure and check the opera-
tion of the horn.
HORN RELAY
Inspection
Check the circuit of the horn relay. Refer to “ILLUSTRATION OF
CONNECTORS”.
EL-12-1
ACCESSORY SYSTEM
CIGARETTE LIGHTER
Inspection
1. Check the continuity, insulation and operation of the ciga-
rette lighter.
2. Check the cigarette lighter while in red-hot condition.
RADIO
Inspection
To check the radio, install the antenna and the speaker with the
radio installed in the vehicle.
To check the radio for proper operation, also check the antenna and
speaker.
Terminal No. Connection
1 Speaker (LH) (+)
2 Illumination (-)
3 Speaker (RH) (+)
4 Speaker (-)
7 Illumination (+)
8 Clock illumination (+)
9 Power source (Back up) (+)
10 Power source (Accessory) (+)
EL-12-2
ACCESSORY SYSTEM
EL-12-3
WIRING DIAGRAM
WIRING DIAGRAM
POWER SUPPLY
RHD model
EL-13-1
WIRING DIAGRAM
EL-13-2
WIRING DIAGRAM
LHD model
EL-13-3
WIRING DIAGRAM
EL-13-4
WIRING DIAGRAM
STARTING SYSTEM
EL-13-5
WIRING DIAGRAM
EL-13-6
WIRING DIAGRAM
CHARGING SYSTEM
EL-13-7
WIRING DIAGRAM
EL-13-8
WIRING DIAGRAM
FUEL GAUGE
EL-13-9
WIRING DIAGRAM
TACHOMETER
EL-13-10
WIRING DIAGRAM
EL-13-11
WIRING DIAGRAM
LHD model
EL-13-12
WIRING DIAGRAM
EL-13-13
WIRING DIAGRAM
EL-13-14
WIRING DIAGRAM
EL-13-15
WIRING DIAGRAM
EL-13-16
WIRING DIAGRAM
EL-13-17
WIRING DIAGRAM
EL-13-18
WIRING DIAGRAM
EL-13-19
WIRING DIAGRAM
HEADLIGHT
EL-13-20
WIRING DIAGRAM
EL-13-21
WIRING DIAGRAM
EL-13-22
WIRING DIAGRAM
FOG LIGHT
EL-13-23
WIRING DIAGRAM
EL-13-24
WIRING DIAGRAM
EL-13-25
WIRING DIAGRAM
- MEMO -
EL-13-26
WIRING DIAGRAM
EL-13-27
WIRING DIAGRAM
EL-13-28
WIRING DIAGRAM
EL-13-29
WIRING DIAGRAM
EL-13-30
WIRING DIAGRAM
EL-13-31
WIRING DIAGRAM
EL-13-32
WIRING DIAGRAM
LHD model
EL-13-33
WIRING DIAGRAM
EL-13-34
WIRING DIAGRAM
CLEARANCE LIGHT
EL-13-35
WIRING DIAGRAM
BACK-UP LIGHT
EL-13-36
WIRING DIAGRAM
ROOM LIGHT
RHD model
EL-13-37
WIRING DIAGRAM
LHD model
EL-13-38
WIRING DIAGRAM
MARKER LIGHT
EL-13-39
WIRING DIAGRAM
EL-13-40
WIRING DIAGRAM
EL-13-41
WIRING DIAGRAM
EL-13-42
WIRING DIAGRAM
EL-13-43
WIRING DIAGRAM
EL-13-44
WIRING DIAGRAM
TRANSMISSION PTO
RHD model
EL-13-45
WIRING DIAGRAM
LHD model
EL-13-46
WIRING DIAGRAM
EL-13-47
WIRING DIAGRAM
WINDSHIELD WIPER
Semi-wide cab model
EL-13-48
WIRING DIAGRAM
EL-13-49
WIRING DIAGRAM
EL-13-50
WIRING DIAGRAM
LHD model
EL-13-51
WIRING DIAGRAM
POWER WINDOW
RHD model
EL-13-52
WIRING DIAGRAM
LHD model
EL-13-53
WIRING DIAGRAM
HORN
EL-13-54
WIRING DIAGRAM
CIGARETTE LIGHTER
EL-13-55
WIRING DIAGRAM
AIR CONDITIONER
RHD model
EL-13-56
WIRING DIAGRAM
LHD model
EL-13-57
WIRING DIAGRAM
AUDIO
EL-13-58
WIRING DIAGRAM
EL-13-59
WIRING DIAGRAM
- MEMO -
EL-13-60
WIRING DIAGRAM
EL-13-61
WIRING DIAGRAM
EL-13-62
WIRING DIAGRAM
ABS
EL-13-63
WIRING DIAGRAM
EL-13-64
WIRING DIAGRAM
EL-13-65
WIRING DIAGRAM
TACHOGRAPH
RHD MODEL
zel934b.tif
EL-13-66
WIRING DIAGRAM
LHD MODEL
EL-13-67
CAB BODY
CONTENTS
SERVICE DATA ........................................ CB-1- 1 CONSTRUCTION ..................................... CB-5- 1
SERVICE DATA ........................................ CB-1- 1 REMOVAL AND INSTALLATION .............. CB-5- 3
TIGHTENING TORQUE ............................ CB-1- 1 DISASSEMBLY AND REASSEMBLY ....... CB-5- 3
TOOLS ........................................................ CB-2- 1 GLASS ........................................................ CB-6- 1
CAB ASSEMBLY ..................................... CB-3- 1 DISASSEMBLY ......................................... CB-6- 1
REMOVAL ................................................. CB-3- 1 REASSEMBLY .......................................... CB-6- 2
REPAIR AND REPLACEMENT ................ CB-3- 3 MIRROR ..................................................... CB-7- 1
INSTALLATION ......................................... CB-3- 4 DISASSEMBLY ......................................... CB-7- 1
DOOR .......................................................... CB-4- 1 REASSEMBLY .......................................... CB-7- 6
DISASSEMBLY ......................................... CB-4- 1 INSTRUMENT PANEL ........................... CB-8- 1
REASSEMBLY .......................................... CB-4- 8 DISASSEMBLY ......................................... CB-8- 1
DISASSEMBLY REMOVAL ................................................. CB-8- 3
(EQUIPPED WITH SAFETY WINDOW) ... CB-4-11 REASSEMBLY .......................................... CB-8- 3
REASSEMBLY INSTALLATION ......................................... CB-8- 3
(EQUIPPED WITH SAFETY WINDOW) ... CB-4-18 CAB HEATER ........................................... CB-9- 1
CAB MOUNTING ..................................... CB-5- 1 FITTING PARTS ....................................... CB-9- 1
In this CAB BODY chapter, descriptions in the CAB ASSEMBLY and INSTRUMENT PANEL sec-
tions have been prepared based on left-hand drive models. For right-hand drive models, operat- CB
ing procedures are the same as those for left-hand drive models except that part locations are
symmetrically opposite.
SERVICE DATA CAB BODY
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Location Item Maintenance standard Shape & remarks
Clearance (A)
9.0 - 12.0
between upper side of
(0.354 - 0.472)
door and cab
Clearance (B)
4.9 - 7.9
between door assem-
(0.193 - 0.311)
Cab and door bly and cab
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Position Item Tightening torque
Cab assembly SMJ (Super Multi Junction) connector bolt 2.9 - 4.9 {0.3 - 0.5, 2.2 - 3.6}
Hinge bolt 14 - 18 {1.4 - 1.8, 10 - 13}
Door Door lock assembly mount- M6 5 - 7 {0.5 - 0.7, 3.6 - 5.1}
ing bolt M8 17 - 26 {1.7 - 2.7, 12 - 20}
Tilt hinge mounting nut 77 - 98 {7.9 - 10.0, 57 - 72}
Torsion arm mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Front cab mount
Hinge bracket mounting bolt 177 - 226 {18.0 - 23.0, 130 - 166}
Torsion bushing bolt 8.4 - 10.8 {0.86 - 1.10, 6.2 - 8.0}
Cab mount bracket mounting bolt 77 - 98 {7.9 - 10.0, 57 - 72}
Leaf spring mounting bolt 43 - 55 {4.4 - 5.6, 32 - 41}
Rear cab mount
Cushion mounting bolt 43 - 55 {4.4 - 5.6, 32 - 41}
Floating bar mounting bolt 43 - 55 {4.4 - 5.6, 32 - 41}
Side window Window glass hinge bolt 2.0 {0.2, 1.4}
Main mirror arm mounting TYPE V only* 38 - 48 {3.9 - 4.9, 28 - 35}
Mirror
bolt and nut Except TYPE V* 25 - 34 {2.5 - 3.5, 18 - 25}
Sleeve yoke lock bolt 51 - 61 {5.2 - 6.2, 38 - 45}
Steering
Steering wheel nut 88 {9, 65}
CB-1-1
TOOLS CAB BODY
TOOLS
Tool name and number Description Shape
SMJ bolt tool Used when installing the stopper ring onto the
99782 Z0000 Super Multi-Junction (SMJ) bolt.
CB-2-1
CAB ASSEMBLY CAB BODY
CAB ASSEMBLY
REMOVAL
Key point of removal
z Move the vehicle to a safe, spacious location so that the
cab can be removed/installed with a hoist or crane. Chock
all wheels securely.
z Stop the engine and turn the key switch “OFF”. (Disconnect
the negative (-) cable from the battery.)
z Completely discharge air and refrigerant (if equipped with
air conditioner), and drain engine coolant and clutch fluid.
2. Remove the cable from the parking brake lever and push
the cable together with the grommet out of the vehicle.
(Mechanical driveline parking brake only)
CB-3-1
CAB ASSEMBLY CAB BODY
CB-3-2
CAB ASSEMBLY CAB BODY
CB-3-3
CAB ASSEMBLY CAB BODY
3. Install a new bolt and washer from the outer side of the
male connector.
4. With the bolt head side placed on a flat surface, install the
stopper ring from the inside.
5. Drive the stopper ring onto the bolt using SMJ BOLT TOOL
(99782 Z0000), and assemble the male connector.
INSTALLATION
Key point of installation
Move the vehicle to a safe, spacious location so that the cab can be
installed with a hoist or crane. Chock all wheels securely.
1. To install the cab assembly, reverse the order of removal.
Replace the parts which require replacement (rubber parts)
with new ones.
3. When installing the torsion arm on the torsion bar, the flat
part of both parts should join.
CB-3-4
CAB ASSEMBLY CAB BODY
CB-3-5
CAB ASSEMBLY CAB BODY
- MEMO -
CB-3-6
DOOR CAB BODY
DOOR
DISASSEMBLY
L.H. DOOR
CB-4-1
DOOR CAB BODY
CB-4-2
DOOR CAB BODY
15 Film
Roll up the lower side of the waterproof film, and remove the follow-
ing parts.
CB-4-3
DOOR CAB BODY
- MEMO -
CB-4-4
DOOR CAB BODY
R.H. DOOR
CB-4-5
DOOR CAB BODY
CB-4-6
DOOR CAB BODY
CB-4-7
DOOR CAB BODY
REASSEMBLY
L.H. DOOR
Key point of reassembly
29 Door ventilator assembly
Open the window. Position the lower bracket in the door panel, and
secure with screws. Fit the weatherstrip to the door panel.
NOTE
z Do not allow the upper and lower brackets to pinch the
weatherstrip.
z Apply soapy water to the weatherstrip in advance to facil-
itate installation.
22 Glass runner
Observe the following note before installing the glass runner.
NOTE
z Ensure that the weatherstrip is free of scratches or
cracks. Replace with a new one if necessary.
19 Guide channel
Position the guide channel in the power window motor (regulator)
assembly, and secure it to the glass holder using screws.
CB-4-8
DOOR CAB BODY
15 Film
Before installing the waterproof film, observe the following note.
NOTE
z Ensure that the film is free of scratches, cuts or holes.
Replace with a new one if necessary.
z Securely install the film on the butyl tape (installed in
advance).
R.H. DOOR
Key point of reassembly
28 Door ventilator assembly
Open the window. Position the lower bracket in the door panel, and
secure with screws. Fit the weatherstrip to the door panel.
NOTE
z Do not allow the upper and lower brackets to pinch the
weatherstrip.
z Apply soapy water to the weatherstrip in advance to facil-
itate installation.
21 Glass runner
Observe the following note before installing the glass runner.
NOTE
z Ensure that the weatherstrip is free of scratches or
cracks. Replace with a new one if necessary.
18 Guide channel
Position the guide channel in the power window motor (regulator)
assembly, and secure it to the glass holder using screws.
CB-4-9
DOOR CAB BODY
14 Film
Before installing the waterproof film, observe the following note.
NOTE
z Ensure that the film is free of scratches, cuts or holes.
Replace with a new one if necessary.
z Securely install the film on the butyl tape (installed in
advance).
CB-4-10
DOOR CAB BODY
DISASSEMBLY
L.H. DOOR
(EQUIPPED WITH SAFETY WINDOW)
CB-4-11
DOOR CAB BODY
CB-4-12
DOOR CAB BODY
CB-4-13
DOOR CAB BODY
R.H. DOOR
(EQUIPPED WITH SAFETY WINDOW)
CB-4-14
DOOR CAB BODY
CB-4-15
DOOR CAB BODY
CB-4-16
DOOR CAB BODY
23 Regulator assembly
24 Power window motor (regulator) assembly
Before removing the power window motor (regulator) assembly or
regulator assembly, remove the following assemblies/parts.
1. Remove the ashtray and bracket.
CB-4-17
DOOR CAB BODY
REASSEMBLY
L.H. DOOR (EQUIPPED WITH SAFETY WINDOW)
Key point of reassembly
45 Side view glass assembly (Safety window)
1. Fit the weatherstrip to the edges of the windshield, and fit a
strong string [5 to 8 mm (0.20 to 0.31 in) dia. and 2 to 3 m (7
to 10 ft) long] in the outer edge of the weatherstrip. Passing
the string through a copper pipe [8 mm (0.31 in), inside dia.]
and using the pipe as a guide facilitates the installation of
the weatherstrip.
CB-4-18
DOOR CAB BODY
NOTE
z Always install the weatherstrip with the water drain hole
facing downward.
NOTE
z Do not tap any part of the glass except the middle portion
shown by hatches in the figure.
z Do not use a rubber-faced hammer. Use the palm of your
hand.
3. Evenly tap the glass with the palm of your hand until the
weatherstrip settles properly.
25 Glass runner
Observe the following note before installing the glass runner.
NOTE
z Ensure that the weatherstrip is free of scratches or
cracks. Replace with a new one if necessary.
CB-4-19
DOOR CAB BODY
18 19 Film
Before installing the waterproof film, observe the following note.
NOTE
z Ensure that the film is free of scratches, cuts or holes.
Replace with a new one if necessary.
z Always install the film on the butyl tape which has been
installed in advance.
CB-4-20
DOOR CAB BODY
NOTE
z Do not tap any part of the glass except the middle portion
shown by hatches in the figure.
z Do not use a rubber-faced hammer. Use the palm of your
hand.
3. Evenly tap the glass with the palm of your hand until the
weatherstrip settles properly.
20 Glass runner
Observe the following note before installing the glass runner.
NOTE
z Ensure that the weatherstrip is free of scratches or
cracks. Replace with a new one if necessary.
CB-4-21
CAB MOUNTING CAB BODY
CAB MOUNTING
CONSTRUCTION
FRONT
* Apply grease to the encircled part and contacting portion of the torsion arm.
CB-5-1
CAB MOUNTING CAB BODY
REAR
CB-5-2
CAB MOUNTING CAB BODY
CB-5-3
CAB MOUNTING CAB BODY
REAR
CB-5-4
CAB MOUNTING CAB BODY
LOCK SYSTEM
CB-5-5
GLASS CAB BODY
GLASS
DISASSEMBLY
CB-6-1
GLASS CAB BODY
REMOVAL
KEY POINT OF REMOVAL
1. Remove the wiper arm.
REASSEMBLY
INSTALLATION
Key point of installation
1. Fit the weatherstrip to the edges of the windshield, and fit a
strong string [5 to 8 mm (0.20 to 0.31 in) dia. and 5 to 7 m
(16 to 23 ft) long] in the outer edge of the weatherstrip.
Passing the string through a copper pipe [8 mm (0.31 in),
inside dia.] and using the pipe as a guide facilitates the
installation of the weatherstrip.
NOTE
z Always install the weatherstrip with the water drain hole
facing downward.
CB-6-2
GLASS CAB BODY
NOTE
z Do not tap any part of the windshield except the middle
portion shown by hatches in the figure.
z Do not use a rubber-faced hammer. Use the palm of your
hand.
3. Evenly tap the windshield with the palm of your hand until
the weatherstrip settles properly.
4. Install the wiper arm.
CB-6-3
MIRROR CAB BODY
MIRROR
DISASSEMBLY
TYPE I (THE LEFT SIDE IS SYMMETRICALLY OPPO-
SITE IN CONSTRUCTION.)
CB-7-1
MIRROR CAB BODY
CB-7-2
MIRROR CAB BODY
CB-7-3
MIRROR CAB BODY
CB-7-4
MIRROR CAB BODY
CB-7-5
MIRROR CAB BODY
REASSEMBLY
Key point of reassembly
}
27 (TYPE I)
24 (TYPE II) Main mirror arm
32 (TYPE III)
4 (TYPE IV)
When installing, align the alignment mark on the main mirror arm
with that on the arm base.
11 (TYPE II)
15 (TYPE III) } Sub mirror arm
When installing, align the alignment mark on the sub mirror arm
with that on the main mirror arm.
When installing the mirror arm, securely tighten the nuts to the
specified torque.
:25 - 34 N·m {2.5 - 3.5 kgf·m, 18 - 25 ft·lbf} (Except TYPE
V)
38 - 48 N·m {3.9 - 4.9 kgf·m, 28 - 35 ft·lbf} (TYPE V only)
NOTE
z When tightening the nuts, ensure sufficient torque, but
do not overtighten.
z When installing the mirror arm, securely install the nuts.
25 29 (TYPE I)
}
12 9 (TYPE V) Mirror bracket
Align the lower end of the mirror bracket with the mirror arm posi-
tioning mark.
CB-7-6
MIRROR CAB BODY
- MEMO -
CB-7-7
INSTRUMENT PANEL CAB BODY
INSTRUMENT PANEL
DISASSEMBLY
INSTRUMENT PANEL
CB-8-1
INSTRUMENT PANEL CAB BODY
INSTRUMENT MEMBER
CB-8-2
INSTRUMENT PANEL CAB BODY
REMOVAL
Remove the steering wheel, and remove the combination switch
and steering column cover.
(For details, refer to the “ST” section.)
REASSEMBLY
Key point of reassembly
27 28 30 Instrument member assembly
Install the left and right supports on the instrument member assem-
bly, position the instrument assembly in the fastening portion of the
heater or air conditioner, and secure with screws and nuts.
2 Cluster lid
Install the speedometer, cluster lid and combination meter assem-
blies in that order.
NOTE
z Ensure that the speedometer cable is connected
securely.
z Be careful not to allow air to leak at the air gauge connec-
tor during installation of the cluster meter (Except VAC
brake). Do not route any harness close to the resistor
located on the rear of the cluster meter since it emits
heat during operation.
INSTALLATION
Install the steering column cover, and install the combination switch
and steering wheel.
(For details, refer to the “ST” section.)
:Steering wheel 88 N·m {9 kgf·m, 65 ft·lbf}
CB-8-3
INSTRUMENT PANEL CAB BODY
- MEMO -
CB-8-4
CAB HEATER CAB BODY
CAB HEATER
FITTING PARTS
CB-9-1
CAB HEATER CAB BODY
1. Blind plug 12. Heater (coreless) assembly 22. Defroster nozzle (R.H. side)
2. Mask 13. Duct assembly 23. Ventilator duct assembly (L.H.)
3. Clamp 14. Resistor assembly 24. Ventilator duct assembly (R.H.)
4. Water hose (outlet) 15. Clip 25. Ventilator duct assembly (Center)
5. Blind plug 16. Drain hose 26. Band
6. Blind plug 17. Blower assembly 27. Duct assembly
7. Connector assembly (out) 18. Defroster nozzle assembly (L.H.) 28. Defroster nozzle assembly (L.H.
8. Clamp 19. Defroster nozzle assembly (Center) side)
9. Connector assembly (in) 20. Defroster nozzle assembly (R.H.) 29. Duct assembly (L.H. foot)
10. Water hose (inlet) 21 Rivet 30. Duct assembly (R.H. foot)
11. Control assembly
NOTE
z Numbers before part names do not indicate the disassembly sequence.
CB-9-2
HEATER
CONTENTS
HOW TO FOLLOW FLOW CHART HARNESS LAYOUT FOR HEATER
IN TROUBLE DIAGNOSES ............. HE-1- 1 SYSTEM ...................................... HE-4- 1
DESCRIPTION — OVERALL WIRING DIAGRAM — HEATER .. HE-4- 1
SYSTEM ........................................... HE-2- 1 MAIN POWER SUPPLY AND
CONTROL OPERATION .............. HE-2- 1 GROUND
AIR FLOW .................................... HE-2- 2 CIRCUIT CHECK ......................... HE-4- 2
DIAGNOSES — OVERALL DIAGNOSTIC PROCEDURE ....... HE-4- 2
SYSTEM ........................................... HE-3- 1 ELECTRICAL COMPONENT
OPERATION CHECK ................... HE-3- 1 INSPECTION ............................... HE-4- 5
TROUBLE DIAGNOSES .................. HE-4- 1 CONTROL LINKAGE
ADJUSTMENT ............................. HE-4- 6
HE
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
E
Check if blower motor rotates properly at
each fan speed. D
Conduct checks as per flow chart at up-
per. C
B
(Go to HE-4-4.)
Note
NG
CHECK BLOWER MOTOR CIRCUIT. Check 15A fuses at fuse
Disconnect blower motor harness connec- block. (No. 12)
tor.
Does battery voltage exist between blower
motor harness terminal No. 1 and body
ground?
OK
A
(Go to next page.)
NOTE
The flow chart indicates work procedures required to diag-
nose problems effectively. Observe the following instruc-
tions before diagnosing.
z Use the flow chart after locating probable causes of a
problem following the “Preliminary Check” or the “Symp-
tom Chart”.
z After repairs, re-check that the problem has been com-
pletely eliminated.
z Refer to Component Parts Location and Harness Layout
for the Systems described in each section for identifica-
tion/location of components and harness connectors.
z When checking circuit continuity, ignition switch should
be “OFF”.
z Before checking voltage at connectors, check battery
voltage.
z After accomplishing the Diagnostic Procedures and Elec-
trical Components Inspection, make sure that all harness
connectors are reconnected as it was.
HE-1-1
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
OK
Direction mark
A direction mark is shown to clarify the side of connector (terminal
side or harness side).
Direction marks are mainly used in the illustrations indicating termi-
nal inspection.
HE-1-2
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
HE-1-3
DESCRIPTION — OVERALL SYSTEM
FAN SWITCH
This lever switches the fan ON and OFF, and controls fan speed.
INTAKE LEVER
position:
Outside air is drawn into the passenger compartment.
position:
Interior air is recirculated inside the vehicle.
HE-2-1
DESCRIPTION — OVERALL SYSTEM
AIR FLOW
Vent door A B C C C — — —
Foot door D C A B D — — —
Def door D D D B A — — —
Intake door — A B —
Air mix door — — A B C
100% — —
55% 45% —
— 100% —
— 70% 30%
— — 100%
HE-2-2
DIAGNOSES — OVERALL SYSTEM
CONDITIONS
Engine running and at normal operating temperature.
PROCEDURE
CHECK BLOWER
1. Slide fan switch to 1. Blower should operate at speed 1.
2. Then slide switch to speed 2.
3. Continue checking blower speed until all speeds are
checked.
4. Leave blower on speed 3 or 4.
Check recirc
1. Slide intake lever to position.
2. Listen for intake door position change (you should hear
sound change slightly).
HE-3-1
DIAGNOSES — OVERALL SYSTEM
HE-3-2
TROUBLE DIAGNOSES
TROUBLE DIAGNOSES
HARNESS LAYOUT FOR HEATER SYSTEM
HE-4-1
TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE
SYMPTOM: Blower motor does not rotate.
Flow chart
INCIDENT
No.
1 Fan fails to rotate.
B
(Go to HE-4-4.)
Note
OK
A
(Go to next page.)
NOTE
z If the result is N.G. after checking circuit continuity, repair
harness or connector.
HE-4-2
TROUBLE DIAGNOSES
OK
NG
OK
NOTE
Check circuit continuity
between blower motor har-
ness terminal No. 2 and
resistor harness terminal
No. 1.
HE-4-3
TROUBLE DIAGNOSES
B
CHECK RESISTOR AFTER DIS-
CONNECTING IT. C
(Refer to Electrical Components
Inspection.)
D
OK NG
Replace resistor.
nector.
3
Body ground Approx. 24V
4
OK NG
NOTE
Check circuit continuity between fan
switch and resistor.
Terminal No.
Fan switch con- Resistor con- Continuity
nector nector
5 1
4 2
Yes
3 3
2 4
OK
NOTE
Check circuit continuity between
fan switch harness terminal No. 6
and body ground?
NOTE
z If the result is N.G. after checking circuit continuity, repair
harness or connector.
HE-4-4
TROUBLE DIAGNOSES
BLOWER MOTOR
Confirm smooth rotation of the blower motor.
z Ensure that there is no foreign matters inside the intake
unit.
BLOWER RESISTOR
Check continuity between terminals.
HE-4-5
TROUBLE DIAGNOSES
HE-4-6
AIR CONDITIONER
CONTENTS
TOOLS ........................................... AC- 1- 1 RECEIVER DRIER ......................... AC-11- 1
SPECIFICATIONS .......................... AC- 2- 1 ON-VEHICLE INSPECTION ...... AC-11- 1
AIR CONDITIONER COOLER PRESSURE SWITCH &
COMPONENTS .............................. AC- 3- 1 RELIEF VALVE .............................. AC-12- 1
DIAGNOSES — COOLER PRESSURE SWITCH AC-12- 1
OVERALL SYSTEM ....................... AC- 4- 1 RELIEF VALVE .......................... AC-12- 1
PERFORMANCE CHART .......... AC- 4- 1 EVAPORATOR ............................... AC-13- 1
PERFORMANCE TEST EXPANSION VALVE ................. AC-13- 1
DIAGNOSES .............................. AC- 4- 3 EVAPORATOR .......................... AC-13- 1
TROUBLE DIAGNOSES ................ AC- 5- 1 THERMOSTAT .......................... AC-13- 2
TABLE OF CONTENTS .............. AC- 5- 1 COMPRESSOR .............................. AC-14- 1
SYMPTOM CHART .................... AC- 5- 1 SERVICE TOOLS ..................... AC-14- 1
PRELIMINARY CHECK .............. AC- 5- 2 SPECIFICATIONS .................... AC-14- 2
MAIN POWER SUPPLY AND DESCRIPTION .......................... AC-14- 3
GROUND CIRCUIT CHECK ...... AC- 5- 3 ON-VEHICLE INSPECTION ..... AC-14- 4
DIAGNOSTIC PROCEDURE 1 .. AC- 5- 4 REMOVAL ................................. AC-14- 4
DIAGNOSTIC PROCEDURE 2 .. AC- 5- 7 INSTALLATION ......................... AC-14- 5
CIRCUIT DIAGRAM ....................... AC- 6- 1 COMPRESSOR DRIVE BELT ... AC-14- 6
A/C WIRING ................................... AC- 7- 1 COMPRESSOR HANDLING ..... AC-14- 6
REFRIGERATION SYSTEM .......... AC- 8- 1 INSTALLATION PRECAUTIONS AC-14- 6
REFRIGERANT .......................... AC- 8- 1 DIRECTION OF ROTATION ..... AC-14- 7
TOOL CONNECTIONS .............. AC- 8- 2 STORING A REPAIRED
CHARGING PROCEDURE ........ AC- 8- 3 COMPRESSOR ........................ AC-14- 7
LEAK INSPECTION ................... AC- 8- 6 OIL HANDLING ......................... AC-14- 7
PIPING TORQUES ..................... AC- 8- 7 OIL RETURN OPERATION ...... AC-14-10
SERVICE PRECAUTIONS ............. AC- 9- 1 REFRIGERANT CHARGE AC
PIPING PRECAUTIONS ............ AC- 9- 1 INSPECTION ........................... AC-14-10
TIGHTENING TORQUES ........... AC- 9- 2 TIGHTENING TORQUES ......... AC-14-11
CONDENSER ................................ AC-10- 1 SERVICE PROCEDURES ............. AC-15- 1
ON-VEHICLE INSPECTION ..... AC-10- 1 MAGNETIC CLUTCH ................ AC-15- 1
When you perform trouble diagnoses, read HE section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES”
TOOLS
TOOLS
NOTE
z All of the following service tools (except for compressor
oil) are commercially available.
THREAD SIZE
Imperial size thread has been changed to ACME size thread.
COUPLER
To prevent cross charging of CFC12 and HFC134a, the charging
valves and coupler have been changed.
AC-1-1
TOOLS
COMPRESSOR OIL
An airtight steel can is used. The label has been changed.
ZEXEL 100PG part number: 569900-0600
SCALE
The scale is used to measure the weight of the refrigerant to deter-
mine how much refrigerant has been changed into the vehicle.
AC-1-2
TOOLS
VACUUM PUMP
The vacuum pump hose fitting is a 1/2″ ACME fitting to prevent
cross contamination of CFC12 and HFC134a oils.
Refer to the user's manual for instructions on operating the vacuum
pump.
CAUTION
z Never use the same vacuum pump without isolator valve
for both HFC134a and CFC12 systems, as cross contami-
nation of oil may occur.
AC-1-3
SPECIFICATIONS
SPECIFICATIONS
Item Description
Cooling capacity 4,100 kcal/h (16,269 BTU/h) (as per JIS standard)
Magnetic clutch 45W (DC24V)
Power consumption Blower motor 210W (DC24V)
Condenser fan motor 110W (DC24V)
Type Swash plate (DKS-15CH)
Displacement 147 cm3 (8.97 cu in)/rev
Compressor
DH-PS
Lubricant
180 cm3
Condenser Multi flow type
Desiccant: 100 g (3.5 oz)
Receiver drier
Fusible plug: melting temp. 105ºC (221ºF)
Evaporator Aluminum laminated type
Expansion valve External equalizing type
Cooling system
Temperature control Reheat air mix type
Air flow control 4 shift control switch
Dual pressure switch
Auxiliary components Thermostat (defrost)
Relief valve
Refrigerant HFC-134a (R134a): 4.9±0.49 N {0.5±0.05 kgf, 1.1±0.11 lbf}
AC-2-1
AIR CONDITIONER COMPONENTS
AC-3-1
DIAGNOSES — OVERALL SYSTEM
TEST READING
Recirculating-to-discharge air temperature graph
AC-4-1
DIAGNOSES — OVERALL SYSTEM
AC-4-2
Recover refrigerant using refrigerant recovery &
Abnormal pressure recycling & recharging equipment and charge A
specified amount of refrigerant.
Normal pressure
Malfunctioning water cock operation
(incorrect valve closure)
No or low air flow Check blower motor operation Magnet clutch slipping Foreign particles on clutch frictional surface or
excessive disc clearance
AC-4-3
Malfunctioning electrical circuit (poor connection,
low battery voltage, etc.)
Belt slipping Check compressor belt and belt tension.
Note: Malfunctioning blower motor
: Refer to Performance Chart-Ambient fan Loose fan/Improper contact of fan and case/Deformed fan
temperature-to-compressor pressure
table.
- : correspond to those in Abnormal operation or Malfunctioning electrical cir- Discontinued wiring or component circuits, or poor
TROUBLE DIAGNOSES FOR not operating at all cuit connection/Malfunctioning resistor, amplifier, etc./Burned-out
ABNORMAL PRESSURE. fuse or low battery voltage
DIAGNOSES — OVERALL SYSTEM
AC-4-4
DIAGNOSES — OVERALL SYSTEM
High-pressure side is too High and low-pressuresides Compressor pressure oper- Replace compressor.
low and low-pressure side is become equal soon after ation is improper.
too high. compressor operation stops. ↓
Damaged inside compres-
sor packings
No temperature difference Compressor discharge Replace compressor.
between high and low-pres- capacity does not change.
sure sides (Compressor stroke is set at
maximum.)
Both high-and low-pressure z There is a big temperature Liquid tank inside is clogged z Replace liquid tank
sides are too low. difference between liquid a little. z Check compressor oil for
tank outlet and inlet. Out- contamination.
let temperature is
extremely low.
z Liquid tank inlet and
expansion valve are
frosted.
z Temperature of expan- High-pressure pipe located z Check and repair malfunc-
sion valve inlet is between liquid tank and tioning parts.
extremely low as com- expansion valve is clogged. z Check compressor oil for
pared with areas near liq- contamination.
uid tank.
z Expansion valve inlet may
be frosted.
z Temperature difference
occurs somewhere in
high-pressure side
AC-4-5
DIAGNOSES — OVERALL SYSTEM
AC-4-6
DIAGNOSES — OVERALL SYSTEM
AC-4-7
TROUBLE DIAGNOSES
TROUBLE DIAGNOSES
TABLE OF CONTENTS
Symptom Chart ................................................................................................................................ AC-5-1
Preliminary Check ........................................................................................................................... AC-5-2
PRELIMINARY CHECK
(A/C does not blow cold air.) .................................................................................................... AC-5-2
Main Power Supply and Ground Circuit Check ............................................................................ AC-5-3
Diagnostic Procedure 1
SYMPTOM: Blower motor does not rotate.................................................................................... AC-5-4
Diagnostic Procedure 2
SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON................ AC-5-7
SYMPTOM CHART
DIAGNOSTIC TABLE
Main Power
Pre-
Supply and
limi- Diagnostic
PROCEDURE Ground Electrical Components Inspection
nary Procedure
Circuit
Check
Check
Compressor
Diagnostic procedure 1
Diagnostic procedure 2
Dual-pressure switch
Thermal protector
Preliminary check
SYMPTOM
Magnet clutch
Blower motor
15A Fuses
Fan switch
A/C switch
15A Fuse
A/C relay
Harness
Resistor
AC-5-1
TROUBLE DIAGNOSES
PRELIMINARY CHECK
PRELIMINARY CHECK
A/C does not blow cold air.
DOES AIR FLOW FROM VENTS? NG IS BLOWER MOTOR OPERATING
Condition NORMALLY?
Ignition switch, A/C switch, and
fan switch are ON. Yes No
Mode lever is in VENT mode and
temperature lever is in full cold CHECK
position. BLOWER MO-
TOR OPERA-
OK TION.
Go to Diagnos-
tic Procedure
1.
CHECK COMPRESSOR BELT TEN- NG CHECK COMPRESSOR OPERA- CHECK FOR EVAPORATOR COIL
SION. TION. FREEZE UP.
Remove intake unit. Check if
NG OK OK evaporator freezes.
NG OK
(Freeze up) (Does not
freeze up)
Go to Diagnostic Procedures 2.
AC-5-2
TROUBLE DIAGNOSES
Check body ground circuit for thermo switch with ignition switch ON
and fan switch ON.
1. Disconnect thermo switch harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. 2 and body
ground.
Ohmmeter terminal
Continuity
+ -
2 Body ground Yes
AC-5-3
TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 1
SYMPTOM: BLOWER MOTOR DOES NOT ROTATE.
Flow chart
INCIDENT
No.
E
Check if blower motor rotates properly
D
at each fan speed.
Conduct checks as per flow chart at left. C
B
(Go to AC-5-6.)
CHECK BLOWER MOTOR CIRCUIT.
Disconnect blower motor harness con-
nector.
Does battery voltage exist between
blower motor harness terminal No. 1
and body ground?
OK
A
(Go to next page.)
AC-5-4
TROUBLE DIAGNOSES
OK
NG
OK
NOTE
Check circuit continuity
between blower motor har-
ness terminal No. 2 and
resistor harness terminal
No. 1.
AC-5-5
TROUBLE DIAGNOSES
B
CHECK RESISTOR AFTER DIS-
CONNECTING IT.
(Refer to Electrical Components C
Inspection.)
D
OK NG
Replace resistor.
nector.
3
Body ground Approx. 24V
4
OK NG
NOTE
Check circuit continuity between fan
switch and resistor.
Terminal No.
Fan switch con- Resistor con- Continuity
nector nector
5 1
4 2
Yes
3 3
2 4
OK
NOTE
Check circuit continuity between
fan switch harness terminal No. 6
and body ground?
NOTE
z If the result is NG after checking circuit continuity, repair
harness or connector.
AC-5-6
TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE 2
SYMPTOM: MAGNET CLUTCH DOES NOT ENGAGE
WHEN A/C SWITCH AND FAN SWITCH ARE
ON.
z Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.
NOTE
Check circuit continuity between compres-
sor relay harness terminal No. 3 and
cooler pressure switch harness terminal
No. 1.
OK
A
NOTE
z If the result is NG after checking circuit continuity, repair
harness or connector.
AC-5-7
TROUBLE DIAGNOSES
NOTE
CHECK VOLTAGE FOR THERMO NG Check circuit continuity be-
SWITCH tween thermo switch harness
Do more than 8 volts exist between terminal No. 3 and compres-
thermo switch harness terminal No. 3 sor relay terminal No. 2.
and body ground?
OK
AC-5-8
TROUBLE DIAGNOSES
NOTE
Check circuit continuity between A/C OK
C (Go to next page.)
switch harness terminal No. 3 and fan
switch harness terminal No. 1.
NOTE
z If the result is NG after checking circuit continuity, repair
harness or connector.
AC-5-9
TROUBLE DIAGNOSES
NOTE
CHECK BODY GROUND CIRCUIT FOR
FAN SWITCH.
Does continuity exist between fan switch
harness terminal No. 6 and body
ground?
OK
NOTE
z If the result is NG after checking circuit continuity, repair
harness or connector.
AC-5-10
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
AC-6-1
A/C WIRING
A/C WIRING
AC-7-1
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
REFRIGERANT
WARNING
WARNING
z Direct contact with refrigerant can cause frostbite or
blindness.
Always wear safety glasses and protective gloves.Do not
work with refrigerant close to the face.
AC-8-1
REFRIGERATION SYSTEM
TOOL CONNECTIONS
AC-8-2
REFRIGERATION SYSTEM
CHARGING PROCEDURE
There are various methods of charging refrigerant into the air conditioner system. These include using refriger-
ant recovery units and direct charging using a scale.
Refer to the user's instruction manual for refrigerant recovery unit handling and operation.
The direct charging method is described below. Refer to the user's manual for weight scale handling and oper-
ation.
FLOW CHART
Preparation
Start evacuation
-98.6 to -101.3 kPa {-740 to -760 mmHg, -29.13 to
-29.92 inHg} for at least 5 min
Stop evacuation
Leaks found
Check for leaks
No leaks
Leaks found
Recheck for leaks
No leaks
System satisfactory
AC-8-3
REFRIGERATION SYSTEM
INITIAL EVACUATION
1. Close both manifold gauge valves.
2. Connect the high and low pressure hoses to the system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to stabilize the
vacuum inside the system.Check that the low pressure
gauge indicates -98.6 to -101.3 kPa {-740 to -760 mmHg, -
29.13 to -29.92 inHg}.
7. Close both valves and stop the vacuum pump.
CHECKING AIR TIGHTNESS
1. Leave the system as it is for 5 to 10 minutes.Ensure the low
pressure gauge needle does not move towards the atmo-
spheric pressure side (gauge pressure 0).
CAUTION
z If the needle moves towards 0, the system is not airtight.
Check the system for leaks and repair.
EVACUATION
1. Operate the vacuum pump.
2. Open both manifold gauge valves.
3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.
AC-8-4
REFRIGERATION SYSTEM
INITIAL CHARGE
1. Put the refrigerant container on the scale.
2. Disconnect the utility hose from the vacuum pump and con-
nect it to the refrigerant container.
3. Purge air from the utility hose.
4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side valve
to charge refrigerant from the low pressure side.
7. Charge with refrigerant until the low pressure gauge
reaches 196 kPa {2 kgf/cm2, 28 psi}.
8. Close the manifold gauge's low pressure valve.
CHARGING
Begin charging and charge the remainder of the specified charge,
referring to the weight scale.
CAUTION
z Do not overcharge the system.
AC-8-5
REFRIGERATION SYSTEM
LEAK INSPECTION
INSPECTION PROCEDURE
AC-8-6
REFRIGERATION SYSTEM
PIPING TORQUES
AC-8-7
SERVICE PRECAUTIONS
SERVICE PRECAUTIONS
PIPING PRECAUTIONS
1. Position the O-ring against the bulge in the pipe when con-
necting hoses and pipes.
2. Coat the piping connections and the O-rings with PAG oil.
CAUTION
z Always use oil specified for HFC134a systems to coat the
O-rings.
3. Fit the nuts and unions tightly against the base of the com-
panion pieces, then hand tighten the nut as much as possi-
ble. Then, tighten to the specified torque.
AC-9-1
SERVICE PRECAUTIONS
TIGHTENING TORQUES
STANDARD BOLT TIGHTENING TORQUES
Bolt hardness indications
Marks indicating bolt hardness are stamped on the tops of bolt
heads.
Tightening torque (without lubricant)
Pitch N·m {kgf·m, ft·lbf}±15%
Thread
(mm)
4T 7T 9T
M6 1.0 5.1 {0.52, 3.8} 8.4 {0.86, 6.2} 12 {1.2, 9}
M8 1.25 13 {1.3, 9} 21 {2.1, 15} 29 {3.0, 22}
M10 1.25 25 {2.6, 19} 43 {4.4, 32} 62 {6.3, 46}
M12 1.25 46 {4.7, 34} 77 {7.9, 57} 108 {11.0, 80}
M14 1.5 74 {7.5, 54} 127 {13.0, 94} 177 {18.0, 130}
AC-9-2
CONDENSER
CONDENSER
ON-VEHICLE INSPECTION
1. Check the condenser fins for blockages or damage. If
clogged, clean them with compressed air. If bent, straighten
them with a screwdriver or pliers.
2. Check the condenser fittings for leaks.Replace the con-
denser if necessary.
CAUTION
z If the condenser is replaced with a new unit, add com-
pressor oil to the compressor.
Add 30 ml (1.1 Imp fl oz).
AC-10-1
RECEIVER DRIER
RECEIVER DRIER
ON-VEHICLE INSPECTION
1. Check the sightglass, fusible plug and the fittings for leaks
using a leak detector.
Repair or replace if necessary.
2. Check the receiver drier for clogging.
z Run the engine at fast idle with the air conditioner ON.
z Check both the inlet and outlet temperatures.
If the difference in temperatures between the inlet and out-
let is large, replace the receiver drier.
CAUTION
z If the condenser is replaced with a new unit, add com-
pressor oil to the condenser.
Add 30 ml (1.1 Imp fl oz).
NOTE
z When removing components (condenser, receiver drier,
etc.) from the system, be sure to recover the refrigerant
from the system before removal.
When repairing or replacing refrigeration system compo-
nents, use new O-rings at piping connections.
AC-11-1
COOLER PRESSURE SWITCH & RELIEF VALVE
RELIEF VALVE
INSPECTION
Unit: MPa {kgf/cm2, psi}
Relief starting pressure 3.63 {37, 526}
Relief ending pressure 2.99 {30.5, 434}
AC-12-1
EVAPORATOR
EVAPORATOR
EXPANSION VALVE
ON-VEHICLE INSPECTION
1. Connect the manifold gauge set to the gauge fittings (see
page AC-8-2).
2. Operate the engine at 1,500 rpm and the air conditioner at
MAX COOLING.
3. Check the low and high pressures.
Normal pressures are:
Low: 0.13 - 0.20 MPa {1.3 - 2.0 kgf/cm2, 18 - 28 psi}
High: 1.47 - 1.67 MPa {15 - 17 kgf/cm2, 213 - 242 psi}
If the low pressure is too low, check and replace the expansion
valve.
If the low pressure is too high, tighten the sensing bulb holder and/
or replace the expansion valve.
EVAPORATOR
INSPECTION
1. Check the evaporator fins for blockages. If the fins are
clogged, clean them with compressed air.
CAUTION
z Never use water to clean the evaporator.
AC-13-1
EVAPORATOR
THERMOSTAT
INSPECTION
Using an electric circuit tester, check for continuity between the ter-
minals.
AC-13-2
COMPRESSOR
COMPRESSOR
SERVICE TOOLS
Tool name and
number Description Shape
(Kent-Moore No.)
Clutch disc wrench Removing center bolt
J-41260
AC-14-1
COMPRESSOR
SPECIFICATIONS
COMPRESSOR
Model DKS-15CH
Type Swash-plate type
Number of cylinders 6
Bore 36 mm (1.42 in)
Stroke 24 mm (0.94 in)
Displacement 147 cm3 (8.97 cu in)
Maximum speed 7,000 rpm
Direction of rotation Clockwise (viewed from front)
Lubrication system Pressure-feed type
Lubricant DH-PS
Refrigerant HFC134a
Shaft seal Lip seal type
Weight 4.4 kg (9.7 lb)
MAGNETIC CLUTCH
Electromagnetic single plate dry
Type
clutch
Rated voltage 24V DC
Power consumption 45W
Stalling torque 50 N·m {5.1 kgf·m, 37 ft·lbf}
Direction of rotation Clockwise (viewed from front)
Weight 2.0 kg (4.4 lb)
AC-14-2
COMPRESSOR
DESCRIPTION
AC-14-3
COMPRESSOR
ON-VEHICLE INSPECTION
1. Install the manifold gauge set.
2. Run the engine at 1,500 rpm.
3. Check the compressor for the following.
z Correct high and low pressure.
z Abnormal noise
z Check to see if the high and low pressure gauges show the
same reading immediately after switching the air condi-
tioner off.
If both gauges show the same reading, it is assumed that
the gasket or valve inside the compressor is damaged.
4. Stop the engine.
5. Check for refrigerant leaks from the shaft seal, etc.
6. Inspect the clutch disc, pulley, and magnetic clutch for signs
of oil.
7. Check the clearance between the clutch disc and pulley.
Specified clearance: 0.3 - 0.6 mm (0.012 - 0.024 in)
If any of the above checks reveal faults, repair the compressor or
the magnetic clutch.
REMOVAL
1. Perform the OIL RETURN OPERATION (see page AC-14-
10).
2. Disconnect the battery's ground cable.
3. Disconnect the clutch connector from the vehicle harness.
4. Discharge the refrigerant from the system (see page AC-8-
1).
5. Loosen the drive belt using the tension pulley.
6. Disconnect the two flexible hoses.
7. Remove the compressor.
CAUTION
z Plug all open fittings immediately to keep moisture out of
the system.
AC-14-4
COMPRESSOR
INSTALLATION
AC-14-5
COMPRESSOR
COMPRESSOR HANDLING
Do not strike, drop or turn the compressor upside down.
If the compressor is knocked over or turned upside down, rotate the
magnetic clutch 5 or 6 times by hand to circulate the oil in the cylin-
der.
Sudden rotation with the oil still in the cylinder can cause valve
damage and adversely affect durability.
INSTALLATION PRECAUTIONS
The new compressor is filled with 180 cm3 of compressor oil and
nitrogen gas (N2).
When mounting the compressor, take the following steps.
1. Loosen the bolt securing the blind plate and gently release
the N2 charge from the compressor.
CAUTION
z Do not let the oil escape.
AC-14-6
COMPRESSOR
DIRECTION OF ROTATION
The compressor may seize if rotated in the reverse direction as the
oil pump does not operate.
The specified direction of rotation is clockwise, as viewed from the
clutch side.
OIL HANDLING
OIL SPECIFICATION
Use only ZXL 100PG refrigeration oil.
ZEXEL part number: 569900-0600
HANDLING PRECAUTIONS
1. The oil must be free from dust, metal filings, etc.
2. The moisture content must not exceed 20 ppm.
3. Do not mix oils.
4. The oil absorbs moisture when the container is open.
Therefore, seal the container immediately after use.
AC-14-7
COMPRESSOR
OIL CONTAMINATION
Unlike engine oil, no cleaning agent is added to the compressor oil.
Even if the compressor is run for a long period (approximately 1
season), the oil never becomes turbid as long as there is nothing
wrong with the compressor or its method of use. Inspect the
extracted oil for any of the following.
z Increased opacity of the oil.
z Color change to red.
z Presence of foreign matter, metal filings, etc.
OIL CHECK
The compressor oil must be checked as follows when being
charged into a used system.
1. Perform the oil return operation (see page AC-14-10).
2. Remove the compressor from the vehicle.
3. Remove the oil plug and drain the oil through the oil plug
and the high and low pressure connectors.
4. Check the oil for contamination.
5. Fill the compressor with the specified amount of oil.
Unit: ml (Imp fl oz)
Collected amount Charging amount
At least 170 (6.0) Same as collected amount
Less than 170 (6.0) 170 (6.0)
CAUTION
z The specified oil quantity differs, depending on the type
of air conditioner system. A label describing the speci-
fied quantity is attached to the compressor. Additionally,
all of the oil cannot be removed when draining the com-
pressor as some remains as an oil film on the inside of
the compressor and the system components.
Therefore, refer to the table at left when recharging the
compressor with oil.
Excess oil adversely affects the cooling capacity and the
compressor.
AC-14-8
COMPRESSOR
AC-14-9
COMPRESSOR
AC-14-10
COMPRESSOR
TIGHTENING TORQUES
AC-14-11
SERVICE PROCEDURES
SERVICE PROCEDURES
MAGNETIC CLUTCH
REMOVAL
1. Remove the center bolt using the clutch disc wrench (J-
41260) to prevent clutch disc rotation.
5. Remove the field coil's lead wire and the three field coil/
compressor screws. Then, remove the field coil.
CAUTION
z Do not hold the field coil by the harness.
AC-15-1
SERVICE PROCEDURES
INSPECTION
1. If the contact surface has been damaged by excessive
heat, the clutch disc and pulley must be replaced.
2. Check the appearance of the pulley assembly. If the contact
surface of the pulley is excessively grooved due to slippage,
both the pulley and clutch disc must be replaced. The con-
tact surfaces of the pulley assembly must be cleaned with a
suitable solvent before reinstallation.
3. Check the field coil for a loose connector or cracked insula-
tion.
INSTALLATION
1. Install the field coil on the compressor (with the harness on
top) and align the field coil's aligning pin with the pin hole in
the shell. Then, tighten the mounting screws to the speci-
fied torque.
Specified torque:3.9 - 5.9 N·m
{0.4 - 0.6 kgf·m, 2.9 - 4.3 ft·lbf}
2. Install the wire harness fixing collar and the harness.
5. Install the clutch disc on the drive shaft together with the
original shim(s).
Press the clutch disc down by hand.
6. Tighten the center bolt to the specified torque using the
holder (J-41260) to prevent clutch disc rotation.
Specified torque:14 - 16 N·m
{1.4 - 1.6 kgf·m, 10 - 12 ft·lbf}
CAUTION
z After tightening the center bolt, check that the pulley
rotates smoothly.
AC-15-2
SERVICE PROCEDURES
AC-15-3
COUPLER
CONTENTS
SERVICE DATA ............................... CP-1- 1 DISASSEMBLY ........................... CP-3- 2
SPECIFICATIONS ....................... CP-1- 1 INSPECTION .................................... CP-4- 1
SERVICE DATA ........................... CP-1- 1 REASSEMBLY ................................. CP-5- 1
TIGHTENING TORQUE .............. CP-1- 2 REASSEMBLY ............................ CP-5- 1
CONSTRUCTION ............................ CP-2- 1 INSTALLATION ........................... CP-5- 1
DISASSEMBLY ............................... CP-3- 1 ADJUSTMENT ................................. CP-6- 1
REMOVAL ................................... CP-3- 1
CP
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Unit: mm (in)
Unit name CP-1300 CP-1320
Coupler type Rubber mounting
Vertical direction Rubber cushion
Buffer
Horizontal direction Rubber cushion
Height of coupler unit (h)
217 (8.54)
50.8 (2.000)
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Kingpin O.D. 50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961) —
Diameter of jaw at kingpin
51.0 - 51.2 (2.008 - 2.016) 52.0 (2.047) —
location
Clearance between jaw and
0.1 - 0.5 (0.004 - 0.020) 2.0 (0.079) —
kingpin
Diameter of jaw pin hole 28.8 (1.134) 29.5 (1.161) —
Jaw pin O.D. 28.6 (1.126) 28.3 (1.114) —
Clearance between jaw and
0.18 - 0.20 (0.0071 - 0.0079) 0.5 (0.020) —
jaw pin
Clearance between jaw pin
head and upper surface of 2.0 - 3.0 (0.079 - 0.118) 0.5 (0.020) —
coupler base
2 years or 200,000 km Replace or remove shims accord-
Cushion rubber —
(120,000 miles) ing to wear on rubber cushion
CP-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Clamp mounting bolt 196 - 265 {20 - 27, 145 - 195}
Sub base mounting bolt 167 - 226 {17 - 23, 123 - 166}
Cam plate mounting nut 34 - 45 {3.5 - 4.6, 25 - 33}
Coupler assembly mounting nut 108 - 147 {11 - 15, 80 - 108}
CP-1-2
CONSTRUCTION
CONSTRUCTION
CP-2-1
DISASSEMBLY
DISASSEMBLY
REMOVAL
Key point of removal
1. Use a crane or a hoist for disassembling. Remain safety
conscious. Before starting disassembly, clean each portion
of the assembly.
CP-3-1
DISASSEMBLY
DISASSEMBLY
CP-3-2
DISASSEMBLY
CP-3-3
INSPECTION
INSPECTION
Kingpin O.D.
Unit: mm (in)
Maintenance standard Service limit
50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961)
CP-4-1
INSPECTION
Cushion rubber
Maintenance standard Service limit Remarks
Replace or remove
2 years or 200,000 km
— shims according to
(120,000 miles)
wear on rubber cushion
CP-4-2
REASSEMBLY
REASSEMBLY
REASSEMBLY
Key point of reassembly
z Discard the old cotter pin, spring pin and washer; replace
with new ones.
z Apply a coating of grease to the sliding and rotating parts of
the coupler.
37 Adjusting nut
Adjust the inside diameter of the jaw at the kingpin location. When
the adjusting nut is loosened, the yoke will move forward reducing
the inside diameter of the jaw. When it is tightened, the inside diam-
eter of the jaw will be increased.
Unit: mm (in)
Maintenance standard Service limit
Diameter of jaw at
kingpin location 51.0 - 51.2
52.0 (2.047)
(2.008 - 2.016)
INSTALLATION
Key point of installation
Always install the coupler assembly to the vehicle with the lever
toward the front.
: 108 - 147 N·m {11 - 15 kgf·m, 80 - 108 ft·lbf}
CP-5-1
ADJUSTMENT
ADJUSTMENT
z Adjust the yoke shaft movement with the yoke shaft adjust-
ing nut. With the trailer connected completely, adjust the
yoke shaft adjusting nut so that it comes into contact with
the coupler base, with the cushion rubber in place. Under
this condition, the limit switch is pushed ON.
CP-6-1