SMCA520E01

TRUCK (CHASSIS)
MODEL
MK, LK, PK, CDA

AND CWA SERIES
Pub.No. SMCA520E02
QUICK REFERENCE INDEX
GENERAL GE
TRUCK(Chassis) MAINTENANCE MA
SERVICE MANUAL TROUBLE DIAGNOSIS TD
ENGINE REMOVAL & INSTALLATION ER
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
FM edition: Mar. 2005

Edition: Jun. 1998
© 2005 NISSAN DIESEL MOTOR CO, LTD 9806K80-20009-200-S(M)
HOW TO USE THIS MANUAL
X This Service Manual is designed as a guide for servicing vehicles.
X This manual deals with the engine and chassis.
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 SERVICE DATA AND SPECIFICATIONS are contained in each section.
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.
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Lock plate 13. Pinion shaft 24. Adjusting shim
+ 2. Adjusting nut 14. Side gear , 25. Adjusting washer
, 3. Side bearing cap 15. Thrust washer 26. Bearing spacer
,+ 4. Differential case assembly , 16. Differential case (LH) , 27. Retaining ring
,+ 5. Drive pinion assembly 17. Drive gear 28. Pilot bearing inner race
6. Lock plate 18. Bearing , 29. Bearing
7. Pilot bearing outer race ,+ 19. Companion flange nut , 30. Oil seal
, 8. Differential case (RH) 20. Companion flange , 31. Bearing
9. Thrust washer ,+ 21. Dust shield 32. Drive pinion
10. Side gear 22. Bearing retainer 33. Differential carrier
11. Thrust washer 23. O-ring
,+ 12. Pinion gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.
-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.
X The following marks and abbreviations are used in this manual.

Marks:
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended multi-pur-
pose grease.
: Should be lubricated with oil.
: Sealing point
: Always replace after every disassembly.
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)
Coil spring type

Clutch Type Diaphragm type single disc, dry Coil spring type single disc, dry
single disc, dry
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 — —
Unit name SRHF-3 SRHF-3

Differential
Gear type Hypoid Hypoid
Unit name RS55 RS55

Rear axle
Type Inboard type Inboard type
Unit name FA30 FA30
Toe-in Bias tire 1 (0.04) 1 (0.04)

mm (in) Radial tire 0 (0) 0 (0)
Front axle
Camber 1º00c or 1º30c [Front axle tread 1,760 mm (69.3 in)]
Caster 3º20c 3º20c

Kingpin inclination 7º00c 7º00c
Steer angle (Inner x Outer) 53ºx 39º 53º x 39º
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
Air over hydraulic Vacuum servo

Type Air over hydraulic brake (AOH. B)
brake (AOH. B) brake (VAC. B)
Front BHS32 BHS32

Wheel brake
Rear BLT32 BLT32
Type Piston type Piston type
Air pressure Pressure regulat- 706 - 834
Brake system governor ing range 706 - 834
{7.2 - 8.5, —
{7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi} 102 - 121}
Unit name — CB52 CB52
Parking brake Spring-activated Mechanical,

Mechanical, drive line parking brake type or
Type rear wheel parking drive line park-
Spring-activated rear wheel parking brake type
brake type ing brake type
Auxiliary brake Exhaust brake
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
D/F - D/F —
Unit name SRHF-3 SRHF-3

Differential
Unit name RS55 RS65 RS55
Rear axle
Type Inboard type Inboard type Inboard type
Unit name FA30 FA35 FA35
Bias tire 1 (0.04) 1 (0.04) 1 (0.04)
Toe-in mm (in)
Radial tire 0 (0) 0 (0) 0 (0)
Front axle 1º00c or 1º30c [Front axle tread 1,760
mm (69.3 in)]
Steer angle (Inner x Outer) 53º x 39º 44º x 35º
Steering system
R.H.D. model PMU-1487 PMU-1487 — PMU-1487
Unit name
L.H.D. model PMU-1488 PSI-Y85-7 PMU-1488 PMU-1488
Vacuum servo
brake (VAC. B) or Air over hydraulic
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}
Unit name CB52 — CB52
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
Front
Rear
GE-1-2
SPECIFICATIONS
Vehicle model
MKD210 LKB212 LKC210
Item
Model FE6T FE6TA FE6B FE6T

Engine Max. gross output (JIS) 151 157 132 135 151
135 {183}/3,000
kW {PS}/rpm {205}/2,800 {213}/2,800 {180}/3,000 {183}/3,000 {205}/2,800
Unit name — CL740 CL740 CL710 CL710 CL740
Coil spring type Coil spring type

Type — Coil spring type single disc, dry
Clutch single disc, dry single disc, dry
Operated by: — Air servo Air servo Air servo
Disc O.D. mm (in) — 350 (13.78) 350 (13.78) 350 (13.78)

Manual transmis- MLS61A MLS61B MLS61A
—
sion NEW MLS62A MLS62B NEW MLS62A
Unit name
Transmission Automatic trans-
MT643 — — —
mission
Operation Floor-shift Floor-shift Floor-shift
P/S - D/F PS860

D/F - D/F —
Unit name SRHF-3 SRHF-3 SRHH-2
Differential
Gear type Hypoid Hypoid Hypoid
Unit name RS55 RS65 RS75

Rear axle
Unit name FA35 FA35 FA35

Toe-in Bias tire 1 (0.04) 1 (0.04) 1 (0.04)

mm (in) Radial tire 0 (0) 0 (0) 0 (0)
Front axle
Caster 3º20c 3º20c 3º20c
Kingpin inclination 7º00c 7º00c 7º00c
Steer angle (Inner x Outer) 44º x 35º 44º x 35º 44º x 35º
Steering system
R.H.D. model PMU-1487 — PMU-1487
Unit name
L.H.D. model — PMU-1488 PSI-Y85-7 PMU-1488
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}
Unit name CB52 CB52 CB52
Parking brake Mechanical, drive line parking brake Spring-activated

Mechanical, drive line parking brake type or Spring-activated
Type type or Spring-activated rear wheel rear wheel parking
rear wheel parking brake type
parking brake type brake type
Front
Rear
GE-1-3
SPECIFICATIONS
Vehicle model
LKC210 LKC212 LKD210
Item
Model FE6TA FE6TA FE6B FE6T

Engine Max. gross output (JIS) 173 157 132 151
kW {PS}/rpm {235}/2,800 {213}/2,800 {180}/3,000 {205}/2,800
Unit name CL740 CL710 CL740
Type Coil spring type single disc, dry

Clutch
Operated by: Air servo
Disc O.D. mm (in) 350 (13.78)
MLS61B MLS61A
Manual transmission
MLS62B NEW MLS62A
Unit name
Transmission Automatic transmis-
— —
sion
P/S - D/F PS860 PS420

D/F - D/F — —
Unit name SRHH-2 SRHL-1

Differential
Unit name RS75 RS75
Rear axle
Unit name FA35 FA35

Bias tire 1 (0.04) 1 (0.04)
Toe-in mm (in)
Radial tire 0 (0) 0 (0)
Front axle
Camber 1º00c or 1º30c [Front axle tread 1,760 mm (69.3 in)] 1º30c

Steering system
R.H.D. model PMU-1487 PMU-1487
Unit name
L.H.D. model PMU-1488 PMU-1488
Front BHS37 or FB52 BHS37 FB52 FB52 or FB37

Wheel brake
Rear RB52 BLT37 RB52 BLT37
Type Piston type Piston type
Brake system Air pressure governor Pressure regulating

range 706 - 834 706 - 834
{7.2 - 8.5, 102 - 121} {7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi}
Unit name CB52 CB41
Parking brake
Type Mechanical, drive line parking brake type or Spring-activated rear wheel parking brake type
Front
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

Clutch
Operated by: Air servo
Disc O.D. mm (in) 350 (13.78)
MLS61A
MLS61A MLS61B
Manual transmission MLS62A
Unit name NEW MLS62A MLS62B
NEW MLS62A
Transmission
Automatic transmission — — — —
Operation Floor-shift
P/S - D/F PS420

D/F - D/F —
Unit name SRHL-1

Differential
Gear type Hypoid
Unit name RS90
Rear axle
Type Inboard type
Unit name FA40
Type Outboard type

Bias tire 1 (0.04)
Toe-in mm (in)
Radial tire 0 (0)
Camber 1º00c
Front axle
Caster 3º20c
Kingpin inclination 7º00c
50º x 38º (STD)
45º x 36º (Tire size 275/70R 22.5)
Steer angle (Inner x Outer) (Tire size 10.00-20) 50º x 38º
(Tire size 10R20)
(Tire size 11R22.5)
Steering system
R.H.D. model 446-02580 446-02580
Unit name
L.H.D. model PSI-Y100-46 —
Front FB37
Wheel brake
Rear BLT40
Type Piston type
Brake system Air pressure governor Pressure regulating

range 706 - 834
{7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi}
Unit name CB41
Parking brake
Type Mechanical, drive line parking brake or Spring-activated rear wheel parking brake type
Front
Rear
GE-1-5
SPECIFICATIONS
Vehicle model
PKC210 PKC212 PKF210
Item
Model FE6T FE6T FE6TA FE6TA FE6T
kW {PS}/rpm {205}/2,800 {220}/2,800 {235}/2,800 {213}/2,800 {220}/2,800
CL740 CL750: (MPS62T)

CL810 CL810: (Eaton 6109)
Clutch Type Coil spring type single disc, dry
Operated by: Air servo Air servo
Disc O.D. mm (in) 350 (13.78) 350 (13.78) 350 (13.78)

MLS61B
MPS62T MPS62T MPS62T
Manual transmission MLS62B MPS62B
Unit name MPS62B Eaton 6109 Eaton 6109
Eaton 6109
Transmission
Automatic transmission — — — — MT643
P/S - D/F PS430 PS420 PS420

D/F - D/F — — —
Unit name SRHL-1 SRHL-1 SRHL-1

Differential
Gear type Hypoid Hypoid Hypoid
Unit name RS1A RS1AA RS90
Rear axle
Unit name FA50 FA50
Bias tire 0 - 4 (0 - 0.16) 0 - 4 (0 - 0.16)

Toe-in mm (in)
Radial tire 0 - 2 (0 - 0.08) 0 - 2 (0 - 0.08)
Front axle Camber 1º00c 1º00c

45º x 36º (STD)
Steer angle (Inner x Outer) 45º x 35º (Tire size 11.00-20) 47º x 36º
(Tire size 11R-20)
Steering system
R.H.D. model 446-02580
Unit name
L.H.D. model PSI-Y100-46
Front BHL41 BAL41 BHL41 BAL41 BHS40
Wheel brake
Rear BLL41 BPL41 BLL41 BPL41 BLT40
Type Piston type
Air pressure Pressure regulating 706 - 834 706 - 834
governor range 667 - 785
{7.2 - 8.5, {7.2 - 8.5,
{6.8 - 8.0, 97 - 114}
Brake system kPa {kgf/cm2, psi} 102 - 121} 102 - 121}
Unit name CB41 — CB41 — CB41 (MPS62T T/M)

Mechanical, drive line
Parking brake Mechanical, drive Spring-activated rear Spring-activated rear parking brake type or
Mechanical, drive line
Type line parking brake wheel parking brake wheel parking brake Spring-activated rear
parking brake type
type type type wheel parking brake
type
Front
Rear
GE-1-6
SPECIFICATIONS
Vehicle model
PKC310 PKC310BT tractor
Item
Model NE6 NE6T NE6TA NE6T NE6TA
kW {PS}/rpm {175}/2,800 {213}/2,800 {250}/2,800 {213}/2,800 {250}/2,800

Type Coil spring type single disc, dry Coil spring type single disc, dry
Clutch
Disc O.D. mm (in) 350 (13.78) 380 (14.96) 380 (14.96)
MPS50W MPS62T MPS62T

Manual transmission MPS62T
MPS62T Eaton 6109 Eaton 6109
Unit name
— — —
sion
P/S - D/F PS430 PS430
D/F - D/F — —
Unit name SRHL-1 SRHL-1

Differential
Unit name RS1A RS1A

Rear axle
Unit name FA50 FA50

Bias tire 0 - 4 (0 - 0.16) 0 - 4 (0 - 0.16)
Toe-in mm (in)
Radial tire 0 - 2 (0 - 0.08) 0 - 2 (0 - 0.08)
Front axle Camber 1º00c 1º00c


47º x 36º (STD) 47º x 36º (STD)
Steer angle (Inner x Outer) 45º x 35º (Tire size 11.00-20) 45º x 35º (Tire size 11.00-20)
(Tire size 11R-20) (Tire size 11R-20)

Steering system
R.H.D. model 446-02580
Unit name
L.H.D. model PSI-Y100-46
Air over hydraulic brake
Type Air over hydraulic brake (AOH. B) or Air brake Air brake
(AOH. B)
Front BHL41 BHL41 or BAL41 BAL41
Wheel brake
Rear BLL41 BLL41 or BPL41 BPL41
Type Piston type
Air pressure gover- Pressure regulating
Brake system nor range AOH: 667 - 785 {6.8 - 8.0, 97 - 114} 706 - 834
AIR: 706 - 834 {7.2 - 8.5, 102 - 121} {7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi}
CB31 (MPS50W T/M)
Unit name CB41 (AOH. B vehicle) —
CB41 (MPS62T T/M)
Parking brake
Mechanical, drive line Mechanical, drive line parking brake type or Spring-activated rear wheel parking brake
Type
parking brake type Spring-activated rear wheel parking brake type type
Front
Rear
GE-1-7
SPECIFICATIONS
Vehicle model
CDA310 CWA310
Item
Model NE6 NE6T NE6T NE6TA

Engine Max. gross output (JIS)
129 {175}/2,800 157 {213}/2,800 157 {213}/2,800 184 {250}/2,800
kW {PS}/rpm

Type Coil spring type single disc, dry Coil spring type single disc, dry
Clutch
Disc O.D. mm (in) 350 (13.78) 380 (14.96) 380 (14.96)

MPS50W MPS62B MPS62T
Manual transmission MPS62T Eaton 6109
MPS62T MPS62T MPS62B
Unit name
— —
sion

P/S - D/F PS430 PS430 PS520
D/F - D/F — PS410 PS410
Unit name SRHL-1 ITHL (Rear front), SRHL-1 (Rear rear)
Differential
Unit name RD90 (Rear front), RD80 (Rear rear) RW1A + RW1A
Rear axle
Type Inboard type Inboard type Outboard type
Unit name FA50 FA50
Type Inboard type Inboard type Outboard type
Bias tire 0 - 4 (0 - 0.16) 0 - 4 (0 - 0.16)

Toe-in mm (in)
Radial tire — 0 - 2 (0 - 0.08)
Front axle
Camber 1º00c 1º00c
Steering system
R.H.D. model 446-02580
Unit name
L.H.D. model —
Type Air over hydraulic brake (AOH. B) Air brake

Front BHS40 BAL41
Wheel brake
Rear RB37 RB41
Type Piston type
Air pressure gover- Pressure regulating
Brake system 706 - 834
nor range
{7.2 - 8.5, 102 - 121}
kPa {kgf/cm2, psi}
Unit name CB31 —
Parking brake
Type Mechanical, drive line parking brake Spring brake type
Front Axle, semi-elliptical, leaf-spring (shackle)

Suspension Type
Rear Trunnion mounted semi-elliptical, leaf-spring with torque rod
GE-1-8
IDENTIFICATION
IDENTIFICATION
CHASSIS SERIAL NUMBER
VIN PLATE
ENGINE SERIAL NUMBER

The engine serial number is stamped on the right of the
cylinder block.
GE-2-1
IDENTIFICATION
UNIT IDENTIFICATION NUMBER

Unit identification numbers are stamped on the transmission, rear
axle, differential carrier and front axle.
Transmission
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
GARAGE JACK AND SAFETY STAND

WARNING
WARNING
z When carrying out operations with the garage jack, be
sure to support the vehicle with safety stands.
z When jacking up the rear (front) of the vehicle, place the
chocks at the front (rear) of the front (rear) wheels to hold
them.
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.
TOWING WITH THE FRONT AXLE RAISED

Remove the propeller shaft or axle shaft before towing. To remove the axle shaft, completely drain the lubricat-
ing oil from each end of the axle housing and place covers over the holes to prevent entry of foreign matter.
TOWING WITH THE REAR AXLE RAISED

Set the front wheels in the straight-forward direction; otherwise, the vehicle cannot be towed.
Drain transmission oil by 0.5 liters (1/2 Imp qt) to prevent it from getting into the clutch housing while the vehi-
cle is being towed.
GE-4-1
GENERAL PRECAUTIONS ON SERVICING

PRECAUTIONS ON MAINTENANCE
Observe the following when servicing the vehicle.
z Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle
may move abruptly.
z Engage the parking brake and chock the wheels securely.
z If the engine is hot, wait until it cools off.
z Set the transmission gear shift lever to “NEUTRAL”.
z Turn the key switch to “OFF”. Disconnect the ground cable when servicing the electrical system.
z Do not touch rotating parts of the engine if servicing requires engine operation. Always operate the
engine in a well-ventilated area.
z When tilting the cab indoors, make sure that there is a

clearance of at least 4 m (13.1 ft) in H and a clearance of 1
m (3.3 ft) in F.
GENERAL PRECAUTIONS IN DISASSEMBLY

Checks before disassembly
Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For
instance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil
leakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engine
needs to be disassembled and which part does not. It will also save time and labor.
Work required during disassembly
Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original posi-
tions. When repairs involve the electrical system, disconnect the ground cable from the battery.
Checks during disassembly
Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work effi-
ciency will be degraded after all parts have been disassembled.
Keeping disassembled parts in order
Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be
replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc.
Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contami-
nated with water or oil. Keep them in one place and away from those having engine oil on them.
Cleaning disassembled parts
Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned,
scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems
after reassembly.
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.
GE-5-1
Adjustment and operational checks

Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for
proper operation.
CLEANING AND INSPECTION

Cleaning
The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include
steam cleaning light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene
steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely
while the cleaning is in process.
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
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.
BOLTS NUTS BOLTS NUTS

Metric Inch Metric Inch Metric Inch Metric Inch
M3x0.5 5-40 M3x0.5 *5-44
M6x1.0 1/4-20 M3.5x0.6 *6-40
M6x1.0 *1/4-28 M4x0.7 8-32
*M8x1.0 *5/16-24 M4x0.7 *8-36
M10x1.5 7/16-14 M5x0.8 *10-32
*M10x1.25 7/16-14 M5x0.8 12-24
*M10x1.0 7/16-14 M5x0.8 *12-28
M12x1.75 1/2-13 *M12x1.25 *1/2-20
M12x1.75 *1/2-20 M18x2.5 3/4-10
*M12x1.5 1/2-13 *M18x1.5 *3/4-16
*M12x1.5 *1/2-20 M24x3 1-8
*M12x1.25 1/2-13 M24x2 *1-12
M14x2 9/16-12 *4-48 M3x0.5
*M14x1.5 *9/16-18 5-40 M3.5x0.6
*M16x1.5 *5/8-18 *6-40 M3.5x0.6
*M24x2 1-8 *8-36 M4x0.7
4-40 M3x0.5 *10-32 M5x0.8
5/16-18 M8x1.25 12-24 M6x1.0
*5/16-24 M8x1.25 *1/4-28 M7x1.0
3/8-16 *M10x1.25 3/8-16 M10x1.5
3/8-16 *M10x1.25 7/16-14 M12x1.75
3/8-16 *M10x1.0 1/2-13 M14x2
3/8-16 M10x1.5 3/4-10 M20x2.5
7/16-14 *M12x1.25 *3/4-16 *M20x1.5
*7/16-20 *M12x1.5 7/8-9 M24x3
*7/16-20 M12x1.75 *: Fine thread
*1/2-20 M14x2
*5/8-18 *M16x1.5
*7/8-14 M24x3
*1-12 M27x3
GE-5-3
TIGHTENING TORQUE OF STANDARD BOLTS
TIGHTENING TORQUE OF STANDARD BOLTS

The tightening torque of the bolts and other fasteners that secure the major components parts is specified in
the text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened accord-
ing to the following table of bolt standard tightening torque.
NOTE
z All bolts and nuts are sized using the metric system. Do not use parts other than those designated.
Standard tightening torque (Without lubricant)

Nominal Bolt dia. Pitch
4T 7T 9T
size mm mm
N·m kgf·m ft·lbf N·m kgf·m ft·lbf N·m kgf·m ft·lbf
M3 3.0 0.5 0.7 0.07 0.5 1.1 0.11 0.8 1.6 0.16 1.2
M4 4.0 0.7 1.5 0.15 1.1 2.5 0.25 1.8 3.5 0.36 2.6
M5 5.0 0.8 2.9 0.3 2.2 5.0 0.51 3.7 7.2 0.73 5.3
M6 6.0 1.0 5.1 0.52 3.8 8.4 0.86 6.2 12 1.2 9
1.25 13 1.3 9 21 2.1 15 29 3.0 22
M8 8.0
1.0 13 1.3 9 22 2.2 16 31 3.2 23
1.5 25 2.5 18 41 4.2 30 59 6.0 43
M10 10.0
1.25 25 2.6 19 43 4.4 32 62 6.3 46
1.75 42 4.3 31 71 7.2 52 98 10.0 72
M12 12.0
1.25 46 4.7 34 77 7.9 57 108 11.0 80
M14 14.0 1.5 74 7.5 54 127 13.0 94 177 18.0 130
M16 16.0 1.5 108 11.0 80 186 19.0 137 275 28.0 203
M18 18.0 1.5 167 17.0 123 275 28.0 203 392 40.0 289
M20 20.0 1.5 226 23.0 166 382 39.0 282 549 56.0 405
M22 22.0 1.5 304 31.0 224 510 52.0 376 736 75.0 542
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
Standard tightening torque of tubing connector

Unit: N·m {kgf·m, ft·lbf}
Item Standard tightening torque
4.75 (0.1870) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
Tube outer diameter 8 (0.31) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut
mm (in) 10 (0.39) 39 - 49 {4.0 - 5.0, 29 - 36}
12 (0.47) 59 - 78 {6.0 - 8.0, 43 - 58}
15 (0.59) 69 - 88 {7.0 - 9.0, 51 - 65}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}
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)
OFF HIGHWAY USE

First 30 hours Change transmission oil on new units.
Every 40 hours*1 Inspect oil level. Check for leaks.
Change transmission oil when severe dirt
Every 500 hours
conditions exist.
Change transmission oil
Every 1,000 hours*2
(Normal off-highway use).
Remove and clean oil strainer at each oil change.

Transmissions fitted with an oil cooler may additionally be fitted with
a filter in the cooler line. Renew the filter at every oil change.
*1: Or 2 months, whichever occurs first.
*2: Or 12 months, whichever occurs first.
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.
RECOMMENDED SAE VISCOSITY NUMBER

Use oil having the proper viscosity beforehand which meets tem-
peratures forecast for areas where you are planning to drive.
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
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
MLS61B With P.T.O. 6.4 5-5/8 qt
MPS50W
With P.T.O. 8.0 7 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
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
LUBRICATION AND FILTER REPLACEMENT INTERVALS
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
Full-flow type R R: Every 10,000 km (6,000 miles) or 6 months (1)

Engine oil and
filter Full-flow and
R R: Every 15,000 km (9,000 miles) or 6 months (1)
bypass type
Fuel filter element R
Primary fuel filter element R R
Air cleaner element
R (2)
(Dry type)
Coolant (incl. anticorrosive) R R (3)
Coolant (incl. antifreeze) R (4)
CHASSIS
Power steering fluid R R: Every 25,000 km (15,000 miles) or 6 months

Power steering filter element R: Every 50,000 km (30,000 miles) or 12 months
Brake fluid R (5)
Differential gear oil R R
Front and rear wheel bearing
R R
grease
Clutch fluid R (6)
Transmission gear oil R R R
Grease lubrication points L: Refer to “GREASE LUBRICATION POINTS AND INTERVALS”
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 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)
Cylinder head and manifold bolts T T
Cylinder compression pressure I
Valve clearance I I
Oil leakage I I I I I I I I I I I I I I
Oil level contamination 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
I : After 200,000 km (125,000 miles)

Crank damper
I: Every 100,000 km (62,500 miles)
Fuel level 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
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
Gear box mounting bolt and nut T T T T T

Gear box bearing rattle I
Steering gear backlash I
Steering linkage I I I I I
Ball joint dust boot I I I I I

Knuckle joint I I
Clearance between knuckle and
I
front axle
Wheel alignment I
Turning angle I
Power steering fluid level I I I I I I I I I I I I I
Power steering system 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
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
AXLE AND WHEEL

Front axle I
Rear axle housing I
Differential gear oil leakage I I I I I I I I I I I I I I
Axle shaft I
Axle shaft mounting bolts T T T T T
Tire air pressure I I I I I I I I I I I I I
Tire cracks or damage I I I I I I I I I I I I I
Tire wear I I I I I I I I I I I I I
Wheel nuts T T T T T T T T T T T T
Rim, side ring and disc wheel I I I I I I I I I I I I
Front and rear wheel bearing I I
SUSPENSION
Leaf spring I I I I I
Spring bracket I
Shock absorber I I I
Stabilizer I I I I I
(4) Mechanically-actuated type. (5) If so equipped.
MA-1-5
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
Clutch fluid level I I I I I I I I I I I I I
Clutch fluid leakage 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
Frame and body I I I I I

Seat belt I
Tilt lock I
Noise shield plate I (1)
Coupler I (2)
Mirrors I
Remarks: (1) If so equipped. (2) Semi-trailer trucks only.
MA-1-6
PERIODIC PARTS REPLACEMENT

Periodic replacement parts are rubber parts such as brake hose and fuel hose which require maintenance and
deteriorate over time. It is necessary to periodically replace these parts in order to maintain driving safety.
PERIODIC PARTS REPLACEMENT INTERVAL
Items Remarks
Number of years 1 2 3 4 5 6 7 8 9 10
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)
(4) Air-actuated type parking brake equipped vehicles. (5) Replace every year. (6) Semi-trailer trucks.
MA-1-7
LUBRICATION POINT AND INTERVALS
GREASE LUBRICATION POINTS
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
GREASE LUBRICATION INTERVALS

Greasing should be performed periodically. Wipe all dust and dirt from the grease nipples with a cloth, and then
apply grease. After greasing, wipe off any excess grease.
The following schedule is for a one-year period only. However, similar maintenance is required for subsequent
years.
MAINTENANCE INTERVALS
Kilometers x 1,000 5 10 15 20 25 30 35 40 45 50 55 60 Re-
Items
Miles x 1,000 3 6 9 12 15 18 21 24 27 30 33 36 marks
Months 1 2 3 4 5 6 7 8 9 10 11 12
1 Helper spring contact seat L L L L L L L L L L L L
2 Rear spring pin and shackle pin L L L L L L L L L L L L
3 Propeller-shaft journal and yoke L L L L L L L L L L L L
4 Clutch release shaft L L
5 Clutch release sleeve L L
6 Cab mounting front torsion bar contact seat L L L L
7 Front spring pin and shackle pin L L L L L L L L L L L L
8 Cab tilt main hook L L L L
9 Engine water pump pulley L L L L (1)
10 Steering column spline L L L L L L L L L L L L
11 Door hinge pin bushing L L (2)
12 Drag link end L L L L L L L L L L L L
13 King pin L L L L L L L L L L L L
14 Tie-rod end L L L L L L L L L L L L
15 Parking brake chamber arm shaft L L L L L L L L L L L L (3)
16 Rear brake camshaft and slack adjuster L L (4)
17 Front brake camshaft and slack adjuster L L (4)
18 Rear spring contact seat L L L L L L L L L L L L
19 Trunnion shaft L L L L L L L L L L L L
Remarks: (1) FE6 series engine only.

(2) Use NLGI No. 000 or equivalent.
(3) If so equipped. (4) Air brake vehicles.
MA-1-9
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)
STEERING WHEEL OPERATION

During a test run, make sure that the steering wheel operates nor-
mally without shimmying, difficult steering, or pulling to one side.
STEERING SYSTEM FLUID LEAKAGE

Check the tube and hose connections of the power steering system
for fluid leakage, and hoses and tubes for fractures, cracks, dam-
age or improper installation. Replace faulty parts as necessary.
After replacing a tube or hose, be sure to bleed air from the power
steering piping system.
MA-2-1
POWER STEERING FLUID

WARNING
WARNING
z To avoid possible burn injury, allow the steering system
to cool before checking or changing the steering system
fluid.
z Do not operate the vehicle when the steering system
fluid is low or contaminated. If the steering system fluid
is low or contaminated, the power steering may not oper-
ate normally which could adversely affect steering con-
trol. If the fluid level is low, check the steering system for
leaks and correct the condition before operating the
vehicle. If the fluid is contaminated, replace the fluid.
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.
To inspect the steering system fluid level

<MK and LKA/B/C series>
1. Visually inspect the steering system for fluid leaks.
2. Clean dirt and debris from the steering fluid reservoir and cap.
3. Remove the filler cap from the fluid reservoir. Wipe the fluid
off the level stick, reinsert the cap and tighten it to its origi-
nal position.
4. Remove the filler cap again and check the fluid level. The
fluid level should be between the cutouts on the level stick.
5. Replace and tighten the filler cap.
<LKD, PK, CDA and CWA series>
1. Visually inspect the steering system for fluid leaks.
2. The fluid level should be between the HIGH and LOW lines.
If the fluid level is below the LOW line, add steering system
fluid to the HIGH line.
Steering system fluid change

<Fluid draining>
1. Block the rear wheels and jack up the front axle to lift the
front wheels off.
WARNING
WARNING
z After lifting the axle off the ground, support it securely
with safety stands.
MA-2-2
2. Disconnect the inlet and outlet pipe connectors from the

steering gear box unit and allow fluid to flow out spontane-
ously.
NOTE
z To prevent dirt, dust, etc. from entering the port, clean the
connector and its surrounding area before removing it.
3. Drain fluid from the gear case by turning the steering wheel
fully to the right and left several times.
<Cleaning steering system interior>

1. Remove the fluid strainer from the fluid reservoir and clean it.
2. Disconnect the return hose from the fluid reservoir return

port and stop the port. All the other hoses should remain
connected. Put the free end of the return hose in a drainage
container.
MA-2-3
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.
To replace the fluid filter or element assembly

<MK and LKA/B/C series>
1. Filter 5. Lifter ring
2. Fluid reservoir ass'y 6. Seat seal assembly
3. Screw 7. O-ring
4. Breather
1. Loosen the screws and remove the breather, packing,
spring and relief valve.
2. Remove the filter.
3. Install a new filter. Reinstall other parts in their original posi-
tions.
<LKD, PK, CDA and CWA series>

1. Remove the cap, and remove the strainer and element.
2. Install a new element and strainer, and install the cap.
Steering fluid refilling and air bleeding

1. Fill the fluid reservoir to its specified level.
2. With the engine idling, turn the steering wheel to the right
and left several times. Add oil if the fluid level drops.
3. Repeat the operation in item 2 until the fluid level stabilizes.
4. Turn the steering wheel to check that both wheels move
smoothly.
5. Lower the front wheels to the ground and check that oil is
not leaking from the pipes and connectors.
6. Check the fluid level.
MA-2-4
GEAR BOX MOUNTING BOLTS AND NUTS

Check the gear box mounting bolts for tightness. Tighten to the
specified torque if necessary.
MK and LKB/C series:
: 206 - 235 N·m {21 - 24 kgf·m, 152 - 174 ft·lbf}
LKD, PK, CDA and CWA series:
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
GEAR BOX BEARING RATTLE

Inspect the engagement of the steering worm shaft with the bear-
ing, excessive wear of the bearing, and the sliding surface for dam-
age.
Replace the steering worm shaft and bearing if they are worn or
damaged on the sliding surfaces.
STEERING GEAR BACKLASH

1. Check to see if the steering worm and sector shaft gear are
worn or damaged on the meshing teeth surfaces.
2. Check the backlash of the gear at the pointed end of the pit-
man arm.
NOTE
z For details, refer to the “ST” section.
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
Disassemble and check.

Check the various sections of the steering linkage for proper tight-
ness. If necessary, tighten loose sections to the specified torque.
Also check the joints for grease leakage.
MK and LKB/C PKC, PKF, CDA
Item Tightening torque LKD series PKB series
series and CWA series
1.Pitman arm 343 - 392 {35 - 40, 253 - 289} z
nut 441 - 490 {45 - 50, 325 - 362} z z z
2.Drag link 167 - 226 {17 - 23, 123 - 166} z
castellated 196 - 255 {20 - 26, 145 - 188} z z

nut 216 - 343 {22 - 35, 159 - 253} z
3.Steering 196 - 265 {20 - 27, 145 - 195} z z
arm mount- 284 - 373 {29 - 38, 210 - 275} z

ing nut 490 - 588 {50 - 60, 362 - 434} z
4.Connection 167 - 294 {17 - 30, 123 - 217} z z
for tie-rod arm 196 - 255 {20 - 26, 145 - 188} z

and ball stud 245 - 304 {25 - 31, 181 - 224} z
5.Tie-rod arm 196 - 265 {20 - 27, 145 - 195} z z
mounting 275 - 343 {28 - 35, 203 - 253} z

nut 284 - 373 {29 - 38, 210 - 275} z
6.Tie-rod end 88 - 113 {9 - 11.5, 65 - 83} z z
clamp bolt 59 - 78 {6 - 8, 43 - 58} z z
MA-2-6
BALL JOINT DUST BOOT

Check the ball joint dust boot for cracks or damage.
Replace cracked or damaged ball joint dust boot.
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.
CLEARANCE BETWEEN FRONT AXLE AND KNUCKLE

1. Jack up the front axle.
2. Place a feeler gauge between the steering knuckle and
front axle to check the axial play. If the axial play exceeds
the specified value, replace shim(s) to adjust the play. (For
adjustment procedures, refer to the “FA” section.)
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.
For procedures used to measure wheel alignment and adjust toe-in

and the steering angle of the wheels, refer to the “FA” section.
If camber, caster or kingpin inclination is not within the specified
range, check the front axle (I-beam) for bending and the frame for
twisting.
MA-2-7
CHECK TURNING ANGLE

1. Get the front wheels on the turning radius gauge. Measure
the respective angles to which the wheels are turned when
the steering wheel is completely turned from the straight
ahead position to the right and to the left. However, the
inspection may be omitted by confirming that the stopper
bolt is not loose or damaged, and that the steering system
smoothly operates until it runs against the stopper bolt.
2. When carrying out the above inspection, also make sure
that the steering wheel does not interfere with other parts.
POWER STEERING SYSTEM

1. Check the oil pump, etc. for loose attachment.
2. Check hoses and pipes for loose connections.
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) —
Adjustment procedures for brake pedal play

For adjustment procedures, refer to the “BR” section.
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
BRAKE FLUID LEVEL

Maintain the fluid level in the reservoir between the HIGH and LOW
marks on the brake fluid reservoir. If the fluid level is below the
LOW mark then add brake fluid.
If brake fluid is contaminated or it is the time for periodic replace-
ment, replace brake fluid observing the following:
WARNING
WARNING
z Brake fluid loss may indicate a leak in the brake system.
When the brake fluid level drops excessively check the
brake line, connections, etc. for leaks before correcting
the level, and repair faulty parts, if any.
z To avoid possible burn injury, allow the engine and brake
system to cool before checking or changing brake fluid.
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.
Brake fluid replacement

1. Start the engine and wait for the pressure in the air reservoir
to reach the standard operating air pressure. In vehicles
equipped with vacuum servo brakes, stop the engine and
wait for the pressure to reach atmospheric pressure.
2. Connect a vinyl tube to the air bleeder of the wheel cylinder.

3. Loosen the air bleeder screw. Depress the brake pedal
repeatedly until all brake fluid runs out of the bleeder.
4. While adding new brake fluid to the reservoir tank, depress
the brake pedal until all the old fluid is replaced by new fluid.
5. Tighten the bleeder screw. Add brake fluid to the specified
level on the reservoir and bleed air from the brake system.
MA-2-9
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.
Bleeding air from the brake system

For air bleeding procedures, refer to the “BR” section.
HOSE AND PIPE FOR FLUID AND/OR AIR LEAKAGE

1. Check brake hoses and pipes for fluid leakage, damage,
and interference with other parts. Also, check hoses for
deterioration.
2. Check pipe joints and connections between hoses and pipe
sleeves for damage.
3. Check that hose clamps are tightened in place.
DRAINING AIR RESERVOIR

To drain accumulated water from the air reservoir
1. Open the drain cocks.
2. Allow the water to drain.
3. After draining, release the drain cock rings and close the
drain cock.
CAUTION
z As vehicles are equipped with an air dryer, water will nor-
mally not drain from the air reservoir when the drain cock
is opened. However, a small amount of water may drain
out under humid conditions. If a large amount of water is
drained, the air dryer may not be functioning properly.
Check the air dryer.
MA-2-10
BRAKE VALVE AND OTHER VALVES

1. Check the brake valve and other valves for proper function.
2. Disassemble the valves and replace parts at specified inter-
vals.
NOTE
z For inspection procedures, refer to the “BR” section.
BRAKE LINING CLEARANCE

VAC and AOH brake for the MK, LK, PK, CDA and CWA
series
<Manual adjusting type>
1. Raise the wheel to be checked, using a jack.
2. Check the brake lining-to-drum clearance with a feeler
gauge inserted through the inspection holes. This check
should be performed for the entire circumference by turning
the wheel.
NOTE
z Be sure to check at the two inspection holes.
Unit: mm (in)
Lining clearance 0.2 - 0.3 (0.008 - 0.012) —
3. In a manner similar to step 2. above, check the other

wheels.
4. If the brake lining clearance is outside specifications, adjust
as follows:
z Remove the rubber plugs from the adjustment hole.
z Using a screwdriver, turn the adjuster in the direction of the

arrow marked on the backing plate until the lining lightly
contacts the drum.
NOTE
z Be sure to adjust at the two adjustment holes.
z Depress the brake pedal several times. Check that the lin-
ing contacts the brake drum.
z Move the adjuster back 4 to 5 notches for the MK and LK
series or 8 to 10 notches for the PK, CDA and CWA series.
z Insert a feeler gauge through the inspection hole and check
the brake lining clearance.
NOTE
z After adjusting, make sure the drum turns smoothly.
z Adjust the other lining in the same manner.
5. After adjusting, install the rubber plugs securely into the
inspection hole and adjustment hole.
<Auto adjuster type>
Shoe will adjust to the correct clearance automatically after
depressing brake pedal several times.
MA-2-11
AOH brake for the PKC210, 310 series

1. Raise the wheel to be checked, using a jack.
2. Check the brake lining-to-drum clearance with a feeler
gauge inserted through the inspection holes. This check
should be performed for the entire circumference by turning
the wheel.
NOTE
Unit: mm (in)
Front
Lining clearance 0.3 - 0.4 (0.012 - 0.016) —
Rear
3. In a manner similar to step 2. above, check the other wheels.

4. If the brake lining clearance is outside specifications, adjust
as follows:
z Remove the back plate grommet, and insert a 0.3 to 0.4 mm
(0.012 to 0.016 in) feeler gauge.
z Rotate the adjuster cam from the “START” position in the

direction of the arrow, until resistance is felt when pulling
out the feeler gauge.
NOTE
z Rotate the drum to check the clearance all around the
brake drum, and make adjustments where the clearance
is the smallest.
z Adjust the clearance of the other lining similarly.
z Rotate the drum by hand to ensure the lining doesn't drag.

NOTE
z If the indicator needle does not point to “END” after
adjustment, replace the lining with a new one.
After the lining has been replaced, return the indicator
needle to the “START” position.
MA-2-12
BRAKE CHAMBER PUSH ROD STROKE

(AIR BRAKE VEHICLES)
To check the brake chamber push rod stroke
The foot brake lining clearance can be judged by checking the
stroke of the brake chamber push rod.
Depress the brake pedal completely to ensure that the push rod
stroke is within specifications.
Push rod stroke
Unit: mm (in)
Front 30 (1.18) 45 (1.77)
PKC210,
30 (1.18) 45 (1.77)
Rear 310 series
CWA310 24 (0.94) 40 (1.57)
To adjust the brake chamber push rod stroke

1. Turn the adjusting screw of the slack adjuster (clockwise for
front brake, and counterclockwise for rear brake) until the
lining comes into contact with the drum.
NOTE
z The adjusting screw is locked by the locking spring and
steel ball. The screw can be unlocked by simply turning it
with a suitable wrench.
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)
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
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
2. Completely depress the brake pedal. When the pedal is

released, check to hear if a sucking air sound is coming
from the hydromaster's air cleaner. If it is, the air cleaner is
not clogged.
NOTE
z Repeat the above test 4 or 5 times by quickly releasing
the brake pedal.
3. Remove the air cleaner cap and replace the element with a
new one if the air cleaner is clogged or excessively contam-
inated.
<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.
2. Completely depress the brake pedal. Then quickly release

the pedal and listen for an exhaust sound emitted from the
air booster's exhaust port. The air cleaner is not clogged if
there is a sound.
NOTE
z Repeat the above test 4 or 5 times by quickly releasing
the brake pedal.
Fluid and air tightness

Check the brake booster and hydromaster for fluid and air leakage.
Check valve and relay valve
For inspection procedures, refer to the “BR” section.
WHEEL CYLINDER FOR PROPER FUNCTIONING

1. Operate the brakes and check that the wheel cylinder func-
tions normally.
2. Check the wheel cylinder for oil leakage and damage by an
external inspection (including the inside of the cylinder
boot).
3. Disassemble the wheel cylinder and check the cylinder, pis-
ton, return spring, etc. for corrosion, wear and damage.
MA-2-15
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.
3. Insert a standard (flat-bladed) screwdriver into the lower

hole and turn the adjuster wheel until the drum-to-lining
clearance is zero.
4. Unscrew the adjusting wheel 8 to 10 notches for type CB52
or 8 notches for type CB41 or 8 to 9 notches for type CB31.
5. Move the parking brake lever back and forth several times;
then rotate the brake drum by hand to ensure that it does
not drag.
6. Replace the rubber plug in its original position.
Parking brake lever stroke

Pull the parking brake lever back completely and then return it back
to its original position.
Pull the parking brake lever back again forcefully until it locks.
z Force required for lever pull: Approx. 196 N {20 kgf, 44 lbf}.
z While pulling the parking brake lever, count the number of
clicks the lever notch makes.
Lever stroke 3 - 11 notches —
z Also check for proper installation of the parking brake lever.
MA-2-16
<Adjustment of parking brake lever stroke>

For adjustment procedures, refer to Parking brake in the “BR” sec-
tion.
Parking brake effectiveness

Use a brake tester, or check to see if the parking brake can hold the
vehicle stationary on a 1/5 gradient.
Parking brake wire

Check the parking brake wire for loose attachment.
Parking brake drum

Refer to the “BR” section (Parking brake) for inspection procedures.
Parking brake lining

Refer to the “BR” section (Parking brake) for inspection procedures.
<WITH SPRING-ACTIVATED REAR WHEEL PARKING

BRAKES>
Parking brake system
Apply the parking brake and check the spring chamber push rod for
smooth movement, free play or looseness.
MA-2-17
Release parking brakes

In case of an emergency when the air pressure cannot be restored
and the vehicle must be towed, the parking brakes must be
released manually as follows.
WARNING
WARNING
z To avoid personal injury or properly damage, when man-
ually releasing the parking brakes, be sure to block the
wheels so that the vehicle cannot move when the brakes
are released.
For towing, make sure the vehicle is securely connected
to tow vehicle before releasing the parking brakes.
<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}.
<LK and PKB/F series>

2. Loosen the lock nut.
3. Turn the release nut to extend the push rod until the brake
shoes are release from the drum.
MA-2-18
Reset procedure
1. Reset the release nut to the dimension shown in the follow-
ing figure.
<PKC and CWA series for the AIR brake>

2. Remove the release stud tool and nut from the carrying
pocket on the brake chamber assembly.
3. Remove the access plug from the end of the spring cham-
ber.
4. Insert the release stud through the opening in the chamber

and into the spring pressure plate.
5. Turn the release stud one-fourth turn to engage the stud
tangs with the slot in the pressure plate.
6. Keep the stud engaged and install the nut on the release
stud. Tighten the nut until the spring is fully compressed and
the brakes are released.
Do not overtorque the release stud nut [47 N·m {4.8 kgf·m,
35 ft·lbf} max.].
MA-2-19
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.
AIR COMPRESSOR AND AIR PRESSURE GOVERNOR

Checking air-charging performance
1. Set air pressure in the air reservoir to 0 kPa {0 kgf/cm2, 0 psi}.
2. Start the engine and measure the length of time required for
air pressure to increase from 0 to 785 kPa {0 to 8.0 kgf/cm2,
0 to 114 psi}.
Length of time
Engine required for Air pressure and
Model
rpm increase in air pres- reservoir capacity
sure
FE6 series 800 260 sec.
engine 3,200 68 sec.
0 - 785 kPa {0 - 8.0
400 260 sec.
NE6 Single kgf/cm2, 0 - 114 psi}
2,000 58 sec.
series 30l (6-5/8 Imp gal)
engine 400 185 sec.
Twin
2,000 37 sec.
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
Air pressure governor performance test

Decrease air pressure to approximately 490 kPa {5 kgf/cm2, 71
psi}. Start the engine and gradually increase air pressure. When air
pressure reaches the specified value, the air pressure governor
activates to set the air compressor in the “unload” cycle. If air pres-
sure is 736 kPa {7.5 kgf/cm2, 107 psi} at this point, the air pressure
governor is functioning properly. To determine whether the com-
pressor is in the “unload” cycle while the governor is in operation,
listen for the stoppage of the air supply sound to the air reservoir.
L.S.P.V. FOR WIRING OR ROD

Check that the installation of the valve body and wire is normal.
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.
AXLE AND WHEEL

FRONT AXLE
Check for bends or damage and replace if faulty.
MA-2-21
REAR AXLE HOUSING

Check the rear axle housing for cracks, deformity or damage.
Replace the axle housing if faulty.
DIFFERENTIAL GEAR OIL LEAKAGE

Check the fastening section of the differential and axle housing for
oil leakage. If oil leaks, correct the cause, check the oil level and
add oil to the specified level as necessary.
REPLACEMENT OF DIFFERENTIAL GEAR OIL

WARNING
WARNING
z Check and/or change the differential gear oil only after
the rear axle cools to avoid possible burn injuries.
To change the differential gear oil

1. Place a container under the differential drain plug. Remove
the drain plug and drain the oil completely.
2. Reinstall and tighten the drain plug using a new gasket.
: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
CAUTION
z The drain plug contains a magnet. Remove any iron fill-
ings on the plug before reinserting the plug.
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
To change the differential gear oil

(Front differential: CWA series)
1. Place a container under the differential drain plugs. Remove
the drain plugs and drain oil completely.
2. Reinstall and tighten the drain plugs using a new gasket.
: A: 88 - 118 N·m {9 - 12 kgf·m, 65 - 87 ft·lbf}
B: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
C: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
CAUTION
ings on the plug before reinserting the plug.
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
AXLE SHAFT MOUNTING BOLTS

Check the axle shaft mounting bolts for looseness with a hammer
or a torque wrench.
Vehicle model Unit name Tightening torque
MKA/B/D series RS55 137 - 157 {14 - 16, 101 - 116}
MKC210, LKB212 RS65 137 - 157 {14 - 16, 101 - 116}
LKC, LKD series RS75 137 - 157 {14 - 16, 101 - 116}
PKB and PKF series RS90 147 - 167 {15 - 17, 108 - 123}
PKC series RS1A 147 - 167 {15 - 17, 108 - 123}
RD80
CDA310 147 - 167 {15 - 17, 108 - 123}
RD90
CWA310 RW1A 147 - 167 {15 - 17, 108 - 123}
TIRE AIR PRESSURE

Check tire pressure using a tire gauge. Also check the spare tire for
air pressure. Do not forget to install the valve cap after checking.
NOTE
z Ensure that the tires are cold when measuring; other-
wise, true air pressure will not be obtained.
MA-2-24
Tire sizes & Standard air pressure

Standard air pressure kPa {kgf/cm2, psi}
Tire size designation 564 588 613 662 686 711 726 736 760 785 794 858
{5.75, {6.00, {6.25, {6.75, {7.00, {7.25, {7.40, {7.50, {7.75, {8.00, {8.10, {8.75,
82} 85} 89} 96} 100} 103} 105} 107} 110} 114} 115} 124}
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
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
235/75R 17.5 130/128 z
245/70R 19.5 133L z
275/70R 22.5 148/145L 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 22.5 141/138L 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
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.
Tire groove depth

WARNING
WARNING
z Worn tread grooves and partial wear of the tires may
cause blowouts, as well as a decrease in braking pres-
sure and vehicle controllability, leading to serious per-
sonal injuries. Inspect the tires carefully and take
necessary measures. Defective tires must not be used
under any circumstances.
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
Abnormal or local tire wear

Check tires for abnormal/local wear. If such wear is present,
replace the tire. Examples of abnormal/local tire wear are shown in
the chart below.
Condition Cause Cause correction
Shoulder wear z Underinflation z Inflate
z Sharp at high speed z Reduce
z Excessive loading z Reduce
Center wear z Overinflation z Inflate

z Slippage due to abrupt braking z Apply brakes slowly
Diagonal wear z Improper toe-in z Adjust toe-in

z Imbalanced braking force z Inspect and adjust service brake
Heel/toe wear z Incorrect toe-in z Adjust toe-in or camber

z Underinflation z Inflate
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).

Vehicle model Tightening torque
MK and LK series 363 - 422 {37 - 43, 268 - 311}
PK, CDA and CWA series 412 - 481 {42 - 49, 304 - 354}
PKC210, CWA series (ISO type) 588 - 637 {60 - 65, 434 - 470}
MA-2-27
z The tightening procedures are for the standard type.

1. Loosen the outer wheel nuts.
2. Tighten the inner wheel nuts.
3. Tighten the outer wheel nuts.

NOTE
z To prevent wheel nuts from becoming loose, be sure to
tighten the inner wheel nuts (after tightening the outer
wheel nuts) as this is often forgotten.
RIM, SIDE RING AND DISC WHEEL

1. Check the rim, side ring and disc wheel for corrosion, defor-
mation and cracks.
2. Raise the axle with a jack. Turn the wheel by hand to check
for disc runout.
FRONT AND REAR WHEEL BEARING

Front wheel bearing
Raise the front axle with a jack. Move the tire by hand to check for
free play. If free play is present, remove the wheel and measure
bearing preload. If free play still exists after adjusting the preload,
the wheel bearing may be worn. Disassemble and replace the
wheel bearing.
MA-2-28
[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
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
4. If preload is outside the specified range, adjust it as outlined

in the “FA” section.
Rear wheel bearing

Measure the rear wheel bearing preload. If it is outside the specified
range, remove the wheel and measure bearing preload.
If free play still exists after adjusting the preload, the wheel bearing
may be worn. Disassemble and replace the wheel bearing.
[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
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
5. If preload is outside the specified range, adjust it as outlined

in the “RA” section.
REPLACEMENT OF FRONT AND REAR WHEEL BEAR-

ING GREASE
Front
Disassemble the front 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 series FA30 395 (13.93)
MKC/D, LK series FA35 395 (13.93)
PKB series FA40 710 (25.04)
PKC, PKF, CDA and
FA50 985 (34.74)
CWA series
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
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.
U-bolt and nuts

Check the U-bolt and nuts for proper torque setting.
Item Tightening torque
MK and LK series 235 - 275 {24 - 28, 174 - 203}
Front
PK, CDA and CWA series 490 - 539 {50 - 55, 362 - 398}
MK and LK series 265 - 324 {27 - 33, 195 - 239}
Rear PK series 490 - 539 {50 - 55, 362 - 398}
CDA and CWA series 716 - 843 {73 - 86, 528 - 622}
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
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.
<Clutch outer lever>

After adjusting the clutch master cylinder, adjust the clutch booster
outer lever assembly.
1. Remove the return spring.
2. Loosen the push rod lock nut.
MA-2-32
3. Rotate the push rod until outer lever play.

Unit: mm (in)
Unit name Outer lever play
CL130 6 - 7 (0.24 - 0.28)
VAC 6 - 7 (0.24 - 0.28)
CL205
AOH 4 - 5 (0.16 - 0.20)
CL207 4 - 5 (0.16 - 0.20)
CL710 5 - 6 (0.20 - 0.24)
CL740 5.5 - 6.5 (0.217 - 0.256)
CL750, CL810 6.0 - 7.5 (0.236 - 0.295)
4. Tighten the lock nut.

5. Install the return spring.
6. Check the clutch pedal for play.
Clutch disc wear

Wear on the clutch disc can be determined by the clutch wear indi-
cator. The clutch disc is suitable for further use if the tip of the
pointer at the clutch outer lever remains between the SET and MIN
positions on the clutch wear indicator. When the clutch disc is new,
the tip of the pointer points to the SET position. As it wears progres-
sively, the tip moves toward the MIN position. Replace the clutch
disc if the tip of the pointer reaches the MIN position.
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
CLUTCH FLUID LEVEL

The clutch fluid level should be between the “HIGH” and “LOW”
marks on the fluid reservoir located behind the front lid. If the fluid
level is low, add DOT 3 clutch fluid until the level is between the
“HIGH” and “LOW” marks. Also check the clutch fluid for contamina-
tion. If the fluid appears contaminated, have the clutch fluid changed.
CAUTION
z Do not expose the clutch fluid to moisture when checking,
adding or changing the clutch fluid. Clutch fluid absorbs
moisture. When it does, its boiling point drops which can
cause corrosion of clutch system components.
z Do not add clutch fluid which has been exposed to mois-
ture to the system. Use fresh DOT 3 clutch fluid from a
sealed container only.
CLUTCH FLUID LEAKAGE

Check the clutch system for leakage at tube and hose connections.
If leakage is present, repair faulty parts and add brake fluid to the
specified level as necessary.
CLUTCH FLUID REPLACEMENT

1. Reduce air pressure inside the air reservoir to 0 kPa {0 kgf/
cm2, 0 psi} or wait for the pressure in the vacuum tank to
reach atmospheric pressure (VAC brake).
2. Remove the bleeder screw cap from the clutch booster and
connect one end of a vinyl tube to the opening of the
bleeder. Insert the other end of the tube into a container.
3. Pour brake fluid into the reservoir. Do not allow air to enter
the reservoir.
4. Depress the clutch pedal. Loosen the bleeder screw to
drain brake fluid and tighten the screw just before brake
fluid runs out. Repeat this step until the old fluid no longer
flows out.
Bleeding air from the clutch system
1. Reduce air pressure inside the air reservoir to 0 kPa {0 kgf/
cm2, 0 psi} or wait for the pressure in the vacuum tank to
reach atmospheric pressure (VAC brake).
2. Remove the bleeder screw cap from the clutch booster and
connect one end of a vinyl tube to the opening of the
bleeder.
Insert the other end of the tube into a container.
3. Pour brake fluid into the reservoir. Do not allow air to enter
the reservoir.
4. Depress the clutch pedal continuously about fifty times at a
rate of two times per second. While holding the pedal down,
loosen the bleeder to bleed air.
5. Tighten the bleeder and release the clutch pedal.
6. Repeat steps 4. and 5. until air is bled completely.
7. Add clutch fluid up to the HIGH mark on the reservoir.
8. Disconnect the vinyl tube from the clutch booster.
MA-2-34
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.
GEAR OIL REPLACEMENT

WARNING
WARNING
z To avoid possible burn injury, allow the transmission to
cool before checking or changing the transmission oil.
1. Place a container under the drain plug. Remove the drain

plug and completely drain the transmission oil.
2. Reinstall and tighten the drain plug using a new gasket.
: 98 - 127 N·m {10 - 13 kgf·m, 72 - 94 ft·lbf}
CAUTION
ings on the plug before reinstalling the plug.
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
TRANSMISSION CONTROL MECHANISM

With the transmission in neutral, check the shift lever and control
cable for looseness, bends and damage. Also, check the condition
of gear meshing and degree of looseness by shifting the gears to
each speed.
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.
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
PROPELLER SHAFT DEFLECTION

Jack up the rear wheels, and check the deflection of the propeller
shaft with a dial gauge by manually turning the rear wheels.
SLIDING SHAFT AND UNIVERSAL JOINT

1. Remove the propeller shaft.
2. Check the splined section of the propeller shaft for free
play, as shown in the figure below. If the free play exceeds
the wear limit, replace the propeller shaft.
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
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
Battery electrolyte level

<Conventional type>
The level of battery electrolyte is correct if it is maintained 10 to 15
mm (0.39 to 0.59 in) above the cell plates. If necessary, add dis-
tilled water to that level and charge the battery for at least thirty
minutes to mix it thoroughly with the electrolyte.
NOTE
z Do not overfill distilled water; otherwise, electrolyte may
spill and damage the vehicle body or other parts.
z Do not add sulfuric acid in place of distilled water. This
will cause an increase in the specific gravity of the elec-
trolyte, resulting in shorter battery life or false indication
of battery charge determined by measurement of specific
gravity.
<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.
To add distilled water

1. Remove the cell plugs using a suitable tool.
2. Add distilled water up to the upper level.
3. Tighten cell plugs.
CAUTION
z Do not add water above the specified level. If the battery
electrolyte spills, it can cause damage to the vehicle
equipment and body.
z Do not add diluted sulfuric acid to the battery. This
increases the specific gravity of the battery electrolyte
and shortens the service life of the battery. It also affects
specific gravity readings made to determine battery
charge.
MA-2-38
Specific gravity of battery electrolyte

The specific gravity is one of the factors in determining the condi-
tion of the battery. It decreases when the battery is discharged and
increases when the battery is charged.
1. Measure the specific gravity of electrolyte with a hydrome-

ter. Always read the hydrometer indication at eye level.
2. The specific gravity decreases when the temperature of the
electrolyte increases, and vice versa. Thus, the temperature
of the electrolyte must be corrected to a standard tempera-
ture of 20ºC (68ºF) to obtain the true specific gravity.
S20 = St + 0.0007 (t - 20)
where;
S20: Specific gravity (at the standard 20ºC)
St: Specific gravity measured
t: Temperature of electrolyte measured
0.0007: Coefficient for variations in temperature of 1ºC
When the battery is fully charged, the specific gravity should be
1.280 at the standard 20ºC (68ºF). If the specific gravity drops
below 1.200, charge the battery.
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
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)
HORN, WIPER, WINDSHIELD WASHER AND

DEFROSTER
1. Push the horn switch, and make sure the horn sounds nor-
mally.
2. Spray the washer fluid and make sure that there is a proper
spray onto the windshield. Also make sure that the wipers
operate normally in each position.
3. Make sure the defroster (if equipped) operates properly.
CHECK METERS AND GAUGES
Make sure meters and gauges operate properly.
EXHAUST TUBING AND MUFFLER
Check the various connections of the exhaust tubing for looseness.
Tighten loose parts as necessary. Also check for any sign of gas
leakage from connections or muffler.
DOOR LOCKS
Make sure that the driver's door is securely locked. Also check the
door lock on the passenger side.
MA-2-40
FRAME AND BODY

1. Check the frame, cross member, etc. for cracks and dam-
age, and rivets for slack.
2. Check the body for damage and mounting bolts for tightness.
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.
NOISE SHIELD PLATE

Check the noise shield plate for improper installation or damage.
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.
PRECAUTIONS ON TROUBLESHOOTING AND REPAIRING

1. Prior to disassembly, confirm the nature of the problem. Determine the following points and the condi-
tions before and after the occurrence of trouble by asking the user.
z Did the trouble occurred suddenly?
z Was there anything unusual before occurrence of the trouble?
z Under what condition did the trouble occur?
z Was there any repair work done recently?
z Is there any other unusual phenomenon?
2. Confirm the nature of the problem in the shop (by the service mechanic himself).
Reconfirm the nature of the problem complained of by user, and perform tests using various testing
equipment in the shop. Then, make a guess as to the cause of the trouble.
3. Thorough investigation of the trouble prior to disassembly can prevent unnecessary procedures,
enabling quick and efficient repair work. Note that disassembly without preliminary investigation often
makes reproduction of the problem difficult, thus making trouble-shooting impossible.
4. Always start with a simple operation.
After making a guess as to the cause of the trouble, perform investigation or repair work starting with
the simplest operation.
5. Always consider the cause of the trouble.
The same problem will occur repeatedly if the symptoms only are corrected without removing the real
cause of the trouble. Be sure to seek out the origin of the trouble and remove it completely.
Example: An engine was brought to the shop because of oil leakage from the crankshaft from oil
seal, and the problem was repaired by simply replacing the oil seal.
If the cause of this problem is faulty oil seal, there is no problem. However, oil leakage is often a sec-
ondary problem resulting from another primary cause, and the primary cause must be removed with-
out fail.
TD-1-1
WARNING LIGHTS
WARNING LIGHTS
The following lists the warning functions when warning lights come
on.
WARNING LIGHT INSTALLATION LOCATION

The vehicle is equipped with system warning lights in the cluster
meter panel. These lights remain unlit if the related system is func-
tioning normally. If a warning light remains unlit with the ignition key
switch in the ON position, it indicates that the warning light bulb is
burned out. After starting the engine, if a warning light comes on
and/or a buzzer sounds, it indicates a system malfunction.
WARNING LIGHT NAME AND FUNCTIONS

Item Warning light name Function
AIR PRESSURE warning light <AIR PRESSURE warning light>
or When the air pressure in the brake system drops to
VACUUM warning light approximately 510 kPa {5.2 kgf/cm2, 74 psi} in AOH
brake vehicles or 539 kPa {5.5 kgf/cm2, 78 psi} in AIR
1 brake vehicles, the warning light comes on and a buzzer
sounds.
<VACUUM warning light>
When the vacuum pressure in the brake system drops to
approximately -65.3 kPa {-490 mmHg, -19.29 inHg}, the
warning light comes on and a buzzer sounds.
PARKING BRAKE warning light <Mechanical drive line parking brake type>
The warning light comes on when the parking brake lever
is pulled up.
2 <Spring-activated rear wheel parking brake type>
The warning light comes on when the parking brake valve
is engaged or air pressure drops below approximately
373 kPa {3.8 kgf/cm2, 54 psi}.
TD-2-1
WARNING LIGHTS

BRAKE warning light <Brake shoe clearance>
The warning light comes on and a warning buzzer sounds
if brake shoe clearance is excessive or if there is a brake
system malfunction.
3
<Brake fluid level>
When the fluid level in the brake fluid reservoir drops
below the normal operating level the warning light comes
on and a warning buzzer sounds.
TRAILER BRAKE warning light This light will go on when the trailer brake is applied.
5 — 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
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

CHARGE warning light The warning light comes on during driving if there is an
abnormality in the charging circuit and it becomes impos-
13 sible to charge.
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.
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.
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

This section discusses trouble symptoms, such as unusual noise,
vibration, and malfunction, as the first step in locating the cause of
the problem; and it describes how to pursue the faulty unit through
the various stages of starting the engine, warming-up the engine,
starting the vehicle, and finally, driving it.
For definite trouble symptoms, and for the cause and correction of
problems in a particular unit, refer to the subsequent section
“PROBABLE CAUSE AND REMEDY”.
WHEN STARTING ENGINE

(GEAR SHIFT LEVER IN “NEUTRAL”)
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
AFTER STARTING ENGINE
Faulty clutch cover

Noise does not stop Faulty engine
Depress clutch pedal and move
UNUSUAL NOISE Faulty exhaust system
shift lever to any gear position
Faulty clutch disc
Noise stops
Faulty transmission
WHEN STARTING TO MOVE VEHICLE
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
WHEN VEHICLE IS RUNNING
Clutch slippage
Foot brake dragging
POOR ACCELERATION
Parking brake dragging
Faulty engine fuel system
Faulty transmission (insufficient gear oil or oil deterioration)

Faulty final drive (insufficient gear oil or oil deterioration)
Continuous groaning sound
Faulty hub bearing (insufficient grease or use of improper grease)
Low tire pressure
UNUSUAL NOISE Faulty transmission
Noise Faulty final drive gear
Faulty propeller shaft
Noise on rounding curves Faulty differential gear
Noise on braking Faulty foot brake
Faulty chassis spring

Faulty shock absorber
Faulty propeller shaft
EXCESSIVE VIBRATION Faulty engine
Uneven tire wear or tire imbalance
Faulty engine mounting
Faulty cab mounting
Improper front wheel alignment

Faulty front axle
POOR RUNNING
STABILITY Faulty chassis spring
(DRIVING ON Faulty steering system
STRAIGHT-AWAY)
Foot brake dragging
Uneven tire pressure
Faulty steering system

Improper front wheel alignment
Heavy steering wheel
Faulty front axle
Low front tire pressure
IMPROPER STEERING
OPERATION
Poor steering wheel return Improper front wheel alignment
Faulty front axle
Insufficient steering angle
Faulty front axle (improper knuckle adjustment)
TD-3-2
Improper clutch disengagement

Hard to shift Faulty transmission
IMPROPER GEAR
Faulty remote control linkage
SHIFTING
Faulty transmission
Gears jump out of position
Faulty remote control linkage
Faulty brake system

Poor braking Worn tires
IMPROPER BRAKE
Excessive play in hub bearing
OPERATION
Faulty brake system
Brake dragging
Excessive play in hub bearing
TD-3-3
PROBABLE CAUSE AND REMEDY

CLUTCH
Clutch disengagement and slippage are as a rule closely related to
clutch pedal play. Excessive pedal play causes defective disen-
gagement of the clutch, and the absence of pedal play causes the
clutch to slip. In the case of a hydraulic clutch, the cause of trouble
in the master cylinder or clutch booster cannot be determined by
checking only the clutch pedal. Perfect troubleshooting will be
accomplished by also checking the play and movement of the mas-
ter cylinder's rod.
IMPROPER DISENGAGEMENT OF CLUTCH

When the clutch does not properly disengage, depress the clutch
pedal as far as it will go and shift the transmission gearshift lever.
You will hear a crunching noise made by the transmission as it par-
tially engages, and will notice that driving force is transmitted to the
rear of the vehicle.
The cause in most cases will be defective movement of the clutch
disc; however, in some cases, improper bonding of the clutch fac-
ings will cause defective engagement of the clutch pedal.
Symptom Probable cause Remedy

Clutch will not disen- WHEN CLUTCH PEDAL OPERATION AND PLAY ARE
gage smoothly or at CORRECT
all. z Runout or distortion on clutch disc, pressure plate or z Correct or replace faulty parts.
flywheel
z Graded wear or jamming on clutch disc splines z Repair or replace clutch disc and apply heat-
resistant grease to splines.
z Jammed flywheel pilot bearing z Replace bearing.
z Twisted pressure spring z Replace pressure spring.
z Foreign matter among clutch disc, pressure plate and z Disassemble and clean.
flywheel
z Distorted or broken diaphragm spring z Check distortion or break, and repair or replace
faulty parts.
CLUTCH PEDAL OPERATION IS CORRECT BUT
PEDAL PLAY IS EXCESSIVE
z Excessive play in clutch pedal lever z Adjust to specifications.
z Worn pedal bushing/linkage pins/pin holes z Replace faulty parts.
z Excessive play in clutch booster push rod z Adjust to specifications.
LITTLE OR NO EFFORT IS REQUIRED FOR CLUTCH
PEDAL OPERATION BUT CLUTCH FLUID LEVEL IS
CORRECT
z Air in fluid line z Bleed air.
z Improper operation of clutch master cylinder or z Disassemble and repair.
booster
NO FLUID IS IN BRAKE OR CLUTCH RESERVOIR
z Leakage z Check and correct leaking point or replace
faulty parts.
z Leakage at operating cylinder z Disassemble and repair.
TD-4-1
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.

Clutch slippage CLUTCH OUTER LEVER PLAY IS CORRECT
z Worn frictional surface of clutch disc, flywheel and/or z Correct or replace parts.
pressure plate; improper contact between these parts
or jamming
z Oil on frictional surface of clutch disc, flywheel and/or z Clean or replace parts.
pressure plate
z Fatigued or broken pressure spring z Replace pressure spring.
z Use of improper pressure spring z Replace with specified spring.
z Loose clutch cover bolts z Tighten to specified torque.
z No clutch pedal free play z Adjust pedal play.
z Worn, broken or fatigued diaphragm spring z Check clutch cover assembly and replace faulty
parts.
NO CLUTCH OUTER LEVER PLAY
z Clutch master cylinder push rod improperly adjusted z Adjust push rod to specified length.
to push piston
z Clutch booster push rod improperly adjusted to push z Adjust push rod to specified length.
clutch lever
z Clutch master cylinder's return port plugged z Disassemble and clean.
z Worn clutch disc z Replace clutch disc.
UNUSUAL CLUTCH NOISE

When noise is heard when clutch is disengaged, it may be caused
by worn or broken bearings. If it is encountered when clutch is
engaged, clutch disc may be worn or broken.

Noise is heard when z Jammed flywheel pilot bearing z Replace bearing.
clutch is disengaged. z Jammed release bearing z Replace bearing.
Noise is heard when z Worn clutch disc z Replace clutch disc.
clutch is engaged. z Broken clutch disc torsion spring z Replace clutch disc.
z Broken transmission bearing or gears z Replace bearing or gears.
TD-4-2
VIBRATION OCCURS WHEN VEHICLE STARTS TO

MOVE WITH CLUTCH PARTIALLY ENGAGED.
The above symptom is called “shudder” In almost all cases, it is due
to use of improper clutch disc material, deterioration of clutch disc
or disc runout.

Vibration occurs z Loose rivets on clutch disc facing z Correct or replace clutch disc.
while clutch is being z Broken or fatigued pressure spring z Replace pressure spring.
engaged.
z Twisted clutch disc, flywheel and pressure plate or z Repair or replace faulty parts.
improper contact pattern or face runout
z Deteriorated clutch disc facing z Replace clutch disc.
z Broken damper spring z Replace clutch disc.
z Uneven height of clutch release levers z Adjust to even height.
HEAVY CLUTCH PEDAL OPERATION

Clutch pedal is z Faulty clutch booster z Disassemble, repair and clean.
heavy. z Jammed release shaft bushing or insufficient lubrica- z Replace bushing or apply grease.
tion
z Seized release bearing collar z Correct or replace bearing collar.
z Insufficient lubrication of release lever bushing z Apply grease.
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.

Noisy transmission z Low viscosity of lubricant z Use proper grade of lubricant.
z Insufficient lubricant z Fill to specified level.
z Scratched or worn gear teeth (Excessive backlash) z Repair or replace faulty parts.
z Worn or broken bearing z Replace bearing.
z Shift fork improperly positioned to interface with gears z Check shift fork and if it is bent, replace it.
TD-4-3
GEARS ARE HARD TO MESH

When the transmission is difficult to shift into gear or is prone jump
out of gear, the cause of the problem must be sought by consider-
ing the external operating mechanism, from shift lever to shift fork,
separately from the internal mechanism of the transmission.
Defective engagement of the transmission is chiefly caused by mal-
functions in the synchromesh mechanism, which usually occur in a
particular gear position, such as second or third gear.

Gears are hard to CONTROL MECHANISM
mesh. z Control linkage improperly adjusted z Adjust control linkage.
z Play in control linkage journals z Correct or replace parts.
z Control linkage bent z Correct or replace control linkage.
TRANSMISSION
z Worn or damaged bearing z Replace bearing.
z Improper operation of synchromesh mechanism z Correct or replace parts.
z Worn or damaged gears or shafts z Correct or replace parts.
z Improper sliding contact of shift shaft z Correct.
OTHER
z Improper disengagement of clutch z Refer to “Clutch will not disengage smoothly or
at all.” section.
z Lubricant viscosity too high z Use oil of proper viscosity.
GEARS JUMP OUT OF POSITION DURING OPERATION

This symptom is encountered while the car is being accelerated or
decelerated.

Gears jump out of CONTROL MECHANISM
position z Control linkage inoperative z Check and correct control linkage.
z Shift lever moves in reaction to vehicle vibration. z Check engine rubber mounting, cab rubber
mounting, etc., for damage, and replace faulty
part(s).
TRANSMISSION
z Shift fork deformed or worn z Check shift fork and, if bent, correct or replace.
z Locking ball and/or shift shaft ball groove worn z Disassemble and replace excessively worn
parts.
z Broken or fatigued locking spring z Replace spring.
z Excessive gear backlash z Adjust gear backlash or replace gear.
z Excessive end play in main gear z Measure end play and, if necessary, replace
thrust washer.
z Worn hub splines or end face z Replace hub.
z Worn main shaft bearing z Replace main bearing.
TD-4-4
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.
PROPELLER SHAFT RUNOUT

Car vibration during z Propeller shaft improperly assembled to splined yoke z Reassemble so that splined yoke is lined up
operation with yoke on opposite side.
z Twisted or bent propeller shaft z Correct or replace propeller shaft.
z Universal joint journal or needle roller bearing worn or z Replace bearing.
damaged
z Propeller shaft loose z Tighten to specified torque.
z Propeller shaft imbalanced z Adjust or replace propeller shaft.
z Center bearing worn or damaged z Replace center bearing.
z Play in center bearing bracket or fatigued rubber z Correct or replace.
material
Unusual noise is emitted when vehicle starts to move

and while being driven
Unusual noise during z Universal joint worn or damaged z Replace universal joint.
starting and driving z Yoke spline worn or damaged z Replace yoke.
z Propeller shaft loose z Tighten to specified torque.
z Lack of lubrication of needle roller bearing, yoke z Apply grease.
splines, center bearing, etc.
TD-4-5
REAR AXLE AND DIFFERENTIAL CARRIER

Trouble with the differential is usually indicated by oil leakage or
unusual noise. In order to locate the cause of unusual noise, the
vehicle should be driven to determine whether the noise is made
during starting, normal driving, or cornering.
In most cases, unusual noise is due to improper gear adjustment,
such as excessive gear backlash. Buzzing, which persists during
driving until the vehicle stops, is sometimes due to the drive pinion
bearing.
Oil leakage most frequently occurs at an axle end or at the flange of
the differential carrier. The main causes are insufficient tightening
and defective oil seals.
UNUSUAL NOISE
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 gear z Correct or replace.
WHEN RUNNING BY INERTIA
z Insufficient backlash between ring gear and drive pin- z Adjust backlash.
ion
z Improper gear contact pattern z Correct or replace faulty gear(s).
TD-4-6
OIL LEAKAGE
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.
WHEEL BEARING SEIZURE

Wheel bearing sei- z Excessive wheel bearing preload z Adjust preload.
zure z Lack of bearing grease or use of improper grease z Apply grease or replace with proper grease.
z Dirt or dust in bearing z Clean and apply grease to bearing.
z Water entry due to faulty hub seal z Replace hub seal.
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
[VACUUM SERVO HYDRAULIC BRAKE]

FAULTY BRAKE PERFORMANCE
Brake will not oper- NO BRAKE PEDAL DEPRESSED ROOM
ate effectively when z Air in hydraulic system z Bleed air.
pedal is depressed.
z Oil leakage z Correct oil leakage.
z Excessive brake shoe clearance z Adjust clearance.
z Damaged master cylinder cup z Replace cup.
z Damaged hydromaster hydraulic piston cup z Replace cup.
z Damaged wheel cylinder cup z Replace cup.
BRAKE PEDAL DEPRESSED ROOM EXISTS
z Burned brake lining z Replace brake lining.
z Improper brake lining contact z Adjust lining contact.
z Oil on lining or inner surface of drum z Clean and re-line.
z Insufficient lubrication of power piston or damaged z Apply grease or replace packing.
piston packing
z Hydromaster power cylinder dented z Replace.
z Deteriorated brake lining z Replace lining.
z Water entry into brake drum z Allow drum to dry by lightly depressing brake
pedal while car is in operation.
UNUSUAL NOISE
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
UNEVEN BRAKING PERFORMANCE

Uneven braking z Uneven tire pressure or difference in tire size. z Inflate to specified pressure or use tires of same
size.
z Improper installation of brake shoes or damaged z Tighten brake shoe anchor pin lock nut or
return spring replace return spring.
z Improper contact of brake lining z Adjust lining contact.
z Left and right brakes improperly adjusted z Adjust brakes.
z Deteriorated brake lining z Replace brake lining.
z Wheel cylinder inoperative z Check cylinder piston and piston cup and
replace faulty parts.
z Oil on brake lining z Clean oil off with gasoline, and eliminate cause
of oil leakage at hub oil seal, wheel cylinder cup
or boot.
z Damaged brake bracket z Replace bracket.
z Loose “U” bolt used with chassis spring z Tighten “U” bolt.
ALL WHEELS DRAGGING

All wheels dragging z No free play in brake pedal and master cylinder outlet z Adjust brake pedal free play.
(Overheated brake port obstructed by piston cup
drum) z Failure of brake pedal arm to return z Grease pedal bushing and replace faulty pedal
or shoe return spring.
z Failure of wheel cylinder piston to return z Replace wheel cylinder or piston.
z Bent hydromaster push rod z Replace push rod.
BRAKE PEDAL KICKS BACK

Brake pedal kick- z Damaged hydraulic piston cup z Replace piston cup.
back z Improper contact of hydraulic piston check valve z Replace hydraulic piston.
TD-4-9
[AIR OVER HYDRAULIC BRAKE]

FAULTY BRAKE PERFORMANCE
Brake will not oper- CORRECT AIR PRESSURE
ate effectively when z Short brake valve stroke z Check and, if necessary, replace brake valve.
pedal is depressed.
z Improper sliding contact of relay valve z Disassemble and repair.
z Air in hydraulic system z Bleed air.
z Fluid leakage z Correct fluid leakage.
z Excessive brake shoe clearance z Adjust clearance.
z Damaged air booster hydraulic piston cup z Replace cup.
z Damaged wheel cylinder cup z Replace cup.
LOW AIR PRESSURE
z Air leakage in air line z Repair leakage point.
z Air compressor inoperative z Disassemble and repair air compressor.
z Air pressure governor improperly adjusted or inopera- z Adjust or clean governor.
tive due 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.

ALL WHEELS DRAGGING

All wheels dragging z Failure of wheel cylinder to return z Replace wheel cylinder or piston.
(Overheated brake z Bent air booster push rod z Replace push rod.
drum)
z Air booster breather plugged z Clean breather.
z Failure of primary or secondary brake valve piston to z Disassemble, check and clean. Replace faulty
return parts.
TD-4-10
[AIR BRAKE]
INSUFFICIENT BRAKING FORCE
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

ALL WHEELS DRAGGING

All wheels dragging z Compressed air in brake chamber z Check and correct relay valve, quick release
(Overheated brake valve exhaust valve.
drum) z Improper sliding of camshaft or improper return of z Correct faulty parts.
slack adjuster lever
z Brake shoe or air chamber return spring broken or z Replace faulty springs.
fatigued
z Spring brake activated z Release spring brake, and eliminate cause of
problem.
z Relay valve or exhaust port of quick release valve z Disassemble and clean faulty parts.
plugged
z Failure of primary or secondary brake valve piston to z Disassemble and clean brake valve and, if nec-
return essary, replace faulty parts.
TD-4-11
STEERING SYSTEM AND FRONT AXLE

Defects in the steering system usually appear as unsmooth turning
excessive play, one-sided turning, or looseness of the steering
wheel. Further, a defective front axle sometimes causes faulty
operation of the steering wheel.
When the steering wheel does not turn smoothly, the front axle
should be jacked-up and a check conducted with the front wheels
raised above the ground. If the steering wheel still does not operate
smoothly, separate the steering gear mechanism and the linkage
from the pitman arm, and check these components.
An abrasion of the kingpin usually will not cause difficult turning of
the steering wheel, unless vehicle weight is not applied to it. This
fact should be kept in mind while troubleshooting. When the steer-
ing wheel can not be easily turned during driving, the cause is usu-
ally improper caster angle.
Unsmooth operation and return of the steering wheel due to insuffi-
cient backlash of the steering gears or due to excessive application
of pre-load cannot occur unless the steering gearbox is disassem-
bled. If such a problem has developed gradually, the cause is usu-
ally insufficient lubrication of the linkage and connections.
Steering failures during driving are generally attributable to uneven
road surfaces. In such cases, the steering should be checked by
driving the vehicle on an even road.
Deflection of the steering wheel may be due to improper wheel
alignment on improper tire balance, particularly in there is an
absence of excessive play or looseness in the steering compo-
nents.
TD-4-12
HEAVY STEERING WHEEL

Heavy steering STEERING SYSTEM
wheel operation z Low power steering fluid level z Replenish fluid to specified level.
z Deteriorated oil or foreign matter in oil z Replace fluid.
z Worn steering linkage joint (ball stud, etc.) z Replace ball stud.
z Faulty power steering system
1) Excessive fluid resistance due to dented piping z Measure back pressure and if above specifica-
tions, repair or replace piping.
2) Low oil pressure due to inoperative hydraulic pump z Measure fluid pressure and flowrate and if
below specifications, disassemble and repair
hydraulic pump.
3) Air in hydraulic line z Bleed air and add fluid.
4) Spool valve inoperative z Disassemble and repair spool valve.
5) Power cylinder and power piston worn or damaged, or z Disassemble and repair.
power piston seal “O” ring worn or damaged
6) Excessive fluid leakage at steering gear box z Disassemble and repair steering gear box.
FRONT AXLE
z Wheel alignment improperly adjusted (Excessive z Check and adjust wheel alignment.
caster)
z Small kingpin-to-bushing clearance z Check and adjust clearance
z Thrust bearing installed backward z Reassemble correctly.
z Lack of lubrication to front axle parts z Apply grease to front axle.
z Low tire pressure z Inflate to specified pressure.
z Excessive tire wear z Replace tire.
STEERING WHEEL SHIMMY

Steering wheel shim- STEERING SYSTEM
mies z Steering gear box bolts or steering column bracket z Tighten to specified torque.
loose
z Excessive play in steering linkage joints z Correct linkage joints.
z Excessive backlash in steering gear z Adjust backlash.
FRONT AXLE
z Imbalance or wear of tire, disc and wheel z Balance all parts and if necessary, replace
faulty parts.
z Worn front wheel bearing z Replace bearing.
z Excessive wear on kingpin and bushings z Correct or replace faulty parts.
z Deformed steering knuckle z Replace steering knuckle.
z Wheel alignment improperly adjusted z Check and adjust wheel alignment.
z Fatigued front spring, loose “U” bolt or damaged cen- z Replace faulty parts.
ter bolt
TD-4-13
STEERING WHEEL FAILS TO RETURN

Steering wheel fails STEERING SYSTEM
to return z Hard gear meshing z Adjust gear mesh.
z Faulty power steering system
1) Improper contact of power piston z Correct or replace power piston.
2) Fatigued reaction spring z Replace spring.
3) Spool valve inoperative z Check spool valve-to-housing contact pattern
and, if necessary, replace spool valve and/or
housing.
FRONT AXLE
z Excessive caster z Check and adjust wheel alignment.
STEERING WHEEL PULLS TO EITHER SIDE

Steering wheel pulls z Wheel alignment not properly adjusted z Check and adjust wheel alignment.
to either side z Left or right front spring fatigued or damaged z Replace faulty spring.
z Front axle bent z Correct or replace front axle.
z Brake dragging z Refer to the “BRAKE” section.
z Front hub bearing nut loose z Tighten to specified torque.
z Uneven tire pressure z Inflate to specified pressure.
z Use of tires of different sizes. z Replace tires with correct ones.
UNEVEN OR PREMATURE TIRE WEAR

Uneven or prema- FRONT AXLE
ture wear on tires z Improper front wheel alignment z Check and adjust front wheel alignment.
z Worn or broken hub bearing or loose bearing nut z Replace hub bearing or tighten nut to specified
torque.
TIRE
z Incorrect tire pressure z Inflate to specified pressure.
z Tire and wheel not centered properly z Replace tire and wheel.
OTHER
z Problem caused by abrupt starting of vehicle or sud- z Operate vehicle correctly.
den braking
z Overload z Observe rated capacity.
OIL OVERFLOW AT POWER STEERING FLUID RESER-

VOIR
Oil overflows at fluid z Strainer or oil filler plugged z Clean strainer or replace oil filter.
reservoir z Air in piping z Add oil and bleed air.
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
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
1. Engine mounting bracket 4. Engine mounting member 6. Engine mounting bracket

2. Cushion 5. Cushion (If so equipped)
3. Engine mounting bracket
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.
1. Disconnect the ground cable from the battery.
2. Tilt the cab.

NOTE
z When tilting the cab indoors, make sure that there is a
clearance of at least 4 m (13.1 ft) in H and a clearance of 1
m (3.3 ft) in F.
3. Remove the compressor related parts (if equipped with air

conditioner).
4. Remove the transmission. Refer to the “TM” section.
5. Drain engine oil, power steering fluid and coolant. Also dis-
charge air. Refer to the engine service manual “MA” sec-
tion.
6. Disconnect the fuel line.
CAUTION
z Before disconnecting fuel line, place a container under
the connection to catch fuel. Plug the openings of pipes
or hoses on the chassis side to prevent dirt or dust from
entering.
7. Disconnect various hoses and pipes from the engine.

CAUTION
z Before disconnecting power steering fluid line, place a
container under the connection to catch fluid. Plug the
openings of pipes or hoses on the chassis side to pre-
vent dirt or dust from entering.
8. Disconnect associated wiring and linkages.

9. Remove the air cooler and air hoses. (FE6TA, NE6TA)
10. Remove the radiator assembly, water tank and cab mount
bracket.
11. Disconnect the exhaust pipe.
12. Using a hoist or crane, attach chain hooks to engine lifters.
NOTE
z Position the hoist or crane directly above the engine.
z Attach the hook from the inner side of the lifter.
z Be sure the chain is neither too tight nor too loose.
13. Remove the front and rear engine mounting bolts.
ER-2-2
ENGINE REMOVAL
14. Raise the engine.

WARNING
WARNING
z Be careful not to strike the engine against adjacent parts
or the cab body or pinch your hand.
15. Place the engine on a work bench.
ER-2-3
ENGINE INSTALLATION
ENGINE INSTALLATION
1. Install both the front and rear engine mounting insulators on
the engine.
2. Install the engine in the vehicle.

NOTE
z Be careful not to strike the engine against adjacent parts
when installing.
3. Tighten the engine mounting bolts.

4. Connect the exhaust connector and exhaust pipe.
5. Install the cab mount bracket.
6. Install the radiator assembly.
7. Connect various hoses and pipes to the engine.
8. Connect the various harnesses.
9. Install the transmission. Refer to the “TM” section.
10. Refill power steering fluid, coolant and engine oil. Refer to
the “MA” section.
11. Bleed air from the fuel system. Refer to the engine service
manual “MA” section.
12. Adjust valve clearances. Refer to the engine service man-
ual “MA” section.
13. Adjust tension of the drive belts. Refer to the engine service
manual “MA” section.
14. Connect the ground cable to the battery.
15. Start the engine and bleed air from the power steering sys-
tem. Refer to the “ST” section.
16. Check all connections and gaskets for signs of air, water or
oil leakage. Refer to the engine service manual “MA” sec-
tion.
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
Type Diaphragm type single disc, dry
Facing dimensions 300 x 190 x 4 325 x 210 x 4
Clutch disc
(OD x ID x thickness) mm (in) (11.81 x 7.48 x 0.16) (12.80 x 8.27 x 0.16)

Facing area (one side) cm2 (sq in) 423 (65.6) 483 (74.9)
Material Semi-mold
Clutch operating system Hydraulic system (vacuum booster or air booster)
UNIT NAME CL710, 740, 750, 810

Facing dimensions 350 x 220 x 4.5 380 x 220 x 5.0
Clutch disc
(OD x ID x thickness) mm (in) (13.78 x 8.66 x 0.177) (14.96 x 8.66 x 0.197)

Facing area (one side) cm2 (sq in) 582 (90.2) 754 (116.9)
Material Semi-mold
Number of pressure springs 12
Clutch operating system Hydraulic system (air booster)
UNIT NAME
CL 1 30
Disc size mm (in) Clutch cover set load N {kgf, lbf}

Clutch
1 300 (11.81) 1 30 8,336 {850, 1,874}
2 325 (12.80) 05 7,846 {800, 1,764}

2
7 350 (13.78) 07 8,140 {830, 1,830}
8 380 (14.96) 10 9,905 {1,010, 2,227}

7 40 11,768 {1,200, 2,646}
50
12,749 {1,300, 2,867}
8 10
CL-1-1
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)
Type I: with engine rear P.T.O.

Type II: without engine rear P.T.O.
CL-1-2
UNIT NAME CL710, 740, 750, 810

Unit: mm (in)
Item Maintenance standard Service limit Remarks
CL710
Less than
CL740 1.0 (0.039)
0.7 (0.028)
Runout CL750
Less than
CL810 1.4 (0.055)
Clutch disc 1.0 (0.039)
Above rivet
Facing thickness (one side) — 0.2 (0.008)
head
Less than
Play in radial direction of spline 0.5 (0.020)
0.24 (0.0094)
CL710
Less than
CL740 0.2 (0.008)
Flatness of con- CL750 0.05 (0.0020)
tact surface
Less than
CL810 0.25 (0.0098)
Clutch pressure 0.1 (0.004)
plate CL710
30.7 - 30.9
Decrease in CL740 29.8 (1.173)
(1.209 - 1.217)
thickness of CL750
contact face 33.9 - 34.1
CL810 33.0 (1.299)
(1.335 - 1.343)
CL710 100.6 (3.96) 96.0 (3.780)
CL740 86.3 (3.398) 83.1 (3.272)
CL750 79.5 (3.130) 77.0 (3.031)
Free length
FE6T 93.0 (3.661) 92.2 (3.630)
CL810 FE6TA
NE6T 86.9 (3.421) 84.2 (3.315)
NE6TA
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)
Tension 1,062.1 - 1,173.9
1,006.2
N {kgf, lbf} CL750 {108.3 - 119.7,
{102.6, 226.2}
Clutch pressure 238.8 - 263.9}
spring
1,323.9 1,258.2
FE6T When com-
{135.0, 297.7} {128.3, 282.9}
pressed to
CL810 FE6TA 1,026.8 - 1,134.7
972.9 59.6 mm
NE6T {104.7 - 115.7, (2.346 in)
{99.2, 218.7}
NE6TA 230.9 - 255.1}
Less than
CL710 5.3 (0.209)
3.5 (0.138)
Less than
CL740 4.5 (0.177)
3.0 (0.118)
Less than
CL750 4.2 (0.165) Measure at
Tilt 2.8 (0.110)
free length
Less than
FE6T —
3.3 (0.130)
CL810 FE6TA
Less than
NE6T —
3.0 (0.118)
NE6TA
CL-1-3
Unit: mm (in)
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
Unit: mm (in)
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
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
99798 Z5003 Used to center clutch O O O O O O O

disc and to inspect
and adjust the height
Setting sleeve of release levers (dia-
phragm spring). The
setting sleeve is used
O O
99798 Z0004 with the setting shaft.
*5 *8
Used for correcting

Adjusting
99794 Z5000 diaphragm spring set- O O O
wrench
tings.
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
= UNIT NAME CL130, 205, 207 =

CONSTRUCTION
CLUTCH COVER AND CLUTCH HOUSING ASSEMBLY
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.
3. Support the transmission with a jack or lifting wires to pre-

vent it from dropping, and remove it from the flywheel hous-
ing.
NOTE
z Do not separate the wear indicator and stay.
4. Measure the amount of wear on the clutch disc with a scale

or the special tool.
Attach the Clutch Disc Setting Shaft and Setting Sleeve to
the flywheel. Measure and record the distance between the
basic line on the shaft to point “N” on the sleeve. Then,
remove the clutch cover from the flywheel housing.
NOTE
Setting sleeve
z CL205 and 207:
Use the basic line on 99798 Z5003 for CL210
CL-3-2
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)

5. Suspend the clutch cover assembly with wire. Remove it

being careful not to drop the clutch disc.
NOTE
z If the clutch cover assembly is hard to remove, carefully
pry the mating area of the flywheel housing and clutch
cover using a suitable bar.
6. Be careful not to loosen the shims located between the

clutch housing and countershaft, and the oil seal between
the clutch housing and main drive shaft.
CL-3-3
DISASSEMBLY
CLUTCH COVER

1. Clutch disc 4. Clutch cover mounting bolt 7. Strap setting bolt
,+ 2. Pressure plate 5. Bracket 8. Lever plate (CL205, 207)
3. Clutch cover 6. Spring washer
Key point of disassembly

2 Pressure plate
Before removing the pressure plate from the clutch cover, put align-
ment marks on them.
CL-3-4
CLUTCH HOUSING

1. Bolt 8. Grease tube 15. Release shaft
2. Housing cover 9. Spring , 16. Release yoke
3. Grease nipple 10. Release sleeve 17. Bolt & nut
4. Lock nut 11. Release bearing , 18. Clutch housing
5. Spring washer 12. Lock bolt 19. Oil seal
6. Washer 13. Lock nut 20. Needle bearing
7. Connector 14. Grease nipple
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)
Less than 1.0 (0.039) 1.3 (0.051)
Tension spring play

Check the torsion spring for lateral play. If any play is present,
replace the clutch disc assembly.
Facing thickness (one side)

Unit: mm (in)
Maintenance standard Service limit (H)
— 0.2 (0.008) (above rivet head)
Play in radial direction of spline

Unit: mm (in)
Less than 0.22 (0.0087) 0.3 (0.012)
CL-3-6
CLUTCH PRESSURE PLATE

Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
CL130 Less than 0.05 (0.0020) 0.2 (0.008)
0.10 - 0.15
CL205, 207 —
(0.0039 - 0.0059)
Thickness of contact surface

Unit: mm (in)
32.58 - 32.68
CL130 32.13 (1.2650)
(1.2827 - 1.2866)
36.66 - 36.76
CL205, 207 36.21 (1.4256)
(1.4433 - 1.4472)
CLUTCH COVER ASSEMBLY

Diaphragm spring height
Unit: mm (in)
CL130 44 - 46 (1.73 - 1.81) —
CL205
56 - 58 (2.20 - 2.28) —
CL207
Diaphragm spring height difference

Unit: mm (in)
Less than 1.0 (0.039) —
FLYWHEEL
Unit: mm (in)
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
Thickness of contact surface

Unit: mm (in)
Unit name Maintenance standard (H) Service limit (H)
Type I 20.5 (0.807) 18.5 (0.728)
Type II 21.5 (0.846) 19.5 (0.768)
CLUTCH RELEASE MECHANISM

Width of lever plate
Unit: mm (in)
CL205
4.0 (0.157) 3.6 (0.142)
CL207
Release shaft outside diameter

Unit: mm (in)
24.96 - 24.98
—
(0.9827 - 0.9835)
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
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
2. Evenly tighten the clutch cover mounting bolts in the order

indicated in the figure at right.
3. A wire ring (painted red for identification) which is used for

suspending the pressure plate, is installed on the clutch
cover assembly as service parts. Be sure to remove the
wire ring after tightening the clutch cover assembly bolts.
4. Adjust the height of the diaphragm spring.

z Use a feeler gauge to see if the difference in heights of the
diaphragm springs is more than 1.0 mm (0.039 in).
z If so, adjust the height of the affected springs to within 1.0

mm (0.039 in) using the adjusting wrench (99794 Z5000).
z Make sure of the height of the diaphragm spring.
[When an old clutch disc is used]
After installing the clutch cover assembly, make sure the basic line
on the setting shaft is positioned at the point on the sleeve, as
determined by the previous measurement.
CL-3-10
[When an new clutch disc is used]

After installing the clutch cover assembly, make sure the basic
line on the setting shaft is at point “N” on the sleeve.
Unit: mm (in)
Unit name Dimension “L”
CL130 65 (2.56)
CL205 Type I 77 (3.03)
CL207 Type II 78 (3.07)
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
Unit: mm (in)
35 - 55 (1.38 - 2.17) —
PEDAL PLAY ADJUSTMENT

Clutch master cylinder
2. Turn the push rod until it touches the piston and there is no
play.
Under this condition, return the push rod one turn and make sure
the free play is approximately 1 mm (0.04 in).
with a wrench.
Clutch outer lever
3. Adjust the play of the outer lever by turning the push rod.
Unit: mm (in)
Clutch outer VAC Type 6.0 - 7.0 (0.236 - 0.276) —
lever play AOH Type 4.0 - 5.0 (0.157 - 0.197) —

5. Reinstall the return spring.
6. Check clutch disc wear with the wear indicator. Clutch disc
wear is within acceptable limits when the pointer at the wear
indicator is between “MIN” and “SET”. If the pointer goes
past “MIN”, replace the clutch disc.
7. When a new clutch disc is installed, adjust the clutch sys-
tem as indicated above and as follows:
z Align the “SET” position of the indicator with the end of the
pointer and secure the indicator.
NOTE
range.
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
= UNIT NAME CL710, 740, 750, 810 =

CONSTRUCTION
CLUTCH COVER AND CLUTCH HOUSING ASSEMBLY
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.
3. Support the transmission with a jack or lifting wires to pre-

vent it from dropping, and remove it from the flywheel hous-
ing.
NOTE
4. Measure the amount of wear on the clutch disc with a scale

or the special tools.
Attach the Clutch Disc Setting Shaft and Setting Sleeve.
Measure and record the distance between the basic line on
the shaft to point “N” on the sleeve.
NOTE
Steering sleeve
z CL740, 750 and CL810 (FE engine and NE engine with
EATON T/M):
Setting shaft
z CL710 (FE engine with MPS T/M):
CL-4-2
z CL710 (NE engine):

Use the basic line L1 on 99797 Z0010
z CL740:
z CL810 (NE engine with MPS T/M):

Use the basic line L2 on 99797 Z0010
z CL810 (FE engine with EATON T/M):

CL-4-3
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)
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
5. Remove the clutch cover assembly and clutch disc.

z Prepare two guide bolts, nuts and plain washers. Install the
nuts and washers on the bolts.
z Tighten the guide bolts into the grooves in the pressure

plate. Tighten the nuts snugly so that the clutch cover is not
lifted.
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
CLUTCH COVER

1. Clutch disc 9. Lock plate , 18. Release lever
, 2. Lever plate [Except CL810 (FE 10. Support nut 19. Bushing
engine with EATON transmission)] ,+ 11. Clutch cover 20. Cotter pin
3. Strap set bolt , 12. Spring cap 21. Plain washer
4. Spring washer , 13. Pressure spring 22. Support pin
5. Clip , 14. Spring seat 23. Return spring
6. Strap plate 15. Cotter pin , 24. Lever support
7. Plain washer 16. Plain washer 25. Pressure plate
8. Lock plate bolt 17. Lever pin
CL-4-5

11 Clutch cover
1. Put alignment marks on the clutch cover and pressure plate
using paint, etc.
2. Using a guide bolt or press, separate the clutch cover from

the pressure plate.
[Disassembly using the guide bolts]
z Remove the 4 support nuts.
z Loosen the guide bolt nuts equally until free play exists at
the pressure spring.
z Remove the guide bolt assembly.
[Disassembly using the press]

z Place a guide plate onto the clutch cover, push the clutch
cover using a press until the two guide bolt nuts are loose.
z Remove the 4 support nuts and 2 guide bolts.
z Gradually loosen the press.
CL-4-6
CLUTCH HOUSING
Transmission models MLS61A, MLS61B and MLS62A

1. Bolt 8. Grease tube 15. Release shaft
2. Housing cover 9. Spring , 16. Release yoke
3. Grease nipple 10. Release sleeve 17. Bolt & nut
4. Lock nut 11. Release bearing 18. Clutch housing
5. Spring washer 12. Lock bolt 19. Oil seal
6. Washer 13. Lock nut 20. Needle bearing
7. Connector 14. Grease nipple
CL-4-7
Transmission models MPS50W, MPS62B, MPS62T and

EATON 6109

1. Grease nipple 8. Wire 15. Needle bearing
2. Lock nut 9. Release yoke set bolt 16. Grease nipple
3. Lock washer 10. Feather key 17. Housing cover
4. Grease hose 11. Release shaft 18. Rubber seat
5. Spring , 12. Release yoke 19. Clutch housing
6. Release sleeve 13. Bolt 20. Grease nipple
7. Release bearing 14. Oil seal
CL-4-8
INSPECTION CL710, 740, 750, 810
INSPECTION
has exceeded, repair or replace faulty parts.
CLUTCH DISC
Runout
Unit: mm (in)
CL710
CL740 Less than 0.7 (0.028) 1.0 (0.039)
CL750
CL810 Less than 1.0 (0.039) 1.4 (0.055)
Tension spring play

Check the torsion spring for lateral play. If any play is present,
replace the clutch disc assembly.
Facing thickness (one side)

Unit: mm (in)
Maintenance standard Service limit (H)
— 0.2 (0.008) (above rivet head)
Play in radial direction of spline

Unit: mm (in)
Less than 0.24 (0.0094) 0.5 (0.020)
CL-4-9
INSPECTION CL710, 740, 750, 810
CLUTCH PRESSURE PLATE

Unit: mm (in)
CL710
CL740 Less than 0.05 (0.0020) 0.2 (0.008)
CL750
CL810 Less than 0.1 (0.004) 0.25 (0.0098)
Decrease in thickness of contact face

Unit: mm (in)
Unit name
(H) (H)
CL710
30.7 - 30.9
CL740 29.8 (1.173)
(1.209 - 1.217)
CL750
33.9 - 34.1
CL810 33.0 (1.299)
(1.335 - 1.343)
CLUTCH PRESSURE SPRING

Free length
Unit: mm (in)
CL710 100.6 (3.96) 96.0 (3.780)
CL740 86.3 (3.398) 83.1 (3.272)
CL750 79.5 (3.130) 77.0 (3.031)
FE6T 93.0 (3.661) 92.2 (3.630)
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
Unit: mm (in)
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)
CL710 FE6B (A) 23.0 (0.906) 21.0 (0.827)
CL740 FE6T
CL750 FE6TA (H) 43.0 (1.693) 45.0 (1.772)
(A) 26.0 (1.024) 24.0 (0.945)

CL710 NE6 42.9 - 43.1
(H) 45.0 (1.772)
(1.689 - 1.697)
FE6T (A) 23.0 (0.906) 21.0 (0.827)
FE6TA (H) 48.0 (1.890) 50.0 (1.969)
CL810 (A) 21.0 (0.827) 19.0 (0.748)
NE6T
NE6TA 47.9 - 48.1
(H) 50.0 (1.969)
(1.886 - 1.894)
Thickness: (A), Height: (H)
CL-4-11
INSPECTION CL710, 740, 750, 810
CLUTCH RELEASE MECHANISM

Bushing inside diameter
Unit: mm (in)
Maintenance standard Service limit Remarks
Measure after bushing
— 10.2 (0.402) has been pressed into
release lever
Lever pin and support pin outside diameter

Unit: mm (in)
— 9.8 (0.386)
Support inside diameter

Unit: mm (in)
— 10.2 (0.402)
Release shaft outside diameter

Unit: mm (in)
MLS61A 24.96 - 24.98
—
MLS62A (0.9827 - 0.9835)
CL710
MPS50W 29.99 - 30.01
—
MPS62T (1.1807 - 1.1815)
24.96 - 24.98
CL740 —
(0.9827 - 0.9835)
CL750 29.99 - 30.01
—
CL810 (1.1807 - 1.1815)
CL-4-12
INSPECTION CL710, 740, 750, 810
Width of lever plate

Unit: mm (in)
7.0 (0.276) 6.3 (0.248)
CL-4-13
REASSEMBLY CL710, 740, 750, 810
REASSEMBLY
REASSEMBLY
CLUTCH COVER
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.
[Reassembly using the guide bolts]

z With the nut and washer in place on the guide bolt, firmly
screw the guide bolt into the hole in the pressure plate.
CL-4-14
REASSEMBLY CL710, 740, 750, 810
z While securely holding the guide bolt with a wrench, tighten

the guide bolt nuts equally until the support nuts engage the
supports.
NOTE
z Compress the clutch cover so that the support's thread
area does not touch the clutch cover.
z Install the support nuts on the supports at four places.
[Reassembly using the press]

z With the nut and washer in place on the guide bolt, firmly
screw the guide bolt into the hole in the pressure plate.
z Place a guide bar onto the clutch cover, push the clutch
cover using a press until the support nuts engage the sup-
ports.
NOTE
z Do not allow the support's threads to touch the clutch
cover when compressing the latter.
z Hand-tighten the guide bolt nut until it touches the clutch

cover so that the cover is not raised.
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
<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
<Transmission models MPS50W, MPS62B, MPS62T,

EATON 6109 and Engine models NE6 series>
12 Release yoke
Insert the feather key to the release shaft and then install the set
bolts to the release shaft through the release yoke.
NOTE
z Be sure to install the release yoke in the proper direction.
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.
2. Adjust the height of the lever plate.

[When a used clutch disc is used]
Install the adjusting sleeve onto the setting shaft; turn the four sup-
port nuts until the basic line on the setting shaft is positioned at the
point on the sleeve, as determined by the previous measurement.
CL-4-16
REASSEMBLY CL710, 740, 750, 810
[When a new clutch disc is used]

Install the adjusting sleeve onto the setting shaft; turn the four sup-
port nuts until the basic line on the setting shaft is at point “N” on the
sleeve.
Unit: mm (in)
CL710 FE6B
CL740 FE6T 100.5 (3.96)
CL750 FE6TA
CL710 NE6 103 (4.06)
CL810 FE6T 99.5 (3.92)
CL810 FE6TA 104.5 (4.11)
NE6T
CL810 103 (4.06)
NE6TA
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.
4. After readjusting, make sure that feeler gauge 0.5 mm

(0.020 in) cannot be inserted into the gap between the lever
plate and release lever.
NOTE
z When measuring the clearance, be careful that the lever
plate does not come up. If the clearance is more than 0.5
mm (0.020 in), readjust the height of the lever plate.
CL-4-17
ADJUSTMENT CL710, 740, 750, 810
ADJUSTMENT
CLUTCH PEDAL PLAY
Unit: mm (in)
35 - 55 (1.38 - 2.17)
PEDAL PLAY ADJUSTMENT

Clutch master cylinder
2. Turn the push rod until it touches the piston and there is no
play.
Under this condition, return the push rod one turn and make sure
the free play is approximately 1 mm (0.04 in).
with a wrench.
Clutch outer lever

3. Adjust the play of the outer lever by turning the push rod.
Unit: mm (in)
Item Maintenance standard
CL710 5.0 - 6.0 (0.197 - 0.236)
CL740 5.5 - 6.5 (0.217 - 0.256)
Clutch outer lever play
CL750
6.0 - 7.5 (0.236 - 0.295)
CL810

5. Reinstall the return spring.
6. Check clutch disc wear with the wear indicator. Clutch disc
wear is within acceptable limits when the pointer at the wear
indicator is between “MIN” and “SET”. If the pointer goes
past “MIN”, replace the clutch disc.
7. When a new clutch disc is installed, adjust the clutch sys-
tem as indicated above and as follows:
z Align the “SET” position of the indicator with the end of the
pointer and secure the indicator.
CL-4-18
ADJUSTMENT CL710, 740, 750, 810
NOTE
range.
8. Fully depress the clutch pedal several times, then check to

be sure the end of the pointer is at the “SET” position.
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)
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)
CLUTCH MASTER CYLINDER AND CLUTCH PEDAL

Unit: mm (in)
Clearance between pedal shaft and
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
bushing
Play of clutch master cylinder push rod 1.0 (0.039) —
Clutch master cylinder ID 19.05 - 19.09 (0.7500 - 0.7516) 19.15 (0.7539)
Play of clutch pedal 35 - 55 (1.38 - 2.17) —
Distance from clutch pedal to floor
50 (1.97) —
(When clutch pedal is released)
CL-1-1
SERVICE DATA CLUTCH UNIT (VAC)
TIGHTENING TORQUE
CLUTCH BOOSTER
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
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
Used to disassemble and assemble the cyl-

inder shell
Plate
910-22061
Used to connect the cylinder shell
Lever
910-22100
Used to connect the plate and lever
Bolt
11000-0123
Used for connection

* Used as a set including 910-22061, 910-
22100, 1100-0123, 1110-0132
Nut
11000-0132
CL-2-1
TOOLS CLUTCH UNIT (VAC)

Used to install the hydraulic piston cup (fluid
pressure side)
Cup guide
910-23284
Used to install the hydraulic piston cup (fluid

pressure side)
Cup guide
910-23285
Used to install the relay piston cup (fluid

pressure side)
Cup insert guide

910-23286
Used to install the relay piston cup (atmo-

spheric pressure side)
Cup insert guide

910-23287
Used to install the valve body assembly
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
DISASSEMBLY

1. Push rod , 17. Cup packing , 33. Cup packing
2. Clamp 18. Relay piston , 34. Hydraulic piston
3. Guard , 19. Cup packing , 35. Cup packing
4. Retaining ring 20. Clamp 36. Cylinder body
5. Plate & cover assembly 21. Hose 37. Front shell
6. Gasket ,+ 22. Rear shell 38. O-ring
7. Poppet spring , 23. Nut 39. O-ring
,+ 8. Poppet valve 24. Retainer 40. Bleeder plug
9. Tube connector 25. Diaphragm 41. Cap
10. Screw 26. Plate 42. Washer
11. Valve body 27. Washer 43. Retainer
12. Gasket 28. Gasket 44. Cup packing
13. Relay valve spring 29. Push rod 45. Bakelite washer
14. Diaphragm 30. Piston return spring 46. O-ring
15. Retaining ring 31. Retaining ring 47. Seal assembly
16. Washer 32. Washer 48. Retaining ring
CL-3-2

8 Poppet valve
Remove the poppet valve by tapping the head of the atmospheric
valve.
z If the poppet valve is not faulty, it does not need to be
removed.
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
INSPECTION
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)
— 0.08 (0.0031)
Clearance between relay piston and valve body

Unit: mm (in)
— 0.13 (0.0051)
Bend of push rod

Unit: mm (in)
— 0.15 (0.0059)
Free length of each spring

Unit: mm (in)
Piston return spring 197 (7.76) —
Relay valve spring 47.7 (1.878) —
Poppet spring 22.8 (0.898) —
Tension of each spring

Unit: N {kgf, lbf}
Maintenance
standard
Piston return When compressed to
— 41.2 {4.2, 9.3}
spring 77 mm (3.03 in)
Relay valve When compressed to
— 10.8 {1.1, 2.4}
spring 28.6 mm (1.126 in)
When compressed to
Poppet spring — 2.9 {0.3, 0.7}
13.1 mm (0.516 in)
CL-3-4
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
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
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.
SIMPLE PERFORMANCE TEST METHOD

A simple performance test used to check the clutch booster perfor-
mance is described below. This test method should be construed
as an approximate yard-stick and should not provide accurate per-
formance test results.
The test is conducted on the booster in its installed condition, so the
clutch pedal play should be adjusted prior to testing.
Overall check
1. Depress the clutch pedal (with a vacuum pressure of zero)
as you do under normal conditions.
2. With the clutch pedal held in that position, idle the engine.
CL-3-7
3. The clutch booster is properly functioning if the clutch pedal

moves slightly toward the floor several seconds after the
clutch pedal has been depressed.
Checking the poppet (atmospheric) valve for air tight-
ness
1. Idle the engine.
2. Move a thin thread near the air cleaner of the clutch
booster. The clutch pedal should not be depressed.
3. If the thread is sucked into the air cleaner, the poppet valve
is leaking.
4. The relay piston and valve are functioning properly if the
clutch pedal is depressed and the thread is forcibly sucked
into the air cleaner. If the thread stops when the clutch
pedal is stopped midway of its travel, the relay piston and
valve are functioning properly.
Checking the poppet (vacuum) valve for air tightness
1. Idle the engine.
2. Depress the clutch pedal to completely close the vacuum
valve and open the atmospheric valve. Move a thin thread
near the air cleaner of the clutch booster.
3. If the thread is sucked into the air cleaner, the poppet valve
or power piston is leaking.
CL-3-8
CLUTCH MASTER CYLINDER CLUTCH UNIT (VAC)
CLUTCH MASTER CYLINDER

CONSTRUCTION
CL-4-1
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.

1. Turn the key switch to the “OFF” position and chock the
wheels to be safe.
2. Plug the tube and hose to prevent dirt or dust from entering.
CL-4-2
DISASSEMBLY

1. Push rod assembly 6. Gasket 10. Spring
2. Dust cover 7. Circlip 11. Seat holder
3. Nipple 8. Washer 12. Seat
4. Gasket , 9. Piston assembly 13. Cylinder
5. Stopper bolt
INSPECTION
Clearance between pedal shaft and bushing
Unit: mm (in)
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
Clutch master cylinder inside diameter

Unit: mm (in)
19.05 - 19.09 (0.7500 - 0.7516) 19.15 (0.7539)
CL-4-3
REASSEMBLY
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
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.
ADJUSTMENT OF CLUTCH PEDAL PLAY

After properly assembling the clutch, adjust the free play of the
clutch pedal. For the procedure, refer to the “CLUTCH” section.
ADJUSTMENT OF CLUTCH SWITCH

To install the stop light switch, adjust the threaded tip so that it pro-
trudes 0 - 1.25 mm (0 - 0.0492 in). Then, secure with a lock nut.
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
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) —
Poppet spring When compressed

Tension N {kgf, lbf} — 2.26 {0.23, 0.51} to 13.0 mm
(0.512 in)
CL-1-1
CLUTCH MASTER CYLINDER AND CLUTCH PEDAL

Unit: mm (in)
Clearance between pedal shaft and
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
bushing
Play of clutch master cylinder push rod 1.0 (0.039) —
Clutch master cylinder ID 19.05 - 19.09 (0.7500 - 0.7516) 19.15 (0.7539)
Play of clutch pedal 35 - 55 (1.38 - 2.17) —
Distance from clutch pedal to floor
50 (1.97) —
(When clutch pedal is released)
TIGHTENING TORQUE
CLUTCH BOOSTER
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
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
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
910- 910- Cup diameter Used to

insert O — — O O O
23280 23281 22.2 mm (0.874 in)
cup
packing
910- 910- Cup diameter into
— O O — — —
Cup 23284 23285 19.05 mm (0.7500 in) hydrau-
lic piston
packing
inserting
guide 910- 910- Cup diameter Used to O — O — — O
24902 24905 16.0 mm (0.630 in) insert
cup
packing
910- 910- Cup diameter into relay — O — O O —
24900 24903 12.7 mm (0.500 in) piston
CL-2-1
CLUTCH BOOSTER CLUTCH UNIT (AIR)
CLUTCH BOOSTER
CONSTRUCTION
CL-3-1
DISASSEMBLY

1. Push rod assembly 15. Cylinder shell 28. Retainer
2. Guard 16. Collar 29. Cup packing
3. Connector 17. O-ring 30. Retainer assembly
4. Gasket 18. Power piston assembly 31. Washer
5. Poppet spring 19. Nut 32. Retainer ring
6. Poppet valve 20. Washer 33. Spring pin
7. Upper valve body 21. Push rod 34. Exhaust cover
8. O-ring 22. O-ring 35. Air bleeder screw
9. Relay piston return spring 23. Cup packing 36. Cylinder body
10. O-ring + 24. Piston plate 37. Eyebolt
11. Relay piston assembly 25. Hydraulic piston 38. Gasket
, 12. Cup packing , 26. Cup packing 39. Eye connector
13. O-ring , 27. Cup packing 40. Gasket
14. Piston return spring
CL-3-2

24 Piston plate
Be sure to use the socket when placing the piston assembly in a
vise.
INSPECTION
Clearance between power piston and cylinder shell

Unit: mm (in)
— 1.5 (0.059)

inder
Unit: mm (in)
— 0.08 (0.0031)
Clearance between relay piston and cylinder body

Unit: mm (in)
Liquid pressure side — 0.11 (0.0043)
Atmospheric side — 0.3 (0.012)
CL-3-3
Bend of push rod

Unit: mm (in)
— 0.15 (0.0059)
Free length
Unit: mm (in)
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
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
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
OIL TIGHTNESS TEST

Depress the clutch pedal, and determine whether oil leaks from the
joints of the hydraulic circuit. Keep the clutch pedal depressed to a
fixed position and determine whether the pedal resistance varies
greatly over time. Also check whether the clutch booster push rod
moves. If no abnormality is found, the piston cup and oil seal can
be considered normal.
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.
SINGLE BOOSTER TEST

The clutch booster can be examined closely by attaching the clutch
booster test kit to a brake booster tester.
PERFORMANCE CURVE (REFERENCE)

Some characteristic diagrams of the clutch booster are given for
reference as they differ somewhat depending on the booster.
The figures show when the stroke is 5 mm (0.20 in).
CL-3-6
CL-3-7
CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)
CLUTCH MASTER CYLINDER

CONSTRUCTION
CL-4-1
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.

1. Turn the key switch to the “OFF” position and chock the
wheels to be safe.
2. Plug the tube and hose to prevent dirt or dust from entering.
CL-4-2
DISASSEMBLY

1. Push rod assembly 6. Gasket 10. Spring
2. Dust cover 7. Circlip 11. Seat holder
3. Nipple 8. Washer 12. Seat
4. Gasket , 9. Piston assembly 13. Cylinder
5. Stopper bolt
INSPECTION
Clearance between pedal shaft and bushing
Unit: mm (in)
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)
Clutch master cylinder inside diameter

Unit: mm (in)
19.05 - 19.09 (0.7500 - 0.7516) 19.15 (0.7539)
CL-4-3
REASSEMBLY
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
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.
ADJUSTMENT OF CLUTCH PEDAL PLAY

After properly assembling the clutch, adjust the free play of the
clutch pedal. For the procedure, refer to the “CLUTCH” section.
ADJUSTMENT OF CLUTCH SWITCH

trudes 0 - 1.25 mm (0 - 0.0492 in). Then, secure with a lock nut.
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
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
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
Gear 1st and reverse Spur gear

used 2nd to 6th Helical gear
1st 7.137 6.314 7.173 6.718 7.173 8.035 7.027 9.008
2nd 4.110 3.913 4.304 4.031 4.304 4.645 4.277 5.483
3rd 2.389 2.262 2.459 2.303 2.459 2.664 2.493 3.196
Gear
4th 1.399 1.393 1.541 1.443 1.541 1.567 1.500 2.056
ratio
5th 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.398
6th — — 0.790 0.740 0.790 — 0.780 1.000
Reverse 6.639 5.874 6.536 6.121 6.536 8.026 7.038 9.022
1st 43/13 43/13 45/12 45/12 45/12 37/11 46/12 46/12
2nd 40/21 41/20 45/20 45/20 45/20 35/18 42/18 42/18
3rd 31/28 32/27 36/28 36/28 36/28 29/26 34/25 34/25
Number
4th 24/37 27/37 29/36 29/36 29/36 21/32 27/33 28/32
of gear
teeth 5th — — — — — — — 25/42
(Main/
6th — 19/46 19/46 19/46 19/46 — 20/44 —
counter)
Reverse 40/13 40/13 41/12 41/12 41/12 36/20 43/16 43/16
Reverse idler gear 23 23 25 25 25 28/15 30/21 30/21
Drive gear 19/41 22/42 23/44 24/43 23/44 18/43 24/44 20/47
5.0 4.5 6.4 6.2 6.4 7.5 7.0 7.0
W/O PTO
(4-3/8) (4) (5-5/8) (5-1/2) (5-5/8) (6-5/8) (6-1/8) (6-1/8)
Oil
quantity 5.2 4.7 6.5 6.4 6.5 8.0 7.7 7.7
Standard
liter (4-5/8) (4-1/8) (5-3/4) (5-5/8) (5-3/4) (7) (6-3/4) (6-3/4)
(Imp qt) W/PTO
High 5.5 5.0 6.8 6.7 6.8 8.3 8.0 8.0
power (4-7/8) (4-3/8) (6) (5-7/8) (6) (7-1/4) (7) (7)
TM-1-1
UNIT MODEL NAME

M H S 5 0 T
Classification of gear ratio:
A - S: Overdrive type
T - Z: Direct drive type
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
UNIT NO. LOCATION

The manufacturing number of each transmission is stamped on the
side of the transmission case or transmission cover.
TM-1-2
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
Unit: mm (in)
Application
Maintenance Service
Item Remarks MLS61A
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
UNIT NAME: MPS50 AND MPS62

Unit: mm (in)
Application
Maintenance
Item Service limit Remarks MPS62A
standard MPS50W
MPS62T
0.1 - 0.4
O —
(0.004 - 0.016)
Shift lever
Clearance 0.1 - 0.5
— O
between shift (0.004 - 0.020)
0.8 (0.031)
lever and select 0.1 - 0.4
lever O —
(0.004 - 0.016)
Select lever
0.1 - 0.5
— O
(0.004 - 0.020)
0.05 - 0.11
O —
Radial play between shaft and shift (0.0020 - 0.0043)
Control cover 0.5 (0.020)
lever splines 0.01 - 0.09
— O
(0.0004 - 0.0035)
0.1 - 0.4
1.0 (0.039) O —
(0.004 - 0.016)
Shift lever
0.7 - 1.0
Clearance 1.5 (0.059) — O
(0.028 - 0.039)
between shift
lever and shifters 0.1 - 0.4
1.0 (0.039) O —
(0.004 - 0.016)
Each shifter
0.7 - 1.0
1.5 (0.059) — O
(0.028 - 0.039)
Clearance between 1st-reverse 0.04 - 0.08
0.2 (0.008) O —
locking lever and lever shaft (0.0016 - 0.0031)
0.10 - 0.24
O —
Clearance between shift fork and (0.0039 - 0.0094)
1.0 (0.039)
sleeve groove 0.10 - 0.29
— O
(0.0039 - 0.0114)
41.0 - 44.0
Free length — O O
(1.614 - 1.732)
Transmission
cover When com-
163.8 - 193.2
163.8 pressed to
Shift fork shaft {16.7 - 19.7, O —
{16.7, 36.8} 26.9 mm
locking spring Tension 36.8 - 43.4}
(1.059 in)
N {kgf, lbf}
When com-
157 - 196
127 {13, 29} pressed to 27 — O
{16 - 20, 35 - 44}
mm (1.06 in)
Clearance between locking lever 0.1 - 0.4
1.0 (0.039) O —
and shifter (0.004 - 0.016)
TM-1-10
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)
Radial play 0.2 - 0.3

2nd-5th or 6th O O
between sleeves (0.008 - 0.012)
1.0 (0.039)
and clutch gear 0.4 - 0.5
splines 1st & Reverse O O
(0.016 - 0.020)
Ball bearing axial direction play — 0.5 (0.020) O O
TM-1-11
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
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
Unit: mm (in)
Maintenance
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
N {kgf, lbf}
3.5 - 4.6} mm (0.512 in)
10.8 - 13.7 When com-
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
TIGHTENING TORQUE
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

MLS61A MPS62B
Item Tightening torque MHS50T MHS60A MLS62A MPS50W
MLS61B MPS62T
Reverse idler gear shaft
19 - 25 {1.9 - 2.6, 14 - 19} — — — — O —
mounting bolt
275 - 314 {28 - 32, 203 - 231} — — — — O —
Main shaft lock nut
490 - 785 {50 - 80, 362 - 579} — — — — — O
Seal plate mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31} — — — — — O
Drain plug & filler-level check
118 - 137 {12 - 14, 87 - 101} — — — — O O
plug
19 - 25 {1.9 - 2.6, 14 - 19} — — — — O —
Control cover guide plate
29 - 44 {3.0 - 4.5, 22 - 33} — — — — — O
Type PS860 88 - 108 {9 - 11, 65 - 80} O O O O — —
211 - 240
Type PS420 — — — — — O
{21.5 - 24.5, 156 - 177}
Propeller shaft
mounting nut 211 - 240
Type PS430 — — — — O O
{21.5 - 24.5, 156 - 177}
211 - 240
Type PS520 — — — — O —
{21.5 - 24.5, 156 - 177}
Center bearing mounting bolts
59 {6, 43} O O O — — —
and nuts
98 - 127 {10 - 13, 72 - 94} — — — — O —
Center bearing
98 {10, 72} — — — — — O
Power shift assembly
32 - 42 {3.3 - 4.3, 24 - 31} — — — — — O
mounting bolt
Power shift output shaft
93 - 108 {9.5 - 11.0, 69 - 80} — — — — — O
J.K.C. make
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
MHS50 MHS60 MLS61 MLS62 MPS50 MPS62
Sliding hammer
O O O O O O
99547 Z0000
Used to drive out the

reverse idler gear
shaft.
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)
Socket wrench
flange. — — O O O —
99535 Z0003
mm (1.97 in)
Socket wrench
flange. — — — — — O
99535 Z0074
mm (2.28 in)
Used when pulling out

Puller assembly
the straight pin on — — — O — O
910-11150 (JKC NO.)
power shift striker.
Used when installing

Guide
valve on power shift — — — O — O
910-24800 (JKC NO.)
rod pipe.
Used when installing

Tool insert
retaining ring on power — — — O — O
910-26500 (JKC NO.)
shift rod pipe.
TM-2-1
CONSTRUCTION MHS50
= UNIT NAME MHS50=

CONSTRUCTION
TRANSMISSION ASSEMBLY
TM-3-1
CONSTRUCTION MHS50
MAIN SHAFT ASSEMBLY
COUNTER SHAFT ASSEMBLY
TM-3-2
DISASSEMBLY MHS50
DISASSEMBLY
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
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
TM-3-3
DISASSEMBLY MHS50
DISASSEMBLY

1. Transmission cover assembly 11. Parking brake drum 20. Ball bearing
2. Gasket 12. Parking brake assembly ,+21. Main shaft assembly
3. Clutch housing assembly 13. Speedometer driven gear 22. Roller bearing
, 4. Gasket + 14. Bearing retainer 23. Roller bearing
, 5. Shim 15. Gasket 24. Counter shaft assembly
6. Cotter pin 16. Speedometer drive gear , 25. Lock plate
,+ 7. Castellated nut , 17. Side cover + 26. Reverse idler shaft
8. Plain washer (PTO gear box: If so equipped) 27. Reverse idler gear
9. Companion flange 18. Gasket 28. Needle bearing
10. O-ring ,+ 19. Main drive gear , 29. Transmission case
TM-3-4
DISASSEMBLY MHS50
MAIN SHAFT ASSEMBLY

, 1. Thrust washer 11. Synchronizer ring 20. Needle bearing
2. Reverse gear ,+ 12. 4th-5th synchronizer hub , 21. Retaining ring
3. Needle bearing assembly 22. Synchronizer ring
, 4. Retaining ring 13. Synchronizer ring ,+ 23. 2nd-3rd synchronizer hub
5. 1st-reverse sleeve 14. 4th gear assembly
6. 1st-reverse hub 15. Spacer 24. Synchronizer ring
7. 1st gear 16. Needle bearing 25. 2nd gear
8. Needle bearing , 17. Retaining ring 26. Needle bearing
9. Pilot bearing , 18. Thrust washer 27. Steel ball
, 10. Retaining ring 19. 3rd gear , 28. Main shaft
TM-3-5
DISASSEMBLY MHS50

1. Roller bearing inner race , 4. Key 7. 3rd counter gear
. 2. Retaining ring 5. Spacer , 8. Key
.+ 3. Counter drive gear , 6. 4th counter gear 9. Counter shaft
TM-3-6
DISASSEMBLY MHS50
TRANSMISSION COVER ASSEMBLY

1. Reverse switch 15. Steel ball 28. Retaining ring
2. Breather 16. Shifter 29. Thrust washer
. 3. Shift cap 17. 4th-5th fork 30. Welch plug
. 4. Shift cap + 18. Fork shaft 31. Inner shaft assembly
5. Plug 19. Steel ball . 32. Lock plate
6. 1st-reverse fork 20. Steel ball 33. Guide plate
7. Shifter 21. Lock spring 34. Select lever assembly
8. Interlock pin 22. Stopper bolt 35. Shift lever
+ 9. Fork shaft 23. Spring 36. Oil seal
10. Steel ball 24. Resist pin 37. Oil seal
11. Steel ball 25. Steel ball 38. Neutral switch
12. 2nd-3rd fork 26. Spring 39. Steel ball
13. Interlock pin 27. Straight pin 40. Transmission cover
+ 14. Fork shaft
TM-3-7
DISASSEMBLY MHS50
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.
z Measure and record the end play of each gear.
z Apply grease to a piece of fuse wire 1 mm (0.04 in) in dia.

and 15 mm (0.59 in) long and attach the fuse wire to the
surface of a gear tooth. Turn the gear one complete rotation
and measure and record the gear backlash.
NOTE
z Measure backlash for each gear at three equally spaced
points.
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
19 Main drive gear

Be sure the cutout section of the synchronizer cone faces down-
ward when removing the main gear.
NOTE
z Do not remove the roller bearing unless necessary.
21 Main shaft assembly

Lift the main shaft assembly with a cable and hoist and remove it
from the transmission case with the front tilting upward.
26 Reverse idler shaft

Remove the lock plate from the reverse idler gear shaft. Drive the
reverse idler gear shaft out with the sliding hammer (99547 Z0000)
and adapter (99808 Z5000).
TM-3-9
DISASSEMBLY MHS50
MAIN SHAFT ASSEMBLY

12 4th-5th synchronizer hub assembly
When disassembling the sleeve, be careful not to lose the strut and
synchronizer spring located between the hub and sleeve.
1. Synchronizer spring 5. 4th-5thsleeve
2. 4th-5th hub 6. Synchronizer ring
3. Strut 7. 4th gear
4. Synchronizer spring
NOTE
z Attach a tag to the synchronizer ring for identification.
23 2nd-3rd synchronizer hub assembly

1. Synchronizer ring 5. Synchronizer spring
2. Synchronizer spring 6. Synchronizer ring
3. 2nd-3rd hub 7. 2nd-3rd sleeve
4. Strut
NOTE

3 Counter drive gear
The gears of the counter shaft need not be disassembled unless
they are being replaced because they have become worn or have
damaged teeth, etc.
TM-3-10
DISASSEMBLY MHS50

9, 14, 18 Fork shafts
1. The fork shafts can be removed in any order, but note that
the interlock pin and steel ball will press against the trans-
mission cover, and cannot be removed, if the interlock pin is
not in neutral when the fork shaft is pulled.
2. 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.
1. 1st-reverse fork shaft 6. 2nd-3rd fork shaft
2. Steel ball 7. Interlock pin
3. Locking spring 8. 4th-5th fork shaft
4. Steel ball 9. Neutral switch
5. Interlock pin
TM-3-11
INSPECTION MHS50
INSPECTION
TRANSMISSION COVER
Clearance between shift lever and select lever assem-
bly
Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
Radial play between inner shaft and shift lever splines

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)
Clearance between transmission cover and fork shaft

Unit: mm (in)
0.1 - 0.2 (0.004 - 0.008) 0.8 (0.031)
Clearance between shift lever and shifters

Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-3-12
INSPECTION MHS50
Clearance between transmission cover and select

lever
Unit: mm (in)
0.04 - 0.07 (0.0016 - 0.0028) 0.1 (0.004)
Clearance between shift fork and sleeve groove

NOTE
z Measure the clearance at the sleeve groove in at least
three points.
Unit: mm (in)
0.10 - 0.29 (0.0039 - 0.0114) 1.0 (0.039)
Fork shaft locking spring force

Unit: N {kgf, lbf}
When compressed to
80.71 {8.23, 18.15} —
26 mm (1.02 in)
Resist pin locking spring force

Unit: N {kgf, lbf}
When compressed
Left side 73.6 {7.5, 16.5} —
to 35 mm (1.38 in)
Resist spring force

Unit: N {kgf, lbf}
When compressed
Left side 50.80 {5.18, 11.42} —
to 35 mm (1.38 in)
TM-3-13
INSPECTION MHS50
TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.35 (0.0138)
Radial play between hub and sleeve splines

Unit: mm (in)
1st-reverse 0.10 - 0.20 (0.0039 - 0.0079) 0.3 (0.012)
2nd-3rd 0.22 - 0.29 (0.0087 - 0.0114) 0.5 (0.020)
4th-main drive 0.10 - 0.20 (0.0039 - 0.0079) 0.3 (0.012)
Radial play between sleeves and clutch gear splines

Unit: mm (in)
1st
2nd
3rd 0.20 - 0.30
0.5 (0.020)
4th (0.0079 - 0.0118)
Reverse
Main drive
Ball bearing axial play

Unit: mm (in)
— 0.5 (0.020)
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)
2nd-3rd
1.9 - 2.1 (0.075 - 0.083) 0.5 (0.020)
4th-5th
TM-3-14
INSPECTION MHS50
Radial clearance between strut and synchronizer ring

Unit: mm (in)
2nd-3rd 4.90 - 5.25 (0.1929 - 0.2067) —
4th-5th 4.20 - 4.55 (0.1654 - 0.1791) —
Clearance between synchronizer hub and strut

Unit: mm (in)
0.04 - 0.19 (0.0016 - 0.0075) —
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.

32 Lock plate
After tightening the bolt, bend the lock plate in four places.
3, 4 Plug
The plug and cap must be securely caulked by tapping them at the
center.
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

Be careful not to drop the reverse gear.

4, 8 Key
When installing a key, make sure that its large chamfered side is on
the side gear installation side.
6 4th counter gear

Press the 4th counter gear into the counter shaft with its exposed
boss facing the front of the shaft.

Face the counter drive gear boss side sticking out of the gear side
towards the shaft and press fit it into the counter shaft.
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
MAIN SHAFT ASSEMBLY

28 Main shaft
Mount the main shaft on a mounting stand, or in a vise, with the
front of the shaft facing upward.
23 2nd-3rd synchronizer hub assembly

Assemble the 2nd-3rd synchronizer hub assembly.
1. Synchronizer spring 4. Synchronizer spring
2. 2nd-3rdhub 5. 2nd-3rd sleeve
3. Strut
NOTE
z When driving the 2nd-3rd synchronizer assembly into
place, be careful not to drop the sleeve, strut, synchro-
nizer spring, etc.
21, 17, 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
2.00 (0.0787)
4 1st-reverse hub 2.15 (0.0846)
2.30 (0.0906)
3.50 (0.1378)
21 2nd-3rd synchronizer assembly 3.65 (0.1437)
3.80 (0.1496)
2.50 (0.0984)
17 3rd gear 2.65 (0.1043)
2.80 (0.1102)
1.75 (0.0689)
10 4th-5th synchronizer assembly 1.90 (0.0748)
2.05 (0.0807)
TM-3-18
REASSEMBLY MHS50
18 Thrust washer (3rd gear)

Install the thrust washer so that its chamfered side on the inside
diameter side faces the 3rd gear.
12 4th-5th synchronizer hub assembly

Assemble the 4th-5th synchronizer hub assembly.
2. 4th-5th hub 5. 4th-5th sleeve
3. Strut
NOTE
z When driving the 4th-5th synchronizer assembly into
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
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
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
= UNIT NAME MHS60 =

CONSTRUCTION
TM-4-1
CONSTRUCTION MHS60
MAIN SHAFT ASSEMBLY
TM-4-2
DISASSEMBLY MHS60
DISASSEMBLY
REMOVAL
safe.
2. Remove the drain plug and transmission gear oil from the
transmission case.
NOTE
TM-4-3
DISASSEMBLY MHS60
DISASSEMBLY

1. Transmission cover assembly 10. O-ring . 18. Lock plate
2. Gasket 11. Parking brake drum + 19. Reverse idler assembly
3. Clutch housing assembly 12. Parking brake assembly ,+ 20. Main drive gear
, 4. Gasket + 13. Bearing retainer 21. Ball bearing
, 5. Shim 14. Gasket ,+ 22. Main shaft assembly
6. Cotter pin 15. Speedometer drive gear 23. Roller bearing
,+ 7. Castellated nut 16. Side cover (PTO gear box: If so 24. Roller bearing
8. Plain washer equipped) ,+ 25. Counter shaft assembly
9. Companion flange 17. Gasket . 26. Transmission case
TM-4-4
DISASSEMBLY MHS60
MAIN SHAFT ASSEMBLY

1. Reverse gear ,+12. Synchronizer assembly (5th-6th) ,+22. Synchronizer assembly (3rd-4th)
2. Needle bearing 13. Synchronizer ring 23. Synchronizer ring
. 3. Retaining ring 14. 6th gear 24. 3rd gear
4. Reverse sleeve 15. Needle bearing 25. Needle bearing
. 5. Reverse hub . 16. Retaining ring . 26. Retaining ring
6. 1st gear . 17. Thrust washer . 27. Thrust washer
7. Needle bearing 18. 4th gear 28. 2nd gear
8. Synchronizer assembly (1st-2nd) 19. Needle bearing 29. Needle bearing
9. Pilot bearing . 20. Retaining ring + 30. Steel ball
. 10. Retaining ring 21. Synchronizer ring 31. Main shaft
11. Synchronizer ring
TM-4-5
DISASSEMBLY MHS60

1. Roller bearing inner race . 4. Key . 7. Key
. 2. Retaining ring ,+ 5. 6th counter gear 8. Counter shaft
,+ 3. Counter drive gear ,+ 6. 4th counter gear
TM-4-6
DISASSEMBLY MHS60

1. Reverse switch 18. Steel ball 35. Lock spring
2. Neutral switch (If so equipped) 19. Setscrew 36. Steel ball
3. Steel ball (If so equipped) 20. 1st-2nd shifter 37. Stopper bolt
, 4. Plug 21. 1st-2nd shift fork 38. Spring
, 5. Shift cap + 22. 1st-2nd fork shaft 39. Resist pin
6. Breather 23. Interlock pin 40. Straight pin
7. Setscrew 24. Steel ball 41. Retaining ring
8. 5th-6th shifter 25. Steel ball 42. Thrust washer
9. 5th-6th shift fork 26. Setscrew 43. Select lever
+ 10. 5th-6th fork shaft 27. Reverse shifter 44. Oil seal
11. Steel ball 28. Reverse shift fork 45. Welch plug
12. Steel ball + 29. Reverse fork shaft 46. Shift lever shaft
13. Setscrew 30. Steel ball 47. Shift lever
14. 3rd-4th shift fork 31. Spring 48. Oil seal
+ 15. 3rd-4th fork shaft 32. Bolt 49. Transmission cover
16. Interlock pin , 33. Lock plate 50. Gasket
17. Steel ball 34. Guide plate
TM-4-7
DISASSEMBLY MHS60

NOTE
points.
7 Castellated nut
When loosening the castellated nut, support the transmission case
13 Bearing retainer
TM-4-8
DISASSEMBLY MHS60
19 Reverse idler assembly

Remove the lock plate from the reverse idler gear shaft. Drive the
reverse idler gear shaft out with the sliding hammer (99547 Z0000)
and adapter (99808 Z5000).
20 Main drive gear

ward when removing the main gear.
NOTE
z Do not remove the roller bearing unless necessary.

Lift the main shaft assembly with a cable and hoist and remove it
from the transmission case with the front tilting upward.
TM-4-9
DISASSEMBLY MHS60
NOTE
z Attach tags to the synchronizer ring for later identifica-
tion.
25 Counter shaft assembly

Lift the counter shaft assembly with a cable and hoist, and remove
it from the transmission case with the front tilting upward.
MAIN SHAFT ASSEMBLY

12 5th-6th synchronizer assembly
1. The figure at right shows the 5th-6th synchronizer assembly
to which the puller is attached after removal of the 5th-6th
sleeve and strut.
2. When disassembling the sleeve, be careful not to lose the

strut and synchronizer spring located between the hub and
sleeve.
1. Synchronizer spring 5. 5th-6th sleeve
NOTE
TM-4-10
DISASSEMBLY MHS60
22 3rd-4th synchronizer assembly

3. 3rd-4th hub 7. 3rd-4th sleeve
4. Strut
NOTE
30 Steel ball
Be careful not to lose the steel ball.

z The gears of the counter shaft need not be disassembled
unless they are worn or have damaged teeth, etc.
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

10, 15, 22, 29 Fork shaft
The fork shafts can be removed in any order, but note that the inter-
lock pin and steel ball will press against the transmission cover, and
cannot be removed, if the interlock pin is not in neutral when the
fork shaft is pulled.
NOTE
z The steel ball used to lock the fork shaft will tend to fly
out when removing the fork shaft. Use a rag, etc. to pre-
vent the steel ball from flying out.
1. Reverse fork shaft 6. 3rd-4th fork shaft
2. Steel ball 7. Steel ball
3. Locking spring 8. 5th-6th fork shaft
4. 1st-2nd fork shaft 9. Neutral switch or plug
5. Interlock pin
TM-4-12
INSPECTION MHS60
INSPECTION
TRANSMISSION COVER
Clearance between shift lever and select lever assembly
Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Unit: mm (in)
0.1 - 0.2 (0.004 - 0.008) 0.8 (0.031)

Unit: mm (in)
0.7 - 1.0 (0.028 - 0.039) 1.4 (0.055)
TM-4-13
INSPECTION MHS60

lever
Unit: mm (in)
0.03 - 0.08 (0.0012 - 0.0031) 0.1 (0.004)

NOTE
three points.
Unit: mm (in)
0.10 - 0.29 (0.0039 - 0.0114) 1.0 (0.039)

Unit: N {kgf, lbf}
When compressed to
80.71 {8.23, 18.15} —
26 mm (1.02 in)

Unit: N {kgf, lbf}
When compressed
Left side 73.6 {7.5, 16.5} —
to 35 mm (1.38 in)
When compressed
Right side 27.56 {2.81, 6.20} —
to 19 mm (0.75 in)
Resist spring force

Unit: N {kgf, lbf}
When compressed to
Left side 27.36 {2.79, 6.15} —
38.5 mm (1.516 in)
When compressed to
Right side 40.80 {4.16, 9.17} —
37 mm (1.46 in)
TM-4-14
INSPECTION MHS60
TRANSMISSION PROPER
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)

Unit: mm (in)
Reverse
1st-2nd 0.20 - 0.30
0.5 (0.020)
3rd-4th (0.0079 - 0.0118)
6th-main drive

Unit: mm (in)
0.98 - 1.08
1st 1.3 (0.051)
(0.0386 - 0.0425)
0.69 - 0.79
2nd 1.0 (0.039)
(0.0272 - 0.0311)
3rd 0.39 - 0.49
0.7 (0.028)
4th (0.0154 - 0.0193)
0.67 - 0.77
6th 1.0 (0.039)
(0.0264 - 0.0303)
0.39 - 0.49
Reverse 0.7 (0.028)
(0.0154 - 0.0193)
0.67 - 0.77
Main drive 1.0 (0.039)
(0.0264 - 0.0303)

Unit: mm (in)
— 0.5 (0.020)
TM-4-15
INSPECTION MHS60
SYNCHROMESH SYSTEM
NOTE
Unit: mm (in)
1.35 - 1.55
3rd-4th
(0.0531 - 0.0610)
0.5 (0.020)
1.30 - 1.70
5th-6th
(0.0512 - 0.0669)

Unit: mm (in)
3rd-4th 3.59 - 3.95 (0.1413 - 0.1555) —
5th-6th 3.39 - 3.75 (0.1335 - 0.1476) —

Unit: mm (in)
0.04 - 0.19 (0.0016 - 0.0075) —
TM-4-16
REASSEMBLY MHS60
REASSEMBLY
REASSEMBLY
others.

33 Lock plate
After tightening the bolt, bend the lock plate in four places.
4 Plug, 5 Shift cap

center.

4, 7 Key
5, 6 4th and 6th counter gear

Press the 4th and 6th counter gear into the counter shaft with its
exposed boss facing the front of the shaft.
TM-4-17
REASSEMBLY MHS60

Face the counter drive gear boss side sticking out of the gear side
towards the shaft and press fit it into the counter shaft.
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).
MAIN SHAFT ASSEMBLY

z Mount the main shaft on a mounting stand, or in a vise, with
the front of the shaft facing upward.
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
26, 20, 16, 10, 3 Retaining ring

Unit: mm (in)
Item Retaining ring
3.50 (0.1378)
26 2nd gear 3.65 (0.1437)
3.80 (0.1496)
2.00 (0.0787)
20 3rd-4th synchronizer assembly 2.15 (0.0846)
2.30 (0.0906)
2.50 (0.0984)
14 4th gear 2.65 (0.1043)
2.80 (0.1102)
1.80 (0.0709)
2.10 (0.0827)
2.00 (0.0787)
3 1st-reverse hub 2.15 (0.0846)
2.30 (0.0906)
22 Synchronizer assembly (3rd-4th)

Assemble the 3rd-4th synchronizer assembly.
3. Strut
NOTE
z When driving the 3rd-4th synchronizer assembly into
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
12 Synchronizer assembly (5th-6th)

Assemble the 5th-6th synchronizer assembly.
3. Strut
NOTE
nizer spring, etc.
5 Reverse hub
Always install the reverse hub with the groove facing the 1st gear.
z Measure each gear end play to the main shaft.

Unit: mm (in)
1st-2nd 0.28 - 0.70 (0.0110 - 0.0276)
3rd-4th 0.26 - 0.70 (0.0102 - 0.0276)
6th 0.26 - 0.70 (0.0102 - 0.0276)
Reverse 0.21 - 0.64 (0.0083 - 0.0252)
TM-4-20
REASSEMBLY MHS60

Be careful not to drop the reverse gear needle bearing and reverse
sleeve.
20 Main drive gear

ward.
18 Lock plate
Make sure the lock plate groove in the reverse idler shaft faces
upward.
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
in the vehicle.
their splines.
inal positions.
TM-4-22
CONSTRUCTION MLS61
= UNIT NAME MLS61 =

CONSTRUCTION
TM-5-1
CONSTRUCTION MLS61
MAIN SHAFT ASSEMBLY
TM-5-2
DISASSEMBLY MLS61
DISASSEMBLY
REMOVAL
safe.
NOTE
TM-5-3
DISASSEMBLY MLS61
DISASSEMBLY

1. Transmission cover assembly 11. Gasket 19. Gasket
2. Gasket 12. Speedometer drive gear ,+ 20. Main drive gear
3. Clutch housing assembly 13. Side cover + 21. Synchronizer ring
4. Gasket 14. Gasket 22. Ball bearing
5. Parking brake drum , 15. Lock plate ,+ 23. Main shaft assembly
,+ 6. Pinion nut + 16. Reverse idler gear shaft 24. Roller bearing
7. Companion flange + 17. Reverse idler gear 25. Roller bearing
8. O-ring 18. PTO side cover (PTO gear box: If so ,+ 26. Counter shaft assembly
9. Parking brake assembly equipped) 27. Transmission case
+ 10. Bearing retainer
TM-5-4
DISASSEMBLY MLS61
MAIN SHAFT ASSEMBLY

1. Reverse washer ,+ 12. Synchronizer assembly (5th-6th) 23. Synchronizer ring
2. Reverse gear 13. Synchronizer ring , 24. Retaining ring
3. Needle bearing 14. 6th gear 25. 3rd gear
, 4. Retaining ring 15. Needle bearing 26. Needle bearing
5. Reverse sleeve , 16. Retaining ring , 27. Retaining ring
6. Reverse hub , 17. Thrust washer 28. Thrust washer
7. 1st gear 18. 4th gear 29. 2nd gear
8. Needle bearing 19. Needle bearing 30. Needle bearing
9. Pilot bearing , 20. Retaining ring ,+ 31. Synchronizer assembly (2nd)
, 10. Retaining ring 21. Synchronizer ring + 32. Steel ball
11. Synchronizer ring ,+ 22. Synchronizer assembly (3rd-4th) , 33. Main shaft
TM-5-5
DISASSEMBLY MLS61

1. Roller bearing inner race ,+ 4. 6th counter gear , 6. Key
,+ 2. Retaining ring ,+ 5. 4th counter gear 7. Counter shaft
,+ 3. Counter drive gear
TM-5-6
DISASSEMBLY MLS61

1. Reverse switch + 18. Steel ball 35. Spring
2. Neutral switch + 19. Steel ball 36. Steel ball
3. Steel ball , 20. 1st-2nd shifter 37. Stopper bolt
, 4. Plug , 21. 1st-2nd shift fork 38. Spring
, 5. Shift cap 22. Interlock pin 39. Resist pin
6. Breather + 23. 1st-2nd fork shaft 40. Retaining ring
, 7. 5th-6th shift fork + 24. Steel ball 41. Thrust washer
8. 5th-6th shift shaft + 25. Steel ball 42. Select lever
, 9. Select lever , 26. Reverse shifter 43. Oil seal
, 10. Select lever , 27. Reverse shift fork 44. Straight pin
11. Interlock pin 28. Shift stopper 45. Plug
+ 12. Fork shaft + 29. Reverse fork shaft 46. Shift lever shaft
+ 13. Steel ball 30. Steel ball 47. Shift lever
+ 14. Steel ball 31. Spring 48. Plate
, 15. 3rd-4th shift fork 32. Lever shaft 49. Oil seal
16. Interlock pin 33. Location lever 50. Transmission cover
+ 17. 3rd-4th fork shaft 34. O-ring
TM-5-7
DISASSEMBLY MLS61
TRANSMISSION ASSEMBLY0

NOTE
points.
6 Pinion nut
When loosening the pinion nut, support the transmission case
NOTE
z Do not re-use the pinion nut after removal.
10 Bearing retainer
TM-5-8
DISASSEMBLY MLS61
16 Reverse idler gear shaft

Remove the lock plate from the reverse idler gear shaft. Using the
sliding hammer (99547 Z0000), withdraw the reverse idler gear
shaft.
17 Reverse idler gear

Disassemble the reverse idler gear.
20 Main drive gear

Do not remove the bearing unless necessary.
21 Synchronizer ring
Attach tags to the synchronizer cone and synchronizer ring for later
identification.

Using a hoist and lifting wires, lift the main shaft assembly. While
tilting the front side up as shown, lift the main shaft assembly out of
TM-5-9
DISASSEMBLY MLS61

Using a hoist and lifting cable, lift the counter shaft assembly. While
tilting the front side up, lift the counter shaft assembly out of the
transmission case.
MAIN SHAFT ASSEMBLY

1. Synchronizer spring 5. 5th-6thsleeve
NOTE
tion, and main shaft so that they can be reinstalled in
their original positions.

4. Strut
NOTE
tion, and main shaft so that they can be reinstalled in
TM-5-10
DISASSEMBLY MLS61
31 2nd synchronizer assembly

Scribe alignment marks on the side of the 2nd synchronizer assem-
bly and main shaft so that they can be reinstalled in their original
positions.
32 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
NOTE

12, 17, 23, 29 Fork shaft
The removal sequence of the fork shafts is not specified. However,
before removing them, set the interlock pin to neutral, otherwise the
transmission cover interferes with the interlock pin and steel ball.
1. Reverse fork shaft 6. Interlock pin
2. Steel ball 7. 3rd-4th fork shaft
3. Lock spring 8. 5th-6th fork shaft
5. 1st-2nd fork shaft
13, 14, 18, 19, 24, 25 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.
TM-5-12
INSPECTION MLS61
INSPECTION
TRANSMISSION COVER
bly
Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Unit: mm (in)
0.1 - 0.2 (0.004 - 0.008) 0.8 (0.031)

Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
TM-5-13
INSPECTION MLS61

lever
Unit: mm (in)
0.03 - 0.08 (0.0012 - 0.0031) 0.1 (0.004)

NOTE
three points.
Unit: mm (in)
0.10 - 0.29 (0.0039 - 0.0114) 1.0 (0.039)

Unit: N {kgf, lbf}
When compressed to
80.71 {8.23, 18.15} —
26 mm (1.02 in)

Unit: N {kgf, lbf}
When compressed to
Left side 73.6 {7.5, 16.5} —
35 mm (1.38 in)
When compressed to
Right side 27.56 {2.81, 6.20} —
19 mm (0.75 in)
Resist spring force

Unit: N {kgf, lbf}
When compressed to
Left side 27.36 {2.79, 6.15} —
38.5 mm (1.516 in)
When compressed to
Right side 38.54 {3.93, 8.67} —
37 mm (1.46 in)
TM-5-14
INSPECTION MLS61
TRANSMISSION PROPER
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)

Unit: mm (in)
Reverse
1st-2nd 0.20 - 0.30
0.5 (0.020)
3rd-4th (0.0079 - 0.0118)
6th-main drive

Unit: mm (in)
0.40 - 0.50
1st 0.7 (0.028)
(0.0157 - 0.0197)
0.20 - 0.30
2nd 0.5 (0.020)
(0.0079 - 0.0118)
3rd 0.40 - 0.50
0.7 (0.028)
4th (0.0157 - 0.0197)
0.20 - 0.30
6th 0.5 (0.020)
(0.0079 - 0.0118)
0.40 - 0.50
Reverse 0.7 (0.028)
(0.0157 - 0.0197)
0.20 - 0.30
Main drive 0.5 (0.020)
(0.0079 - 0.0118)

Unit: mm (in)
— 0.5 (0.020)
TM-5-15
INSPECTION MLS61
SYNCHROMESH SYSTEM
NOTE
Unit: mm (in)
3rd-4th 1.35 - 1.55 (0.0531 - 0.0610)
0.5 (0.020)
5th-6th 1.30 - 1.70 (0.0512 - 0.0669)

Unit: mm (in)
3rd-4th
3.50 - 3.85 (0.1378 - 0.1516) —
5th-6th

Unit: mm (in)
0.04 - 0.19 (0.0016 - 0.0075) —
TM-5-16
REASSEMBLY MLS61
REASSEMBLY
REASSEMBLY
others.

48 Plate
7, 9, 10, 15, 20, 21, 26, 27 Shift fork & shifter
Install the setscrew and secure with lock wire on each shift fork and
shifter.
4 Plug, 5 Shift cap

center.

6 Key

Ensure that the protruding boss side of each gear points to the
direction in which the gear is installed.
TM-5-17
REASSEMBLY MLS61

Ensure that the protruding boss side of gear points to the rear of the
shaft.
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).
MAIN SHAFT ASSEMBLY

33 Main shaft
31 2nd synchronizer assembly

Install the 2nd synchronizer assembly.
NOTE
z Align the marks scribed during disassembly when rein-
stalling the 2nd synchronizer assembly.
TM-5-18
REASSEMBLY MLS61
22 Synchronizer assembly (3rd-4th)

3. Strut
NOTE
z When driving the 3rd-4th synchronizer assembly into
nizer spring, etc.
17 Thrust washer
Install the thrust washer with the oil groove side facing the gear.
12 Synchronizer assembly (5th-6th)

3. Strut
NOTE
nizer spring, etc.
27, 24, 20, 16, 10, 4 Retaining ring
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)
2.80 (0.1102)
2.50 (0.0984)
2.80 (0.1102)
2.50 (0.0984)
4 Reverse hub 2.65 (0.1043)
2.80 (0.1102)
TM-5-19
REASSEMBLY MLS61
z Measure each gear's end play of the main shaft.

Unit: mm (in)
1st gear 0.28 - 0.70 (0.0110 - 0.0276) 0.9 (0.035)
2nd gear 0.28 - 0.70 (0.0110 - 0.0276) 0.9 (0.035)
3rd gear 0.20 - 0.80 (0.0079 - 0.0315) 0.9 (0.035)
4th gear 0.20 - 0.74 (0.0079 - 0.0291) 0.9 (0.035)
6th gear 0.20 - 0.70 (0.0079 - 0.0276) 0.9 (0.035)
Reverse gear 0.20 - 0.50 (0.0079 - 0.0197) 0.7 (0.028)
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).

Using a hoist and lifting cable, lift the main shaft assembly into the
transmission case.
NOTE
z Be careful not to drop the reverse gear, needle bearing
and reverse sleeve.
20 Main drive gear

Select the retaining ring that minimizes the hub's axial play.
The thicknesses of the available retaining rings are 2.00, 2.15 and
2.30 mm (0.0787, 0.0846 and 0.0906 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.
z Using the same procedure as used during disassembly,

measure backlash in each gear on the main shaft to ensure
that it is within maintenance standard.
Maintenance standard:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
INSTALLATION
in the vehicle.
their splines.
inal positions.
TM-5-21
CONSTRUCTION MLS62
= UNIT NAME MLS62 =

CONSTRUCTION
TM-6-1
CONSTRUCTION MLS62
MAIN SHAFT ASSEMBLY
TM-6-2
CONSTRUCTION MLS62
POWER SHIFT ASSEMBLY
TM-6-3
DISASSEMBLY MLS62
DISASSEMBLY
REMOVAL
safe.
NOTE
TM-6-4
DISASSEMBLY MLS62
DISASSEMBLY

1. Transmission cover assembly + 10. Bearing retainer 19. Gasket
2. Gasket 11. Gasket ,+ 20. Main drive gear assembly
, 3. Clutch housing assembly 12. Speedometer drive gear + 21. Synchronizer ring
4. Gasket 13. Side cover 22. Ball bearing
5. Parking brake drum 14. Gasket ,+ 23. Main shaft assembly
,+ 6. Pinion nut , 15. Lock plate 24. Roller bearing
7. Companion flange ,+ 16. Reverse idler shaft 25. Roller bearing
8. O-ring 17. Reverse idler gear ,+ 26. Counter shaft assembly
9. Parking brake assembly 18. PTO side cover (PTO gear box: If so 27. Transmission case
equipped)
TM-6-5
DISASSEMBLY MLS62
MAIN SHAFT ASSEMBLY

, 1. Thrust washer 16. Pilot bearing 31. 3rd-4th sleeve
2. Reverse gear , 17. Retaining ring 32. Detent
3. Needle bearing 18. 5th synchronizer ring 33. Plunger
, 4. Retaining ring ,+ 19. 5th-6th hub assembly 34. Synchronizer spring
5. Reverse sleeve 20. 5th-6th sleeve 35. 3rd synchronizer ring assembly
6. Reverse hub 21. 6th synchronizer ring , 36. Retaining ring
7. 1st gear 22. 6th gear 37. 3rd gear
8. Needle bearing 23. Needle bearing 38. Needle bearing
, 9. Retaining ring , 24. Retaining ring , 39. Retaining ring
,+ 10. 1st-2nd hub assembly , 25. Thrust washer , 40. Thrust washer
11. 1st-2nd sleeve 26. 4th gear 41. 2nd gear
12. Detent 27. Needle bearing 42. Needle bearing
13. Plunger , 28. Retaining ring + 43. Steel ball
14. Synchronizer spring 29. 4th synchronizer ring , 44. Main shaft
15. 2nd synchronizer ring assembly ,+ 30. 3rd-4th hub assembly
TM-6-6
DISASSEMBLY MLS62

1. Roller bearing inner race ,+ 4. 6th counter gear , 6. Key
, 2. Retaining ring ,+ 5. 4th counter gear 7. Counter shaft
,+ 3. Counter drive gear
TM-6-7
DISASSEMBLY MLS62

, 1. Reverse switch 11. Lock bolt , 21. Reverse shifter
+ 2. Steel ball + 12. 3rd-4th fork shaft 22. Bolt
, 3. Neutral switch , 13. 3rd-4th shift fork 23. Lock nut
,+ 4. Steel ball 14. Lock bolt 24. Location lever
, 5. Interlock pin + 15. 1st-2nd fork shaft 25. Spacer
, 6. Welch plug , 16. 1st-2nd shift fork 26. Guide plate
7. Lock bolt , 17. 1st-2nd shifter + 27. Steel ball
+ 8. 5th-6th fork shaft 18. Lock bolt 28. Lock spring
, 9. 5th-6th shift fork + 19. Reverse fork shaft 29. Transmission cover
, 10. 5th-6th shifter , 20. Reverse shift fork 30. Gasket
TM-6-8
DISASSEMBLY MLS62
TRANSMISSION CONTROL COVER ASSEMBLY

1. Stopper bolt 8. Select lever ,+ 15. Shift shaft
+ 2. Resist spring + 9. Oil seal 16. Shift lever
3. Reset pin 10. Stopper bolt + 17. Oil seal
4. Steel ball 11. Spring 18. Breather
5. Lock spring 12. Steel ball 19. Control cover
6. Retaining ring ,+ 13. Welch plug 20. Gasket
7. Thrust washer 14. Straight pin
TM-6-9
DISASSEMBLY MLS62

1. Housing boot 22. O-ring 43. Retaining ring 63. Plate
2. Cylinder cover 23. Plate 44. Piston 64. Spring
3. Breather 24. Spring 45. X-ring 65. O-ring
4. O-ring 25. Plate 46. O-ring 66. Sleeve
5. Bracket assy 26. Valve assy 47. Piston 67. Separater
6. Lever assy 27. Cap 48. Retaining ring 68. O-ring
7. Roller 28. Filter 49. Cylinder assy 69. Spring
8. In-put rod 29. Screw 50. Screw 70. Plate
9. Retaining ring 30. Pibot 51. Slider 71. O-ring
10. Plate 31. O-ring 52. Pin 72. O-ring
11. X-ring 32. Retaining ring 53. Rod B 73. Piston
12. Retaining ring 33. Cover 54. Pin 74. Plate
13. Plate 34. O-ring 55. Rod A 75. O-ring
14. X-ring 35. O-ring 56. Retaining ring 76. Rod C
15. Stay assy 36. Plate 57. Guide 77. Straight pin
16. Body assy 37. Spring 58. Retaining ring 78. Cover
17. O-ring 38. Plate 59. Plate 79. Ball joint
18. Retaining ring 39. Valve assy 60. Piston 80. Bush
19. Plate 40. O-ring 61. O-ring 81. Stopper pin
20. Cover 41. O-ring 62. O-ring 82. Stopper
21. O-ring 42. Lifter
TM-6-10
DISASSEMBLY MLS62

NOTE
points.
6 Pinion nut
NOTE
10 Bearing retainer
TM-6-11
DISASSEMBLY MLS62

Remove the lock plate from the reverse idler shaft. Using the sliding
hammer (99547 Z0000), withdraw the reverse idler gear shaft.
20 Main drive gear assembly

Do not remove the bearing unless necessary.
21 Synchronizer ring
Attach tags to the synchronizer cone and synchronizer ring for later
identification.


Using a hoist and lifting wires, lift the counter shaft assembly. While
tilting the front side up as shown, lift the counter shaft assembly out
of the transmission case.
TM-6-12
DISASSEMBLY MLS62
MAIN SHAFT ASSEMBLY

10 1st-2nd hub assembly
When disassembling the sleeve, be careful not to lose the detent,
plunger and synchronizer spring located between the hub and
sleeve.
1. 2nd synchronizer ring 5. Plunger
2. Synchronizer sleeve 6. Detent
3. Synchronizer hub 7. Retaining ring
4. Synchronizer spring 8. 1st gear
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.
19 5th-6th hub assembly

1. Synchronizer cone 6. Synchronizer spring
2. Synchronizer ring 7. Synchronizer ring
3. Synchronizer spring 8. Synchronizer sleeve
4. Synchronizer hub 9. 6th gear
5. Strut
NOTE
TM-6-13
DISASSEMBLY MLS62
30 3rd-4th hub assembly

sleeve.
1. 3rd synchronizer ring assembly 5. Plunger
2. Synchronizer sleeve 6. Detent
3. Synchronizer hub 7. Snap ring
4. Synchronizer spring 8. 3rd gear
NOTE
43 Steel ball

NOTE
TM-6-14
DISASSEMBLY MLS62

8, 12, 15, 19 Fork shaft
The fork shafts can be removed in any order, but note that the inter-
lock pin and steel ball will press against the transmission cover, and
cannot be removed, if the interlock pin is not in neutral when the
fork shaft is pulled.
1. Reverse fork shaft 6. Interlock pin
2. Steel ball 7. 3rd-4th fork shaft
3. Lock spring 8. 5th-6th fork shaft
5. 1st-2nd fork shaft
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.

9, 17 Oil seal
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.

1. Secure the power shift assembly in a vise and remove the
boot.
NOTE
z Secure only the flange in the vise. Do not secure any
other parts.
2. Remove the cover.
3. Remove the bracket assembly.
4. Remove the lever assembly.

NOTE
z When removing the lever assembly, be careful not to
drop the roller.
z Do not disassemble the lever assembly.
TM-6-16
DISASSEMBLY MLS62
5. Remove the stopper and input rod.

NOTE
z Be careful not to allow foreign matter to enter the rod.
z It is not necessary to disassemble the pin unless the
stopper is worn excessively.
6. Remove the packing.

z Remove the retaining ring at the rear side and then remove
the plate and packing.
z Remove the retaining ring at the front side and then move
the packing and plate toward the joint.
7. Remove the body assembly.

NOTE
z Be careful not to allow foreign matter to enter the cylin-
der.
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.
11. Remove the slider.
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
TRANSMISSION COVER
bly
Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Unit: mm (in)
0.1 - 0.2 (0.004 - 0.008) 0.8 (0.031)

Unit: mm (in)
0.4 - 0.7 (0.016 - 0.028) 0.8 (0.031)
TM-6-19
INSPECTION MLS62

lever
Unit: mm (in)
0.03 - 0.08 (0.0012 - 0.0031) 0.1 (0.004)

NOTE
three points.
Unit: mm (in)
0.10 - 0.29 (0.0039 - 0.0114) 1.0 (0.039)

Unit: N {kgf, lbf}
When compressed to
80.71 {8.23, 18.15} —
26 mm (1.02 in)

Unit: N {kgf, lbf}
When compressed to
Left side 39.2 {4.0, 8.8} —
15.5 mm (0.610 in)
When compressed to
Right side 25.5 {2.6, 5.7} —
15.2 mm (0.598 in)
Resist spring force

Unit: N {kgf, lbf}
Left side When compressed to
29.42 {3.0, 6.62} —
Right side 36 mm (1.42 in)
TM-6-20
INSPECTION MLS62
TRANSMISSION PROPER
Unit: mm (in)
0.10 - 0.20 (0.0039 - 0.0079) 0.50 (0.0197)

Unit: mm (in)
Reverse
1st-2nd 0.20 - 0.30
0.5 (0.020)
3rd-4th (0.0079 - 0.0118)
6th-main drive

Unit: mm (in)
0.40 - 0.50
1st 0.7 (0.028)
(0.0157 - 0.0197)
2nd
3rd 0.20 - 0.30
0.5 (0.020)
4th (0.0079 - 0.0118)
6th
Reverse 0.40 - 0.50
0.7 (0.028)
Main drive (0.0157 - 0.0197)

Unit: mm (in)
— 0.5 (0.020)
TM-6-21
INSPECTION MLS62

Spring (Valve assembly) free length
Unit: mm (in)
Free length 14.1 (0.555) 13.0 (0.512)
Spring (Rod assembly) free length

Unit: mm (in)
Free length 16.3 (0.642) 15.5 (0.610)
TM-6-22
REASSEMBLY MLS62
REASSEMBLY
REASSEMBLY
others.

15 Shift shaft
inner shaft during disassembly.
13 Welch plug
Be sure to drive the cap plug while aligning it with the end face of
boss on the control cover.

1. Insert the joint ball into the bushing. Then, insert the bush-
ing into the rod and secure them with the cover and spring
pin.
NOTE
z Apply a coat of grease to joint ball and bushing.
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.
3. Insert the rod assembly (inner) into the rod.
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.
5. Secure the slider with a screw.

: 13 - 16 N·m {1.3 - 1.6 kgf·m, 9 - 12 ft·lbf}
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
7. Install the retaining ring, piston half, O-ring, X-ring, piston

half and retaining ring in that order onto the rod assembly.
Then, install the cylinder assembly and O-ring.
NOTE
ward.
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
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.
14. Center the lifter.

z Measure the clearance at both ends of the pivot and secure
the center of the lifter.
15. Install the lever.

z Insert the lever roller into the square hole in the slider and
then guide the oblong hole in the lever over the pin.
z Temporarily tighten the bracket assembly.
z Measure the forward and backward movement of the
bracket assembly and secure its center.
16. Apply sealant (Three Bond No. 1215 or equivalent) to the

O-ring and install the cover.
: 8 - 10 N·m {0.8 - 1.0 kgf·m, 5.8 - 7.2 ft·lbf}
TM-6-26
REASSEMBLY MLS62
17. Install the boot.
18. Perform air leakage test.

z When not operating
Apply an air pressure of 735.5 kPa {7.5 kgf/m2, 106.7 psi} to
the inlet port. Apply soapy water to the breather exhaust
port to make sure there is no air leakage.
z When operating
After the boot stops with the input rod pushed or pulled,
apply soapy water to the exhaust port of the breather, the
same as in not operating conditions. Make sure air leakage
is less than 11 cm3 (0.67 cu in)/min. (A bubble with a diam-
eter of 10 mm (0.39 in) is produced in about 1.5 seconds
with soapy water.)

4, 5 Steel ball & interlock pin
Be sure to install the steel ball and interlock pin in their positions.
NOTE
z Do not attempt to rotate the shaft if the interlock pin is
already installed.
9, 10, 13, 16, 17, 20, 21 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 positions are properly
clinched.
6 Welch plug
Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.
TM-6-27
REASSEMBLY MLS62
1 Reverse switch, 3 Neutral switch

Position the steel ball in the cover, and install the reverse switch
and neutral switches (if so equipped) using gaskets.

6 Key

Ensure that the protruding boss side of each gear points to the
direction in which the gear is installed.

Ensure that the protruding boss side of gear points to the rear of the
shaft.
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
MAIN SHAFT ASSEMBLY

44 Main shaft
30 3rd-4th hub assembly

1. 4th synchronizer ring 6. Detent
2. Synchronizer sleeve 7. 3rd synchronizer ring
3. Synchronizer hub assembly
4. Synchronizer spring 8. Snap ring
5. Plunger 9. 3rd gear
19 5th-6th hub assembly

2. Synchronizer ring 7. Synchronizer ring
3. Synchronizer spring 8. Synchronizer sleeve
4. Synchronizer hub 9. 6th gear
5. Strut
10 1st-2nd hub assembly

Assemble the 1st-2nd synchronizer assembly.
1. 2nd synchronizer ring 5. Plunger
assembly 6. Detent
2. Synchronizer sleeve 7. Retaining ring
3. Synchronizer hub 8. 1st gear
TM-6-29
REASSEMBLY MLS62
4, 9, 17, 24, 28, 36, 39 Retaining ring

Unit: mm (in)
Item Retaining ring
2.50 (0.0984)
39 2nd gear 2.65 (0.1043)
2.80 (0.1102)
36 3rd gear 2.80 (0.1102)
2.50 (0.0984)
24 4th gear 2.65 (0.1043)
2.80 (0.1102)
2.50 (0.0984)
9 1st-2nd synchronizer assembly 2.65 (0.1043)
2.80 (0.1102)
2.50 (0.0984)
2.80 (0.1102)
2.50 (0.0984)
2.80 (0.1102)
2.50 (0.0984)
4 Reverse hub 2.65 (0.1043)
2.80 (0.1102)
z Measure each gear's end play of the main shaft.

End play
Unit: mm (in)
1st-2nd 0.28 - 0.42 (0.0110 - 0.0165) 0.9 (0.035)
3rd 0.34 - 0.56 (0.0134 - 0.0220) 0.9 (0.035)
4th 0.06 - 0.54 (0.0024 - 0.0213) 0.9 (0.035)
6th 0.26 - 0.44 (0.0102 - 0.0173) 0.9 (0.035)
Reverse 0.26 - 0.44 (0.0102 - 0.0173) 0.7 (0.028)
1, 25, 40 Thrust washer

Install the thrust washer with the oil groove side facing the gear.
TM-6-30
REASSEMBLY MLS62
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).

transmission case.
NOTE
z Be careful not to drop the reverse gear, needle bearing
and reverse sleeve.
20 Main drive gear

1. Select the retaining ring that minimizes the hub's axial play.
The thicknesses of the available retaining rings are 2.00,
2.15 and 2.30 mm (0.0787, 0.0846 and 0.0906 in).
2. Be sure the cutout section of the synchronizer cone faces
downward.

Align the lock plate with the groove in the reverse idler shaft and
install.
15 Lock plate
Make sure the lock plate groove in the reverse idler shaft faces
upward.
3. Needle bearing
TM-6-31
REASSEMBLY MLS62
6 Pinion nut
1. When tightening the pinion nut, support the transmission
other.
3 Clutch housing assembly

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).

Maintenance standard:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
INSTALLATION
in the vehicle.
their splines.
inal positions.
TM-6-32
CONSTRUCTION MPS50
= UNIT NAME MPS50 =

CONSTRUCTION
TM-7-1
CONSTRUCTION MPS50
MAIN SHAFT ASSEMBLY
TM-7-2
DISASSEMBLY MPS50
DISASSEMBLY
REMOVAL
safe.
NOTE
TM-7-3
DISASSEMBLY MPS50
DISASSEMBLY

1. Transmission cover assembly 11. Speedometer drive gear + 19. Reverse idler shaft
2. Clutch housing assembly 12. Spacer ,+ 20. Reverse idler gear
3. O-ring ,+ 13. Main drive gear 21. Counter shaft cover
,+ 4. Bearing cap , 14. Ball bearing 22. Gasket
5. Gasket ,+ 15. Main shaft assembly 23. Retaining ring
,+ 6. Pinion nut 16. Side cover (PTO gear box: If so , 24. Spacer
7. O-ring equipped) , 25. Ball bearing
8. Companion flange 17. Gasket ,+ 26. Counter shaft assembly
+ 9. Bearing retainer 18. Lock plate 27. Transmission case
10. Gasket
TM-7-4
DISASSEMBLY MPS50
MAIN SHAFT ASSEMBLY

, 1. Thrust washer ,+ 13. Detent 25. 2nd gear
2. 1st gear ,+ 14. 4th-5th synchronizer hub 26. Needle bearing
3. Needle bearing ,+ 15. 4th synchronizer ring 27. Spacer
, 4. Retaining ring 16. 4th gear 28. Needle bearing
+ 5. Pilot bearing 17. Needle bearing 29. 2nd inner race
, 6. Lock nut 18. 4th inner race , 30. Thrust washer
, 7. Lock washer , 19. Thrust washer , 31. Reverse gear
,+ 8. Synchronizer ring 20. 3rd gear 32. Needle bearing
,+ 9. 4th-5th synchronizer sleeve 21. Needle bearing 33. 1st-reverse sleeve
,+ 10. Lock plunger 22. 3rd inner race 34. Dowel pin
,+ 11. Synchronizer spring ,+ 23. 2nd-3rd synchronizer assembly , 35. Main shaft
,+ 12. Plunger 24. 2nd-3rd hub
TM-7-5
DISASSEMBLY MPS50

, 1. Retaining ring , 4. Key ,+ 7. 3rd counter gear
2. Roller bearing 5. Spacer , 8. Key
,+ 3. Counter drive gear ,+ 6. 4th counter gear 9. Counter shaft
TM-7-6
DISASSEMBLY MPS50

+ 1. Spring 13. 4th-5th shift fork 24. 2nd-3rd shift fork
+ 2. Steel ball , 14. Interlock pin , 25. Interlock pin
3. Reverse switch 15. 4th-5th shift shaft 26. 2nd-3rd shift shaft
4. Gasket , 16. Spring pin , 27. Spring pin
+ 5. Steel ball 17. 1st-reverse shifter 28. 1st-reverse shift fork
6. Neutral switch , 18. Spring pin 29. 1st-reverse shift shaft
7. Gasket 19. 1st-reverse shifter 30. Self-locking nut
+ 8. Steel ball 20. Spring pin 31. Plain washer
,+ 9. Welch plug , 21. Spring pin 32. Locking lever shaft
,+ 10. Welch plug 22. 2nd-3rd shifter 33. 1st-reverse locking lever
11. Shift guide bolt , 23. Spring pin 34. Transmission cover
, 12. Spring pin
TM-7-7
DISASSEMBLY MPS50

1. Breather 10. Plug 19. Bushing
, 2. Lock plate , 11. Lock plate 20. Gasket
3. Shield plate 12. Checking spring , 21. Return spring
4. Guide plate 13. Steel ball 22. Shift lever
5. Spacer + 14. Welch plug , 23. Return spring
6. Retaining ring 15. Straight pin 24. Control cover
7. Thrust washer ,+ 16. Inner shaft 25. Plug
8. Select lever 17. Plate 26. Spring
9. O-ring + 18. Oil seal 27. Plunger
TM-7-8
DISASSEMBLY MPS50

NOTE
z Measure the backlash at least three equally spaced
points for each gear.
4 Bearing cap
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.
6 Pinion nut
NOTE
TM-7-9
DISASSEMBLY MPS50
9 Bearing retainer
after removal.
13 Main drive gear

ward when removing the main drive gear.
NOTE
z Do not remove the ball bearing unless necessary.

TM-7-10
DISASSEMBLY MPS50

Drive the reverse idler gear shaft out with the sliding hammer
(99547 Z0000).

Remove the needle bearing and spacer from the reverse idler gear.
Remove the O-ring from the reverse shaft.
1. Needle bearing 5. Needle bearing
2. Needle bearing 6. Reverse idler gear
3. Spacer 7. Reverse idler gear shaft
4. Needle bearing 8. O-ring

While tilting the front of the counter shaft assembly up using a hoist
and lifting wire, remove the counter shaft assembly from the trans-
mission case.
MAIN SHAFT ASSEMBLY

5 Pilot bearing
1. Place the main shaft on the work bench with the front facing
upward. Using the lock nut wrench (99809 Z0000), loosen
the lock nut all the way.
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
8-15 4th-5th synchronizer assembly (Type I)

sleeve.
2. 4th-5th hub 6. Lock plunger
3. Detent 7. 4th-5th sleeve
4. Plunger 8. Synchronizer ring
NOTE
ring for later identification.
8-15 4th-5th synchronizer assembly (Type II)

sleeve.
1. Synchronizer ring 5. Synchronizer spring (Large)
2. 4th-5th hub 6. Lock plunger
3. Detent 7. 4th-5th sleeve
4. Synchronizer spring (Small) 8. Synchronizer ring
NOTE
23 2nd-3rd synchronizer assembly

Before removing the 2nd-3rd gear synchronizer assembly from the
main shaft, mark the side face of the 3rd gear synchronizer ring.
NOTE
TM-7-12
DISASSEMBLY MPS50

z The counter shaft assembly need not be disassembled
unless gears are replaced due to wear or damage to gear
teeth, etc.
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the countershaft on the
floor.

NOTE
z Before removing the shaft, set each interlock pin to the
neutral position. Failure to do so may cause the interlock
pin and steel ball to interfere with the transmission cover
during shaft removal.
z Do not attempt to forcefully hammer the shaft as shift
forks, shifters, etc. may be hard to remove.
1, 2 Locking spring and steel ball
Be careful not to lose locking spring and steel ball.
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.

14 Welch plug
16 Inner shaft
Place an alignment mark on the shift lever and inner shaft before
removal.
18 Oil seal
21, 23 Return spring

Tag the left and right resist springs for identification.
TM-7-14
INSPECTION MPS50
INSPECTION

Clearance between shift lever and select lever
Unit: mm (in)
Shift lever
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
Select lever
Radial play between shaft and shift lever splines

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Unit: mm (in)
Shift lever
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
Each shifter

Clearance between 1st-reverse locking lever and lever
shaft
Unit: mm (in)
0.04 - 0.08 (0.0016 - 0.0031) 0.2 (0.008)
TM-7-15
INSPECTION MPS50
Clearance between locking lever and shifter

Unit: mm (in)
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

NOTE
three points.
Unit: mm (in)
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)
Shift fork shaft locking spring

Unit: mm (in)
41.0 - 44.0
Free length —
(1.614 - 1.732)
Unit: N {kgf, lbf}

When com-
163.8 - 193.2 163.8
Tension pressed to 26.9
{16.7 - 19.7, 36.8 - 43.4} {16.7, 36.8}
mm (1.059 in)
Main gear and counter gear backlash
Unit: mm (in)
0.1 - 0.2 (0.004 - 0.008) 0.5 (0.020)
TM-7-16
INSPECTION MPS50
Radial play between hub (incl. main shaft) and sleeve

splines
Unit: mm (in)
0.2 - 0.3 (0.008 - 0.012) 0.5 (0.020)

Unit: mm (in)
0.2 - 0.3
2nd-5th or 6th
(0.008 - 0.012)
1.0 (0.039)
0.4 - 0.5
1st-Reverse
(0.016 - 0.020)
Clearance between 5th bushing and 5th gear

Unit: mm (in)
0.10 - 0.14
— Overdrive mechanism
(0.0039 - 0.0055)

Unit: mm (in)
— 0.5 (0.020)
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)
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc
<Lock plunger type>

Clearance between synchronizer ring and their cone
Unit: mm (in)
1.6 - 2.5 (0.063 - 0.098) —
Tangential clearance between synchronizer ring and

synchronizer hub
Unit: mm (in)
5.3 - 5.7 (0.209 - 0.224) —
Radial clearance between synchronizer hub and syn-

chronizer detent
Unit: mm (in)
0.05 - 0.35 (0.0020 - 0.0138) —
TM-7-18
INSPECTION MPS50
Detent spring
Unit: N {kgf, lbf}
Maintenance
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
6.6 - 7.9} When compressed to

6.4 - 7.8 12 mm (0.47 in)
*1 {0.65 - 0.8,
1.4 - 1.8}
B 4.9 {0.5, 1.1}
5.9 - 7.4
*3 {0.6 - 0.75,
1.3 - 1.7}
40.31 - 44.62
40.31
A *2 {4.11 - 4.55,
{4.11, 9.06}
Tension
Type III
9.06 - 10.03} When compressed to

10.30 - 11.47 11.07 mm (0.4358 in)
10.30
B *3 {1.05 - 1.17,
{1.05, 2.32}
2.32 - 2.58}
NOTE
z Identification paint
*1: Without *2: Blue *3: White
TM-7-19
REASSEMBLY MPS50
REASSEMBLY
REASSEMBLY
others.
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

14, 25 Interlock pin
Do not attempt to rotate the shaft if the interlock pin is already
installed.
12, 16, 18, 21, 23, 27 Spring pin

Face the groove of the spring pin in the axial direction when install-
ing the spring pin in the shift fork shaft and shifter shaft.
9, 10 Welch plug
Be careful not to damage the plug.

4, 8 Key
TM-7-21
REASSEMBLY MPS50
6, 7 3rd, 4th counter gear

Face the boss portion which protrudes from the side of the gear
toward the gear inserting side and press the 3rd and 4th counter
gears onto the counter shaft.

Face the chamfered side of the counter drive gear (at the boss
location) toward the counter shaft.
1 Retaining ring
Make sure the retaining ring is fitted into the groove properly.
MAIN SHAFT ASSEMBLY

35 Main shaft
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.
23 2nd-3rd synchronizer assembly

Ensure the synchronizer assembly is positioned so that the mark
scribed during disassembly faces the appropriate side when install-
ing.
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.
15 4th synchronizer ring

The protruding end should face upward.
14 4th-5th synchronizer hub

With the oil groove in the synchronizer hub facing down, align the
three cutout sections (detents) with the three protruding points of
the synchronizer ring.
TM-7-23
REASSEMBLY MPS50
8-15 4th-5th synchronizer assembly

Ensure that the wide end of the detent coincides with the rotating
direction of the synchronizer hub.
9 4th-5th synchronizer sleeve

Be careful not allow the lock plunger to fall out of the detent assem-
bly.
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.

NOTE
z Measure the end play of the 1st gear after installing the
main shaft assembly in the transmission case.
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

Install the needle bearing and spacer on the reverse idler gear.
Install the O-ring on the reverse shaft.
1. Needle bearing 5. Needle bearing
2. Needle bearing 6. Reverse idler gear
3. Spacer 7. Reverse idler gear shaft

transmission case.
14 Ball bearing
Drive the ball bearing until it reaches the “butt-up” point.
13 Main drive gear

1. Face the cutout section of the synchronizer cone downward
and drive the gear assembly until it contacts the retaining
ring.
2. While rotating the main drive gear assembly and aligning it
with the cone, drive it into place until it touches the retaining
ring.
6 Pinion nut
1. Secure the transmission case to prevent it from turning
when tightening the pinion nut.
TM-7-26
REASSEMBLY MPS50
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
in the vehicle.
their splines.
inal positions.
TM-7-27
CONSTRUCTION MPS62
= UNIT NAME MPS62 =

CONSTRUCTION
TM-8-1
CONSTRUCTION MPS62
MAIN SHAFT ASSEMBLY
TM-8-2
CONSTRUCTION MPS62
TM-8-3
DISASSEMBLY MPS62
DISASSEMBLY
REMOVAL
safe.
NOTE
TM-8-4
DISASSEMBLY MPS62
DISASSEMBLY

1. Transmission cover assembly 11. Speedometer drive gear ,+ 20. Main shaft assembly
2. Clutch housing assembly 12. Side cover 21. Retaining ring
,+ 3. Bearing cap 13. Welch plug , 22. Spacer
4. Gasket 14. Setscrew , 23. Roller bearing
+ 5. Pinion nut + 15. Reverse idler shaft ,+ 24. Counter shaft assembly
6. Plain washer 16. Spacer ,+ 25. Roller bearing
7. O-ring , 17. Reverse idler gear , 26. Counter plug
8. Companion flange + 18. Main drive gear 27. Transmission case
+ 9. Bearing retainer 19. Ball bearing 28. Transmission case
10. Speedometer gear
TM-8-5
DISASSEMBLY MPS62
MAIN SHAFT ASSEMBLY

, 1. Thrust washer 17. Needle bearing + 33. Inner race
2. 1st gear , 18. Reverse sleeve 34. Thrust washer
3. Needle bearing 19. Synchronizer cone 35. 4th gear
4. Inner race , 20. Retaining ring 36. Needle bearing
5. Synchronizer ring (If so equipped) , 21. Pilot bearing 37. Inner race
6. 1st-2nd sleeve , 22. Lock nut 38. Synchronizer ring
7. Detent , 23. Lock washer 39. 3rd-4th sleeve
8. Lock plunger 24. Synchronizer ring 40. Detent
9. Synchronizer spring 25. 5th-6th sleeve 41. Lock plunger
,+ 10. 1st-2nd synchronizer assembly 26. Detent 42. Synchronizer spring
11. Synchronizer ring assembly 27. Lock plunger ,+ 43. 3rd-4th synchronizer assembly
12. 2nd gear 28. Synchronizer spring 44. Synchronizer ring assembly
13. Needle bearing ,+ 29. 5th-6th synchronizer assembly 45. 3rd gear
+ 14. Inner race 30. Synchronizer ring 46. Needle bearing
15. Thrust washer 31. 5th gear 47. Inner race
16. Reverse gear 32. Needle bearing 48. Main shaft
TM-8-6
DISASSEMBLY MPS62

1. Roller bearing inner race , 4. Key , 7. Key
, 2. Retaining ring ,+ 5. 5th counter gear 8. Counter shaft
,+ 3. Counter drive gear ,+ 6. 4th counter gear 9. Roller bearing inner race
TM-8-7
DISASSEMBLY MPS62

+ 1. Locking spring , 11. Reverse shifter ,+ 21. Steel ball
,+ 2. Steel ball 12. Spacer , 22. 3rd-4th shifter
, 3. Reverse switch , 13. Reverse shift fork , 23. 3rd-4th shift fork
4. Gasket ,+ 14. Interlock pin , 24. Interlock pin
,+ 5. Steel ball 15. Reverse shift shaft 25. 3rd-4th shift shaft
, 6. Neutral switch ,+ 16. Steel ball ,+ 26. Steel ball
7. Gasket , 17. 1st-2nd shifter , 27. 3rd-4th shift fork
,+ 8. Steel ball , 18. 1st-2nd shift fork 28. 3rd-4th shift shaft
,+ 9. Welch plug ,+ 19. Interlock pin 29. Transmission cover
,+ 10. Welch plug 20. 1st-2nd shift shaft
TM-8-8
DISASSEMBLY MPS62
TRANSMISSION CONTROL COVER ASSEMBLY (TYPE I)

1. Breather 8. Oil seal 14. Spring seat
2. Bolt 9. Plug 15. Shift lever
3. Shield plate ,+ 10. Cap plug 16. Spring seat
4. Guide plate 11. Straight pin ,+ 17. Resist spring
5. Retaining ring ,+ 12. Inner shaft + 18. Oil seal
6. Thrust washer ,+ 13. Resist spring 19. Control cover
7. Select lever
TM-8-9
DISASSEMBLY MPS62
TRANSMISSION CONTROL COVER ASSEMBLY (TYPE II)

1. Push joint 11. Oil seal ,+ 21. Resist spring
2. Power shift assembly 12. Select lever 22. Seat
3. Lock washer 13. Straight pin ,+ 23. Resist spring
4. Guide plate 14. Plug 24. Plug
5. Nut 15. Spring 25. Plunger spring
6. Shift lever 16. Steel ball 26. Plunger
7. Spacer ,+ 17. Cap plug 27. Control cover
8. Lever shaft ,+ 18. Shift shaft 28. Breather
9. Retaining ring 19. Shift lever + 29. Oil seal
10. Washer 20. Seat
TM-8-10
DISASSEMBLY MPS62
, 1. Cylinder boots 18. Lifter ring 35. Cylinder O-ring

2. Connector nut ,+ 19. Seat seal assembly + 36. Cylinder packing
3. Cylinder connector 20. O-ring 37. Rod plate
4. Retaining ring 21. Seal spring 38. Cap packing
+ 5. Retaining ring plate 22. O-ring 39. Striker
6. Straight pin ,+ 23. Seat seal assembly 40. Piston ring
7. Tube filter 24. Spring seat 41. Piston
8. Tube collar 25. Lifter ring , 42. Piston packing
9. Tube 26. Lifter spring 43. Piston O-ring
10. Lifter ring 27. Lifter 44. Piston ring
11. O-ring 28. Lifter O-ring 45. Rod pipe
, 12. Tube ring 29. Tube 46. Housing hose clamp
13. Rod pipe plate 30. Lifter ring 47. Housing hose
14. Lifter 31. Rod pipe 48. Housing boot clamp
15. Lifter O-ring , 32. Rod cap assembly 49. Housing boot
16. Lifter spring , 33. Housing setscrew 50. Housing
17. Spring seat 34. Cylinder
NOTE
TM-8-11
DISASSEMBLY MPS62

NOTE
z Measure the backlash at least three equally spaced
points for each gear.
3 Bearing cap
after removal.
5 Pinion nut
NOTE
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.

Remove the idler gear using sliding hammer (99547 Z0000).
18 Main drive gear

Do not remove the roller bearing unless necessary.

NOTE
z Be careful not to drop the synchronizer ring and syn-
chronizer cone into the transmission case.

TM-8-13
DISASSEMBLY MPS62

While tilting the front of the counter shaft assembly up using a hoist
and lifting wire, remove the counter shaft assembly from the trans-
mission case.
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.
MAIN SHAFT ASSEMBLY

10 1st-2nd synchronizer assembly
sleeve.
1. Synchronizer ring assembly 4. Detent
2. Lock plunger 5. 1st-2nd sleeve
3. Synchronizer spring 6. Synchronizer hub
NOTE
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

sleeve.
2. Synchronizer ring 6. Detent
3. 5th-6th sleeve 7. Synchronizer hub
4. Lock plunger 8. Synchronizer ring
NOTE
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.

sleeve.
2. 3rd-4th sleeve 6. Double synchronizer ring
3. Lock plunger assembly

z The counter shaft assembly need not be disassembled
unless gears are replaced due to wear or damage to gear
teeth, etc.
TM-8-15
DISASSEMBLY MPS62
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the counter shaft on the
floor.

z Before removing the shaft, set each interlock pin to the neu-
tral position. Failure to do so may cause the interlock pin
and steel ball to interfere with the transmission cover during
shaft removal.
z Do not attempt to forcefully hammer the shaft as shift forks,
shifters, etc. may be hard to remove.
1, 2 Locking spring and steel ball

Be careful not to lose locking spring and steel ball.
5, 8, 16, 21, 26 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.
9, 10 Welch plug
Make sure that the welch plug is driven out together with the shift
fork shaft.
TM-8-16
DISASSEMBLY MPS62

10 Type I
17 Type II }
Cap plug
12 Type I: Inner shaft

18 Type II: Shift shaft
Place an alignment mark on the shift lever and inner shaft before
removal.
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
old oil seal, and install a new one.

5 Retaining ring plate
Remove the retaining ring and retaining ring plate. Using the puller
assembly (910-11150, JKC NO.) pull out the straight pin.
TM-8-17
DISASSEMBLY MPS62
19, 23 Seat seal assembly

Remove the valve assembly.
NOTE
z Be careful not to damage spring seat and lifter ring dur-
ing removal.
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
CONTROL COVER ASSEMBLY

Clearance between shift lever and select lever
Unit: mm (in)
Shift lever 0.1 - 0.5
0.8 (0.031)
Select lever (0.004 - 0.020)
Radial play between shaft and shift lever splines

Unit: mm (in)
0.01 - 0.09 (0.004 - 0.0035) 0.5 (0.020)

Unit: mm (in)
Shift lever 0.7 - 1.0
1.5 (0.059)
Each shifter (0.028 - 0.039)

NOTE
three points.
Unit: mm (in)
0.10 - 0.29 (0.0039 - 0.0114) 1.0 (0.039)
TM-8-19
INSPECTION MPS62
Shift fork shaft locking spring

Unit: mm (in)
41.0 - 44.0
Free length —
(1.614 - 1.732)
Unit: N {kgf, lbf}

157 - 196 When compressed to
Tension 127 {13, 29}
{16 - 20, 35 - 44} 27 mm (1.06 in)
Main gear and counter gear backlash
Unit: mm (in)
0.09 - 0.19 (0.0035 - 0.0075) 0.5 (0.020)
Radial play between hub (incl. main shaft) and sleeve

splines
Unit: mm (in)
0.2 - 0.3
Except 5th & 6th
(0.008 - 0.012)
0.5 (0.020)
0.07 - 0.34
5th & 6th only
(0.0028 - 0.0134)

Unit: mm (in)
0.4 - 0.5 (0.016 - 0.020) 1.0 (0.039)
Ball bearing axial direction play

Unit: mm (in)
— 0.5 (0.020)
TM-8-20
INSPECTION MPS62
SYNCHRONIZER SYSTEM (LOCK PLUNGER TYPE)

Clearance between synchronizer ring and their cone
Unit: mm (in)
Maintenance
standard
1.7 - 2.3
Outer ring-
(0.067 - — Measure a
Double cone inner ring
0.091) set includ-
type (2nd-
0.8 - 1.2 ing three
3rd) Cone-inner
(0.031 - — parts.
ring
0.047)
1.5 - 2.5
Single cone type (4th-6th) (0.059 - —
0.098)
Radial clearance between synchronizer ring and syn-

chronizer hub
Unit: mm (in)
Maintenance
standard
6.4 - 6.8
Double cone type (2nd-3rd) (0.252 -
0.268)
The wear
6.9 - 7.3
limit is speci-
4th (0.272 - 1.0 (0.039)
Single cone fied as a sin-
0.287)
type (4th- gle ring.
6th) 4.9 - 5.3
5th-6th (0.193 -
0.209)
Radial clearance between synchronizer hub and syn-

chronizer detent
Unit: mm (in)
0.1 - 0.3
2nd-6th —
(0.004 - 0.012)
TM-8-21
INSPECTION MPS62
Synchronizer spring
Unit: N {kgf, lbf}
Maintenance
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
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.
Valve seal dent depth

Unit: mm (in)
0.15 (0.0059), max. —
TM-8-22
REASSEMBLY MPS62
REASSEMBLY
REASSEMBLY
others.

42 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.
33 Housing setscrew
Install the housing setscrew and clinch in two locations.
32 Rod cap assembly

Apply air master paste to various parts. Place a tube rod of 10 to
11.5 mm (0.394 to 0.453 in) in diameter in a vise.
Install the rod pipe and tube on the rod cap assembly, and pass the
assembled unit through the hole in the rod.
19, 23 Seat seal assembly

Install the O-ring on the lifter, the lifter ring on the spring seat and
the O-ring on the seat seal assembly.
1. Lifter 5. Lifter ring
2. Lifter O-ring 6. Seat seal assembly
3. Lifter spring 7. O-ring
4. Spring seat
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.

12 Type I: Inner shaft
18 Type II: Shift shaft
inner shaft (or shift shaft) during disassembly.
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.

2, 5, 8, 14, 16, 19, 21, 24, 26 Steel ball & interlock pin
1. 5th-6th fork shaft 6. 3rd-4th fork shaft
2. Steel ball 7. Reverse fork shaft
3. Lock spring 8. 1st-2nd fork shaft
5. Interlock pin
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.
3 Reverse switch, 6 Neutral switch

Position the steel ball in the cover, and install the backup light and
neutral switches (if so equipped) using gaskets.

6 4th counter gear
Make sure that the 4th counter gear is installed with the boss (pro-
truding beyond the gear surface) side toward the front of the
counter shaft.
5 5th counter gear

Make sure that the 5th counter gear is installed with the boss (pro-
truding beyond the gear surface) side toward the rear of the counter
shaft.
4, 7 Key
TM-8-26
REASSEMBLY MPS62

Make sure that the counter drive gear is installed with the boss
(protruding beyond the gear surface) side toward the rear of the
counter shaft.
2 Retaining ring
Make sure that the retaining ring is fitted into the groove.
MAIN SHAFT ASSEMBLY

z Mount the main shaft on a mounting stand, or in a vise, with
the front of the shaft facing upward.

Make sure that the splined side of the sleeve (shown by “C” in the
figure) faces in the same direction as the non-splined side of the
hub when installing the sleeve into the hub.
2. 3rd-4th sleeve 6. Double synchronizer ring
3. Lock plunger assembly
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

Reassemble the 5th-6th synchronizer assembly.
3. 5th-6th sleeve 7. Synchronizer hub
4. Lock plunger 8. Synchronizer ring
NOTE
z Make sure that synchronizer assembly is installed with
the oil groove side facing the 5th gear.
22, 23 Lock nut and lock washer

Bend two adjacent tongues of the lock washer.
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.
10 1st-2nd synchronizer assembly

Make sure that the splined side of the sleeve (shown by “A” in the
figure) faces in the same direction as the non-splined side of the
hub during installation.
1. Synchronizer ring assembly 4. Detent
2. Lock plunger 5. 1st-2nd sleeve
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
z Measure each gear end play on the mainshaft.

NOTE
z Be sure to measure the 1st gear end play with main shaft
installed in the transmission case.
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.

Install the counter shaft assembly in the transmission case using a
hoist and lifting wire.
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).

transmission case.
NOTE
z Be extremely careful not to drop the synchronizer cone
and ring.
z Remove the lifting wire after installing the main drive
gear.

Install the reverse idler gear on the transmission case using a thrust
washer. Insert the reverse idler gear shaft into the bore of the
reverse idler gear and secure with the setscrew.
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.

measure the backlash in each gear on the main shaft to
ensure that it is within maintenance standard.
TM-8-31
REASSEMBLY MPS62
INSTALLATION
in the vehicle.
their splines.
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
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
VACUUM SHIFT TYPE
TM-1-5
CONSTRUCTION PTO
CONSTRUCTION
AIR SHIFT TYPE
Type I
Type II
TM-2-1
CONSTRUCTION PTO
Types III-a and V-a
Type IV-a
TM-2-2
CONSTRUCTION PTO
Types III-b and V-b
Type IV-b
TM-2-3
CONSTRUCTION PTO
VACUUM SHIFT TYPE

Type I
Types II and III
TM-2-4
DISASSEMBLY PTO
DISASSEMBLY
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)
z Measure and record the backlash of the counter shaft 4th

gear and idler gear. (Air shift types III, IV, V and vacuum
shift types II and III)
TM-3-1
DISASSEMBLY PTO
DISASSEMBLY
AIR SHIFT TYPE
Type I

1. Nut 9. Gasket , 16. Retaining ring
2. Lock plate 10. Return spring ,+ 17. PTO gear
3. Plain washer 11. Cylinder ,+ 18. PTO shaft
4. Key 12. O-ring + 19. Shift fork
5. Rear bearing cover 13. Ball bearing 20. O-ring
+ 6. Oil seal 14. PTO sleeve 21. PTO case
7. Gasket 15. Ball bearing 22. Gasket
8. Front bearing cover
TM-3-2
DISASSEMBLY PTO
Type II

1. Switch 11. Front bearing cover 20. Air cylinder
2. Steel ball 12. Gasket 21. X-ring
3. Flange nut 13. Rear ball bearing 22. Piston
4. Lock washer 14. Front ball bearing 23. Setscrew
5. Tab 15. PTO gear + 24. Shift fork
6. Companion flange ,+ 16. PTO shaft 25. Shift shaft
7. Key 17. Cap 26. Return spring
8. Rear bearing cover 18. Cylinder cap 27. PTO case
9. Gasket 19. Gasket 28. Gasket
+ 10. Oil seal
TM-3-3
DISASSEMBLY PTO
Type IV

1. Nut 12. Return spring 23. Ball bearing
2. Lock plate 13. Cylinder 24. PTO sleeve
3. Tab 14. O-ring , 25. Roller bearing
4. Key 15. Lock plate , 26. Retaining ring
5. Rear bearing cover 16. Idler shaft 27. PTO gear
6. Gasket 17. Idler gear 28. PTO shaft
+ 7. Oil seal 18. Roller bearing 29. Shift fork
8. Retaining ring 19. Inner spacer , 30. X-ring
9. Rear ball bearing 20. Plain washer 31. Gasket
10. Front bearing cover 21. Needle bearing 32. PTO case
11. Gasket 22. Spacer
TM-3-4
DISASSEMBLY PTO
Types III and V

1. Nut 11. O-ring 21. Ball bearing
2. Lock plate 12. Cylinder 22. PTO sleeve
3. Tab 13. Lock plate , 23. Roller bearing
4. Key 14. Idler shaft , 24. Retaining ring
5. Rear bearing cover 15. Spacer ,+ 25. PTO gear
+ 6. Oil seal 16. Needle bearing 26. PTO shaft
7. Gasket 17. Plate , 27. X-ring
8. Front bearing cover ,+ 18. Idler gear 28. Shift fork
9. Gasket 19. Roller bearing 29. PTO case
10. Return spring 20. Spacer
TM-3-5
DISASSEMBLY PTO
VACUUM SHIFT TYPE

Type I

1. Nut 10. Return spring 19. Lock washer
2. Lock plate 11. Front ball bearing , 20. Plain washer
3. Plain washer 12. PTO sleeve 21. Plate
4. Key 13. Rear ball bearing 22. Diaphragm
5. Rear bearing cover , 14. Retaining ring 23. Plain washer
6. Gasket 15. PTO gear 24. O-ring
+ 7. Oil seal ,+ 16. PTO shaft ,+ 25. Shift fork
8. Front bearing cover 17. Cotter pin 26. PTO case
, 9. O-ring 18. Castellated nut
TM-3-6
DISASSEMBLY PTO
Types II and III

1. Nut 12. Idler shaft 23. Cotter pin
2. Lock plate 13. Thrust washer 24. Castellated nut
3. Tab 14. Idler gear 25. Lock washer
4. Key 15. Roller bearing , 26. Plain washer
5. Rear bearing cover 16. Spacer 27. Plate
6. Gasket 17. Front ball bearing 28. Diaphragm
+ 7. Oil seal 18. PTO sleeve 29. Plain washer
8. Front bearing cover ,+ 19. Rear ball bearing 30. O-ring
, 9. O-ring , 20. Snap ring 31. Shift fork
10. Return spring 21. PTO gear 32. PTO case
11. Lock plate ,+ 22. PTO shaft
TM-3-7
DISASSEMBLY PTO
AIR SHIFT TYPE (TYPES I AND II)

z Measure and record the PTO gear end play.
6 (Type I)
10 (Type II) } Oil seal
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.
AIR SHIFT TYPE (TYPES III, IV AND V)

z Measure and record the backlash of idler gear and PTO
gear.
z Measure and record the idler gear end play.
TM-3-8
DISASSEMBLY PTO
6 (Types III and V)

7 (Type IV) } Oil seal
VACUUM SHIFT TYPE (TYPE I)

z Measure and record the PTO gear end play.
7 Oil seal
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
VACUUM SHIFT TYPE (TYPES II AND III)

z Measure and record the backlash of idler gear and PTO
gear.
z Measure and record the idler gear end play.
7 Oil seal
19 Rear ball bearing

1. Tap the front end of the PTO shaft until the groove of the
rear ball bearing is exposed at the bore in the PTO case.
2. Attach the bearing remover to the groove of the rear ball
bearing and drive the bearing out.
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
Gear backlash (Idler gear and PTO gear)

Unit: mm (in)
Application Maintenance standard Service limit
Type I 0.1 - 0.2 (0.004 - 0.008) 0.35 (0.0138)
0.15 - 0.25
Type II 0.5 (0.020)
(0.0059 - 0.0098)
Air shift type
Type III
Type IV 0.1 - 0.2 (0.004 - 0.008) 0.35 (0.0138)
Type V
Type I
Vacuum shift
Type II 0.1 - 0.2 (0.004 - 0.008) 0.35 (0.0138)
type
Type III
(Counter shaft 4th gear and idler gear)

Unit: mm (in)
Type III
Air shift type Type IV
Type V 0.1 - 0.2 (0.004 - 0.008) 0.35 (0.0138)
Vacuum shift Type II
type Type III
PTO gear end play

Unit: mm (in)
Air shift type Type I
0.25 - 0.79
Vacuum shift 1.1 (0.043)
Type I (0.0098 - 0.0311)
type
TM-4-1
INSPECTION PTO
Idler gear end play

Unit: mm (in)
Type III
0.25 - 0.52
Air shift type Type IV 0.8 (0.031)
(0.0098 - 0.0205)
Type V
Vacuum shift Type II 0.23 - 0.47
0.7 (0.028)
type Type III (0.0091 - 0.0185)

Unit: mm (in)
Type I
Type III 0.03 - 0.12
—
Type IV (0.0012 - 0.0047)
Air shift type
Type V
0.08 - 0.15
Type II 0.2 (0.008)
(0.0031 - 0.0059)
Clearance between case and cylinder

Unit: mm (in)
Type I
Type III
Air shift type 0 - 0.07 (0 - 0.0028) —
Type IV
Type V
Clearance between case and shift fork

Unit: mm (in)
Type I
Vacuum shift 0.03 - 0.09
Type II 0.11 (0.0043)
type (0.0012 - 0.0035)
Type III
TM-4-2
INSPECTION PTO
Clearance between shift fork and sleeve

Unit: mm (in)
Type I
Type III 0.05 - 0.95
Air shift type 1.4 (0.055)
Type IV (0.0020 - 0.0374)
Type V
Type I
Type II 1.4 (0.055)
type (0.0020 - 0.0374)
Type III
Radial play between PTO shaft and PTO gear spline

Unit: mm (in)
0.45 - 0.54
Type I 0.7 (0.028)
(0.0177 - 0.0213)
0.07 - 0.14
Type II 0.3 (0.012)
Air shift type (0.0028 - 0.0055)
Type III
0.40 - 0.50
Type IV 0.7 (0.028)
(0.0157 - 0.0197)
Type V
Type I
Type II 0.7 (0.028)
type (0.0157 - 0.0189)
Type III
Radial play between PTO shaft and sleeve spline

Unit: mm (in)
0.45 - 0.54
Type I 0.7 (0.028)
(0.0177 - 0.0213)
Air shift type Type III
0.20 - 0.30
Type IV 0.7 (0.028)
(0.0079 - 0.0118)
Type V
Type I
Type II 0.7 (0.028)
type (0.0157 - 0.0189)
Type III
TM-4-3
INSPECTION PTO
Clearance between PTO case and shift shaft

Unit: mm (in)
0.02 - 0.07
Air shift type Type II 0.2 (0.008)
(0.0008 - 0.0028)
Clearance between shift fork and shift shaft

Unit: mm (in)
Air shift type Type II 0 - 0.05 (0 - 0.0020) 0.2 (0.008)
Clearance between shift fork and PTO gear

Unit: mm (in)
0.1 - 0.3
Air shift type Type II 1.0 (0.039)
(0.004 - 0.012)
Return spring free length

Unit: mm (in)
Type I 50 (1.97) —
Type II 80 (3.15) —
Air shift type Type III
Type IV 50 (1.97) —
Type V
Type I
Vacuum shift
Type II 60 (2.36) —
type
Type III
TM-4-4
INSPECTION PTO
Return spring tension

Unit: N {kgf, lbf}
Maintenance
Application Service limit Remarks
standard
35.70 - 45.50 When compressed
{3.64 - 4.64, to 32.75 mm
8.03 - 10.23} (1.2894 in)
Type I —
{5.56 - 6.56, to 24.75 mm
12.26 - 14.46} (0.9744 in)
186.3 - 225.6
Air shift 147.1 When compressed
Type II {19 - 23,
type {15, 33.1} to 39 mm (1.54 in)
41.9 - 50.7}
{3.64 - 4.64, to 32.75 mm
Type III 8.03 - 10.23} (1.2894 in)
Type IV —
Type V 54.53 - 64.33 When compressed
{5.56 - 6.56, to 24.75 mm
12.26 - 14.46} (0.9744 in)
38.44 - 48.25
When compressed
{3.92 - 4.92,
Type I to 38 mm (1.50 in)
Vacuum 8.64 - 10.85}
Type II —
shift type 53.94 - 63.75
Type III When compressed
{5.50 - 6.50,
to 30 mm (1.18 in)
12.13 - 14.33}
Ball bearing axial direction play

Unit: mm (in)
Maintenance
Application Service limit Remarks
standard
Type I
Type II
Air shift type Type III — 0.5 (0.020) One side
Type IV
Type V
Type I
Vacuum shift
Type II — 0.5 (0.020) One side
type
Type III
TM-4-5
REASSEMBLY PTO
REASSEMBLY
REASSEMBLY
AIR SHIFT TYPE (TYPES I AND II)
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.
16 (Type I) 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.
z Measure the PTO gear end play.
Unit: mm (in)
Air shift type Type I 0.25 - 0.79 (0.0098 - 0.0311) 1.1 (0.043)
AIR SHIFT TYPE (TYPES III, IV AND V)

27 (Types III and V)
30 (Type IV) } X-ring
Install the X-ring onto the PTO case.
NOTE
z Be careful not to twist the X-ring.

26 (Type IV) } Retaining ring
Do not expand the retaining ring excessively when installing. After
installing the retaining ring, ensure it is properly placed into the
groove in the PTO shaft.
TM-5-1
REASSEMBLY PTO

25 (Type IV) }Roller bearing
Install the roller bearing inner race, after installing the roller bearing
outer race.
NOTE
z Be careful not to bend the retaining ring.
z Measure the backlash of the idler gear and PTO gears.
z Measure the idler gear end play.

Unit: mm (in)
Type III 0.25 - 0.52 (0.0098 - 0.0205) 0.8 (0.0031)
Air shift type Type IV 0.25 - 0.52 (0.0098 - 0.0205) 0.8 (0.0031)
Type V 0.25 - 0.52 (0.0098 - 0.0205) 0.8 (0.0031)
VACUUM SHIFT TYPE (TYPE I)

25 Shift fork
If a cutout is provided on the shift fork thread and plate hole, align
them.
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.
z Measure the PTO gear end play.

Unit: mm (in)
Vacuum shift type Type I 0.25 - 0.79 (0.0098 - 0.0311) 1.1 (0.043)
VACUUM SHIFT TYPE (TYPES II AND III)

26 Plain washer
Make sure the outer edge of the plain washer is facing away from
the diaphragm.
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.
19 Rear ball bearing

Install the ball bearing with its outer groove facing the cover side.
NOTE
z Be careful not to bend the retaining ring.
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.
z Measure the backlash of the idler gear and PTO gears.
z Measure the idler gear end play.

Unit: mm (in)
Maintenance
Application Service limit
standard
Type II 0.23 - 0.47
Vacuum shift type 0.7 (0.028)
Type III (0.0091 - 0.0185)
TM-5-4
REASSEMBLY PTO
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
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)
z Measure and record the backlash of the counter 4th gear

and idler gear. (Air shift types III, IV, V and vacuum shift
types II and III)
Unit: mm (in)
Maintenance stan-
dard
Type III
Air shift type Type IV
0.1 - 0.2
Type V 0.35 (0.0138)
(0.004 - 0.008)
Type II
Vacuum shift type
Type III
z Test air tightness and operating load.

Pour soapy water over the connections of the air cylinder.
Apply an air pressure of 490 to 736 kPa {5.0 to 7.5 kgf/cm2,
71 to 107 psi} to the connections to check for signs of leak-
age. Also check the air shift mechanism for smooth move-
ment.
NOTE
z Perform this test 30 minutes or more after the air cylinder
has been installed.
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
UNIT NAME MPS SERIES
TM-1-2
CONSTRUCTION
UNIT NAME EATON 6109 WITH FE ENGINE
TM-1-3
CONSTRUCTION
UNIT NAME EATON 6109 WITH NE ENGINE
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
PRECAUTIONS DURING INSTALLATION

1. Ensure the control cable and control rod are set to specified
dimensions as indicated.
Control cable:
Dimension A (Cab side)
Dimension B (Transmission side)
Control rod:
Dimension (L)
2. Do not handle the boot with your bare hand, or strike the
boot on any adjacent parts during installation.
3. Do not twist the control cable boot on the transmission end

of the cable.
TM-2-2
REASSEMBLY
4. Do not sharply bend the end of the control cable.
5. Route the transmission control cable so that the bending

radius (R) is more than 200 mm (7.87 in) on the select
cable, and more than 250 mm (9.84 in) on the shift cable.
6. When the control rod is removed, install the cross shift and
shift lever in the positions shown in the figure.
7. When installing the control cable, align the mark on the

cable with the clip shown in the figure. Lay the cable so that
there are not twists. Then secure the cables with clips.
NOTE
z Clamp the control cable with a clip so that the white mark
is in the center of the clip.
TM-2-3
REASSEMBLY
8. When installing the control cable onto the change lever, be

careful not to twist the cable.
Install the grommet so that the mark on it faces the front of
the vehicle. Secure the grommet with the lock plate.
NOTE
z Use a new lock plate; do not reuse.
CONTROL CABLE ADJUSTMENT

z When removing and installing the transmission, adjust as
follows if shift position is not clear or shifting cannot be done
smoothly in the neutral position.
1. Make sure the change lever inside the vehicle is correctly in
the neutral position.
TM-2-4
REASSEMBLY
2. If the change lever is not in the neutral position, remove the

cable from the select lever and, shift the select lever in the
neutral position.
Then, lightly push the ball joint of the select cable toward
the front of the vehicle and make sure the ball joint aligns
with the select lever hole.
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.
4. After adjusting location, connect the ball joint and select

lever. Make sure they operate properly.
5. After ensuring operation, release the change lever to make
sure it returns automatically to the neutral position (3 and 4
speed column).
Under this condition, make sure shifting can smoothly be
done into the 3 and 4 speed positions.
6. If it is not possible to shift smoothly, slightly push the
change lever to the 1 and 2 speed column or 3 and 4 speed
column. Then, make sure shifting can be done smoothly
into the 3 speed or 4 speed position the same as described
above.
NOTE
z If shifting into the 3 or 4 speed gear position can be done
smoothly with the change lever pushed to the 1 and 2
speed column, the select cable adjustment is a little
short.Readjust the select cable in the same manner as
shown in step 3 in the direction where it lengthens. (If
this is not the case, adjust the select cable in the direc-
tion where it shortens.)
7. The forward-backward distance of the change lever neutral

position in the vehicle must be 272 mm (10.71 in) (from the
rear of the instrument panel to the center of the knob).
TM-2-5
REASSEMBLY
8. Before adjusting the change lever forward and backward,

adjust the length of the control rod that is connected to the
shift lever on the transmission side.
NOTE
z Remove the rod before adjusting the control rod (ball
joint on both ends).
9. After adjustment, make sure the change lever operates

smoothly without twist, drag, interference or abnormal noise
in all operating ranges. Also, the change lever should shift
securely and should not go out of gear.
Make sure the change lever securely returns to the neutral
position (3 and 4 speed column) when it is released after
being moved towards shifting position.
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)
Bearing assembly Needle O.D. x 3.194 x 17.25 - 25

length - number (0.1257 x 0.6791 - 25)
E 3.5 (0.138)
F 22 (0.87)
G 35.5 (1.398)
Flange yoke H 113.08 (4.45)
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
UNIT NAME PS410, 420, 430, 520

Unit: mm (in)
Item *1 PS410 PS420 PS430 PS520
Propeller shaft tube O.D. 90 (3.54) 101.6 (4.00)
Universal joint journal
A 126 (4.96) 153 (6.02)
B 36.5 (1.437) 45.4 (1.787)
C 26.5 (1.043) 31 (1.22)
D 30.019 (1.1818) 38.11 (1.5004)
Bearing assembly Needle O.D. x 3.5 x 20.8 - 30 4.0 x 24.8 - 33

length - number (0.138 x 0.819 - 30) (0.157 x 0.976 - 33)
E 43 (1.69) 55 (2.17)
F 33.6 (1.323) 37.8 (1.488)
G 25 (0.98) 26 (1.02)
Flange yoke H — 136 (5.35) 164 (6.46)

I — 68 (2.68) 75 (2.95)
J — 43 (1.69) 55 (2.17)
K — 80 (3.15) 104.6 (4.12)
L — 116 (4.57) 134 (5.28)
Type SAE
Involute spline Number of teeth 16 18
Diameter 53.2 (2.094) 59.6 (2.346)
*1 Differential to differential
PS-1-2
TABLE OF PROPELLER SHAFT SHAPE AND

COMBINATION
UNIT NAME PS860 No. Shape
Combination (No.)
2
1+2
1
1+1+2
PS-1-3
UNIT NAME PS420, 430, 520, 410 No. Shape

Differential to
Combination (No.)
differential
1+2
PS420 — 1
1+1+2
2
1+2 —
PS430 1+1+2
2
*13
1+2
2
PS520 *1
3
1+2 2
*1 PS410
PS-1-4
SERVICE DATA
Unit: mm (in)
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
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
= UNIT NAME PS860 =

CONSTRUCTION
PS-2-1
DISASSEMBLY PS860
DISASSEMBLY
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

, 1. Retaining ring , 6. Nut , 10. Dust cap
2. Needle roller bearing ,+ 7. Companion flange 11. Felt retainer
, 3. Journal ,+ 8. Center bearing 12. Felt seal
, 4. Grease nipple 9. Splined shaft + 13. Splined yoke
,+ 5. Flange yoke
PS-2-2
DISASSEMBLY PS860

5 Flange yoke
1. Before removing the yoke, match up marks as shown in the
figure.
2. Tap the yoke shoulder with a copper mallet to remove the

needle roller bearing assembly. If the bearing cannot be
removed in the above manner because of rusting, etc.,
place on insertion tool against the head of the bearing cap
and remove with a hydraulic press or with a hammer.
NOTE
z Be careful not to damage the needle rollers.
z Use an insertion tool having an outside diameter of 32 to
35 mm (1.26 to 1.38 in) and shaped so that it does not
touch the center of the bearing cap head.
7 Companion flange
1. Retainer
2. Slinger
3. Companion flange
4. Nut
5. Propeller shaft
6. Propeller shaft
1. When loosening the nut, ensure the propeller shaft is
secured in the vise.
2. Ensure that an alignment mark to indicate the “phase” is
stamped on the companion flange.
3. Do not remove the slinger unless it is to be replaced with a
new one.
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.
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.

Unit: mm (in)
Less than 0.3 (0.012) 0.5 (0.020)

Unit: mm (in)
0.20 - 0.33 (0.0079 - 0.0130) 0.5 (0.020)
Journal-to-journal bearing clearance

Unit: mm (in)
0.03 - 0.07 (0.0012 - 0.0028) 0.25 (0.0098)

Unit: mm (in)
0.18 - 0.25 (0.0071 - 0.0098) 0.25 (0.0098)
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 cush-
ionrubber. Replace if damage or cracking is found.
PS-2-5
REASSEMBLY PS860
REASSEMBLY
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.
6 NutInstall the nut, then clinch it.

NOTE
z Use a new nut when reassembling.
CAUTION
z When tightening the nut ensure that the propeller shaft is
secured in the vise.
: 520 - 628 N·m {53 - 64 kgf·m, 383 - 463 ft·lbf}
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.
3. From the measured result, select a retaining ring so that the

end play is within the specified value. Exchange it for the
retaining ring fitted for measurement.
Unit: mm (in)
Bearing end play
0.01 - 0.05 (0.0004 - 0.0020) 0.25 (0.0098)
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

1. Ensure that the alignment marks are aligned.
2. Always install the bolts from the rear axle side.
: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
PS-2-9
CONSTRUCTION PS410, 420, 430, 520
= UNIT NAME PS410, 420, 430, 520 =

CONSTRUCTION
UNIT NAME PS420, 430, 520
PS-3-1
CONSTRUCTION PS410, 420, 430, 520
UNIT NAME PS410 (DIFFERENTIAL TO DIFFERENTIAL)
PS-3-2
DISASSEMBLY PS410, 420, 430, 520
DISASSEMBLY
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

1. Bolt , 8. Journa 15. Slinger (PS520 only)
2. Lock platey + 9. Flange yoke ,+16. Center bearing
, 3. Side plate 10. Grease nipple 17. Slinger (PS520 only)
4. Bearing 11. Cotter pin 18. Propeller shaft
, 5. Thrust washe , 12. Castellated nut , 19. Dust cap
6. Sea 13. Washer 20. Felt washer
7. Dust shield ,+ 14. Companion flange
PS-3-3
UNIT NAME PS410 (DIFFERENTIAL TO DIFFERENTIAL)

1. Lock plate 6. Dust seal 11. Plug
, 2. Side plate , 7. Journal 12. Spline yoke
3. Bearing 8. Grease nipple 13. Splined shaft
, 4. Thrust washer 9. Relief valve
5. Seal 10. Grease nipple

9 Flange yoke (Except PS410)
1. Before removing the yoke, match up marks as shown in the
figure.
2. If the needle roller bearing assembly is hard to extract,

remove the side plate on the opposite side and drive the
bearing out by hammering the head section. Be careful not
to scatter the needle rollers.
PS-3-4
14 Companion flange (Except PS410)

1. Retainer
2. Slinger (PS520 only)
3. Companion flange
4. Washer
5. Castellated nut
6. Cotter pin
7. Propeller shaft
1. When loosening the castellated nut, ensure the propeller
shaft is secured in the vise.
2. Ensure that an alignment mark to indicate the “phase” is
stamped on the companion flange.
16 Center bearing (Except PS410)

1. Propeller shaft
2. Slinger (PS520 only)
1. Do not attempt to disassemble the center bearing assem-
bly. (Cannot be disassembled)
2. Be careful not to damage the dust seal.
new one. (PS520 only)
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.
Unit: mm (in)
Less than 0.7 (0.028) 0.9 (0.035)

Unit: mm (in)
0.11 - 0.20 (0.0043 - 0.0079) 0.5 (0.020)
Journal-to-journal bearing clearance

Unit: mm (in)
0.03 - 0.07 (0.0012 - 0.0028) 0.25 (0.0098)

Unit: mm (in)
0.18 - 0.24 (0.0071 - 0.0094) 0.25 (0.0098)
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
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.
16 Center bearing (Except PS410)

1. Ensure that the slinger is new and free from defects.
(PS520 only)
2. Charge the center bearing case with grease.

3. Do not strike the dust seal.
14 Companion flange (Except PS410)

1. Ensure that the slinger is new and free from defects.
(PS520 only)
2. Ensure that the alignment marks (to indicate “phase”) are
aligned.
PS-3-7
REASSEMBLY PS410, 420, 430, 520
12 Castellated nut (Except PS410)

1. Bend the cotter pin as shown in the figure to lock the castel-
lated nut.
2. If the split pin hole does not align with the pin, align with the
hole which is nearest in the tightening direction.
3. When tightening the castellated nut, ensure that the propel-
ler shaft is secured in the vise.
: 343 - 402 N·m {35 - 41 kgf·m, 253 - 297 ft·lbf}
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)
Bearing end play
0 (0) —
PS-3-8
REASSEMBLY PS410, 420, 430, 520
2. Determine the proper side plate from the measured end

play and install using a lock plate.
NOTE
z To provide the journal with preload, select a side plate so
that the end play is between 0 to -0.05 mm (0 to -0.0020
in) (reference).
z Ensure that the side plates are the same thickness.
: 25 - 31 N·m {2.5 - 3.2 kgf·m, 18 - 23 ft·lbf}

Unit: mm (in)
A
0.00 (0.00)
0.02 (0.0008)
0.05 (0.0020)
0.08 (0.0031)
0.11 (0.0043)
0.14 (0.0055)
0.17 (0.0067)
0.20 (0.0079)
0.23 (0.0091)
0.26 (0.0102)
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.
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}
4. Bend the lock plate to lock the bolt.
PS-3-9
REASSEMBLY PS410, 420, 430, 520
INSTALLATION

1. Ensure that the alignment marks are aligned.
2. Always install the bolts from the rear axle side.
: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}
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
CONSTRUCTION ............................. DF-3-1 = UNIT NAME ITHL =

DISASSEMBLY ................................ DF-3-3
REMOVAL .................................... DF-3-3 CONSTRUCTION .............................. DF-5-1
DISASSEMBLY ............................ DF-3-5 DISASSEMBLY ................................. DF-5-2
INSPECTION .................................... DF-3-9 REMOVAL ..................................... DF-5-2
REASSEMBLY ............................... DF-3-10 DISASSEMBLY ............................. DF-5-3
REASSEMBLY ........................... DF-3-10 INSPECTION ..................................... DF-5-8
INSTALLATION .......................... DF-3-18 REASSEMBLY ................................ DF-5-11
REASSEMBLY ............................ DF-5-11
= UNIT NAME SRHL, SRHL-1 = INSTALLATION ........................... DF-5-20
CONSTRUCTION ............................. DF-4-1

SERVICE DATA DIFFERENTIAL
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
Type In-line tandem

Unit name ITHL
Type of reduction gear Hypoid gear
Gear ratio
Refer to the table below.
Number of teeth
Ring gear diameter mm (in) 428 (16.85)
Pinion offset mm (in) 35 (1.38)
Type and number of differential gears and
Direct bevel gear: Large 2, Small 4
intermediate axle differential gears
Gear oil capacity liter (Imp qt) 12 (10-5/8)
Gear ratio and number of teeth

Gear ratio 4.111 4.333 4.555 4.625 4.875 5.143 5.285 5.571 5.714 5.857 6.166 6.500 6.833 7.571
Number of teeth 37/9 39/9 41/9 37/8 39/8 36/7 37/7 39/7 40/7 41/7 37/6 39/6 41/6 53/7
SRHF-3 z z z z z z
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
Type of main Outside diameter of Model No.

Type reduction gear axle housing mm (in)
SR Single reduction H Hypoid F 400 (15.75)
IT In-Line Tandem L 490 (19.29)

H 438 (17.24)
DF-1-1

The unit identification number is stamped on the surface of the left
flange on the differential carrier.
DF-1-2
SERVICE DATA
UNIT NAMES SRHF-3, SRHH-2, SRHL AND SRHL-1
Unit: mm (in)
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
Unit: mm (in)
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
UNIT NAME ITHL

Unit: mm (in)
0.30 - 0.40
Drive gear backlash 0.60 (0.0236)
(0.0118 - 0.0157)
0.20 - 0.35
Side gear and differential pinion gear backlash 0.60 (0.0236)
(0.0079 - 0.0138)
Helical gears (Divider, idler, pinion drive) back- 0.20 - 0.30
0.45 (0.0177)
lash (0.0079 - 0.0118)
0.15 - 0.25
Intermediate axle differential gear backlash 0.45 (0.0177)
(0.0059 - 0.0098)
20.6 - 27.5 With new
— Starting
{2.1 - 2.8, 4.6 - 6.2} bearing
Drive pinion bearing preload N {kgf, lbf} preload
10.8 - 17.7 With reused (w/oil seal)
—
{1.1 - 1.8, 2.4 - 4.0} bearing
46.1 - 61.8
{4.7 - 6.3, 10.4 - 13.9}
Differential side bearing preload N {kgf, lbf}
30.4 - 40.2
— With reused bearing
{3.1 - 4.1, 6.8 - 9.0}
10.8 - 17.7
{1.1 - 1.8, 2.4 - 4.0}
Idler gear bearing preload N {kgf, lbf}
3.9 - 10.8
— With reused bearing
{0.4 - 1.1, 0.9 - 2.4}
0.10 - 0.14
Clearance between pinion gear and pinion shaft 0.3 (0.012)
(0.0039 - 0.0055)
Clearance between side gear boss and differen- 0.21 - 0.31
0.6 (0.024)
tial case (0.0083 - 0.0122)
0.10 - 0.18
Clearance between shift fork and sliding clutch 1.0 (0.039)
(0.0039 - 0.0071)
0.06 - 0.13
Clearance between intermediate Front 0.3 (0.012)
(0.0024 - 0.0051)
axle differential case and side gear
boss 0.07 - 0.14
Rear 0.3 (0.012)
(0.0028 - 0.0055)
Clearance between intermediate axle differential 0.10 - 0.14
0.3 (0.012)
pinion and pinion shaft (0.0039 - 0.0055)
0.10 - 0.17
Divider gear play in axial direction — Adjust with shim
(0.0039 - 0.0067)
Shift fork return spring free length 78.8 (3.102) 73.0 (2.874)
DF-1-5
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
Engine stand Used for disassembling and reassembling differ-

99550 96001 ential carrier
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]
99823 Z0003 Used when disassembling and assembling the

Diff. stand
[SRHH-2] differential carrier
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
Oil seal replacer

Used when installing the oil seal into the bearing
99828 Z5001
retainer
[SRHF-3]
Oil seal replacer

Used when installing the oil seal into the bearing
99828 Z0016
retainer
[ITHL]
Dust shield replacer

Used when driving the dust shield into the com-
99828 Z5002
panion flange
[SRHF-3]
Dust shield replacer

Used when driving the dust shield into the com-
99828 Z0017
panion flange
[ITHL]
DF-2-2
CONSTRUCTION SRHF-3, SRHH-2
=UNIT NAME SRHF-3, SRHH-2 =

CONSTRUCTION
UNIT NAME SRHF-3
DF-3-1
CONSTRUCTION SRHF-3, SRHH-2
UNIT NAME SRHH-2
DF-3-2
DISASSEMBLY SRHF-3, SRHH-2
DISASSEMBLY
z Chock the wheels.
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.
2. Remove the axle shaft.

NOTE
z Be careful not to scratch the oil seal when removing the
axle shaft.
3. Scribe matching marks on the splined section of the propel-

ler shaft.
DF-3-3
4. Scribe matching marks on the companion flange, and sepa-

rate the propeller shaft from the differential carrier.
5. Remove bolts and nuts which secure the differential carrier.

CAUTION
z Do not remove the upper nuts until the differential jack is
in position.
6. Remove the differential carrier assembly, using a differential

jack and lever block.
7. Install the differential carrier assembly on the differential

attachment or differential stand.
z SRHF-3
Attach the differential attachment (99823 Z0005) to the
engine stand and then secure the differential carrier to the
attachment.
z SRHH-2
Install the differential carrier on the differential stand (99823
Z0003).
DF-3-4
DISASSEMBLY
UNIT NAME SRHF-3

1. Lock plate 13. Pinion shaft , 25. Adjusting washer
+ 2. Adjusting nut 14. Side gear 26. Bearing spacer
, 3. Side bearing cap 15. Thrust washer , 27. Retaining ring
,+ 4. Differential case assembly , 16. Differential case (LH) 28. Pilot bearing inner race
,+ 5. Drive pinion assembly 17. Drive gear , 29. Taper roller bearing (inner and
6. Lock plate 18. Bearing outer)
, 8. Differential case (RH) 20. Companion flange , 31. Taper roller bear (ingnner and outer)
9. Thrust washer ,+ 21. Dust shield 32. Drive pinion
,+ 12. Pinion gear 24. Adjusting shim
UNIT NAME SRHH-2
DF-3-5

1. Lock plate ,+ 13. Pinion gear 25. Adjusting shim
+ 2. Adjusting nut 14. Pinion shaft 26. Bearing spacer
, 3. Side bearing cap 15. Side gear , 27. Adjusting washer
4. Bearing outer race 16. Thrust washer , 28. Retaining ring
,+ 5. Differential case assembly , 17. Differential case (LH) 29. Pilot bearing inner race
,+ 6. Drive pinion assembly 18. Drive gear , 30. Taper roller bearing (inner and
7. Lock plate 19. Bearing , outer)
, 9. Differential case (RH) 21. Companion flange 32. Taper roller bearing (inner and
10. Thrust washer + 22. Dust shield outer)
11. Side gear 23. Bearing retainer 33. Drive pinion
12. Thrust washer 24. O-ring 34. Differential carrier
DF-3-6

2 Adjusting nut
1. Measure and record the drive gear backlash before remov-
ing the adjusting nut.
2. Place the aligning marks on the side bearing cap and car-
rier case.
3. Loosen the side bearing cap mounting bolt slightly and

remove the adjusting nut with a differential wrench (SRHF-
3: 99826 Z5001, SRHH-2: 99826 Z0000).
4. Mark the identification marks on the left and right adjusting

nuts, outer races of the side bearings and side bearing caps
so that they can be installed in their original positions.
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
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
has been exceeded, repair or replace faulty parts.
DRIVE GEAR BACKLASH

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
bearing is worn.
Unit: mm (in)
0.20 - 0.30
SRHF-3 0.5 (0.020)
(0.0079 - 0.0118)
0.25 - 0.35
SRHH-2 0.55 (0.0217)
(0.0098 - 0.0138)
SIDE GEAR AND DIFFERENTIAL PINION GEAR BACK-

LASH
thrust washer is worn.
Unit: mm (in)
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)
CLEARANCE BETWEEN DIFFERENTIAL PINION GEAR

AND PINION SHAFT
Unit: mm (in)
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)
CLEARANCE BETWEEN SIDE GEAR BOSS AND DIF-

FERENTIAL CASE
NOTE
z Always replace the left and right differential cases as a
unit.
Unit: mm (in)
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
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.
30 Using the special tool (99828 Z5001), install the SRHF-3.
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
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}
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
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
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)
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
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)
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
2. Install the differential case assembly using a bar.

NOTE
z Be careful not to drop the side bearing outer race into the
case assembly.
3 Side bearing cap

1. Install the adjusting nuts and temporarily tighten the bearing
cap.
NOTE
z Observe the matching marks made prior to disassembly,
making sure that the original positioning of the cap is
maintained.
2. Adjust the drive gear backlash and preload after installing

the side bearing cap.
1) Adjust the drive gear backlash. First, loosen the right side
adjusting nut and tighten the left side adjusting nut to make
the backlash zero by using the diff-wrench (SRHF-3: 99826
Z5001, SRHH-2: 99826 Z0000). Then loosen the left side
adjusting nut and adjust the backlash by tightening the right
side adjusting nut.
Unit: mm (in)
SRHF-3 0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)
SRHH-2 0.25 - 0.35 (0.0098 - 0.0138) 0.55 (0.0217)
2) After the backlash has been adjusted, equally tighten both

the right and left adjusting nuts to apply preload. The
increase in the fit-in diameter should be the previously mea-
sured and recorded bearing cap fit-in diameter plus the fit-in
diameter shown in the following table.
Unit: mm (in)
Item Increase in fit-in diameter after preload has been applied
SRHF-3 0.14 - 0.21 (0.0055 - 0.0083)
SRHH-2 0.15 - 0.20 (0.0059 - 0.0079)
DF-3-14
z For reference, when the specified preload has been applied

to the differential side bearing, starting force at the drive
gear bolt is as shown below.
Unit: N {kgf, lbf}
Starting force
Item Remarks
(Reference value)
New(*)
SRHF-3 19.6 - 44.1 {2.0 - 4.5, 4.4 - 9.9}
Old(*) Measure at drive
New(*) 19.6 - 34.3 {2.0 - 3.5, 4.4 - 7.7} gear bolt location.
SRHH-2
Old(*) —
NOTE
used bearings.
Adjusting gear contact pattern

Apply a thin coat of red lead to two or three of the drive gear's teeth
faces, and then check the gear contact pattern for the drive pinion.
If the gear contact pattern is incorrect, add or remove the necessary
amount of shims between the bearing retainer and differential car-
rier until the specified gear contact pattern is obtained.
DF-3-15
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)
z Tighten bolts in the order shown in the figure to the speci-

fied torque. Finally, retighten the bolt which was tightened
first.
DF-3-16
Tooth contact pattern Adjustment procedure
Tooth contact pattern is

1. equally distributed over the — Adjustment is not required.
tooth.
Increase backlash by loos-

ening the left adjusting nut
2. toward the “toe” of the
and tightening the right
tooth.
one.
Decrease backlash by
loosening the right adjust-
3. toward the “heel” of the
ing nut and tightening the
tooth.
left one.
Move the pinion closer to

4. the drive gear using a thin-
high on the tooth.
ner adjusting shim.
Move the pinion away from

Tooth contact pattern is low
5. the drive gear using a
on the tooth.
thicker shim.
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
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.
2. Apply RTV (Room Temperature Vulcanizing) liquid gasket

(THREE BOND #1215 or equivalent) to the flange surfaces
of the axle housing (in two places on the inside and outside
peripheries of the threaded hole for the differential carrier
mounting bolt).
NOTE
z Finish preparation for installing the differential carrier
before applying liquid gasket.
1) Apply liquid gasket so that the width of the bead coated is

more than 3 mm (0.12 in).
2) The inside bead should be in the center between the inner

end of the flange and the threaded holes of the bolt, and the
outside bead should be between the outer end of the flange
and the threaded holes of the bolt (preferably near the
threaded hole of the bolt). The bead should be continuously
coated without any gaps [bead width more than 3 mm (0.12
in)].
DF-3-18
3) The bead should not be too thin, broken or protruding in

portions where the width of the flange is narrow due to a
cutout.
3. Install the differential carrier assembly using a differential

jack or lever block.
: 78 - 98 N·m {8 - 10 kgf·m, 58 - 72 ft·lbf}
NOTE
z Install the differential carrier assembly within 2 to 20 min-
utes after applying liquid gasket.
z After installation, do not allow the flanged surfaces to
move in relation to each other until liquid gasket hardens
(for approximately 2 hours). Do not operate the differen-
tial carrier during this period.
z Add gear oil to the differential carrier approximately 2
hours after installing it.
4. Install the axle shafts through the gasket.

NOTE
z Be careful not to damage the oil seal when installing the
axle shaft. Otherwise, oil will leak.
: 137 - 157 N·m {14 - 16 kgf·m, 101 - 116 ft·lbf}
5. Align matching marks when installing the propeller shaft.

: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
DF-3-19
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
= UNIT NAME SRHL, SRHL-1 =

CONSTRUCTION
DF-4-1
DISASSEMBLY SRHL, SRHL-1
DISASSEMBLY
z Chock the wheels.
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
NOTE
12 liters (10-5/8 Imp qt) ... SRHL, 13 liters (11-1/2 Imp qt) ...
SRHL-1.

NOTE
axle shaft.

ler shaft.
DF-4-2
4. Scribe matching marks on the companion flange or yoke

and journal (CWA model only), and separate the propeller
shaft from the differential carrier.

CAUTION
in position.

7. Attach the differential attachment (99823 Z0004) to the

engine stand and then secure the differential carrier to the
attachment.
DF-4-3
DISASSEMBLY

1. Lock plate , 14. Differential case (LH) 25. Adjusting shim
+ 2. Adjusting nut 15. Drive gear , 26. Adjusting washer
, 3. Side bearing cap 16. Bearing 27. Bearing spacer
,+ 4. Differential case assembly 17. Cotter pin (Type SRHL) , 28. Retaining ring
,+ 5. Drive pinion assembly , 18. Castellated nut (Type SRHL) 29. Pilot bearing
, 6. Differential case (RH) ,+ 19. Companion flange or splined , 30. Taper roller bearing (inner and
7. Thrust washer yoke nut (Type SRHL-1) outer)
8. Side gear 20. O-ring , 31. Oil seal
9. Thrust washer 21. Companion flange 32. Taper roller bearing (inner and
,+ 10. Pinion gear + 21. -1 Splined yoke (CWA only) outer)
11. Pinion shaft 22. Dust shield 33. Drive pinion
DF-4-4

2 Adjusting nut
rier case.

remove the adjusting nut with a differential wrench (99826
Z0000).

nuts, outer races of the side bearings and side bearing caps
so that they can be installed in their original positions.
4 Differential case assembly

NOTE
case assembly.
DF-4-5
5 Drive pinion assembly

Before disassembling the drive pinion assembly, measure and
record the preload.
NOTE
10 Pinion gear
results.
NOTE
shaft in position.
19 Companion flange or splined yoke nut (SRHL-1 only)

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.
DF-4-6
22 Dust shield
NOTE
z Do not remove the dust shield unless it is faulty.
DF-4-7
INSPECTION SRHL, SRHL-1
INSPECTION
scratches, cracks of damage and replace faulty parts.
DRIVE GEAR BACKLASH

bearing is worn.
Unit: mm (in)
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)
SIDE GEAR AND DIFFERENTIAL PINION GEAR BACK-

LASH
Unit: mm (in)
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)
CLEARANCE BETWEEN DIFFERENTIAL PINION GEAR

AND PINION SHAFT
Unit: mm (in)
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)
CLEARANCE BETWEEN SIDE GEAR BOSS AND DIF-

FERENTIAL CASE
NOTE
unit.
Unit: mm (in)
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)
DF-4-8
REASSEMBLY SRHL, SRHL-1
REASSEMBLY
NOTE
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
26 Adjusting washer
Measure the preload of the drive pinion bearing.
If the preload is not within the specified range, add or remove
Unit: N {kgf, lbf}
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
used bearings.
range.
DF-4-9
19 Companion flange or splined yoke nut (SRHL-1 only)

Lock the two nuts at the grooves in the drive pinion after adjusting
the drive pinion preload.
Measure the preload again after reassembly to check that it is
within maintenance standards.
18 Castellated nut (SRHL only)

After adjusting the preload, remove the companion flange and
install the O-ring. Then, reinstall the companion flange and tighten
the castellated nut to the specified torque. Secure with the cotter
pin.
: 392 - 539 N·m {40 - 55 kgf·m, 289 - 398 ft·lbf}
NOTE
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.
14 Differential case (LH)

fied torque.
: 588 - 686 N·m {60 - 70 kgf·m, 434 - 506 ft·lbf}
NOTE
10 Pinion gear
Unit: mm (in)
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)
DF-4-10
Thrust washers
1.60 mm (0.0630 in)
NOTE
against the differential case.
6 Differential case (RH)

: 216 - 275 N·m {22 - 28 kgf·m, 159 - 203 ft·lbf}

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.

Install the differential case assembly using a bar.
NOTE
case assembly.
DF-4-11
3 Side bearing cap

cap.
NOTE
maintained.

the backlash zero by using the diff-wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the back-
lash by tightening the right side adjusting nut.
Unit: mm (in)
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

the left and right adjusting nuts while adjusting the preload
until it is within maintenance standards.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks
New (*) 46.1 - 61.8 {4.7 - 6.3, 10.4 - 13.9} Measure at

Preload of
drive gear
differential
bolt loca-
side bearing Old (*) 30.4 - 39.2 {3.1 - 4.0, 6.8 - 8.8} tion.
NOTE
used bearings.
DF-4-12

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.
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)
z Tighten bolts in the order shown in the figure to the spec-

ified torque. Finally, retighten the bolt which was tight-
ened first.
DF-4-13
Tooth contact pattern Adjustment procedure

1. equally distributed over the — Adjustment is not required.
tooth.
Increase backlash by loos-

ening the left adjusting nut
2. toward the “toe” of the
and tightening the right
tooth.
one.
Decrease backlash by
loosening the right adjust-
3. toward the “heel” of the
ing nut and tightening the
tooth.
left one.
Move the pinion closer to

4. the drive gear using a thin-
high on the tooth.
ner adjusting shim.
Move the pinion away from

Tooth contact pattern is low
5. the drive gear using a
on the tooth.
thicker shim.
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
INSTALLATION
NOTE

mounting bolt).
NOTE


in)].
DF-4-15

cutout.

: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
NOTE
4. Install the axle shafts through the gasket.

NOTE
z Be careful not to damage the oil seal when installing the
axle shaft. Otherwise, oil will leak.
: 147 - 167 N·m {15 - 17 kgf·m, 108 - 123 ft·lbf} (SRHL-1)
137 - 177 N·m {14 - 18 kgf·m, 101 - 130 ft·lbf} (SRHL)
5. Align matching marks when installing the propeller shaft.

: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}
DF-4-16
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
- MEMO -
DF-4-18
CONSTRUCTION ITHL
= UNIT NAME ITHL =

CONSTRUCTION
DF-5-1
DISASSEMBLY ITHL
DISASSEMBLY
z Chock the wheels.
REMOVAL
1. Remove the drain plugs (A, B and C) and drain the gear oil
completely.
WARNING
WARNING
NOTE
12 liters (10-5/8 Imp qt).
NOTE
axle shaft.
3. Remove the bearing cover and withdraw the through shaft.

4. Remove the air tubing.
ler shaft.
6. Scribe matching marks on the companion flange, and sepa-

rate the propeller shaft from the differential carrier.

CAUTION
in position.

DF-5-2
DISASSEMBLY ITHL
DISASSEMBLY
DF-5-3
DISASSEMBLY ITHL

, 1. Intermediate axle differential 28. O-ring ,+ 57. Drive pinion assembly
assembly 29. Ring , 58. Differential case (RH)
2. Flange washer 30. Pin 59. Thrust washer
,+ 3. Companion flange assembly 31. Shift shaft 60. Side gear
4. O-ring 32. O-ring 61. Thrust washer
, 5. Oil seal retainer 33. Shift fork ,+ 62. Pinion gear
, 6. Oil seal 34. Gasket 63. Pinion shaft
,+ 7. Intermediate axle differential case 35. Control cover 64. Side gear
assembly ,+ 36. Carrier cover assembly 65. Thrust washer
8. Ball bearing 37. Inspection cover , 66. Differential case (LH)
9. Intermediate axle differential case 38. Cotter pin 67. Drive gear
(FR) 39. Castellated nut 68. Tapered roller bearing
10. Thrust washer 40. Washer 69. Shim
11. Side gear (FR) 41. Lock plate 70. Cotter pin
12. Thrust washer 42. Idler shaft 71. Castellated nut
, 13. Pinion gear , 43. Idler gear , 72. Pinion drive gear
14. Pinion shaft 44. Tapered roller bearing , 73. Taper roller bearing (inner and outer)
, 15. Side gear (RR) 45. Spacer 74. Adjusting washer
16. Thrust washer 46. Adjusting washer 75. Spacer
17. Intermediate axle differential case (RR) 47. O-ring 76. Bearing retainer
18. Intermediate axle differential cover + 48. Bearing retainer , 77. Retaining ring
, 19. Control cover assembly 49. Shim 78. Pilot bearing
20. Sliding clutch , 50. Divider gear , 79. Taper roller bearing (inner and outer)
21. Filler plug 51. Tapered roller bearing 80. Drive pinion
22. Cylinder 52. Carrier cover 81. Centering piece
23. O-ring 53. Lock plate ,+ 82. Oil catcher
24. Spring + 54. Adjusting nut 83. Shim
25. O-ring , 55. Side bearing cap 84. Differential carrier case
26. Felt oiler ,+ 56. Differential case assembly
27. Piston

3 Companion flange assembly
Do not remove the dust shield unless it is faulty.
7 Intermediate axle differential case assembly

1. Drive the intermediate axle differential case assembly out
by lightly tapping around it with a soft faced hammer.
DF-5-4
DISASSEMBLY ITHL
2. Measure and record the backlash between the side gear

and pinion gear.
NOTE
shaft in position.
36 Carrier cover assembly

Before disassembling the differential carrier assembly, measure
and record the backlash of the divider gear, idler gear and pinion
drive gear, as follows:
NOTE
z Be careful not to allow the fuse wire to be caught by the
divider gear.
z When removing the liquid gasket from the mounting sur-
faces, use a suitable tool such as a scraper blade so as
not to damage both the mounting surfaces.
48 Bearing retainer
Utilizing the puller bolt hole.
54 Adjusting nut
DF-5-5
DISASSEMBLY ITHL
rier case.

remove the adjusting nut with a differential wrench (99826
Z0000).

nuts and side bearing caps so that they can be installed in

NOTE
case assembly.

1. Utilizing the puller bolt hole in the bearing retainer, remove
the drive pinion and shim(s).
DF-5-6
DISASSEMBLY ITHL
2. Press the drive pinion out and disassemble the bearing

retainer, tapered roller bearing, spacer, shim(s) and pinion
drive gear.
NOTE
62 Pinion gear
results.
NOTE
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
scratches, cracks of damage and replace faulty parts.
Intermediate axle differential gear backlash

Unit: mm (in)
0.15 - 0.25 (0.0059 - 0.0098) 0.45 (0.0177)
Helical gears (divider, idler, pinion drive) backlash

bearing is worn.
Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 0.45 (0.0177)
Drive gear backlash

bearing is worn.
Unit: mm (in)
0.30 - 0.40 (0.0118 - 0.0157) 0.60 (0.0236)
Side gear and differential pinion gear backlash

Unit: mm (in)
0.20 - 0.35 (0.0079 - 0.0138) 0.60 (0.0236)
DF-5-8
INSPECTION ITHL
Clearance between differential pinion gear and pinion

shaft
Unit: mm (in)
0.10 - 0.14 (0.0039 - 0.0055) 0.3 (0.012)
Clearance between side gear boss and differential

case
NOTE
unit.
Unit: mm (in)
0.21 - 0.31 (0.0083 - 0.0122) 0.6 (0.024)
Clearance between intermediate axle differential pin-

ion gear and pinion shaft
Unit: mm (in)
0.10 - 0.14 (0.0039 - 0.0055) 0.3 (0.012)
Clearance between intermediate axle differential case

and differential gear boss
Unit: mm (in)
0.06 - 0.13
Front 0.3 (0.012)
(0.0024 - 0.0051)
0.07 - 0.14
Rear 0.3 (0.012)
(0.0028 - 0.0055)
Clearance between shift fork and sliding clutch

Unit: mm (in)
0.10 - 0.18 (0.0039 - 0.0071) 1.0 (0.039)
DF-5-9
INSPECTION ITHL
Shift fork return spring

Unit: mm (in)
78.8 (3.102) 73.0 (2.874)
Divider gear play in axial direction

Unit: mm (in)
0.10 - 0.17 (0.0039 - 0.0067) —
DF-5-10
REASSEMBLY ITHL
REASSEMBLY
NOTE
REASSEMBLY
82 Oil catcher
Confirm the number stamped on the removed shims and the num-
ber of shims.
73 79 Taper roller bearing (inner and outer)

Press the bearing outer race in.
77 Retaining ring
Drive the pilot bearing in and secure it with the retaining ring.
NOTE
DF-5-11
REASSEMBLY ITHL
72 Pinion drive gear

Measure the preload of the drive pinion gear bearing.
If the preload is not within the specified range, and or remove
Unit: N {kgf, lbf}
Preload of New (*) 20.6 - 27.5 {2.1 - 2.8, 4.6 - 6.2}
drive pinion
bearing Old (*) 10.8 - 17.7 {1.1 - 1.8, 2.4 - 4.0}
NOTE
used bearings.
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.
66 Differential case (LH)

fied torque.
: 588 - 686 N·m {60 - 70 kgf·m, 434 - 506 ft·lbf}
NOTE
62 Pinion gear
Unit: mm (in)
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
against the differential case.
58 Differential case (RH)

: 216 - 275 N·m {22 - 28 kgf·m, 159 - 203 ft·lbf}

NOTE
z Make sure the thickness of the shim(s) is the same as
that recorded during disassembly.
z Use at least two shims if they are single types.

Install the differential case assembly using a bar.
NOTE
case assembly.
55 Side bearing cap

cap.
NOTE
maintained.
DF-5-13
REASSEMBLY ITHL

the backlash zero by using the diff-wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the back-
lash by tightening the right side adjusting nut.
Unit: mm (in)
0.30 - 0.40 (0.0118 - 0.0157) 0.60 (0.0236)

the left and right adjusting nuts while adjusting the preload
until it is within maintenance standards.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks
New (*) 46.1 - 61.8 {4.7 - 6.3, 10.4 - 13.9} Measure

Preload of
at drive
differential
gear bolt
side bearing Old (*) 30.4 - 40.2 {3.1 - 4.1, 6.8 - 9.0} location.
NOTE
used bearings.

NOTE
z Tighten bolts in the order shown in the figure to the spec-
ified torque. Finally, retighten the bolt which was tight-
ened first.
DF-5-14
REASSEMBLY ITHL
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)
Gear contact pattern Adjustment procedure
1. Typical tooth contact — Not necessary
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.)
Drive pinion is too far from

Contact is too high on drive drive gear.
4.
gear. (Reduce thickness of
adjusting shim.)
Drive pinion is too close to

Contact is too low on drive drive gear.
5.
gear. (Increase thickness of
adjusting shims.)
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)
2. Tighten the remaining bearing retainer bolts.

: 78 - 88 N·m {8 - 9 kgf·m, 58 - 65 ft·lbf}
3. Measure the backlashes among the divider, idler and pinion
drive gears.
Unit: mm (in)
0.20 - 0.30 (0.0079 - 0.0118) 0.45 (0.0177)
43 Idler gear
1. Face the idler shaft cutout to the lock plate mounting bolt
hole in the carrier cover.
2. Tighten the castellated nut to the specified torque, and turn

the idler gear 2 or 3 turns to smooth bearing rotation.
: 343 - 392 N·m {35 - 40 kgf·m, 253 - 289 ft·lbf}
DF-5-16
REASSEMBLY ITHL
3. Measure the idler gear preload. If the preload is not within

the specified range, add or remove the adjusting washers
until it is.
Unit: N {kgf, lbf}
Preload of New (*) 10.8 - 17.7 {1.1 - 1.8, 2.4 - 4.0}
idler gear
bearing Old (*) 3.9 - 10.8 {0.4 - 1.1, 0.9 - 2.4}
NOTE
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.
36 Carrier cover assembly

Apply RTV (Room Temperature Vulcanizing) liquid gasket (THREE
BOND #1215) to the carrier cover mounting surface of the carrier
case.
1) Install the nozzle, attachment to the liquid gasket, on the tip
of the tube and cut the nozzle so that the diameter of the
bead is 2.5 to 3.0 mm (0.098 to 0.118 in) as shown below.
2) Cut under the first step and the bead diameter will be less
than 3 mm (0.12 in), liquid gasket can be applied with a
width from 2.5 to 3.0 mm (0.098 to 0.118 in).
[Procedures for applying the liquid gasket]
1) In those places where there are bolt holes, apply the liquid
gasket continuously in the center between the outside of the
carrier case and bolt hole as shown in the figure.
2) In those places between the bolts, apply the liquid gasket
continuously to line the bolt center as shown above. (Inside
of the center line is better than outside it)
3) Instead of around the oil port, apply the liquid gasket contin-
uously in the center between outside of the carrier case and
oil port as shown below.
DF-5-17
REASSEMBLY ITHL
[Installing the differential carrier]

Install the carrier cover on the carrier case within 2 to 20 minutes
after applying the liquid gasket.
NOTE
z Apply the liquid gasket only after being prepared to
install the carrier cover as it is necessary to install the
carrier cover within 2 to 20 minutes after applying the liq-
uid gasket.
z After installation, tighten the bolts to the specified
torque. Do not allow the mounting surfaces to move rela-
tive to each other until the liquid gasket hardens (for
approximately 2 hours.) Do not operate the vehicle dur-
ing this period.
: 78 - 88 N·m {8 - 9 kgf·m, 58 - 65 ft·lbf}
z Pouring gear oil into the differential carrier should be
done approximately 2 hours after installation.
19 Control cover assembly

Do not confuse the ends of the shift shaft.
Proceed carefully when placing the cylinder over the piston to avoid
turning the felt oilers up.
Make sure there is no air leakage.
DF-5-18
REASSEMBLY ITHL
15 Side gear (RR)

NOTE
z Make sure that the side gear is free to rotate smoothly.
13 Pinion gear
Measure the backlash of the differential gear and make sure the
measured value is within the maintenance standard.
Unit: mm (in)
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.
7 Intermediate axle differential case assembly

Install the intermediate axle differential case.
Be sure to engage the spigot joint securely by lightly tapping it with
a soft-faced hammer.
Temporarily tighten the bolts.
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.
5 Oil seal retainer

Attach the oil seal, install the oil seal retainer, and tighten the
retainer bolt.
NOTE
z Before installing the oil seal retainer, apply RTV (Room
Temperature Vulcanizing) liquid gasket (THREE BOND
#1215 or equivalent) to the oil seal retainer installation
surface on the intermediate differential axle cover. For
coating procedures, refer to item 36 Carrier cover assem-
bly.
DF-5-19
REASSEMBLY ITHL
3 Companion flange assembly

Press-fit a new dust shield (if the old shield is removed) to the com-
panion flange.
Driving tool (99828 Z0017)
1 Intermediate axle differential assembly

Apply RTV (Room Temperature Vulcanizing) liquid gasket (THREE
BOND #1215) to the intermediate axle differential assembly mount-
ing surface of the carrier cover assembly. For coating procedures,
refer to item 36 carrier cover assembly.
INSTALLATION
NOTE

mounting bolt).
NOTE

DF-5-20
REASSEMBLY ITHL

in)].

cutout.

: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}
NOTE
4. Connect the air tubes.
5. Insert the through shaft, and install the bearing cover.
: 59 - 69 N·m {6 - 7 kgf·m, 43 - 51 ft·lbf}
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
Unit name RS90 RS1A RD80 RD90 RW1A

Dead axle
Type of rear axle Full-floating, axle tube type Full-floating, axle tube type
type
Type of axle housing Pressed, banjo type — Pressed, banjo type
50 (1.97)
Axle shaft diameter mm (in) 50 (1.97) — 50 (1.97) 50 (1.97)
52.5 (2.067)
Type of brake drum Inboard type
Inboard type
installation Outboard type
Oil capacity liter (Imp qt) 13 (11-1/2) 13 (11-1/2) — 13 (11-1/2) 12 (10-5/8)
Hub bolt number 8 8 10 8 8 8 10
Type of brake drum installation

NOTE
z *1 and *2 indicate respectively the inboard type and out-
board type installation methods of the brake drum.
RA-1-1
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
Unit identification number

Unit identification numbers of rear axles are stamped on the right
rear section of the axle housing.
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)
Item RS90 RS1A RD80 RD90 RW1A

Semi-elliptic leaf spring
Type of spring Semi-elliptic leaf spring (trunnion type)
(shackle type)
Type of shock absorber
Cylindrical single-action —
(if so equipped)
RA-1-2
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
)
Main: 1,300 x 70 x 11 - 6 (51.18 x 2.76 x 0.43 - 6)

RS55 Helper: 980 x 70 x 11 - 6 (38.58 x 2.76 x 0.43 - 6)
MKB210
MKB212 Main: 1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
Helper: 980 x 70 x 11 - 7 (38.58 x 2.76 x 0.43 - 7)
Main: 1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
MKD210
Helper: 980 x 70 x 9 - 9 (38.58 x 2.76 x 0.35 - 9)
Main: 1,300 x 70 x 11 - 7 (51.18 x 2.76 x 0.43 - 7)
RS65 MKC210
Helper: 980 x 70 x 11 - 7 (38.58 x 2.76 x 0.43 - 7)
RS70 or LKC210 Main: 1,300 x 70 x 11 - 8 (51.18 x 2.76 x 0.43 - 8)
RS75 LKC212 Helper: 980 x 70 x 9 - 9 (38.58 x 2.76 x 0.35 - 9)
RS70 LKD210
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
Main: 1,600 x 80 x { 13 - 2
14 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
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 - 5
(62.99 x 3.15 x { 0.51 - 2
0.55 - 5
)
Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
{ {
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
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
RS1A Helper: 1,100 x 80 x 12 - 7 (43.31 x 3.15 x 0.47 - 7)
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
)
Helper: 1,100 x 80 x 12 - 6 (43.31 x 3.15 x 0.47 - 6)

RD90
CDA310 1,300 x 90 x 18 - 10 (51.18 x 3.54 x 0.71 - 10)
RD80
RW1A CWA310 1,300 x 90 x { 18 - 3

20 - 6
(51.18 x 3.54 x { 0.71 - 3
0.79 - 6
)
RA-1-4
SERVICE DATA
REAR AXLE
Unit: mm (in)
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
SUSPENSION
Unit: mm (in)
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
TIGHTENING TORQUE
REAR AXLE
Models
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 — — — — —
Brake assem- RB37 — — — — — — O O O

216 - 284 {22 - 29, 159 - 210}
bly mounting BLT40 — — — — O — — — —
bolts and nuts BLL41 216 - 294 {22 - 30, 159 - 217} — — — — — O — — —
RB41 216 - 265 {22 - 27, 159 - 195} — — — — — — — — O
BPL41 216 - 294 {22 - 30, 159 - 217} — — — — — O — — —
Differential carrier 78 - 98 {8 - 10, 58 - 72} O O O O — — — — —
mounting bolts and
nuts 127 - 147 {13 - 15, 94 - 108} — — — — O O — O O
PS860 88 - 108 {9 - 11, 65 - 80} O O O O — — — — —

Propeller shaft PS420
mounting 211 - 240
PS430 — — — — O O — O O
{21.5 - 24.5, 156 - 177}
PS520
Lock plate mounting
7 - 9 {0.7 - 0.9, 5.1 - 6.5} O O O O O O O O O
bolt
Spring contact seat
88 - 108 {9 - 11, 65 - 80} — — — — — — O O O
mounting bolt
Torque rod mounting
196 - 265 {20 - 27, 145 - 195} — — — — — — O O O
bolts and nuts
RA-1-7
SUSPENSION
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
99820 Z5001
1 99829 Z5000 O O O O — — — — —
2 99540 Z0000
Adjust- 99820 Z0004 Used to install/

ing nut 1 99829 Z0002 remove adjusting — — — — — — — — —
wrench 2 99540 Z0000 nut
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
Models
Used to drive oil

seal into the hub
99828 Z0006
(Inside and out-
O O O O O O O O O
side)
Oil seal
replacer
99828 Z0005 — — — — — — — — —
Used to drive oil

seal into axle tube
99828 Z0000 — — — — — — — O O
Used to install the

99827 Z5003 inner hub bearing — — — — — — — — —
inner races
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
Models
99843 Z5005 — — — — — — — — —
Used to install the

inner hub bearing
99843 Z5006 outer races — — — — O O O O O
(A set including
99844 Z5000)
O O O O — — — — —
Hub
bearing 99843 Z5003
replacer
— — — — — — — — —
Used to install the

outer hub bearing
99843 Z5002 outer races O O O O — — — — —
(A set including
99844 Z5000)
99843 Z5005 — — — — O O O O O
Hub Used when simul-

inner taneously remov-
bearing ing the inner
puller
99843 Z0005
bearing and the
— — — — — O O O O
attach- oil seal retainer of
ment the rear axle
99827 Z0009 O O O — — — — — —
Oil seal Used to install the

retainer oil seal retainer of
replacer inner hub bearing
99827 Z0061 — — — — O O O O O
RA-2-3
SUSPENSION
Models
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
Wrench Used for turning

socket the U-bolt nut
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
Models
Used to remove
Replac- and install the
ing tool
99888 Z0065
torque rod bush- — — — — — — O O O
ing
Bush- Used to remove

ing 99896 Z0005 the spring seat — — — — — — O O O
remover bushing
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
- MEMO -
RA-2-6
REAR AXLE RS55, RS65, RS70, RS75
=UNIT NAME RS55, RS65, RS70, RS75=

REAR AXLE
CONSTRUCTION
RS55 AND RS65
RA-3-1
RS70 AND RS75
RA-3-2
DISASSEMBLY
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.
6. When removing the tire, be careful not to damage the hub

bolt threads.
7. Because the wheel is heavy, take care not to allow it to fall
toward you.
Refer to the “DISASSEMBLY” section for the disassembled view.
8. Remove the drain plug, and drain the gear oil.
NOTE
z Use an oil container which is larger in proportion to the
required amount.
9. When removing brake hose and tube, have a tray on hand

for the parts to be removed.
RA-3-3
DISASSEMBLY

1. Filler plug 9. Lock washer 16. Outer bearing outer race
2. Gasket 10. Outer bearing inner race 17. Inner bearing outer race
3. Drain plug 11. Brake drum 18. Hub bolt
4. Gasket ,+ 12. Hub ,+ 19. Brake assembly
,+ 5. Axle shaft , 13. Inner bearing inner race 20. Breather
+ 6. Oil seal , 14. Oil seal retainer ,+ 21. Axle housing
7. Lock plate 15. Oil seal
,+ 8. Adjusting nut
RA-3-4

5 Axle shaft
Be careful not to scratch the oil seal when removing the axle shaft.
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
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
Axle shaft flange surface runout

Unit: mm (in)
0.1 (0.004) max. 0.5 (0.020) (6.18 in) dia. point of flange sur-
face.
REPAIR AND REPLACEMENT

BRAKE DRUM AND HUB
1. Remove the hub nut from the inner side of the brake drum,
and separate the brake drum and hub.
1. Nut 3. Hub
2. Brake down 4. Hub bolt
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
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
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
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.
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
14 Oil seal retainer M

Drive the oil seal retainer into the axle housing tube with the oil seal
retainer replacer (99827 Z0009).
13 Inner bearing inner race

Drive the inner race of the housing tube with the inner hub bearing
replacer (99827 Z0063).
NOTE
z Remove all excess grease from the perimeter of the bear-
ing.
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
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
2. Tighten the axle shaft bolts.

: 137 - 157 N·m {14 - 16 kgf·m, 101 - 116 ft·lbf}
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.
Installing the road wheel

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 rear axle housing and

raise the rear of vehicle. Remove the right and left trestles
from the rear of the frame, and slowly lower the vehicle.
WARNING
WARNING
z Apply the jack at the jacking-up point accurately.
RA-3-11
3. Tighten the wheel nuts so that disc closely contacts the

neck of each bolt.
: 363 - 422 N·m {37 - 43 kgf·m, 268 - 311 ft·lbf}
CAUTION
z Tighten the wheel nuts diagonally as shown at right.
Tighten to the specified torque in several steps, not all at
once.
RA-3-12
SUSPENSION RS55, RS65, RS70, RS75
SUSPENSION
CONSTRUCTION
RA-4-1
DISASSEMBLY
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.
2. Remove the upper and lower ends of the shock absorber

and remove the shock absorber. (if so equipped)
3. Remove the shock absorber bracket. (if so equipped)
4. Using the extension bar (99535 Z0012) and wrench socket

(99535 Z0008), loosen the U-bolt nuts and remove the U-
bolts and upper and lower rear spring pads.
RA-4-2
DISASSEMBLY
RA-4-3

1. Washer 12. Spring pad 22. Center pin (For MKD, LKB and LKC
2. Cushion rubber 13. Grease nipple vehicles)
3. Washer 14. Lock bolt 23. Spacer (For LKD vehicle only)
4. Washer ,+ 15. Spring pin 24. Grease nipple
5. Cushion rubber 16. Shim (For LKD vehicle only) 25. Lock bolt
6. Washer 17. Grease nipple ,+ 26. Shackle pin
7. Shock absorber 18. Lock bolt 27. Shim (For LKD vehicle only)
, 8. U-bolt nut ,+ 19. Spring pin 28. Shackle
9. Shock absorber bracket 20. Spring assembly 29. Bushing
10. Lower pad (RS70 only) 21. Shim (For MKD, LKB and LKC vehi- 30. Helper spring bracket
11. U-bolt cles) 31. Spring bracket

15, 19 Spring pin and 26 Shackle pin
Remove the bolt (shackle pin lock bolt), then remove the shackle
pin, spring pin and shackle.
NOTE
z Use a copper hammer to remove the shackle pin and
spring pin.
RA-4-4
INSPECTION
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)
28.0 (1.102) 27.5 (1.083)
Spring pin and shackle pin bushing inside diameter

Unit: mm (in)
28.0 (1.102) 28.8 (1.134)
Clearance between spring (shackle) pin and bushing

Unit: mm (in)
0.07 - 0.12 (0.0028 - 0.0047) 1.0 (0.039)
RA-4-5

Leaf spring
1. Remove the clip bolt with the T-type socket (99535 Z0005).
2. Apply a C-clamp to the middle of the spring so that it is held
securely.
3. Remove the center bolt.
4. Loosen the C-clamp slowly, and separate the leaves.
5. Assemble the spring leaves in leaf number sequence on a
new center bolt.
NOTE
z Apply chassis grease to both sides of each spring leaf.
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).
2. Attach a new bushing to the bushing replacer (99888

Z0002) and install it.
RA-4-6
REASSEMBLY
26 Shackle pin
1. Align the cutout section for the shackle pin lock bolt with the
bracket before installing the shackle pin.
2. Insert the bolt from the front.
19, 15 Spring pin

1. Align the cutout section for the spring pin lock bolt with the
bracket when driving in the spring pin.
shackle before driving the spring pin into place.
RA-4-7
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
=UNIT NAME RS90, RS1A=

REAR AXLE
CONSTRUCTION
RS90 AND RS1A (SAE TYPE)
RS1A (ISO TYPE)
RA-5-1
DISASSEMBLY
REMOVAL
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.
WARNING
WARNING
bility.

bolt threads.
toward you.
NOTE
required amount.
RA-5-2
DISASSEMBLY
RS90 and RS1A models
RA-5-3

1. Drain plug 9. Lock washer 17. Inner bearing outer race
2. Gasket 10. Outer bearing inner race ,+ 18. Brake assembly
3. Filler plug 11. Brake drum ,+ 19. Brake bracket
4. Gasket ,+ 12. Hub 20. Shock absorber bracket
,+ 5. Axle shaft ,+ 13. Inner bearing inner race 21. Spring pad (Lower)
+ 6. Oil seal (RS90, RS1A) ,+ 14. Oil seal retainer 22. Breather
7. Lock plate 15. Oil seal ,+ 23. Axle housing
,+ 8. Adjusting nut 16. Outer bearing outer race

5 Axle shaft
1. Be careful not to scratch the oil seal when removing the
axle shaft.
2. Discard the old gasket and use a new one.
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
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.

14 Oil seal retainer
Using a bearing puller attachment (99843 Z0005), remove the inner
bearing inner race together with the oil seal retainer.
18 Brake assembly
19 Brake bracket
For disassembly procedure of the brake assembly, refer to the “BR”
section.
RA-5-5
23 Axle housing
Carefully lower the jack and extract the axle housing.
CAUTION
INSPECTION
Axle shaft flange surface runout

Unit: mm (in)
Maintenance
Models Service limit Remarks
standard
RS90
0.1 (0.004) 0.5 (0.020) (8.07 in) dia. point of flange
RS1A
surface.
RA-5-6

HUB AND HUB BOLT
<SAE type>
1. Remove the hub nut from the inner side of the brake drum,
and separate the brake drum and hub.
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 - 412 N·m {30 - 42 kgf·m, 217 - 304 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.
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.
Removal and installation using a press

1. Remove hub bolts from the hub.
z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Place the bolts on a cloth or similar material when they are
pressed out.
z Press the hub and brake drum straight out using a press
and wooden pad. Be careful not to damage threads.
RA-5-7
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.
<Pressing hub bolts into a new hub>

z Apply engine/gear oil to the entire perimeter of serrations.
z Using a press and pad, press hub bolts into the hub with a
force of approximately 49 to 59 kN {5 to 6 tons, 4.9 to 5.9
Imp tons}.
NOTE
z Be careful not to scratch the hub and brake drum.
grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.
<Pressing hub bolts into an old hub>

z Align hub bolt hole serrations with hub bolt serrations.
z Using a hammer, lightly tap hub bolt heads to properly
mesh with the mating hole serrations.
z Using a press, press hub bolts straight into place.
RA-5-8
Removal and installation using hammer

If hub bolts need to be replaced in emergencies, such as when
trouble occurs, etc., proceed as follows:
z Place the hub and brake drum on a firm mount, etc. to pre-
vent them from becoming deformed.
z Place hub bolts on a cloth as they are removed.
z Remove hub bolts by lightly applying hammer ten times or
so via a pad. Use a hammer of 10 N {1 kgf, 2 lbf} or greater
weight.
NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
grease.
2. Press new hub bolts into the hub.

z Place the hub and brake drum on a firm mount to prevent
z Using a hammer (10 N {1 kgf, 2 lbf} weight, min.) and pad,
drive hub bolts straight into hub holes. The hub bolt will be
properly driven into place by hammering them approxi-
mately 20 times.
NOTE
grease.

z Align hub bolt serrations with hub bolt hole serrations.
z Lightly tap hub bolt heads to properly mesh with the mating
serrations.
drive hub bolts straight into place.
RA-5-9
NOTE
z Be careful not to scratch the hub or brake drum.
grease.
z Ensure hub bolts are flush and pressed properly.
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.
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
Unit: g (oz)
Models Amount of grease
RS90
1,620 (57.14)
RS1A
RA-5-10
REASSEMBLY
REASSEMBLY
23 Axle housing
Install the axle housing. Install the upper pad above the leaf spring.
Tighten the pad with U-bolts.
CAUTION
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
section.
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

Drive the inner race of the housing tube with the inner hub bearing
replacer.
Models Hub bearing replacer
RS90
99827 Z0062
RS1A
NOTE
z Remove all excess grease from the perimeter of the bear-
ing.
RA-5-11
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
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.
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
CAUTION
RA-5-13

Models Tightening torque
RS90
147 - 167 {15 - 17, 108 - 123}
RS1A
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
and tube.
For AIR.B
Connect the brake air hose.
NOTE
z Do not twist the brake air hose.
CAUTION
and tube.
RA-5-14

rarily.
CAUTION
NOTE
<SAE type>
<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.

WARNING
WARNING

neck of each bolt.
: 412 - 481 N·m {42 - 49 kgf·m, 304 - 354 ft·lbf}
(SAE type)
: 588 - 637 N·m {60 - 65 kgf·m, 434 - 470 ft·lbf}
(ISO type)
CAUTION
Tighten to the specified torque in several steps.
RA-5-15
- MEMO -
RA-5-16
SUSPENSION RS90, RS1A
SUSPENSION
CONSTRUCTION
RA-6-1
DISASSEMBLY
REMOVAL
WARNING
WARNING
2. Remove the upper and lower ends of the shock absorber

and remove the shock absorber. (if so equipped)
3. Remove the shock absorber bracket. (if so equipped)
4. Using the extension bar (99535 Z0012) and wrench socket

(99535 Z0008), loosen the U-bolt nuts and remove the U-
bolts and upper and lower rear spring pads.
RA-6-2
DISASSEMBLY
RA-6-3

1. Washer 11. U-bolt 20. Spring assembly
2. Cushion rubber
3. Washer
4. Washer
12. Spring pad
13. Grease nipple
14. Lock bolt
21. Spacer
22. Center pin
23. Grease nipple
} For PKB and
PKF vehicles
5. Cushion rubber ,+ 15. Spring pin 24. Lock bolt

6. Washer 16. Shim ,+ 25. Shackle pin
7. Shock absorber 17. Grease nipple 26. Shim
, 8. U-bolt nut 18. Lock bolt 27. Shackle
9. Shock absorber bracket ,+ 19. Spring pin 28. Bushing
10. Lower pad

15, 19 Spring pin and 25 Shackle pin
Remove the bolt (shackle pin lock bolt), then remove the shackle
pin, spring pin and shackle.
NOTE
z Use a copper hammer to remove the shackle pin and
spring pin.
RA-6-4
INSPECTION
Leaf spring

Unit: mm (in)
30.0 (1.181) 29.5 (1.161)

Unit: mm (in)
30.0 (1.181) 31.0 (1.220)

Unit: mm (in)
0.02 - 0.14 (0.0008 - 0.0055) 1.0 (0.039)
RA-6-5

Leaf spring
securely.
new center bolt.
NOTE
6. Clamp the spring leaves together with the C-clamp and

tighten with the center bolt and nut.
: 108 - 127 N·m {11 - 13 kgf·m, 80 - 94 ft·lbf}
8. Install the clip bolt with the T-type socket (99535 Z0005).
: 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
Z0003).

Z0003) and install.
RA-6-6
REASSEMBLY
25 Shackle pin
1. Align the cutout section for the shackle pin lock bolt with the
bracket before installing the shackle pin.
19, 15 Spring pin

bracket when driving in the spring pin.
shackle before driving the spring pin into place.
RA-6-7
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
=UNIT NAME RD90, RD80, RW1A=

REAR AXLE
CONSTRUCTION
RD90 model
RA-7-1
RD80 model
RA-7-2
RW1A model
RA-7-3
DISASSEMBLY
REMOVAL
threads. (SAE type)
hand threads.
WARNING
WARNING
bility.

bolt threads.
toward you.
NOTE
required amount.
RA-7-4
DISASSEMBLY
RD90 and RD80 models
RA-7-5

1. Level plug 9. Outer bearing inner race ,+ 18. Brake assembly
2. Gasket 10. Brake drum 19. Oil seal (RD90 model only)
3. Drain plug + 11. Hub ,+ 19-1. Axle tube (Dead axle RD80 model
4. Gasket ,+ 12. Inner bearing inner race only)
,+ 5. Axle shaft (except RD80 model) ,+ 13. Oil seal retainer 20. Differential carrier mounting bolt
5-1. Hub cap (RD80 model only) 14. Oil seal 21. Differential carrier mounting nut
6. Gasket (except RD80 model) 15. Outer bearing outer race 22. Air breather
7. Lock plate 16. Inner bearing outer race ,+ 23. Axle housing
,+ 8. Adjusting nut 17. Hub bolt 24. Spring contact seat
RA-7-6
RW1A MODEL
RA-7-7

1. Level plug ,+ 13. Oil seal retainer 24. O-ring
2. Gasket 14. Oil seal 25. Dust cover
3. Drain plug 15. Outer bearing outer race 26. Oil seal
4. Gasket 16. Inner bearing inner race 27. Bearing retainer
,+ 5. Axle shaft 17. Hub bolt (SAE type) 28. Bearing
6. Gasket 17-1. Hub bolt (ISO type) 29. Through shaft
7. Lock plate ,+ 18. Brake assembly 30. Differential carrier mounting bolt
,+ 8. Adjusting nut 19. Oil seal 31. Differential carrier mounting nut
9. Outer bearing inner race 20. Cotter pin 32. Air breather
10. Brake drum 21. Castellated nut ,+ 33. Axle housing
+ 11. Hub 22. Washer 34. Spring contact seat
,+ 12. Inner bearing inner race 23. Yoke

5 Axle shaft
Be careful not to damage the oil seal which is attached to the end of
the axle shaft when removing the axle shaft.
8 Adjusting nut
Use an adjusting nut wrench to remove the adjusting nut (99820
Z0009).
RA-7-8
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.

Using a bearing puller attachment (99843 Z0005), remove the inner
bearing inner race together with the oil seal retainer.
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
2. Support the axle housing or axle tube (RD80 only) (Rear

rear axle) with a wire, and support the axle housing (Rear
front axle) with a jack.
RA-7-9
NOTE
z Secure the spring assembly to prevent it from turning.
3. Remove the spring contact seat.
INSPECTION
Rear axle shaft flange surface runout

Unit: mm (in)
0.1 (0.004) max. 0.5 (0.020) (8.07 in) dia. point of flange sur-
face.
RA-7-10

REAR AXLE
z Install the rear axle.
z Put the contact seat on the upper portion of the housing so
that the bottom of the contact seat comes into contact with
the upper portion (shaded area) of the housing.
: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
z Connect the axle housing (Rear rear axle) with the torque
rod. Suspend the axle housing with a wire and hoist.
: 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
z Connect the axle housing (Rear front axle) with the torque
rod; and then remove the wire used to suspend the axle
housing (Rear rear axle).
: 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
BRAKE DRUM AND HUB

1. Align the flanged portion of the hub bolt with the groove in
the hub. Tighten the hub bolt with the nut (with the lock
washer) placard between the hub and brake drum.
: 294 - 412 N·m {30 - 42 kgf·m, 217 - 304 ft·lbf}
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
HUB BEARING
Use a hub bearing replacer.
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
GREASE
Rear hub greasing procedure
<Drive axle type>
<Dead axle type>
RA-7-13
REASSEMBLY
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
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
section.

Use an oil seal retainer replacer (99827 Z0061) to install the oil seal
retainer.
RA-7-14

Use a bearing replacer (99827 Z0062) to install the bearing.
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.
Unit: N {kgf, lbf}

Maintenance standard (At hub bolt location) Service limit
29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3} —
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
5 Axle shaft
1. Install the axle shaft.
WARNING
WARNING
CAUTION

: 147 - 167 N·m {15 - 17 kgf·m, 108 - 123 ft·lbf}
INSTALLATION
Connect the brake hose with the connector on the axle housing.
CAUTION
and tube.
NOTE
z Be careful not to twist the air hose.

rarily.
CAUTION
NOTE
<SAE type>
<ISO type>
the disc wheel.
RA-7-16

washers (the tapered portion).
Wipe away any excess with a clean wastecloth.
purpose.

WARNING
WARNING

neck of each bolt.
: 412 - 481 N·m {42 - 49 kgf·m, 304 - 354 ft·lbf}
(SAE type)
: 588 - 637 N·m {60 - 65 kgf·m, 434 - 470 ft·lbf}
(ISO type)
CAUTION
Tighten to the specified torque in several steps.
RA-7-17
SUSPENSION RD90, RD80, RW1A
SUSPENSION
CONSTRUCTION
TYPE I
[Rear 1-axle drive model]
RA-8-1
TYPE II
RA-8-2
DISASSEMBLY
REMOVAL
WARNING
WARNING
RA-8-3
DISASSEMBLY
TYPE I
RA-8-4

+ 1. U-bolt 12. Dowel pin 23. Spacer
2. Spring pad 13. Spring seat ,+ 24. Torque rod (Rear upper)
+ 3. Spring assembly 14. Thrust washer ,+ 25. Torque rod (Front upper)
4. Spacer 15. Dowel pin ,+ 26. Torque rod (Front lower)
5. Clip 16. Oil seal ,+ 27. Torque rod (Rear lower)
6. Grease nipple 17. Bushing 28. Torque rod bushing
7. Cover , 18. Thrust washer 29. Torque rod bracket
8. Gasket 19. Dowel pin 30. Knock bolt and nut
9. Side plate 20. O-ring ,+ 31. Trunnion bracket
, 10. Shim 21. Relief valve 32. Trunnion shaft
11. Thrust washer 22. Bumper rubber
RA-8-5
TYPE II
RA-8-6

+ 1. U-bolt 12. Dowel pin 23. Spacer
2. Spring pad 13. Spring seat ,+ 24. Torque rod (Rear upper)
+ 3. Spring assembly 14. Thrust washer ,+ 25. Torque rod (Front upper)
4. Pipe 15. Dowel pin ,+ 26. Torque rod (Front lower)
5. Clip 16. Oil seal ,+ 27. Torque rod (Rear lower)
6. Grease nipple 17. Bushing 28. Torque rod bushing
7. Cover , 18. Thrust washer 29. Torque rod bracket
8. Gasket 19. Dowel pin 30. Knock bolt and nut
9. Side plate 20. O-ring ,+ 31. Trunnion bracket
, 10. Shim 21. Relief valve 32. Trunnion shaft
11. Thrust washer 22. Bumper rubber

1 U-bolt
To remove the U-bolt, support the front and rear axles securely with
garage jacks.
3 Spring assembly
When removing the spring assembly, fix it to a suitable device to
prevent it from dropping.
24, 25, 26, 27 Torque rod

1. Before removing the torque rod, put a mark which shows
the installation location on each torque rod end.
2. Remove the torque rod of the jointly tightened side (frame
side or trunnion bracket side) first.
NOTE
z Do not remove all the torque rods at one time. The upper
side front and rear torque rods should be regarded as a
pair, and the front and rear torque rods of the lower right
or left side be also considered as a paired set for
removal.
RA-8-7
31 Trunnion bracket
Place a jack under the trunnion shaft when removing the trunnion
bracket.
INSPECTION
Leaf spring
Trunnion shaft outside diameter

Unit: mm (in)
99.93 - 99.98
RD90/RD80 99.4 (3.913)
(3.9342 - 3.9362)
99.95 - 99.99
RW1A 99.4 (3.913)
(3.9350 - 3.9366)
Trunnion shaft bushing inside diameter

Unit: mm (in)
100.17 - 100.22 (3.9437 - 3.9457) 100.60 (3.9606)
RA-8-8
Clearance between trunnion shaft and bushing

Unit: mm (in)
0.19 - 0.29
RD90/RD80 1.0 (0.039)
(0.0075 - 0.0114)
0.18 - 0.27
RW1A 1.0 (0.039)
(0.0071 - 0.0106)
Thickness of thrust washer

Unit: mm (in)
Steel
4.95 - 5.05 (0.1949 - 0.1988) —
(Without oil groove)
Bearing metal
4.95 - 5.05 (0.1949 - 0.1988) 4.70 (0.1850)
(With oil groove)

Leaf spring
2. Press the center portion of the leaf spring with a press to

keep the leaves in the compressed position, then remove
the center bolt.
3. Gradually release the press, and disassemble the leaf
spring.
new center bolt.
NOTE
5. Press the center portion of the leaf spring with a press to

keep the leaves in the compressed position, then tighten
the center bolt to the specified torque.
: 167 - 196 N·m {17 - 20 kgf·m, 123 - 145 ft·lbf}
6. After tightening the clip bolt with the T-type socket (99535
Z0005), stake the threaded end of the clip bolt with the
punch so that it is locked.
: 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}
RA-8-9
Torque rod bushing

1. Place the torque rod on a press, set the replace tool (99888
Z0065) and drive out the bushing with the press.
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.
Spring seat (trunnion shaft) bushing

1. Place the spring seat on a press, set the replacing tool
(99896 Z0005) and drive out the bushing with the press.
2. Place the spring seat on a press, set the replacing tool

(99883 Z0007) and press fit the bushing until the bushing
and spring seat top surface are matched at the spring seat.
RA-8-10
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.
27, 26, 25, 24 Torque rod

Install the torque rod by aligning the match mark provided on each
rod end when disassembling.
196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
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
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
Type of brake drum installation
UNIT NAME
F A 30
Unit classification Axle shape Nominal weight on axle

F Front axle A I-section 30 3 ton
35 3.5 ton
40 4 ton
50 5 ton
FA-1-1

The unit identification number of the front axle is stamped on
its front right side.
SUSPENSION
Item FA30, FA35 FA40, FA50
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
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
)
PKC210 z z 1,400 x 80 x 12 - 9 (55.12 x 3.15 x 0.47 - 9)

PKC212
PKF210
PKC310
—
z
z
z
z
z
1,400 x 80 x { 12 - 7
11 - 1
(55.12 x 3.15 x { 0.47 - 7
0.43 - 1
)
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
)
1,400 x 80 x 11 - 8 (55.12 x 3.15 x 0.43 - 9)

PKC310-T z z
1,400 x 80 x { 20 - 1
21 - 2
(55.12 x 3.15 x { 0.79 - 1
0.83 - 2
)
FA-1-3
SERVICE DATA
FRONT AXLE
Unit: mm (in)
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)
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
TIGHTENING TORQUE
FRONT AXLE
Application
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
SUSPENSION
Application
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
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
Application
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
Application
FA30 FA35 FA40 FA50
99831 Z5001 O O — —
Used to
remove and
install the king-
pin bushing
99831 Z0001 — — O —
Kingpin
bushing tool
99831 Z0008 Used to remove

and install the
1 99833 kingpin bushing
Z0003 1 Replacer bar
2 99834 2 Bushing
Z0012 replacer
3 99834 (Upper)
Z0013 3 Bushing
4 99834 replacer
(Lower) — — — O
Z0009
5 99835 4 Oil seal
Z0004 replacer
6 89- 5 Replacer
11144-1A guide
7 99847 6 Nut
Z0003 (M14x1.5)
7 Bushing
remover
FA-2-3
Application
FA30 FA35 FA40 FA50
Oil seal Used to install the

99828 Z0006 O O O O
replacer oil seal
Used to install the

99843 Z5000 outer hub bearing O O — —
outer race
{Used with brace
99843 Z5002 rod (99844 — — O O
Z5000) as a set}
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 —
Used to install the

oil seal retainer or
hub bearing inner
99827 Z5007 — — O —
race
(Used with 99827
Z5001 as a set)
Used to install the
99827 Z5004 hub bearing inner O O — —
race
Used with 99827
99827 Z5005 Z5000 and 99827 — — O —
Z5001 as a set
FA-2-4
Application
FA30 FA35 FA40 FA50
Used to install the

Hub bearing inner and outer
99827 Z0014 — — — O
replacer hub bearing inner
races
Hub cap Used to install the

99827 Z0066 O O — —
replacer hub cap
FA-2-5
SUSPENSION
Application
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.
Wrench Used to turning

99535 Z0008 O O O O
socket the U-bolt nut.
FA-2-6
FRONT AXLE FA30, FA35
=UNIT NAME FA30, 35=

FRONT AXLE
CONSTRUCTION
FA-3-1
DISASSEMBLY
REMOVAL
1. Apply chocks to the rear wheels.
threads.
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
bility.

bolt threads.
toward you.
FA-3-2
DISASSEMBLY
FA-3-3

1. Wheel nut , 14. Inner bearing inner race ,+ 28. Steering arm
,+ 2. Hub cap , 15. Oil seal retainer , 29. Kingpin cap mounting bolt
2-1Gasket (Type 2 only) 16. Cotter pin 30. Kingpin cap (Upper)
3. Lock plate + 17. Castellated nut 31. Packing
+ 4. Adjusting nut 18. Dust cover 32. Kingpin cap (Lower)
5. Knuckle plate 19. Grease nipple , 33. Lock pin
6. Outer bearing inner race + 20. Tie-rod clamp bolt 34. King pin
,+ 7. Hub , 21. Tie-rod end 35. Dust seal
+ 8. Brake drum 22. Tie-rod tube , 36. Shim
9. Outer bearing outer race 23. Clinch nut , 37. Thrust bearing
10. Oil seal , 24. Tie-rod arm 38. Kingpin bushing
11. Inner bearing outer race + 25. Brake assembly mounting bolt , 39. Steering knuckle
,+ 12. Stopper bolt , 26. Brake assembly ,+ 40. Front axle
13. Plug 27. Clinch nut

2 Hub cap (Type 1 only)
To remove the hub cap, use a suitable tool with a thin, flat tip.
Lightly tap along the flanged portion to extract the hub cap.
5 Adjusting nut
Using the adjusting nut socket (99535 Z0100), remove the adjust-
ing nut.
FA-3-4
7 Hub and 8 Brake drum

Using the front hub puller (99840 Z0016), 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.
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.
20 Tie-rod clamp bolt

Separate the tie-rod and tie-rod end by removing the tie-rod clamp
bolt.
NOTE
z The right-hand tie-rod end has right-hand threads and
the left-hand end left-hand threads.
z Be careful not to damage the dust cover.
FA-3-5
25 Brake assembly mounting bolt

1. When removing the brake assembly, be careful not to dam-
age the steering knuckle spindle.
2. Be careful not to soak the brake linings with oil or brake
fluid.
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
INSPECTION
Kingpin outside diameter

Unit: mm (in)
34.98 - 35.00 (1.3772 - 1.3780) 34.90 (1.3740)
Clearance between kingpin and bushing

Unit: mm (in)
0.02 - 0.07 (0.0008 - 0.0028) 0.15 (0.0059)
Clearance between front axle hole and kingpin

Unit: mm (in)
0 - 0.04 (0 - 0.0016) 0.1 (0.004)
FA-3-7
Front axle alignment and kingpin angle

1. Place the front axle on a bench in such a manner that the
spring seat surfaces lie in a horizontal plane.
2. Suspend a thin wire or string from the center of the left and
right kingpin mounting holes, tie a weight to the end of the
wire (string) and determine if there is any bending by check-
ing if the wire (string) coincides with the center of the dowel
pin hole at the center of the left and right spring seat. If the
center of the dowel pin hole does not coincides with the
center line of the axle, it indicates that the axle is bent in the
front-rear direction. To check the top-bottom bend, measure
the height up to the wire (string) from the top of the spring
seat at the center of the left and right spring seat and check
if the height is equal on both left and right sides.
When the height on the left and right sides differ, the axle is
bent in the top-bottom direction.
3. Install the kingpin or centering pin at the left and right kingpin
mounting holes of the axle and check if the left and right cen-
tering pins overlap by viewing them from the side as illus-
trated in the figure.
Also check if the left and right spring seat and centering pins
are at right angles.
If there is even the slightest difference in the left and right cen-
tering pins, or they are not at right angles, the axle is twisted.
4. Perform this check using an axle gauge and centering pin
as shown in the figure.
Place the axle gauge at the center of the spring seat, place
the scale plate at the end of the gauge in parallel with the
centering pin and read the angle indicated at the scale plate.
When this reading is not the maintenance standard value,
the kingpin angle is incorrect or the kingpin mounting hole is
eccentrically worn.
Kingpin angle
7º±10´ —
5. If the front axle has been badly bent or twisted, or if the

kingpin angle is out of specification, replace the front axle. If
the bend or twist is not too great, the front axle may be
straightened with a press.
Checking the ball studs for rattling
1. To check the drug link and tie-rod end, stop the engine and
turn the steering wheel to the right and left. Check the link
end ball joints for rattling.
2. If there is rattling, replace the drug link and tie-rod end as
an assembly, respectively.
NOTE
z If it is not clear whether rattling exists or not with the ball
stud installed in the vehicle, remove the ball stud from
the vehicle. Check if rattling exists by shaking the ball
studs manually.
z If you hear any rattling, replace the drug link and tie-rod
end as an assembly, respectively.
Brake drum
For inspection of the brake drum, refer to the “BRAKE” section.
FA-3-8

KINGPIN BUSHING
Remove and install the kingpin bushing using the kingpin bushing
tool assembly (99831 Z5001).
1. Pull the upper and lower bushings by pressing to the inside
using the bushing remover. Moreover, when pulling the top
bushing, also remove the dust seal.
2. Coat the outside periphery of the bushing with oil and
remove any burrs, dirt, dust, etc., from the steering knuckle
bushing hole.
3. Set the bushing so that the clinch is at a 45º angle to the
outside at the rear of the vehicle and press fit the bushing to
the steering knuckle with a press, using the kingpin bushing
tool.
4. Using an adapter, bushing shaft and guide, drive the bush-

ing into place from the lower side.
Be careful not to mar the clinched portion.
1. Kingpin bushing 3. Shaft
2. Adapter 4. Guide
5. Using an adapter and bushing shaft, drive the lower bush-

ing into place from the upper side.
Be careful not to mar the clinched portion.
1. Shaft 3. Kingpin bushing
2. Adapter
BRAKE DRUM AND HUB

1. Loosen the hub bolt nuts.
2. Detach the hub and brake drum.
3. To install the hub, hub bolt and brake drum, align the flange
of the hub bolt with the groove in the hub. Install the hub
bolt and tighten the nut on the rear side of the drum
together with the hub and brake drum.
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
FA-3-9
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.
2. After cleaning the contact surfaces of the outer race.

3. Drive in the inner bearing outer race and outer bearing
outer race.
NOTE
z Use a hub bearing replacer (as a set including the brace
rod).
1. 99843 Z5000 3. 99844 Z5000
2. 99843 Z5001

Z0006).
Apply grease to the oil seal lips before installation.
FA-3-10
Front hub greasing procedure
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
Dust cover replacement

1. Using a standard screwdriver, remove the dust cover from
the tie-rod assembly.
2. Charge the new dust cover with approximately 17 g (0.60
oz) of grease.
NOTE
z Apply a coat of grease to the dust and seal lips of the
dust cover before installation.
z Be careful not to apply grease to the press-fit portion of
the dust cover and exterior.
z Be careful that grease does not contain air bubbles.
3. Slowly press the dust cover into place using a press.

NOTE
z Ensure that the engagement portion of the tie-rod is free
from rust.
z Do not use a hammer when installing the cover.
REASSEMBLY
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
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.
: 235 - 275 N·m {24 - 28 kgf·m, 174 - 203 ft·lbf}
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.
2. Before assembling, apply antirust lubricant NOX-RUST·X-

110 (made by DAUBERT CHEMICAL COMPANY, INC.) or
equivalent to the shaded portions of each part shown in the
figure.
1. Steering knuckle 3. Front axle
2. Kingpin
3. Using the same procedures as in the temporary installation,

install the selected shim and the thrust bearing on the upper
and lower parts of the front axle, respectively.
WARNING
WARNING
knuckle and the front axle during removal and installa-
tion.
FA-3-13
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.
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
3. 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.
Unit: N {kgf, lbf}

Less than 9.8 {1.0, 2.2} —
29 Kingpin cap bolt

Install the kingpin cap, associated parts, etc., on the upper and
lower sides of the kingpin.
Kingpin cap mounting bolt
15 - 18 N·m {1.5 - 1.8 kgf·m, 11 - 13 ft·lbf}
1. Boltand lock washer 4. Packing

2. Grease nipple 5. Kingpin cap (lower)
3. Kingpin cap (upper)
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
26 Brake assembly and 24 Tie-rod arm

1. Install the left and right tie rods using new clinch nuts.
Tighten these nuts to the specified torque and then lock
them securely.
: 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}
2. Install the brake assembly on the steering knuckle and

tighten with bolts and nuts.
Model Tightening torque
FA30 127 - 147 {13 - 15, 94 - 108}
FA35 147 - 167 {15 - 17, 108 - 123}
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
2. Install the tie-rod assembly on the tie-rod arms using the

castellated nuts. Lock the nut with a cotter pin.
: 167 - 226 N·m {17 - 23 kgf·m, 123 - 166 ft·lbf}
NOTE
z Install the tie-rod so that the ball stud can be placed from
the lower side of the tie-rod.
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.
3. Insert the tie-rod end clamp bolt and tighten it temporarily.

Tighten the clamp bolt after properly adjusting the toe-in.
Refer to the “Wheel Alignment” section for the toe-in adjust-
ment procedure.
: 88 - 113 N·m {9.0 - 11.5 kgf·m, 65 - 83 ft·lbf}

Attach the hub bearing replacer (99827 Z5000) to the steering
knuckle and press the oil seal into place.

Install the inner hub bearing inner race on the steering knuckle,
using a replacer (99827 Z5000).
NOTE
z After installing the hub bearing, remove any grease that
has been forced out.
FA-3-17
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.
2. Install the hub (with drum) on the steering knuckle. Using

the hub bearing replacers (99827 Z5000 and 99827
Z5004), press the outer bearing's inner race into place.
WARNING
WARNING
use a lifting cable and hoist to install it. To assure safety,
people. Be careful not to drop the hub and drum onto
your feet.
3. Using the adjusting nut wrench (99535 Z0100), tighten the

adjusting nut with the knuckle washer in place until there is
more resistance in hub rotation.
4. Tighten the adjusting nut so that preload becomes the spec-

ified value when the spring balance is pulled horizontally.
Preload
22.6 - 46.1 N {2.3 - 4.7 kgf, 5.1 - 10.4 lbf}
FA-3-18
5. After adjusting preload

7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
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.
Adjusting angle for locating:

within 12º

Using the special tool hub cap replacer (99827 Z0066), press the
hub cap into the hub. Before doing this, pack the inside of the cap
with grease and coat the outer periphery of the contact surface with
Three Bond #1215 or equivalent so that there will be no leakage.
Amount of grease packed in the hub cap:
60 g (2.12 oz)

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-3-11.
FA-3-19
INSTALLATION
rarily.
CAUTION
NOTE
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

neck of each bolt.
6-stud:
: 370 - 420 N·m {37 - 43 kgf·m, 273 - 309 ft·lbf}
8-stud:
: 540 - 590 N·m {55 - 60 kgf·m, 398 - 435 ft·lbf}
CAUTION
once.
FA-3-20
FRONT WHEEL ALIGNMENT

NOTES CONCERNING WHEEL ALIGNMENT
When inspecting wheel alignment (toe-in, camber, caster, kingpin
inclination) and tire turning angle, park the vehicle on a level sur-
face and check the following items. Correct any malfunctions
before making wheel alignment.
z Tire inflation pressure
z Rattling of front wheel bearings
z Installation of steering gear box and steering linkage
z Operation of shock absorber
z Vehicle is not loaded (empty vehicle)
Note on empty vehicle
Engine oil, cooling water, and brake fluid are filled to the spec-
ified level. The fuel tank is filled with fuel. Also, the spare tire
and hand tools are stored in the proper places.
MEASURING AND ADJUSTING TOE-IN

CAUTION
z When adjusting the toe-in, make sure that the tires are on
the ground.
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”.
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”.
FA-3-21
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.
Bias tire 1 mm (0.04 in)

Toe-in
Radial tire 0 mm (0 in)
Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.

Toe-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.
 ： 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)]
FA-3-22
MEASURING THE CASTER AND KINGPIN INCLINATION

C : Caster
1. After measuring the camber, slowly turn the steering wheel

with the turning radius gauge set at zero, until the wheels
turn 20º. When measuring the camber of the left wheel, turn
the steering wheel in that direction; when measuring the
right wheel, turn the steering wheel toward the right.
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.
3. With the brake pedal depressed, slowly turn the steering

wheel in the opposite direction until the wheels are turned
20º from the straight forward position.
Caster and kingpin inclination are now determined by read-
ing the center of the air bubbles of both the caster and king-
pin inclination scales.
4. If both caster and kingpin inclination are not properly
aligned, check the front spring for fatigue, the kingpin and
bushings for wear, and the front axle for bending.
Improper caster can be corrected to some degree by add-
ing shim(s), however, camber, caster and kingpin inclination
are all directly related to each other so that correcting caster
alone does not always lead to accurate wheel alignment.
Wheel alignment is seldom out of adjustment. If checks
reveal the wheel is out of alignment, track down the cause
of misalignment and eliminate the problem.
Caster 3º20´
ADJUSTING MAXIMUM STEERING ANGLE

NOTE
z Adjust the maximum steering angle after completing
wheel alignment.
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
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.
3. Lock the knuckle screw.

: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
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
DISASSEMBLY
REMOVAL
threads.
WARNING
WARNING
bility.

bolt threads.
toward you.
8. Remove the front stabilizer. (Models equipped with front
stabilizer)
Refer to the “FRONT STABILIZER” section for procedures.
FA-4-2
DISASSEMBLY
FA-4-3

1. Washer 12. Shock absorber bracket 23. Castellated nut
2. Rubber cushion 13. U-bolt ,+ 24. Spring pin
3. Rubber cushion 14. Bumper rubber , 25. Grease nipple
4. Washer , 15. *Shim , 26. Lock bolt
5. Washer , 16. *Shim ,+ 27. Spring pin
6. Rubber cushion , 17. *Caster shim 28. Spring assembly
7. Washer , 18. *Caster shim 29. Grease nipple
8. Shock absorber , 19. *Center pin [L: 40 mm (1.57 in)] 30. Cotter pin
9. Rubber cushion , 20. *Center pin [L: 30 mm (1.18 in)] 31. Castellated nut
10. Washer 21. Grease nipple ,+ 32. Shakle pin
,+ 11. U-bolt nut 22. Cotter pin 33. Shakle
z 15 *Shim, 16 *Shim, 17 *Caster shim, 18 *Caster shim, 19 *Center pin and 20 *Center pin. For
details, refer to the “REASSEMBLY” section.
FA-4-4
STABILIZER

, 1. Bushing pin 6. Stabilizer holder 11. Clamp (front)
, 2. Sub-stabilizer lever 7. Washer , 12. Link rod
3. Washer 8. Cushion rubber , 13. Stabilizer bushing
4. Cushion rubber 9. Washer 14. Stabilizer bar
5. Washer 10. Clamp (rear)
SUSPENSION
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
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
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>
Leaf spring
Unit: mm (in)
28.0 (1.102) 27.5 (1.083)
FA-4-6

Unit: mm (in)
28.0 (1.102) 28.8 (1.134)

Unit: mm (in)
0 - 0.1 (0 - 0.004) 1.0 (0.039)

<SUSPENSION>
Leaf spring
securely.

new center bolt.
NOTE
: 47 - 72 N·m {4.8 - 7.3 kgf·m, 35 - 53 ft·lbf}
: 8 - 13 N·m {0.8 - 1.3 kgf·m, 5.8 - 9.4 ft·lbf}
FA-4-7
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.

32 Shackle pin
If the pin hole is not aligned properly with the slot in the nut, loosen
the nut until the hole and slot are aligned.
27, 24 Spring pin

Align the bracket with the cutout section of the spring pin lock bolt.
FA-4-8
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.
20, 19 Center pin 18, 17 Caster shim 16, 15 Shim

20 Center pin [L: 30 mm (1.18 in)]
19 Center pin [L: 40 mm (1.57 in)]
18 Caster shim [H: 9 mm (0.35 in)]
17 Caster shim [H: 22 mm (0.87 in)]
16 Shim [t: 40 mm (1.57 in)]
15 Shim [t: 6 mm (0.24 in)] x 2
Axle model FA30 FA35
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
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>
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
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
- MEMO -
FA-4-12
FRONT AXLE (FA40) FA40
=UNIT NAME FA40, FA50=

FRONT AXLE (FA40)
CONSTRUCTION
FA-5-1
DISASSEMBLY
REMOVAL
threads.
WARNING
WARNING
bility.

bolt threads.
toward you.
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
DISASSEMBLY
FA-5-3

1. Wheel nut , 16. Dowel pin 31. Bolt
, 2. Hub cap 17. Cotter pin ,+ 32. Steering arm
3. Gasket + 18. Castellated nut , 33. Kingpin cap mounting bolt
4. Lock plate 19. Dust cover 34. Grease nipple
+ 5. Adjusting nut + 20. Tie-rod clamp bolt 35. Kingpin cap
6. Knuckle plate , 21. Tie-rod end 36. Packing
7. Outer bearing inner race 22. Tie-rod tube , 37. Lock pin
+ 8. Brake drum 23. Cotter pin 38. King pin
,+ 9. Hub 24. Castellated nut 39. Upper grease seal
10. Outer bearing outer race , 25. Tie-rod arm , 40. Shim
11. Oil seal + 26. Brake assembly mounting bolt , 41. Thrust bearing
12. Inner bearing outer race 27. Lock plate 42. Kingpin bushing
,+ 13. Stopper bolt , 28. Brake assembly , 43. Steering knuckle
, 14. Inner bearing inner race 29. Cotter pin ,+ 44. Front axle
, 15. Oil seal retainer 30. Castellated nut

5 Adjusting nut
ing nut.
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
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
13 Stopper bolt
18 Castellated nut

bolt.
NOTE

fluid.
32 Steering arm
if necessary.
FA-5-5
44 Front axle
bolts.
WARNING
WARNING
INSPECTION

Unit: mm (in)
39.96 - 39.98 (1.5732 - 1.5740) 39.9 (1.571)

Unit: mm (in)
0.03 - 0.07 (0.0012 - 0.0028) 0.2 (0.008)
FA-5-6

Unit: mm (in)
0 - 0.04 (0 - 0.0016) 0.15 (0.0059)
FA-5-7

front-rear direction. To check the top-bottom bend, measure
the height up to the wire (string) from the top of the spring
seat at the center of the left and right spring seat and check
if the height is equal on both left and right sides.
3. Install the kingpin or centering pin at the left and right king-
pin mounting holes of the axle and check if the left and right
centering pins overlap by viewing them from the side as
illustrated in the figure.
Also check if the left and right spring seat and centering
pins are at right angles.
eccentrically worn.
Kingpin angle
7º±10´ —

NOTE
studs manually.
Brake drum
FA-5-8

KINGPIN BUSHING
Remove and install the kingpin bushing using the kingpin bushing
tool assembly (99831 Z0001).
1. Using the kingpin bushing tool and a press, remove the

upper and lower bushings. The upper bushing must be
removed together with the grease seal.
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.
4. Install the upper grease seal.
FA-5-9
HUB AND HUB BOLT

NOTE

pressed out.
NOTE
cent parts.
grease.

Imp tons}.
NOTE
grease.
FA-5-10


If hub bolts need to be replace in emergencies, such as when trou-
ble occurs, etc., proceed as follows:
weight.
NOTE
cent parts.
grease.

z Place the hub and brake drum on a film mount to prevent
mately 20 times.
FA-5-11
NOTE
grease.

serrations.
NOTE
grease.
HUB BEARING
NOTE
FA-5-12

outer race.
NOTE
rod).
1. 99843 Z5002 3. 99844 Z5000
2. 99843 Z5003

Z0006).
FA-5-13
FA-5-14
TIE-ROD ASSEMBLY
Inspection
assembly.
NOTE

oz) of grease.
NOTE

NOTE
from rust.
FA-5-15
REASSEMBLY
REASSEMBLY
44 Front axle
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
of the vehicle.
: 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}
43 Steering knuckle
WARNING
WARNING
NOTE
FA-5-16

figure.
2. Kingpin
WARNING
WARNING
tion.
CAUTION
hammer.
clearance.
NOTE
lation.
the shim.
41 Thrust bearing
NOTE
FA-5-17
40 Shim
nance standard.
CAUTION
hammer.
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
spindle.
Unit: N {kgf, lbf}

Less than 9.8 {1.0, 2.2} —
FA-5-18
33 Kingpin cap mounting bolt

Install the kingpin cap, associated parts, etc., on the upper and
lower sides of the kingpin.
Kingpin cap mounting bolt
: 15 - 18 N·m {1.5 - 1.8 kgf·m, 11 - 13 ft·lbf}
1. Lock washer 6. Packing

2. Bolt 7. Cap
3. Grease nipple 8. Lock washer
4. Cap 9. Bolt
5. Packing
NOTE
z Discard the old packing and use a new one.
32 Steering arm and 25 Tie-rod arm

1. Insert the bolt into the bore in the steering knuckle with the
upper lock plate in place and brake assembly, secure the
steering arm on the opposite side of the steering knuckle
and temporarily tighten with the castellated nut.
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
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
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.

ment procedure.
: 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}
FA-5-20
16 Dowel pin and 15 Oil seal retainer

While aligning the dowel pin with the steering knuckle pin hole,
press the oil seal retainer into place using the hub bearing replacers
(99827 Z5001 and 99827 Z5007).

Install the inner hub bearing inner race on the steering knuckle,
using the hub bearing replacers (99827 Z5001 and 99827 Z5007).
NOTE
13 Stopper bolt
installing the wheel and adjusting the steering angle. Refer to the
“FRONT WHEEL ALIGNMENT” section for instructions.
: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
9 Hub
NOTE
page FA-5-14.
2. Install the hub on the steering knuckle.

WARNING
WARNING
z Because the hub is heavy, use a lifting cable and hoist to
install it. To assure safety, this operation should be per-
formed by more than two people. Be careful not to drop
the hub onto your feet.
FA-5-21
3. Install the brake drum.

WARNING
WARNING
hoist to install it. To assure safety, this operation should
be performed by more than two people. Be careful not to
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).
5. Using the adjusting nut wrench (99535 Z0100), tighten the

adjusting nut with the knuckle washer in place until there is
more resistance in hub rotation.
Tighten the adjusting nut so that preload becomes the specified
value when the spring balance is pulled horizontally.
Preload
: 24.5 - 49.0 N {2.5 - 5.0 kgf, 5.5 - 11.0 lbf}
6. After adjusting preload, install the lock plate and secure it
with a bolt.
: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
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.
Adjusting angle for locating:

within 12º
FA-5-22
2 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
ing procedure” on page FA-5-14.
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 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

neck of each bolt.
: 540 - 590 N·m {55 - 60 kgf·m, 398 - 435 ft·lbf}
CAUTION
once.
FA-5-23

z Installation of steering gear box and steering linkage

CAUTION
the ground.
Measure procedure
“A”.

tires 180 degrees.
CAUTION
step 1.
FA-5-24


Toe-in

Toe-in
NOTE
torque.
 ： 59 - 78 N•m {6.0 - 8.0 kgf•m, 43 - 58 ft•lbf}
MEASURING CAMBER
A : Camber
B : Kingpin inclination

1. Place the rear wheels on stands that are the same height
as the turning radius gauge.
head.
Camber 1º00´
FA-5-25

C : Caster

air bubbles.

Caster 3º20´

NOTE
wheel alignment.
Item Maximum turning angle

Inside 50º
Outside 38º
FA-5-26
NOTE

: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
OVERALL INSPECTION
FA-5-27
FRONT AXLE (FA50)

CONSTRUCTION
FA-6-1
DISASSEMBLY
REMOVAL
threads. (SAE type)
hand threads.
WARNING
WARNING
bility.

bolt threads.
toward you.
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
necting it.
FA-6-2
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
hoist to move it. To assure safety, this operation should
be performed by more than two men. Be careful not to
FA-6-3
DISASSEMBLY
FA-6-4

Outboard type 6-1 Hub bolt (Serration type) , 26. Tie-rod arm
1. Brake drum 7. Brake drum ,+ 27. Brake assembly mounting bolt
, 2. Hub cap ,+ 8. Hub 28. Cotter pin
3. Gasket 9. Outer bearing inner race 29. Castellated nut
,+ 4. Lock plate 10. Oil seal ,+ 30. Steering arm
,+ 5. Adjusting nut 11. Outer bearing outer race 31. Grease nipple
6. Knuckle washer 12. Inner bearing outer race 32. Kingpin cap
,+ 7. Hub 32-1 Brake chamber bracket
8. Outer bearing inner race 13. Plug (Air brake type)
9. Oil seal + 14. Stopper bolt 33. Gasket
10. Outer bearing outer race , 15. Lock nut ,+ 34. Kingpin plug
11. Inner bearing outer race , 16. Inner bearing inner race 35. Kingpin cap
12. Hub bolt (Serration type) , 17. Oil seal retainer , 36. Lock pin
18. Cotter pin 37. Kingpin
Inboard type + 19. Castellated nut , 38. Shim
, 1. Hub cap 20. Dust cover , 39. Thrust bearing
2. Gasket + 21. Tie-rod clamp bolt 40. Oil seal
,+ 3. Lock plate , 22. Tie-rod end 41. Kingpin bushing
,+ 4. Adjusting nut 23. Tie-rod tube , 42. Steering knuckle
5. Knuckle washer 24. Cotter pin ,+ 43. Front axle
6. Hub bolt 25. Castellated nut

3 Inboard type
4 Outboard type }
Lock plate
To remove the lock plate securing screw, use the special wrench
socket (99545 Z0003).
4 Inboard type
5 Outboard type }
Adjust nut
ing nut.
FA-6-5
8 Inboard type
7 Outboard type } Hub
WARNING
WARNING
use a lifting cable and hoist to move it. To assure safety,
men. Be careful not to drop the hub and drum onto your
feet.
14 Stopper bolt
19 Castellated nut

bolt.
NOTE
FA-6-6

fluid.
30 Steering arm
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
bolts.
WARNING
WARNING
FA-6-7
INSPECTION

Unit: mm (in)
46.98 - 47.00 (1.8496 - 1.8504) 46.9 (1.846)

Unit: mm (in)
0.01 - 0.10 (0.0004 - 0.0039) 0.2 (0.008)

Unit: mm (in)
0 - 0.04 (0 - 0.0016) 0.15 (0.0059)
FA-6-8

front-rear direction.
To check the top-bottom bend, measure the height up to the
wire (string) from the top of the spring seat at the center of
the left and right spring seat and check if the height is equal
on both left and right sides.
3. Install the kingpin or centering pin at the left and right king-
pin mounting holes of the axle and check if the left and right
centering pins overlap by viewing them from the side as
illustrated in the figure.
Also check if the left and right spring seat and centering
pins are at right angles.
eccentrically worn.
KINGPIN ANGLE
7º±10´ —
NOTE
studs manually.
Brake drum
FA-6-9

KINGPIN BUSHING
1. Use the kingpin bushing tool (99831 Z0008) to remove and
install the kingpin bushing.
Drive the upper bushing out of the upper side of the steer-
ing knuckle and the lower bushing out of the lower side.
2. Remove foreign matter (dirt, dust, etc.) from the kingpin
bore in the steering knuckle, and apply a coat of gear oil.
3. Drive the upper bushing into the bore until the lower surface
of the replacer is in contact with the upper surface A of the
steering knuckle.
Drive the lower bushing into the bore until the lower surface
of the replacer is in contact with the lower surface B of the
steering knuckle.
NOTE
z Ensure that the upper and lower kingpin bushings are
installed so that they can be “clinched” 45º toward the
outer rear side of the vehicle.
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
CAUTION
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.
BRAKE DRUM AND HUB

1. Separate the brake drum from the hub by removing the hub
nuts on the inside of the brake drum.
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
those without any stamp for the right-hand hub. The hub
bolts must be installed with the shorter flange portion
facing outward.
HUB AND HUB BOLT

NOTE
FA-6-11

pressed out.
NOTE
cent parts.
grease.

Imp tons}.
NOTE
grease.
FA-6-12


If hub bolts need to be replace in emergencies, such as when trou-
ble occurs, etc., proceed as follows:
weight.
NOTE
cent parts.
grease.
FA-6-13

z Place the hub and brake drum on a film mount to prevent
mately 20 times.
NOTE
grease.

serrations.
NOTE
grease.
FA-6-14
HUB BEARING
NOTE

outer race.
NOTE
rod).
1. 99843Z5002 3. 99844 Z5000
2. 99843Z5004
Z0006).
FA-6-15

Type 1
FA-6-16
Type 2
z PKC210 (for AUSTRALIA) and PKC310 (for AUSTRALIA, NEW ZEALAND) only
FA-6-17
TIE-ROD ASSEMBLY
Inspection
assembly.
NOTE

oz) of grease.
NOTE

NOTE
from rust.
FA-6-18
4. Before installing tie-rod assembly on the tie-rod arm,

remove traces of rust and paint on the mating surface of the
tie-rod arm and dust cover lip using sandpaper.
NOTE
z Do not paint the dust cover. If paint gets on the dust
cover, clean if immediately.
REASSEMBLY
REASSEMBLY
43 Front axle
2. Insert a caster shim between the front axle and leaf spring,
with the center bolt holes aligned.
CAUTION
of the vehicle.
: 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}
FA-6-19
42 Steering knuckle
WARNING
WARNING
NOTE

figure.
2. Kingpin

WARNING
WARNING
tion.
CAUTION
hammer.
clearance.
NOTE
lation.
the shim.
FA-6-20
39 Thrust bearing
NOTE
38 Shim
nance standard.
CAUTION
hammer.
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
Hang a spring balance from the steering knuckle spindle, as shown

in the figure below. Measure the starting force of the steering
knuckle.
CAUTION
spindle.
Unit: N {kgf, lbf}

Less than 9.8 {1.0, 2.2} —
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
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.
27 Brake assembly mounting bolt and 26 Tie-rod arm

1. Fit the brake assembly and tie-rod arm together. Install the
upper two mounting bolts through a spring washer. Insert
the lower two bolts through the lock plate. Using the castel-
lated nuts and cotter pins on the other side of the knuckle,
tighten the tie-rod arm to the brake assembly.
Upper bolt (width across flats)
19 mm (0.75 in)
: 216 - 294 N·m {22 - 30 kgf·m, 159 - 217 ft·lbf}
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
2. Install the tie-rod assembly on the tie-rod arms using the

castellated nuts. Lock the nut with a cotter pin.
: 245 - 304 N·m {25 - 31 kgf·m, 181 - 224 ft·lbf}
NOTE
z Install the tie-rod so that the ball stud can be placed from
the lower side of the tie-rod.
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.

ment procedure.

Install the oil seal retainer onto the steering knuckle with the oil seal
retainer replacer (99827 Z0011).

Install the inner hub bearing on the steering knuckle, using a
replacer (99827 Z0008).
NOTE
FA-6-24
15 Lock nut
installing the wheel and adjusting steer-angle. For adjusting the
steering angle, refer to the “FRONT WHEEL ALIGNMENT” section.
: 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}
8 Inboard type
7 Outboard type }
Hub
NOTE
page FA-6-16 or FA-6-17.
2. Install the hub with the drum attached to the steering

knuckle, and install the outer hub bearing inner race with an
installer.
WARNING
WARNING
use a lifting cable and hoist to install. For safety this
operation must be performed by more than two people.
Take care not to drop the hub and drum onto your feet.
3. Apply grease to the threads on the steering knuckle and

knuckle washer. Install the knuckle washer and tighten with
the castellated nut.
: 196 N·m {20 kgf·m, 145 ft·lbf}
4. Pull the spring balance horizontally until the hub rotates at
least 90º, and measure the preload by reading the mean
value of the spring balance indication.
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
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}
3. Tighten the lock plate with the screw.

: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
CAUTION
z If preload cannot be set within specifications, replace the
adjusting nut and adjust preload again.
1 Inboard type
2 Outboard type } 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
ing procedure” on page FA-6-16 or FA-6-17.
1. Bolt 3. Hub cap
2. Lock washer 4. Gasket
FA-6-26
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
NOTE
<SAE type>
<ISO type>
the disc wheel.
washers (the tapered portion).
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
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

z Installation of steering gear box and steering
z linkage

CAUTION
the ground.
Measure procedure
FA-6-28
“A”.
tires 180 degrees.
CAUTION
step 1.
Bias tire 0 - 4 mm (0 - 0.16 in)

Toe-in
Radial tire 0 - 2 mm (0 - 0.08 in)
Bias tire 0 - 4 mm (0 - 0.16 in)
Toe-in
Radial tire 0 - 2 mm (0 - 0.08 in)
NOTE
torque.
 ： 59 - 78 N•m {6.0 - 8.0 kgf•m, 43 - 58 ft•lbf}
FA-6-29
MEASURING CAMBER
A: Camber
B: Kingpin inclination
1. Place the rear wheels on stands that are the same height
as the turning radius gauge.
head.
Camber 1º00´

C: Caster
air bubbles.

FA-6-30

Caster 3º20´

NOTE
wheel alignment.
Item Maximum turning angle
Inside 47º
Outside 36º
NOTE

: 78 - 98 N·m {8.0 - 10.0 kgf·m, 58 - 72 ft·lbf}
OVERALL INSPECTION
FA-6-31
SUSPENSION
CONSTRUCTION
SUSPENSION
STABILIZER
FA-7-1
DISASSEMBLY
REMOVAL
threads. (SAE type)
hand threads.
WARNING
WARNING
bility.

bolt threads.
toward you.
9. Remove the front stabilizer. (Models equipped with front
stabilizer)
Refer to the “FRONT STABILIZER” section for procedures.
FA-7-2
DISASSEMBLY
<SUSPENSION>
FA-7-3

1. Washer 12. Self-locking nut ,+ 23. Spring pin
2. Rubber cushion 13. Shock absorber pin 24. Shim
3. Rubber cushion ,+ 14. U-bolt nut , 25. Grease nipple
4. Washer 15. U-bolt , 26. Lock bolt
5. Washer 16. Bumper rubber ,+ 27. Spring pin
6. Rubber cushion 17. Caster shim 28. Spring assembly
7. Washer
8. Shock absorber
9. Washer
10. Rubber cushion
18. Spacer
19. *Shim (Except PKB212)
20. *1Center pin
21. Grease nipple
} FA40
model only
29. Grease nipple
, 30. Lock bolt
,+ 31. Shackle pin
32. Shim
11. Washer , 22. Spring lock bolt 33. Shackle
* z 19 Shim: used only on the left side of the FA40 left-hand drive vehicles
*1 z 20 Center pin: L = 20 is used on the right and left sides of FA40 right-hand drive vehicles.
L = 30 is used on the left side only of FA40 left-hand drive vehicles.
FA-7-4
<STABILIZER> (FA40 ONLY)

1. Nut , 9. Stabilizer clamp 17. Rubber cushion
2. Pin , 10. Stabilizer clamp 18. Washer
3. Bushing 11. Stabilizer bar 19. Link rod
4. Nut 12. Self-locking nut 20. Nut
5. Bolt 13. Washer 21. Bolt
6. Nut 14. Rubber cushion 22. Bolt
7. Bolt 15. Washer 23. Stabilizer bracket
, 8. Bushing 16. Washer
FA-7-5
<SUSPENSION>
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.
23, 27Spring pin

Remove the spring pin.
NOTE
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
INSPECTION
<SUSPENSION>
Leaf spring
Unit: mm (in)
30.0 (1.181) 29.5 (1.161)

Unit: mm (in)
30.0 (1.181) 31.0 (1.220)

Unit: mm (in)
0.02 - 0.14 (0.0008 - 0.0055) 1.0 (0.039)
FA-7-7

<SUSPENSION>
Leaf spring
securely.

new center bolt.
NOTE

: 108 - 127 N·m {11 - 13 kgf·m, 80 - 94 ft·lbf}

8. Install the clip bolt with the T-type socket (99535 Z0005).
Bushing
1. Remove the bushing with the bushing replacer (99888
Z0003).

FA-7-8
REASSEMBLY
<SUSPENSION>
NOTE
z Always face the thinner side of the caster shim towards
the front of the vehicle.

31 Shackle pin
Install the shackle on the bracket by driving the shackle pin into
place. Place shim on each side of the shackle. Use a copper ham-
mer to drive the shackle pin.
Thickness of shim
1.8 mm (0.071 in)
NOTE
z Align the bracket with the cutout section of the shackle
pin lock bolt when driving the shackle pin into place.
30, 26 Lock bolt

: 64 - 78 N·m {6.5 - 8.0 kgf·m, 47 - 58 ft·lbf}
27, 23 Spring pin

Align the bracket with the cutout section of the spring pin lock bolt.
FA-7-9
25 Grease nipple
The “L” grease nipple for the front spring pin should face the front.
22 Spring lock bolt

: 64 - 78 N·m {6.5 - 8.0 kgf·m, 47 - 58 ft·lbf}
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
<STABILIZER>
(Models equipped with front stabilizer)

10, 9 Stabilizer clamp
1. Temporarily install the stabilizer bar on the stabilizer holder
using the bushing and clamp.
2. Tighten the stabilizer clamp securely after installing the sta-
bilizer bar on the stabilizer bracket.
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.
TIRE SIZE DESIGNATION

Truck type radial
245 / 70 R 19.5 G (14PR)

Load range
Rim diameter in inches
Indicates radial construction
Height to width ratio of tire
Nominal section width in millimeters
11 R 22.5 L (16PR)
Load range
Indicates radial construction
Nominal section width in inches
Truck type bias
7.50 - 20 - F (12PR)
Load range
Nominal section width in inches
WHEEL SIZE DESIGNATION
22.5 × 6.75 - 152

Offset (in mm)
Rim width (in inches)
Rim diameter (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
16 x 6.00GS-135 Horizontal 2.0 (0.079) —

20 x 6.00S-135
20 x 6.50T-152
20 x 7.50V-165 Vertical 1.8 (0.071) —
Type 1
Horizontal 2.0 (0.079) —
20 x 6.50T-145
Disc Vertical 2.0 (0.079) —
wheel Horizontal 1.8 (0.071) —
runout 20 x 7.00T-162
Vertical 1.8 (0.071) —
17.5 x 6.00-135
17.5 x 6.75-135 Horizontal 2.0 (0.079) —
19.5 x 6.75-135
19.5 x 6.75-136 Type 2
22.5 x 6.75-152
22.5 x 7.50-162 Vertical 1.8 (0.071) —
22.5 x 8.25-165
2-7
Side ring end clearance —
(0.08 - 0.28)
NOTE
z Disc wheel sectional area and measuring points differ
between type 1 and type 2. (Refer to the figure.)
TIGHTENING TORQUE
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
1. Apply the parking brake and chock all tires except the one
to be removed.
2. Be careful as the wheel nuts differ between the SAE type

and ISO type.
SAE type
The wheel nuts on the right side of the vehicle have right-handed
threading; the left side wheel nuts have left-handed threading.
ISO type
The left and right wheel nuts have the same right-hand thread
designs.
TW-2-1
DISASSEMBLY
3. Using a jack, raise the axle on the side of the tire to be

removed until the tire clears the ground. Refer to the GE
section for the jack-up point.
<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.
<GARAGE JACK AND SAFETY STAND>

WARNING
WARNING
z When carrying out operations with the garage jack, be
sure to support the vehicle with safety stands.
z When jacking up the rear (front) of the vehicle, place the
chocks at the front (rear) of the front (rear) wheels to hold
them.
4. Changing wheel types

WARNING
WARNING
Use only the same type and style wheels and mounting
hardware to replace original parts. Do not use unauthorized
wheel components. Failure to do so may result in an assem-
bly which does not fit together properly resulting in prema-
ture wheel or fastener failures.
z Fasteners like bolts and nuts removed from the vehicle
should be re-used in the same spot whenever possible.
If not possible, new fasteners selected must match those
replaced and obtain good metal-to-metal contact. It is
imperative to identify and use only those fasteners des-
ignated for use with the respective vehicle being ser-
viced. Mismatched or incorrect fasteners can result in
vehicle damage or possible personal injury.
z Do not attempt to mix ball seat wheels or fasteners with
flange nut wheels or fasteners.
z Do not change from aluminum wheels to steel or vice
versa without changing the mounting hardware. In the
case of some flange nut assemblies, the hub must be
changed also.
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
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.
Disassembling the tubeless type

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.
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.
3. Spread lubricant or soapy water on the tire bead and rim

flange.
4. Insert the curved end of both levers at point 25 cm (9.8 in)

from the valve on both sides.
Insert both levers, and step on the tire opposite the valve to
direct the first bead into the well.
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
6. Stand the tire assembly up in the vertical position. Insert the

straight end of the lever between the tire bead and back rim
flange. Lean the tire assembly slowly toward the lever.
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.
RIM AND DISC WHEEL

Check for cracks or damage. If any of the following faults are
noticed, replace the rim and disc wheel as a unit.
TW-3-1
INSPECTION
Cracked bead seat

If left unheeded, the cracked area will increase with operation,
resulting in damage to the tire. This is very dangerous.
Deformed flange
A deformed flange results from heating due to partial movement of
the tire or trapped foreign matter.
Corroded bead seat
Excessive corrosion reduces the thickness of the seat, resulting in
a decrease in strength and safety.
Damaged seating surface of nuts
Fatigue or cracks will result with operation if the nut is not tightened
to the specified torque.
Cracks on designed holes
This is due to overloading. If left unheeded, the cracked area will
enlarge resulting in breakage.
TW-3-2
REASSEMBLY
REASSEMBLY
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
7. Install the side ring using two levers.
8. Lightly tap the side ring with a plastic hammer so that it is

correctly installed. After that, check for side ring end clear-
ance.
Unit: mm (in)
2 - 7 (0.08 - 0.28) —
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.
9. Insert iron bars into the ornamental hole in the wheel in a

minimum of two places and inflate to the specified air pres-
sure.
NOTE
z Do not inflate to the specified air pressure at one time.
Inflate in several steps, confirming the air pressure each
time using a gauge.
z When inflating, apply air perpendicularly to the valve.
Keep the face away from this area.
z If the tire comes into contact with the side ring while
inflating with air, tap the ring with a plastic hammer, etc.
so that the side ring fits into the wheel.
10. Coat the valve core with soapy water and check for air leak-
age. After that, install the valve cap.
Assembling the tubeless type

1. Spread lubricant or soapy water on the entire circumference
of tire bead and rim flange.
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.
4. In a manner similar to step 3. above, pry the bead on the

other side and press into the rim flange.
Ensure that valve is in proper position.
5. Inflate the tire to the specified pressure. If air leaks due to

poor contact between the tire and wheel, stand the tire on
end. Press the top of the tire while rolling it back and forth
until the tire and wheel contact properly before inflating
again. It is good practice to supply a large amount of air at
one time to the valve while the core is removed; this will
allow the tire to make good contact with the wheel.
6. When the tire and wheel make good contact, install the core
and inflate the tire to the specified pressure.
NOTE
z Do not inflate the tire to the specified pressure all at
once. Inflate in several steps, while checking with an air
pressure gauge.
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
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.
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
3. 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.
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).
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
STEERING GEAR BOX AND HYDRAULIC PUMP

STEERING LINKAGE
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)
Made by JIDOSHA KIKI Co., Ltd.

Unit: mm (in)
Item 446-02580
O.D. of steering wheel 460 (18.11)
Type Integral
Gear ratio 22.42
Operating angle of sector shaft 2 x 48º+2.5º
0
Center-to-center distance between sector
91 (3.58)
shaft and ball screw
Type of sector shaft Gear
Type Straight ball groove
Dia. of piston 100 (3.94)
Ball Torsional direction of ball screw Right
screw O.D. of ball x number of balls - ball
7.14 x 32 - 35 (0.2811 x 32 - 1.38)
pitch
Lead 14.288 (0.5625)
ST-1-1
HYDRAULIC PUMP
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}
STEERING GEAR BOX AND CORRESPONDING HYDRAULIC PUMP

Vehicle model
Item MKA MKB MKB MKC MKD LKB LKC LKC LKD PKB PKB PKC PKC PKF PKC PKC CDA CWA
210 210 212 210 210 212 210 212 210 210 212 210 212 210 310 310-T 310 310
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
STEERING GEAR BOX
<PMU-1487, PMU-1488 and PSI-Y85-7>
Unit: mm (in)
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)
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)
— 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

<446-02580>
Unit: mm (in)
Clearance between gear case and ball screw
— 0.15 (0.0059)
assembly
Axial play of ball screw — 0.04 (0.0016)
— arm 300 mm (11.81 in) with
assembly (0.0020 - 0.0118)
gears in Neutral.
Less than
End play of piston and worm shaft —
0.5 (0.020)
Wear of sector shaft Adjusting bolt side 47.975 (1.8888) 47.93 (1.8870)
O.D. Pitman arm side 57.975 (2.2825) 57.93 (2.2807)
0.01 - 0.10
Axial play of adjusting bolt —
(0.0004 - 0.0039)
HYDRAULIC PUMP
Unit: mm (in)
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
Thicknesses of relief valve adjusting shim and corresponding pressure changes

Relief set pressure Thickness of shim Change in pressure
Model
kPa {kgf/cm2, psi} mm (in) kPa {kgf/cm2, psi}
475-04271 0.2 (0.008) 520 {5.3, 75} approx.
475-04273
TYPE II 12,259 {125, 1,778}
475-04279
475-04293 0.5 (0.020) 1,314 {13.4, 191} approx.
475-04270 0.2 (0.008) 451 {4.6, 65} approx.

475-04272
TYPE III 10,297 {105, 1,493}
475-04278
475-04292 0.5 (0.020) 1,128 {11.5, 164} approx.
475-04233 0.2 (0.008) 520 {5.3, 75} approx.

TYPE IV 12,259 {125, 1,778}
475-04333 0.5 (0.020) 1,314 {13.4, 191} approx.
ST-1-4
TIGHTENING TORQUE
STEERING GEAR BOX
<PMU-1487, PMU-1488 and PSI-Y85-7>
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>
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}

<446-02580>
Adjusting screw lock nut 118 - 127 {12 - 13, 87 - 94}
Ball tube clip mounting screw 4.4 - 5.4 {0.45 - 0.55, 3.3 - 4.0}
Adjusting plug 226 - 245 {23 - 25, 166 - 181}
After completely tightening, back off 180º.
Retainer Retighten to 39 N·m {4 kgf·m, 29 ft·lbf} and then back off 20º.
Ensure that adjusting screw turns smoothly.
Gear box mounting bolt 294 - 343 {30 - 35, 217 - 253}
ST-1-5
HYDRAULIC PUMP
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
Applicable
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
Used to tighten front cover lock nut
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
Applicable
steering unit
PMU -1487
*Remover (push rod)
-1488
EKC-10100201
PSI -Y85-7
Used to remove needle bearing

from side cover and gear case
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
Applicable
steering unit
PMU -1487
23431-
-1488
06908
PSI -Y85-7
Torque cap
23431- Used to measure torque
06908
PSJIG-
PSI -Y100-46
00184-5
Lock nut tool

Used to tighten lock nut PSI -Y100-46
PSJIG-00174
Used to remove and install pin

Block
which connects worm shaft and tor- PSI -Y100-46
PSJIG-00184-1
sion bar
Pin remover
Used to drive out pin PSI -Y100-46
PSJIG-00184-2
Insert tool Used to press-fit oil seal into gear

PSI -Y100-46
PSJIG-00184-3 case
ST-2-3
Applicable
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
* Use removers, EKC-10100201, EKC-10100202 and EKC-10100203 as a set.

** The hydraulic circuit measuring tool (915-00082) is of JKC make.
ST-2-4
<Made by JIDOSHA KIKI Co., Ltd.>

Tool assembly
Used to install the thrust bearing
910-10611
Guide tool Used together with bearing installation

910-23033 guide 910-10611
Attachment assembly
Used to secure the valve housing
910-10671
Wrench assembly Used to remove/install the adjusting

910-10743 plug
ST-2-5
Insert tool assembly Used by connecting with insert 910-

910-11001 21704
Insert
Used to set the Y-packing correctly
910-21704
Press fit
Used to press-fit the adjusting plug
910-20404
Needle Used to remove the O-ring, seal, ring,

910-21200 etc.
ST-2-6
Insert Used to set the piston and seal ring

910-21701 correctly
Squeezer
Used to crimp the adjusting screw
910-21801
Insert Used to set the seal ring correctly in

910-22772 the valve housing
Bar Used to remove/install the adjusting

910-22811 screw retainer
ST-2-7
Hydraulic circuit measuring tool Used to test performance of hydraulic

915-00082 lines
ST-2-8
CONSTRUCTION PMU-1487, PMU-1488 AND PSI-Y85-7
= STEERING GEAR BOX

(UNIT NAMES PMU-1487, PMU-1488 AND PSI-Y85-7) =
CONSTRUCTION
ST-3-1
DISASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
DISASSEMBLY
REMOVAL
1. Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.
2. Clean the area around the connectors to prevent foreign

matter from getting into the ports.
3. Plug the pipe connectors to prevent entry of foreign matter.
4. Do not drain oil immediately after stopping the engine to
prevent scalding yourself. Drain when the oil temperature
drops below 50ºC (122ºF).
5. Remove the pitman arm, using a pitman arm puller (99850

Z0001).
NOTE
z Before removing the pitman arm, align the mark on the
sector shaft with the punch mark on the pitman arm.
ST-3-2
DISASSEMBLY

+ 1. Sector shaft and side cover assembly 15. Dust cover 29. O-ring
2. Side cover ,+ 16. Valve housing assembly 30. Teflon ring
+ 3. O-ring 17. Thrust bearing 31. O-ring
, 4. Sector shaft 18. O-ring 32. O-ring
,+ 5. Needle bearing 19. O-ring 33. Teflon ring
,+ 6. U-packing 20. Retaining ring , 34. Piston
7. Adjuster 21. Oil seal 35. Worm shaft assembly
, 8. Adjuster bolt 22. Needle bearing 36. Slipper ring
,+ 9. Lock nut , 23. Valve housing 37. O-ring
10. Front cover ,+ 24. Ball screw assembly ,+ 38. Needle bearing
11. O-ring , 25. Sleeve , 39. U-packing
12. Thrust race 26. O-ring , 40. Dust seal
13. Thrust bearing , 27. Rotor 41. Gear case
, 14. Thrust race 28. Teflon ring
ST-3-3

CAUTION
z The integral power steering system is designated as a
“security” part and is precisely adjusted and tested
before installation.
z Do not attempt to disassemble unless absolutely neces-
sary. If it must be disassembled, carefully read this sec-
tion and familiarize yourself with the contents and
instructions.
Use proper test equipment.
z Do not disassemble the ball screw assembly unless nec-
essary.
z Discard old O-rings and seals and install new ones.
z Turn the worm shaft to set the gear to Neutral.
1 Side cover and sector shaft assembly

1. Do not use a iron-faced hammer when removing the sector
shaft.
2. Be careful not to drop the side cover and sector shaft
assembly.
3 O-ring, 5 Needle bearing and 6 U-packing

Remove the needle bearing, U-packing and O-ring. (tools: EKC-
10100201, EKC-10100202 and EKC-10100203)
NOTE
z The needle bearing need not be removed unless neces-
sary.
2. U-packing 4. Side cover
9 Lock nut
Remove the nuts and front cover. (tools: 23431-06912 and PSJIG-
00183-2)
ST-3-4
16 Valve housing assembly

1. When removing the dust cover and valve housing, do not
allow the thrust bearing to drop out.
NOTE
z Do not remove the needle bearing unless necessary.
2. Separate the sleeve, O-ring and rotor.

NOTE
z Set the ball screw horizontally and position the ball nut in
the center.
z Be careful because the ball nut and worm shaft move
under their own weight and ride over the incomplete
threaded section.
24 Ball screw assembly

1. Use an oil pan to catch the balls.
2. Prevent the steel balls from being caught in the threaded
sections by applying force in the axial direction of the worm
shaft.
3. Record the number of steel balls.
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
Clearance between gear case and ball screw assembly
Unit: mm (in)
0.04 - 0.09 (0.0016 - 0.0035) 0.15 (0.0059)
Wear of worm shaft O.D.

While supporting the ball nut horizontally, rotate the worm shaft
slowly to see if it rotates smoothly. If it does not, replace the ball
screw assembly.
Unit: mm (in)
22.00 (0.8661) 21.87 (0.8610)
Axial play of piston and worm shaft

Unit: mm (in)
0.02 (0.0008) 0.12 (0.0047)
Wear of sector shaft O.D. (Pitman arm side)

Unit: mm (in)
44.98 - 45.00 (1.7709 - 1.7717) 44.95 (1.7697)
Axial play of adjusting bolt

Unit: mm (in)
0 (0) 0.1 (0.004)
ST-3-6
REASSEMBLY PMU-1487, PMU-1488 AND PSI-Y85-7
REASSEMBLY
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.
: 4 - 5 N·m {0.4 - 0.5 kgf·m, 2.9 - 3.6 ft·lbf}
ST-3-7
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

1. Hold the ball screw assembly horizontally and handle it
carefully.
2. Be careful not to damage the seals and other parts of the
ball screw.
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
16 Valve housing assembly

1. Affix the bearing to the valve housing assembly using
grease.
2. Ensure that the O-ring is installed in the oil groove.
: 108 - 147 N·m {11 - 15 kgf·m, 80 - 108 ft·lbf}
ST-3-8
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.
6 U-packing and 5 Needle bearing

Install the needle bearing, U-packing and O-ring on the side cover.
(tool: 23431-06917)
NOTE
z Apply a coat of grease to the needle bearing, U-packing
and the O-ring.
2. U-packing 4. Side cover
4 Sector shaft assembly

1. When installing the side cover assembly on the sector shaft
assembly, insert a screwdriver through the center hole in
the side cover and turn the adjusting bolt.
ST-3-9
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.
<Adjusting the backlash>

1. After installing the sector shaft on the pitman arm, operate
the piston through two or three complete cycles by manually
moving the pitman arm. Then, set the gear engagement at
“Neutral”.
NOTE
z Face the gear chamber upward when determining the
Neutral position.
ST-3-10
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)
0.15 - 0.35 (0.0059 - 0.0138) 0.5 (0.020)
: 59 - 78 N·m {6 - 8 kgf·m, 43 - 58 ft·lbf}

NOTE
z After backlash adjustment, move the pitman arm to oper-
ate the piston. Check that the piston moves smoothly
over the entire operating range of the pitman arm.
z Make sure the sector shaft operating angle totals more
than 90 degrees in which right and left turns are at least
45 degrees, respectively.
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}
2. Do not confuse the inlet and the outlet connections; other-

wise, starting the pump will turn the steering wheel abruptly.
This could create a dangerous situation.
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
z After completing installation, carry out performance check.

Refer to page ST-5-15 for check procedures.
ST-3-12
CONSTRUCTION PSI-Y100-46
= STEERING GEAR BOX (UNIT NAME PSI-Y100-46) =

CONSTRUCTION
ST-4-1
DISASSEMBLY PSI-Y100-46
DISASSEMBLY
REMOVAL
wheels.


Z0002).
NOTE
sector shaft with the punch mark on the pitman arm.
6. Remove the dust cover.

NOTE
z Do not remove the dust cover unless it is damaged.
ST-4-2
DISASSEMBLY

,+ 1. Side cover and sector shaft assembly ,+15. Plug 29. Seal ring
2. Side cover 16. Thrust race 30. O-ring
3. O-ring 17. Thrust bearing 31. O-ring
,+ 4. Sector shaft 18. Seal ring 32. O-ring
5. Needle bearing 19. O-ring 33. Seal ring
6. U-packing 20. Thrust bearing 34. O-ring
,+ 7. Lock nut 21. Worm shaft 35. Piston cap
,+ 8. Valve housing and ball screw assembly + 22. Straight pin + 36. Needle bearing
9. Dust cover , 23. Stub shaft assembly 37. U-packing
10. Valve housing , 24. Sleeve , 38. Tapered plug
, 11. Ball screw assembly 25. O-ring , 39. Oil seal
12. Retaining ring 26. Seal ring 40. Gear case
, 13. Oil seal 27. O-ring
14. Thrust bearing 28. Spool
ST-4-3

CAUTION
Do not attempt to disassemble unless absolutely neces-
instructions.
essary.
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.

shaft.
assembly.
NOTE
z The needle bearing need not be removed unless neces-
sary.

Using a chisel, unlock the clinched portion of the adjuster of the
sector shaft assembly. Remove the adjuster by turning it counter-
clockwise.
7 Lock nut
Using the Wrench (PSJIG-00174), remove the lock nut.
ST-4-4
8 Valve housing and ball screw assembly

Turn the stub shaft fully counterclockwise to raise the valve housing
and place a spatula or a similar tool underneath it. Remove the
valve housing and ball screw assembly by prying them out with the
spatula. Be careful not to scratch these parts.
CAUTION
z Use an oil pan to catch the balls.
z Prevent the steel balls from being caught in the threaded
sections by applying force in the axial direction of the
worm shaft.
z Record the number of steel balls.
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
Unit: mm (in)
0.03 - 0.095 (0.0012 - 0.0037) 0.15 (0.0059)
Axial play of ball screw

Unit: mm (in)
Less than 0.02 (0.0008) 0.04 (0.0016)
Clearance between sleeve and spool

Unit: mm (in)
— 0.02 (0.0008)
Clearance between groove in sleeve and straight pin

Unit: mm (in)
Less than 0.035 (0.0014) 0.10 (0.0039)
Wear of sector shaft O.D.

Measure the outside diameter of the sector shaft. Adjusting screw
side and pitman arm side.
Unit: mm (in)
Adjusting screw side 50.00 (1.9685) 49.95 (1.9665)
Pitman arm side 57.12 (2.2488) 57.07 (2.2468)
Axial play of adjusting screw

Unit: mm (in)
— Less than 0.10 (0.0039)
ST-4-6
REASSEMBLY PSI-Y100-46
REASSEMBLY
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.
23 Stub shaft assembly

1. Insert the stub shaft assembly into the worm until the pin
holes (at the ends) are aligned. Install and tighten the set-
screw which has the same size as the thread hole (M6 x
1.0) at the end of the worm.
2. Measure the outside diameter of the straight pin (which was
previously removed), and select a new straight pin from
among those listed in the following table.
Unit: mm (in)
Outside diameter of old straight pin Outside diameter of new straight pin
4.5 (0.177) dia. 0
4.6 -0.005 0
(0.181 -0.0002 ) dia.
4.6 (0.181) dia. 0 0

4.7 -0.005 (0.185 -0.0002 ) dia.
4.7 (0.185) dia. 0 0

4.8 -0.005 (0.189 -0.0002 ) dia.
If the outside diameter of the old straight pin exceeds [4.8 mm

(0.189 in)], replace the ball screw and stub shaft assemblies.
ST-4-7
3. Using a reamer, ream the straight pin hole and remove

burrs.
Unit: mm (in)
Diameter of straight pin hole
Outside diameter of the new straight pin
(after reaming)
0 0 4.6 -0.013 -0.0005 ) dia.
(0.181 -0.0011
4.6 -0.005 (0.181 -0.0002 ) dia. -0.028
0 0 4.7 -0.013 -0.0005
4.7 -0.005 (0.185 -0.0002 ) dia. -0.028 (0.185 -0.0011 ) dia.
0 0 4.8 -0.013 -0.0005
4.8 -0.005 (0.189 -0.0002 ) dia. -0.028 (0.189 -0.0011 ) dia.
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

1. Set the ball nut in the horizontal direction with the steel ball
circulation holes facing up. Align the circulation hole with
the screw groove in the worm.
2. Drop one steel ball through the hole as shown in the figure
at right, and turn the worm slightly counterclockwise.
Repeating this operation, drop a total of twenty-six balls—
one at a time.
NOTE
z Ensure that there is no gap between adjacent steel balls.
After inserting all of the twenty-six balls, check that the
first and the last balls can be seen through the two holes,
respectively.
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.
8 Valve housing and ball screw assembly

1. Apply a coat of grease to the inner wall of the gear case and
insert the ball screw assembly and valve housing in the
case.
NOTE
z Be sure to point the teeth face of the ball nut to the
upward direction during insertion.
2. Tighten the hex bolts using spring washers.

: 127 - 157 N·m {13 - 16 kgf·m, 94 - 116 ft·lbf}
ST-4-9
3. Using the Plug Tool (PSJIG-00183-2), back off the plug 10

to 20º to reduce the thrust bearing preload.
4. Using the Measuring Tool (PSJIG-00184-5) and a torque
wrench, measure the rotating torque of the stub shaft.
5. Tighten the plug to such a degree that the rotating torque
will be 20 to 49 N·m {2 to 5 kgf·m, 14 to 36 ft·lbf} greater
than the value measured in step 4. above to preload the
thrust bearing.
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}

1. Apply a coat of grease to the head of the adjusting screw
and install the adjusting screw on the sector shaft using an
adjuster. Tighten the adjusting screw. Ensure that there is
no axial play when the rotating torque of the adjusting screw
is less than 2 N·m {0.2 kgf·m, 1.4 ft·lbf}.
2. Using a caulking tool and a press, clinch the adjuster in the
groove on the sector shaft.
NOTE
z Use a new adjuster.
z After complete assembly of the sector shaft assembly,
ensure that the adjusting screw turns smoothly, and that
there is no axial play.
ST-4-10

1. Align the thread hole in the center of the side cover with the
adjusting screw of the sector shaft. Turn the adjusting screw
counterclockwise until the side cover and sector shaft are
combined properly.
NOTE
z Be sure to turn the adjusting screw until the sector shaft
assembly butts against the side cover assembly.
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}
Adjusting the sector shaft backlash

1. After installing the pitman arm on the sector shaft, move it
so that the piston operates for two or three cycles. Ensure
that the gears are engaged at neutral.
2. Completely tighten the adjusting screw (= backlash “0”) and
set a dial gauge to the end of the pitman arm [L = 300 mm
(11.81 in)].
3. Gradually back off the adjusting screw until the backlash is
within the specified range. Tighten the lock nut.
Backlash
Maintenance standard
0.06 - 0.30 mm (0.0024 - 0.0118 in)
: 59 - 78 N·m {6 - 8 kgf·m, 43 - 58 ft·lbf}
INSTALLATION
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}
ST-4-11

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.
NOTE
on the pitman arm.
: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ftvlbf}

ST-4-12
CONSTRUCTION 446-02580
= STEERING GEAR BOX (UNIT NAME 446-02580) =

CONSTRUCTION
ST-5-1
DISASSEMBLY 446-02580
DISASSEMBLY
REMOVAL
wheels.


Z0002).
NOTE
sector shaft with punch mark on the pitman arm.

NOTE
ST-5-2
DISASSEMBLY

,+ 1. Side cover and sector shaft assembly 13. O-ring + 25. Piston
2. O-ring 14. O-ring ,+ 26. Seal ring
3. Back-up ring 15. Adjusting plug ,+ 27. O-ring
4. Y-packing ,+ 16. Y-packing 28. Ball tube clip
5. Needle bearing 17. Ball bearing , 29. Ball tube
,+ 6. Side cover 18. O-ring 30. Needle bearing
7. Retainer , 19. Thrust bearing ,+ 31. Back-up ring
8. Adjusting screw + 20. Seal ring ,+ 32. Y-packing
,+ 9. Sector shaft 21. Stub shaft ,+ 33. Oil seal
10. Dust cover , 22. Worm shaft assembly 34. Gear case
,+ 11. Ball screw and valve housing assembly ,+ 23. Seal ring
12. Valve housing ,+ 24. O-ring
ST-5-3

CAUTION
Do not attempt to disassemble unless absolutely neces-
instructions.
essary.
z Turn the worm shaft until gears are set in neutral, and place
the steering gear box in a vise.

shaft.
assembly.
3. Before removing the side cover, place the sector shaft in the
“soft” jaws of 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
2. Using the Bar (910-22811), loosen the retainer. Remove the

retainer and adjusting screw from the sector shaft.
11 Ball screw and valve housing assembly

1. Using the Wrench (910-10743), loosen (do not remove) the
15 adjusting plug approximately 180º at the valve housing.
NOTE
z If the adjusting plug is removed, the bearing will pop out
of the valve housing.
z Be careful not to damage the inner wall of the steering
body, especially at the contact surface of the piston. Do
not allow the ball to pop out of the ball screw.
2. Place the valve housing on a workbench with the piston

side facing down. Remove the worm shaft while holding the
valve housing with one hand and turning the stub shaft with
the other.
NOTE
z Be careful not to drop the piston as it contains steel
balls. Do not lose them.
3. Place the Attachment Assembly (910-10671) in a vise.

Remove the O-ring from the contact surface of the housing.
Attach the housing assembly to the Attachment Assembly
and remove the plug and seal assembly which were loos-
ened previously.
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
20 Seal ring
Remove the rotor from the worm shaft assembly. Using the Needle
(910-21200), remove the seal ring from the rotor.
23 Seal ring and 24 O-ring

Using the Needle (910-21200), remove the three seal rings and
three O-rings from the grooves on the inner wall of the valve hous-
ing.
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
26 Seal ring and 27 O-ring

Using the Needle (910-21200), remove the seal ring and O-ring
from the perimeter of the piston.
31 Back-up ring, 32 Y-packing and 33 Oil seal

Remove the oil seal, back-up ring and Y-packing from the mating
surface of the output shaft of the steering body assembly.
Do not remove the needle bearing and tapered plug unless they are
damaged.
ST-5-6
INSPECTION 446-02580
INSPECTION
Unit: mm (in)
— 0.15 (0.0059)
Axial play of ball screw

Unit: mm (in)
— 0.04 (0.0016)
End play of piston and worm shaft

Unit: mm (in)
Less than 0.5 (0.020) —
Wear of sector shaft O.D.

Measure the outside diameter of the sector shaft. Adjusting screw
side and pitman arm side.
Unit: mm (in)
Adjusting screw side 47.975 (1.8888) 47.93 (1.8870)
Pitman arm side 57.975 (2.2825) 57.93 (2.2807)
Axial play of adjusting screw

Unit: mm (in)
0.01 - 0.10 (0.0004 - 0.0039) —
ST-5-7
REASSEMBLY 446-02580
REASSEMBLY
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.
32 Y-packing and 31 Back-up ring

1. Position the Y-packing and back-up ring in the groove in
front of the needle bearing at the output shaft end hole of
the steering body. It is easy to install the back-up ring while
bending it like a heart shape with your fingers as shown.
NOTE
z Fill the groove with grease before installing the Y-pack-
ing. Face the sealing lip of the Y-packing toward the nee-
dle bearing.
2. Using the Insert Tool Assembly (910-11001), reform the

back-up ring to the original shape.
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.
27 O-ring and 26 Seal ring

Position the O-ring and seal ring in the outer grooves of the piston.
Reform the seal ring to its original shape using the Insert Tool (910-
21701).
NOTE
z Be careful not to twist the O-ring.
z Do not expand the seal ring more than necessary.
ST-5-8
24 O-ring and 23 Seal ring

Position the O-rings and seal rings in the three narrow grooves, and
reform them to their original shapes using the Insert Tool (910-
22772).
22 Worm shaft assembly

1. Position the seal ring in the groove on the perimeter of the
rotor and reform to the original shape using the Insert Tool
(910-22772).
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.
2. Remove the Guide (910-23033) and install the other side

race.
ST-5-9
3. Insert the valve housing thrust bearing subassembly into

the shaft assembly from the worm shaft side.
NOTE
z Be careful not to damage the seal ring of the valve hous-
ing during installation.
4. Place the Attachment Assembly (910-10671) in a vise.

Install the shaft assembly and valve housing (assembled in
step 3. above) on the Attachment Assembly. Position the O-
ring in the groove on the inner perimeter of the valve hous-
ing and screw the plug and seal assembly into the valve
housing.
NOTE
z Do not confuse the groove in the valve housing with the
recess groove when installing the O-ring.
z Be careful not to damage the sealing lip of the Y-packing
with the serrated portion of the stub shaft when installing
the plug and seal assembly.
5. Using the Wrench Assembly (910-10743), tighten the plug
and seal assembly. After tightening, ensure that the stub
shaft smoothly turns without binding. Back off the plug and
seal assembly approximately 180º.
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.
2. Apply grease to the Y-packing and install the ball bearing.
ST-5-10
11 Ball screw and valve housing assembly

1. Insert the valve housing and shaft assembly into the piston.
While turning the stub shaft and aligning the ball race of the
piston with that of the shaft, drop the remaining steel balls
one after another through the hole in the ball tube.
NOTE
z Do not extend the shaft and housing assembly to the
extreme end of travel.
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.
3. Measure the axial play of the ball screw.

A F B
Less than 0.5 mm
20 mm (0.79 in) 49 N {5 kgf, 11 lbf}
(0.020 in)
4. Position the screw and housing assembly in the steering

body.
NOTE
z Be careful not to damage the piston seal ring.
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
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.
2. After tightening the retainer, clinch two places using the

Squeezer (910-21801).
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.
3. Attach the Insert Tool (910-21704) to the Insert Tool Assem-

bly (910-11001) when reforming the back-up ring to its origi-
nal shape.

1. Align the screw hole in the center of the side cover assem-
bly with the adjusting screw, and turn the adjusting screw
counterclockwise until they are combined.
ST-5-12
2. Position the O-ring in the groove on the outer perimeter of

the side cover and insert the side cover into the steering
body.
NOTE
z Ensure that the centers of the piston gear and sector
shaft gear are engaged.
z Be careful not to damage the sealing lip of the Y-packing.
: 55 - 64 N·m {5.5 - 6.5 kgf·m, 40 - 47 ft·lbf}
3. Tighten the adjusting plug to the specified torque.

NOTE
z Apply liquid gasket Three Bond 1102 or equivalent to the
threaded part of the adjusting plug.
: 226 - 245 N·m {23 - 25 kgf·m, 166 - 181 ft·lbf}
4. Put two punch marks 180º apart from each other on the
periphery of the valve housing and adjusting plug contact-
ing area.
<Adjusting the sector shaft backlash>

1. Install the pitman arm on the sector shaft. Move the pitman
arm with your hand so that the piston makes two or three
cycles of operation. Then, set the gears at the neutral posi-
tion.
2. Completely tighten the adjusting screw (= zero backlash)
and attach a dial gauge to the end of the pitman arm [L: 300
mm (11.81 in)].
3. Gradually back off the adjusting screw until the backlash is
within the specified range. Tighten the lock nut to the speci-
fied torque.
Specified backlash
0.2 - 0.4 mm (0.008 - 0.016 in)
: 118 - 127 N·m {12 - 13 kgf·m, 87 - 94 ft·lbf}
NOTE
z Apply liquid gasket (Three Bond 1102 or equivalent) to
the lock nut before tightening it.
ST-5-13
INSTALLATION
: 294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}

shaft (if the dust cover was removed).
NOTE
NOTE
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
No. Part No. Description Remarks

1/4″ — 19 [19,614 kPa
1. 1360-0007 Oil pressure gauge
{200 kgf/cm2, 2,844 psi}]
M12 x 1.5, 1/4″ x 14
2. 1203-0088 Connector
Internal threads
3. 1220-1024 Copper tube
4. 1203-0092 Connector M12 x 1.5, PT 1/8
5. 1202-0159 Connector M12 x 1.5, PT 1/2
7. 915-20001 Valve
8. 1202-0159 Connector M12 x 1.5, PT 1/2
M12 x 1.5, M18 x 1.5
10. 1202-0158 Connector
Internal threads
11. — Gasket
12. — Connector
13. — Inlet pipe
14. — Gasket
15. 1202-0161 Connector M12 x 1.5, M18 x 1.5
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
Preparations before checks

Check the fluid level in the oil reservoir. If necessary, add oil. Bleed
air from the steering system.
Next, start the engine and operate it at idle speed. Turn the steering
wheel left and right as fluid reaches operating temperature [50 to
60ºC (122 to 140ºF)].
Checking the pressure
The normal pressure is below 490 kPa {5 kgf/cm2, 71 psi} when the
engine is idling and the steering wheel is released. If higher than
this, check the power steering control valve and piping for clogging.
CHECKING THE RELIEF PRESSURE

Procedure
Operate the engine at 1,500 to 1,600 rpm. Gradually close the cock
while observing the pressure rise on the gauge indicator. Then,
measure the maximum pressure (relief valve control pressure).
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. 12,749 kPa {130 kgf/cm2, 1,849 psi}, min. ... Malfunctioning
relief valve
3. 12,014 kPa {122.5 kgf/cm2, 1,742 psi}, max. ... Faulty pump
or relief valve or weak spring
Hydraulic pump Type III
1. 10,052 - 10,788 kPa {102.5 - 110 kgf/cm2, 1,458 - 1,564 psi}
... Normal
2. 10,788 kPa {110 kgf/cm2, 1,564 psi}, min. ... Malfunctioning
relief valve
3. 10,052 kPa {102.5 kgf/cm2, 1,458 psi}, max. ... Faulty pump
or relief valve or weak spring
Disassemble faulty parts and repair or replace as required. If nec-
essary, replace hydraulic pump.
CAUTION
z Do not close the cock for more than 15 seconds while
testing.
CHECKING THE FLOW CONTROL VALVE

Procedure
1. Idle the engine. Gradually close the cock until pressure is
4,904 kPa {50 kgf/cm2, 711 psi}.
2. Increase engine speed to approximately 1,500 rpm and
abruptly decrease it. Record the drop in pressure. Repeat
this step four to five times.
3. Change the pressure setting to 3,923, 2,942, 1,961, 981
kPa {40, 30, 20, 10 kgf/cm2, 569, 427, 284 , 142 psi},
respectively, and repeat tests outlined in step 2. above.
ST-5-17
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 THE POWER STEERING SYSTEM

Check the following. The hydraulic pump should operate normally.
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
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.
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
ST-5-18
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.
TESTING PRESSURE AT EXTREME LIMITS OF STEER-

ING WHEEL TRAVEL
Procedure
Open the cock fully and turn the steering wheel fully to left and right
several times. Then, measure pressure.
Judgement
1. 12,014 - 12,749 kPa {122.5 - 130 kgf/cm2, 1,742 - 1,849
psi} ... Normal
2. Outside the range indicated in 1. above ... Faulty pressure
circuit.
1. 10,052 - 10,788 kPa {102.5 - 110 kgf/cm2, 1,458 - 1,564 psi}
... Normal
2. Outside the range indicated in 1. above ... Faulty pressure
circuit.
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
Type II*2 and Type III*3
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
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).
2. Disconnect the inlet and outlet tube connections.

3. Remove the hydraulic pump assembly.
ST-6-3
DISASSEMBLY
Type I

1. Woodruff key 7. Packing 13. Retaining ring
2. Connector 8. Straight pin ,+ 14. Shaft
3. O-ring , 9. Cartridge assembly 15. Ball bearing
, 4. Flow control valve assembly 10. Pressure plate 16. Retaining ring
5. Flow control valve spring 11. O-ring 17. Oil seal
, 6. Rear body 12. O-ring 18. Front body
ST-6-4
Type II and Type III

1. Woodruff key 8. Pressure plate 15. Retaining ring
2. Plug , 9. Cartridge assembly 16. Ball bearing
3. O-ring 10. Side plate 17. Retaining ring
, 4. Flow control valve assembly 11. O-ring 18. Washer
5. Flow control valve spring 12. O-ring 19. Oil seal
, 6. Rear body 13. Retaining ring 20. Needle bearing
7. Straight pin ,+ 14. Shaft 21. Front body
ST-6-5
Type IV

1. Woodruff key 9. Straight pin 17. Retaining ring
2. Connector 10. Pressure plate 18. Ball bearing
3. O-ring , 11. Cartridge assembly 19. Retaining ring
4. Plug 12. Side plate 20. Oil seal
5. O-ring 13. O-ring 21. Needle bearing
, 6. Flow control valve assembly 14. O-ring 22. Front body
7. Flow control valve spring 15. Retaining ring
, 8. Rear body ,+ 16. Shaft
ST-6-6

NOTE
z Disassemble only if the discharge pressure is not within
the standard.
14 (Type I, Type II and Type III)

16 (Type IV) } Shaft
Remove the retaining ring with retaining ring pliers, and drive out
the shaft by striking the splined side lightly with a copper hammer.
ST-6-7
INSPECTION HYDRAULIC PUMP
INSPECTION
Clearance between relief valve outside diameter and
body inside diameter
Unit: mm (in)
— 0.03 (0.0012)
ST-6-8
REASSEMBLY HYDRAULIC PUMP
REASSEMBLY
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.

11 Type IV } Cartridge assembly
Install the vanes with their rounded ends facing outward.

8 Type IV } Rear body
: 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}
ST-6-9

6 Type IV } Flow control valve assembly
Position the spring and the assembled flow control valve assembly
in the rear body assembly, then tighten with the plug using the O-
ring.
: 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}
NOTE
z Install the flow control valve assembly with the correct
facing.
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
INSPECTING RELIEF VALVE PRESSURE

1. Disconnect a suitable pipe joint in the hydraulic line from the
oil pump to the power steering, and connect a stop valve
and a pressure gauge 19,614 kPa {200 kgf/cm2, 2,844 psi},
as shown in the figure. Check that oil does not leak from the
connections and that the stop valve is fully opened. Then
bleed air from the hydraulic lines.
NOTE
z Before starting inspection, idle the engine to warm up the
oil to 80 to 100ºC (176 to 212ºF).
2. Set the engine speed to 1,000 to 1,500 rpm, and gradually
tighten the stop valve while watching the pressure gauge.
When the stop valve has been tightened all the way, the
pressure gauge indicates the regulated pressure of the
relief valve.
Relief valve regulated pressure
Type I, Type II and Type IV
12,014 - 12,749 kPa {122.5 - 130 kgf/cm2, 1,742 - 1,849 psi}
Type III
10,052 - 10,788 kPa {102.5 - 110 kgf/cm2, 1,458 - 1,564 psi}
If the hydraulic pressure exceeds the regulated pressure by 981
kPa {10 kgf/cm2, 142 psi}, the relief valve is malfunctioning. On the
other hand, if hydraulic pressure does not build up, the oil pump is
defective and/or the relief valve open.
CAUTION
z During inspection, do not close the stop valve for more
than fifteen seconds.
z When the relief valve regulated pressure is out of adjust-
ment, adjust the shim fitted in the valve assembly.
Relief set pressure Thickness of shim Change in pressure

Type
kPa {kgf/cm2, psi} mm (in) kPa {kgf/cm2, psi}
I — — —
0.2 (0.008) 520 {5.3, 75} approx.
II 12,259 {125, 1,778} 1,314 {13.4, 191}
0.5 (0.020)
approx.
0.2 (0.008) 451 {4.6, 65} approx.
III 10,297 {105, 1,493} 1,128 {11.5, 164}
0.5 (0.020)
approx.
0.2 (0.008) 520 {5.3, 75} approx.
IV 12,259 {125, 1,778} 1,314 {13.4, 191}
0.5 (0.020)
approx.
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
BLEEDING AIR FROM THE POWER STEERING SYSTEM

MK and LK series
If the power steering oil level is below the “L” (Low) level on the cut-
out in the level stick, it is not possible to bleed air. When bleeding
air, ensure that the amount of oil is at the “H” (High) level on the cut-
out in the level stick.
PK, CDA and CWA series

Air cannot be bled when the power steering fluid is lower than the
“LOW LEVEL” mark on the reservoir. Be sure to bleed air with the
fluid at the “HIGH LEVEL” mark.
Air bleeding procedures

1. Pour oil into the oil reservoir to the specified level.
2. With the front axle jacked up, turn the steering wheel to the
right and left. If the hydraulic oil level lowers, add oil each
time.
3. Idle the engine and turn the steering wheel to the right- and
leftmost position several times until there are no bubbles. If
the oil level lowers, add oil.
4. Repeat the above procedure until the oil level stabilizes.
5. Turn the steering wheel to make sure that the right and left
tires move smoothly.
6. Lower the front wheels and check that there is no oil leak-
age around the pipes and connectors.
7. Check the oil level. Add oil if it is insufficient.
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)
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
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
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
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
SYSTEM DIAGRAM
STEERING SYSTEM
Model MK and LK series (without LKD210 models)
Model LKD210, PK, CDA and CWA series
ST-1-2
POWER STEERING TUBING

Model MK and LK series
Model PK, CDA and CWA series
ST-1-3
TOOLS ST LINKAGE
TOOLS
Used when removing steering wheel.
Steering wheel puller

99851 Z0002
Used when removing pitman arm.
Pitman arm puller

99850 Z0001
(MK and LK series without LKD)
99850 Z0002
(LKD, PK, CDA and CWA series)
Used when driving dust cover into ball stud.
Dust cover inserter

99853 Z5000
(MK and LK series without LKD)
99853 Z0001
(LKD, PK, CDA and CWA series)
ST-2-1
STEERING COLUMN ST LINKAGE
STEERING COLUMN
CONSTRUCTION
ST-3-1
DISASSEMBLY
REMOVAL

1. Horn pad ,+ 6. Yoke bolt , 11. Steering column
,+ 2. Steering wheel assembly 7. Tilt handle ,+ 12. Key switch assembly
3. Switch cover (Lower) , 8. Self-locking nut 13. Boot
4. Switch cover (Upper) , 9. Rivet 14. Steering cover
5. Combination switch assembly , 10. Clamp assembly
ST-3-2

z Before disassembling the steering column, turn the key
switch to “OFF” and chock the wheels.
z Also disconnect the ground cable from the battery.
2 Steering wheel assembly

Using the steering wheel puller (99851 Z0002) and attachment
(99854 Z0000), remove the steering wheel.
NOTE
z The attachment (99854 Z0000) is designed for use on
models equipped with the telescopic lever.
z Do not tap the head of the column shaft directly with a
steel-faced hammer.
z Scribe an alignment mark on the steering wheel and col-
umn shaft before dismantling the steering column.
6 Yoke bolt
Scribe an alignment mark on the steering gear box and yoke before
loosening the yoke bolt.
12 Key switch assembly

The key switch assembly is secured to the steering column with the
self-shear type screw. Remove the screw using a commercially
available screw extractor.
ST-3-3
z Punch the center of the self-shear type screw breaking sur-

face.
z Drill a 10 to 15 mm (0.39 to 0.59 in) deep hole into the bolt
using a 5.5 to 6.0 mm (0.217 to 0.236 in) dia. drill.
z Drive the screw out by turning the Screw Extractor (special
service tool) counterclockwise. Remove the key switch
assembly.
DISASSEMBLY

1. Retaining ring 5. Retaining ring 9. Lower shaft dust cover
2. Ball bearing 6. Ball bearing 10. Sleeve yoke
3. Column assembly 7. Spline yoke shaft assembly 11. Grease nipple
4. Column shaft 8. Dust seal cover
ST-3-4
INSPECTION
Axial play at journal locations

Unit: mm (in)
Less than 0.2 (0.008) —
Free play at ball bearing locations

Unit: mm (in)
Less than 0.05 (0.0020) —
Free play at steering wheel

Check the free play of the steering wheel.
z Idle the engine.
z 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)
30 - 50 (1.18 - 1.97) —
ST-3-5
REASSEMBLY
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}
2 Steering wheel assembly

While aligning the alignment mark on the steering wheel and col-
umn shaft, insert the latter into the former.
NOTE
z Ensure that the wheels face straight ahead.
ST-3-6
STEERING LINKAGE ST LINKAGE
STEERING LINKAGE
DISASSEMBLY
REMOVAL
Model MK and LK series (without LKD210)

, 1. Drag link
,+ 2. Pitman arm
ST-4-1
Model LKD210, PK, CDA and CWA series

, 1. Drag link 3. Dust cover 4. Dust cover
,+ 2. Pitman arm
ST-4-2

2 Pitman arm
1. Remove the pitman arm, using a pitman arm puller.
Special service tool
99850 Z0001 ... Models MK and LK series (without LKD)
99850 Z0002 ... Models LKD, PK, CDA and CWA series
NOTE
sector shaft with the punch mark on-the pitman arm.

NOTE
INSPECTION
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
4. Check the dust lip for wear. If worn, replace the dust cover
with a new one.
BALL STUD CONTAMINATION

If grease leaks at or around the dust cover during inspection,
remove the dust cover and check the ball stud.
Check if grease inside the dust cover is contaminated with mud.
z If the grease is entirely contaminated with mud, replace the
ball stud assembly with a new one.
z If only the grease surface is contaminated with mud, wipe
the entire ball stud surface clean and replace the dust cover
with a new one.
NOTE
z Do not re-use the dust cover.
BALL STUD PLAY

Turn the steering wheel to the left and right to check the condition of
the drag link and tie rod end ball joints. The engine must be stopped
during inspection.
z If the drag link and/or tie rod ball joint have free play,
replace the drag link and/or tie rod end assembly.
NOTE
z If, during the on-vehicle inspection, it is not clearly deter-
mined whether there is free play in the ball joint or not,
remove the drag link and tie rod end and manually
vibrate the ball stud to check for free play.
z If free play exists, replace the drag link and/or tie rod
assembly.

DUST COVER
The drag link and tierod ball joints are non-disassembling types.
They are totally enclosed with grease-packed bearings, press-fit to
the sockets and then clinched at the ends.
The dust cover has its interior filled with grease and is press-fit to
the socket end.
ST-4-4
1. Dust cover removal

Pry the dust cover off the socket using a standard screwdriver.
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.
3. Filling the dust cover with grease

Fill the dust cover with grease by inserting a 29.6 mm (1.165 in) dia.
round rod into it.
NOTE
z Recommended grease: Shell Sunlight No. 2
z Grease quantity: 20 g (0.71 oz)
If a round rod is not available, fill with grease as follows:
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
4. Dust cover installation

Place the dust cover over the socket as shown in the figure, and
install using special service tool and a press.
Special service tool
99853 Z0000 ... Models MK and LK series (without LKD)
99853 Z0001 ... Models LKD, PK, CDA and CWA series
Pressing force: 3,923 N {400 kgf, 882 lbf}
NOTE
z Do not use a hammer to install the dust cover.
z Ensure that the contact surface of the socket is clean and
free of rust before pressing the dust cover into place.
5. Ball joint installation

Install the drag link or tie rod assembly to the steering arm.
NOTE
z Ensure that the sealing lip of the dust cover is clean and
free of rust or paint sag. Clean if necessary using sand-
paper.
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
2 Pitman arm
shaft (if the dust cover was removed except models MK and
LK series without LKD models).
NOTE
ST-4-6
NOTE
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)”.
Unit name BHL41 BAL41

Brake system Air-over hydraulic brake system Full air brake system
Brake shoe type Leading-trailing shoe type
Brake drum I.D. mm (in) 410 (16.14)
Width 150 (5.91)
Thickness 16.0 (0.630)
Wheel cylinder type Hydraulic piston type —
Wheel cylinder I.D. mm (in) 50.80 (2.0000) —
Brake cam type — Involute
Brake lining clearance adjusting
— Slack adjuster
system
BR-1-1
SERVICE DATA
REAR WHEEL BRAKE

Unit name *BLT32 *RB50 *RB52 *BLT37 *RB37 *BLT40
Vacuum
servo
Brake system Air-over hydraulic brake system
brake
system
Brake shoe type Dual-two-leading shoe type
Brake drum I.D. mm (in) 320 (12.60) 370 (14.57) 400 (15.75)
115
Width 135 (5.31) 155 (6.10)
Brake lining mm (in) (4.53)
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) 36.51 (1.4374) 38.10 (1.5000) 42.86 (1.6874)
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)”.
Unit name BLL41 RB41 BPL41

Air-over hydraulic
Brake system Full air brake system
brake system
Brake shoe type Leading-trailing shoe type
Brake drum I.D. mm (in) 410 (16.14)
Width 220 (8.66)
Thickness 16.0 (0.630) 15.0 (0.591) 16.0 (0.630)
Wheel cylinder type Hydraulic piston type —
Wheel cylinder I.D. mm (in) 55.56 (2.1874) —
Brake cam type — Involute
Brake lining clearance adjusting
— Slack adjuster
system
BR-1-2
SERVICE DATA
UNIT NAME
FB 5 2
WHEEL BRAKE ABBREVIATION BRAKE OPERATING SYSTEM MODEL CLASSIFICATION

FB Front wheel brake 5 For middle-sized vehicles
RB Rear wheel brake 3 Hydraulic brake for large-sized vehicles

4 Air brake for large-sized vehicles
B H S 32
UNIT CLASSIFICATION IDENTIFICATION OF THE FRONT TYPE CLASSIFICATION DRUM SIZE

AND REAR (Decimal point rounded up)
B Brake S Two-leading
H Front liquid pressure 32 32 cm
T Dual two-leading
L Rear liquid pressure 37 37 cm
L Leading-trailing
A Front air pressure 40 40 cm
P Rear air pressure 41 41 cm
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 —
Rear wheel brake

Brake lining clearance Spring-activated rear
Item Anti-lock Brake System (ABS)
adjusting system wheel parking brake vehicles
Manual-
Unit name Without With Auto-adjuster Without With
adjuster
Type I O — O — O —
BLT32
RB50 Type II O — O — — O
(Type II Type III O — — O — O
only)
Type IV — O — O — O
RB52
Type II O — O — — O
Type III O — — O — O
BLT37
Type IV — O — O — O
RB37
BLT40
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)
Clearance Back off 4-5 notches from zero O O O O O — — — — — —

0.20 - 0.30
between — clearance (*1: Type I only, *2: *1 *2 *1 *2
(0.0079 - 0.0118)
brake drum Type I and Type II only)
and brake 0.20 - 0.30 Back off 8-10 notches from zero — — — — — — — O O O O
lining —
(0.0079 - 0.0118) clearance
319.0 - 320.0 O O O — — — — — — — —
—
(12.55 - 12.60)
Wheel
Brake brake 369.3 - 369.6 — — — O O O O — — — —
—
lining assembly (14.54 - 14.55)
O.D.
399.3 - 399.6 — — — — — — — O O O O
—
(15.72 - 15.73)
Brake lin- 12.0 (0.472) 4.0 (0.157) O O O — — — — — — — —
ing thick-
ness 12.9 (0.508) 4.0 (0.157) — — — O O O O — — — —
(Remain-
ing thick- — — — — — — — O O O O
ness) 15.0 (0.591) 5.5 (0.217)
Clearance 0.030 - 0.090 O O O — — — — — — — —

0.15 (0.0059)
between (0.0012 - 0.0035)
wheel cylin-
0.025 - 0.126 — — — O O O O O O O O
der and pis- 0.20 (0.0079)
ton (0.0010 - 0.0050)
Wheel cylinder I.D. 34.93 mm O — — — — — — — — — —
36.8 - 37.2 More than
(1.3752 in)
Wheel (1.449 - 1.465) 0.65 (0.0256)
Type I only
cylinder
Wheel cyl- Wheel cylinder I.D. 34.93 mm
34.8 - 35.4 More than
inder pis- (1.3752 in)
(1.370 - 1.394) 0.65 (0.0256)
ton cup Type II and Type III only
O.D.
Wheel cylinder I.D. 36.51 mm — O — — — — — — — — —
38.4 - 38.8 More than (1.4374 in)
(1.512 - 1.528) 0.65 (0.0256) [Type I and Type II (Without
wedge wheel cylinder) only]
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
return Measure tension

441 - 539
spring Tension 441 when spring is set
{45.0 - 55.0,
N {kgf, lbf} {45.0, 99.2} at 106.0 mm (4.17
99.2 - 121.3}
in) in length
Free length 210.3 (8.28) — — — — O — O — — — — —
Measure tension
353 - 432
{36.0, 79} at 224.5 mm (8.84
79 - 97}
in) in length
Free length 215.2 (8.47) — — — — — O — O O — O —
Measure tension
344.2 - 420.7
344.2 when spring is set
{35.1, 77.4} at 228.4 mm (8.99
77.4 - 94.6}
in) in length
Free length 245.1 (9.65) — — — — — — — — — O — O
Measure tension
423.7 - 517.8
423.7 when spring is set
{43.2, 95.3} at 266.5 mm (10.49
95.3 - 116.4}
in) in length
Spring — — — — — — — — O — O
cham- Clearance between 0.030 - 0.143
0.2 (0.008) Type II only
ber lever and lever pin (0.0012 - 0.0056)
bracket
BR-1-6
SERVICE DATA
UNIT NAME BHL41, BLL41, BAL41, RB41, BPL41

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
I.D. 410 (16.14) 414 (16.30) O O O O O
Brake
drum Less than 0.025 Difference between max. O O O O O
Out-of-roundness 0.20 (0.0079)
(0.0010) and min. drum diameters
Clearance between brake drum and 0.3 - 0.4 O O — — —
—
brake lining (0.012 - 0.016)
Brake
lining Brake lining thickness 16.0 (0.630) 5.0 (0.197) O O O — O
(Remaining thickness) 15.0 (0.591) 5.0 (0.197) — — — O —
30.0 (1.181) 29.85 (1.1752) O O O — O
Anchor pin O.D.
32.0 (1.260) 31.80 (1.2520) — — — O —
30.0 (1.181) 30.15 (1.1870) O O O — O
Brake shoe bushing I.D.
32.0 (1.260) 32.20 (1.2677) — — — O —
0.07 - 0.20 O O O — O
0.25 (0.0098)
Clearance between anchor pin and (0.0028 - 0.0079)
brake shoe bushing 0.10 - 0.25 — — — O —
0.50 (0.0197)
(0.0039 - 0.0098)
Brake 20.3 (0.799) 20.7 (0.815) — — O — O

Brake shoe roller I.D.
shoe 26.0 (1.024) 26.4 (1.039) — — — O —
40.3 (1.587) 39.9 (1.571) — — O — O
Brake shoe roller O.D.
57.0 (2.244) 56.6 (2.228) With oil seal — — — O —
20.0 (0.787) 19.6 (0.772) — — O — O
Brake shoe roller pin O.D.
26.0 (1.024) 25.6 (1.008) — — — O —
0.20 - 0.43 — — O — O
0.80 (0.0315)
Clearance between brake shoe (0.0079 - 0.0169)
roller and brake shoe roller pin 0.09 - 0.15 — — — O —
0.40 (0.0157)
(0.0035 - 0.0059)
0.120 - 0.234 O — — — —
0.25 (0.0098)
Clearance between wheel cylinder (0.0047 - 0.0092)
and piston 0.128 - 0.248 — O — — —
Wheel 0.25 (0.0098)
(0.0050 - 0.0098)
cylin-
der 50.6 - 51.2 Wheel cylinder I.D. 50.80 O — — — —
—
(1.992 - 2.016) mm (2.0000 in)
Wheel cylinder piston cup O.D.
55.4 - 56.0 Wheel cylinder I.D. 55.56 — O — — —
—
(2.181 - 2.205) mm (2.1874 in)
Cam- 40.0 (1.575) 40.3 (1.587) — — O — O

Camshaft bushing I.D.
shaft 44.0 (1.732) 44.3 (1.744) — — — O —
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
{55.5 - 65.5, —
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
{56.0 - 65.0, —
123 - 143}
Free length 242.6 (9.55) —
Inner 198 - 233
{20.2 - 23.8, —
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
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

BLT32 (Type II, Type III and Type IV), RB50
Wheel cylinder shield 6 - 10 {0.6 - 1.0, 4.3 - 7.2}
With wedge wheel cylinder only
cover mounting bolt
BHS37, BLT37, RB37, BLT40 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Wheel cylinder adjust- BHS32 (Type I), BLT32 (Type I and Type II), RB50 6 - 10 {0.6 - 1.0, 4.3 - 7.2}
ing spring mounting
screw or bolt FB52, RB52, FB37, RB37, BHS40, BLT40 2.4 - 3.5 {0.24 - 0.36, 1.7 - 2.6}
Joint assembly mount-
BHS32 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
ing bolt
Connector assembly
FB52, BHS37, FB37, BHS40 18 - 26 {1.8 - 2.7, 13 - 20}
mounting nut
Tube assembly flared BHS32, BLT32, RB50 12 - 16 {1.2 - 1.6, 9 - 12}

nut FB52, RB52, BHS37, BLT37, FB37, RB37, BHS40, BLT40 13 - 18 {1.3 - 1.8, 9 - 13}
Tube clamp mounting
BHS32, BLT32, RB50 4 - 6 {0.4 - 0.6, 2.9 - 4.3}
bolt
Vehicle speed sensor BHS32 (Type III), BLT32 (Type IV), BHS37 (Type III), BLT32 (Type
16 - 21 {1.6 - 2.1, 12 - 15}
bracket mounting bolt IV), BLT37 (Type IV)
Wheel cylinder plate BLT32 (Type II, Type III and Type IV), RB50
2.5 - 3.4 {0.25 - 0.35, 1.8 - 2.5}
mounting screw With wedge wheel cylinder side
Spring hanger mounting BLT32 (Type III and Type IV)
14 - 24 {1.4 - 2.4, 10 - 17}
bolt With wedge wheel cylinder only
BHS32, BLT32, RB50 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Air bleeder screw
FB52, RB52, BHS37, BLT37, FB37, RB37, BHS40, BLT40 7 - 12 {0.7 - 1.2, 5.1 - 8.7}
BLT32 (Type II, Type III and Type IV), RB50
6 - 10 {0.6 - 1.0, 4.3 - 7.2}
Wedge cover mounting
bolt or screw RB52 (Type II), BLT37 (Type III and Type IV), RB37 (Type II),
BLT40 (Type II) 2.4 - 3.5 {0.24 - 0.36, 1.7 - 2.6}
Holder pin lock nut BHS32, BLT32, RB50 24 - 35 {2.4 - 3.6, 17 - 26}
Spring chamber bracket BLT32 (Type II, Type III and Type IV), RB50, RB52 (Type II), BLT37
88 - 108 (9.0 - 11.0, 65 - 80)
mounting nut (Type III and Type IV), BLT40 (Type II)
Spring chamber (actua- BLT32 (Type II, Type III and Type IV), RB50, RB52 (Type II), BLT37
104 - 157 {10.6 - 16.0, 77 - 116}
tor) mounting bolt or nut (Type III and Type IV), BLT40 (Type II)
BR-1-10
SERVICE DATA
UNIT NAME BHL41, BLL41, BAL41, RB41, BPL41

Castellated nut 490 - 588 {50.0 - 60.0, 362 - 434}
BHL41, BAL41
Brake bracket mounting bolt Bolt 216 - 294 {22.0 - 30.0, 159 - 217}
or nut BLL41, BPL41 216 - 294 {22.0 - 30.0, 159 - 217}
RB41 216 - 265 {22.0 - 27.0, 159 - 195}
BHL41 75 - 91 {7.6 - 9.3, 55 - 67}
Wheel cylinder mounting bolt
BLL41 113 - 157 {11.5 - 16.0, 83 - 116}
Wheel cylinder shield cover
BLL41 8 - 18 {0.8 - 1.8, 5.8 - 13.0}
mounting bolt
Air bleeder screw BHL41, BLL41 10 - 34 {1.0 - 3.5, 7 - 25}
Anchor pin setscrew BHL41, BLL41, BAL41, BPL41 21 - 34 {2.1 - 3.5, 15 - 25}
Dust cover mounting bolt BHL41, BLL41, BAL41, RB41, BPL41 21 - 34 {2.1 - 3.5, 15 - 25}
BAL41 69 - 88 {7.0 - 9.0, 51 - 65}
Brake chamber bracket
RB41 127 - 147 {13.0 - 15.0, 94 - 108}
mounting bolt
BPL41 137 - 157 {14.0 - 16.0, 101 - 116}
Chamber size No. 20 81 - 108 {8.3 - 11.0, 60 - 80}
BAL41
Chamber size No. 24 167 - 186 {17.0 - 19.0, 123 - 137}
Brake chamber mounting nut
Chamber size 3030
RB41, BPL41 167 - 186 {17.0 - 19.0, 123 - 137}
(With spring brake)
STEEL BRAKE TUBE JOINTS

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
mm (in) 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
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-1-11
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.
assembly remove/install
99867 Z0001 return spring
1 99868 Z0000 (inner side)
2 99868 Z0001 1 Handle
2 Hanger
— — — — — — — — — — — — O — — —

assembly remove/install
99867 Z0002 return spring
1 99868 Z0000 (inner side)
2 99868 Z0002 1 Handle
3 99524 Z0000 2 Hanger
3 Spacer — — — — — — — — — — — — — — — O
Adjusting cam Used to

assembly spring remove/install
tool brake shoe
99842 Z0000 clearance
adjusting
— — — — — — — — — — — O O — — —
mechanism,
and cam spin-
dle pin of the
adjusting cam
assembly
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
= BRAKE PROPER (UNIT NAME BHS32, BLT32, RB50) =

FRONT BRAKE (UNIT NAME BHS32)
CONSTRUCTION
Type I
BR-3-1
BR-3-2
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
necting it.
4. Remove the hub (with drum) assembly.

If the brake drum cannot be removed, proceed as follows:
z To compress the shoe, turn the adjusting screw in the direc-
tion of compression through the brake lining adjusting hole
(grommet hole on the side of the wheel cylinder) behind the
back plate.
NOTE
z Be careful not to damage the adjusting screw adjuster.
Also be careful not to damage the wheel cylinder boot.
BR-3-3
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II and Type III

,+ 1. Return spring assembly 6. Tube , 11. Wheel cylinder assembly
2. Cotter pin 7. Joint assembly 12. Vehicle speed sensor assembly
3. Castellated nut 8. Tube clamp (Type III only)
4. Washer 9. Tube assembly 13. Back plate assembly
, 5. Brake shoe assembly 10. Air bleeder screw
BR-3-4

1 Return spring assembly
Remove the return spring using a spring tool (99867 Z0000).
NOTE
z Attach a band or ring [325 mm (12.80 in) in inside diame-
ter] to the edge of the brake lining to prevent it from
expanding.
<WHEEL CYLINDER>
Manual adjuster type

1. Adjusting spring 4. Adjuster 7. Spring retainer
2. Wheel cylinder boot 5. Piston assembly 8. Spring
3. Adjusting screw 6. Piston cup 9. Wheel cylinder body
BR-3-5
Auto adjuster type

1. Wheel cylinder boot 4. Piston seal 7. Back-up ring
2. Adjusting holder 5. Piston assembly 8. Wheel cylinder body
3. Adjusting screw 6. Piston cup
BR-3-6
REASSEMBLY
REASSEMBLY
<WHEEL BRAKE>
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
5 Brake shoe assembly

Adjust squareness of the brake lining to the fastening section of the
brake.
Assemble the washer and castellated nut to the shoe holder pin, in
that order. Tighten the castellated nut until there is no more play,
then back off the castellated nut 0 to 60º. Insert the cotter pin at the
initial pin hole and lock the castellated nut.
NOTE
z After installing the brake shoe assembly, attach the band
or ring [325 mm (12.80 in) in inside diameter] to the edge
of the brake lining.
1. Install the return spring using the spring tool (99867 Z0000).
2. Detach the band or ring.
NOTE
z Make sure that oil or grease is not applied to the face of
the lining. If oil or grease is applied, clean the lining with
a cloth and dress with an emery cloth.
INSTALLATION
1. Install the hub (with drum) assembly.
2. Adjust the pre-load.
BR-3-7
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.
BR-3-8
REAR BRAKE (UNIT NAME BLT32, RB50) BHS32, BLT32, RB50
REAR BRAKE (UNIT NAME BLT32, RB50)

CONSTRUCTION
Type I
BR-3-9
Type II
BR-3-10
Type III and Type IV
BR-3-11
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
necting it.
4. Remove the spring chamber (actuator).

Check that the specified air pressure is maintained. Then,
disengage the wheel parking brake.
NOTE
z For releasing the wheel parking brake when the brake air
system is out of order, refer to the MA section.

back plate.
NOTE
BR-3-12
DISASSEMBLY
<WHEEL BRAKE>
Type I and Type II

,+ 1. Rod boot (Type II only) , 6. Brake shoe assembly 10. Air bleeder screw
,+ 2. Return spring assembly 7. Tube clamp 11. Wheel cylinder cover
3. Cotter pin 8. Tube assembly , 12. Wheel cylinder
4. Castellated nut 9. Plate 13. Back plate assembly
5. Washer
BR-3-13

,+ 1. Rod boot , 6. Brake shoe assembly 11. Wheel cylinder cover
,+ 2. Return spring assembly 7. Tube clamp , 12. Wheel cylinder assembly
3. Cotter pin 8. Tube 13. Vehicle speed sensor assembly
4. Castellated nut 9. Plate (Type IV only)
5. Washer 10. Air bleeder screw 14. Back plate assembly
BR-3-14

1 Rod boot (Type II, Type III and Type IV only)
Before removing the wheel brake assembly, remove the boot.
2 Return spring assembly (Type I and Type II only)

NOTE
expanding.
2 Return spring assembly (Type III and Type IV only)

Remove the return spring.
NOTE
expanding.
BR-3-15
<WHEEL CYLINDER>
Manual adjuster type (Without wedge)

1. Adjusting spring 7. Piston cup 12. Back-up ring
2. Wheel cylinder boot 8. Spring retainer 13. Piston cup
3. Adjusting screw 9. Wheel cylinder boot 14. Spring retainer
4. Adjuster 10. Anchor piece 15. Spring
5. Piston 11. Piston 16. Wheel cylinder body
6. Back-up ring
BR-3-16
Manual adjuster type (With wedge)

1. Wheel cylinder shield cover 8. Wheel cylinder boot , 14. Wedge assembly
2. Adjusting detent 9. Piston assembly , 15. Tappet
3. Wheel cylinder boot 10. Piston cup 16. O-ring
4. Adjusting screw 11. Back-up ring 17. Tappet
5. Piston assembly 12. Wedge cover 18. O-ring
6. Piston cup 13. Packing 19. Wheel cylinder body
7. Back-up ring
BR-3-17
Auto adjuster type (Without wedge)

1. Spring hanger 4. Adjusting screw 7. Piston cup
2. Wheel cylinder boot 5. Piston seal 8. Back-up ring
3. Adjusting holder 6. Piston assembly 9. Wheel cylinder body
BR-3-18
Auto adjuster type (With wedge)

1. Lock plate 6. Piston cup , 10. Wedge assembly
2. Spring hanger 7. Back-up ring , 11. Tappet
3. Wheel cylinder shield cover 8. Wedge cover 12. O-ring
4. Wheel cylinder boot 9. Packing 13. Wheel cylinder
5. Anchor piston
BR-3-19
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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.
10 Auto adjuster type }

14 Manual adjuster type Wedge assembly
(With wedge only)
1. Apply an ample amount of rubber grease to the periphery of
the wedge assembly roller and roller cage, then install
them.
2. After installing the wheel cylinder, make sure the axial play
of the wedge assembly is approximately 5 mm (0.20 in) with
the piston pushed in.
<WHEEL BRAKE>
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.
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.
RH Right hand of rear wheel
LH Left hand of rear wheel
BR-3-20
6 Type I and Type II

}
6 Type III and Type IV Brake shoe assembly
Adjust squareness of the brake lining surface to the fastening sec-
tion of the brake.
Assemble the washer and castellated nut to the shoe holder pin, in
that order. Tighten the castellated nut until there is no more play,
then back off the castellated nut 0 to 60º. Insert the cotter pin at the
initial pin hole and lock the castellated nut.
NOTE
2 Return spring assembly (Type I and Type II)

NOTE
2 Return spring assembly (Type III and Type IV)

1. Install the return spring.
NOTE

Direct the “TOP” mark on the rod boot to the upper part of the vehi-
cle, and install the wheel cylinder assembly on the wheel brake
body. Then, install the rod boot.
BR-3-21
INSTALLATION
3. Installing the spring chamber (actuator).

z Install the spring chamber (actuator) bracket.
: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
z Install the spring chamber (actuator).
NOTE
z Face the drain hole of the spring chamber (actuator)
downward and align with clamps.
: 104 - 157 N·m {10.6 - 16.0 kgf·m, 77 - 116 ft·lbf}
z Supply air 736 kPa {7.5 kgf/cm2, 107 psi} to the spring
chamber (actuator).
z Align the hole in the wedge rod with the hole in the spring
chamber (actuator) push rod; insert the clevis pin into the
holes and lock with the cotter pin.
z Loosen the lock nut.
z Adjust dimension “A” of the push rod by turning the turn-

buckle and tighten it with the lock nut. Adjustment should be
made with the stud held in position.
A = 224 mm (8.82 in)
WARNING
WARNING
z Do not adjust the length of the rod if the specified air
pressure 736 kPa {7.5 kgf/cm2, 107 psi} is not supplied to
the spring chamber (actuator) [The spring chamber
(actuator) is not released completely]; otherwise, dam-
age to the brake system may result if the upper limit
pressure of the governor is applied and the spring cham-
ber (actuator) does not operate properly.
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
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
ing it.
6. Install the rear roadwheel.
BR-3-23
INSPECTION BHS32, BLT32, RB50
INSPECTION
BRAKE DRUM
Inside diameter
Unit: mm (in)
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)
BHS32
Less than 0.08 (0.0031) 0.20 (0.0079)
BLT32
Checking brake drum inner surface

Check the brake drum for wear (scores, uneven wear and stepped
wear on the inside face of drum), heat cracks, and damage.
NOTE
z Light heat cracks or stepped wear may be corrected by
re-grinding the drum inner surface within the service
limit. If unable to correct by re-grinding, replace the
brake drum with a new one.
BRAKE LINING
Wheel brake assembly outside diameter
Unit: mm (in)
BHS32
319.0 - 320.0 (12.55 - 12.60) —
BLT32
BR-3-24
Brake lining thickness

Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
BHS32
12.0 (0.472) 4.0 (0.157) Remaining thickness (H)
BLT32
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
BHS32
0.030 - 0.090 (0.0012 - 0.0035) 0.15 (0.0059)
BLT32
Wheel cylinder piston cup outside diameter

Unit: mm (in)
Maintenance
standard
36.8 - 37.2
*1
(1.449 - 1.465) Wheel cylinder I.D.
BHS32
34.8 - 35.4 34.93 mm (1.3752 in)
*2
(1.370 - 1.394) *5 More than
38.4 - 38.8 0.65 (0.0256)
*3
(1.512 - 1.528) Wheel cylinder I.D.
BLT32
36.4 - 37.0 36.51 mm (1.4374 in)
*4
(1.433 - 1.457)
*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
BRAKE SHOE RETURN SPRING

Free length
Unit: mm (in)
Maintenance
Unit name Service limit
standard
BHS32 180.5 (7.11) —
Type I
208.0 (8.19) —
Type II
BLT32
Type III Small 95.5 (3.760) —
Type IV Large 88.0 (3.465) —
Tension
Unit: N {kgf, lbf}
Maintenance Service
Unit name Remarks
standard limit
Measure tension
291 - 356
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

1. Drill out rivet heads on the front (rear) of the brake shoe
assembly, remove the rivets with a punch and detach the
brake lining.
NOTE
z Be careful not to drill the brake shoe.
1. Drill 3. Brake shoe
2. Rivet 4. Brake lining
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
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.
5. Insert the feeler gauge through the inspection hole, and

make sure that the clearance is correct.
NOTE
z Be sure to adjust at the two inspection holes.
Unit: mm (in)
BHS32 0.20 - 0.30
—
BLT32, RB50 (0.0079 - 0.0118)
6. Adjust the other lining in the same manner.

inspection hole and adjusting hole.
Auto adjuster type

1. Adjust the adjuster so that the clearance between the brake
lining and drum is 0.7 mm (0.028 in).
NOTE
z Check whether or not the clearance is correct in the three
places.
z Figure EBR028A on the right shows the measuring points of
the front wheel brake. For measuring points, the front wheel
brake and rear wheel brake are the same. Accordingly, to
measure the rear wheel brake, use the same procedure as
that for the front wheel brake.
BR-3-28
ADJUSTMENT BHS32, BLT32, RB50
2. Install the hub drum assembly and adjust the preload.

z For installation of the hub drum assembly and adjustment of
the preload, refer to the “FRONT AXLE” or “REAR AXLE”
section procedures.
3. Install the tire assembly.
z For installation of the tire assembly, refer to the “FRONT
AXLE” or “REAR AXLE” section procedures.
4. Turn the brake drum. Depress the brake pedal all the way.
5. Repeat step 4 five or six times to properly adjust the brake
drum clearance.
NOTE
z As the clearance can be adjusted automatically, depress-
ing the brake pedal all the way repeatedly will adjust the
lining clearance to the proper value.
ADJUSTING THE HOLDER PIN

Do not turn or remove the holder pin to adjust the perpendicularity
of the brake shoe. If turned or removed, the perpendicularity of the
brake shoe must be adjusted.
1. With the drum mounted, turn the holder pin to the left (shoe
clearance at the back plate side becomes larger).
2. Insert a feeler gauge [0.2 mm (0.008 in) thick] through the
inspection hole and, while measuring shoe clearance at the
inner-radius and outer-radius of the drum, gradually turn the
holder pin clockwise.
3. Lock the holder pin with the lock nut at the point where the
shoe clearance at the inner-radius and outer-radius is
equal.
: 24 - 35 N·m {2.4 - 3.6 kgf·m, 17 - 26 ft·lbf}
BR-3-29
FRONT BRAKE (UNIT NAME FB52, BHS37) FB52, RB52, BHS37, BLT37
= BRAKE PROPER (UNIT NAME FB52, RB52, BHS37, BLT37) =

FRONT BRAKE (UNIT NAME FB52, BHS37)
CONSTRUCTION
Type I
BR-4-1
BR-4-2
DISASSEMBLY
REMOVAL
NOTE
necting it.

back plate.
NOTE
BR-4-3
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II and Type III

,+ 1. Return spring assembly , 5. Brake shoe assembly 9. Wheel cylinder assembly
2. Cotter pin 6. Air bleeder screw 10. Vehicle speed sensor assembly
3. Lock plate 7. Tube (Type III only)
4. Nut 8. Connector assembly 11. Back plate assembly
BR-4-4

NOTE
expanding.
<WHEEL CYLINDER>

1. Washer 4. Adjusting screw , 7. Back-up ring
2. Adjusting spring 5. Piston assembly 8. Wheel cylinder body
3. Wheel cylinder boot 6. Piston cup
BR-4-5
Auto adjuster type

1. Wheel cylinder cover 6. Adjuster assembly 11. Piston cup
, 2. Set spring 7. Plain washer A , 12. Back-up ring
3. Cover , 8. Plain washer B 13. Wheel cylinder boot
4. Lever assembly 9. O-ring 14. Wheel cylinder body
5. Adjusting screw 10. Piston assembly
BR-4-6
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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.
8 Plain washer B (Auto adjuster type only)

Install plain washer B with its black surface facing plain washer A.
2 Set spring (Auto adjuster type only)

Install the set spring with the closed hook on the pin side.
<WHEEL BRAKE>
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

NOTE
3. Adjust squareness of the brake lining to the fastening sec-
tion of the brake.
Install the brake shoe. Place a 0.55 mm (0.0217 in) thick-
ness gauge between the shoe rim and the ledge on the
back plate and tighten the nut completely. Back off the nut
until one of the flats is aligned with the stud pin hole. Bend
the lock plate and secure it and the nut with a cotter pin.
INSTALLATION
NOTE
ing it.
BR-4-8
REAR BRAKE (UNIT NAME RB52, BLT37) FB52, RB52, BHS37, BLT37
REAR BRAKE (UNIT NAME RB52, BLT37)

CONSTRUCTION
Type I
BR-4-9
Type II
BR-4-10
BR-4-11
DISASSEMBLY
REMOVAL
2. Remove the rear road wheels.
NOTE
necting it.
4. Remove the spring chamber (actuator) (if so equipped).

NOTE

grommet hole on the side of the wheel cylinder) behind the
back plate.
NOTE
BR-4-12
DISASSEMBLY
<WHEEL BRAKE>
Type I, Type II, Type III and Type IV

,+ 1. Rod boot (Type II, Type III and Type , 6. Brake shoe assembly 10. Wheel cylinder assembly
IV only) 7. Air bleeder screw 11. Vehicle speed sensor assembly
,+ 2. Return spring assembly 8. Tube (Type IV only)
3. Cotter pin 9. Bracket assembly (Type II, Type III 12. Back plate assembly
4. Lock plate and Type IV only)
5. Nut
BR-4-13


NOTE
expanding.
BR-4-14
<WHEEL CYLINDER>
Manual adjuster type (Without wedge)

1. Washer 5. Piston cup 9. Piston assembly
2. Adjusting spring , 6. Back-up ring 10. Piston cup
3. Wheel cylinder boot 7. Wheel cylinder boot , 11. Back-up ring
4. Piston assembly 8. Adjusting screw 12. Wheel cylinder body
BR-4-15
Manual adjuster type (With wedge)

1. Washer 9. Plunger 16. Pin
2. Adjusting spring 10. Retainer 17. Wedge
3. Wheel cylinder boot 11. Barrel pin 18. Rod
4. Adjusting screw 12. Fork end 19. Plunger
5. Piston assembly , 13. Wedge cover 20. Piston cup
6. Piston cup 14. Spring clip , 21. Back-up ring
, 7. Back-up ring 15. Roller 22. Wheel cylinder body
8. Wheel cylinder boot
BR-4-16
Auto adjuster type (Without wedge)

1. Wheel cylinder cover 7. O-ring 13. Wheel cylinder boot
, 2. Set spring 8. Plain washer A 14. Piston assembly
3. Cover , 9. Plain washer B 15. Piston cup
4. Lever assembly 10. Piston assembly , 16. Back-up ring
5. Adjusting screw 11. Piston cup 17. Wheel cylinder boot
6. Adjuster assembly , 12. Back-up ring 18. Wheel cylinder body
BR-4-17
Auto adjuster type (With wedge)

1. Wheel cylinder cover 11. Piston cup 20. Spring clip
, 2. Set spring , 12. Back-up ring 21. Roller
3. Cover 13. Wheel cylinder boot 22. Pin
4. Lever assembly 14. Plunger 23. Wedge
5. Adjusting screw 15. Wheel cylinder boot 24. Rod
6. Adjuster assembly 16. Retainer 25. Plunger
7. O-ring 17. Barrel pin 26. Piston cup
8. Plain washer A 18. Fork end , 27. Back-up ring
, 9. Plain washer B , 19. Wedge cover 28. Wheel cylinder boot
10. Piston assembly
BR-4-18
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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)
BR-4-19
9 Auto adjuster type (Without wedge)

9 Auto adjuster type (With wedge) } Plain washer B
Install plain washer B with its black surface facing plain washer A.
2 Auto adjuster type (Without wedge)

2 Auto adjuster type (With wedge) } Set spring
Install the set spring with the closed hook on the pin side.
<WHEEL BRAKE>
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

NOTE
3. Adjust squareness of the brake lining surface to the fasten-
ing section of the brake.
Install the brake shoe. Place a 0.55 mm (0.0217 in) thick-
ness gauge between the shoe rim and the ledge on the
back plate and tighten the nut completely. Back off the nut
until one of the flats is aligned with the stud pin hole. Bend
the lock plate and secure it and the nut with a cotter pin.

The boot should be installed after installing the wheel cylinder
assembly on the wheel brake body.
INSTALLATION
3. Installing the spring chamber (actuator) (if so equipped).

: 88 - 108 N·m {9.0 - 11.0 kgf·m, 65 - 80 ft·lbf}
z Install the lever assembly.
NOTE
z Pay attention to the direction of the lever.
z Be sure to insert the pin from the top and align the pin
head with the lock.
z Apply grease to the lever bushing.
BR-4-21
NOTE
: 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.
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 Turn the rod to adjust dimension “A”.

LKA210: A = 202 mm (7.95 in)
LKC210: A = 233 mm (9.17 in)
WARNING
WARNING
NOTE
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
parts.
(frame side).
NOTE
ing it.

6. Install the rear road wheel.
BR-4-22
INSPECTION FB52, RB52, BHS37, BLT37
INSPECTION
BRAKE DRUM
Inside diameter
Unit: mm (in)
FB52, BHS37
370 (14.57) 372 (14.65)
RB52, BLT37
Out-of-roundness
Unit: mm (in)
FB52, BHS37 0.04 - 0.05
0.20 (0.0079)
RB52, BLT37 (0.0016 - 0.0020)

NOTE
BRAKE LINING
Unit: mm (in)
FB52, BHS37 369.3 - 369.6
—
RB52, BLT37 (14.54 - 14.55)
BR-4-23

Unit: mm (in)
Maintenance
standard
FB52, BHS37
RB52, BLT37
WHEEL CYLINDER
Unit: mm (in)
FB52, BHS37 0.025 - 0.126
0.20 (0.0079)
RB52, BLT37 (0.0010 - 0.0050)

Unit: mm (in)
Maintenance
standard
38.4 - 38.8 Wheel cylinder I.D.
FB52, BHS37 *More than
(1.512 - 1.528) 36.51 mm (1.4374 in)
0.65
39.75 - 40.25 (0.0256) Wheel cylinder I.D.
RB52, BLT37
(1.5650 - 1.5846) 38.10 mm (1.5000 in)
* Difference between O.D. of piston cup and I.D. of wheel cylinder

Free length
Unit: mm (in)
FB52, BHS37 210.3 (8.28) —
RB52, BLT37 215.2 (8.47) —
Tension
Unit: N {kgf, lbf}
Maintenance
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

brake lining.
NOTE
NOTE
4. Brake lining
BR-4-25
ADJUSTMENT FB52, RB52, BHS37, BLT37
ADJUSTMENT
wheel bearing.
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.

NOTE
z Be sure to adjust at the two inspection holes.
Unit: mm (in)
FB52, BHS37 0.20 - 0.30
—
RB52, BLT37 (0.0079 - 0.0118)

inspection hole and adjusting hole.
Auto adjuster type

1. Adjust the adjuster so that the clearance between the brake
lining and drum is 0.7 mm (0.028 in).
NOTE
z Check whether or not the clearance is correct in the three
places.
z Figure EBR054A on the right shows the measuring points of
the front wheel brake. For measuring points, the front wheel
brake and rear wheel brake are the same. Accordingly, to
measure the rear wheel brake, use the same procedure as
that for the front wheel brake.
BR-4-26
2. Install the hub drum assembly and adjust the preload.

z For installation of the hub drum assembly and adjustment of
the preload, refer to the “FRONT AXLE” or “REAR AXLE”
section procedures.
3. Install the axle shaft.
z For installation of the axle shaft, refer to the “REAR AXLE”
section procedures.
4. Install the tire assembly.
z For installation of the tire assembly, refer to the “FRONT
AXLE” or “REAR AXLE” section procedures.
5. Turn the brake drum. Depress the brake pedal all the way.
6. Repeat step 5 five or six times to properly adjust the brake
drum clearance.
NOTE
z As the clearance can be adjusted automatically, depress-
ing the brake pedal all the way repeatedly will adjust the
lining clearance to the proper value.
BR-4-27
= BRAKE PROPER (UNIT NAME FB37, RB37, BHS40, BLT40) =

FRONT BRAKE (UNIT NAME FB37, BHS40)
CONSTRUCTION
BR-5-1
DISASSEMBLY
REMOVAL
2. Remove the front road wheel.
NOTE
necting it.

(cover hole on the side of the wheel cylinder) behind the
back plate.
NOTE
BR-5-2
DISASSEMBLY
<WHEEL BRAKE>

,+ 1. Return spring assembly , 5. Brake shoe assembly 8. Connector assembly
2. Cotter pin 6. Air bleeder screw 9. Wheel cylinder assembly
3. Castellated nut 7. Tube 10. Back plate assembly
4. Washer
BR-5-3

NOTE
expanding.
<WHEEL CYLINDER>

1. Washer 4. Adjusting screw , 7. Back-up ring
2. Adjusting spring 5. Piston assembly 8. Wheel cylinder body
3. Wheel cylinder boot 6. Piston cup
BR-5-4
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
7 Back-up ring
<WHEEL BRAKE>
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.

NOTE
After installing the return spring, tighten the castellated nut
until the brake shoe contacts the bolt. From the position,
back off the castellated nut 1/3 turn and secure with the cot-
ter pin. If the groove in the nut is not properly aligned with
the stud hole, back off the castellated nut within the range of
1/2 turn and align. Then, secure with the cotter pin.
INSTALLATION
BR-5-5
NOTE
ing it.
BR-5-6
REAR BRAKE (UNIT NAME RB37, BLT40)

CONSTRUCTION
Type I
BR-5-7
Type II
BR-5-8
DISASSEMBLY
REMOVAL
2. Remove the rear road wheel.
Then, remove the brake hose from the rear axle housing
side.
NOTE
necting it.
4. Remove the spring chamber (actuator).

NOTE

back plate.
NOTE
BR-5-9
DISASSEMBLY
<WHEEL BRAKE>
Type I and Type II

,+ 1. Rod boot (Type II only) 5. Washer 9. Bracket assembly (Type I only)
,+ 2. Return spring assembly , 6. Brake shoe assembly 10. Wheel cylinder assembly
3. Cotter pin 7. Air bleeder screw 11. Back plate assembly
4. Castellated nut 8. Tube
BR-5-10

1 Rod boot

NOTE
expanding.
BR-5-11
<WHEEL CYLINDER>
Without wedge

1. Washer 5. Piston cup 9. Piston assembly
2. Adjusting spring , 6. Back-up ring 10. Piston cup
3. Wheel cylinder boot 7. Wheel cylinder boot , 11. Back-up ring
4. Piston assembly 8. Adjusting screw 12. Wheel cylinder body
BR-5-12
With wedge

1. Washer 9. Plunger 16. Pin
2. Adjusting spring 10. Retainer 17. Wedge
3. Wheel cylinder boot 11. Barrel pin 18. Rod
4. Adjusting screw 12. Fork end 19. Plunger
5. Piston assembly , 13. Wedge cover 20. Piston cup
6. Piston cup 14. Spring clip , 21. Back-up ring
, 7. Back-up ring 15. Roller 22. Wheel cylinder body
8. Wheel cylinder boot
BR-5-13
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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>
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

NOTE
After installing the return spring, tighten the castellated nut
until the brake shoe contacts the bolt. From the position,
back off the castellated nut 1/3 turn and secure with the cot-
ter pin. If the groove in the nut is not properly aligned with
the stud hole, back off the castellated nut within the range of
1/2 turn and align. Then, secure with the cotter pin.
1 Rod boot (Type II only)

The boot should be installed after installing the wheel cylinder
assembly on the wheel brake body.
INSTALLATION
BR-5-15
3. Installing the spring chamber (actuator) (if so equipped).

: 88 - 108 N·m {9 - 11 kgf·m, 65 - 80 ft·lbf}
z Install the lever assembly.
NOTE
z Pay attention to the direction of the lever.
z Be sure to insert the pin from the top and align the pin
head with the lock.
z Apply grease to the lever bushing.

NOTE
: 104 - 157 N·m {10.6 - 16.0 kgf·m, 77 - 116 ft·lbf}
z Connect the spring chamber (actuator) and lever with a pin
and secure with a cotter pin.
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.
BR-5-16
z Turn the rod to adjust dimension “A”.

PKA210: A = 236 mm (9.29 in)
PKB210: A = 246 mm (9.69 in)
WARNING
WARNING
NOTE
: 34 - 45 N·m {3.5 - 4.6 kgf·m, 25 - 33 ft·lbf}
parts.
(frame side).
NOTE
ing it.
BR-5-17
INSPECTION
BRAKE DRUM
Inside diameter
Unit: mm (in)
FB37, BHS40
400 (15.75) 403 (15.87)
RB37, BLT40
Out-of-roundness
Unit: mm (in)
FB37, BHS40 0.04 - 0.05
0.20 (0.0079)
RB37, BLT40 (0.0016 - 0.0020)

NOTE
BRAKE LINING
Unit: mm (in)
FB37, BHS40 399.3 - 399.6
—
RB37, BLT40 (15.72 - 15.73)
BR-5-18

Unit: mm (in)
Maintenance
standard
FB37, BHS40
RB37, BLT40
WHEEL CYLINDER
Unit: mm (in)
FB37, BHS40 0.025 - 0.126
0.20 (0.0079)
RB37, BLT40 (0.0010 - 0.0050)

Unit: mm (in)
Maintenance
standard
39.75 - 40.25 Wheel cylinder I.D.
FB37, BHS40
(1.5650 - 1.5846) *More than 38.10 mm (1.5000 in)
44.6 - 45.2 0.65 (0.0256) Wheel cylinder I.D.
RB37, BLT40
(1.756 - 1.780) 42.86 mm (1.6874 in)
* Difference between O.D. of piston cup and I.D. of wheel cylinder

Free length
Unit: mm (in)
FB37, BHS40 215.2 (8.47) —
RB37, BLT40 245.1 (9.65) —
BR-5-19
Tension
Unit: N {kgf, lbf}
Maintenance
standard
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
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
SPRING CHAMBER BRACKET

Clearance between lever and lever pin
Unit: mm (in)
0.030 - 0.143
RB37, BLT40 0.2 (0.008)
(0.0012 - 0.0056)
BR-5-20
REPAIR AND REPLACEMENT FB37, RB37, BHS40, BLT40

brake lining.
NOTE
NOTE
4. Brake lining
BR-5-21
ADJUSTMENT
wheel bearing.
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.

NOTE
Unit: mm (in)
Unit name Maintenance standard
FB37, BHS40
0.20 - 0.30 (0.0079 - 0.0118)
RB37, BLT40

inspection hole and adjustment hole.
BR-5-22
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41
= BRAKE PROPER (UNIT NAME BHL41, BLL41) =

FRONT BRAKE (UNIT NAME BHL41)
CONSTRUCTION
<WHEEL BRAKE>
BR-6-1
<WHEEL CYLINDER>
BR-6-2
DISASSEMBLY
REMOVAL
NOTE
necting it.
BR-6-3
DISASSEMBLY
<WHEEL BRAKE>

,+ 1. Return spring assembly 7. Shoe guide pin 13. Cover
, 2. Lock washer 8. Back plate 14. Adjuster boots
3. Lock plate 9. Wheel cylinder cover 15. Adjuster spring
4. Anchor pin 10. Wheel cylinder assembly 16. Adjuster washer
, 5. Brake shoe assembly ,+ 11. Cam spindle pin , 17. Adjuster cam assembly
6. Return spring pin 12. Indicator 18. Brake bracket
BR-6-4

NOTE
expanding.
11 Cam spindle pin

Remove the cam adjuster spindle pin using adjusting cam assem-
bly spring tool (99842 Z0000), and disassemble the adjuster.
NOTE
z When removing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installation
length.
BR-6-5
<WHEEL CYLINDER>

1. Boot , 4. Back-up ring 7. Bleeder screw
2. Push rod ,+ 5. Piston cup 8. Body
3. Piston 6. Spring
5 Piston cup
When removing piston cup from the piston, pay attention so as not
to scratch or damage the piston.
BR-6-6
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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>
17 Adjuster cam assembly
Apply bearing grease sparingly when installing.
11 Cam spindle pin

Install the cam adjuster spindle pin using adjusting cam assembly
spring tool (99842 Z0000).
NOTE
z When installing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installed length.

When installing the brake shoe assembly to the brake bracket,
apply bearing grease sparingly to the inner surface (groove) of the
bushing and the two grooves of the anchor pin.
NOTE
BR-6-7
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}

NOTE
INSTALLATION
2. Adjust the preload.
NOTE
ing it.
BR-6-8
REAR BRAKE (UNIT NAME BLL41) BHL41, BLL41
REAR BRAKE (UNIT NAME BLL41)

CONSTRUCTION
<WHEEL BRAKE>
BR-6-9
<WHEEL CYLINDER>
BR-6-10
DISASSEMBLY
REMOVAL
NOTE
necting it.
BR-6-11
DISASSEMBLY
<WHEEL BRAKE>

,+ 1. Return spring assembly (Outer) 9. Shoe guide pin 16. Indicator
2. Return spring pin 10. Return spring pin 17. Cover
3. Guide pin 11. Back plate 18. Adjuster boots
,+ 4. Return spring assembly (Inner) 12. Shield cover (Upper) 19. Adjuster spring
, 5. Lock washer 13. Wheel cylinder cover 20. Adjuster washer
6. Lock plate 14. Shield cover (lower) , 21. Adjuster cam assembly
7. Anchor pin ,+ 15. Cam spindle pin 22. Brake bracket
, 8. Brake shoe assembly
BR-6-12

1 Return spring assembly (Outer)
NOTE
z Attach a band or ring [410 mm (16.14 in) inside diameter]
to the edge of the brake lining to prevent it from expand-
ing.
4 Return spring assembly (Inner)

15 Cam spindle pin

Remove the cam spring pin using adjusting cam assembly spring
tool (99842 Z0000).
NOTE
z Do not compress the spring more than 1 mm (0.04 in)
from its installation length when removing the pin.
BR-6-13
<WHEEL CYLINDER>

1. Boots , 4. Back-up ring 7. Bleeder
2. Push rod ,+ 5. Piston cup 8. Body
3. Piston 6. Spring
5 Piston cup
When removing the piston cap from the piston, use care not to
scratch the piston.
BR-6-14
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
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>
21 Adjuster cam assembly
Apply bearing grease sparingly when installing.
15 Cam spindle pin

Install the cam adjuster spindle pin using adjusting cam assembly
spring tool (99842 Z0000).
NOTE
z When installing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installed length.

apply bearing grease sparingly to the inner surface (groove) of the
bushing and the two grooves of the anchor pin.
NOTE
z After installing the brake shoe assembly, attach a band or
ring [410 mm (16.14 in) in inside diameter] to the edge of
the brake lining.
BR-6-15
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}
4 Return spring assembly (Inner)

Install the return spring using the spring tool (99867 Z0001).
NOTE
1 Return spring assembly (Outer)

NOTE
INSTALLATION
(frame side).
NOTE
ing it.
BR-6-16
INSPECTION BHL41, BLL41
INSPECTION
BRAKE DRUM
Inside diameter
Unit: mm (in)
BHL41
410 (16.14) 414 (16.30)
BLL41
Out-of-roundness
Unit: mm (in)
BHL41 Less than
0.20 (0.0079)
BLL41 0.025 (0.0010)

NOTE
BRAKE LINING
Unit: mm (in)
Maintenance
standard
BHL41
BLL41
BR-6-17
BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
BHL41
30.0 (1.181) 29.85 (1.1752)
BLL41
Brake shoe bushing inside diameter

Unit: mm (in)
BHL41
30.0 (1.181) 30.15 (1.1870)
BLL41
Clearance between anchor pin and brake shoe bushing

Unit: mm (in)
BHL41 0.07 - 0.20
0.25 (0.0098)
BLL41 (0.0028 - 0.0079)
WHEEL CYLINDER
Unit: mm (in)
0.120 - 0.234
BHL41
(0.0047 - 0.0092)
0.25 (0.0098)
0.128 - 0.248
BLL41
(0.0050 - 0.0098)

Unit: mm (in)
Maintenance
standard
50.6 - 51.2 Wheel cylinder I.D. 50.80
BHL41 —
(1.992 - 2.016) mm (2.0000 in)
55.4 - 56.0 Wheel cylinder I.D. 55.56
BLL41 —
(2.181 - 2.205) mm (2.1874 in)
BR-6-18

Free length
Unit: mm (in)
BHL41 195.9 (7.71) —
Outer 192.0 (7.56) —
BLL41
Inner 243.9 (9.60) —
Tension
Unit: N {kgf, lbf}
Maintenance
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
Outer {47.15 - 53.75, — spring is set at 219.0
104.0 - 118.5} mm (8.62 in) in length
BLL41
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

brake lining.
NOTE
NOTE
4. Brake lining
BRAKE SHOE BUSHING

1. Drive out the bushing.
2. Remove all dirt and foreign matter from the brake shoe
bushing hole.
3. Tap the bushing into the brake shoe.
After press-fitting the bushing, measure the bushing inside
diameter. If it is over 30.00 to 30.05 mm (1.1811 to 1.1831
in), ream the bushing so that the inside diameter is within
the standard value.
NOTE
z Do not coat the shoe bushing with grease or oil.
BR-6-20
REPAIR AND REPLACEMENT BHL41, BLL41
ADJUSTMENT
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)
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.
4. Adjust the clearance of the other lining similarly.

5. Rotate the drum by hand to ensure the lining doesn't drag.
NOTE
z If the indicator needle does not point to “END” after
adjustment, replace the lining with a new one.
After the lining has been replaced, return the indicator
needle to the “START” position.
BR-6-21
FRONT BRAKE (UNIT NAME BAL41) BAL41, RB41, BPL41
= BRAKE PROPER (UNIT NAME BAL41, RB41, BPL41) =

FRONT BRAKE (UNIT NAME BAL41)
CONSTRUCTION
BR-7-1
DISASSEMBLY
REMOVAL
NOTE
necting it.
BR-7-2
DISASSEMBLY

,+ 1. Return spring assembly 8. Roller 15. Camshaft spacer
, 2. Lock washer 9. Cotter pin 16. Felt ring
3. Lock plate 10. Clevis pin 17. Camshaft
4. Anchor pin 11. Retaining ring 18. Dust cover
, 5. Brake shoe assembly , 12. Wear indicator 19. Brake bracket
6. Clip 13. Camshaft spacer , 20. Brake chamber assembly
, 7. Roller pin + 14. Slack adjuster assembly
BR-7-3

Remove the return spring assembly by using a spring tool (99867
Z0000).
NOTE
expanding.
14 Slack adjuster assembly

If the slack adjuster assembly is hard to remove, take it off using a
puller.
REASSEMBLY
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

apply bearing grease sparingly to the inner groove of the bushing
and anchor pin grooves (two places).
NOTE
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}

1. Install the return spring assembly using spring tool (99867
Z0000).
NOTE
INSTALLATION
NOTE
ing it.
BR-7-5
REAR BRAKE (UNIT NAME RB41, BPL41) BAL41, RB41, BPL41
REAR BRAKE (UNIT NAME RB41, BPL41)

CONSTRUCTION
UNIT NAME RB41
BR-7-6
UNIT NAME BPL41
BR-7-7
DISASSEMBLY
REMOVAL
NOTE
necting it.
BR-7-8
DISASSEMBLY
UNIT NAME RB41

,+ 1. Return spring assembly 8. Cotter pin 14. Camshaft spacer
2. Setscrew 9. Plain washer 15. Camshaft
3. Anchor pin 10. Shim 16. Dust cover
, 4. Brake shoe assembly 11. Clevis pin , 17. Brake chamber assembly
5. Clip 12. Retaining ring , 18. Brake chamber bracket
, 6. Roller pin + 13. Slack adjuster assembly 19. Brake bracket
7. Roller
BR-7-9
UNIT NAME BPL41

,+ 1. Return spring assembly (outer) , 9. Roller pin 17. Camshaft spacer
,+ 2. Return spring assembly (inner) 10. Roller 18. Felt ring
3. Return spring pin 11. Cotter pin 19. Camshaft
, 4. Lock washer 12. Clevis pin 20. Ring
5. Lock plate 13. Retaining ring 21. Dust cover
6. Anchor pin , 14. Wear indicator , 22. Brake chamber assembly
, 7. Brake shoe assembly 15. Camshaft spacer , 23. Brake chamber bracket
8. Clip + 16. Slack adjuster assembly 24. Brake bracket
BR-7-10

1 Return spring assembly (outer)
Remove the return spring assembly (outer) using spring tool
(99867 Z0000).
NOTE
z Attach a band or ring [410 mm (16.14 in) inside diameter]
to the edge of the brake lining to prevent it from expand-
ing.
z Figure CBR1-019A on the right shows the removal proce-
dure for the unit name RB41.
2 Return spring assembly (inner)
(Unit name BPL41 only)
Remove the return spring assembly (inner) using spring tool (99867
Z0002).
Attach the hanger to the spring tip and turn the handle. When a
clearance appears between the pin and spring tip, extract the pin.
13 UNIT NAME RB41

}
16 UNIT NAME BPL41 Slack adjuster assembly
If the slack adjuster assembly is hard to remove by hand, use a
puller for removal.
REASSEMBLY
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
17 Unit name RB41

}
22 Unit name BPL41 Brake chamber assembly
Before installing the brake chamber assembly, make sure dimen-
sion “L” is 60 mm (2.36 in).
: 167 - 186 N·m {17.0 - 19.0 kgf·m, 123 - 137 ft·lbf}
14 Wear indicator (Unit name BPL41 only)

When installing the wear indicator, align it with the arrow mark on
the camshaft.
6 Roller pin (Unit name RB41 only)

1. Face the clip in the direction shown in the figure.
2. When installing the roller pin, be careful not to scratch the
roller oil seal.
9 Roller pin (Unit name BPL41 only)

Install the roller pin paying attention to its installation direction, and
check the roller for smooth rotation.
NOTE
z Do not apply grease to any part of the roller and roller
pin.
4 Unit name RB41

7 Unit name BPL41 }
Brake shoe assembly
apply bearing grease sparingly to the inside face (groove) of the
bushing and anchor pin grooves (two places).
NOTE
z For unit name RB41, apply bearing grease to the bushing
only. Do not apply to the anchor pin.
BR-7-12
4 Lock washer (Unit name BPL41 only)

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}
2 Return spring assembly (inner) (Unit name BPL41 only)

Install the return spring assembly using spring tool (99867 Z0002).
1 Unit name RB41

}
1 Unit name BPL41 Return spring assembly (outer)
1. Install the return spring assembly using spring tool (99867
Z0000).
NOTE
INSTALLATION
(frame side).
NOTE
ing it.
BR-7-13
INSPECTION BAL41, RB41, BPL41
INSPECTION
BRAKE DRUM
Inside diameter
Unit: mm (in)
BAL41
410 (16.14) 414 (16.30)
RB41, BPL41
Out-of-roundness
Unit: mm (in)
BAL41
Less than 0.025 (0.0010) 0.20 (0.0079)
RB41, BPL41

NOTE
BRAKE LINING
Unit: mm (in)
Maintenance
standard
BAL41, BPL41 16.0 (0.630)
5.0 (0.197) Remaining thickness (H)
RB41 15.0 (0.591)
BR-7-14
BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
BAL41, BPL41 30.0 (1.181) 29.85 (1.1752)
RB41 32.0 (1.260) 31.80 (1.2520)
Brake shoe bushing inside diameter

Unit: mm (in)
BAL41, BPL41 30.0 (1.181) 30.15 (1.1870)
RB41 32.0 (1.260) 32.20 (1.2677)
Clearance between anchor pin and brake shoe bushing

Unit: mm (in)
0.07 - 0.20
BAL41, BPL41 0.25 (0.0098)
(0.0028 - 0.0079)
0.10 - 0.25
RB41 0.50 (0.0197)
(0.0039 - 0.0098)
Brake shoe roller inside diameters

Unit: mm (in)
BAL41, BPL41 20.3 (0.799) 20.7 (0.815)
RB41 26.0 (1.024) 26.4 (1.039)
Brake shoe roller outside diameter

Unit: mm (in)
BAL41, BPL41 40.3 (1.587) 39.9 (1.571)
RB41 57.0 (2.244) 56.6 (2.228)
BR-7-15
Brake shoe roller pin outside diameters

Unit: mm (in)
BAL41, BPL41 20.0 (0.787) 19.6 (0.772)
RB41 26.0 (1.024) 25.6 (1.008)
Clearance between brake shoe roller and brake shoe

roller pin
Unit: mm (in)
0.20 - 0.43
BAL41, BPL41 0.80 (0.0315)
(0.0079 - 0.0169)
0.09 - 0.15
RB41 0.40 (0.0157)
(0.0035 - 0.0059)
CAMSHAFT
Camshaft bushing inside diameter
Unit: mm (in)
BAL41, BPL41 40.0 (1.575) 40.3 (1.587)
RB41 44.0 (1.732) 44.3 (1.744)
BR-7-16
Camshaft outside diameter

Unit: mm (in)
BAL41, BPL41 40.0 (1.575) 39.7 (1.563)
RB41 44.0 (1.732) 43.7 (1.720)
Clearance between camshaft bushing and camshaft

Unit: mm (in)
0.05 - 0.12
BAL41, BPL41
(0.0020 - 0.0047)
0.60 (0.0236)
0.37 - 0.44
RB41
(0.0146 - 0.0173)

Free length
Unit: mm (in)
Maintenance
standard
195.9 (7.71) — Inboard type
BAL41
194.3 (7.65) — Outboard type
RB41 229.8 (9.05) —
Outer 195.9 (7.71) —
BPL41
Inner 242.6 (9.55) —
BR-7-17
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

brake lining.
NOTE
NOTE
4. Brake lining
BRAKE SHOE BUSHING

<UNIT NAME BAL41 AND BPL41>
bushing hole.
After press-fitting the bushing, measure the bushing inside
diameter. If it is over 30.00 to 30.05 mm (1.1811 to 1.1831
in), ream the bushing so that the inside diameter is within
the standard value.
BR-7-19
NOTE
<UNIT NAME RB41>

bushing hole.
NOTE
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.
<UNIT NAME RB41>

bushing hole.
bracket.
BR-7-20
<UNIT NAME BPL41>

bushing hole.
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.
5. Press-fit the new bushing onto the brake bracket. After
press-fitting the bushing, measure the bushing inside diam-
eter. 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.
RETURN SPRING PIN

<UNIT NAME BAL41 AND BPL41>
1. Drive out the return spring pin.
2. Install the new return spring pin, press-fit the spring pin so
that dimension “L” to 52 mm (2.05 in).
BR-7-21
ADJUSTMENT BAL41, RB41, BPL41
ADJUSTMENT
ADJUSTING THE BRAKE CHAMBER PUSH ROD
STROKE
wheel bearing.
2. Measure the push rod stroke when the brake pedal is
depressed with normal pressure.
Unit: mm (in)
BAL41, BPL41 30 (1.18) 45 (1.77)
RB41 24 (0.94) 40 (1.57)
3. Adjust the push rod stroke if it is outside the allowable limit.

z Check the installation length of the brake chamber push
rod.
Push rod set length “L”
BAL41: 225 mm (8.86 in)
RB41·BPL41: 60 mm (2.36 in)
(Distance from the chamber end face to the center of
clevis pin hole)
z After adjusting the installation length of the push rod, mea-

sure the push rod again by pressing the brake pedal.
z If the push rod stroke is outside the allowable limit, fully
tighten the adjusting bolt of the slack adjuster, then back off
two clicks.
z Rotate the brake drum by hand to see that the brake shoe is
not touching the brake drum.
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
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
(0.0016 - 0.0055) (0.0098)
99.0
Master cylinder Free length —
(3.898)
Piston spring
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
Spring tension N {kgf, lbf} —
{1.5, 3.3} 43 mm (1.69 in)
BR-1-1
SERVICE DATA BRAKE UNIT (VAC)
TIGHTENING TORQUES
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}
DIAGRAM OF AIR PIPING
BR-1-2
TOOLS BRAKE UNIT (VAC)
TOOLS
HYDROMASTER
z Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Stand Used to disassemble and assemble
910-10140 the hydromaster
Box wrench Used to install and remove the valve

910-21981 fitting
Wrench Used to install and remove the hydrau-

910-20130 lic cylinder and hydraulic cylinder plug
Special tool Used to press-fit and remove the oil

910-20191 seal
Retaining ring insertion tool Used to install the check valve retain-
910-22010 ing ring
Ring assembly Used to center the power piston when

910-11030 installing it
Socket assembly Used to tighten the nut when installing

910-23531 the power piston and remove the nut
when disassembling the power piston
BR-2-1
TOOLS BRAKE UNIT (VAC)

Hook clamp Used to compress the return spring
910-20100 when installing the hydraulic piston
Cup insertion tool Used to insert the piston cup

910-20010
Guide pin Used as a guide when installing the

910-20061*1 diaphragm assembly and relay valve
or body Length
910-20064*2 *1 = 40 mm (1.57 in)
*2 = 85 mm (3.35 in)
BR-2-2
MASTER CYLINDER BRAKE UNIT (VAC)
MASTER CYLINDER
CONSTRUCTION
BR-3-1
DISASSEMBLY AND REASSEMBLY

REMOVAL AND INSTALLATION
1. E-clip 4. Return spring 7. Bushing

2. Clevis pin 5. Pedal shaft 8. Pedal bracket
3. Master cylinder assembly 6. Brake pedal assembly
NOTE
BR-3-2

1. Clevis 7. Piston 12. Connector cap
2. Nut 8. Cup seat 13. O-ring
3. Rod assembly 9. Primary cup 14. Bolt
4. Boot 10. Spring retainer 15. Packing
5. Retaining ring 11. Return spring 16. Cylinder body
6. Secondary cup
BR-3-3
INSPECTION
Unit: mm (in)
0.04 - 0.14 (0.0016 - 0.0055) 0.25 (0.0098)
PISTON SPRING
Free length
Unit: mm (in)
99.0 (3.898) —
Tension
Unit: N {kgf, lbf}
Maintenance standard Service limit Remark
—
{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.
5. Depress the brake pedal to ensure that free play exists.

Unit: mm (in)
Brake pedal play 8 - 15 (0.31 - 0.59) —
BR-3-4
ADJUSTMENT OF STOP LIGHT SWITCH

trudes 0 to 0.125 mm (0 to 0.0049 in). Then, secure with a lock nut.
BR-3-5
HYDROMASTER BRAKE UNIT (VAC)
HYDROMASTER
CONSTRUCTION
BR-4-1
DISASSEMBLY
DISASSEMBLY
BR-4-2

1. Clamp 20. Washer 39. Washer
2. Retaining ring 21. Spring 40. Retainer plate
3. Pipe and cover assembly 22. Outlet valve assembly 41. Piston packing
4. Gasket 23. Connector bolt 42. Gasket
5. Spring 24. Gasket 43. Piston plate
6. Elbow 25. Air bleeder assembly 44. Washer
, 7. Valve body ,+ 26. Hydraulic cylinder 45. Push rod
8. Gasket 27. Gasket 46. Push rod pin
9. Poppet valve assembly 28. Hydraulic cylinder lock nut 47. Retaining ring
10. Spring 29. Gasket 48. Stop washer
11. Diaphragm assembly ,+ 30. Hydraulic piston 49. Retainer
,+ 12. Valve fitting 31. Cup 50. Packing
13. Retaining ring 32. Hook bolt 51. Washer
14. O-ring 33. Hose ,+ 52. Oil seal
15. Piston 34. Clamp 53. Air bleeder assembly
, 16. Piston cup + 35. End plate 54. Connector bolt
, 17. Hydraulic cylinder plug 36. O-ring 55. Gasket
18. Gasket 37. Spring 56. Connector
19. Retaining ring ,+ 38. Nut 57. Cylinder shell

Clamp the assembly stand (910-10140) in a vise and mount the
hydromaster to this stand.
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
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
INSPECTION
inder
Unit: mm (in)
0.04 - 0.13 (0.0016 - 0.0051) 0.15 (0.0059)
Clearance between relay valve piston and valve fitting

Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.15 (0.0059)
Push rod run-out

Unit: mm (in)
— Less than 0.6 (0.024)
REASSEMBLY
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
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.
4. Connect compressed air to the control tube and install the

hydraulic piston using the push rod pin.
5. Insert the hydraulic piston into the hydraulic cylinder and
thread the hydraulic cylinder onto the end plate (tempo-
rarily).
NOTE
z Be careful not to damage the piston cup when inserting
the piston.
z When compressed air is not used.
1. Position the return spring with the small end facing the pis-
ton and install the end plate. Using the hook clamp (910-
20100), compress the return spring and install the hydraulic
piston using the push rod pin.
NOTE
z When installing the push rod, be careful not to damage
the oil seal around the hole in the end plate.
2. Insert the hydraulic piston into the hydraulic cylinder and
thread the hydraulic cylinder onto the end plate (tempo-
rarily).
NOTE
z Be careful not to damage the piston cup when inserting
the piston.
3. Insert the hook bolt into the guide in the assembly stand
(910-10140).
4. Install the cylinder shell assembly to the assembly stand
(910-10140).
BR-4-6
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}
17 Hydraulic cylinder plug

Install the outlet valve, spring, washer and retaining ring into the
hydraulic cylinder plug using the retaining ring insertion tool (910-
22010).
NOTE
z Before installing the hydraulic piston, assemble the
hydraulic cylinder plug.
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
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
Simple test method

This simple test method should be used for emergencies only. If the
simple test is used, functions must be reconfirmed for each of the
test standard items using a fixed tester.
z Adjust the brakes before checking their function.
Overall check
1. Depress the brake pedal with the pedal force normally used
in the negative pressure 0 state.
2. Start and idle the engine in this state.
3. After 2 to 3 seconds, the brake pedal will move a little in the
depressed direction. The operation of the hydromaster is
normal if this state is attained.
Fluid pressure system check
1. Start the engine and attain maximum negative pressure.
2. Depress the brake pedal fully.
3. The fluid-tightness of the fluid pressure system (hydraulic
piston cup, ball check valve) is faulty if the pedal rises in this
state.
Poppet valve (atmosphere valve) air tightness check

1. Idle the engine.
2. With the brake pedal released, place a piece of thin string
near the end of the atmosphere tube of the hydraulic cylin-
der.
3. If the string is sucked toward the tube, there is leakage
around the poppet valve (atmosphere valve).
4. If the string is sucked into the tube when the brake pedal is
depressed, the relay valve piston and valve are operating
normally.
Poppet valve (vacuum valve) check
1. Idle the engine.
2. Depress the brake pedal (vacuum valve fully closed and
atmosphere valve fully open) and place your finger against
the atmosphere tube.
3. If a suction force is felt at your finger, there is air leaking
from the poppet valve (vacuum valve) or power piston.
Power piston check
1. Perform this check when the operation of the power piston
is thought to be faulty.
2. Set the vacuum tank to atmospheric pressure and stop the
engine. Then remove the oil filler plug at the rear end of the
power cylinder.
3. With the brake pedal released, measure the position of the
power piston with calipers.
4. Start and idle the engine.
5. The actual stroke of the power piston can be found by mea-
suring its position when the brake pedal is depressed and
the power piston is operated sufficiently.
BR-4-9
SAFETY CYLINDER BRAKE UNIT (VAC)
SAFETY CYLINDER
CONSTRUCTION
BR-5-1


1. Cylinder cap 7. O-ring 12. Retaining ring
2. Packing 8. Packing 13. Gasket
3. Spring 9. Switching valve 14. Air bleeder valve
4. Piston 10. Boot 15. O-ring
5. Plate 11. Plate 16. Cylinder
6. Switching valve cap
BR-5-2
INSPECTION
Unit: mm (in)
— 0.17 (0.0067)
Spring tension
Unit: N {kgf, lbf}
—
{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)
LOAD SENSING PROPORTION VALVE

CONSTRUCTION
BR-6-1

Do not remove the chain bolt lock nut installed on the axle bracket
unless necessary. If removal is necessary, measure the dimension
(L) shown in the figure below and record it. When installing the
chain bolt, observe the original dimension. Otherwise, proper brak-
ing force will not be obtained.

1. Spring 8. Pin 15. Plunger assembly
2. Collar 9. Lever 16. Retaining ring
3. Socket bolt 10. Guard 17. Retainer
4. Retainer 11. Retainer 18. Packing cup
5. Spring 12. Stem 19. O-ring
6. Split pin 13. Spring 20. Valve body
7. Washer 14. Washer
BR-6-2
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.
Performance test under no-load condition

1. If the chain bolt is removed from the axle bracket, reinstall
the chain bolt to its original position.
2. Depress the brake pedal and increase the oil pressure of
the supply side. When the oil pressure reaches 7,846 kPa
{80 kgf/cm2, 1,138 psi}, adjust it by turning the stem so that
the pressure at the delivery side is P kPa {kgf/cm2, psi}.
Secure the stem with the lock nut.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
BR-6-3
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (VAC)
BLEEDING AIR FROM THE BRAKE SYSTEM

AIR BLEEDING PROCEDURE
When bleeding air, stop the engine and wait for the vacuum tank to
reach atmospheric pressure.
Bleed the air from each air bleeder screw, in the order shown
below.
(Ensure that the check bolt for the safety cylinder is loose.) →
(Loosen the air vent valve on the safety cylinder.) → Hydromaster
relay valve bleeder screw → Hydromaster hydraulic cylinder plug →
Wheel cylinder air bleeder screw → (Tighten the air bleeder valve of
the safety cylinder)
1. Make sure the safety cylinder open-close valve is turned

fully clockwise. Then, turn the air release valve clockwise.
2. Pour brake fluid into the brake fluid reservoir. While bleed-
ing air, be sure to add brake fluid in the reservoir so that air
will not enter the fluid.
NOTE
z When adding brake fluid, be careful not to allow any for-
eign matter to mix into the fluid.
BR-7-1
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (VAC)
3. Bleed air from the hydromaster.

z Remove the cap from the relay valve air bleeder screw.
Connect a vinyl air bleeding pipe to the bleeder tip, and
insert the pipe tip into the container.
z Depress the brake pedal several times. When brake pedal
resistance is felt, loosen the bleeder screw to allow air con-
taminated fluid to flow out. Then, tighten the bleeder screw.
Repeat this procedure to remove air from fluid.
z In the same manner, bleed air from the hydromaster
hydraulic cylinder plug, using the air bleeder screw.
4. Bleed air from the wheel cylinders in the same manner as
that for the hydromaster.
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
= AOH-2 = = LEAF SPRING TYPE =
CONSTRUCTION ................................... BR- 4-25 CONSTRUCTION .................................... BR- 8- 4
DISASSEMBLY ....................................... BR- 4-25 DISASSEMBLY ........................................ BR- 8- 5
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
(Made by NABCO Ltd.)

Model AOH-31 AOH-2
I.D. 114.3 (4.50) 138.0 (5.43)
Air cylinder mm (in)
Stroke 79 (3.11) 120 (4.72)
I.D. 23.8 (0.937) 29.0 (1.142)
Hydraulic cylinder mm (in)
Stroke 77.4 (3.047) 118 (4.65)
Residual pressure kPa {kgf/cm2, psi} 78 - 127 {0.8 - 1.3, 11 - 18}
SERVICE DATA
BRAKE VALVE
MODEL E6-R15, E6-RP4, E6-ER1 AND E6-ERP1
Unit: mm (in)
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) —
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
AIR BOOSTER
Made by JIDOSHA KIKI CO., LTD.
<Model Type I, Type II, Type III and Type IV>
Unit: mm (in)
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)
Type IV —
{10.5, 23.2} 175.2 mm (6.90 in)
Made by NABCO Ltd.

<Model AOH-31 and AOH-2>
Unit: mm (in)
Clearance between inlet valve 0.052 - 0.252
AOH-2 0.28 (0.0110)
assembly valve and valve guide (0.0020 - 0.0099)
Less than
Piston assembly (push rod) run-out 0.15 (0.0059)
0.05 (0.0020)
0.020 - 0.105
AOH-31 0.20 (0.0079)
Clearance between hydraulic (0.0008 - 0.0041)
cylinder and piston 0.040 - 0.123
AOH-2 0.20 (0.0079)
(0.0016 - 0.0048)
0.3 - 0.7
Protrusion of vale (Hydraulic piston) —
(0.012 - 0.028)
AOH-31 98 {10.0, 22}
Power piston spring tension {10.8 - 13.2, 24 - 29} 114.5 mm (4.51 in)
N {kgf, lbf} 177 - 216 When compressed to
AOH-2 157 {16.0, 35.3}
{18.0 - 22.0, 39.7 - 48.5} 204.0 mm (8.03 in)
BR-1-3
AIR PRESSURE GOVERNOR

Unit: kPa {kgf/cm2, psi}
647 - 686
Low range —
{6.6 - 7.0, 94 - 100}
Type I
765 - 814
High range —
Pressure adjustment {7.8 - 8.3, 111 - 118}
range 686 - 726
Low range —
{7.0 - 7.4, 100 - 105}
Type II
814 - 863
High range —
{8.3 - 8.8, 118 - 125}
PARKING BRAKE VALVE

Unit: mm (in)
Distance from body end to cam holder 38.3 - 38.7
—
assembly (1.508 - 1.524)
Main spring 31.7 (1.248) 30.7 (1.209)
Free length Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)
SPRING BRAKE CHAMBER

Type II only
Unit: N {kgf, lbf}
7,846 - 8,826 When compressed to
Return spring tension —
{800 - 900, 1,764 - 1,985} 50.0 mm (1.969 in)
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}
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}
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

Air bleeder screw 7 - 13 {0.7 - 1.3, 5.1 - 9.4}
Retainer (Cover) 8 - 20 {0.8 - 2.0, 5.8 - 14.5}
Type I Switch assembly 25 - 34 {2.5 - 3.5, 18 - 25}
Type II Power piston mounting nut 20 - 29 {2.0 - 3.0, 14 - 22}
Cylinder shell assembly fitting nut 20 - 29 {2.0 - 3.0, 14 - 22}
Exhaust cover assembly 8 - 20 {0.8 - 2.0, 5.8 - 14.5}
Retainer (Cover) 8 - 20 {0.8 - 2.0, 5.8 - 14.5}
Switch assembly 25 - 34 {2.5 - 3.5, 18 - 25}
Power piston mounting nut 20 - 29 {2.0 - 3.0, 14 - 22}
Type III Cylinder shell assembly fitting nut 20 - 29 {2.0 - 3.0, 14 - 22}
Type IV Relay valve cover mounting bolt 12 - 19 {1.2 - 1.9, 9 - 14}
Relay valve assembly mounting nut 20 - 29 {2.0 - 3.0, 14 - 22}
L-type connector 15 - 20 {1.5 - 2.0, 11 - 14}
Connector 29 - 39 {3.0 - 4.0, 22 - 29}
Exhaust cover mounting screw 0.69 - 1.27 {0.07 - 0.13, 0.51 - 0.94}
Air booster
Cap assembly 196 - 294 {20.0 - 30.0, 145 - 217}
Cylinder shell mounting nut 9 - 14 {0.9 - 1.4, 6.5 - 10}
AOH-31
Cylinder body mounting nut 15 - 23 {1.5 - 2.3, 11 - 17}
Switch assembly 44 - 65 {4.5 - 6.6, 33 - 48}
Air bleeder 29 - 39 {3.0 - 4.0, 22 - 29}
Air bleeder screw 2.9 - 13 {0.3 - 1.3, 2.2 - 9.4}
Cap assembly 147 - 196 {15.0 - 20.0, 108 - 145}
Cylinder shell mounting nut 20 - 25 {2.0 - 2.5, 14 - 18}
Cylinder body mounting bolt 20 - 25 {2.0 - 2.5, 14 - 18}
Switch assembly 20 - 29 {2.0 - 3.0, 14 - 22}
AOH-2
Connector 29 - 39 {3.0 - 4.0, 22 - 29}
Relay valve assembly mounting nut 20 - 25 {2.0 - 2.5, 14 - 18}
Relay valve cover mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Service port 15 - 25 {1.5 - 2.5, 11 - 18}
Flare connector
Supply port 29 - 39 {3.0 - 4.0, 22 - 29}
Air pressure governor Lock nut 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Purge chamber and body mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
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}
Air dryer
Oil filter mounting rolling screw 2 - 4 {0.2 - 0.4, 1.4 - 2.9}
DR-41 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}
BR-1-5

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}
Socket bolt lock nut 13 - 18 {1.3 - 1.8, 9 - 13}
Chain type
Stem lock nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Plug 177 - 235 {18.0 - 24.0, 130 - 174}
Load sensing pro- Seal retainer 20 - 39 {2.0 - 4.0, 14 - 29}
portion valve Shell mounting nut 13 - 18 {1.3 - 1.8, 9 - 13}
Leaf spring type
Actuating rod lock nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Leaf spring mounting nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Wire assembly mounting nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Double check valve Nipple 34 - 44 {3.5 - 4.5, 25 - 33}
Protection valve Type I Cover mounting screw 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Mounting nut 88 - 108 {9.0 - 11.0, 65 - 80}
Type I Clevis lock nut 34 - 45 {3.5 - 4.6, 25 - 33}
Turnbuckle mounting nut 34 - 45 {3.5 - 4.6, 25 - 33}
Spring brake
Mounting nut 104 - 157 {10.6 - 16.0, 77 - 116}
chamber
Clamp band mounting bolt and nut 18 - 20 {1.8 - 2.0, 13 - 14}
Type II
Clevis lock nut 34 - 45 {3.5 - 4.6, 25 - 33}
Adapter mounting nut 122 - 142 {12.4 - 14.5, 90 - 105}
4.76 (0.1874) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut Tube O.D. mm (in)
Steel brake tube 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
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-1-6
DIAGRAM OF PIPING
MK, LK AND PKB SERIES
MK, LK AND PKB SERIES (FOR HONG KONG)
BR-1-7
MK AND LK SERIES (FOR NORWAY)

Without anti-lock brake system
With anti-lock brake system
BR-1-8
PKC SERIES (AOH BRAKE VEHICLE)
CD AND CW SERIES (AOH BRAKE VEHICLE)
BR-1-9
TOOLS BRAKE UNIT (AOH)
TOOLS
AIR BOOSTER
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
Needle Used when removing the

910-21200 cup packing or O-ring
O O O O
L-spanner Used when removing/install-

910-23370 ing the exhaust cover
O O — —
Cup insert guide Used when inserting the

910-23289 hydraulic piston cup
O O — —
Cup insert guide

910-23290
— — O O
Holder Used when removing/install-

910-24831 ing the power piston
O O O O
BR-2-1
TOOLS BRAKE UNIT (AOH)
LOAD SENSING PROPORTION VALVE (Leaf spring type)

Tool name and
Description Shape
number
Special spanner Used when removing/installing the actuating rod
X7237-323
Pin Used when driving out the spring pin

X7237-321
Spanner Used when removing/installing the seal retainer

X7237-322
Seal insert tool Used when inserting the seal

X7237-324
BR-2-2
BRAKE VALVE BRAKE UNIT (AOH)
BRAKE VALVE
CONSTRUCTION
R.H.D. MODEL
Brake valve
<E6-R15>
BR-3-1
<E6-ER1>
BR-3-2
L.H.D. MODEL
Brake valve link assembly
Brake pedal assembly
BR-3-3
Brake valve
<E6-RP4>
BR-3-4
<E6-ERP1>
BR-3-5
DISASSEMBLY
REMOVAL
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
3. Tilt the cab upward.
WARNING
WARNING
z Be sure to insert the safety pin into the lock hole after tilt-
ing the cab upward.
4. Disconnect the various connectors.

NOTE
z Plug the connectors to prevent the entry of foreign mat-
ter.
5. Remove the brake valve link (L.H.D. model only).

NOTE
z Do not remove except when necessary.
BR-3-6
DISASSEMBLY
<R.H.D. MODEL>
Brake valve
<E6-R15>

1. Cotter pin 16. Lock screw 31. Relay piston 46. Valve retainer
2. L-pin 17. Special washer 32. Retaining ring 47. Lower valve
3. Pin 18. Spring seat 33. Check valve assembly 48. Retaining ring
4. Roller 19. Sub spring seat 34. Lower valve assembly 49. O-ring
5. Collar 20. Sub spring 35. O-ring 50. Upper valve assembly
6. Pedal 21. Main spring 36. Screw 51. Retaining ring
7. Lock nut 22. Shim 37. Set nut 52. Special washer
8. Setscrew 23. O-ring 38. Diaphragm washer 53. O-ring
9. Boot 24. Upper piston 39. Exhaust check 54. O-ring retainer
10. Plunger 25. Lower body 40. Check valve seat 55. Upper valve spring
11. Mounting plate 26. O-ring 41. Retaining ring 56. Valve retainer
12. Retaining ring 27. Relay piston return spring 42. Lower valve guide 57. Upper valve
13. Upper piston assembly 28. Relay piston assembly 43. O-ring 58. Upper body
14. Piston return spring 29. O-ring 44. Special washer
15. O-ring 30. O-ring 45. Lower valve spring
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.
BR-3-7
<E6-ER1>

1. Pedal bolt 16. Piston return spring 31. Retaining ring 46. O-ring
2. Cotter pin 17. Lock screw 32. Check valve seat 47. O-ring
3. Pin 18. Special washer 33. Special washer 48. Upper valve assembly
4. L-pin 19. Spring seat 34. Lower piston assembly 49. Retaining ring
5. Roller 20. Sub spring seat 35. O-ring retainer 50. Special washer
6. Collar 21. Sub spring 36. O-ring 51. O-ring retainer assembly
7. Pedal 22. Main spring 37. O-ring 52. O-ring retainer
8. Lock nut 23. Shim 38. Lower valve spring 53. O-ring
9. Setscrew 24. Upper piston 39. Valve retainer 54. O-ring
10. Plunger 25. O-ring 40. Lower valve 55. Upper valve spring
11. Boot 26. O-ring 41. Lower valve body 56. Valve retainer
12. Bushing 27. Lower body assembly 42. O-ring 57. Upper valve
13. Mounting plate 28. Lock screw 43. Relay piston return spring 58. Upper body
14. Bushing 29. Diaphragm washer 44. Relay piston assembly
15. Upper piston assembly 30. Diaphragm 45. Relay piston
BR-3-8
<L.H.D. MODEL>

1. Cotter pin 4. Roller 7. Lock nut 10. Plunger
2. L-pin 5. Collar 8. Setscrew 11. Mounting plate
3. Pin 6. Pedal 9. Boot
BR-3-9
Brake valve
<E6-RP4>

1. Boot 18. O-ring 35. O-ring
2. Plunger 19. Relay piston return spring 36. Special washer
3. Mounting plate 20. Relay piston assembly 37. Lower valve spring
4. Retaining ring 21. O-ring 38. Valve retainer
5. Upper piston assembly 22. O-ring 39. Lower valve
6. Piston return spring 23. Relay piston 40. Retaining ring
7. O-ring 24. Retaining ring 41. O-ring
8. Lock screw 25. Check valve assembly 42. Upper valve assembly
9. Special washer 26. Lower valve assembly 43. Retaining ring
10. Spring seat 27. O-ring 44. Special washer
11. Sub spring seat 28. Screw 45. O-ring
12. Sub spring 29. Set nut 46. O-ring retainer
13. Main spring 30. Diaphragm washer 47. Upper valve spring
14. Shim 31. Exhaust check 48. Valve retainer
15. O-ring 32. Check valve seat 49. Upper valve
16. Upper piston 33. Retaining ring 50. Upper body
17. Lower body 34. Lower valve guide
BR-3-10
<E6-ERP1>

1. Boot 16. Lower body 31. Lower valve spring
2. Plunger 17. O-ring 32. Valve retainer
3. Mounting plate 18. Relay piston return spring 33. Lower valve
4. Upper piston assembly 19. Relay piston assembly 34. Upper valve assembly
5. Piston return spring 20. O-ring 35. Retaining ring
6. Lock screw 21. O-ring 36. Special washer
7. Special washer 22. Relay piston 37. O-ring
8. Spring seat 23. Retaining ring 38. O-ring
9. Sub spring seat 24. Holder 39. O-ring retainer
10. Sub spring 25. Diaphragm 40. Upper valve spring
11. Main spring 26. Check valve seat 41. Valve retainer
12. Shim 27. Special washer 42. Upper valve
13. O-ring 28. O-ring 43. Upper body
14. O-ring 29. O-ring
15. Upper piston 30. O-ring retainer
BR-3-11

Remove dust or dirt which is in contact with part surfaces and make
alignment marks, where necessary, so that the parts can be re-
installed in their original positions.
}
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
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
INSPECTION
Pin hole inside diameter

Unit: mm (in)
10.0 (0.394) 10.25 (0.4035)
Pin outside diameter (Except for E6-ER1)

Unit: mm (in)
10.0 (0.394) 9.85 (0.3878)
Roller (Except for E6-ER1)

Unit: mm (in)
Inside diameter 10.0 (0.394) 10.25 (0.4035)
Outside diameter 18.7 (0.736) 17.60 (0.6929)
Mounting plate bushing inside diameter (Except for

E6-ER1)
Unit: mm (in)
26.5 (1.043) 26.70 (1.0512)
BR-3-14
Piston outside diameter (E6-ER1 only)

Unit: mm (in)
48.7 (1.917) 49.6 (1.953)
Relay piston outside diameter (E6-ER1 only)

Unit: mm (in)
74.77 (2.9437) 74.67 (2.9398)
Plunger outside diameter

Unit: mm (in)
26.5 (1.043) 26.20 (1.0315)
Spring free length

Unit: mm (in)
Maintenance
standard
Main spring 35.8 (1.409) —
Sub spring 19.1 (0.752) —
Relay piston return
24.7 (0.972) —
spring
Piston return
78.9 (3.106) —
spring
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
BR-3-15
Spring tension
Unit: N {kgf, lbf}
Maintenance
standard
235 When compressed to
Main spring —
{24.0, 52.9} 34.0 mm (1.339 in)
Sub spring —
{25.4, 56.0} 15.3 mm (0.602 in)
—
—
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
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.
z Align the alignment mark (scribed during disassembly)

when installing the cover assembly and mounting plate.
BR-3-16
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
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
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.
<When the brake valve link assembly is removed>

z In advance, install the brake valve assembly on the brake
valve link assembly.
: 23 - 32 N·m {2.3 - 3.3 kgf·m, 17 - 24 ft·lbf}
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}
2. Connect each brake tube.

3. Install on the cab the cover on the link assembly pedal side.
BR-3-18
4. Adjust the link rod length (dimension L).

z Butt the link rod against the plunger.
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
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
Pedal step E6-R15 7.5º 15º

angle E6-ER1 8º 15.3º - 18.3º
L.H.D. model
6.0 - 7.2
Plunger stroke mm (in) 3.0 (0.118)
(0.236 - 0.283)
3. When pressures in the rapid-pressure rise points are exces-

sively low, it is necessary to replace the upper valve spring.
4. Make sure the air pressure difference between the second-
ary side and primary side is within 29.4 kPa {0.3 kgf/cm2,
4.3 psi} and it changes smoothly corresponding to the pres-
sure changes.
5. With the air pressure gauge fitted, make sure the pressure
rises and falls smoothly by depressing the brake pedal sev-
eral times.
BR-3-20
AIR BOOSTER BRAKE UNIT (AOH)
AIR BOOSTER
= TYPE I AND TYPE II =
CONSTRUCTION
DISASSEMBLY
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
DISASSEMBLY

1. Switch assembly 11. O-ring 21. O-ring 31. Retaining ring
2. Shim 12. Spring retainer 22. Power piston 32. Spring
3. Retainer (Cover) 13. Spring 23. Cup packing 33 -1. Valve assembly (Type I)
4. Spring 14. Residual valve 24. Power piston spring 33 -2. Ball (Type II)
5. Rod 15. Air bleeder screw 25. Retaining ring 34. Retainer assembly
6. Retaining ring 16. Cylinder shell assembly 26. Washer 35. O-ring
7. Bracket 17. O-ring 27. Straight pin 36. Straight pin
8. Exhaust cover assembly 18. Push rod nut 28. Hydraulic piston assembly 37. Push rod
9. Retaining ring 19. Washer 29. Cup packing 38. Cylinder body
10. Connector 20. Washer 30. Back-up ring
BR-4-2

z Before disassembling, put an alignment mark on each con-
nection (cylinder shell/cylinder body, cylinder body/connec-
tor) to use as a reference mark when installing.
z Install the air booster onto the stand (910-00450).
8 Exhaust cover assembly

Using the L-wrench (910-23370), remove the exhaust cover
assembly.
NOTE
z It is not necessary to remove the exhaust cover assem-
bly if there are no malfunctions.
11 O-ring
Using the needle (910-21200), remove the O-ring from the connec-
tor.
18 Push rod nut

1. Remove the cylinder shell assembly from the stand and
install the cylinder body upside down onto the stand.
2. Secure the power piston rib with the holder (910-24831)
and remove the push rod nut.
NOTE
z When removing the power piston, be careful not to allow
the O-ring to get caught in the push rod thread.
23 Cup packing
Using the needle (910-21200), remove the cup packing from the
power piston assembly.
BR-4-3
25 Retaining ring
Remove the retaining ring and then remove the back-up ring and
push rod together with the hydraulic piston assembly.
28 Hydraulic piston assembly

Using the needle (910-21200), extract the straight pin and separate
the hydraulic piston assembly from the push rod.
NOTE
z When extracting the straight pin, compress the hydraulic
piston spring. Do not expand the pin.
29 Cup packing
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
INSPECTION
Clearance between cylinder shell and power piston

Unit: mm (in)
— 1.8 (0.071)
Push rod run-out

Unit: mm (in)
— 0.15 (0.0059)
Clearance between hydraulic cylinder and piston

Unit: mm (in)
— 0.15 (0.0059)
Power piston spring tension

Unit: N {kgf, lbf}
Maintenance standard Service limit Remark
When compressed to
— 63.7 {6.5, 14.3}
120.0 mm (4.72 in)
BR-4-5
REASSEMBLY
REASSEMBLY
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
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.

Insert the straight pin slightly into the pin hole in the hydraulic pis-
ton. Align the straight pin with the hole in the push rod. Push the pin
into the hole with a finger to connect the hydraulic piston and push
rod.
24 Power piston spring

1. Apply 98 kPa {1 kgf/cm2, 14 psi} of compressed air to the
outlet on the wheel cylinder side of the cylinder body. Pull
out the push rod completely.
BR-4-6
2. Place the power piston spring on the cylinder body and

insert the straight pin into the tip of the push rod.
NOTE
z Install the power piston spring taking care that it does
not come off the guide in the cylinder body.
23 Cup packing
Install the power piston, paying attention to the installation direction
of the cup packing.
18 Push rod nut

1. Install the power piston assembly, O-ring and two washers
in that order, and secure them with the push rod nut.
and tighten the push rod nut.
NOTE
z When tightening the push rod nut, securely tighten the
power piston. Otherwise, the piston may be raised by the
spring pressure causing the O-ring to be damaged by the
push rod thread.
3. After tightening the push rod nut, dot punch two places 180º
apart on the connecting portion (threaded portion) of the nut
and push rod to prevent them from turning.
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
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
z Performance curve.
Test method and rated values

Test item Test method Rated values
Hydraulic tightness test Apply a hydraulic pressure of 11,768 {120, 1,706} to the 10 secs or more
hydraulic system and measure the time required for the
pressure to drop by 981 {10, 142} when the system is
blocked.
Operation start pressure test Supply a command pressure to the control valve by gradu- 69 {0.7, 10} or less
ally depressing the brake pedal and measure the command
pressure at which the wheel cylinder hydraulic pressure
begins to rise.
Operation test with full load Hydraulic cylinder hydraulic pressure for command 686 {7, 14,514 - 16,476
100}. {148 - 168, 2,105 - 2,389}
Air tightness test with full load Block the command pressure and reservoir supply pressure 59 {0.6, 9} or less
and measure the pressure drop in 15 seconds from the full
load operation state and confirm air tightness.
Residual pressure test Measure the wheel cylinder hydraulic pressure when the 59 - 157 {0.6 - 1.6, 9 - 23}
brake pedal has been released.
Detector switch operation test Loosen the air bleeder of the plug and apply a pressure of Must operate
196 to 294 {2 to 3, 28 to 43} to the air booster to operate the
power piston and confirm that the switch is operating prop-
erly, using an electric tester.
BR-4-9
= TYPE III AND TYPE IV =
CONSTRUCTION
DISASSEMBLY
REMOVAL
BR-4-10
DISASSEMBLY

1. Body assembly 16. Valve seat 31. Spring 46. Retainer assembly
2. Collar 17. Cover 32. Valve 47. Washer
3. O-ring 18. O-ring 33. Retainer 48. O-ring
4. O-ring 19. Spring 34. Cylinder shell assembly 49. Back-up ring
5. Pipe 20. O-ring 35. O-ring 50. Cup packing
6. Cover assembly 21. Piston 36. Push rod nut 51. Retaining ring
7. Exhaust cover 22. O-ring 37. Washer 52. Spring
8. Retaining ring 23. Retainer 38. Washer 53. Valve
9. Inlet valve assembly 24. Spring 39. O-ring 54. Rod
10. Spring 25. Road 40. Power piston assembly 55. Straight pin
11. Valve retainer 26. Retaining ring 41. Cup packing 56. Switch assembly
12. O-ring 27. Retaining ring 42. Power piston spring 57. Gasket
13. O-ring 28. Connector 43. Retaining ring 58. Air bleeder screw
14. Valve guide 29. O-ring 44. Straight pin 59. Cylinder
15. Retaining ring 30. Spring retainer 45. Hydraulic piston
BR-4-11

z Before disassembling, put an alignment mark on each con-
nection (cylinder shell/cylinder body, cylinder body/connec-
tor) to use as a reference mark when installing.
z Install the air booster onto the stand (910-00450).
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.
36 Push rod nut

1. Remove the cylinder shell assembly from the stand and
install the cylinder body upside down onto the stand.
and remove the push rod nut.
z When removing the power piston, be careful not to allow
the O-ring to get caught in the push rod thread.
41 Cup packing
power piston assembly.
BR-4-12
43 Retaining ring
Remove the retaining ring and then remove the back-up ring and
push rod together with the hydraulic piston assembly.

Using the needle (910-21200), extract the straight pin and separate
the hydraulic piston assembly from the push rod.
NOTE
z When extracting the straight pin, compress the hydraulic
piston spring. Do not expand the pin.
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
48 O-ring
Using the needle (910-21200), remove the O-ring from the retainer
assembly.
50 Cup packing
hydraulic piston assembly.
BR-4-13
INSPECTION
Clearance between cylinder shell and power piston

Unit: mm (in)
— 1.8 (0.071)
Push rod run-out

Unit: mm (in)
— 1.2 (0.047)

Unit: mm (in)
— 0.15 (0.0059)
Power piston spring tension

Unit: N {kgf, lbf}
Maintenance
Model Service limit Remarks
standard
Type III —
{10.5, 23.2} 245.2 mm (9.65 in)
Type IV —
{10.5, 23.2} 175.2 mm (6.90 in)
BR-4-14
REASSEMBLY
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.
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

Insert the straight pin slightly into the pin hole in the hydraulic pis-
ton. Align the straight pin with the hole in the push rod. Push the pin
into the hole with a finger to connect the hydraulic piston and push
rod.
42 Power piston spring

1. Apply 98 kPa {1 kgf/cm2, 14 psi} of compressed air to the
outlet on the wheel cylinder side of the cylinder body. Pull
out the push rod completely.
2. Place the power piston spring on the cylinder body and

insert the straight pin into the tip of the push rod.
NOTE
z Install the power piston spring taking care that it does
not come off the guide in the cylinder body.
BR-4-15
41 Cup packing
Install the power piston, paying attention to the installation direction
of the cup packing.
36 Push rod nut

1. Install the power piston assembly, O-ring and two washers
in that order, and secure them with the push rod nut.
and tighten the push rod nut.
NOTE
z When tightening the push rod nut, securely tighten the
power piston. Otherwise, the piston may be raised by the
spring pressure causing the O-ring to be damaged by the
push rod thread.
3. After tightening the push rod nut, dot punch two places 180º
apart on the connecting portion (threaded portion) of the nut
and push rod to prevent them from turning.
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
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
z Performance curve.
z Test method and rated values

Hydraulic tightness test Apply a hydraulic pressure of 11,768 {120, 1,706} to the 10 secs or more
hydraulic system and measure the time required for the
pressure to drop 981 {10, 142} when blocked.
Air tightness test without load Apply 588 {6, 85} compressed air to the air booster and 39 {0.4, 6} or less
block the compressed air source and measure the pressure
drop over 15 seconds.
Operation start pressure test Supply a command pressure to the control valve by gradu- 98 {1.0, 14} or less
ally depressing the brake pedal and measure the command
pressure at which the wheel cylinder hydraulic pressure
begins to rise.
Operation test with full load Hydraulic cylinder hydraulic pressure of command 588 {6, 12,259 - 13,632
85}. {125 - 139, 1,778 - 1,977}
Air tightness test with full load Block the command pressure and reservoir supply pressure 59 {0.6, 9} or less
and measure the pressure drop in 15 seconds from the full
load operation state and confirm air tightness.
Residual pressure test Measure the wheel cylinder hydraulic pressure when the 59 - 157 {0.6 - 1.6, 9 - 23}
brake pedal has been released.
Detector switch operation test Loosen the air bleeder of the plug and apply a pressure of Must operate
196 to 294 {2 to 3, 28 to 43} to the air booster to operate the
power piston and confirm that the switch is operating prop-
erly, using an electric tester.
BR-4-18
= AOH-31 =
CONSTRUCTION
BR-4-19
DISASSEMBLY
REMOVAL
DISASSEMBLY

1. Cylinder body assembly 12. Cylinder body cover 23. Retaining ring
2. Cap assembly 13. O-ring 24. Washer
3. O-ring 14. Push rod pin 25. Cup packing
4. Check valve 15. Ring guide 26. Cup guide
5. Spring 16. Piston guide 27. Washer
6. Plate 17. Hydraulic piston assembly 28. Cup packing
7. Air bleeder screw 18. Cup 29. Cup guide
8. Retaining ring 19. Back-up ring 30. Bushing
9. Connector 20. Piston spring 31. Switch assembly
10. O-ring 21. Piston assembly 32. Air bleeder
11. Filter 22. Cup packing 33. Cylinder shell assembly
BR-4-20

Before disassembling, put an alignment mark on each connection
so that it can be used as a reference mark when installing.
14 Push rod pin

1. Before extracting the push rod pin, wind the ring guide
around the lower portion of the hydraulic piston.
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
BR-4-21
Piston assembly (push rod) run-out

Unit: mm (in)
Less than 0.05 (0.0020) 0.15 (0.0059)

Unit: mm (in)
0.020 - 0.105 (0.0008 - 0.0041) 0.20 (0.0079)
Protrusion of valve (Hydraulic piston assembly)

Unit: mm (in)
0.3 - 0.7 (0.012 - 0.028) —
Piston spring tension

Unit: N {kgf, lbf}
98 {10.0, 22}
{10.8 - 13.2, 24 - 29} 114.5 mm (4.51 in)
REASSEMBLY
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
2. Place the piston assembly so that it faces upward. Install

the piston spring and cylinder body cover assembly and
hold the cover by hand. Then, install the piston guide and
hydraulic piston assembly and insert the push rod pin into
the pin hole.
3. Insert the ring guide into the normal position on the hydrau-
lic piston and then release the cover gradually.
FUNCTIONAL CHECK
TEST EQUIPMENT
BR-4-23
PERFORMANCE CURVE
TEST METHOD
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
= AOH-2 =
CONSTRUCTION
DISASSEMBLY
REMOVAL
BR-4-25
DISASSEMBLY

1. Relay valve assembly 13. Inlet valve assembly 24. O-ring 35. Piston assembly
2. Cover assembly 14. Sealing ring 25. Filter 36. Cup packing
3. Spring 15. Cylinder body 26. Cylinder body cover 37. Retainer ring
4. O-ring 16. Cap assembly 27. O-ring 38. Cup support
5. Piston assembly 17. O-ring 28. Push rod pin 39. Cup packing
6. O-ring 18. Check valve 29. Ring guide 40. Spacer
7. O-ring 19. Valve seat 30. Piston guide 41. Cup packing
8. O-ring 20. Spring 31. Hydraulic piston assembly 42. Cup support
9. Ring 21. Plate 32. Cup 43. Cylinder bushing
10. Cover 22. Air bleeder screw 33. Back-up ring 44. Switch assembly
11. Check valve 23. Connector 34. Piston spring 45. Cylinder shell assembly
12. Retaining ring
BR-4-26

5 Piston assembly
It is not necessary to disassemble the piston assembly if there is no
damage on the valve seat.
28 Push rod pin

1. Before extracting the push rod pin, wind the ring guide
around the lower portion of the hydraulic piston.
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
BR-4-27
Clearance between inlet valve assembly valve and

valve guide
Unit: mm (in)
0.052 - 0.252
0.28 (0.0110)
(0.0020 - 0.0099)
Piston assembly (push rod) run-out

Unit: mm (in)
Less than 0.05 (0.0020) 0.15 (0.0059)

Unit: mm (in)
0.040 - 0.123
0.20 (0.0079)
(0.0016 - 0.0048)
Protrusion of valve (Hydraulic piston assembly)

Unit: mm (in)
0.3 - 0.7
—
(0.012 - 0.028)
Piston spring tension

Unit: N {kgf, lbf}
177 - 216 157 When compressed to
{18.0 - 22.0, 39.7 - 48.5} {16.0, 35.3} 204.0 mm (8.03 in)
BR-4-28
REASSEMBLY
REASSEMBLY
28 Push rod pin
1. Wind the ring guide around the hydraulic piston groove. Do
not insert the ring guide into the groove.
2. Place the piston assembly so that it faces upward. Install

the piston spring and cylinder body cover assembly and
hold the cover by hand. Then, install the piston guide and
hydraulic piston assembly and insert the push rod pin into
the pin hole.
3. Insert the ring guide into the normal position on the hydrau-
lic piston and then release the cover gradually.
FUNCTIONAL CHECK
TEST EQUIPMENT
BR-4-29
PERFORMANCE CURVE
TEST METHOD
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)

CONSTRUCTION
BR-5-1

DISASSEMBLY

1. Cover 6. Piston 10. O-ring
2. Retaining ring 7. Valve spring 11. Washer
3. Adjusting screw assembly 8. Valve 12. O-ring
4. Exhaust stem 9. O-ring 13. Body
5. Exhaust stem spring
BR-5-2
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
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.
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
2. If the air pressure is not within the specified range, adjust it

as follows:
Adjust the operating pressure by using the adjusting screw after
loosening the lock nut.
z Screw in the adjusting screw to set the high adjusting point;
unscrew it to set the low adjusting point.
NOTE
z If the operating pressure is not within the specified
range, the air pressure governor assembly should be
replaced because the low or high air pressure alone can-
not correct it.
z After adjustments have been completed, tighten the lock
nut.
: 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
BR-5-4
AIR DRYER BRAKE UNIT (AOH)
AIR DRYER
= DR-31 =
CONSTRUCTION
BR-6-1
DISASSEMBLY
DISASSEMBLY

1. Purge chamber 11. Filter 21. Exhaust cover
2. O-ring 12. Filter plate 22. Valve body
3. Check valve 13. Case 23. Piston
4. Cover 14. Oil filter 24. Valve spring
5. Set spring 15. Filter gasket 25. Valve seat
6. Filter plate 16. Oil filter assembly 26. O-ring
7. Filter 17. Gasket ring 27. O-ring
8. Case guide 18. Body 28. O-ring
9. Sealing ring 19. O-ring 29. Thermostat
10. Desiccant 20. Retaining ring 30. Heater
BR-6-2
Key points of disassembly

1 Purge chamber
To remove the purge chamber and cover, remove the nut and bolt
on one side, place that section in a vise (to prevent the purge
chamber from popping out due to the set spring) and remove the
nut and bolt located diagonally in relation to those previously
removed.
INSPECTION
REASSEMBLY
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
2. To properly seat the desiccant, lightly tap around the case

with a plastic hammer prior to installing the filter.
NOTE
z Be sure to install the filter with the thick, soft layer side
facing down.
INSPECTION AFTER MOUNTING ON VEHICLE

1. Start the engine, and check to ensure that air is discharged
from the air dryer exhaust port when the maximum pressure
is reached when switching from “Load” to “Unload”. Air dis-
charge will be reduced in approximately 3 seconds to the
extent that the air noise is no longer overly loud.
2. Check for leaks from the air dryer exhaust port when the air
pressure drops to the minimum when switching from
“Unload” to “Load”.
The amount of air leakage must be less than 20 cm3 (1.22
cu in) per minute [or 15 mm (0.59 in) diameter in a soap
bubble within 6 seconds].
3. Check pipe connections for leaks.
BR-6-4
= DR-41 AND DR-42 =
CONSTRUCTION
DR-41
BR-6-5
DR-42
BR-6-6
DISASSEMBLY
DISASSEMBLY
DR-41

1. Purge chamber 11. Oil filter 21. O-ring
2. Case cover 12. O-ring 22. Valve assembly
3. Check valve 13. O-ring 23. Valve spring
4. O-ring 14. Case 24. Retaining ring
5. Set spring 15. Gasket ring 25. Valve body
6. Filter plate 16. Gasket 26. O-ring
7. Filter 17. Gasket ring 27. Thermostat assembly
8. Desiccant 18. Stop ring 28. Heater
9. Filter 19. Exhaust cover 29. Body
10. Filter plate 20. Piston
BR-6-7
DR-42

3. Case cover 12. Case 21. O-ring
4. Check valve 13. Oil filter 22. Valve
5. O-ring 14. O-ring 23. Piston
6. Set spring 15. Cover 24. O-ring
7. Filter plate 16. Gasket ring 25. Valve spring
8. Filter 17. Gasket ring 26. Body
9. Desiccant 18. Retaining ring
BR-6-8

2 DR-41
3 DR-42 } Case cover
While holding the case cover, remove the rolling screw and case
cover.
WARNING
WARNING
z Always hold the upper side of the case cover. Otherwise,
the tension of the set spring will force the case cover out.
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
REASSEMBLY
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
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

BR-6-11
PARKING BRAKE VALVE BRAKE UNIT (AOH)
PARKING BRAKE VALVE

CONSTRUCTION
BR-7-1
DISASSEMBLY
DISASSEMBLY

1. Handle assembly 10. Return spring 19. O-ring
2. Spring seat 11. Cam holder assembly 20. Piston
3. Spring 12. Shim 21. Exhaust valve seat
4. Spring seat 13. O-ring 22. Cam ring
5. Cover 14. C-ring 23. Guide
6. Shim(s) 15. C-ring 24. O-ring
7. Main spring 16. Feed valve seat 25. Holder
8. Valve spring 17. O-ring 26. Pin
9. Piston assembly 18. Feed valve 27. Body
BR-7-2

1 Handle assembly
The handle head is spring-loaded. When removing the screw, hold
the handle head by hand.
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
Free length
Unit: mm (in)
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
REASSEMBLY
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.
21 Exhaust valve seat

Install the guide into the exhaust valve seat, and apply grease to
the I.D. and O.D. surfaces. After this, install the guide onto the cam
ring side of the cam holder, and set it as shown.
16 Feed valve seat

Apply grease to the feed valve stem, install the feed valve into pis-
ton, and fix the valve with a C-ring.
NOTE
z Do not allow dirt and dust to contact the feed valve seat-
ing surface. Do not expand the C-ring excessively.
11 Cam holder assembly

Install the cam ring to body so that the cutout portion of the cam
ring is aligned with the two pins which are driven to body. Adjust
dimension (Z) from the body end face to the exhaust valve seating
surface to 38.1 to 38.5 mm (1.500 to 1.516 in) using shim(s).
BR-7-4
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
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)

= CHAIN TYPE =
CONSTRUCTION
BR-8-1

Do not remove the chain bolt lock nut installed on the axle bracket
unless necessary. If removal is necessary, measure the dimension
(L) shown in the figure below and record it. When installing the
chain bolt, observe the original dimension. Otherwise, proper brak-
ing force will not be obtained.

1. Spring 8. Pin 15. Plunger assembly
2. Collar 9. Lever 16. Retaining ring
3. Socket bolt 10. Guard 17. Retainer
4. Retainer 11. Retainer 18. Packing cup
5. Spring 12. Stem 19. O-ring
6. Split pin 13. Spring 20. Valve body
7. Washer 14. Washer
BR-8-2
FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTION TEST
2,844 psi} in the line between the hydromaster and supply
PERFORMANCE TEST UNDER NO-LOAD CONDITION

1. If the chain bolt is removed from the axle bracket, reinstall
the chain bolt to its original position.
{80 kgf/cm2, 1,138 psi}, adjust it by turning the stem so that
the pressure at the delivery side is P kPa {kgf/cm2, psi}.
Secure the stem with the lock nut.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
BR-8-3
= LEAF SPRING TYPE =
CONSTRUCTION
BR-8-4
DISASSEMBLY
DISASSEMBLY

1. Dust cover 12. Spring pin 23. O-ring
2. Wire assembly 13. Straight pin 24. Cup packing
3. Bracket 14. Lever assembly 25. Back-up ring
4. Leaf spring 15. Shell & bracket assembly 26. Washer
5. Plate 16. Gasket 27. Plunger & rod assembly
6. Clip 17. Spacer 28. O-ring
7. Clamp 18. Actuating rod 29. Plug
8. Guard 19. Seat retainer 30. Gasket
9. Clevis 20. Spring 31. Spring
10. Spring pin 21. Spring 32. Steel ball
11. Straight pin 22. Seal retainer 33. Body assembly
BR-8-5

9 Clevis
Using the special spanner (X7237-323), turn the actuating rod and
remove the clevis.
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
BR-8-6
REASSEMBLY
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.
27 Plunger & rod assembly

Install the washer over the flange & rod assembly (w/O-ring in
place), and insert it into position through the cup section of the seal
retainer using the seal inserted tool (X7237-324).
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
21 Spring
Install the spring so that the side with a smaller diameter is on the
rod side.
15 Shell & bracket assembly

Install the valve body assembly to the shell & bracket assembly with
the gasket placed between them.
: 13 - 18 N·m {1.3 - 1.8 kgf·m, 9 - 13 ft·lbf}
NOTE
z Evenly tighten down in 4 places.
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
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
FUNCTIONAL CHECK
2,844 psi} in the line between the air booster and supply
3. Measure and record the “free” position at the leaf spring end.
PERFORMANCE TEST UNDER NO-LOAD CONDITION

AND WIRE POSITIONING
1. Lower center position A (free position) of the bolt at the end
of the leaf spring to center position B (no-load position) of
the lever's straight pin. Then secure the wire with the axle
bracket.
{80 kgf/cm2, 1,138 psi}, adjust it by turning the actuating rod
so that the pressure at the delivery side is P kPa {P kgf/cm2,
P psi}. Secure the actuating rod with the lock nut.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
NOTE
z Fine adjustment should be done by raising and lowering
the wire.
z Use the performance chart which corresponds to the part
number shown on the name plate of the body.
3. After adjusting the wire, measure the length (L) between the
“free” (A) and the “no-load” (B) positions at the center of the
bolt. Stamp the value different on the name plate.
4. After performing the above steps, remove the air pressure
gauge and reconnect the lines. Then, bleed air from the
brake system.
BR-8-9
QUICK RELEASE VALVE BRAKE UNIT (AOH)
QUICK RELEASE VALVE

CONSTRUCTION


1. Cover 3. Filter 5. Body
2. O-ring 4. Diaphragm
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)
DOUBLE CHECK VALVE

CONSTRUCTION
Type I
Type II
BR-10-1

Type I

1. Nipple 3. Guide 5. Body
2. Packing 4. Valve
BR-10-2
Type II

1. Nipple 4. Shim 7. Filter
2. Gasket 5. Spring 8. Body
3. Valve 6. O-ring
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
z When the following exhaust air speed is reached on the out-

let side, inlet sides (A) and (B) should hold a pressure of
402 to 481 kPa {4.1 to 4.9 kgf/cm2, 58 to 70 psi}.
z When the following exhaust air speed is reached on inlet
side (A) or (B), the remaining inlet line (A) or (B), as well as
the outlet side should hold a pressure of 402 to 481 kPa
{4.1 to 4.9 kgf/cm2, 58 to 70 psi}.
(Exhaust air speed: Initial pressure of 490 kPa {5 kgf/cm2,
71 psi} should drop to 392 kPa {4 kgf/cm2, 57 psi} over a
period of 3 to 10 seconds.)
AIR LEAKAGE TEST

1. With the outlet side opened to the outside air, and inlet
sides (A) and (B) at a pressure of 0 to 490 kPa {0 to 5 kgf/
cm2, 0 to 71 psi}, there should be no leakage from the outlet
side.
2. When inlet side (A) or (B) is opened to the outside air, and
the outlet side plus the remaining inlet side (A) or (B) at a
pressure of 0 to 490 kPa {0 to 5 kgf/cm2, 0 to 71 psi}, there
should be no leakage from inlet side (A) or (B), whichever is
opened to the outside air.
3. When inlet sides (A) and (B), as well as the outlet side are
at a pressure of 0 to 785 kPa {0 to 8 kgf/cm2, 0 to 114 psi},
there should be no leakage at all.
BR-10-4
PROTECTION VALVE BRAKE UNIT (AOH)
PROTECTION VALVE
CONSTRUCTION
Type I
Type II
BR-11-1

Type I

1. Cover assembly 6. Cap 11. Cover
2. Spring seat 7. Spring 12. O-ring
3. Spring 8. Valve 13. Spring
4. Cap 9. Spring 14. Valve
5.. Diaphragm 10. Retaining ring
A , B and C :
Disassemble the remaining three places in a manner similar to
steps 1 from 9 above.
BR-11-2
Type II

1. Retaining ring 4. Shim(s) 6. O-ring
2. Plate 5. Piston 7. Body
3. Spring
FUNCTIONAL CHECK
<TYPE I>
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
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).
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
3. The guaranteed pressure can be adjusted by turning the

socket screw. When the screw is tightened, the pressure
will increase; when the screw is loosened, the pressure will
decrease.
<TYPE II>
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}.
reservoir.
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})
AIR LEAKAGE TEST

1. When air pressure at the inlet is maintained at 0 to 490 kPa
{0 to 5 kgf/cm2, 0 to 71 psi}, there should be no air leakage.
2. When air pressure at the inlet and outlet is maintained at 0
to 834 kPa {0 to 8.5 kgf/cm2, 0 to 121 psi}, there should be
no air leakage at any point.
BR-11-4
SPRING BRAKE CHAMBER BRAKE UNIT (AOH)
SPRING BRAKE CHAMBER

= TYPE I =
CONSTRUCTION
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.
BR-12-1
DISASSEMBLY

1. Lock nut 6. Clamp band 10. Spring seat
2. Turn buckle 7. Pressure plate 11. Bushing
3. Lock nut 8. Diaphragm 12. Return spring
4. Stud bolt 9. Push rod assembly 13. Non-pressure plate
5. Dust cover
BR-12-2

6 Clamp band
1. Put matching mark on the pressure plate, non-pressure
plate, and clamp band.
2. Use a press to remove the clamp band, pressure plate, dia-

phragm push rod, spring and spring seat.
INSPECTION
REASSEMBLY
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
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
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
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
= TYPE II =
CONSTRUCTION
BR-12-6
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

1. Nut 5. Diaphragm retainer 9. Piston plate
2. Dust cover 6. Pressure plate 10. Retainer
3. Adapter 7. Diaphragm 11. Return spring
4. Clamp band 8. Push rod 12. Non-pressure plate
BR-12-7

4 Clamp band
1. Put matching marks on the pressure plate, non-pressure
2. Use a press to remove the clamp band, pressure plate, dia-

phragm, push rod, spring and spring seat.
NOTE
z Set the spring brake chamber (actuator) with the stroke
of the press adjusted to approximately 100 mm (3.94 in).
INSPECTION
Return spring tension
Unit: N {kgf, lbf}
7,846 - 8,826 When compressed to
—
{800 - 900, 1,764 - 1,985} 50.0 mm (1.969 in)
REASSEMBLY
REASSEMBLY
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
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
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
FUNCTIONAL CHECK
AIR LEAKAGE TEST
Supply air to the inlet at a pressure of 490 to 785 kPa {5 to 8 kgf/
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)
BLEEDING AIR FROM THE BRAKE SYSTEM

Adjust the air pressure in the air reservoir to approximately 196 to
294 kPa {2 to 3 kgf/cm2, 28 to 43 psi}. If the air pressure drops
below this range during the bleeding operation, start the engine.
When the air pressure is 196 to 294 kPa {2 to 3 kgf/cm2, 28 to 43
psi}, stop the engine. Bleed the air from each air bleeder screw, in
the order shown below.
Rear single rear axle type
1. Front brakes
Air booster hydraulic cylinder plug → Front wheel air
bleeder screw
2. Rear brakes
Air booster hydraulic cylinder plug → Rear wheel air bleeder
screw
Rear double rear axle type

1. Front brakes and Rear rear brakes
Air booster hydraulic cylinder plug → Front wheel air
bleeder screw → Rear rear wheel air bleeder screw
2. Rear front brakes
Air booster hydraulic cylinder plug → Rear front wheel air
bleeder screw
BR-13-1
BLEEDING AIR FROM THE BRAKE SYSTEM BRAKE UNIT (AOH)
AIR BLEEDING PROCEDURE

1. Fill the brake reservoir with brake fluid. Refill the reservoir
frequently during air bleeding so that no air enters the brake
lines.
2. Remove the rubber cap from the bleeder screw and attach
a vinyl tube. Insert the end of the vinyl tube into a bottle.
3. Depress the brake pedal slowly, and at the same time, turn
the bleeder screw to the left.
4. Observe the bubbles in the vinyl tube, and tighten the
bleeder screw when the pedal reaches to full stroke. Next,
release the pedal.
5. Repeat this work until no bubbles are observed.
6. Fill the brake fluid reservoir with brake fluid up to the pre-
scribed level.
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
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 VALVE
Model E6-R15, E6-RP4, E6-ER1 and E6-ERP1
Unit: mm (in)
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) —
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

647 - 686
Low range —
{6.6 - 7.0, 94 - 100}
Type I
765 - 814
Pressure High range —
{7.8 - 8.3, 111 - 118}
adjustment
range 686 - 726
Low range —
{7.0 - 7.4, 100 - 105}
Type II
814 - 863
High range —
{8.3 - 8.8, 118 - 125}
PARKING BRAKE VALVE

Unit: mm (in)
Distance from body end to cam holder 38.3 - 38.7
—
assembly (1.508 - 1.524)
Main spring 31.7 (1.248) 30.7 (1.209)
Valve spring 28.5 (1.122) 27.0 (1.063)
TRAILER BRAKE HAND CONTROL VALVE

Unit: mm (in)
Distance between body end and exhaust 38.3 - 38.7
—
valve seat end (1.508 - 1.524)
Main spring 31.7 (1.248) 30.7 (1.209)
Valve spring 28.5 (1.122) 27.0 (1.063)
AIR BRAKE CHAMBER

NO. 20B
Unit: mm (in)
Free length 115.1 (4.531) —
Return spring When compressed to
Tension N {kgf, lbf} 137 {14, 31} —
70.0 mm (2.756 in)
NO. 24
Unit: mm (in)
Return spring free length 160.0 (6.299) —
BR-1-3

+30º 686 {7.0, 100} —
304 - 363
Pressure on bake Operating arm 0º —
{3.1 - 3.7, 44 - 53}
chamber side angle
157 - 216
-30º —
{1.6 - 2.2, 23 - 31}
2-WAY RELAY VALVE

Unit: mm (in)
Free length 46.0 (1.811) —
Valve spring When compressed to
Tension N {kgf, lbf} 59 {6.05, 13} —
30.0 mm (1.181 in)
Difference between signal pressure and dis-
Less than 29.4 {0.3, 4.3} —
charge pressure kPa {kgf/cm2, psi}
SYNCHRO VALVE
Unit: mm (in)
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
TIGHTENING TORQUE
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}
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}
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}
Parking brake valve
Trailer brake hand control valve
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

Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
Spring brake chamber Clamp band mounting nut 25 - 33 {2.5 - 3.4, 18 - 25}
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
Cover mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Relay valve NABCO only
Exhaust check mounting screw 2.9 - 5 {0.3 - 0.5, 2.2 - 3.6}
Cap mounting bolt 75 - 78 {7.6 - 8.0, 55 - 58}
2-way relay valve
Cover mounting bolt 12 - 15 {1.2 - 1.5, 9 - 11}
Exhaust cover mounting screw 1.5 - 2.5 {0.15 - 0.25, 1.1 - 1.8}
Synchro valve
Cover mounting screw 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
4.76 (0.1874) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut Tube O.D. mm (in)
Steel brake tube 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
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-1-6
DIAGRAM OF PIPING
PKC series (Air brake vehicle)
PKC tractor
BR-1-7
CW series (for AUSTRALIA)
BR-1-8
BRAKE VALVE BRAKE UNIT (AIR)
BRAKE VALVE
CONSTRUCTION
R.H.D. MODEL
Brake valve
<E6-R15>
BR-2-1
<E6-ER1>
BR-2-2
L.H.D. MODEL
Brake valve link assembly
BR-2-3
Brake valve
<E6-RP4>
BR-2-4
<E6-ERP1>
BR-2-5
DISASSEMBLY
REMOVAL
2. Completely discharge compressed air from the air reservoir.
3. Tilt the cab upward.

WARNING
WARNING
z Be sure to insert the safety pin into the lock hole after tilt-
ing the cab upward.
4. Disconnect the various connectors.

NOTE
z Plug off the connectors to prevent the entry of foreign
matter.
5. Remove the brake valve link (L.H.D. model only).

NOTE
z Do not remove except when necessary.
BR-2-6
DISASSEMBLY
<R.H.D. MODEL>
Brake valve
<E6-R15>

1. Cotter pin 16. Lock screw 30. O-ring 45. Lower valve spring
2. L-pin 17. Special washer 31. Relay piston 46. Valve retainer
3. Pin 18. Spring seat 32. Retaining ring 47. Lower valve
4. Roller 19. Sub spring seat 33. Check valve assembly 48. Retaining ring
5. Collar 20. Sub spring 34. Lower valve assembly 49. O-ring
6. Pedal 21. Main spring 35. O-ring 50. Upper valve assembly
7. Lock nut 22. Shim 36. Screw 51. Retaining ring
8. Setscrew 23. O-ring 37. Set nut 52. Special washer
9. Boot 24. Upper piston 38. Diaphragm washer 53. O-ring
10. Plunger 25. Lower body 39. Exhaust check 54. O-ring retainer
11. Mounting plate 26. O-ring 40. Check valve seat 55. Upper valve spring
12. Retaining ring 27. Relay piston return spring 41. Retaining ring 56. Valve retainer
13. Upper piston assembly 28. Relay piston assembly 42. Lower valve guide 57. Upper valve
14. Piston return spring 29. O-ring 43. O-ring 58. Upper body
15. O-ring 44. Special washer
BR-2-7
<E6-ER1>

1. Pedal bolt 21. Sub spring 40. Lower valve
2. Cotter pin 22. Main spring 41. Lower valve body
3. Pin 23. Shim 42. O-ring
4. L-pin 24. Upper piston 43. Relay piston return spring
5. Roller 25. O-ring 44. Relay piston assembly
6. Collar 26. O-ring 45. Relay piston
7. Pedal 27. Lower body assembly 46. O-ring
8. Lock nut 28. Lock screw 47. O-ring
9. Setscrew 29. Diaphragm washer 48. Upper valve assembly
10. Plunger 30. Diaphragm 49. Retaining ring
11. Boot 31. Retaining ring 50. Special washer
12. Bushing 32. Check valve seat 51. O-ring retainer assembly
13. Mounting plate 33. Special washer 52. O-ring retainer
14. Bushing 34. Lower piston assembly 53. O-ring
15. Upper piston assembly 35. O-ring retainer 54. O-ring
16. Piston return spring 36. O-ring 55. Upper valve spring
17. Lock screw 37. O-ring 56. Valve retainer
18. Special washer 38. Lower valve spring 57. Upper valve
19. Spring seat 39. Valve retainer 58 .Upper body
20. Sub spring seat
BR-2-8
<L.H.D. MODEL>

1. Cotter pin 5. Collar 9. Boot
2. L-pin 6. Pedal 10. Plunger
3. Pin 7. Lock nut 11. Mounting plate
4. Roller 8. Setscrew
BR-2-9
Brake valve
<E6-RP4>

1. Boot 18. O-ring 35. O-ring
2. Plunger 19. Relay piston return spring 36. Special washer
3. Mounting plate 20. Relay piston assembly 37. Lower valve spring
4. Retaining ring 21. O-ring 38. Valve retainer
5. Upper piston assembly 22. O-ring 39. Lower valve
6. Piston return spring 23. Relay piston 40. Retaining ring
8. Lock screw 25. Check valve assembly 42. Upper valve assembly
9. Special washer 26. Lower valve assembly 43. Retaining ring
10. Spring seat 27. O-ring 44. Special washer
11. Sub spring seat 28. Screw 45. O-ring
12. Sub spring 29. Set nut 46. O-ring retainer
13. Main spring 30. Diaphragm washer 47. Upper valve spring
14. Shim 31. Exhaust check 48. Valve retainer
15. O-ring 32. Check valve seat 49. Upper valve
16. Upper piston 33. Retaining ring 50. Upper body
17. Lower body 34. Lower valve guide
BR-2-10
<E6-ERP1>

1. Boot 16. Lower body 30. O-ring retainer
2. Plunger 17. O-ring 31. Lower valve spring
3. Mounting plate 18. Relay piston return spring 32. Valve retainer
4. Upper piston assembly 19. Relay piston assembly 33. Lower valve
5. Piston return spring 20. O-ring 34. Upper valve assembly
6. Lock screw 21. O-ring 35. Retaining ring
7. Special washer 22. Relay piston 36. Special washer
8. Spring seat 23. Retaining ring 37. O-ring
9. Sub spring seat 24. Holder 38. O-ring
10. Sub spring 25. Diaphragm 39. O-ring retainer
11. Main spring 26. Check valve seat 40. Upper valve spring
12. Shim 27. Special washer 41. Valve retainer
13. O-ring 28. O-ring 42. Upper valve
14. O-ring 29. O-ring 43. Upper body
15. Upper piston
BR-2-11

z Remove dust or dirt which is in contact with part surfaces
and make alignment marks, where necessary, so that the
parts can be re-installed in their original positions.
}
13 E6-R15
5 E6-RP4
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
NOTE
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
Pin hole inside diameter

Unit: mm (in)
10.0 (0.394) 10.25 (0.4035)
BR-2-13
Pin outside diameter (Except for E6-ER1)

Unit: mm (in)
10.0 (0.394) 9.85 (0.3878)
Roller (Except for E6-ER1)

Unit: mm (in)
Inside diameter 10.0 (0.394) 10.25 (0.4035)
Outside diameter 18.7 (0.736) 17.60 (0.6929)
Mounting plate bushing inside diameter (Except for

E6-ER1)
Unit: mm (in)
26.5 (1.043) 26.70 (1.0512)
Piston outside diameter (E6-ER1 only)

Unit: mm (in)
48.7 (1.917) 49.6 (1.953)
Relay piston outside diameter (E6-ER1 only)

Unit: mm (in)
74.77 (2.9437) 74.67 (2.9398)
BR-2-14
Plunger outside diameter

Unit: mm (in)
26.5 (1.043) 26.20 (1.0315)
Spring free length

Unit: mm (in)
Maintenance
standard
Main spring 35.8 (1.409) —
Sub spring 19.1 (0.752) —
Relay piston return
24.7 (0.972) —
spring
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
Spring tension
Unit: N {kgf, lbf}
Maintenance
standard
235 When compressed to
Main spring —
{24.0, 52.9} 34.0 mm (1.339 in)
Sub spring —
{25.4, 56.0} 15.3 mm (0.602 in)
—
—
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
REASSEMBLY
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.
z Align the alignment mark (scribed during disassembly)

when installing the cover assembly and mounting plate.
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
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
NOTE
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.
<When the brake valve link assembly is removed>

z In advance, install the brake valve assembly on the brake
valve link assembly.
: 23 - 32 N·m {2.3 - 3.3 kgf·m, 17 - 24 ft·lbf}
BR-2-17
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}
2. Connect each brake tube.

3. Install on the cab the cover on the link assembly pedal side.
4. Adjust the link rod length (dimension L).

z Butt the link rod against the plunger.
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}
BR-2-18
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
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
R.H.D. model
Pedal step E6-R15 7.5º 15º
angle E6-ER1 8º 15.3º - 18.3º
L.H.D. model
6.0 - 7.2
Plunger stroke mm (in) 3.0 (0.118)
(0.236 - 0.283)
3. When pressures in the rapid-pressure rise points are exces-

sively low, it is necessary to replace the upper valve spring.
4. Make sure the air pressure difference between the second-
ary side and primary side is within 29.4 kPa {0.3 kgf/cm2,
4.3 psi} and it changes smoothly corresponding to the pres-
sure changes.
5. With the air pressure gauge fitted, make sure the pressure
rises and falls smoothly by depressing the brake pedal sev-
eral times.
BR-2-20
AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)

CONSTRUCTION
BR-3-1

DISASSEMBLY

1. Cover 6. Piston 10. O-ring
2. Retaining ring 7. Valve spring 11. Washer
3. Adjusting screw assembly 8. Valve 12. O-ring
4. Exhaust stem 9. O-ring 13. Body
5. Exhaust stem spring
BR-3-2
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
1. Disconnect the check valve from the air reservoir and con-
nect a 981 kPa {10 kgf/cm2, 142 psi} pressure gauge to it.
reservoir.
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.
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
2. If the air pressure is not within the specified range, adjust it

as follows:
Adjust the operating pressure by using the adjusting screw after
loosening the lock nut.
z Screw in the adjusting screw to set the high adjusting point;
unscrew it to set the low adjusting point.
NOTE
z If the operating pressure is not within the specified
range, the air pressure governor assembly should be
replaced because the low or high air pressure alone can-
not correct it.
z After adjustments have been completed, tighten the lock
nut.
: 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
BR-3-4
AIR DRYER BRAKE UNIT (AIR)
AIR DRYER
= DR-5 =
CONSTRUCTION
BR-4-1
DISASSEMBLY
DISASSEMBLY

1. Bracket 14. Gasket ring 26. Valve assembly
2. Stopper plate 15. Filter plate 27. Valve
3. Stopper ring 16. Oil filter assembly 28. Piston
4. Purge chamber 17. Gasket ring 29. O-ring
5. Case 18. O-ring 30. O-ring
6. Case cover 19. Spacer 31. Valve body
7. Check valve 20. O-ring 32. O-ring
8. O-ring 21. O-ring 33. O-ring
9. Set spring 22. Retaining ring 34. Thermostat assembly
10. Filter plate 23. Exhaust cover 35. Heater
11. Filter 24. Exhaust body 36. Gasket
12. Desiccant 25. O-ring 37. Body
13. Filter
BR-4-2

3 Stopper ring
Insert a flat-blade screwdriver into the cutout of the stopper ring on
the purge chamber side and pry off the stopper ring.
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
REASSEMBLY
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
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.
2. To properly seat the desiccant, lightly tap the outer periph-

ery of the case with a plastic hammer while turning it.
BR-4-4
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

BR-4-6
= DR-31 =
CONSTRUCTION
BR-4-7
DISASSEMBLY
DISASSEMBLY

3. Check valve 13. Case 23. Piston
4. Cover 14. Oil filter 24. Valve spring
5. Set spring 15. Filter gasket 25. Valve seat
6. Filter plate 16. Oil filter assembly 26. O-ring
7. Filter 17. Gasket ring 27. O-ring
8. Case guide 18. Body 28. O-ring
9. Sealing ring 19. O-ring 29. Thermostat
10. Desiccant 20. Retaining ring 30. Heater
BR-4-8

1 Purge chamber
To remove the purge chamber and cover, remove the nut and bolt
on one side, place that section in a vise (to prevent the purge
chamber from popping out due to the set spring) and remove the
nut and bolt located diagonally in relation to those previously
removed.
INSPECTION
REASSEMBLY
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
2. To properly seat the desiccant, lightly tap around the case

with a plastic hammer prior to installing the filter.
NOTE
z Be sure to install the filter with the thick, soft layer side
facing down.

BR-4-10
= DR-42 =
CONSTRUCTION
BR-4-11
DISASSEMBLY
DISASSEMBLY

3. Case cover 12. Case 21. O-ring
4. Check valve 13. Oil filter 22. Valve
5. O-ring 14. O-ring 23. Piston
6. Set spring 15. Cover 24. O-ring
7. Filter plate 16. Gasket ring 25. Valve spring
8. Filter 17. Gasket ring 26. Body
9. Desiccant 18. Retaining ring
BR-4-12

3 Case cover
While holding the case cover, remove the rolling screw and case
cover.
WARNING
WARNING
z Always hold the upper side of the case cover. Otherwise,
the tension of the set spring will force the case cover out.
23 Piston
While holding the piston using a 10 mm (0.39 in) hex. wrench,
remove the bolts, piston, valve and valve spring.
INSPECTION
REASSEMBLY
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
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.
8 Filter, 7 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.
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

BR-4-15
PARKING BRAKE VALVE BRAKE UNIT (AIR)
PARKING BRAKE VALVE

CONSTRUCTION
BR-5-1
DISASSEMBLY
DISASSEMBLY

1. Handle assembly 10. Return spring 19. O-ring
2. Spring seat 11. Cam holder assembly 20. Piston
3. Spring 12. Shim 21. Exhaust valve seat
4. Spring seat 13. O-ring 22. Cam ring
5. Cover 14. C-ring 23. Guide
6. Shim(s) 15. C-ring 24. O-ring
7. Main spring 16. Feed valve seat 25. Holder
8. Valve spring 17. O-ring 26. Pin
9. Piston assembly 18. Feed valve 27. Body
BR-5-2

1 Handle assembly
The handle head is spring-loaded. When removing the screw, hold
the handle head by hand.
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
INSPECTION
Free length
Unit: mm (in)
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
REASSEMBLY
REASSEMBLY
z Reassemble after greasing the O-ring groove, pin, shim,
and sliding sections.
22 Cam ring
ring into the holder so that the pin is positioned as shown.

Install the guide into the exhaust valve seat, and apply grease to
the I.D. and O.D. surfaces. After this, install the guide onto the cam
ring side of the cam holder, and set it as shown.
16 Feed valve seat

Apply grease to the feed valve stem, install the feed valve into pis-
ton, and fix the valve with a C-ring.
NOTE
z Do not allow dirt and dust to contact the feed valve seat-
ing surface. Do not expand the C-ring excessively.
11 Cam holder assembly

Install the cam ring to body so that the cutout portion of the cam
ring is aligned with the two pins which are driven to body. Adjust
dimension (Z) from the body end face to the exhaust valve seating
surface to 38.3 to 38.7 mm (1.508 to 1.524 in) using shim(s).
BR-5-4
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
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:
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)
TRAILER BRAKE HAND CONTROL VALVE

CONSTRUCTION
BR-6-1
DISASSEMBLY
DISASSEMBLY

1. Handle assembly 10. O-ring 19. Exhaust valve seat
2. Pin 11. O-ring 20. Cam ring
3. Shim 12. C-ring 21. Pin
4. O-ring 13. C-ring 22. Guide
5. Cover 14. Feed valve 23. Cam holder
6. Spring shim 15. O-ring 24. O-ring
7. Main spring 16. Feed valve assembly 25. O-ring
8. Valve spring 17. O-ring 26. Shim
9. Piston 18. Return spring 27. Body
BR-6-2

12 C-ring
Remove the C-ring from the piston assembly, and remove the feed
valve seat and O-ring. Remove the C-ring from the feed valve, and
remove the feed valve. Remove the O-ring from the piston OD sec-
tion.
NOTE
INSPECTION
Free length
Unit: mm (in)
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
z Reassemble after greasing the O-ring groove, pin, shim and
sliding sections.
20 Cam ring
ring so that the pin is positioned as shown.
BR-6-3

1. Assemble the guide to the exhaust valve seat, and apply
grease to the I.D. and O.D. surfaces, then install the
exhaust valve seat onto the cam ring side as shown.
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).
16 Feed valve assembly

Install the feed valve paying attention not to allow dirt and dust to
contact the valve seating surface. Do not expand the C-ring exces-
sively when installing.
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
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:
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)
QUICK RELEASE VALVE

CONSTRUCTION


1. Cover 3. Filter 5. Body
2. O-ring 4. Diaphragm
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)
DOUBLE CHECK VALVE

CONSTRUCTION


1. Nipple 3. Guide 5. Body
2. Packing 4. Valve
BR-8-1
DOUBLE CHECK VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK (TYPE I ONLY)

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.
BR-8-2
PROTECTION VALVE BRAKE UNIT (AIR)
PROTECTION VALVE
CONSTRUCTION


1. Retaining ring 4. Shim(s) 6. O-ring
2. Plate 5. Piston 7. Body
3. Spring
BR-9-1
PROTECTION VALVE BRAKE UNIT (AIR)
FUNCTIONAL CHECK
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}.
reservoir.
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}
AIR LEAKAGE TEST

1. When air pressure at the inlet is maintained at 0 to 490 kPa
{0 to 5 kgf/cm2, 0 to 71 psi}, there should be no air leakage.
2. When air pressure at the inlet and outlet is maintained at 0
to 834 kPa {0 to 8.5 kgf/cm2, 0 to 121 psi}, there should be
no air leakage at any point.
BR-9-2
AIR BRAKE CHAMBER BRAKE UNIT (AIR)
AIR BRAKE CHAMBER

= NO. 20B =
CONSTRUCTION
DISASSEMBLY
DISASSEMBLY

1. Clamp band 3. Diaphragm 5. Return spring
2. Pressure plate 4. Push rod 6. Non-pressure plate
BR-10-1

z Put matching marks on the pressure plate, non-pressure
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.
Place the push rod side downward on the work bench. Hold down
the non-pressure plate and remove the hand clamp.
INSPECTION
Return spring
Unit: mm (in)
Maintenance
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
REASSEMBLY
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.
2. Place the diaphragm between the pressure plate and non-

pressure plate, then align the matching marks (made at the
time of disassembly), and install the clamp. Seat the com-
ponents with a mallet.
Secure the clamp band with a bolt and nut.
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/
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
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
= NO. 24 =
CONSTRUCTION
DISASSEMBLY
DISASSEMBLY

1. Clamp band 3. Diaphragm 5. Return spring
2. Pressure plate 4. Push rod 6. Non-pressure plate
BR-10-5

z Put matching marks on the pressure plate, non-pressure
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
Return spring free length

Unit: mm (in)
160.0 (6.299) —
REASSEMBLY
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
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}
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)
SPRING BRAKE CHAMBER (ANCHORLOK MAKE)

= MODEL 3030 =
CONSTRUCTION
BR-11-1

REMOVAL
1. Shift the parking brake lever to the “PARK” position.

3. Disconnect the air lines and push rod from slack adjuster,
then remove the spring brake chamber from the chamber
bracket.
NOTE
z Before dismounting the chamber, turn the release stud
assembly nut clockwise fully to release the spring brake.
(Refer to INSTRUCTIONS FOR MECHANICAL RELEASE
OF SPRING BRAKE for details).
z Mark the chamber with an R or L to indicate which side
the chamber was installed on.
BR-11-2

1. Emergency clamp assembly 4. Service clamp assembly 7. Service push rod
2. Spring chamber 5. Service housing 8. Service diaphragm
3. Emergency diaphragm 6. Service return spring 9. Adapter assembly
BR-11-3
INSTRUCTIONS FOR MECHANICAL RELEASE AND

DIAPHRAGM REPLACEMENT OF ANCHORLOK
SPRING BRAKES
DANGER
z A spring brake contains a very powerful compression
spring. Failure to comply with all of the following instruc-
tions may result in forceful release of the spring chamber
and its contents which could cause death, severe per-
sonal injury and/or property damage.
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.
INSTRUCTIONS FOR MECHANICAL RELEASE OF

SPRING BRAKE
DANGER
z Do not attempt to mechanically release (cage) the spring
when spring brake shows structural damage and/or
when safety hooks have been removed. Caging the
spring or disassembly of the chamber may result in the
forceful release of the spring chamber and its contents
which could cause death, severe personal injury and/or
properly damage. Remove complete spring brake and
replace with new unit.
BR-11-4
1. Remove dust plug from release tool keyhole in center of

spring chamber.
2. Remove release tool assembly from side pocket of adapter.
3. Insert release stud through keyhole in chamber into the
pressure plate.
4. Turn release stud 1/4 turn clockwise.

5. Pull on release stud to seat release stud crosspin in
crosspin area of the pressure plate.
6. Assemble release stud washer and nut on release stud fin-

ger tight.
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.
7. To cage compression spring, tighten release stud nut with

handwrench (DO NOT USE IMPACT WRENCH) and make
certain push rod is retracting.
8. DO NOT OVER TORQUE RELEASE STUD ASSEMBLY:
47 N·m {4.84 kgf·m, 35 ft·lbf}
9. To ensure compression spring is fully caged, the stud length
beyond the nut (see “X” above) should measure:
69 mm (2.72 in) Minimum
BR-11-5
WARNING
WARNING
z If the recommended “X” dimension is not correct for
chamber size and torque value, the spring brake should
be replaced.
INSTRUCTIONS FOR EMERGENCY/PARKING BRAKE

DIAPHRAGM REPLACEMENT
WARNING
WARNING
z First follow steps 1 through 9 for mechanical release.
1. Follow steps 1 through 9 for mechanical release of spring

brake.
2. If vehicle air pressure was used to aid in the caging pro-
cess, exhaust the air pressure.
NOTE
z The use of “one way air valves” in the disassembly of
spring brakes is not recommended.
3. Remove emergency clamp assembly only if the safety
hooks are intact and air pressure has been exhausted from
spring brake.
4. To break diaphragm seal, rotate chamber as shown. To aid
breaking the diaphragm loose a knife edge may be inserted
between the diaphragm and adapter lip. Do not pry or strike
any part of the chamber. Do not cut or remove chamber
safety hooks (ears).
5. Slide chamber sideways off the adapter and discard old dia-
phragm.
6. Inspect the clamp assembly, the chamber ears, lip and side-
wall and the adapter lip and sidewall.
Inspect adapter push rod seal, adapter push rod plate and
return spring. If any structural damage or leak is noted
replace complete piggy back assembly.
7. Carefully wipe pressure plate surface clean of any oil or
grease. Check to see that weep holes in chamber are not
plugged. If plugged, open weep holes so chamber can
drain.
DANGER
z Do not attempt to remove the compression spring. Disas-
sembly of the release tool from the chamber assembly
will result in the forceful release of the compression
spring and pressure plate and may result in severe per-
sonal injury or death.
BR-11-6
8. To reassemble, place the piloted emergency diaphragm in

chamber and slide the chamber assembly sideways back
on the adapter.
NOTE
z Piloted diaphragms to be used only on Anchorlok Spring
Brakes and only on the emergency side. Use on the ser-
vice side will result in a reduction of stroke length.
9. Check if diaphragm is properly seated between the adapter
and chamber lip and reassemble clamps. Torque carriage
nut to 25 to 34 N·m {2.5 to 3.5 kgf·m, 18 to 25 ft·lbf}. Check
carriage bolts and clamps for proper seating. Do not strike
the clamps or any other part with hammer.
10. Apply a maximum of 827 kPa {8.4 kgf/cm2, 120 psi} air
pressure to the emergency port and check diaphragm seal
for leakage by applying a water and soap solution to the
emergency clamp area (no leakage is allowed).
11. Uncage compression spring and reassemble release tool in
side pocket of adapter.
12. Re-install dust plug in release tool keyhole in center of
chamber.
WARNING
WARNING
z After reassembly, check for proper emergency and ser-
vice operation.
INSTRUCTIONS FOR SERVICE DIAPHRAGM

REPLACEMENT
WARNING
WARNING

brake.
NOTE
z Always cage compression spring with release tool. Do
not rely on air pressure to keep spring compressed.
2. To prevent sudden release of the piggy back or service
push rod assembly and to facilitate the installation of the
new diaphragm, the service push rod should be prevented
from retracting by clamping the service push rod in place
with vise grip pliers as shown.
3. Remove service clamp assembly and discard old dia-
phragm.
4. Inspect the service clamp assembly, the adapter wall and lip,
the housing, the service return spring and service push rod. If
any structural damage is noted, replace with new part.
5. Wipe the surface of the service push rod plate clean of any
oil, grease or dirt. Check to see that weep holes in housing
are not plugged.
6. Place the new service diaphragm in adapter and center the
housing over the diaphragm and adapter.
BR-11-7

and housing lip and reassemble the service clamp assem-
bly. Torque carriage nuts to 25 to 34 N·m {2.5 to 3.5 kgf·m,
18 to 25 ft·lbf}. Check carriage bolts and clamp assembly for
proper seating around the adapter and housing lip and
remove vise grip pliers from service push rod.
pressure to the service port and check diaphragm seal for
leakage by applying a water and soap solution to the ser-
vice clamp area (no leakage allowed).
10. Replace dust plug in release tool keyhole in center of cham-
ber.
WARNING
WARNING
vice operation.
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
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
= MODEL 3030 LC =
CONSTRUCTION

REMOVAL
1. Shift the parking brake lever to the “PARK” position.

3. Disconnect the air lines and push rod from slack adjuster,
then remove the spring brake chamber from the chamber
bracket.
NOTE
z Before dismounting the chamber, turn the release stud
assembly nut clockwise fully to release the spring brake.
(Refer to INSTRUCTIONS FOR MECHANICAL RELEASE
OF SPRING BRAKE for details.)
z Mark the chamber with an R or L to indicate which side
the chamber was installed on.
BR-11-9

1. Service clamp assembly 3. Service return spring 5. Service diaphragm
2. Service housing 4. Service push rod 6. Adapter assembly
BR-11-10
INSTRUCTIONS FOR MECHANICAL RELEASE AND

DIAPHRAGM REPLACEMENT OF ANCHORLOK
SPRING BRAKES
DANGER
z A spring brake contains a very powerful compression
spring. Failure to comply with all of the following instruc-
tions may result in forceful release of the spring chamber
and its contents which could cause death, severe per-
sonal injury and/or property damage.
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.

SPRING BRAKE
DANGER
z Do not attempt to mechanically release (cage) the spring
when spring brake shows structural damage and/or
when safety hooks have been removed. Caging the
spring or disassembly of the chamber may result in the
forceful release of the spring chamber and its contents
which could cause death, severe personal injury and/or
properly damage. Remove complete spring brake and
replace with new unit.
BR-11-11
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.

REPLACEMENT
WARNING
WARNING
1. To cage compression spring, tighten release stud nut with

handwrench (DO NOT USE IMPACT WRENCH) and make
certain push rod is retracting.
2. DO NOT OVER TORQUE RELEASE STUD ASSEMBLY:
47 N·m {4.84 kgf·m, 35 ft·lbf}
3. To ensure compression spring is fully caged, the stud length
beyond the nut (see “X” above) should measure:
63.6 mm (2.504 in) Minimum
WARNING
WARNING
z If the recommended “X” dimension is not correct for
chamber size and torque value, the spring brake should
be replaced.

REPLACEMENT
WARNING
WARNING
BR-11-12

brake.
NOTE
z Always cage compression spring with release tool. Do
not rely on air pressure to keep spring compressed.
2. To prevent sudden release of the piggy back or service
push rod assembly and to facilitate the installation of the
new diaphragm, the service push rod should be prevented
from retracting by clamping the service push rod in place
with vise grip pliers as shown.
3. Remove service clamp assembly and discard old dia-
phragm.
4. Inspect the service clamp assembly, the adapter wall and
lip, the housing, the service return spring and service push
rod. If any structural damage is noted, replace with new
part.
5. Wipe the surface of the service push rod plate clean of any
oil, grease or dirt. Check to see that weep holes in housing
are not plugged.
6. Place the new service diaphragm in adapter and center the
housing over the diaphragm and adapter.
and housing lip and reassemble the service clamp assem-
bly. Torque carriage nuts to 25 to 34 N·m {2.5 to 3.5 kgf·m,
18 to 25 ft·lbf}. Check carriage bolts and clamp assembly for
proper seating around the adapter and housing lip and
remove vise grip pliers from service push rod.
pressure to the service port and check diaphragm seal for
leakage by applying a water and soap solution to the ser-
vice clamp area (no leakage allowed).
10. Replace dust plug in release tool keyhole in center of cham-
ber.
WARNING
WARNING
vice operation.
L = 60 mm (2.362 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}
BR-11-13
INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
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)

CONSTRUCTION
DISASSEMBLY
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
DISASSEMBLY

1. Pipe retainer 11. Diaphragm retainer 21. Oil seal
2. Pipe 12. Diaphragm 22. Oil seal
3. Cover 13. Diaphragm protector 23. Plunger
4. Diaphragm guide 14. Retaining ring 24. O-ring
5. Retaining ring 15. Piston guide 25. Plunger
6. Piston 16. Cap 26. O-ring
7. Valve spring 17. Hexagon socket screw 27. Plunger return spring
8. Valve 18. Exhaust check 28. Cap
9. Piston packing 19. Cam 29. Body
10. Piston 20. Connecting rod assembly
BR-12-2
INSPECTION
REASSEMBLY
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
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
SUPPLY PRESSURE PERFORMANCE TEST

Set the pressure on the brake valve side (supply port) at 686 kPa {7
kgf/cm2, 100 psi}, fix the operating arm angle as shown below, then
supply pressure to the brake valve side (supply port) using a cock.
Measure the pressure on the brake chamber side (delivery port) at
the same time.
Operating arm angle Maintenance standard
+30º 686 {7.0, 100}
0º 304 - 363 {3.1 - 3.7, 44 - 53}
-30º 157 - 216 {1.6 - 2.2, 23 - 31}
BR-12-4
RELAY VALVE BRAKE UNIT (AIR)
RELAY VALVE
= NABCO =
CONSTRUCTION
BR-13-1


1. Cover 6. O-ring 11. O-ring
2. Piston return spring 7. Exhaust check 12. O-ring
3. Relay valve 8. Exhaust cover 13. Valve spring
4. O-ring 9. Retaining ring 14. Valve retainer
5. Body 10. Valve guide 15. Inlet exhaust
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.
AIR LEAKAGE TEST

1. Apply soapy water to the exhaust port with the parking
brake valve button pushed in and check if there is air leak-
age in the exhaust valve.
Standard
Size of soap bubble is less than 25 mm (0.98 in) within 5
seconds
2. Apply soapy water to the contacting portion of the cover and
body under the same condition as above and check if there
is air leakage in the O-ring.
Standard
Size of soap bubble is less than 25 mm (0.98 in) within 5
seconds
BR-13-2
= JIDOSHA KIKI =
CONSTRUCTION
BR-13-3


1. Cover 7. Body 12. O-ring
3. Relay piston 9. Exhaust cover 14. Spring
4. Spring 10. Retaining ring 15. Valve retainer
5. O-ring 11. Valve guide 16. Inlet valve
6. O-ring
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)
2-WAY RELAY VALVE

CONSTRUCTION
BR-14-1
DISASSEMBLY
DISASSEMBLY

1. Connector 8. Diaphragm 14. Packing
2. Packing 9. Diaphragm washer 15. Valve spring
3. Valve guide 10. Shim 16. Feed valve
4. Valve 11. Exhaust valve 17. O-ring
5. Cover 12. O-ring 18. Filter
6. Retaining ring 13. Cap 19. Body
7. Washer
BR-14-2
INSPECTION
Valve spring
Maintenance
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
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
10 (0.4) 0 - 294 {0 - 3, 0 - 43}

Feed valve Tank pressure
0 (0) 294 - 785 {3 - 8, 43 - 114}
10 (0.4) 0 - 294 {0 - 3, 0 - 43} Tank pressure: 785 kPa
Exhaust valve Signal pressure
0 (0) 294 - 785 {3 - 8, 43 - 114} {8 kgf/cm2, 114 psi}
10 (0.4) 0 - 294 {0 - 3, 0 - 43}
Double check valve Signal pressure In both directions
0 (0) 294 - 785 {3 - 8, 43 - 114}
Each tightening section 0 (0) — 785 {8, 114}
BR-14-3
AIR DIFFERENTIAL PRESSURE TEST

Confirm the difference between signal pressure (A or B) and dis-
charge pressure.
Less than 29.4 {0.3, 4.3} —
BR-14-4
SYNCHRO VALVE BRAKE UNIT (AIR)
SYNCHRO VALVE
CONSTRUCTION
BR-15-1
DISASSEMBLY
DISASSEMBLY

1. Cover 7. Exhaust check 13. O-ring
2. O-ring 8. Exhaust cover 14. Valve spring
3. Piston 9. Retaining ring 15. Valve retainer
4. O-ring 10. Special washer 16. Lower valve
5. O-ring 11. Valve guide 17. Body
6. Piston spring 12. O-ring
BR-15-2
INSPECTION
Clearance between lower valve and valve guide

Unit: mm (in)
— More than 0.28 (0.011)
Clearance between piston and body

Unit: mm (in)
— More than 0.28 (0.011)
REASSEMBLY
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
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
2. Verify amount of leakage from the exhaust port when 686

kPa {7 kgf/cm2, 100 psi} pressure is applied to the supply
and control ports.
Unit: ml (Imp fl oz)/min
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.
314 - 373 {3.2 - 3.8, 46 - 54} —
2. Verify the holding pressure of both supply and control pres-

sures when the delivery pressure is slowly decreased to 0
kPa {0 kgf/cm2, 0 psi} after maintaining the supply and con-
trol pressure at 686 kPa {7 kgf/cm2, 100 psi}.
245 - 304 {2.5 - 3.1, 36 - 44} —
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)
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
PARKING BRAKE DRUM SIZE BRAKE TYPE SYMBOL

ABBREVIATION (Unit: in) 1 INTERNAL EXPANSION DUO SERVO TYPE (AKEBOND BRAKE MAKE)
CB PARKING BRAKE 3 12 2 INTERNAL EXPANSION DUO SERVO TYPE (NISSINBO BRAKE MAKE)
4 10
5 8
SERVICE DATA
Unit: mm (in)
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
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}
Transmission model: MLS61, MLS62,
598 - 745 {61 - 76, 441 - 550} MPS50
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)
598 - 745 {61 - 76, 441 - 550}
CB31
686 - 981 {70 - 100, 506 - 723}
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
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 Used to remove/install main shaft companion

99535 Z0003 flange
Width across flats = 50 mm NOTE
(1.97 in) z Manual transmission model only
Socket wrench
99535 Z0011
Width across flats = 46 mm
(1.81 in)
Socket wrench
99535 Z5007
(2.17 in)
Socket wrench
99535 Z0074
(2.28 in)
BR-2-1
CONSTRUCTION CB52
= UNIT NAME CB52 =

CONSTRUCTION
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
<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
BR-3-2
DISASSEMBLY CB52
DISASSEMBLY

1. Brake drum , 5. Adjusting screw assembly 9. Camshaft
,+ 2. Return spring 6. Brake shoe assembly 10. Brake lever
3. Plate 7. Return spring , 11. Support plate
4. Adjusting screw spring 8. Lock pin 12. Dust cover

2 Return spring
Using return spring remover (99878 Z0000), remove the brake
shoe return spring.
BR-3-3
INSPECTION CB52
INSPECTION
BRAKE DRUM I.D.

Unit: mm (in)
203.2 (8.00) 204.2 (8.04)
UNEVEN BRAKE DRUM WEAR

Measure the inside diameter of the drum at 4 points and machine
the inside periphery of the drum when the difference between the
maximum and minimum measured values exceeds the service
limit.
Unit: mm (in)
0.02 (0.0008) 0.2 (0.008)
BRAKE LINING THICKNESS

Unit: mm (in)
5.0 (0.197) 1.5 (0.059)
BR-3-4
REASSEMBLY CB52
REASSEMBLY
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
5 Adjusting screw assembly

Retract the adjusting screw fully and install it with its adjusting
wheel facing right.
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
<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
BR-3-6
ADJUSTMENT CB52
ADJUSTMENT
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 to 10 turns (moving the screw-
driver from the lower to the upper portion). The clearance
between the lining and drum is 0.3 to 0.5 mm (0.012 to
0.020 in).
4. After adjustment, install the rubber plug on the adjusting
hole.
PARKING BRAKE LEVER STROKE
Adjust the parking brake lever stroke after adjusting the brake lining
clearance.
1. Completely release the parking brake lever.
2. Loosen the lock nut at the connected portion on top of the
parking brake lever. Turn the adjusting nut to adjust the
parking brake lever stroke so that it is within the range of 3
to 11 notches. Then, tighten the adjusting nut and lock nut.
3. Pull and release the parking brake lever several times.
Then, pull the parking brake lever completely and make
sure its stroke is proper and the brake operates securely.
BR-3-7
CONSTRUCTION CB41
= UNIT NAME CB41 =

CONSTRUCTION
BR-4-1
DISASSEMBLY CB41
DISASSEMBLY
peller shaft.
REMOVAL
socket wrench. Remove the companion flange and O-ring.
Socket wrench:
99535 Z0003 ... width across flats = 50 mm (1.97 in)
NOTE
BR-4-2
DISASSEMBLY CB41
DISASSEMBLY

1. Brake drum 7. Rivet 12. Camshaft lever
,+ 2. Return spring 8. Brake lining 13. Wave washer
3. Plate 9. Brake shoe 14. Camshaft
4. Adjusting screw spring 10. Return spring , 15. Support plate
, 5. Adjusting screw assembly 11. Bolt 16. Dust cover
6. Brake shoe assembly

2 Return spring
Using the return spring remover (99878 Z0000), remove the brake
shoe return spring.
BR-4-3
INSPECTION CB41
INSPECTION
BRAKE DRUM I.D.

Unit: mm (in)
254 (10.00) 256 (10.08)

maximum and minimum measured values exceeds the repair limit.
Unit: mm (in)
0.02 (0.0008) 0.2 (0.008)

Unit: mm (in)
5.7 (0.224) 3.1 (0.122)
BR-4-4
REPAIR AND REPLACEMENT CB41

REPLACING THE BRAKE LINING
brake lining.
NOTE
NOTE
4. Brake lining
BR-4-5
REASSEMBLY CB41
REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate

wheel facing right.
2 Return spring
(99879 Z0000).
NOTE
correctly.
BR-4-6
REASSEMBLY CB41
INSTALLATION
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
each other.
BR-4-7
ADJUSTMENT CB41
ADJUSTMENT
be seen).
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).
hole.

clearance.
BR-4-8
CONSTRUCTION CB31
= UNIT NAME CB31 =

CONSTRUCTION
BR-5-1
DISASSEMBLY CB31
DISASSEMBLY
peller shaft.
REMOVAL
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
BR-5-2
DISASSEMBLY CB31
DISASSEMBLY

1. Brake drum 7. Rivet , 12. Camshaft lever
,+ 2. Return spring 8. Brake lining 13. Wave washer
3. Plate 9. Brake shoe 14. Camshaft
4. Adjusting screw spring 10. Return spring , 15. Support plate
, 5. Adjusting screw assembly 11. Bolt 16. Dust cover
6. Brake shoe assembly

2 Return spring
Using the return spring remover (99878 Z0000), remove the brake
shoe return spring.
BR-5-3
INSPECTION CB31
INSPECTION
BRAKE DRUM I.D.

Unit: mm (in)
305 (12.00) 307 (12.09)

maximum and minimum measured values exceeds the service
limit.
Unit: mm (in)
0.02 (0.0008) 0.2 (0.008)

Unit: mm (in)
6.1 (0.240) 3.7 (0.146)
BR-5-4
REPAIR AND REPLACEMENT CB31

REPLACING THE BRAKE LINING
brake lining.
NOTE
NOTE
scratches before fastening with rivets.
Fasten the brake shoe and lining with rivets, starting in
the middle and alternately moving outward.
4. Brake lining
BR-5-5
REASSEMBLY CB31
REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate
12 Camshaft lever
Align the match mark on the camshaft lever with that on the cam-
shaft.

wheel facing right.
2 Return spring
(99879 Z0000).
NOTE
correctly.
BR-5-6
REASSEMBLY CB31
INSTALLATION
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
each other.
BR-5-7
ADJUSTMENT CB31
ADJUSTMENT
be seen).

3. Turn back the adjuster 8 to 9 turns (moving the screwdriver

from the lower to the upper portion). Then, insert the feeler
gauge into the right and left holes in the dust cover. Check
the clearance between the lining and drum. The clearance
between the lining and drum is 0.2 to 0.3 mm (0.008 to
0.012 in).
hole.

clearance.

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.
The electric wiring diagrams contained within this service manual

use abbreviations, symbols, and numbers. This chapter explains
their meanings and how to read the wiring diagrams.
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.
Wire size and color code

As shown below, the number indicates the size of the wire (nominal
sectional area of the conductor, mm2), and the letter at the end of
each number indicates the color of the covering.
Wire color code and symbol

The color of a wire covering is indicated by an alphabetical symbol.
There are two types of wire colors; one is of a unicolor, the other of
a ground unicolor with an identifying stripe color.
EL-1-2
INTRODUCTION
The alphabetical symbols are as follows.

Mainly-used locations
Alphabetical symbol Color
(Circuit name)
W White Power supply
B Black Grounding
R Red Lighting
Y Yellow Meter
G Green Signal
L Blue Window wiper
BR Brown
LG Light green
GY Gray
With marking (stripe)

Example
Alphabetical symbol Ground color Stripe color
W/B White Black
B/R Black Red
L/G Blue Green
G/W Green White
BR/Y Brown Yellow
LG/R Light green Red
Indication of wire joint

When another wire is connected to a wire on the route, the joint
position is indicated in the wiring circuit by a black dot and the wire
joined thereto by an arrow, as shown in the figure.
Indication of joint to same terminal

The figure below indicates that a terminal connecting to a unit is
also used to connect the wire leading to another unit.
EL-1-3
INTRODUCTION
Indication of joint between connectors

A single lead or wire is indicated by a connector at the joint in wiring
diagrams.
Multiple leads or wires are indicated by terminals of a connector at
the joints. The connector style is separately indicated near the joints
to identify the terminals.
Indication of joint between unit and connector

(When unit is provided with terminals)
When leads emerge directly from a unit or when a unit is provided
with a terminal connector, the terminal numbers corresponding to
the leads are indicated by the 1st connector counting from the unit
Indication of ground and battery

The ground (GND) symbol is indicated only when a unit or compo-
nent is directly grounded to body metal (GND) without using a lead.
A combination of the ground and connector symbols are indicated
for a unit or component which is grounded using a lead.
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.
Circuit operation chart

All wiring diagrams show the relays in a “break” state in which cur-
rent does not flow through the electrical components.
With the exception of the above, relays which switch from one posi-
tion to another, such as multi-position switches, are shown in the
circuit operation chart to clearly indicate the relationship of the con-
nections.
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.
HOW TO TRACE CONNECTIONS

When tracing a connection between two connections, match them
with connector guide placed on the other guide (as if you were clos-
ing a book). The squares facing each other in this condition are the
corresponding terminals. It is wrong to trace in parallel.
NOTE
z The connector guide is the positioning convex part of the
connector.
How to trace SMJ connections

The SMJ connector is designed so that each terminal position is
indicated by an alphanumerical “address”.
Since only the “address” is indicated in wiring diagrams, the SMJ
connector chart should also be used as a guide in determining a
terminal position on the SMJ connector side.
The terminals of the SMJ connector can be traced in a manner sim-
ilar to a conventional connector.
EL-1-7
INTRODUCTION
How to trace respective system power supply

In each wiring diagram, power supplies located upstream of the applicable fuses are abbreviated as shown in
Figures EL-13-2 & EL-13-4.
To trace a power supply, the leading wiring diagrams (pages EL-13-1 to EL-13-4) should be referred to first and
the required power supply can be traced back from the applicable fuse.
EL-1-8
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
SMJ
EL-2-2
RELAY
EL-2-3
BATTERY AND CIRCUIT PROTECTOR

BATTERY
Rated 5-hour Charging
Item RC (min.)/
voltage ampere rate current
Type CCA (A)
V AH A
65D23R 12 52 6.5 300
65D23R-MF 12 52 6.5 300
115F51S 12 96 12 500
115F51-MF 12 96 12 500
145F51 12 112 14 500
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
2. Using a gravimeter, measure the specific gravity of the elec-

trolyte in each cell.
Maintenance standard Remarks
1.200 - 1.290 Electrolyte temperature at 20ºC (68ºF)
EL-3-2
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
Charging the battery

1. Charge the battery with a charger while measuring the spe-
cific gravity of the electrolyte every 30 minutes. Charge until
the specific gravity reads between 1.25 and 1.29 for 3 con-
secutive readings and all cells reach a voltage of 2.5 to 2.7
volts.
NOTE
z Charging should be done in a well ventilated area free
from fire.
z Be careful not to allow the temperature of the electrolyte
to go over 45ºC (113ºF).
z If the electrolyte level lowers during charging, add dis-
tilled water.
2. When distilled water is added to the battery due to low elec-
trolyte, always charge the battery according to step 1
above.
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-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-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
M-35 Fuse block M-80 Exhaust brake cut relay

M-36 Blower motor M-81 Exhaust brake relay
M-37 Resistor M-82 DDS-2
M-38 Thermo switch M-83 Rack out
M-39 OPT connector (batt) M-84 Cab front harness (CF-21)
M-40 OPT connector (acc) M-85 Cab front harness (CF-22)
M-41 OPT connector (ign) M-86 Diode
M-42 OPT connector (earth) M-91 Diagnosis switch
M-43 Diode M-94 Transmission high-low relay
M-44 Engine overrun buzzer M-98 Speedometer
M-45 Cigarette lighter M-99 Tachograph
M-46 Radio M-100 Diode
M-47 Heater control (For illumination) M-101 Diode
ZEL903B
HARNESS LAYOUT
CHASSIS HARNESS AND TAIL HARNESS

RHD model
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
C-34 Air pressure switch C-64 Frame earth

C-35 Air pressure switch C-65 Transmission neutral switch
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
CHASSIS HARNESS (FOR TRACTOR)

RHD model
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

SWITCH (CAB SIDE)
RHD model
EL-5-1
LHD model
EL-5-2
RELAY (CAB SIDE)

RHD model
EL-5-3
LHD model
EL-5-4
CONTROL UNIT (CAB SIDE)

RHD model
EL-5-5
LHD model
EL-5-6
ELECTRICAL UNIT (CHASSIS SIDE)
EL-5-7
SUPER MULTIPLE JUNCTION (SMJ)

Connector mounting bolt
: 3 - 5 N·m {0.3 - 0.5 kgf·m, 2.2 - 3.6 ft·lbf}
FUSE
FUSIBLE LINK
EL-5-8
EL-5-9
EARTH POINT
EARTH POINT
CHASSIS SIDE
ONLY VEHICLES WITH D, E OR F WHEELBASE
EL-6-1
EARTH POINT
EXCEPT VEHICLES WITH D, E OR F WHEELBASE
EL-6-2
EARTH POINT
CAB SIDE
EL-6-3
STARTING SYSTEM
STARTING SYSTEM
STARTER CIRCUIT
CAUTION
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.
IGNITION SWITCH (KEY SWITCH)

Specifications
Rated voltage V 24
Voltage drop V 0.4 or less in 10 amperes
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
STARTER BLOCK RELAY

Specifications
Rated voltage V 24
Pull-in voltage V 18 or less
Release voltage V 8 or less
Excitation current A 3 or less
EL-7-1
STARTING SYSTEM
Inspection
Check the continuity, operation and insulation of the starter safety
relay.
AIR HEATER RELAY

Specifications
Rated voltage V 24
40 sec. (220A)
Rated time
10 min. (110A)
Attraction voltage V 18 or less
Release voltage V 8.5 or less at 20ºC (68ºF)
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”.
ENGINE COOLANT TEMPERATURE SENSOR

Specifications
Temperature range -40 to 120ºC (-40 to 248ºF)
Rated resistance valve 1.011 - 1.411 kΩ
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
SUB STARTER SWITCH

Specifications
Rated voltage V 24
Operation power N {kgf, lbf} 20 - 39 {2 - 4, 4 - 9}
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”.
ENGINE STOP MOTOR

Specifications
Rated voltage V 24
Pull-in 1.5/24
Rated current A/V
Hold-on 11.0/24
Operation power N {kgf, lbf} 147 {15, 33} or more
Minimum operation voltage V 16 or less
Operation time sec 1 or less
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)
TRANSMISSION NEUTRAL SWITCH

Inspection
1. Check the continuity between the terminals with a circuit
tester (ohm range).
2. L should be 23 to 24 mm (0.91 to 0.94 in) when the switch is
off.
Connection chart
OFF ON
Terminal
1 O
2 O
AIR DRYER HEATER AND THERMOSTAT

Specifications
Heater 24V - 50W
ON 0 - 8ºC (32 - 46ºF)
Thermostat
OFF Less than 20ºC (Less than 68ºF)
Inspection
Check the continuity between the terminal and heater body with a
circuit tester (ohm range).
EL-7-4
STARTING SYSTEM
AIR HEATER TIMER

Inspection
Check the operation mode of the air heater timer.
AIR HEATER
Inspection
Conduct continuity tests in air heater circuits.
EL-7-5
STARTING SYSTEM
EL-7-6
METER CLUSTER
METER CLUSTER
CAUTION
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
Removing the meter cluster

1. Move the steering wheel away from the meter cluster as far
as possible by operating the tilt/telescopic mechanisms.
2. Remove the screws securing the meter cluster assembly.
3. Disconnect the tube from the air pressure gauge.
4. Disconnect various connectors and speedometer cable
from the meter cluster assembly; remove the meter cluster
assembly.
Replacement of bulbs
Installing the meter cluster

1. Connect various connectors and speedometer cable to the
meter cluster assembly.
2. Connect the tube to the air pressure gauge.
: 20 N·m {2.0 kgf·m, 14 ft·lbf}
3. Install the meter cluster.
Removing the speedometer or tachograph

1. Remove the meter cluster. (For removal procedures, refer
to “METER CLUSTER”.)
2. Remove the screws. Pull the speedometer (tachograph)
assembly out from the instrument panel.
3. Disconnect the harness connectors and speedometer cable
from the speedometer (tachograph) assembly. Then
remove the speedometer (tachograph) assembly.
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
Installing the speedometer or tachograph

1. Connect the harness connector and speedometer cable to
the speedometer or tachograph. Install the speedometer or
tachograph.
2. Install the meter cluster. (For installation procedures, refer
to “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)
TRAILER BRAKE SWITCH

Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
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 Before servicing the electrical unit, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
For warning system circuit diagrams, refer to “METER CLUSTER”.
ENGINE COOLANT LEVEL AND OVERHEAT WARNING

BUZZER
Inspection
Check the continuity, insulation and operation of the buzzer.
ENGINE OVERRUN BUZZER

Inspection
Rated voltage 24V
PARKING BRAKE SWITCH

Inspection
Check the continuity between the respective terminals with a circuit
tester (ohm range).
Connection chart
Terminal ON I ON II
a O O
b O
c O
EL-9-1
WARNING SYSTEM
LOW AIR PRESSURE WARNING BUZZER

Inspection
Rated voltage 24V
WARNING BUZZER CANCEL SWITCH

Inspection
Using a circuit tester (ohm range), check the switch to see that it
makes (ground) or breaks the circuit under the specified air pres-
sure.
Operating air pressure
20 - 39 kPa {0.2 - 0.4 kgf/cm2, 3 - 6 psi}
AIR PRESSURE SWITCH

Inspection
makes (body earth) and breaks the circuit under the specified air
pressure.
Turn-on Type I 324 - 373 kPa {3.3 - 3.8 kgf/cm2, 47 - 54 psi}
pressure Type II 49 - 69 kPa {0.5 - 0.7 kgf/cm2, 7 - 10 psi}
Turn-off Type I 343 - 441 kPa {3.5 - 4.5 kgf/cm2, 50 - 64 psi}

pressure Type II 49 - 98 kPa {0.5 - 1.0 kgf/cm2, 7 - 14 psi}
VACUUM SWITCH
Inspection
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
WHEEL PARKING SWITCH

Inspection
ENGINE COOLANT LEVEL SENSOR

Inspection
Check the continuity between terminal (1) and the electrode, and
terminal (2) and the conductor. Check the insulation of the sensor
body.
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.
OIL PRESSURE SWITCH

Inspection
makes (body earth) and breaks the circuit under the specified oil
pressure.
Turn-on pressure 49 kPa {0.5 kgf/cm2, 7 psi} or less
Turn-off pressure 49 kPa {0.5 kgf/cm2, 7 psi} or more
EL-9-3
WARNING SYSTEM
OIL FILTER SWITCH (For FE6 Series Engine)

Specifications
Rated voltage 24V
Turn-on pressure 98 - 137 kPa {1.0 - 1.4 kgf/cm2, 14 - 20 psi}
Turn-off pressure 73.6 - 137.3 kPa {0.75 - 1.4 kgf/cm2, 10.7 - 19.9 psi}
Inspection
Raise the pressure and check if the oil filter switch operates within
the specifications.
INDICATOR (AIR FILTER WARNING SWITCH)

Inspection
Check the indicator for continuity when the specified negative pres-
sure is applied to it. Use a tester set in the ohm range to check.
TYPE I TYPE II
Specified 5.9166 - 6.5383 kPa 6.9875 - 7.7230 kPa
negative {603.3 - 666.7 mmAq, {712.5 - 787.5 mmAq,
pressure 23.752 - 26.248 inAq} 28.051 - 31.004 inAq}
Operating temperature range: -30 to 110ºC (-22 to 230ºF)

BRAKE FLUID LEVEL SWITCH
Inspection
1. Keep the reservoir level and add the specified amount of
brake fluid (to the LOW level).
2. Connect a circuit tester between the level switch terminals,
and drain the brake fluid slowly.
3. Check that there is the specified amount of brake fluid when
the switch turns on.
Unit: ml (Imp fl oz)

292.5 (10.30) —
EL-9-4
WARNING SYSTEM
AIR BOOSTER STROKE SWITCH

Rated 4A
Voltage drop 0.1V or less
Operating force 24.5 N {2.5 kgf, 5.5 lbf}
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.
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)]
TILT LOCK WARNING SWITCH

Specifications
Rated voltage 24V
Rated load 0.5A + 0.05A
Voltage drop Less than 0.2V
Operating force Less than 4.9 N {0.5 kgf, 1.1 lbf}
Inspection
(ohm range).
WARNING LIGHT CHECK RELAY

Inspection
Check the circuit of the warning light check relay.
Refer to “ILLUSTRATION OF CONNECTORS”.
EL-9-5
LIGHTING SYSTEM
LIGHTING SYSTEM
HEADLIGHT
REPLACEMENT
Specifications
Type
24V 75W/70W
Semi-sealed beam (Halogen bulb)
Removing the headlight

1. Tilt the cab, then disconnect the wiring connector.
2. Lower the cab, then open the front lid.
3. Remove the headlight lower cover.
4. Remove the headlight.
Bulb replacement (as installed in the vehicle)

1. Tilt the cab, then disconnect the wiring connector.
2. Remove the retaining ring.
4. Push the set spring to compress it inwards and remove it.
5. Remove the bulb.
NOTE
z Never touch the glass envelope.
z Do not leave the bulb out of the headlight reflector for a
long period of time as dust, moisture, and smoke may
enter the headlight body and affect the performance of
the headlight.
PREPARATIONS FOR AIMING ADJUSTMENT

z Be sure all tires are inflated to the specified pressure.
z Park the vehicle on a flat surface.
z Be sure the vehicle is in a no-load condition (except the
driver).
EL-10-1
LIGHTING SYSTEM
AIMING ADJUSTMENT (LOW BEAM)

Method I: Beam projecting method
1. Turn headlight low beam on.
2. Use adjusting screws to perform aiming adjustment.
NOTE
z First tighten the adjusting screw all the way and then
make adjustment by loosening the screw.
z To adjust vertical aim, use the adjusting screw below the
headlight. To adjust horizontal aim, use the adjusting
screw above the headlight.
z Adjust the headlights so that the upper edge and left
edge of the high intensity zone are within the acceptable
range as shown in the figure.
z The dotted lines in the illustration show the center of the
headlight.
Method II: Using a mechanical aimer

Aimer adjustment mark
1. When using a mechanical aimer, adjust adapter legs to the
data marked on the headlight.
2. Use adjusting screws to perform aiming adjustment.
NOTE
z First tighten the adjusting screw all the way, then make
adjustment by loosening the screw.
EL-10-2
LIGHTING SYSTEM
LIGHTING SWITCH (COMBINATION SWITCH)

Removing the lighting switch
1. Remove the horn pad, and then the steering wheel.
NOTE
z Put aligning marks on the steering wheel and the steer-
ing column prior to removal.
z Use a puller whenever the steering wheel is removed; do
not strike the end of the shaft.
2. Remove the steering column cover.

3. Remove the combination switch.
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
Installing the lighting switch

1. Install the column cover and combination switch.
2. Install the steering wheel, and then install the horn pad.
NOTE
z Be sure that the alignment marks are aligned when
installing the steering wheel.
: 88 N·m {9 kgf·m, 65 ft·lbf}
EL-10-3
LIGHTING SYSTEM
HEADLIGHT RELAY
Inspection
Check the circuit of the headlight relay.
DAY TIME LIGHT RELAY AND DAY TIME CUT RELAY

Inspection
Check the circuit of the day time light relay and day time light cut
relay.
TAIL, FOG, CLEARANCE AND OTHER LIGHTS

TAIL LIGHT RELAY
Inspection
Check the circuit of the tail light relay. Refer to “ILLUSTRATION OF
CONNECTORS”.
FOG LIGHT
Specifications
Type 24V/35W
FOG LIGHT SWITCH

Inspection
Turn the switch on and off and check for continuity.
OFF ON
1 O
2 O
3 O
4 O
EL-10-4
LIGHTING SYSTEM
FRONT CLEARANCE LIGHT

Specifications
With cornering light 24V 25W
Without cornering light 24V 5W
Removing the front clearance light

1. Open the door and remove the screw behind the light
assembly.
2. Loosen the screw at the front of the light assembly and
remove the light assembly.
3. Disconnect the wiring connector.
4. Remove the bulb.
Installing the front clearance light

1. Install the bulb.
2. Connect the wiring connector.
3. Install the light assembly.
INTERIOR LIGHT
Circuit
EL-10-5
LIGHTING SYSTEM
Removing the overhead console

1. Remove the room mirror.
2. Pull out the overhead console.
3. Disconnect the wiring connector, then remove the overhead
console.
DOOR SWITCH
TURN SIGNAL SWITCH

(COMBINATION SWITCH)
Removing the turn signal switch
Refer to “LIGHTING SWITCH (Combination 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
Installing the turn signal switch

Refer to “LIGHTING SWITCH (Combination switch)”.
EL-10-6
LIGHTING SYSTEM
COMBINATION FLASHER UNIT

Specifications
Nominal voltage 24V
Type I 88.4W - 138.4W
Service load range
Type II 63.4W - 113.4W
Number of flashes Normal 60 - 120
(times/minute) Wire brake 80 - 140
Rated current Type I 3.03A - 4.74A (2.17A - 3.89A)
(wire brake) Type II 2.17A - 3.89A (1.31A - 3.03A)
0.5V max. (between terminals 3
Voltage drop
and 4 , 3 and 5 )
Inspection
FRONT TURN SIGNAL LIGHT
SIDE TURN SIGNAL LIGHT

Specifications
Type I 24V/12W
Type II 24V/10W
EL-10-7
LIGHTING SYSTEM
REAR COMBINATION LIGHT

Specifications
Type I Type II
Turn signal light 24V 25W 24V 21W
Tail & stop light 24V 25W/10W 24V 21W/5W
1. Cover 4. Packing
2. Housing 5. Lens
3. Bulb
BACK-UP LIGHT
Specifications
Type I 24V 25W
Type II 24V 21W
BACK-UP LIGHT SWITCH

Inspection
(ohm range).
L should be 23 to 24 mm (0.91 to 0.94 in) when the switch is off.
EL-10-8
LIGHTING SYSTEM
BACK BUZZER
Specifications
Rated voltage 24V
Working voltage 18 - 32V
Number of buzzer sounding 60 - 100 times/minute
LICENSE PLATE LIGHT

Specifications
Type I 24V 12W
Type II 24V 10W
STOP LIGHT SWITCHES

Inspection
1. Using a circuit tester (ohm range), check the continuity and
insulation between the switch terminals.
2. Apply an air pressure of 98 kPa {1 kgf/cm2, 14 psi} to the
switch to check for operation.
NOTE
z When installing the switches, be sure to wind sealing
tape around the threads as shown in the figure.
MARKER LIGHT AND ENDOUT LIGHT

Specifications
Marker light 24V 5W
Endout light 24V 5W
EL-10-9
LIGHTING SYSTEM
Removing the marker light and endout light

1. Remove the lens.
2. Remove the bulb.
3. To remove the light body, remove the sunvisor and headlin-
ing while working inside the cab.
Installing the marker light and endout light

1. Install the bulb.
2. Install the lens using the rubber seal.
EL-10-10
OPERATION SYSTEM
OPERATION SYSTEM
CAUTION
z Before servicing the electrical units, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
EXHAUST BRAKE SWITCH

Removing the exhaust brake switch
Refer to the “LIGHTING SYSTEM” section.
Inspection
(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
(ohm range).
Terminal OFF ON
1 O
2 O
EXHAUST BRAKE MAGNETIC VALVE

Inspection
Check that the following circuits hold good when DC24V is applied
or shut off.
OFF ON
Inlet port O
Outlet port O O
Exhaust port O
EXHAUST BRAKE RELAY AND EXHAUST CUT RELAY

Inspection
Check the circuit of the exhaust brake relay and exhaust cut relay.
TRANSMISSION PTO SWITCH

Rated voltage 24V
Rated load 100W
Inspection
(ohm range).
Terminal OFF ON
1 O
2 O
EL-11-2
OPERATION SYSTEM
PTO CLUTCH SWITCH

The PTO clutch switch and exhaust brake switch are the same. For
removal, installation and inspection, refer to “EXHAUST BRAKE
CLUTCH SWITCH”.
PTO RELAY
Inspection
Check the circuit of the PTO relay. Refer to “ILLUSTRATION OF
CONNECTORS”.
PTO MAGNETIC VALVE

The PTO magnetic valve and exhaust brake magnetic valve are the
same. Refer to “EXHAUST BRAKE MAGNETIC VALVE”.
THIRD DIFFERENTIAL LOCK SWITCH

Inspection
(ohm range).
OFF ON
1 O
2
3 O
THIRD DIFFERENTIAL LOCK MAGNETIC VALVE

The third differential lock magnetic valve, PTO magnetic valve and
exhaust magnetic valve are the same. Refer to “EXHAUST BRAKE
MAGNETIC VALVE”.
EL-11-3
OPERATION SYSTEM
WIPER AND WASHER SWITCH

Removing the wiper and washer switch
Refer to the “LIGHTING SYSTEM” section.
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).
INTERMITTENT WIPER RELAY

Specifications
Rated voltage 24V
Resting time Intermittent 4±20% sec.
Wiper starts to operate within 0.2 to 0.6 sec-
Washer interlocking onds after washer is turned on
circuit Wiper operates 2 to 3 times and then stops
after washer is turned off
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
Removing the window washer reservoir assembly

1. Disconnect the washer tube connector.
2. Remove the window washer reservoir.
3. Disconnect the wiring connector.
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
POWER WINDOW SWITCH (DRIVER'S SIDE)

Inspection
Check the continuity between the respective terminals of the power
window switch with a circuit tester (ohm range).
POWER WINDOW SWITCH (PASSENGER SIDE)

Inspection
window switch with a circuit tester (ohm range).
OPERA- OPERATION
TION
CONNECTED TO
TERMINAL
NO. U N D
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
POWER WINDOW MOTOR

Specifications
Rated voltage 24V
Rated current 4.5A or less
Rated revolution 70 - 90 rpm
No load current 2A or less
No load revolution 110 rpm
Constraint current 10A or less
Torque 6.4 N·m {65 kgf·cm, 56 in·lbf}
Insulation resistance 1 MΩ or more
Inspection
between the terminals and inspect the motor.
2. Check the operation of the motor (refer to the specifica-
tions).
POWER WINDOW RELAY

Inspection
Check the circuit of the power window relay. Refer to “ILLUSTRA-
TION OF CONNECTORS”.
CIRCUIT BREAKER
Inspection
Rated voltage 24V
Cycle 5 sec. (Action) - 1 sec. (Lock)
EL-11-8
OPERATION SYSTEM
POWER DOOR LOCK SWITCH

(Built in the driver's side door)
OPERATION
UNLOCK LOCK
TERMINALS
1 O O
2 O O
3 O O
4 O O
Inspection
door lock switch with a circuit tester (ohm range).
EL-11-9
OPERATION SYSTEM
POWER DOOR LOCK MOTOR (ACTUATOR)

(Built in the passenger side door)
OPERATION
UNLOCK LOCK
TERMINALS
1 + -
2 - +
Inspection
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) (+)
SEAT BELT SWITCH

Specifications
Terminal OFF ON
1 O
2 O
EL-12-2
ACCESSORY SYSTEM
SEAT BELT TIMER

Inspection
It is difficult to check the timer unit (seat belt timer function) as a sin-
gle part. Therefore, check system operating conditions as a whole
and other individual units. Then, judgment can be made whether or
not the timer unit is operating properly.
SEAT BELT BUZZER

Inspection
Refer to warning buzzer.
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
ENGINE AIR HEATER SYSTEM
EL-13-6
WIRING DIAGRAM
CHARGING SYSTEM
EL-13-7
WIRING DIAGRAM
TRAILER BRAKE INDICATOR LIGHT
EL-13-8
WIRING DIAGRAM
FUEL GAUGE
EL-13-9
WIRING DIAGRAM
TACHOMETER
EL-13-10
WIRING DIAGRAM
AIR PRESSURE AND VACUUM WARNING LIGHT

RHD model
EL-13-11
WIRING DIAGRAM
LHD model
EL-13-12
WIRING DIAGRAM
ENGINE COOLANT LEVEL AND OVERHEAT WARNING LIGHT
EL-13-13
WIRING DIAGRAM
OIL PRESSURE WARNING LIGHT
EL-13-14
WIRING DIAGRAM
OIL FILTER WARNING LIGHT
EL-13-15
WIRING DIAGRAM
AIR FILTER WARNING LIGHT
EL-13-16
WIRING DIAGRAM
BRAKE WARNING LIGHT
EL-13-17
WIRING DIAGRAM
TILT LOCK WARNING LIGHT
EL-13-18
WIRING DIAGRAM
WARNING LIGHT BULB CHECK SYSTEM
EL-13-19
WIRING DIAGRAM
HEADLIGHT
EL-13-20
WIRING DIAGRAM
DAY TIME LIGHT
EL-13-21
WIRING DIAGRAM
EL-13-22
WIRING DIAGRAM
FOG LIGHT
EL-13-23
WIRING DIAGRAM
TURN SIGNAL AND HAZARD LIGHT

Except tractor (RHD model)
EL-13-24
WIRING DIAGRAM
TRACTOR (RHD MODEL)
EL-13-25
WIRING DIAGRAM
- MEMO -
EL-13-26
WIRING DIAGRAM
TURN SIGNAL, HAZARD AND CORNERING LIGHT

Except tractor (LHD model)
EL-13-27
WIRING DIAGRAM
EL-13-28
WIRING DIAGRAM
Tractor (LHD model)
EL-13-29
WIRING DIAGRAM
EL-13-30
WIRING DIAGRAM
TAIL AND STOP LIGHT

RHD model
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
ILLUMINATION LIGHT CONTROL
EL-13-40
WIRING DIAGRAM
EXHAUST BRAKE SYSTEM

STD (RHD model)
EL-13-41
WIRING DIAGRAM
STD (LHD model)
EL-13-42
WIRING DIAGRAM
With ABS (For Norway)
EL-13-43
WIRING DIAGRAM
With ABS and engine control (For Norway)
EL-13-44
WIRING DIAGRAM
TRANSMISSION PTO
RHD model
EL-13-45
WIRING DIAGRAM
LHD model
EL-13-46
WIRING DIAGRAM
THIRD DIFFERENTIAL LOCK SYSTEM
EL-13-47
WIRING DIAGRAM
WINDSHIELD WIPER
Semi-wide cab model
EL-13-48
WIRING DIAGRAM
Extra-wide cab model
EL-13-49
WIRING DIAGRAM
POWER DOOR LOCK

RHD model
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
SEAT BELT WARNING
EL-13-59
WIRING DIAGRAM
- MEMO -
EL-13-60
WIRING DIAGRAM
VNT CONTROL SYSTEM
EL-13-61
WIRING DIAGRAM
EL-13-62
WIRING DIAGRAM
ABS
EL-13-63
WIRING DIAGRAM
EL-13-64
WIRING DIAGRAM
SPEED LIMITER SYSTEM
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
Alignment (C) of door -2.0 to 1.0

with cab (-0.079 to 0.039)
TIGHTENING TORQUE
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}
* For mirror types, refer to the MIRROR section.
CB-1-1
TOOLS CAB BODY
TOOLS
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
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 Secure clearances H: 4 m (13.1 ft) and F: 1 m (3.3 ft) so the

cab can be tilted. Then, chock the 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.
1. Remove the accelerator control cable from the pedal

bracket and push the cable out of the vehicle.
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
3. Disconnect the parking brake valve piping and harness con-

nector, and push them out of the vehicle. (Spring-activated
rear wheel parking brake only)
4. Remove the select and shift cables from the transmission

control lever and push them together with the grommet out
of the vehicle.
5. Open the front lid and perform the following:

z Remove the lower grille together with the bracket.
z Disconnect the heater hose and speedometer cable.
z Disconnect the SMJ (Super Multi-Junction).
CB-3-2
6. Place an alignment mark on the steering gear box and

sleeve yoke, and disconnect the steering column.
7. Disconnect the hose and tube connected to the cab.

NOTE
z Place a container under the clutch hose connection to
collect the clutch fluid.
8. Remove the tilt stopper bracket connected to the cab.

CAUTION
z When removing the bracket, securely lift the cab assem-
bly with a crane and support the cab.
9. Separate the cab assembly from the hinge bracket. Slightly

lift the cab to make sure that each connection is discon-
nected. After that, slowly move the crane and lower the cab
assembly on a stable place.
WARNING
WARNING
z When the cab is lifted, do not place any part of your body
under the cab.

SMJ (SUPER MULTI-JUNCTION) CONNECTOR
The SMJ connector bolt will fracture to protect the connector and
terminals from damage if it is tightened to “excessive” torque 12 to
18 N·m {1.2 to 1.8 kgf·m, 9 to 13 ft·lbf}. It must always be tightened
to the specified torque.
: 2.9 - 4.9 N·m {0.3 - 0.5 kgf·m, 2.2 - 3.6 ft·lbf}
CB-3-3
SMJ connector bolt replacement

1. Separate the female and male connectors by prying apart
with a flat-blade screwdriver.
2. Remove the bolt from the female connector by loosening
the screw while holding the bolt with pliers.
NOTE
z Always replace the bolt after removing the connector
cover.
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
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.
2. When installing the torsion bar on the hinge bracket, make

sure that the rotating direction and right and left sides are
correct.
NOTE
z Install the torsion bar with the flat part of the serration
joining that of the hinge bracket.
3. When installing the torsion arm on the torsion bar, the flat
part of both parts should join.
CB-3-4
4. Install the steering yoke shaft on the sleeve yoke.

NOTE
z Ensure the alignment marks are aligned properly before
installation.
: 51 - 61 N·m {5.2 - 6.2 kgf·m, 38 - 45 ft·lbf}
5. Connect the select and shift cables to the transmission con-

trol lever.
NOTE
z Install the grommet so that the mark on it faces the front
of the vehicle.
6. Replenish engine coolant, clutch fluid, air and refrigerant (if

equipped with an air conditioner).
CB-3-5
- MEMO -
CB-3-6
DOOR CAB BODY
DOOR
DISASSEMBLY
L.H. DOOR
Inner L.H. door
CB-4-1
DOOR CAB BODY
Outer L.H. door

1. Cap 18. Door molding assembly 33. Power window breaker assembly*
2. Glass protector , 19. Guide channel 34. Actuator assembly*
3. Ash tray 20. Regulator assembly 35. Relay assembly*
4. Ash tray bracket ,+ 21. Power window motor (regulator) 36. Door lock switch assembly*
5. Pull handle cap assembly* 37. Door lock knob
6. Pull handle , 22. Glass runner 38. Door lock assembly
7. Handle escutcheon 23. Center sash assembly 39. Seal
+ 8. Power window switch assembly* 24. Door glass 40. Door handle
9. Switch finisher* 25. Door glass holder 41. Cylinder assembly
10. Door window handle 26. Rear lower sash assembly 42. Side turn signal light assembly
+ 11. Lower finisher assembly 27. Door glass weatherstrip 43. Wiring harness assembly*
12. Upper finisher assembly 28. Door glass 44. Clip
13. Handle support , 29. Door ventilator assembly*1 45. Check link kit
14. Finisher bracket 30. Ventilator glass weatherstrip*1 46. Striker assembly
,+ 15. Film 31. Ventilator glass*1 47. Door hinge assembly
16. Film 32. Ventilator sash assembly*1 48. Door panel assembly
17. Escutcheon
Parts with an asterisk (*) are only for vehicles with power window.
Parts with an asterisk (*1) are only for vehicles with door ventilator assembly.
CB-4-2
DOOR CAB BODY

8 Power window switch assembly
Pry the power window switch finisher up and off using a flat-blade
screwdriver.
11 Lower finisher assembly

Pry the door lower finisher assembly clips off using a flat-blade
screwdriver.
NOTE
z Do not forcefully pry the trim clip off as this may scratch
the door panel or door finisher.
z Locate the screwdriver as close to the trim clip as possi-
ble before prying the clip off.
15 Film
Roll up the lower side of the waterproof film, and remove the follow-
ing parts.
21 Power window motor (regulator) assembly

1. Remove the screws securing the guide channel, and sepa-
rate the power window motor (regulator) assembly from the
door glass.
2. Remove the four bolts securing the power window motor

(regulator) assembly to the door, and remove the motor
assembly through the access hole in the door panel.
CB-4-3
DOOR CAB BODY
- MEMO -
CB-4-4
DOOR CAB BODY
R.H. DOOR
Inner R.H. door
CB-4-5
DOOR CAB BODY
Outer R.H. door

1. Cap 16. Escutcheon 30. Ventilator glass*1
2. Glass protector 17. Door molding assembly 31. Ventilator glass sash assembly*1
3. Ash tray , 18. Guide channel 32. Power window breaker assembly*
4. Ash tray bracket 19. Regulator assembly 33. Door lock knob
5. Pull handle cap ,+ 20. Power window motor (regulator) 34. Door lock assembly
6. Pull handle assembly* 35. Seal
7. Handle escutcheon , 21. Glass runner 36. Door handle
8. Power window switch assembly* 22. Center sash assembly 37. Cylinder assembly
9. Door window handle 23. Door glass 38. Side turn signal light assembly
+ 10. Lower finisher assembly 24. Door glass holder 39. Wiring harness assembly*
11. Upper finisher assembly 25. Rear lower sash assembly 40. Clip
12. Handle support 26. Door glass weatherstrip 41. Check link kit
13. Finisher bracket 27. Door glass 42. Striker assembly
,+ 14. Film , 28. Door ventilator assembly*1 43. Door hinge assembly
15. Film 29. Ventilator glass weatherstrip*1 44. Door panel assembly
CB-4-6
DOOR CAB BODY

screwdriver.
NOTE
14 Film
ing parts.

1. Remove the screws securing the guide channel, and sepa-
rate the power window motor (regulator) assembly from the
door glass.
2. Remove the four bolts securing the power window motor

(regulator) assembly to the door, and remove the motor
assembly through the access hole in the door panel.
CB-4-7
DOOR CAB BODY
REASSEMBLY
L.H. DOOR
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.

Insert the power window motor (regulator) assembly into the
access hole in the door panel, and secure with bolts.
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
NOTE
weatherstrip.
itate installation.
21 Glass runner
NOTE

Insert the power window motor (regulator) assembly into the
access hole in the door panel, and secure with bolts.
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
NOTE
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)
Inner L.H. door
CB-4-11
DOOR CAB BODY
Outer L.H. door
CB-4-12
DOOR CAB BODY

NOTE
z The drawing shows the right-hand drive model equipped with safety window.
1. Cap , 19. Film 37. Door lock knob

2. Glass protector 20. Escutcheon 38. Door lock assembly
3. Ash tray 21. Door molding assembly 39. Seal
4. Ash tray bracket 22. Rubber seal 40. Door handle
5. Pull handle ,+ 23. Regulator assembly 41. Door handle finisher
6. Handle escutcheon ,+ 24. Power window motor (regulator) 42. Cylinder assembly
7. Side view inner door glass assembly assembly* 43. Side turn signal light assembly
8. Side view inner door glass lock , 25. Glass runner 44. Wiring harness assembly*
9. Side view inner door glass hinge 26. Center sash assembly , 45. Side view glass assembly (Safety
10. Striker 27. Door glass window)
11. Spacer 28. Door glass holder 46. Side view outer door glass weather-
,+ 12. Side view inner door glass weather- 29. Rear lower sash assembly strip
strip 30. Door glass weatherstrip 47. Side view outer door glass
13. Door window handle 31. Door glass 48. Door finisher
+ 14. Door finisher assembly , 32. Door ventilator assembly*1 49. Check link kit
15. Power window switch assembly* 33. Ventilator glass weatherstrip*1 50. Striker assembly
16. Handle support 34. Ventilator glass*1 51. Door hinge assembly
17. Finisher bracket 35. Ventilator glass sash assembly*1 52. Door panel assembly
, 18. Film 36. Power window breaker assembly*
CB-4-13
DOOR CAB BODY
R.H. DOOR
(EQUIPPED WITH SAFETY WINDOW)
Inner R.H. door
CB-4-14
DOOR CAB BODY
Outer R.H. door
CB-4-15
DOOR CAB BODY

NOTE
z The drawing shows the left-hand drive model equipped with safety window.
1. Cap 17. Door molding assembly 32. Door lock knob

2. Glass protector 18. Regulator assembly 33. Door lock assembly
3. Ash tray 19. Power window motor (regulator) 34. Seal
4. Ash tray bracket assembly* 35. Door handle
5. Pull handle cap , 20. Glass runner 36. Cylinder assembly
6. Pull handle 21. Center sash assembly 37. Side turn signal light assembly
7. Handle escutcheon 22. Door glass 38. Wiring harness assembly*
8. Power window switch assembly* 23. Door glass holder 39. Clip
9. Door window handle 24. Rear lower sash assembly , 40. Side view glass assembly (Safety
+ 10. Lower finisher assembly 25. Door glass weatherstrip window)
11. Upper finisher assembly 26. Door glass 41. Side view glass weatherstrip
12. Handle support , 27. Door ventilator assembly*1 42. Side view door glass
13. Finisher bracket 28. Ventilator glass weatherstrip*1 43. Check link kit
+ 14. Film 29. Ventilator glass*1 44. Striker assembly
15. Film 30. Ventilator glass sash assembly*1 45. Door hinge assembly
16. Escutcheon 31. Power window breaker assembly* 46. Door panel assembly
CB-4-16
DOOR CAB BODY
L.H. DOOR (EQUIPPED WITH SAFETY WINDOW)

12 Side view inner door glass weatherstrip
Remove the inner door glass weatherstrip.
NOTE
z Butyl sealant is applied to the inner side of the weather-
strip. Do not allow it to come in contact with the door fin-
isher during disassembly.
z Discard the weatherstrip after removal.
14 Door finisher assembly
Pry the clips off the door finisher assembly using a standard screw-
driver. Remove the door finisher assembly while lifting it away from
the door.
NOTE
z Do not forcefully remove the trim clip as this may scratch
the door panel or door finisher assembly.
23 Regulator assembly
Before removing the power window motor (regulator) assembly or
regulator assembly, remove the following assemblies/parts.
1. Remove the ashtray and bracket.
2. Remove the handle finisher and escutcheon.
3. Remove the door inner glass assembly.
CB-4-17
DOOR CAB BODY
4. Remove the inner door glass weatherstrip and door finisher

assembly.
NOTE
z Refer to items 12 and 14 .
5. Remove the film.
6. Remove the screws securing the power window (regulator)
assembly or regulator assembly to the door glass, and sep-
arate the power window assembly and door glass.
7. Remove the bolts securing the power window motor (regu-

lator) assembly or regulator assembly to the door, and
remove the power window motor assembly or regulator
assembly through the access hole.
R.H. DOOR (EQUIPPED WITH SAFETY WINDOW)

screwdriver.
NOTE
14 Film
ing parts.
REASSEMBLY
L.H. DOOR (EQUIPPED WITH SAFETY WINDOW)
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.
2. While placing the end of the string inside the compartment,

align the glass with the door flange. Have a co-worker align
the glass with the door flange. While press the glass against
the flange, from the outside, and tapping with the palm of
your hand at the middle portion of the glass, from the out-
side, fit the weatherstrip over the flange, pulling the string
out inside the compartment.
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.

NOTE
weatherstrip.
itate installation.
25 Glass runner
NOTE
CB-4-19
DOOR CAB BODY

23 Regulator assembly
Insert the power window motor (regulator) assembly or regulator
assembly into the access hole in the door panel, and secure with
the bolts.
18 19 Film
NOTE
z Always install the film on the butyl tape which has been
installed in advance.
12 Side view Inner door glass weatherstrip

Before installing the weatherstrip, observe the following note.
NOTE
z Always use new weatherstrip.
z Apply butyl sealant to the inner side of the weatherstrip
before installation. Do not allow the sealant to come in
contact with the door finisher.
R.H. DOOR (EQUIPPED WITH SAFETY WINDOW)

40 Side view glass assembly (Safety window)
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.
NOTE
facing downward.
CB-4-20
DOOR CAB BODY

align the glass with the door flange. Have a co-worker align
the glass with the door flange. While press the glass against
the flange, from the outside, and tapping with the palm of
your hand at the middle portion of the glass, from the out-
side, fit the weatherstrip over the flange, pulling the string
out inside the compartment.
NOTE
z Do not tap any part of the glass except the middle portion
shown by hatches in the figure.
hand.
3. Evenly tap the glass with the palm of your hand until the
weatherstrip settles properly.

NOTE
weatherstrip.
itate installation.
20 Glass runner
NOTE
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
REAR
CB-5-2
REMOVAL AND INSTALLATION

Open the front lid, and remove and install the center lower grill assembly.

FRONT

1. Tilt hinge 5. Bolt 9. Tilt hinge bracket
2. Bolt 6. Torsion bushing 10. Torsion bar (L.H.)
3. Washer 7. Nut 11. Torsion bar (R.H.)
4. Torsion arm 8. Bolt
CB-5-3
REAR

1. Cushion 4. Spacer 7. Cab mounting bracket
2. Floating bar 5. Leaf spring 8. Stopper rubber
3. Shock absorber 6. Spacer 9. Support
CB-5-4
LOCK SYSTEM

1. Tilt switch assembly 3. Hook 5. Tilt lock lever
2. Tilt lock assembly 4. Rod bracket 6. Sub hook lever
CB-5-5
GLASS CAB BODY
GLASS
DISASSEMBLY

1. Front weatherstrip 4. Rear window glass 7. Side weatherstrip
2. Front windshield 5. Hinge 8. Side window glass
3. Rear weatherstrip 6. Handle assembly
CB-6-1
GLASS CAB BODY
z Since the windshield, rear and safety windows can be

removed or installed similarly, this section deals with the
windshield only.
REMOVAL
1. Remove the wiper arm.
2. Using a spatula or a flat-blade screwdriver, remove the

windshield and weatherstrip.
REASSEMBLY
INSTALLATION
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
facing downward.

align the windshield with the cab flange. Have a co-worker
align the windshield with the cab flange. While press the
windshield against the flange, from the outside, and tapping
with the palm of your hand at the middle portion of the wind-
shield, from the outside, fit the weatherstrip over the flange,
pulling the string out inside the compartment.
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.
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.)
1. Plain washer 14. Washer 26. Screw

2. Sheet 15. Arm base , 27. Main mirror arm
3. Screw 16. Pack base 28. Screw
4. Sub mirror arm 17. Screw , 29. Bracket
5. Nut 18. Plain washer 30. Washer
6. Plain washer 19. Nut 31. Washer
7. Washer 20. Spring-washer 32. Spring washer
8. Arm base 21. Washer 33. Nut
9. Pack base 22. Washer 34. Screw
10. Bracket 23. Nut 35. Spacer
11. Cap 24. Bracket 36. Mirror assembly
12. Nut , 25. Bracket 37. Spacer
13. Plain washer
NOTE
CB-7-1
MIRROR CAB BODY
TYPE II (ASSISTANT SIDE) (THE RIGHT SIDE IS SYM-

METRICALLY OPPOSITE IN CONSTRUCTION.)
1. Plain washer 10. Washer 19. Nut

2. Sheet , 11. Sub mirror arm 20. Plain washer
3. Sub mirror arm 12. Holder 21. Cap
4. Washer 13. Screw 22. Bolt
5. Screw 14. Cover 23. Washer
6. Sub mirror arm 15. Cap , 24. Main mirror arm
7. Pack base 16. Bolt 25. Screw
8. Mirror assembly 17. Arm base 26. Grommet
9. Screw 18. Cap
NOTE
CB-7-2
MIRROR CAB BODY
TYPE III (ASSISTANT SIDE) (THE RIGHT SIDE IS SYM-

METRICALLY OPPOSITE IN CONSTRUCTION.)
1. Cover 13. Screw 24. Washer

2. Screw 14. Washer 25. Cap
3. Holder , 15. Sub mirror arm 26. Bolt
4. Side under mirror assembly 16. Holder 27. Washer
5. Plain washer 17. Screw 28. Cover
6. Sheet 18. Cover 29. Screw
7. Sub mirror arm 19. Cap 30. Holder
8. Washer 20. Bolt 31. Under mirror assembly
9. Sub mirror arm 21. Arm base , 32. Main mirror arm
10. Screw 22. Cap 33. Screw
11. Pack base 23. Nut 34. Grommet
12. Back mirror assembly
NOTE
CB-7-3
MIRROR CAB BODY
TYPE IV (THE RIGHT SIDE IS SYMMETRICALLY OPPO-

1. Mirror assembly 7. Nut 13. Washer

2. Holder 8. Plain washer 14. Screw
3. Cover 9. Washer 15. Nut
, 4. Main mirror arm 10. Base pack 16. Plain washer
5. Screw 11. Arm base 17. Base pack
6. Cap 12. Screw 18. Arm base
NOTE
CB-7-4
MIRROR CAB BODY
TYPE V (THE RIGHT SIDE IS SYMMETRICALLY OPPO-

1. Spacer 14. Plain washer 27. Plain washer

2. Mirror assembly 15. Lock washer 28. Nut
3. Spacer 16. Nut 29. Sheet
4. Nut 17. Plain washer 30. Sub mirror arm
5. Lock washer 18. Plain washer 31. Sheet
6. Plain washer 19. Mirror arm base 32. Sub mirror arm
7. Plain washer 20. Plain washer 33. Sub mirror arm
8. Mirror bracket (rear) 21. Nut 34. Sub mirror arm
, 9. Mirror bracket (front) 22. Plain washer 35. Plain washer
10. Main mirror arm 23. Plain washer 36. Sheet
11. Mirror bracket (rear) 24. Nut 37. Mirror arm base
, 12. Mirror bracket (front) 25. Plain washer 38. Plain washer
13. Plain washer 26. Sub mirror arm 39. Nut
NOTE
CB-7-5
MIRROR CAB BODY
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 MEMBER
1. Ventilator assembly 12. Ventilator assembly 22. Support bracket

, 2. Cluster lid 13. Instrument lower cover 23. Instrument stay
3. Grille assembly 14. Cluster lid 24. Instrument support
4. Instrument pad assembly 15. Ash tray bracket 25. Reinforce
5. Instrument pad assembly 16. Ash tray 26. Reinforce
6. Glove box 17. Glove box lock , 27. Instrument support
7. Instrument pad striker 18. Tray assembly , 28. Instrument member assembly
8. Hinge 19. End finisher assembly 29. Unit support assembly
9. Cluster lid 20. Instrument upper panel assembly , 30. Instrument support
10. Cluster lid 21. Rubber bumper 31. Instrument side bracket
11. Rubber bumper
NOTE
CB-8-2
REMOVAL
Remove the steering wheel, and remove the combination switch
and steering column cover.
(For details, refer to the “ST” section.)
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
- 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
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
When you read wiring diagrams

z Read EL section, “HOW TO READ WIRING DIAGRAMS”.
z See EL section, “POWER SUPPLY” for power distribution circuit.
For the air conditioners, refer to the AC section.
HE
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
HOW TO FOLLOW FLOW CHART IN TROUBLE

DIAGNOSES
EXAMPLE
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 THIS FLOW CHART

Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
enclosed blocks, as shown in the following example.
CHECK BLOWER MOTOR CIRCUIT. Check item being per-

Disconnect blower motor harness con- formed.
nector.
Does battery voltage exist between
blower motor harness terminal No. 1
} Procedure, steps or
measurement results
and body ground?
OK
Cross reference of work symbols in the text and

illustrations
Illustrations are provided as visual aids for work procedures.
For example, symbol indicated in the left upper portion of
each illustration corresponds with the symbol in the flowchart
for easy identification.
Symbols used in illustrations
Symbols included in illustrations refer to measurements or pro-
cedures. Before diagnosing a problem, familiarize yourself
with each symbol.
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.
: View from terminal side ... T.S.
z All connector symbols shown from the terminal side are

enclosed by a single line.
: View from harness side ... H.S.
z All connector symbols shown from the harness side are

enclosed by a double line.
HE-1-2
Key to symbols signifying measurements or procedures
HE-1-3
DESCRIPTION — OVERALL SYSTEM

CONTROL OPERATION
FAN SWITCH
This lever switches the fan ON and OFF, and controls fan speed.
AIR CONTROL LEVER

This lever allows you to select the outlet air flow.
TEMPERATURE CONTROL LEVER

This lever allows you to adjust the temperature of the outlet air.
INTAKE LEVER
position:
Outside air is drawn into the passenger compartment.
position:
Interior air is recirculated inside the vehicle.
AIR CONDITIONER SWITCH (A/C EQUIPPED MODEL)

Start the engine, set the fan lever to the desired position (1 to 4) and push the air conditioner switch to turn ON
the air conditioner. The indicator light will come on when the air conditioner is ON. To stop the air conditioner,
push the switch again to return it to the original position.
The air conditioner cooling function operates only when the engine is running.
HE-2-1
AIR FLOW
Air control lever Intake lever Temperature control lever

VENT B/L FOOT F/D DEF
Position
Door
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
Discharge air flow

Switch mode/ Air outlet/distribution
indicator Face Foot Defroster
100% — —
55% 45% —
— 100% —
— 70% 30%
— — 100%
HE-2-2
DIAGNOSES — OVERALL SYSTEM

OPERATION CHECK
The purpose of the operational check is to confirm that the system
is as it should be. The systems which will be checked are the
blower, mode (discharge air), intake air temperature decrease, tem-
perature increase and A/C switch (A/C equipped model).
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 discharge air

1. Slide air control lever to position.
2. Confirm that all discharge air comes out of face vents.
4. Confirm that discharge air comes out of face vents and foot
vents.
6. Confirm that discharge air comes out of foot vents, with
some air from defroster vents.
8. Confirm that discharge air comes out of foot vents with
some air from defroster vents.
10. Confirm that all discharge air comes out of defroster vents.
Check recirc
1. Slide intake lever to position.
2. Listen for intake door position change (you should hear
sound change slightly).
HE-3-1
Check temperature decrease

1. Slide temperature control lever to full cold.
2. Check for cold air at discharge air outlets.
Check temperature increase

1. Slide temperature control lever to full hot.
2. Check for hot air at discharge air outlets.
Check A/C switch (A/C equipped model)

Move fan switch to the desired position (1 to 4) and press air condi-
tioner button to turn ON air conditioner.
Indicator light will come on when air conditioner is ON.
HE-3-2
TROUBLE DIAGNOSES
TROUBLE DIAGNOSES
HARNESS LAYOUT FOR HEATER SYSTEM
WIRING DIAGRAM — HEATER
HE-4-1
TROUBLE DIAGNOSES
MAIN POWER SUPPLY AND GROUND CIRCUIT

CHECK
POWER SUPPLY CIRCUIT CHECK FOR HEATER SYS-
TEM
Check power supply circuit for heater system.
Refer to “POWER SUPPLY” in EL section and Wiring Diagram.
DIAGNOSTIC PROCEDURE
SYMPTOM: Blower motor does not rotate.
Flow chart
INCIDENT
No.
1 Fan fails to rotate.
2 Fan fails to rotate at 1-speed.

Check if blower motor rotates properly at D

each fan speed.
Conduct checks as per flow chart at left. C
B
(Go to HE-4-4.)
Note
CHECK BLOWER MOTOR CIRCUIT. NG Check 15A fuses at fuse

Disconnect blower motor harness con- block. (No. 12)
nector.
and body ground?
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
Check circuit continuity between blower NG Reconnect blower motor

motor harness terminal No. 2 and body harness connector.
ground?
OK
CHECK BLOWER MOTOR.

(Refer to Electrical Components Inspec-
tion.)
NG
Replace blower motor.
CHECK BLOWER MOTOR CIRCUIT BE- NG Disconnect blower motor

TWEEN BLOWER MOTOR AND RESIS- and resistor harness con-
TOR. nector.
Does battery voltage exist between resis-
tor harness terminal No. 1 and body
ground?
OK
NOTE
Check circuit continuity
between blower motor har-
ness terminal No. 2 and
resistor harness terminal
No. 1.
(Go to next page.)

NOTE
HE-4-3
TROUBLE DIAGNOSES
B
CHECK RESISTOR AFTER DIS-
CONNECTING IT. C
(Refer to Electrical Components
Inspection.)
D
OK NG
Replace resistor.
Reconnect resistor harness con- E
nector.
CHECK FAN SWITCH CIRCUIT.

each fan switch harness terminal and
body ground?
Terminal No.
Flow chart No. Voltage
+ -
2
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
CHECK FAN SWITCH AFTER NG Replace fan switch.

DISCONNECTING IT.
Inspection.)
OK
NOTE
Check circuit continuity between
fan switch harness terminal No. 6
and body ground?
NOTE
HE-4-4
TROUBLE DIAGNOSES
ELECTRICAL COMPONENT INSPECTION

FAN SWITCH
Check continuity between terminal at each position.
POSITION
TERMINAL
OFF 1 2 3 4
5 O
4 O
3 O
2 O
6 O O O O
1 O O O O
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.
A/C SWITCH (A/C EQUIPPED MODEL)

Check continuity between terminals.
HE-4-5
TROUBLE DIAGNOSES
CONTROL LINKAGE ADJUSTMENT

AIR CONTROL CABLE
z Move air control lever to position. Set side link in
VENT mode. Pull on outer cable in direction of arrow and
then clamp it.
After positioning control cable, check it operates properly.
WATER COCK CONTROL ROD

z When adjusting water cock control rod, first disconnect
temperature control cable from air mix door lever and
then adjust control rod. Reconnect temperature control
cable and readjust it. (Refer to next item.)
1. Set air mix door lever in full cold mode.
2. Pull control rod of water cock in direction of arrow so as to
make clearance of about 2 mm (0.08 in) between ends of
rod and link lever and connect the rod to door lever.
After connecting control rod, check it operates properly.
TEMPERATURE CONTROL CABLE
z When adjusting ventilator door rod and defroster door
rod, first disconnect air control cable from side link.
Reconnect and readjust air control cable.
z Move temperature control lever to full HOT position. Set air
mix door lever in full hot mode. Pull on outer cable in direc-
tion of arrow and then clamp it.
INTAKE DOOR CONTROL CABLE
z Move intake lever to position.

Set intake door lever in FRESH mode.
Pull on outer cable in direction of arrow and then clamp it.
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.
HFC134a AND CFC12 SERVICE TOOLS ARE NOT INTER-

CHANGEABLE
In order to distinguish HFC134a service tools from those for CFC12

systems, the service tools for HFC134a systems have all been
changed.
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
GAS LEAK DETECTOR

Sensitivity of the gas leak detectors for CFC12 is low, therefore
they cannot be used to detect HFC134a.
A gas leak detector specifically for HFC134a or a suitable dual
CFC12/HFC134a detector must be used.
REFRIGERANT RECOVERY UNIT

Refer to the user's instruction manual for refrigerant recovery unit
handling and operation.
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
AIR CONDITIONER COMPONENTS
AC-3-1

PERFORMANCE CHART
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a INTAKE lever position: (Recirculation)
well-ventilated place)
Doors: Closed FAN switch: Max. speed
Door window: Open (Front driver side only) Engine speed: 1,000 rpm
TEMP. control lever position: Max. COLD Time required before starting testing after air con-
ditioner starts operating:
AIR control lever position: (Ventilation) More than 10 minutes
TEST READING
Recirculating-to-discharge air temperature graph
AC-4-1
Ambient air temperature-to-compressor pressure graph
AC-4-2
Recover refrigerant using refrigerant recovery &
Abnormal pressure recycling & recharging equipment and charge A
specified amount of refrigerant.
Both high and low-pressure sides are too high.
Check system pres- High-pressure side is too high and low-pressure

sure. side is too low.
High-pressure side is too low and low-pressure

Abnormal pressure side is too high.
Both high and low-pressure sides are too low.
A Check system pressure. Low-pressure side sometimes becomes negative.
Normal operation Low pressure side becomes negative.
Check compressor op- Malfunctioning temperature control operation

Normal air flow eration. (Air mix door position improperly adjusted)
INSUFFICIENT COOLING
Normal pressure
Malfunctioning water cock operation
(incorrect valve closure)
INSUFFICIENT COOL- Check air flow. Check magnet clutch

ING Abnormal operation or Magnet clutch does not engage (coil circuit, disc to pulley clearance).
not operating at all
Check electrical circuit (wiring, component circuit).
Activation of safety/protection devices

(such as pressure switch, etc.)
Normal operation
Malfunctioning internal parts of clutch, compres-
PERFORMANCE TEST DIAGNOSES
Clogged blower inlet/Clogged duct/Loose connec- sor

tion of duct/Air leakage, etc.
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
(Go to next page)

Malfunctioning blower motor internal circuit
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE

Whenever there is abnormal pressure of high and/or low sides of the system, diagnosis must be conducted by
using a manifold gauge. The large-line zone on the gauge scale (see illustrations.) shown in the following table
refers to the standard (normal) pressure range for the corresponding pressure side (high or low). Since the
standard (normal) pressure, however, differs from vehicle to vehicle, refer to the “Ambient air temperature-to-
compressor pressure table”.
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high and low-pressure z Pressure is reduced soon Excessive refrigerant Reduce refrigerant until
sides are too high. after water is splashed on charge in refrigeration cycle specified pressure is
condenser. obtained.
Air suction by radiator or Insufficient condenser cool- z Clean condenser.
condenser fan is insufficient. ing performance z Check and repair radiator
↓ or condenser fan as nec-
1 Condenser fins are essary.
clogged.
2 Improper rotation of cool-
ing fan or condenser fan
z Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser recharge system.
z When compressor is (After compressor operation
stopped high-pressure stops, high pressure
value quickly drops by decreases too slowly.)
approximately 196 kPa {2 ↓
kgf/cm2, 28 psi}. It then Air in refrigeration cycle
decreases gradually
thereafter.
Engine tends to overheat. Engine cooling systems Check and repair each
malfunction. engine cooling system.
z Areas near low-pressure z Excessive liquid refriger- Replace expansion valve.
pipe connection and ser- ant on low-pressure side
vice valves are consider- z Excessive refrigerant dis-
ably cold compared with charge flow
areas near expansion z Expansion valve is open a
valve outlet or evaporator. little compared with the
z Plates are sometimes cov- specification.
ered with frost. ↓
1 Improper thermal valve
installation
2 Improper expansion valve
adjustment
AC-4-4

High-pressure side is too Upper side of condenser High-pressure tube or parts z Check and repair or
high and low-pressure side and high-pressure side are located between compres- replace malfunctioning
is too low. hot, however, liquid tank is sor and condenser are parts.
not so hot. clogged or crushed. z Check compressor oil for
contamination.
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

Both high and low-pressure There is a big temperature Expansion valve closes a lit- z Remove foreign particles
sides are too low. difference between expan- tle compared with the speci- by using compressed air.
sion valve inlet and outlet fication. z Check compressor oil for
while the valve itself is ↓ contamination.
frosted. 1 Improper expansion valve
adjustment
2 Malfunctioning thermal
valve
3 Outlet and inlet may be
clogged.
Areas near low-pressure Low-pressure pipe is z Check and repair malfunc-
pipe connection and service clogged or crushed. tioning parts.
valve are extremely cold as z Check compressor oil for
compared with areas near contamination.
expansion valve outlet and
evaporator.
Air flow volume is not Evaporator is frozen. Replace compressor.
enough or is too low. ↓
Compressor discharge
capacity does not change.
(Compressor stroke is set at
maximum length.)
Low-pressure side some- z Air conditioning system Refrigerant does not dis- z Drain water from refriger-
times becomes negative. does not function and charge cyclically. ant or replace refrigerant.
does not cyclically cool ↓ z Replace liquid tank.
the compartment air. Moisture is frozen at expan-
z The system constantly sion valve outlet and inlet.
functions for a certain ↓
period of time after com- Water is mixed with refriger-
pressor is stopped and ant.
restarted.
AC-4-6

Low-pressure side becomes Liquid tank or front/rear side High-pressure side is closed After the system is left at
negative. of expansion valve’s pipe is and refrigerant does not rest, start it again in order to
frosted or dewed. flow. confirm whether or not prob-
↓ lem is caused by water or
Expansion valve or liquid foreign particles.
tank is frosted. z If the problem is due to
water, drain water from
refrigerant or replace
refrigerant.
z If it is due to foreign parti-
cles, remove expansion
valve and remove them
with dry and compressed
air.
z If either of the above
methods cannot correct
the problem, replace
expansion valve.
z Replace liquid tank.
z Check compressor oil for
contamination.
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
A/C does not blow cold air. 1 O O O O O O O O O O O O

Blower motor does not rotate. 1 2 O O O O O
Magnet clutch does not
engage when A/C switch and 1 2 O O O O O O O O
fan switch are ON.
1, 2 :The number means checking order.

O :As for checking order, refer to each flow chart. (It depends on malfunctioning portion.)
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)
Adjust or re- CHECK REFRIGERATION CYCLE CHECK VENTI-

place compres- PRESSURE WITH LATOR DUCT
sor belt. RECOVERY/RECYCLING EQUIP- FOR AIR
MENT CONNECTED. LEAKS.
Refer to Performance Chart.
NG OK
CHECK AMOUNT OF REFRIGER- Go to Perfor- CHECK THERMO CONTROL

ANT. mance Test AMP. OPERATION.
Check amount of refrigerant using Diagnoses.
refrigerant recovery & recharging
equipment.
OK NG
Evacuate sys- CHECK FOR

tem and re- REFRIGERANT
charge with re- LEAKS.
frigerant.
Go to Diagnostic Procedures 2.
CHECK AIR CONTROL CABLE AD- OK CHECK EVAPORATOR OUTLET

JUSTMENT. AIR TEMPERATURE.
NG
CHECK THERMO CONTROL

AMP. OPERATION.
AC-5-2
TROUBLE DIAGNOSES
MAIN POWER SUPPLY AND GROUND CIRCUIT

CHECK
POWER SUPPLY CIRCUIT CHECK FOR A/C SYSTEM
Check power supply circuit for air conditioning system.
Refer to “POWER SUPPLY” in EL section and “Wiring Dia-
gram”.
THERMO SWITCH CHECK

Check power supply circuit for thermo switch with ignition switch
ON.
1. Disconnect thermo switch harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. 1 and body ground.
Voltmeter terminal
Voltage
+ -
1 Body ground Approx. 24V
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
POWER SUPPLY CIRCUIT CHECK FOR HEATER SYS-

TEM
Check power supply circuit for heater system.
Refer to “POWER SUPPLY” in EL section and Wiring Dia-
gram.
DIAGNOSTIC PROCEDURE 1
SYMPTOM: BLOWER MOTOR DOES NOT ROTATE.
Flow chart
INCIDENT
No.
1 Fan fails to rotate.
z Perform PRELIMINARY CHECK before referring to the

following flow chart.
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.
and body ground?
OK
A
(Go to next page.)
AC-5-4
TROUBLE DIAGNOSES
Check circuit continuity between blower NG Reconnect blower motor

motor harness terminal No. 2 and body harness connector.
ground?
OK
CHECK BLOWER MOTOR.

(Refer to Electrical Components Inspec-
tion.)
NG
Replace blower motor.
CHECK BLOWER MOTOR CIRCUIT BE- NG Disconnect blower motor

TWEEN BLOWER MOTOR AND RESIS- and resistor harness con-
TOR. nector.
Does battery voltage exist between resis-
tor harness terminal No. 1 and body
ground?
OK
NOTE
Check circuit continuity
between blower motor har-
resistor harness terminal
No. 1.
(Go to next page.)

NOTE
z If the result is NG after checking circuit continuity, repair
AC-5-5
TROUBLE DIAGNOSES
B
CHECK RESISTOR AFTER DIS-
CONNECTING IT.
(Refer to Electrical Components C
Inspection.)
D
OK NG
Replace resistor.
Reconnect resistor harness con- E
nector.
CHECK FAN SWITCH CIRCUIT.

each fan switch harness terminal and
body ground?
Terminal No.
Flow chart No. Voltage
+ -
2
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
CHECK FAN SWITCH AFTER NG Replace fan switch.

DISCONNECTING IT.
Inspection.)
OK
NOTE
Check circuit continuity between
fan switch harness terminal No. 6
and body ground?
NOTE
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.
CHECK POWER SUPPLY FOR COM- NG CHECK COOLER PRES-

PRESSOR. SURE SWITCH.
Disconnect compressor harness connector. OK NG
Do approx. 24 volts exist between com-
pressor harness terminal and body
ground?
OK
Check magnet clutch coil. Replace

OK cooler pres-
sure switch.
Replace magnet clutch.

Refer to COMPRESSOR — Model DKS-
15CH.
NOTE
Check circuit continuity between compres-
sor relay harness terminal No. 3 and
cooler pressure switch harness terminal
No. 1.
OK
A
(Go to next page.)
NOTE
AC-5-7
TROUBLE DIAGNOSES
CHECK POWER SUPPLY FOR COM- NG CHECK POWER SUPPLY

PRESSOR RELAY. CIRCUIT AND 15A FUSE AT
Disconnect compressor relay. FUSE BLOCK.
Do approx. 24 volts exist between
compressor relay harness terminal No.
5 and body ground?
OK
CHECK POWER SUPPLY FOR COM- NG CHECK POWER SUPPLY

PRESSOR RELAY. CIRCUIT AND 15A FUSE AT
Do approx. 24 volts exist between FUSE BLOCK.
compressor relay harness terminal No. (Refer to “POWER SUPPLY”
1 and body ground? in EL section and Wiring Dia-
gram.)
OK
CHECK COMPRESSOR RELAY AF- NG Replace compressor relay.

TER DISCONNECTING IT.
Refer to Electrical Components Inspec-
tion.
OK
Reconnect compressor relay.

OK
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
(Go to next page.)

NOTE
AC-5-8
TROUBLE DIAGNOSES
CHECK POWER SUPPLY FOR THERMO

SWITCH
Go to Main Power Supply and Ground
Circuit Check.
OK
CHECK BODY GROUND CIRCUIT FOR NG Disconnect A/C switch har-

THERMO SWITCH ness connector.
Disconnect thermo switch harness con-
nector.
Does continuity exist between thermo
switch harness terminal No. 2 and body
NOTE
ground?
Check circuit continuity be-
OK tween thermo switch har-
A/C switch harness termi-
nal No. 1.
OK
Replace thermo switch.
CHECK A/C SWITCH. NG Replace A/C switch.

OK
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
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
CHECK FAN SWITCH.

NG
Replace fan switch.
NOTE
AC-5-10
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
AC-6-1
A/C WIRING
A/C WIRING
AC-7-1
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.
Do not mistake refrigerants

If an HFC134a air conditioner system is mistakenly charged with
CFC12, serious problems, such as compressor seizing, can result.
Therefore, confirm before charging with refrigerant that the type of
air conditioner system is in fact an HFC134a system.
Countermeasures to avoid charging with the wrong refrigerant have
been taken. These include different shaped service valves, different
service tool thread sizes, and caution stickers and labels.
Do not release into the air

Although HFC134a is not subject to CFC regulations, it can have
an effect on global warming, and so should not be released into the
air. When removing refrigerant from the air conditioner system,
always use a refrigerant recovery unit made especially for
HFC134a.
AC-8-1
TOOL CONNECTIONS
AC-8-2
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
Leave for 5 - 10 min
Check air tightness Not airtight

Repair
Airtight
Evacuate for at least 20 min
Charge with refrigerant until the low-

pressure gauge reaches 196 kPa {2
kgf/cm2, 28 psi}.
Leaks found
Check for leaks
No leaks
Charge with specified quantity of refrig-

erant
Leaks found
Recheck for leaks
No leaks
System satisfactory
AC-8-3
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
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.
INITIAL LEAK CHECK

Using the leak detector, check the system connections for leaks.
NOTE
z As the system pressure is not yet high, only large leaks
can be detected as this time.
CHARGING
Begin charging and charge the remainder of the specified charge,
referring to the weight scale.
CAUTION
z Do not overcharge the system.
Specified refrigerant charge:

6.86 N {0.7 kgf, 1.54 lbf}
AC-8-5
LEAK INSPECTION
INSPECTION PROCEDURE
To facilitate refrigerant leak detection, operate the air conditioner at

the full cooling setting with the fan running at maximum speed for at
least 5 minutes.
Initial inspection
Stop the engine and, using a leak detector, check for refrigerant
leaks on the high pressure side.
This must be done immediately because when the refrigerant stops
circulating, the high pressure side pressure decreases gradually, as
shown in the graph at right, while the low pressure side pressure
increases gradually.
AC-8-6
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
4. Always use a backup spanner when tightening nuts. Use a

torque spanner on the side to be tightened.
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}
STANDARD PIPE TIGHTENING TORQUES

Bolt and screw sizes
Example 1
Bolt; M10, L = 40
M10 bolt
Length = 40 mm
Example 2
Screw; M4, L = 10
M4 screw
Length = 10 mm
Outer dia. (mm) Tightening torque N·m {kgf·m, ft·lbf}
8 - 10 9.8 - 20 {1.0 - 2.0, 7.2 - 14}
12 15 - 25 {1.5 - 2.5, 11 - 18}
16 20 - 29 {2.0 - 3.0, 14 - 22}
19 25 - 34 {2.5 - 3.5, 18 - 25}
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
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.
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
COOLER PRESSURE SWITCH & RELIEF VALVE

COOLER PRESSURE SWITCH
INSPECTION
Check the switch function referring to the table below.
Unit: MPa {kgf/cm2, psi}
High pressure side line pressure Operation
Decreasing to 0.18 {1.8, 26}
Turns OFF
Increasing to 2.65 {27, 384}
Increasing to 0.19 {1.9, 27}
Turns ON
Decreasing to 1.47 {15, 213}
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
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.
2. Check the fittings for cracks or scratches.

Repair or replace if necessary.
CAUTION
z If the evaporator is replaced with a new unit, add com-
pressor oil to the compressor.
AC-13-1
EVAPORATOR
THERMOSTAT
INSPECTION
Using an electric circuit tester, check for continuity between the ter-
minals.
Position the thermostat capillary tube as shown below.
AC-13-2
COMPRESSOR
COMPRESSOR
SERVICE TOOLS
Tool name and
number Description Shape
(Kent-Moore No.)
Clutch disc wrench Removing center bolt
J-41260
Clutch disc puller Removing clutch disc

J-38874
Pulley installer Installing pulley

J-41261
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
1. Bolt 4. Snap ring 7. Field coil screw

2. Clutch disc 5. Pulley assembly 8. Compressor unit
3. Shim 6. Field coil
AC-14-3
COMPRESSOR
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
1. Install the compressor using the mounting bolts.

2. Install the compressor drive belt.
3. Adjust the belt tension using the tension pulley.
4. Connect the two hoses to the compressor.
5. Connect the clutch connector to the vehicle harness.
6. Connect the battery ground cable.
7. Evacuate, charge and test the refrigeration system (see
pages AC-8-2 - AC-8-6).
AC-14-5
COMPRESSOR
COMPRESSOR DRIVE BELT

1. Inspect the belt for cracks or damage. The belts should not
contact the bottom of the pulley grooves.
2. Check belt tension as shown below.
Belt adjustment
at a force of 98 N {10 kgf, 22 lbf}
Deflection
mm in
7 - 12 0.28 - 0.47
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.
2. Rotate the clutch disc several times by hand to distribute

any oil which has settled in the cylinders.
3. When installing on an in-service system, the compressor
must be installed after adjusting the oil charge (refer to page
AC-14-8).
When installing the compressor on a new system, it should
be installed as it is.
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.
STORING A REPAIRED COMPRESSOR

If it is necessary to store a repaired compressor for some time
before installation, evacuate the compressor and fill it with refriger-
ant or dry nitrogen gas through the suction fitting to raise the pres-
sure to 49 to 147 kPa {0.5 to 1.5 kgf/cm2, 7.1 to 21 psi}.
The compressor must be stored within the range shown in the left
hand figure.
If stored outside this range, turn the compressor's magnetic clutch 5
or 6 times by hand before installation.
OIL HANDLING
OIL SPECIFICATION
Use only ZXL 100PG refrigeration oil.
ZEXEL part number: 569900-0600
OIL INSPECTION INTERVAL

There is no particular need for frequent inspection or replacement,
although the oil must be inspected or replaced in the following
cases.
z At the start of the season.
z Every 5,000 km (3,200 miles) or every 5 months for com-
mercial vehicles and vehicles that are in constant use.
z When gas leaks from hoses or pipes.
z When gas or oil leaks from the compressor.
z When there is any compressor malfunction other than the
above.
z When the evaporator, condenser or receiver drier is
replaced.
z When refrigerant is suddenly discharged from the system
(when the relief valve, etc., operate).
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.
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
6. Install the oil plug and tighten it to the specified torque.

Specified torque:14 - 16 N·m
{1.4 - 1.6 kgf·m, 10 - 12 ft·lbf}
CAUTION
z The oil plug O-ring must be replaced with a new one.
REPLACEMENT OF COMPONENT PARTS

When replacing the system's component parts, supply the following
amount of oil to the compressor.
Component parts to be mounted Amount of oil
Evaporator 50 (1.8)
Condenser 30 (1.1)
Receiver drier 30 (1.1)
Pipe or hose 10 (0.4)
After installing these component parts, check the compressor oil.

Refer to page AC-14-8.
AC-14-9
COMPRESSOR
OIL RETURN OPERATION

Compressor oil mixed with refrigerant is circulated in the refrigera-
tion system.
Perform the oil return operation to return this oil to the compressor
before removing components from the system.
1. Open the doors and operate the blower motor at maximum
speed.
2. Operate the vehicle engine at idling for at least 20 minutes.
NOTE
z The maximum amount of oil cannot be recovered at other
speeds.
REFRIGERANT CHARGE INSPECTION

As shown in the left hand figure, HFC134a compressor oil will not
blend with refrigerant (HFC134a) at certain temperatures. At these
temperatures, the refrigerant may appear “cloudy” when checked
using the sightglass, and the charge may be mistakenly judged as
insufficient.
AC-14-10
COMPRESSOR
TIGHTENING TORQUES

Part Thread size Tightening torque
1. Bolt M8 x 1.0 14 - 16 {1.4 - 1.6, 10 - 12}
2. Field coil screw M5 x 0.8 3.9 - 5.9 {0.4 - 0.6, 2.9 - 4.3}
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.
2. Remove the clutch disc using the puller (J-38874).

Remove the shims from the compressor drive shaft or
armature assembly.
3. Remove the snap ring using external snap ring pliers.
4. Remove the pulley assembly using a suitable pulley puller.
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.
3. Install the pulley assembly using the pulley installer (J-

41261) and a hand press.
4. Install the snap ring (beveled edge down) using external
snap ring pliers.
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
7. Check that the clutch clearance is as specified. If necessary

adjust the clearance using shim(s).
Adjusting shims are available in the following thicknesses:
Shim Part No. Thickness
596541-0000 0.1 mm (0.004 in)
596541-0100 0.3 mm (0.012 in)
596541-0200 0.5 mm (0.020 in)
596541-0300 0.8 mm (0.031 in)
596541-0500 2.2 mm (0.087 in)
Specified clearance: 0.3 - 0.6 mm (0.012 - 0.024 in)
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)
Pitch angle 15º

Kingpin used (f)
50.8 (2.000)
SERVICE DATA
Unit: mm (in)
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
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
1. Use a crane or a hoist for disassembling. Remain safety
conscious. Before starting disassembly, clean each portion
of the assembly.
2. Before disassembling the coupler assembly, measure the

clearance between the coupler base and jaw pin. If the
clearance exceeds the service limit, replace the coupler
base with a new one.
Unit: mm (in)
2.0 - 3.0 (0.079 - 0.118) 0.5 (0.020)
3. Make sure the jaw is completely closed (The lock guard is

disengaged from the jaw or the hole in the coupler base is
plugged completely with the stopper rod). After that, turn
over the coupler (with the sliding surface of the coupler
base facing down).
CP-3-1
DISASSEMBLY
DISASSEMBLY
CP-3-2
DISASSEMBLY

1. Bolt 19. Plain washer 36. Limit switch
2. Nut 20. Roller 37. Limit dog
3. Earth wire 21. Cotter pin , 38. Adjusting nut
4. Sub base 22. Castellated nut 39. Plain washer
5. Bracket 23. Plain washer 40. Rubber
6. Base spring 24. Roller 41. Yoke spring
7. Bolt 25. Plain washer 42. Yoke shaft
8. Lock washer 26. Bolt 43. Yoke
9. Clamp 27. Lock spring 44. Snap pin
+ 10. Shim 28. Spring pin 45. Lock guard pin
+ 11. Cushion rubber , 29. Secondary lock 46. Lock guard spring
+ 12. Cushion rubber 30. Cam plate , 47. Lock guard
13. Lever spring 31. Plain washer 48. Cotter pin
14. Lever 32. Nut 49. Jaw pin
15. Spring (model CP-1320 only) 33. Lock washer 50. Jaw spring
16. Bolt 34. Bolt 51. Jaw
17. Square lock washer 35. Switch bracket 52. Coupler base
18. Bolt

10 Shim and 11 , 12 Cushion rubber
When replacing the cushion rubber, make sure shims are properly
installed between the clamp and coupler base and confirm the
number of shims.
CP-3-3
INSPECTION
INSPECTION
Kingpin O.D.
Unit: mm (in)
50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961)
Diameter of jaw at kingpin location

Unit: mm (in)
51.0 - 51.2 (2.008 - 2.016) 52.0 (2.047)
Clearance between jaw and kingpin

Unit: mm (in)
0.1 - 0.5 (0.004 - 0.020) 2.0 (0.079)
Diameter of jaw pin hole

Unit: mm (in)
28.8 (1.134) 29.5 (1.161)
Jaw pin O.D.

Unit: mm (in)
28.6 (1.126) 28.3 (1.114)
CP-4-1
INSPECTION
Clearance between jaw and jaw pin

Unit: mm (in)
0.18 - 0.20 (0.0071 - 0.0079) 0.5 (0.020)
Clearance between jaw pin head and upper surface of

coupler base
Unit: mm (in)
2.0 - 3.0 (0.0079 - 0.118) 0.5 (0.020)
Cushion rubber
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
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.
47 Lock guard and 29 Secondary lock

When installing the secondary lock and lock guard, apply grease to
the pins. Make sure they operate smoothly.
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)
Diameter of jaw at
kingpin location 51.0 - 51.2
52.0 (2.047)
(2.008 - 2.016)
INSPECTION AFTER ASSEMBLY

1. Make sure that the latch is properly engaged with the lever
pulled.
2. Make sure that the jaw moves smoothly by hand. If neces-
sary, apply grease to the parts involved.
3. Ensure that the latch spring is installed properly.
4. Ensure that the lock handle moves properly.
5. Ensure that the bolts and nuts are tight in place.
6. Ensure that the coupler base pitches and rolls properly with
the wedge at standstill.
7. Check all parts for proper installation.
8. Check the lubrication points to ensure that they are lubri-
cated properly.
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

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TRUCK (CHASSIS)

MK, LK, PK, CDA

ENGINE REMOVAL & INSTALLATION ER

FM edition: Mar. 2005

X This Service Manual is designed as a guide for servicing vehicles.

X This manual deals with the engine and chassis.

X SERVICE DATA AND SPECIFICATIONS are contained in each section.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

X The following marks and abbreviations are used in this manual.

Coil spring type

Unit name SRHF-3 SRHF-3

Unit name RS55 RS55

Toe-in Bias tire 1 (0.04) 1 (0.04)

Caster 3º20c 3º20c

Air over hydraulic Vacuum servo

Front BHS32 BHS32

Unit name — CB52 CB52

Parking brake Spring-activated Mechanical,

Unit name SRHF-3 SRHF-3

Unit name CB52 — CB52

Model FE6T FE6TA FE6B FE6T

Coil spring type Coil spring type

Operated by: — Air servo Air servo Air servo

Disc O.D. mm (in) — 350 (13.78) 350 (13.78) 350 (13.78)

Operation Floor-shift Floor-shift Floor-shift

P/S - D/F PS860

Unit name RS55 RS65 RS75

Unit name FA35 FA35 FA35

Toe-in Bias tire 1 (0.04) 1 (0.04) 1 (0.04)

Unit name CB52 CB52 CB52

Parking brake Mechanical, drive line parking brake Spring-activated

Auxiliary brake Exhaust brake

Model FE6TA FE6TA FE6B FE6T

Type Coil spring type single disc, dry

P/S - D/F PS860 PS420

Unit name SRHH-2 SRHL-1

Unit name FA35 FA35

Type Inboard type Inboard type

Steer angle (Inner x Outer) 44º x 35º 36º x 30º

Front BHS37 or FB52 BHS37 FB52 FB52 or FB37

Brake system Air pressure governor Pressure regulating

Unit name CL710 CL740 CL740

P/S - D/F PS420

Unit name SRHL-1

Type Outboard type

Type Piston type

Brake system Air pressure governor Pressure regulating

Auxiliary brake Exhaust brake

CL740 CL750: (MPS62T)

Clutch Type Coil spring type single disc, dry

Operated by: Air servo Air servo

Disc O.D. mm (in) 350 (13.78) 350 (13.78) 350 (13.78)

P/S - D/F PS430 PS420 PS420

Unit name SRHL-1 SRHL-1 SRHL-1

Unit name FA50 FA50

Type Inboard type Inboard type

Bias tire 0 - 4 (0 - 0.16) 0 - 4 (0 - 0.16)

Front axle Camber 1º00c 1º00c

Unit name CB41 — CB41 — CB41 (MPS62T T/M)

Unit name CL710 CL810 CL810 CL810

MPS50W MPS62T MPS62T

Unit name SRHL-1 SRHL-1

Unit name RS1A RS1A

Unit name FA50 FA50