TRUCK (CHASSIS)

MODEL

CK, CW, CD
AND CG SERIES

Pub.No. SMCA450E02
TRUCK(Chassis) QUICK REFERENCE INDEX

SERVICE MANUAL GENERAL GE

MAINTENANCE MA

TROUBLE DIAGNOSIS TD

ENGINE REMOVAL & INSTALLATION ER

CLUTCH SYSTEM CL

FOREWORD TRANSMISSION TM
This manual describes the service, by system, of
the chassis of heavy duty trucks CK, CW, CD and CG PROPELLER SYSTEM PS
series.
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be performed DIFFERENTIAL DF
properly. Also, overhaul and repair should be effected
in accordance with prescribed service standards.
This manual should be kept readily available in the REAR AXLE AND SUSPENSION RA
workshop as a helpful reference for those engaged in
servicing vehicles. Nissan diesel Motor Co., Ltd.
reserves the right to make changes for improvement FRONT AXLE AND SUSPENSION FA
at any time without notice.
This manual is based on vehicles that were manu- TIRE AND WHEEL TW
factured on or before November. 1, 1995. Revisions,
if any, will be introduced in the Technical Bulletin.
STEEERING SYSTEM ST

BRAKE SYSTEM BR

ELECTRICAL SYSTEM EL

CAB BODY CB

COUPLER CP

0707-14702-S
© 2005 NISSAN DIESEL MOTOR CO, LTD 0502K1D-14702-pdf-S
 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.

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.

-2-
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
CK series: CKA, B, C450 L.H.D. model: Left-hand drive model
CKA530 AOH brake: Air over hydraulic brake
CKB453, 520, 533 Air brake: Full air brake
CW series: CWA520, 530 O.D.: Outside diameter
CWB450, 451, 452, 453, 520, I.D.: Inside diameter
530, 533 Dia.: Diameter
CWC450, 610
CD series: CDA450 S.T.D.: Standard
CG series: CGB450, 520, 533 O.S.: Oversize
LH, RH: Left-Hand, Right-Hand U.S.: Undersize
R.H.D. model: Right-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-
 GE

GENERAL

CONTENTS
SPECIFICATIONS .............................. GE-1-1 TIGHTENING TORQUE OF
IDENTIFICATION ............................... GE-2-1 STANDARD BOLTS........................... GE-6-1
LIFTING POINT .................................. GE-3-1 LUBRICATION ................................... GE-7-1
TOWING ............................................. GE-4-1
GENERAL PRECAUTIONS
ON SERVICING.................................. GE-5-1
 SPECIFICATIONS

SPECIFICATIONS
Vehicle model CKA Series CKB Series
Item CKA450-BT CKA530-BT CKB450 CKB450-BT
Mode PF6TB RG8 PF6 PF6TA PF6T PF6TA
Engine Max. gross out put (JIS) 257 {350}/ 257 {350}/ 173 {235}/ 235 {320}/ 235 {320}/
213 {290}/2,100
kw {PS/rpm} 2,100 2,200 2,100 2,100 2,100
Unit name CL420 CL640 CL535 CL420 CL635 CL420
Type Coil spring type single disc, dry (CL420: Coil spring type twin disc, dry)
Clutch Operated by: Air servo
380 430 410 380 430
Disc O.D. mm (in) 380 (14.96)
(14.96) (16.93) (16.14) (14.96) (16.93)
MTS60B
MPS50A MTS60A MTS60A
MTS60D
Transmis- Unit name (Manual Transmission) MTS60A RTX11609A RTX11609A RT11715 RTX11609A
MTS70A
sion RTX11609B RTX11710B RTX11710B
MRT20A
Operation Floor shift

Propeller T/M - D/F PS520 PS430 (MPS50A) PS580 PS520

Unit name
shaft D/F - D/F
Unit name SRHQ-2 SRHP-1 SRHQ-2
Differential
Gear type Hypoid
Rear axle Unit name RS1A RS1B RS1A
Unit name FA50
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)

Front axle Camber 1°

Caster 3°20’
Kingpin inclination 7°
Steer angle 50° x 38°
Tire &
Tire size Refer to the “Tire and wheel size table” section
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-26

system model JKC 446-02560
Unit name
L.H.D. NPS PSI-Y100-21
model JKC 446-02563
Type Full air brake on all wheel, internal expanding and trailing shoe type
Front BAL41
Wheel brake
Rear BPL41
Air pressure Type Piston type
governor
Pressure regulat-
Brake sys- kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
tem ing range
psi}
CB31 (MPS50A)
Unit name
CB41
Parking brake
Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Semi-elliptic two stage leaf spring

GE-1-1
 SPECIFICATIONS

Vehicle model CKB Series CKC Series

Item CKB450-CT CKB453-BT CKB520-BT CKB533-BT CKC450 CKC450-DT
Mode PF6T PF6TA PF6TB RF8 RG8 PF6T PF6TA
Engine Max. gross out put (JIS) 213 {290}/ 235 {320}/ 257 {350}/ 250 {340}/ 257 {350}/ 213 {290}/ 235 {320}/
kw {PS/rpm} 2,100 2,100 2,100 2,200 2,200 2,100 2,100
CL420
Unit name CL420 CL635 CL640 CL635 CL420
CL635
Coil spring type single disc, dry
Type
Clutch (CL420: Coil spring type twin disc, dry)
Operated by: Air servo
380 (14.96): CL420 430 380
Disc O.D. mm (in) 430 (16.93)
430 (16.93): CL635 (16.93) (14.96)
MTS60A MTS60A MTS60A
Transmis- Unit name (Manual Transmission) RT011609A MRT20A
RTX11609A MRT20A RTX11609A
sion
Operation Floor shift

Propeller T/M - D/F PS580 PS520

Unit name
shaft D/F - D/F
Unit name SRHQ-2 SRHP-1 SRHQ-2
Differential
Gear type Hypoid
Rear axle Unit name RS1A RS1D
Unit name FA50 FA60
Toe-in Bias tire 2 (0.08) 2 (0.08)
mm (in) Radial tire 0 (0) 0 (0)

Camber 1° 1°
Front axle
Caster 3°20’ 3°20’
Kingpin inclination 7° 7°
42° x3 3°
Steer angle 50° x 38°
40° x 32° (Trilex)
Tire &
Tire size Refer to the “Tire and wheel size table” section
wheel
Type Integral power steering
Gear box Recirculating ball screw type

R.H.D. NPS PSI-Y100-26

Steering model JKC 446-02560
system
Unit name PSI-Y100-
NPS PSI-Y100-21 PSI-Y100-21
L.H.D. 21
model 446-
JKC 446-02563 446-02563
02563
Type Full air brake on all wheel, internal expanding and trailing shoe type
Front BAL41 FB43
Wheel brake
Rear Front BPL41 RB41
Air pressure Type Piston type
governor
Brake sys- Pressure regulat-
tem kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Semi-elliptic two stage leaf spring

GE-1-2
 SPECIFICATIONS

CWA
Vehicle model CWB Series
Series
Item CWA530 CWB450 CWB450-PP
Mode RG8 PF6T PF6TA PF6T PF6TB
Engine Max. gross out put (JIS) 257 {350}/ 213 {290}/ 257 {350}/
213 {290}/2,100 235 {320}/2,100
kw {PS/rpm} 2,200 2,100 2,100
Unit name CL640 CL635 CL420 CL640 CL420
Coil spring type single disc, dry
Type
(CL420: Coil spring type twin disc, dry)
Clutch
Operated by: Air servo
430 430 380 430
Disc O.D. mm (in) 380 (14.96)
(16.93) (16.93) (14.96) (16.93)
MTS60A RTX11609B MTS60A RTX11609B
RT11715
Transmis- Unit name (Manual Transmission) MTS60A RTX11609B RT11715 RTX11609B RT11715
RT14915
sion RTX11710B RTX11710B RTX11710B RTX11710
Operation Floor shift
PS520 (MTS60A)
Propeller T/M - D/F PS520 PS520 PS580 PS590
Unit name PS580
shaft
D/F - D/F PS430
IPHM-2
Unit name
Differential SRHM-2
Gear type Hypoid
Rear axle Unit name RW1A (Rear front) RW1A (Rear rear)
Unit name FA50
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)

Front axle Camber 1°

Caster 3°20’
Kingpin inclination 7°
Steer angle 50° x 38°
Tire &
Tire size Refer to the “Tire and wheel size table” section.
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-26

system model JKC 446-02560
Unit name
L.H.D. NPS PSI-Y100-21
model JKC 446-02563
Air over
Type hydraulic Full air brake on all wheels, Internal expanding and trailing shoe type
brake
Front BHL41 BAL41
Wheel brake
Rear Front BLL41 BPL41
Air pressure Type Piston type
Brake sys- governor
tem Pressure regulat-
kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Trunnion-mounted, Semi-elliptic leaf spring, With torque rods

GE-1-3
 SPECIFICATIONS

Vehicle model CWB Series

Item CWB450-HT CWB450-KT
Mode PF6T PF6TA PF6TB PF6T PF6TA PF6TB
Engine Max. gross out put (JIS) 213 {290}/ 235 {320}/ 257 {350}/ 213 {290}/ 235 {320}/ 257 {350}/
kw {PS/rpm} 2,100 2,100 2,100 2,100 2,100 2,100
Unit name CL635 CL420 CL635 CL420
Coil spring type single disc, dry
Type
(CL420: Coil spring type twin disc, dry)
Clutch
Operated by: Air servo
430 430
Disc O.D. mm (in) 380 (14.96) 380 (14.96)
(16.93) (16.93)
RTX11609B RT011613
RT011613
Transmis- Unit name (Manual Transmission) RT11715 RT011609A
RT11715
sion RT14915 RT11715
Operation Floor shift
PS580
Propeller T/M - D/F
Unit name PS590 (RT11715)
shaft
D/F - D/F PS430
IPHM-2
Unit name
Differential SRHM-2
Gear type Hypoid
RW1A (Rear front)
Rear axle Unit name
RW1A (Rear rear)
Unit name FA50
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)

Front axle Camber 1°

Caster 3°20’
Kingpin inclination 7°
Steer angle 50° x 38°
Tire &
Tire size Refer to the “Tire and wheel size table” section.
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-26

system model JKC 446-02560
Unit name
L.H.D. NPS PSI-Y100-21
model JKC 446-02563
Type Full air brake on all wheels, Internal expanding and trailing shoe type
Front BAL41
Wheel brake
Rear Front BPL41
Air pressure Type Piston type
governor
Brake sys- Pressure regulat-
tem kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Trunnion-mounted, Semi-elliptic leaf spring, With torque rods

GE-1-4
 SPECIFICATIONS

Vehicle model CWB Series

Item CWB451-KT CWB452-HT CWB453-HT
Mode PF6T PF6TB PF6T PF6TB
Engine Max. gross out put (JIS) 213 {290}/ 257 {350}/ 213 {290}/
257 {350}/2,100
kw {PS/rpm} 2,100 2,100 2,100
Unit name CL420 CL640 CL420
Coil spring type single disc, dry
Type
(CL420: Coil spring type twin disc, dry)
Clutch
Operated by: Air servo
430
Disc O.D. mm (in) 380 (14.96) 380 (14.96)
(16.93)
RT011613
Transmis- Unit name (Manual Transmission) RT11715 RT011609A MRT20A
sion RT11715
Operation Floor shift

Propeller T/M - D/F PS590 PS580

Unit name
shaft D/F - D/F PS430
IPHM-2
Unit name
Differential SRHM-2
Gear type Hypoid
RW1A (Rear front)
Rear axle Unit name
RW1A (Rear rear)
Unit name FA50
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)

Front axle Camber 1°

Caster 3°20’
Kingpin inclination 7°
Steer angle 50° x 38°
Tire &
Tire size Refer to the “Tire and wheel size table” section.
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-26

system model JKC 446-02560
Unit name
L.H.D. NPS
model JKC
Type Full air brake on all wheels, Internal expanding and trailing shoe type
Front BAL41
Wheel brake
Rear Front BPL41
Air pressure Type Piston type
governor
Brake sys- Pressure regulat-
tem kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled
Type
spring brake operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Trunnion-mounted, Semi-elliptic leaf spring, With torque rods

GE-1-5
 SPECIFICATIONS

Vehicle model CWB Series CWC Series

Item CWB520 CWB520-HT CWB533 CWC450 CWC450-KTCWC610-KT
Mode RF8 RG8 PF6TA RE10
Engine Max. gross out put (JIS) 257 {350}/ 272 {370}/
250 {340}/2,200 235 {320}/2,100
kw {PS/rpm} 2,200 2,200
Unit name CL635 CL640 CL420
Coil spring type single disc, dry
Type
(CL420: Coil spring type twin disc, dry)
Clutch
Operated by: Air servo
430
Disc O.D. mm (in) 430 (16.93) 380 (14.96)
(16.93)
RTX11609B MTP00B MTS60A MTS60A
MTS60A RTX11609B
Transmis- Unit name (Manual Transmission) RT11715 RTX11609B MRT20A RTX11609A RT11715
RTX11609A RT11715
sion RTX11710B RT11715 RTX11609B RTX11710B
Operation Floor shift
PS520 (MTS60A) PS520 (MTS60A)
Propeller T/M - D/F PS520
Unit name PS580 PS580
shaft
D/F - D/F PS430
IPHM-2
Unit name
Differential SRHM-2
Gear type Hypoid
RW1A (Rear front)
Rear axle Unit name
RW1A (Rear rear)
Unit name FA50 FA60
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)
Camber 1°
Front axle
Caster 3°20’
Kingpin inclination 7°
42° x 33°
Steer angle 50° x 38°
40° x 32° (Trilex)
Tire &
Tire size Refer to the “Tire and wheel size table” section.
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-26

system model JKC 446-02560
Unit name
L.H.D. NPS PSI-Y100-21 PSI-Y100-21
model JKC 446-02563 446-02563
Type Full air brake on all wheels, Internal expanding and trailing shoe type
Front BAL41 FB43
Wheel brake
Rear Front BPL41 BPL41
Air pressure Type Piston type
governor
Brake sys- Pressure regulat-
tem kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Trunnion-mounted, Semi-elliptic leaf spring, With torque rods

GE-1-6
 SPECIFICATIONS

Vehicle model CGB Series CDA Series

Item CGB450 CGB450-TP CGB520 CGB533 CDA450-RH
Model PF6TA PF6TB RF8 RG8 PF6TA
Engine Max. gross out put (JIS) 235 {320}/ 257 {350}/ 250 {340}/ 257 {350}/
235 {320}/2,100
kw {PS/rpm} 2,100 2,100 2,200 2,200
Unit name CL635 CL420 CL635 CL640 CL640
Coil spring type single disc, dry
Type
Clutch (CL420: Coil spring type twin disc, dry)
Operated by: Air servo
Disc O.D. mm (in) 430 (16.93) 380 (14.96) 430 (16.93) 430 (16.93)
MTP00B
RT011613 RTX11609A MTS60A MTS60B
Transmis- Unit name (Manual Transmission) RT11715
RTX11609A RTX11609B MRT20A MTS70A
sion RT11715
Operation Floor shift

Propeller T/M - D/F PS580 PS590 PS580 PS480

Unit name
shaft D/F - D/F PS430
IPHM-2
Unit name SRSP-1
Differential SRHM-2
Gear type Hypoid
RD1A
RW1A (Rear front) (Rear front)
Rear axle Unit name
RW1A (Rear rear) RD60
(Rear rear)
Unit name FA50
Toe-in Bias tire 2 (0.08)
mm (in) Radial tire 0 (0)

Front axle Camber 1°

Caster 3°20’
Kingpin inclination 7°
Steer angle 50° x 38°
Tire &
Tire size Refer to the “Tire and wheel size table” section.
wheel
Type Integral power steering
Gear box Recirculating ball screw type

Steering R.H.D. NPS PSI-Y100-36

system model JKC 446-2586
Unit name
L.H.D. NPS PSI-Y100-21
model JKC 446-02563

Full air brake on all wheels, Internal expanding and trailing

Type Air over hydraulic brake
shoe type
Front BAL41 BHL41
Wheel brake
Rear Front BPL41 BLL41
Air pressure Type Piston type
Brake sys- governor
Pressure regulat-
tem kPa {kgf/cm2, 706 - 834 {7.2 - 8.5, 102 - 121}
ing range
psi}
Unit name CB41
Parking brake Mechanically operated by hand brake lever or pneumatically controlled spring brake
Type
operated by gradual control valve
Auxiliary brake Exhaust brake

Suspen- Front Semi-elliptic leaf spring

Type
sion Rear Trunnion-mounted, Semi-elliptic leaf spring, With torque rods

GE-1-7
 SPECIFICATIONS

Tire & wheel size table

Applicable model Tire & wheel size
10.00-20-14 (7.00T x 20-162-12T)
10.00-20-16 (7.00T x 20-162-12T)
11.00-20-14 (7.50V x 20-165-12T)
11.00-20-16 (7.50V x 20-165-12T)
11R22.5-14 (7.50 x 22.5-162-12T)
CKA, CKB, CDA, CWB Series
12R22.5-14 (8.25 x 22.5-165-13T)
(Except for Australia and New
11R22.5-16 (7.50 x 22.5-162-12T)
Zealand)
12R22.5-16 (8.25 x 22.5-165-13T)
10.00R-20-14 (7.00T x 20-162-12T)
10.00R-20-16 (7.00T x 20-162-12T)
11.00R-20-14 (7.50V x 20)
11.00R-20-16 (7.50V x 20)
CKB, CWB Series 11R22.5-16 (8.25 x 22.5-165-13TCS)
(For Australia and New Zealand) 10.00R-20-16 (7.50 x 20-165-12TCS)
12.00-20-16 (8.50V x 20-180)
12.00-20-18 (8.50V x 20)
CKC, CWC Series 12.00R-20-16 (8.50V x 20-180)
12.00R-20-18 (8.50V x 20)
12.00R-20-18 (8.50V x 20)
10.00-20-16 (7.00T x 20-162-12T)
11.00-20-14 (7.50V x 20-165-12T)
11.00-20-16 (7.50V x 20-165-12T)
11R22.5-14 (7.50 x 22.5-162-12T)
12R22.5-14 (8.25 x 22.5-165-13T)
CWA Series 11R22.5-16 (7.50 x 22.5-162-12T)
12R22.5-16 (8.25 x 22.5-165-13T)
10.00R-20-14 (7.00T x 20-162-12T)
10.00R-20-16 (7.00T x 20-162-12T)
11.00R-20-14 (7.50V x 20)
11.00R-20-16 (7.50V x 20)

GE-1-8
 SPECIFICATIONS

Tire & wheel size table

Applicable model Tire & wheel size
10.00-20-14 (7.00T x 20-162-12T)
10.00-20-16 (7.00T x 20-162-12T)
11.00-20-14 (7.50V x 20-165-12T)
11.00-20-16 (7.50V x 20-165-12T)
11R22.5-14 (7.50 x 22.5-162-12T)
CKA, CKB, CDA, CWB Series
12R22.5-14 (8.25 x 22.5-165-13T)
(Except for Australia and New
11R22.5-16 (7.50 x 22.5-162-12T)
Zealand)
12R22.5-16 (8.25 x 22.5-165-13T)
10.00R-20-14 (7.00T x 20-162-12T)
10.00R-20-16 (7.00T x 20-162-12T)
11.00R-20-14 (7.50V x 20)
11.00R-20-16 (7.50V x 20)
CKB, CWB Series 11R22.5-16 (8.25 x 22.5-165-13TCS)
(For Australia and New Zealand) 10.00R-20-16 (7.50 x 20-165-12TCS)
12.00-20-16 (8.50V x 20-180)
12.00-20-18 (8.50V x 20)
CKC, CWC Series 12.00R-20-16 (8.50V x 20-180)
12.00R-20-18 (8.50V x 20)
12.00R-20-18 (8.50V x 20)
10.00-20-16 (7.00T x 20-162-12T)
11.00-20-14 (7.50V x 20-165-12T)
11.00-20-16 (7.50V x 20-165-12T)
11R22.5-14 (7.50 x 22.5-162-12T)
12R22.5-14 (8.25 x 22.5-165-13T)
CWA Series 11R22.5-16 (7.50 x 22.5-162-12T)
12R22.5-16 (8.25 x 22.5-165-13T)
10.00R-20-14 (7.00T x 20-162-12T)
10.00R-20-16 (7.00T x 20-162-12T)
11.00R-20-14 (7.50V x 20)
11.00R-20-16 (7.50V x 20)

GE-1-8
 IDENTIFICATION

IDENTIFICATION
CHASSIS SERIAL NUMBER

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

Rear axle

GE-2-2
 IDENTIFICATION

Differential

GE-2-3
 LIFTING POINT

LIFTING 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.

Lifting point

GE-3-1
 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-3-2
 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 transmis-
sion oil by 0.5 liters (1/2 Imp qt) to prevent it from getting into the clutch housing while the vehicle is being
towed.

GE-4-1
 GENERAL PRECAUTIONS ON SERVICING

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
 GENERAL PRECAUTIONS ON SERVICING

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 view point.
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 Graded wear
z Scratches
z Cracks

GE-5-2
 GENERAL PRECAUTIONS ON SERVICING

z Deformity
z Fatigue or weakness (for springs)
z Bends
z Loose fit
z Unusual noise (for bearings)
z Discoloration or jamming
z Rust formation
z Deterioration (for brake linings, etc.)

GE-5-3
 GENERAL PRECAUTIONS ON SERVICING

IMPORTANT
Your vehicle may utilize parts which have either metric and/or inch unit dimensions.Any fasteners, like bolts
and nuts used to replace old ones, must have the same dimensions and strength as those removed.
Numbers on the heads of metric bolts and on the surfaces of metric nuts indicate their strength. Inch bolts use
radial lines for this identification, while most inch nuts do not have strength markings.
Potential thread mismatch condition may occur with certain metric thread-inch thread fastener combinations
involving incompatible fastener systems. Mismatched or incorrect thread fasteners combinations can result in
stripped threads and/or assembly weakness leading to vehicle damage, malfunction or possible personal
injury.
The following combinations of metric and inch bolts and nuts (or tapped holes) must not be utilized in service.

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-5-4
 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 desig-
nated.

Standard tightening torque (Without lubricant)

Bolt dia. Pitch
Nominal size 4T 7T 9T
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 12 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 5.7 108 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
2.0 275 28 203 461 47 340 667 68 492
M24 24.0
1.5 284 29 210 481 49 354 686 70 506

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 DEXRON®II or higher grade 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 -7°C (20°F) 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 -7°C (20°F)
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 Fuller transmissions, refer to the respective recommendations.

Fuller Recommendations
<Lubrication change and inspection>
Highway use
First 4,827 to 8,045 km
Change transmission oil on new units.
(3,000 to 5,000 miles)
Every 16,090 km
Inspect oil level. Check for leaks.
(10,000 miles)
Every 80,450 km
Change transmission oil.
(50,000 miles)

Off-highway use
First 30 hours Change transmission oil on new units.
Every 40 hours Inspect oil level. Check for leaks.
Change transmission oil where severe
Every 500 hours
dirt conditions exist.
Change transmission oil
Every 1,000 hours
(Normal off-highway use).

The transmission should not be operated consistently at temperatures above 120°C (250°F).
When the average operating temperature is above 120°C (250°F) the transmission may require more frequent
oil changes or external cooling.

GE-7-1
 LUBRICATION

<Recommended lubricants>
Celsius (Fahrenheit)
Grade
Type Ambient temperature
(SAE)
°C (°F)

Heavy duty engine oil 50 Above -12 (10)

MIL-L-2104B, C or D API SF or API CD 40 Above -12 (10)
(Previous API designations acceptable) 30 Below -12 (10)
Mineral gear oil with rust and oxidation 90 Above -12 (10)
inhibitor API GL-1 80W Below -12 (10)

The use of mild EP gear oil or multi-purpose gear oil is not recommended, but if these gear oils are used, be
sure to adhere to the following limitations:
Do not use mild EP gear oil or multi-purpose gear oil when operating temperatures are above 110°C (230°F).
Many of these gear oils, particularly 85W-140, break down above 110°C (230°F) and coat seals, bearings and
gears with deposits that may cause premature failures. If these deposits are observed (especially a coating on
seal areas causing oil leakage), change to heavy duty engine oil or mineral gear oil to assure maximum com-
ponent life and to maintain your warranty with Eaton.
Additives and friction modifiers are not recommended for use in Fuller transmissions.
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 temperatures forecast for areas where you are
planning to drive.

GE-7-2
 LUBRICATION

CAPACITIES (APPROXIMATELY)
Item Liter Imp measure
PF6
PF6T
21 4-5/8 gal
PF6TA
Engine oil pan PF6TB
RF8 24 5-1/4 gal
RG8 24 5-1/4 gal
Engine oil RE10 29 6-3/8 gal
PF6
PF6T
29 6-3/8 gal
PF6TA
PF6TB
System total
RF8 34 (36) 7-1/2 (7-7/8) gal
RG8 34 (36) 7-1/2 (7-7/8) gal
RE10 39 8-5/8 gal
Power steering system fluid 7.2 1-5/8 gal
MPS50 Without P.T.O. 7.5 1-5/8 gal
Without P.T.O. 11.0 2-3/8 gal
MTS60 With P.T.O. 11.5 2-1/2 gal
With high power P.T.O. 13.0 2-7/8 gal
Without P.T.O. 9.0 2 gal
MTS70
With P.T.O. 9.5 2-1/8 gal
Without P.T.O. 10.0 2-1/4 gal
MTP00B
Manual transmission With P.T.O. 10.5 2-3/8 gal
Without P.T.O. 10.0 2-1/4 gal
MTP00C
With P.T.O. 10.5 2-3/8 gal
Without P.T.O. 12.8 2-7/8 gal
MRT20A
With P.T.O. 13.3 2-7/8 gal
RTX11609 Without P.T.O. 13.0 2-7/8 gal
RT011613 Without P.T.O. 13.0 2-7/8 gal
RT11715 Without P.T.O. 13.0 2-7/8 gal
SRHP-1 15 3-1/4 gal
CK Series *115 3-1/4 gal
SRHQ-2
17 3-3/4 gal
Differential
CD Series SRSP-1 12 2-5/8 gal
CW Front IPHM-2 18 4 gal
Series Rear SRHM-2 14 3-1/8 gal
PF6 engine series 37 8-1/8 gal
RF8 engine series 42 9-1/4 gal
Cooling system
RG8 engine series
47 10-3/8 gal
RE10 engine series

NOTE
z *1 For Australia and Hong Kong
z Capacities shown are for reference only. When filling, observe the specified level.

GE-7-3
 MA
MAINTENANCE

CONTENTS
MAINTENANCE SCHEDULES ........ MA-1- 1 BRAKE SYSTEM ......................... MA-2- 8
LUBRICATION AND FILTER AXLE AND WHEEL..................... MA-2-18
REPLACEMENT INTERVALS ...... MA-1- 2 SUSPENSION............................. MA-2-27
MAINTENANCE INTERVALS....... MA-1- 3 CLUTCH...................................... MA-2-29
PERIODIC PARTS REPLACEME MA-1- 7 TRANSMISSION ......................... MA-2-31
LUBRICATION POINT AND PROPELLER SHAFT .................. MA-2-34
INTERVALS .................................. MA-1- 8 ELECTRICAL SYSTEM .............. MA-2-35
MAINTENANCE PROCEDURE ....... MA-2- 1 OTHERS ..................................... MA-2-38
STEERING SYSTEM ................... MA-2- 1
 MAINTENANCE SCHEDULES

MAINTENANCE SCHEDULES
Abbreviations:
I = Inspect. Correct, adjust or replace if necessary. T = Tighten to specified torque
A = Adjust C = Cleaning L = Lubricate
R = Replace RB = Rebuilding F = Initial maintenance

NOTE
z The maintenance or lubrication services shown below are to be performed at the indicated
intervals (miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 miles (36,000 km) 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
— Operation at extremely low or high ambient temperature
— Extended high-speed operation with vehicle fully-loaded to its GVWR
— Extended low-speed operation
— Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine
parts or equivalent in quality and design to genuine parts.

MA-1-1
 MAINTENANCE SCHEDULES

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 35
Months – 1 2 3 4 5 6 7 8 9 10 11 12

ENGINE
Engine oil and Oil R R: Every 10,000 km (6,000 miles) or 6 months
(1)
filter
Oil filter R: Every 10,000 km (6,000 miles) or 6 months

Engine oil and Oil R R: Every 15,000 km (9,000 miles) or 6 months

(1), (9)
filter
Oil filter R: Every 15,000 km (9,000 miles) or 6 months
Fuel filter element R
Primary fuel filter element R R
Air cleaner element
R (2)
(Dry type)
Air cleaner element
R: Every 3 years (2)
(Metallic type)
Coolant (incl. anticorrosive) R R (3)
Coolant (incl. antifreeze) R (4)

CHASSIS
Power steering fluid R R

Power steering filter element R

Power steering air cleaner R
Brake fluid R (5)

Differential gear oil and oil filter R R R (6)

Hub reduction gear oil R R R

Front and rear wheel bearing

grease R R

Clutch fluid R (7)

Transmission gear oil and oil fil-
R R R (8)
ter
Power tilt hydraulic oil R: Every 2 years
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 indicator turns red even before the scheduled replacement, clean or replace element.
(3) Service every 6 months. (4) Service every 12 months.
(5) AOH brake vehicles. Replace every year. (6) Oil filter is applicable only for CW series.
(7) Replace every year. (8) Transmission oil filter: if so equipped.
(9) With large size bypass oil filter (for CGB520 and 533 series only).

MA-1-2
 MAINTENANCE SCHEDULES

MAINTENANCE 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 35
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)

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
Fuel filter (2)
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
I
pattern)
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

Water tank cap I

Thermostat I
Turbocharger I (3)
Fan clutch I

Crank damper I : After 200,000 km (125,000 miles)

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) Center bolt type.
(3) With turbocharger engine equipped vehicle only.

MA-1-3
 MAINTENANCE SCHEDULES

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 35
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
Brake fluid level I I I I I I I I I I I I I (1)
Hose and pipe for fluid and/or air
leakage I I I I I I I I I I I I I

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 (1)
Brake chamber push rod stroke I I I I I I I I I I I I (2)
Brake lining I I I I I I I I I I I I
Brake drum I
Back plate I
Brake booster exhaust port clog-
I I I I (1)
ging
Brake booster for fluid and air
I (1)
tightness
Brake booster's check valve and
I (1)
relay valve

Remarks: (1) AOH brake vehicles. (2) Air brake vehicles.

MA-1-4
 MAINTENANCE SCHEDULES

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 35
Months – 1 2 3 4 5 6 7 8 9 10 11 12

BRAKE SYSTEM
Wheel cylinder for proper func-
I (1)
tioning
Brake chamber I (2)
Brake camshaft I (2)

Parking brake lining clearance I I I I I (3)

Parking brake lever stroke I I I I I I I I I I I I I (3)

Parking brake effectiveness I I I I I I I I I I I I

Parking brake wire I I I I I (3)

Parking brake drum T T T T/I (3)

Parking brake lining I (3)
Air dryer I I I I
Oil mist separator I: Every 20,000 km (12,000 miles) or 3 months
Air compressor and air pressure
I
governor
L.S.P.V. for wiring or rod I (4)
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 I 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

Remarks:(1) AOH brake vehicles.(2) Air brake vehicles.

(3) Mechanically-actuated type.(4) If so equipped.

MA-1-5
 MAINTENANCE SCHEDULES

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 35
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 elec-
trolyte 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
I I I I I
and 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)
Pintle hook and lunette eye I (3)
Power tilt hydraulic oil level I (4)
Mirrors I

Remarks: (1) If so equipped.(2) Semi-trailer trucks only.(3) Full trailer trucks only.(4) Every year.

MA-1-6
 MAINTENANCE SCHEDULES

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

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)
Brake fluid reservoir hose R R R R R (1)
Brake booster rubber parts R R R R R R R R R R (1)
Brake booster piston packing and hydraulic piston assem-
R R R R R (1)
bly
Wheel cylinder cup, dust seal, etc. R R R R R R R R R R (1)
Brake valve rubber parts R R R R R R R R R R
Relay valve rubber parts R R R R R R R R R R (2)
Quick release valve rubber parts R R R R R R R R R R (3)
Spring brake valve rubber parts R R R R R R R R R R (2)
Brake chamber rubber parts R R R R R R R R R R (2)
Trailer brake valve rubber parts R R R R R R R R R R (4)
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 (3)
Oil mist separator filter element and rubber parts R R R R R R R R R R (5)

OTHERS
Jumper hoses R R R R R (4)

Remarks:(1) AOH brake vehicles.(2) Air brake vehicles.

(3) Replace every year.(4) Semi and full-trailer trucks.
(5) Replace every year or 100,000 km (60,000 miles).

MA-1-7
 MAINTENANCE SCHEDULES

LUBRICATION POINT AND INTERVALS

GREASE LUBRICATION POINTS (CK SERIES)

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

GREASE LUBRICATION INTERVALS (CK SERIES)

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. Be sure to put the caps back on if so equipped.
The following schedule is for a one-year period only. However, similar maintenance is required for subsequent
years.
MAINTENANCE INTERVALS
Kilometersx1,000 5 10 15 20 25 30 35 40 45 50 55 60 Rema
Items
Milesx1,000 3 6 9 12 15 18 21 24 27 30 33 36 rks

Months 1 2 3 4 5 6 7 8 9 10 11 12
1 Lubricate steering column journal and yoke L L
2 Lubricate drag link end L L
3 Lubricate front brake camshaft and slack adjuster L L
4 Lubricate king pin L L
5 Lubricate tie-rod end L L
6 Lubricate engine water pump pulley L L (1)
Manual tilt cab L L
7 Lubricate cab tilting system
Electric tilt cab L L L L L L L L L L L L
8 Lubricate rear brake camshaft and slack adjuster L L
9 Lubricate rear spring pin and shackle pin L L L L L L L L L L L L
10 Lubricate front spring pin and shackle pin L L L L L L L L L L L L
11 Lubricate clutch release sleeve and shaft L L

REMARKS: (1)Only for models equipped with RF8 and RG8 engines

MA-1-8
 MAINTENANCE SCHEDULES

MAINTENANCE INTERVALS
Kilometersx1,000 5 10 15 20 25 30 35 40 45 50 55 60 Rema
Items
Milesx1,000 3 6 9 12 15 18 21 24 27 30 33 36 rks

Months 1 2 3 4 5 6 7 8 9 10 11 12
12 Lubricate propeller-shaft journal and yoke L L
13 Lubricate rear spring contact seat L L L L L L L L L L L L
14 Lubricate couplers (Base plate and jaw) L L L L L L L L L L L L (2)
15 Lubricate door hinge pin bushing L L (3)

Remarks:
(2) Tractor model only.
(3) For lubrication points, refer to the figure below. Use NLGI No. 000 or equivalent.

GREASE LUBRICATION POINTS (CW AND CD SERIES)

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

MA-1-9
 MAINTENANCE SCHEDULES

GREASE LUBRICATION INTERVALS (CW AND CD SERIES)

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. Be sure to put the caps back on if so equipped.
The following schedule is for a one-year period only. However, similar maintenance is required for subsequent
years.
MAINTENANCE INTERVALS
Kilometersx1,000 5 10 15 20 25 30 35 40 45 50 55 60 Rema
Items
Milesx1,000 3 6 9 12 15 18 21 24 27 30 33 36 rks

Months 1 2 3 4 5 6 7 8 9 10 11 12
1 Lubricate steering column journal and yoke L L
2 Lubricate drag link end L L
3 Lubricate front brake camshaft and slack adjuster L L (1)
4 Lubricate king pin L L
5 Lubricate tie-rod end L L
6 Lubricate engine water pump pulley L L (2)
Manual tilt cab L L
7 Lubricate cab tilting system
Electric tilt cab L L L L L L L L L L L L
8 Lubricate rear brake camshaft and slack adjuster L L (1)
9 Lubricate rear spring contact seat L L L L L L L L L L L L
10 Lubricate front spring pin and shackle pin L L L L L L L L L L L L
11 Lubricate clutch release sleeve and shaft L L
12 Lubricate propeller-shaft journal and yoke L L
13 Lubricate trunnion shaft L L L L L L L L L L L L
14 Lubricate couplers (Base plate and jaw) L L L L L L L L L L L L (3)
15 Lubricate center bearing L L (4)
16 Lubricate door hinge pin bushing L L (5)

Remarks: (1) Air brake vehicles

(2) Only for models equipped with RF8, RG8 and RE10 engines
(3) Tractor model only
(4) Grease requiring type only
(5) For lubrication points, refer to the illustration (CK-343E) on page MA-1-9. Use NLGI No. 000 or
equivalent.

MA-1-10
 MAINTENANCE SCHEDULES

GREASE LUBRICATION POINTS (CG SERIES)

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

GREASE LUBRICATION INTERVALS (CG SERIES)

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. Be sure to put the caps back on if so equipped.
The following schedule is for a one-year period only. However, similar maintenance is required for subsequent
years.
MAINTENANCE INTERVALS
Kilometersx1,000 5 10 15 20 25 30 35 40 45 50 55 60 Rema
Items
Milesx1,000 3 6 9 12 15 18 21 24 27 30 33 36 rks

Months 1 2 3 4 5 6 7 8 9 10 11 12
1 Lubricate rear brake camshaft and slack adjuster L L
2 Lubricate propeller-shaft journal and yoke L L
3 Lubricate tie-rod end L L
4 Lubricate front spring pin and shackle pin L L L L L L L L L L L L
5 Lubricate center bearing L L
6 Lubricate king pin L L
7 Lubricate front brake camshaft and slack adjuster L L
Manual tilt cab L L
8 Lubricate cab tilting system
Electric tilt cab L L L L L L L L L L L L
9 Lubricate clutch release sleeve and shaft L L
10 Lubricate engine water pump pulley L L (1)
11 Lubricate steering column journal and yoke L L

REMARKS: (1)Only for models equipped with RF8 and RG8 engines

MA-1-11
 MAINTENANCE SCHEDULES

:
MAINTENANCE INTERVALS
Kilometersx1,000 5 10 15 20 25 30 35 40 45 50 55 60 Rema
Items
Milesx1,000 3 6 9 12 15 18 21 24 27 30 33 36 rks

Months 1 2 3 4 5 6 7 8 9 10 11 12
12 Lubricate idler arm shaft L L
13 Lubricate drag link end L L
14 Lubricate pitman link end L L
15 Lubricate drag link end L L
16 Lubricate steering booster end L L
17 Lubricate propeller-shaft journal and yoke L L
18 Lubricate trunnion shaft L L L L L L L L L L L L
19 Lubricate rear spring contact seat L L L L L L L L L L L L
20 Lubricate door hinge pin bushing L L (2)

Remarks:
(1) For lubrication points, refer to the illustration (CK-343E) on page MA-1-9. Use NLGI No. 000 or equivalent.

MA-1-12
 MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE
CAUTION
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
CHECK 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)
Item Maintenance standard
Free play 30 - 50 (1.18 - 1.97)

CHECK 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.

CHECK STEERING SYSTEM FOR 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
 MAINTENANCE PROCEDURE

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

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.

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.

MA-2-2
 MAINTENANCE PROCEDURE

<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.
CAUTION
z Use normal hexane to remove oil from the inlet side hose
junction.
z Do not use toluene or chroline based solvent as it could
cause plastics to crack.

NOTE
z Apply sealant to the inlet side hose when installing it.
Use genuine Nissan Diesel part 49751 00Z00 or equiva-
lent sealant.
z Apply a constant bead of sealant around the hose. Make
sure there are no gaps.
z Pay attention to the clamp installation direction.

： 2.9 - 3.4 N·m {0.3 - 0.35 kgf·m, 2.2 - 2.5 ft·lbf}

3. Fill the fluid reservoir up to the filler port with new power
steering fluid and then crank the engine using the starting
motor, but shut off fuel and do not run the motor longer than
1 or 2 seconds to prevent the engine from starting.
4. Repeat the operation in item 3 while adding fluid to keep the
fluid reservoir filled.
5. When fluid drained becomes clean, connect the return hose
to the reservoir to restore the piping to its normal condition.

MA-2-3
 MAINTENANCE PROCEDURE

To replace the element assembly

1. Remove the cap, and remove the strainer and element.
2. Install a new element and strainer, and install the cap.

To replace the air cleaner

Replace the air cleaner as an assembly.

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.

CHECK GEAR BOX MOUNTING BOLTS AND NUTS

Check the gear box mounting bolts for tightness. Tighten to the
specified torque if necessary.
CK and CW series:
： 343 - 392 N·m{35 - 40 kgf·m, 253 - 289 ft·lbf}
CGB series:
：294 - 343 N·m {30 - 35 kgf·m, 217 - 253 ft·lbf}

CHECK 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.

MA-2-4
 MAINTENANCE PROCEDURE

CHECK 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
pitman arm.
NOTE
z For details, refer to the “ST” section.

CHECK STEERING LINKAGE FOR LOOSENESS, RAT-

TLE AND DAMAGE
Move the drag link and tie rod back and forth and then to the left
and right by hand to check for free play at the fastening section. If
free play is present, the ball joint may be worn.

MA-2-5
 MAINTENANCE PROCEDURE

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.
Unit: N·m {kgf·m, ft·lb}
Item Tightening torque
CK, CD and CW series CGB series
1. Pitman arm nut 441 - 490 {45 - 50, 325 - 362}
2. Drag link castellated nut 216 - 343 {22 - 35, 159 - 253}
3. Steering arm mounting nut 490 - 588 {50 - 60, 362 - 434}
4. Tie-rod mounting nut 245 - 304 {5 - 31, 181 - 224}
5. Tie-rod arm mounting nut 490 - 588 {50 - 60, 362 - 434}
6. Tie-rod end clamp bolt 59 - 78 {6 - 8, 43 - 58}
7. Pitman link end clamp bolt — 77 - 98 {7.9 - 10, 57 - 72}
8. Power cylinder end mounting nut — 216 - 343 {22 - 35, 159 - 253}
9. Idler arm mounting nut — 177 - 206 {18 - 21, 130 - 152}
10. Idler arm bracket mounting nut — 137 - 157 {14 - 16, 101 - 116}
11. Clevis pin mounting bolt — 13 - 16 {1.3 - 1.6, 9 - 12}

CHECK BALL JOINT DUST BOOT FOR CRACKS AND DAMAGE

Check the ball joint dust boot for cracks or damage.
Replace cracked or damaged ball joint dust boot.

MA-2-6
 MAINTENANCE PROCEDURE

CHECK KNUCKLE JOINT FOR LOOSENESS

1. Jack up the front axle, and check if the kingpin rattles by
axially shaking each wheel by hand. When the wheel bear-
ing 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.)

CHECK 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.

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.

MA-2-7
 MAINTENANCE PROCEDURE

CHECK POWER STEERING SYSTEM

1. Check the oil pump, etc. for loose attachment.
2. Check hoses and pipes for loose connections.

BRAKE SYSTEM
CHECK BRAKE PEDAL PLAY
Check the brake pedal for a proper play by depressing it with a light
force.
Unit: mm (in)
Maintenance standard Service limit
12 - 18 (0.47 - 0.71) —

Adjustment procedures for brake pedal play

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

CHECK 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.

CHECK 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 replacement, 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.

MA-2-8
 MAINTENANCE PROCEDURE

CAUTION
z Remove any dirt accumulation from the brake fluid reser-
voir cap and surrounding area before removing the res-
ervoir cap. Do not allow dirt, debris, water or other
foreign materials to enter the reservoir while it is open.
z To avoid fire hazard, do not allow brake fluid to contact
the hot parts of the exhaust system.
z Use only DOT 3 brake fluid from a sealed container.
z Do not add brake fluid above the HIGH mark.
z Do not allow brake fluid to contact the painted surfaces
of your vehicle. Brake fluid contact may result in paint
damage.
z Remove the reservoir strainer and clean any foreign mat-
ter from it. If the reservoir contains sediment, inspect and
clean the reservoir.

Brake fluid replacement

1. Start the engine and wait for the pressure in the air reservoir
to reach the standard operating air 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.
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.

CHECK 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.

MA-2-9
 MAINTENANCE PROCEDURE

2. Check pipe joints and connections between hoses and pipe

sleeves for damage.
3. Check that hose clamps are tightened in place.

CHECK AIR RESERVOIR FOR WATER ACCUMULA-

TION AND DRAIN WATER
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.

CHECK 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

AOH brake vehicles
Shoe will adjust to the correct clearance automatically after
depressing brake pedal several times.
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)
Item Maintenance standard Service limit
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.

MA-2-10
 MAINTENANCE PROCEDURE

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.

CHECK 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)
Item Maintenance Service limit\ Remarks
standard
Front 30 (1.18) 45 (1.77) *1 L = 165 (6.50)
30 (1.18) 45 (1.77) *1 L = 150 (5.91)
Rear
24 (0.94) 40 (1.57) *1 L = 125 (4.92)

z Referring to *1
165 mm (6.50 in), 150 mm (5.91 in) and 125 mm (4.92 in)
are dimensions (L) between the centers of holes in both
ends of the slack adjuster.

MA-2-11
 MAINTENANCE PROCEDURE

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)
Item Maintenance Service limit Remarks
standard
Front 30 (1.18) — L = 165 (6.50)
30 (1.18) — L = 150 (5.91)
Rear
24 (0.94) — L = 125 (4.92)

NOTE
z Adjusting screw lock grooves are provided at six places
on the screw shaft at 60° intervals.

CHECK BRAKE LINING FOR WEAR

(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.

MA-2-12
 MAINTENANCE PROCEDURE

CHECK BRAKE DRUM WEAR AND DAMAGE

(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.

CHECK BACK PLATE

Check the back plate for deformation or damage.

BRAKE BOOSTER
Exhaust port clogging
1. Check the exhaust port for contamination, clogging or other
damage.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 Iisten for an exhaust sound emitted from the
air booster's exhaust port. The exhaust port 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 for fluid and air leakage.
Check valve and relay valve
For inspection procedures, refer to the “BR” section.

CHECK 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.

CHECK 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.

MA-2-13
 MAINTENANCE PROCEDURE

2. Disassemble the brake chamber and check the condition of

component parts. Replace parts which should be changed
at regular intervals.

CHECK BRAKE CAMSHAFT FOR WEAR AND DAMAGE

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 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.

Item Maintenance standard Service limit

Lever stroke 3 - 12 notches —

z Also check for proper installation of the parking brake lever.

<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.

MA-2-14
 MAINTENANCE PROCEDURE

CHECK 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.

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.

Manual release procedure

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.

CAUTION
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 chamber and its contents which
could cause death, severe personal injury and/or prop-
erly damage. remove complete spring brake and replace
with new unit.

1. Block the wheels to prevent the vehicle from moving.

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.

MA-2-15
 MAINTENANCE PROCEDURE

5. Turn the release stud one-fourth turn to engage the stud

tangs with the slot in the pressure plate.
CAUTION
z Instruction 6 listed below only applies when spring brake
is not pressurized. If air pressure is used to compress
spring, do not tighten release stud nut more than finger
tight. Torquing the nut can cause pressure plate damage
resulting in sudden release of the spring causing death
or severe personal injury.

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 over torque release stud
nut. (Do not use INPACT WRENCH.)

: ANCHORLOK type
Less than 47 N·m {4.84 kgf·m, 35 ft·lbf}
TR3036 (MGM) type
Less than 68 N·m {6.9 kgf·m, 50 ft·lbf}
7. To ensure compression spring is fully caged, the stud
length beyond the nut (see X above) should be:
ANCHORLOK: 63.6 mm (2.504 in) minimum
TR3036 (MGM): 69 mm (2.72 in) minimum

Reset procedure
1. Unscrew and remove the release stud nut.
2. Reinstall the release stud and nut in the carrying pocket.
Install the access plug in the housing opening.

CHECK 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 res-
ervoir. If a large amount of water is drained, have the air dryer
repaired. (Refer to the “BR” section for disassembly and reassem-
bly procedures.) If the drained liquid contains a large amount of oil,
additionally have the air compressor checked.

MA-2-16
 MAINTENANCE PROCEDURE

CHECK OIL MIST SEPARATOR

Check that the oil mist separator operates properly and that there is
drainage from the exhaust port.
If no damage or any abnormality is found, check the oil mist sepa-
rator and replace the cartridge if necessary [Refer to Air brake unit
in the “BR” section].

CHECK AIR COMPRESSOR AND AIR PRESSURE GOV-

ERNOR 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}.
Compressor Length of time required for Air pressure and reservoir
rpm increase in air pressure capacity
400 124 sec. 0 - 785 kPa
{0 - 8.0 kgf/cm2, 0 - 114 psi}
2,000 32 sec.
30 liter (6-5/8 Imp. gal)

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.

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.

MA-2-17
 MAINTENANCE PROCEDURE

CHECK EXHAUST BRAKE PROPER FUNCTIONING

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

CHECK FRONT AXLE
Check for bends or damage and replace if faulty.

CHECK REAR AXLE HOUSING

Check the rear axle housing for cracks, deformity or damage.
Replace the axle housing if faulty.

CHECK 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.

CHECK DIFFERENTIAL GEAR OIL AND OIL FILTER

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}

MA-2-18
 MAINTENANCE PROCEDURE

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}

To change the differential gear oil

(Front differential: CW and CG series)
1. Place a container under the differential drain plug. Remove
the drain plug and drain oil completely.
2. Reinstall and tighten the drain plugs 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. Replace the oil filter at the same time that the gear oil is
replaced. Oil filter plug
: 216 - 255 N·m {22 - 26 kgf·m, 159 - 188 ft·lbf}

4. Remove the filler plug. o refill, remove the filler plug and
pour oil into the case until oil overflows the filler plug hole.
NOTE
z When refilling, be extremely careful not to allow dirt or
dust to enter 0the filler plug hole.

5. Install the filler plug.

: Filler plug: 127 - 147 N·m {13 - 15 kgf·m, 94 - 108 ft·lbf}

MA-2-19
 MAINTENANCE PROCEDURE

CHANGE HUB REDUCTION GEAR OIL

1. Position the drain plug so that it is at the lower position.
Remove the drain plug and drain oil. Then install the drain
plug.
2. Remove the level plug, and add oil until it flows out of the
level plug hole. Install the level plug.
NOTE
z When adding oil, take extra care to keep out dirt and
dust.

CHECK AXLE SHAFT

1. Remove the rear axle shaft, and check for bends, cracks
and oilleakage.
2. Check to see if the rear axle shaft oil seal is damaged, and
if the differential breather is clogged or leaking oil.

CHECK AXLE SHAFT MOUNTING BOLTS FOR LOOSE-

NESS
Check the axle shaft mounting bolts for looseness with a hammer
or a torque wrench.
Unit: N·m {kgf·m, ft·lbf}
Vehicle model Unit name Tightening torque
CKA/B Tractor
RS1A 147 - 167 {15 - 17, 108 - 123}
CKB450LP
CKB450 series RS1B 147 - 167 {15 - 17, 108 - 123}
CKC series RS1D *196 - 216 {20 - 22, 145 - 159}
CWA/B/C series, *196 - 216 {20 - 22, 145 - 159}
RW1A
CGB series 147 - 167 {15 - 17, 108 - 123}
CDA series RD1A 147 - 167 {15 - 17, 108 - 123}

NOTE
z *: Hub reduction type only.

MA-2-20
 MAINTENANCE PROCEDURE

CHECK 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.

Unit: kPa {kgf/cm2, psi}

Tire size Standard inflation pressure
12.00-20-16PR 637 {6.5, 92}
10.00-20-14PR
662 {6.75, 96}
11.00-20-14PR
10.00-20-16PR
12.00-20-18PR 686 {7.00, 100}
11R22.5-14PR
11.00-20-16PR
11.00R20-14PR
10.00R20-14PR 711 {7.25, 103}
12R22.5-14PR
12.00R20-16PR
12.00R24-18PR 736 {7.50, 107}
11.00R20-16PR
760 {7.75, 110}
12.00R20-18PR
10.00R20-16PR 825 {8.40, 120}
11R22.5-16PR
785 {8.00, 114}
12R22.5-16PR

CHECK 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.
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.

MA-2-21
 MAINTENANCE PROCEDURE

CHECK 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 1.6 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-2-22
 MAINTENANCE PROCEDURE

CHECK 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.
Item 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 z Apply brakes slowly
braking

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

CHECK TIGHTNESS OF WHEEL NUTS

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:

Refer to the chapter “TIRES AND WHEELS” in this manual, for the
tightening torque of the wheel nut.

MA-2-23
 MAINTENANCE PROCEDURE

z The tightening procedures are for the standard type.

NOTE
z The wheel nuts on the right side of the vehicle have right-
handed threading; the left side wheel nuts have left-
handed threading.

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.

CHECK 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.

CHECK 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-2-24
 MAINTENANCE PROCEDURE

[Preload measurement]
1. Remove the wheel.
2. Wrap a string around the hub bolt.
3. Pull the string horizontally with a spring scale until the hub
rotates at least 90°. Read the scale indication (average
value).
Unit: N {kgf, lbf}
Vehicle model Unit name Maintenance standard Service
limit
CKA/B series,
CWA/B series, 19.6 - 53.9
FA50 —
CDA series, {2.0 - 5.5, 4.4 - 12.1}
CGB series
CKC series, 29.4 - 47.1
FA60 —
CWC series {3.0 - 4.8, 6.6 - 10.6}
FA50, 60
CKB/C series, 25.5 - 40.2
(Trilex —
CWB/C series {2.6 - 4.1, 5.7 - 9.0}
wheel)

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 speci-
fied 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 90°. Read the scale indication (average
value).

MA-2-25
 MAINTENANCE PROCEDURE

Unit: N {kgf, lbf}

Vehicle model Unit Maintenance standard Service limit
name
CKA/B Tractor, 29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —
RS1A
CKB450LP *1 25 - 54 2.5 - 5.5, 18 - 40 —
29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —
CKB450 series RS1B
*1 25 - 54 2.5 - 5.5, 18 - 40 —
29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —
CKC series RS1D
*2 30 - 67 3.1 - 6.8, 22 - 49 —

CWA/B/C 29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —

series, RW1A *1 25 - 54 2.5 - 5.5, 18 - 40 —
CGB series *2 30 - 67 3.1 - 6.8, 22 - 49 —
RD1A 29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —
CDA series
RD60 29.4 - 63.7 3.0 - 6.5, 6.6 - 14.3 —

NOTE
z *1: Trilex wheel type
z *2: With hub reduction
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 name Unit Amount of grease (Approximately)
name
CKA/B series,
CWA/B series,
FA50 700 (24.69)
CDA series,
CGB series
CKC series,
FA60 1,000 (35.27)
CWC series

NOTE
z For details, refer to the “FA” section.

MA-2-26
 MAINTENANCE PROCEDURE

Rear
Disassemble the rear axle hub. Remove the old grease and charge
new grease as shown below.
Unit: g (oz)
Vehicle model Unit Amount of Remarks
name grease (Approxi-
mately)
CKA/B Tractor,
RS1A 1,100 (38.80) Drive axle
CKB450 LP
CKB450 series RS1B 1,100 (38.80) Drive axle
CKC series RS1D 1,100 (38.80) Drive axle
CWA/B/C series,
RW1A 1,100 (38.80) Drive axle
CGB series
RD1A 1,100 (38.80) Drive axle
CDA series
RD60 1,150 (40.56) Dead axle

NOTE
z For details, refer to the “RA” section.

SUSPENSION
CHECK LEAF SPRING FOR DAMAGE
Check the leaf spring for damage, displacement of leaves or
looseness. If loose, tighten bolts and nuts to the specified torque.
For tightening torque, refer to the “SU” section.

MA-2-27
 MAINTENANCE PROCEDURE

U-bolt and nuts

Check the U-bolt and nuts for proper torque setting.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Front 490 - 539 {50 - 55, 362 - 398}
CKA/B series 588 - 637 {60 - 65, 434 - 470}
Rear CKC series *716 - 843 {73 - 86, 528 - 622}
CW, CD and CG series *716 - 843 {73 - 86, 528 - 622}

*: Apply engine oil or grease (wet) to the nut thread, nut seat, U-bolt
thread and spring seat and tighten the nut.

CHECK SPRING BRACKET FOR LOOSENESS AND

DAMAGE
Inspect rivets on the spring bracket for looseness by tapping with a
hammer. Also, visually inspect the bracket for cracks and damage.

CHECK SHOCK ABSORBER

Check the shock absorber for proper installation, damage or leak-
age. If leakage is present, replace the shock absorber.

CHECK STABILIZER
Check the stabilizer for proper installation or damage.

MA-2-28
 MAINTENANCE PROCEDURE

CLUTCH
CHECK 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.
3. Under this condition, return the push rod 4/5 turn and make
sure the free play is approximately 1 mm (0.04 in). 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.
3. Rotate the push rod until outer lever play.
Unit: mm (in)
Item Maintenance standard Service limit
CL535, CL635
and CL640 5 - 7 (0.20 - 0.28) —
Outer (Single disc)
lever play
CL420
5 - 6 (0.20 - 0.24) —
(Dual disc)

4. Tighten the lock nut.

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

<Clutch outer lever: with Fuller transmission>

After adjusting the clutch master cylinder, adjust the clutch booster
outer lever assembly.
1. Before adjusting the clutch outer lever, bleed the air from
the clutch system.
2. To adjust, loosen the lock nuts on the turnbuckle, and turn
the turnbuckle until the correct play is obtained.
NOTE
z When doing this, first detach the return spring.

MA-2-29
 MAINTENANCE PROCEDURE

Unit: mm (in)
Item Maintenance standard Service limit
CL535, CL635
and CL640 5 - 7 (0.20 - 0.28) —
Outer (Single disc)
lever play
CL420
5 - 6 (0.20 - 0.24) —
(Dual disc)

3. Measure the “L” dimension after adjusting the free play.

Replace the clutch disc if it reaches the limit indicated
below.
Unit: mm (in)
Dimension L Limit: 117 (4.61)

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.

CHECK 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 contami-
nation. If the fluid appears contaminated, have the clutch fluid
changed.
CAUTION
z Do not expose the clutch fluid to moisture when check-
ing, adding or changing the clutch fluid. Clutch fluid
absorbs moisture. When it does, its boiling point drops
which can cause corrosion of clutch system compo-
nents.
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.

MA-2-30
 MAINTENANCE PROCEDURE

CHECK 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}.
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}.
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.

TRANSMISSION
CHECK 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 neces-
sary.

MA-2-31
 MAINTENANCE PROCEDURE

GEAR OIL AND OIL FILTER REPLACEMENT

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(s). Remove the drain

plug(s) and completely drain the transmission oil.
2. Reinstall and tighten the drain plug(s) using a new gasket.
： 118 - 137 N·m {12 - 14 kgf·m, 87 - 101 ft·lbf}
CAUTION
z The drain plug(s) contains a magnet. Remove any iron
fillings on the plug before reinstalling the plug(s).

3. Fill the transmission with fresh oil through the filler plug(s)
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(s), transmission housing, and
surrounding 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.
z On 6-speed transmissions with a splitter, be sure to sup-
ply oil through the two filler plug holes. If oil is supplied
through only the main or sub case, oil will be insufficient.
This will result in a malfunctioning transmission such as
a seizure.

5. After checking the oil level, replace the filler plug gasket
with a new one.
6. On the transmission equipped with an oil filter, replace the
oil filter at the same time that the gear oil is replaced.

MA-2-32
 MAINTENANCE PROCEDURE

7. Make sure the transmission is in the neutral position. Start

the engine and idle it for more than 3 minutes.
8. Stop the engine. After more than 3 minutes, remove the
filler plugs and supply gear oil through the filler plug holes
until it overflows.
9. Reinstall and tighten the filler plug using a new gasket.
： 118 - 137 N·m {12 - 14 kgf·m, 87 - 101 ft·lbf}

Oil filter replacement

1. Place a container under the oil filter.
2. Clean the filter exterior. Do not allow dust or dirt to enter the
oil filter during disassembly.
3. Remove the oil filter by turning it counterclockwise (when
viewed from the rear of the vehicle).

4. Apply a thin coat of clean gear oil to the gasket of the new
filter.
5. Install the new oil filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an addi-
tional two-thirds of a turn.
CAUTION
z Installation of the oil filter without coating the gasket with
oil may damage the gasket resulting in loss of transmis-
sion fluid and damage to the transmission.

6. Start the engine, and make sure that there is no oil leakage
from the sealing surface.
Fuller transmission 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. After draining, reinsert the plug and tighten.

MA-2-33
 MAINTENANCE PROCEDURE

CAUTION
z The drain plug contains a magnet. Remove any iron fill-
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.
4. Visually check the oil level and add oil, if necessary, until it
reaches the bottom of the filler plug hole.

CHECK TRANSMISSION CONTROL MECHANISM

With the transmission in neutral, check the shift lever and control
rods 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
CHECK SHAFT JOINT
Inspect that the fitting bolts, etc. of the yoke flange, joint yoke, bear-
ing cover and center bearing case are tight.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Propeller shaft mounting bolt 211 - 240 {21.5 - 24.5, 156 - 177}
Center bearing retainer mounting bolt 98 {10, 72}

CHECK 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.

CHECK 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.
： 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}

MA-2-34
 MAINTENANCE PROCEDURE

CHECK CENTER BEARING

Check the center bearing for free play and grease leakage and
replace it if faulty.

ELECTRICAL SYSTEM
CHECK CHARGING FUNCTION OF GENERATOR
Check charging condition by observing warning light indication.

CHECK BATTERY
Observe the following when handling battery electrolyte.
WARNING
WARNING
z The battery produces hydrogen gas, which is harmful to
the human body. ever 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 immediately see doctor.

NOTE
z When the battery is replaced, perform maintenance in
accordance with the battery manufacturer's instructions.

MA-2-35
 MAINTENANCE PROCEDURE

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.

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.

MA-2-36
 MAINTENANCE PROCEDURE

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 20°C (68°F) to obtain the true specific gravity.
S 20 = St + 0.0007 (t - 20)
where;
S 20 : Specific gravity (at the standard 20°C)
St : Specific gravity measured
t : Temperature of electrolyte measured
0.0007 : Coefficient for variations in temperature of 1°C
When the battery is fully charged, the specific gravity should be
1.280 at the standard 20°C (68°F). 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 luke-
warm water on the terminals and wipe clean; if excessively
corroded, disconnect the battery cables and clean using a wire
brush or sandpaper. 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.

CHECK 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.

MA-2-37
 MAINTENANCE PROCEDURE

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 Side turn signal light
4 Front turn signal light
5 Side clearance light and cornering light
6 Headlight
7 Fog light
8 Search light (tractor)
9 Rear combination light (tail and stop light)
10 Rear turn signal light
11 Back-up light
12 License plate 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.

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 tight-
ness.

MA-2-38
 MAINTENANCE PROCEDURE

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
3. shaft and bearing locations for wear or damage. Also check
the pin hole in the jaw for wear or damage. Check the upper
surface of the coupler base for wear, lubricating condition,
etc.

PINTLE HOOK AND LUNETTE EYE

Check for wear, cracks or damage. Also check the mounting sec-
tion for looseness, damage, etc.

POWER TILT HYDRAULIC OIL LEVEL

1. Remove the filler plug from hydraulic oil pump reservoir,
and check the oil level.
2. The oil level is correct it is even with the filler neck. If it is
lower than the neck, add oil to that level.
NOTE
z Make sure the cab is tilted down when checking the oil
level or adding hydraulic oil.
z Do not allow foreign matter to enter the reservoir during
inspection. Keep the area surrounding the reservoir
clean at all times.
z Always use the specified hydraulic oil in the reservoir.

POWER TILT HYDRAULIC OIL REPLACEMENT

1. Place a container under the OUT connector of the tilt cylin-
der to catch oil.
2. Lower the cab and loosen the OUT connector.

MA-2-39
 MAINTENANCE PROCEDURE

3. Move the selector lever (located on the pump) to the UP

position. Manually operate the pump to drain oil from the
OUT connector.
4. After completely draining the oil, tighten the connector.
5. Remove the filler plug from the pump and replenish with
new oil.
6. Manually operate the pump to feed the oil. Replenish oil
when the oil level drops below the filler neck.
7. Raise or lower the cab using the motor, and check the oil
level again. If it is lower than the filler neck, replenish up to
the neck.

MA-2-40
 TROUBLE DIAGNOSIS
TD

CONTENTS
FOREWORD...........................................TD-1 PROBABLE CAUSE AND REMEDY.....TD-9
WARNING LIGHTS ................................TD-2 CLUTCH............................................ TD-9
TROUBLE SYMPTOMS AND TRANSMISSION ............................. TD-11
FAULTY UNITS ......................................TD-6 PROPELLER SHAFT ...................... TD-13
WHEN STARTING ENGINE ............. TD-6 REAR AXLE AND
AFTER STARTING ENGINE ............ TD-6 DIFFERENTIAL CARRIER.............. TD-14
WHEN STARTING TO MOVE BRAKE ............................................ TD-15
VEHICLE .......................................... TD-6 STEERING SYSTEM AND
WHEN VEHICLE IS RUNNING ........ TD-7 FRONT AXLE.................................. TD-18
 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 con-
ditions 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 leak-
age 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
 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 on the left side of the instrument panel. These lights remain
unlit if the related system is functioning 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.

TD-2
 WARNING LIGHTS

WARNING LIGHT NAME AND FUNCTION

Item Warning light name Function

1
This warning light will illuminate when
(15) Oil filter warning light
the oil filter element is clogged.
*1

3 Air cleaner element warn- This warning light illuminates when the
(16) ing light air cleaner element is clogged.

5 This light illuminates when the parking

Parking brake warning light
(17) brake has been actuated.

This light comes on while the spring

6
Spring brake warning light brake installed on the rear axle is oper-
(12)
ating.

If the stroke of the clutch booster power

Clutch disc wear warning piston exceeds the specified value due
(13)
light to wear of the clutch disc, the clutch
disc wear warning light comes on.

Remarks: *1( ): L.H.D. model

TD-3
 WARNING LIGHTS

Item Warning light name Function

The warning light comes on briefly and

then goes off upon starting the engine.
23 The light will come on if the oil pressure
Oil pressure warning light
(20) drops below 49 kPa {0.5 kgf/cm2, 7 psi}
while the engine is running. Stop the
vehicle and shut off the engine.

The warning light comes on during driv-

25 ing if there is an abnormality in the
Charge warning light
(21) charging circuit and it becomes impos-
sible to charge.

If the coolant drops below a specified

27 Coolant level and overheat level, or its temperature rises above
(19) warning light 100ºC (212ºF) the warning light comes
on and a warning buzzer sounds.

<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. The buzzer
will stop when the vehicle is stopped
and the parking brake valve is engaged.
Brake warning light
(18) <Brake fluid level>
(A.O.H. brake vehicle)
When the fluid level in the brake fluid
reservoir drops below the normal oper-
ating level the warning light comes on
and a warning buzzer sounds. The
buzzer stops when the vehicle is
stopped and the parking brake valve is
engaged.

TD-4
 WARNING LIGHTS

Item Warning light name Function

When the air pressure in the brake sys-

8 tem drops to approximately 539 kPa
Air pressure warning light
(22) {5.5 kgf/cm2, 78 psi}, the warning light
comes on and a buzzer sounds.

11 This light will go on when the trailer

Trailer brake warning light
(14) brake is applied.

TD-5
 TROUBLE SYMPTOMS AND FAULTY UNITS

TROUBLE SYMPTOMS AND FAULTY UNITS

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”
No sound Faulty starting sys-
tem
Listen to sound as
ENGINE FAILS Engine does
the starting motor
TO START Faulty engine
pinion pops out not runs
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
NOT MOVE Foot brake dragging
SMOOTHLY
Faulty clutch
Vehicle jerks or stutters Excessive play in power train
Engine rubber mounting fatigued

TD-6
 TROUBLE SYMPTOMS AND FAULTY UNITS

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
Faulty steering system
OPERATION
Poor steering wheel return Improper front wheel alignment
Faulty front axle
Faulty steering system
Insufficient steering angle
Faulty front axle (improper knuckle adjustment)

TD-7
 TROUBLE SYMPTOMS AND FAULTY UNITS

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-8
 PROBABLE CAUSE AND REMEDY

PROBABLE CAUSE AND REMEDY

CLUTCH
Clutch disengagement and slippage are as a rule closely related to clutch pedal play. Excessive pedal play
causes defective disengagement 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 master 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 trans-
mission gearshift lever. You will hear a crunching noise made by the transmission as it partially 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 facings will cause defective engagement of the clutch pedal.
Symptom Probable cause Remedy
Clutch will not dis- WHEN CLUTCH PEDAL OPERATION AND PLAY
engage smoothly ARE CORRECT
or at all.
z Runout or distortion on clutch disc, pres- z Correct or replace faulty parts.
sure plate or flywheel
z Graded wear or jamming on clutch disc z Repair or replace clutch disc and
splines 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 z Disassemble and clean.
plate and flywheel
z Destroyed 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 cylin- z Disassemble and repair.
der or 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-9
 PROBABLE CAUSE AND REMEDY

CLUTCH SLIPPAGE
When the clutch begins to slip, pedal play decreases and many things begin to occur simultaneously. It should
be kept in mind that a short time after the start of clutch slippage, the clutch disc will completely wear out, fre-
quently 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.
Symptom Probable cause Remedy
Clutch slippage CLUTCH OUTER LEVER PLAY IS CORRECT
z Worn frictional surface of clutch disc, fly- z Correct or replace parts.
wheel and/or pressure plate; improper con-
tact between these parts or jamming
z Oil on frictional surface of clutch disc, fly- z Clean or replace parts.
wheel and/or 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.
NO CLUTCH OUTER LEVER PLAY
z Clutch master cylinder push rod improperly z Adjust push rod to specified
adjusted to push piston length.
z Clutch booster push rod improperly z Adjust push rod to specified
adjusted to push clutch lever length.
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 encoun-
tered when clutch is engaged, clutch disc may be worn or broken.
Symptom Probable cause Remedy
Noise is heard z Jammed flywheel pilot bearing z Replace bearing.
when clutch is dis-
engaged.
z Jammed release bearing z Replace bearing.

Noise is heard
z Worn clutch disc z Replace clutch disc.
when clutch is z Broken clutch disc torsion spring z Replace clutch disc.
engaged.
z Broken transmission bearing or gears z Replace bearing or gears.

TD-10
 PROBABLE CAUSE AND REMEDY

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.
Symptom Probable cause Remedy
Vibration occurs z Loose rivets on clutch disc facing z Correct or replace clutch disc.
while clutch is
being engaged.
z Broken or fatigued pressure spring z Replace pressure spring.
z Twisted clutch disc, flywheel and pressure z Repair or replace faulty parts.
plate or 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

Symptom Probable cause Remedy
Clutch pedal is z Faulty clutch booster z Disassemble, repair and clean.
heavy.
z Jammed release shaft bushing or insuffi- z Replace bushing or apply grease.
cient lubrication
z Seized release bearing collar z Correct or replace bearing collar.
z Insufficient lubrication of release lever bush- z Apply grease.
ing

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 troubleshooting. In addition, it
should be determined whether the usual noise is being emitted from the gears or from the bearings.
Symptom Probable cause Remedy
Noisy transmis- z Low viscosity of lubricant z Use proper grade of lubricant.
sion
z Insufficient lubricant z Fill to specified level.
z Scratched or worn gear teeth (Excessive z Repair or replace faulty parts.
backlash)
z Worn or broken bearing z Replace bearing.
z Shift fork improperly positioned to interface z Check shift fork and if it is bent,
with gears replace it.

TD-11
 PROBABLE CAUSE AND REMEDY

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 considering 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 malfunctions in the synchromesh mechanism,
which usually occur
in a particular gear position, such as second or third gear.
Symptom Probable cause Remedy
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 mecha- z Correct or replace parts.
nism
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.
Symptom Probable cause Remedy
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 z Check engine rubber mounting,
vibration. 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, cor-
rect or replace.
z Locking ball and/or shift shaft ball groove z Disassemble and replace exces-
worn sively 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 neces-
sary, replace thrust washer.
z Worn hub splines or end face z Replace hub.
z Worn main shaft bearing z Replace main bearing.

TD-12
 PROBABLE CAUSE AND REMEDY

PROPELLER SHAFT
When there is something wrong with the propeller shaft, it frequently 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 particular rotating speed of the
propeller shaft.
Often overlooked in troubleshooting is propeller shaft vibration caused by its improper installation on the com-
panion 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

Symptom Probable cause Remedy
Car vibration dur- z Propeller shaft improperly assembled to z Reassemble so that splined yoke
ing operation splined yoke is lined up with yoke on opposite
side.
z Twisted or bent propeller shaft z Correct or replace propeller shaft.
z Universal joint journal or needle roller bear- z Replace bearing.
ing worn or 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 z Correct or replace.
rubber material

Unusual noise is emitted when vehicle starts to move

and while being driven
Symptom Probable cause Remedy
Unusual noise z Universal joint worn or damaged z Replace universal joint.
during 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, z Apply grease.
yoke splines, center bearing, etc.

TD-13
 PROBABLE CAUSE AND REMEDY

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
Symptom Probable cause Remedy
UNUSUAL NOISE WHEN VEHICLE STARTS TO MOVE
z Excessive backlash in differential gear z Adjust backlash.
z Excessive backlash between ring gear and z Adjust backlash.
drive pinion
z Loose connection between companion z Tighten to specified torque.
flange and propeller 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, z Correct or replace faulty parts.
side bearing, etc. worn or damaged
z Low oil level z Replenish oil.
WHEN DRIVING
z Excessive backlash between ring gear and z Adjust backlash.
drive pinion
z Worn or damaged bearing z Replace bearing.
z Worn or damaged gear z Correct or replace.
z Low oil level z Replenish oil.
WHEN RUNNING BY INERTIA
z Insufficient backlash between ring gear and z Adjust backlash.
drive pinion
z Worn or damaged bearing z Replace bearing.
z Improper gear contact pattern z Correct or replace faulty gear(s).
z Low oil level z Replenish oil.

TD-14
 PROBABLE CAUSE AND REMEDY

OIL LEAKAGE
Symptom Probable cause Remedy
Oil leakage z Oil seal worn, loose or damaged z Replace oil seal.
z Differential carrier retaining nuts loose or z Replace gasket and tighten nuts
gasket damaged to specified torque.
z Scratches on mating surface of differential z Correct or, if necessary, replace
carrier differential carrier.
z Loose drain plug or damaged gasket z Replace gasket and tighten loose
plug to specified 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 z Correct or replace companion
or deformed flange.
z Companion flange runout due to faulty drive z Replace bearing.
pinion bearing
z Deformed axle housing due to overload z Correct or replace axle housing.

WHEEL BEARING SEIZURE

Symptom Probable cause Remedy
Wheel bearing z Excessive wheel bearing preload z Adjust preload.
seizure
z Lack of bearing grease or use of improper z Apply grease or replace with
grease proper grease.
z Dirt or dust in bearing z Clean and apply grease to bear-
ing.
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 deteriorated lining surface.

TD-15
 PROBABLE CAUSE AND REMEDY

[AIR BRAKE]

INSUFFLCLENT BRAKING FORCE

Symptom Probable cause Remedy
Brake do not CORRECT AIR PRESSURE
apply completely
z Short brake valve stroke z Check and, if necessary, replace
or at all
brake valve.
z Camshaft inoperative (Lack of lubrication to z Check camshaft for operation
bushing) and, if necessary, replace.
z Brake chamber push rod stroke improperly z Adjust stroke.
adjusted
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 com-
pressor.
z Air pressure governor improperly adjusted z Adjust or clean governor.
or inoperative due to entry of foreign matter
z Air leakage at brake valve z Disassemble and repair brake
valve.

UNUSUAL NOISE
Symptom Probable cause Remedy
Unusual noise is z Exposed rivets or bolts due to worn linings z Replace linings.
emitted when
brake pedal is
z Hardened linings z Replace linings.
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 z Correct or re-tighten drum.
loose installation
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-16
 PROBABLE CAUSE AND REMEDY

UNEVEN BRAKING PERFORMANCE

Symptom Probable cause Remedy
Uneven braking z Uneven tire pressure or difference in tire z Inflate to specified pressure or use
size tires of same size.
z Improper installation of brake shoes or dam- z Tighten brake shoe anchor pin
aged return spring lock nut or 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

Symptom Probable cause Remedy
All wheels drag- z Compressed air in brake chamber z Check and correct valve, quick
ging (Overheated release valve exhaust valve
brake drum)
z lmproper sliding of camshaft of improper z Correct faulty parts.
return of slack adjuster lever.
z Brake shoe or air chamber return spring z Replace faulty springs
broken or fatigued
z spring brake activated z Release spring brake, and elimi-
nate problem.
z Relay valve or exhaust port of quick release z Disassemble and clean faulty
valve plugged. parts.
z Failure of secondary brake valve pis-Ton to z Disassemble and clean brake
return valve and, if necessary, replace
faulty parts.

TD-17
 PROBABLE CAUSE AND REMEDY

[AIR OVER HYDRAULIC BRAKE]

FAULTY BRAKE PERFORMANCE

Symptom Probable cause Remedy
Brake will not CORRECT AIR PRESSURE
operate effec-
z Short brake valve stroke z Check and, if necessary, replace
tively when pedal
is depressed.
brake valve.
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 com-
z Air pressure governor improperly adjusted pressor.
or inoperative due to entry of foreign matter z Adjust or clean governor.
z Air leakage at brake valve z Disassemble and repair brake
valve.

UNUSUAL NOISE
Refer to the “AIR BRAKE” section.

UNEVEN BRAKING PERFORMANCE

Refer to the “AIR BRAKE” section.

ALL WHEELS DRAGGING

Symptom Probable cause Remedy
All wheels drag- z Failure of wheel cylinder to return z Replace wheel cylinder or piston.
ging (Overheated
brake drum)
z Bent air booster push rod z Replace push rod.
z Air booster breather plugged z Clean breather.
z Failure of primary or secondary brake valve z Disassemble, check and clean.
piston to return Replace faulty parts.

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 steer-
ing 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 pit-man 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 steering wheel can not be
easily turned during driving, the cause is usually improper caster angle.
Unsmooth operation and return of the steering wheel due to insufficient backlash of the steering gears or due
to excessive application of pre-load cannot occur unless the steering gearbox is disassembled. If such a prob-
lem has developed gradually, the cause is usually insufficient lubrication of the linkage and connections.

TD-18
 PROBABLE CAUSE AND REMEDY

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 components.

HEAVY STEERING WHEEL

Symptom Probable cause Remedy
Heavy steering STEERING SYSTEM
wheel operation
z Low power steering oil level z Replenish fluid to specified level.
z Deteriorated oil or foreign matter in oil z Replace oil.
z Worn steering linkage joint (ball stud, etc.) z Replace ball stud.
z Faulty power steering system
Measure back pressure and if above speci-
1) Excessive oil resistance due to dented piping
fications, repair or replace piping.
Measure fluid pressure and flowrate and if
2) Low oil pressure due to inoperative hydraulic pump below specifications, disassemble and
repair hydraulic pump.
3) Air in hydraulic line Bleed air and add fluid.
4) Spool valve inoperative Disassemble and repair spool valve.
5) Power cylinder and power piston worn or damaged,
Disassemble and repair.
or power piston seal “O” ring worn or damaged
6) Excessive oil leakage at steering gear box Disassemble and repair steering gear box.
FRONT AXLE
z Wheel alignment improperly adjusted z Check and adjust wheel align-
(Excessive caster) ment.
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.

TD-19
 PROBABLE CAUSE AND REMEDY

STEERING WHEEL SHIMMY

Symptom Probable cause Remedy
Steering wheel STEERING SYSTEM
shimmies
z Steering gear box bolts or steering column z Tighten to specified torque.
bracket 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 align-
ment.
z Fatigued front spring, loose “U” bolt or dam- z Replace faulty parts.
aged center bolt

STEERING WHEEL FAILS TO RETURN

Symptom Probable cause Remedy
Steering wheel STEERING SYSTEM
fails 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.
z Check spool valve-to-housing
contact pattern and, if necessary,
3) Spool valve inoperative
replace spool valve and/or hous-
ing.
FRONT AXLE
z Excessive caster z Check and adjust wheel align-
ment.

TD-20
 PROBABLE CAUSE AND REMEDY

STEERING WHEEL PULLS TO EITHER SIDE

Symptom Probable cause Remedy
Steering wheel z Wheel alignment not properly adjusted z Check and adjust wheel align-
pulls to either side ment.
z Left or right front spring fatigued or dam- z Replace faulty spring.
aged
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

Symptom Probable cause Remedy
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 bear- z Replace hub bearing or tighten
ing nut 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 vehi- z Operate vehicle correctly.
cle or sudden braking
z Overload z Observe rated capacity.

FLUID OVERFLOW AT POWER STEERING FLUID RES-

ERVOIR
Symptom Probable cause Remedy
Fluid overflows at Strainer or fluid filler plugged Clean strainer or replace fluid filter.
fluid reservoir Air in piping Add fluid and bleed air.

TD-21
 ENGINE REMOVAL & INSTALLATION

ER

CONTENTS
SERVICE DATA................................. ER-1-1 CONSTRUCTION ......................... ER-2-1
TIGHTENING TORQUE ................ ER-1-1 ENGINE INSTALLATION ................... ER-3-1
ENGINE REMOVAL ........................... ER-2-1
 SERVICE DATA

SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Bracket 29 {3.0, 22}
Front engine mounting bolt and nut
Cushion 49 {5.0, 36}
Front cushion mounting bolt 49 {5.0, 36}
Engine 49 {5.0, 36}
Rear cushion mounting bolt
Member 127 {13.0, 94}

ER-1-1
 ENGINE REMOVAL

ENGINE REMOVAL
CONSTRUCTION

1. Engine mounting bracket 3. Engine mounting bracket 5. Cushion

2. Cushion 4. Engine mounting member
NOTE
z Numbers before part names do not indicate the disassembly sequence.

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.

ER-2-1
 ENGINE REMOVAL

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.
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.

ER-2-2
 ENGINE REMOVAL

13. .Remove the front and rear engine mounting bolts.

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 (AIR SERVO TYPE)
 CLUTCH

CONTENTS
SERVICE DATA................................. CL-1-1 INSTALLATION ............................ CL-3-16
SPECIFICATIONS......................... CL-1-1 ADJUSTMENT ................................ CL-3-19
SERVICE DATA............................. CL-1-2
TIGHTENING TORQUE ................ CL-1-5 = UNIT NAME CL535, 635, 640 =
TOOLS............................................... CL-2-1 CONSTRUCTION.............................. CL-4-1
DISASSEMBLY ................................. CL-4-2
= UNIT NAME CL420 = REMOVAL ...................................... CL-4-2
CONSTRUCTION .............................. CL-3-1 DISASSEMBLY .............................. CL-4-4
DISASSEMBLY ................................. CL-3-2 INSPECTION..................................... CL-4-9
REMOVAL ..................................... CL-3-2 REASSEMBLY ................................ CL-4-13
DISASSEMBLY ............................. CL-3-4 REASSEMBLY ............................. CL-4-13
INSPECTION ..................................... CL-3-8 INSTALLATION ............................ CL-4-14
REASSEMBLY ................................ CL-3-13 ADJUSTMENT ................................ CL-4-16
REASSEMBLY ............................ CL-3-13
 SERVICE DATA CLUTCH PROPER

SERVICE DATA
SPECIFICATIONS
UNIT NAME CL420, 535, 630, 635, 640
Unit name CL420 CL535 CL635 CL640
Coil spring type
Type Coil spring type single disc, dry
dual disc, dry
Facing dimensions
380 x 240 x 4 410 x 250 x 5
(OD x ID x thickness when 430 x 250 x 5
(14.96 x 9.45 (16.14 x 9.84
Clutch disc

compressed) (16.93 x 9.84 x 0.20)

x 0.16) x 0.20)
mm (in)
Facing area (one side)
682.2 (105.74) 830 (128.7) 961 (149.0)
cm2 (sq in)
Material Semi-mold
Outer: 12
Number of pressure springs 12
Inner: 12
Clutch operating system Hydraulic system (air booster)

UNIT NAME

CL 1 30

Clutch Clutch Disc size mm (in) Clutch cover set load N {kgf, lbf}
4 380 (14.96) 4 20 13,239 {1,350, 2,977}
5 410 (16.14) 5 35 13,485 {1,375, 3,032}
6 430 (16.93)
35 19,124 {1,950, 4,300}
6
40 20,055 {2,045, 4,509}

CL-1-1
 SERVICE DATA CLUTCH PROPER

SERVICE DATA
UNIT NAME CL420
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Runout Less than 1.0 (0.039) 1.4 (0.055)
Wear limit on one
Facing thickness (one side) — 0.2 (0.008) side: 1.3 mm (0.051
Clutch disc
in)
Less than
Play in radial direction of spline 0.5 (0.020)
0.27 (0.0106)
Flatness of contact surface Less than 0.1 (0.004) 0.25 (0.0098)
Below zero indi-
0.2 - 0.3 (0.008 - 0.012) Less than 0
Clutch pres- Taper of contact surface at outer cates that inner end
(Outer end is higher than More than 0.5
sure plate section is higher than outer
inner end.) (0.020)
end.
Thickness of contact face — 20.1 (0.791)
Flatness of con-
Less than 0.1 (0.004) 0.15 (0.0059)
tact surface
Pressure Below zero indi-
plate side Taper of contact 0.2 - 0.3 (0.008 - 0.012) Less than 0
cates that inner end
surface at outer (Outer end is higher than More than 0.5
Clutch inter- is higher than inner
section inner end.) (0.020)
mediate plate end.
Flatness of con-
Flywheel side Less than 0.05 (0.0020) 0.15 (0.0059)
tact surface
Wear limit on one
Thickness of contact surface — 33.6 (1.323)
side: 2 mm (0.08 in)
Outer — 100.3
Free length
Inner — 103.6 (4.078)
759.1 - 839.5 When compressed
719.8
Outer {77.4 - 85.6, 170.7 - to 58.2 mm (2.291
{73.4, 161.8}
Tension 188.7} in)
Clutch pres- N {kgf, lbf} When compressed
sure spring 320.7 - 354.0 304.0
Inner to 57.4 mm (2.260
{32.7 - 36.1, 72.1 - 79.6} {31.0, 68.4}
in)
Less than
Outer 5.5 (0.217)
3.7 (0.146) Measure at free
Tilt
Less than length
Inner 5.7 (0.224)
3.8 (0.150)
Flatness of contact surface Less than 0.1 (0.004) 0.15 (0.0059)
Thickness (A): — 51.5 (2.028)
Flywheel Decrease in thickness of contact
surface Height (H): 91.3 - 91.5
—
(3.594 - 3.602)

CL-1-2
 SERVICE DATA CLUTCH PROPER

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Measure after
bushing has been
Release lever bushing ID — 17.66 (0.6953)
pressed into
release lever
Lever pin and support pin OD — 12.5 (0.492)
Support ID — 12.9 (0.508)
29.99 - 30.01
Release shaft OD —
(1.1807 - 1.1815)
6.9 - 7.1
Width of lever plate 6.4 (0.252)
(0.272 - 0.280)
Clutch
release mech- 152.2 - 153.6 PF6T, PF6TA and
—
anism (5.992 - 6.047) PF6TB
152.7 - 154.1
— RE10
(6.012 - 6.067)
Height of release lever plate (L)
From upper clutch
18.3 - 19.7 cover surface to
—
(0.720 - 0.776) upper lever plate
surface
Clearance between release lever Less than
—
and lever plate 0.5 (0.020)
5.0 - 6.0
Clutch outer lever play —
(0.197 - 0.236)

CL-1-3
 SERVICE DATA CLUTCH PROPER

UNIT NAME CL535, 635, 640

Unit: mm (in)
Item Maintenance standard Service limit Remarks
CL535 Less than 1.0 (0.039) 1.4 (0.055)
Runout CL635
— 1.4 (0.055)
CL640
Facing thickness (one side) — 0.2 (0.008) Above rivet head
Clutch disc
Less than
Play in radial CL535 0.5 (0.020)
0.24 (0.0094)
direction of
spline CL635 Less than
0.5 (0.020)
CL640 0.27 (0.0106)
Flatness of CL535 Less than 0.1 (0.004) 0.2 (0.008)
contact sur- CL635
face Less than 0.1 (0.004) 0.25 (0.0098)
CL640
Clutch pres- Taper of con-
sure plate 0.05 - 0.15 Outer side is higher
tact surface at CL635 —
(0.0020 - 0.0059) than inner side
outer section
Decrease in thickness of contact 59.7 - 59.9
57.8 (2.276)
face (2.350 - 2.358)
CL635 — 96.2 (3.787)
Free length CL635 94.9 (3.736) 91.7 (3.610)
CL640 96.4 (3.795) 93.0 (3.661)
1,107.2 - 1,222.9
1,048.4
CL635 {112.9 - 124.7,
{106.9, 235.7}
249.0 - 275.0}
1,557.4 - 1,722.1
Tension 1,476.0 When compressed
CL635 {158.8 - 175.6,
N {kgf, lbf} {150.5, 331.9} to 63 mm (2.48 in)
Clutch pres- 350.2 - 387.2}
sure spring 1,630.9 - 1,802.5
1,544.6
CL640 {166.3 - 183.8,
{157.5, 347.3}
366.7 - 405.3}
Less than
CL635 5.2 (0.205)
3.5 (0.138)
Less than Measure at free
Tilt CL635 5.0 (0.197)
3.3 (0.130) length
Less than
CL640 5.0 (0.197)
3.4 (0.134)

CL-1-4
 SERVICE DATA CLUTCH PROPER

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Less than
Flatness of contact surface 0.2 (0.008)
0.1 (0.004)
Thickness (A): — 48.5 (1.909)
Rise toward outer
CL535 Height (H): side
47.9 - 48.1 — To flange end face
Decrease in (1.886 - 1.894)
Flywheel
thickness of Thick- 50.5 (1.988) 48.5 (1.909) P series engine
contact sur- ness
face (A) 55.5 (2.185) 53.5 (2.106) R series engine
CL635
CL640 Rise toward outer
Height 47.9 - 48.1 2.0 (0.079)
side
(H) (1.886 - 1.894) (Grinding depth)
To flange end face
Measure after
bushing has been
Release lever bushing ID 12.7 (0.500) —
pressed into
release lever
Lever pin and support pin OD 12.7 (0.500) 12.5 (0.492)
Support ID 12.7 (0.500) 12.9 (0.508)
Clutch
29.99 - 30.01
release mech- Release shaft OD —
(1.1807 - 1.1815)
anism
Height above the
76.3 - 77.7 frictional surface of
Height of release lever plate (L) —
(3.004 - 3.059) the flywheel (For
CL535)
Release bearing wear — 0.5 (0.020) Except for CL535
Clutch outer lever play 5.0 - 7.0 (0.197 - 0.276) —

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
CL420 59 - 68 {6.0 - 6.9, 43 - 50}
Clutch cover mounting bolt
CL535, 635, 640 44 {4.5, 33}
Strap plate mounting reamer bolt CL420 98 - 108 {10 - 11, 72 - 80}
Strap set bolt CL535, 635, 640 44 - 49 {4.5 - 5.0, 33 - 36}
Lock plate mounting bolt or nut 10 - 15 {1.0 - 1.5, 7 - 11}
Support lock nut CL535 98 {10, 72}
7T-M12 58 - 77 {5.9 - 7.9, 43 - 57}
Clutch housing mounting bolt
7T-M16 137 - 186 {14.0 - 19.0, 101 - 137}
CL420 40 - 54 {4.1 - 5.5, 30 - 40}
Transmission mounting nut
CL535, 635, 640 37 - 49 {3.8 - 5.0, 27 - 36}

CL-1-5
 TOOLS CLUTCH PROPER

TOOLS

Tool name and number Description Shape CL CL CL CL

420 535 635 640

99797 Z0061
O
*1

99797 Z0069
O
Used to center clutch disc and to *2
inspect and adjust the height of
Setting shaft 99797 Z0017 release levers (diaphragm spring).
O O O
The setting shaft is used with the *3 *6

99797 Z0018
setting sleeve. O O
*4 *7

99797 Z0008
O O
*5 *8

Used to center clutch disc and to

inspect and adjust the height of
Setting sleeve 99798 Z0008 release levers (diaphragm spring). O O O O
The setting sleeve is used with the
setting shaft.

NOTE
z *1 PF6T, PF6TA and PF6TB engines
z *2 PF6T, PF6TA, PF6TB and RE10 engines (For Fuller transmission)
z *3 PF6T engine
z *4 RF8 engine
z *5 PF6T, PF6TA and RF8 engines (For Fuller transmission)
z *6 PF6TA engine
z *7 RG8 engine
z *8 PF6TA and RG8 engines (For Fuller transmission)

CL-2-1
 CONSTRUCTION CL420

= UNIT NAME CL420 =

CONSTRUCTION
CLUTCH COVER AND CLUTCH HOUSING ASSEMBLY

CL-3-1
 DISASSEMBLY CL420

DISASSEMBLY
REMOVAL
Key point of removal
<Removal of transmission equipped with pull type clutch>
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 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
z When the reference line is located to the left of gradua-
tion W on the setting sleeve, it is necessary to replace
the clutch disc.

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.

CL-3-2
 DISASSEMBLY CL420

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-3-3
 DISASSEMBLY CL420

DISASSEMBLY
CLUTCH COVER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Reamer bolt A 10. Lock plate 19. Lever pin
, 2. Clutch disc 11. Support nut , 20. Release lever
, 3. Lever plate ,+ 12. Clutch cover 21. Cotter pin
4. Reamer bolt B 13. Spring seat B 22. Washer
5. Intermediate plate , 14. Pressure spring (Outer) 23. Lever pin
6. Reamer bolt C , 15. Pressure spring (Inner) 24. Return spring
7. Strap plate 16. Spring seat A , 25. Lever support
8. Clutch disc 17. Cotter pin 26. Bushing
9. Lock nut 18. Washer 27. Pressure plate

Marks“+” and “,” indicate that the key points of operation are explained in the text.

CL-3-4
 DISASSEMBLY CL420

Key point of disassembly

Key point of disassembly
12 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-3-5
 DISASSEMBLY CL420

CLUTCH HOUSING
Transmission model MTS60, MTS70, MTP00

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Grease nipple 8. Wire 15. Needle bearing
2. Lock nut 9. Release yoke set bolt 16. Air cleaner
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
Marks“+” and “,” indicate that the key points of operation are explained in the text.

CL-3-6
 DISASSEMBLY CL420

Transmission model MRT20

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Grease nipple + 8. Feather key 15. Rubber seat
2. Grease hose , 9. Release yoke 16. Clutch housing (Front case)
3. Spring 10. Release yoke bearing 17. Grease nipple
4. Release sleeve 11. Oil seal 18. Plug
5. Release bearing 12. Needle bearing 19. Taper plug
6. Release yoke set bolt 13. Air cleaner 20. Gasket
7. Release shaft 14. Housing cover 21. Under cover
Marks“+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

10 MRT60, MTS70, MTP00 and
8 MRT20 feather key
Remove the wires, set bolts and feather key.
NOTE
z Always remove the release yoke from the feather key
first, and then detach the key from the release shaft
assembly.

CL-3-7
 INSPECTION CL420

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has exceeded, repair or replace faulty parts.

CLUTCH DISC
Runout
Unit: mm (in)
Maintenance standard Service limit
Less than 1.0 (0.039) 1.4 (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) Remarks
0.2 (0.008) Wear limit on one side:
—
(above rivet head) 1.3 mm (0.051 in)

Play in radial direction of spline

Unit: mm (in)
Maintenance standard Service limit
Less than 0.27 (0.0106) 0.5 (0.020)

CL-3-8
 INSPECTION CL420

CLUTCH PRESSURE PLATE

Flatness of contact surface
Unit: mm (in)
Maintenance standard Service limit
Less than 0.1 (0.004) 0.25 (0.0098)

Taper of contact face at outer section

Unit: mm (in)
Maintenance standard Service limit Remarks
0.2 - 0.3
Below zero indicates
(0.008 - 0.012) Less than 0
that inner end is higher
(Outer end is higher More than 0.5 (0.020)
than outer end
than inner end.)

Thickness of contact surface

Unit: mm (in)
Maintenance standard Service limit
— 20.1 (0.791)

CLUTCH INTERMEDIATE PLATE

Flatness of contact surface (Pressure plate side)
Unit: mm (in)
Maintenance standard Service limit
Less than 0.1 (0.004) 0.15 (0.0059)

Taper of contact face at outer section

(Pressure plate side)
Unit: mm (in)
Maintenance standard Service limit Remarks
0.2 - 0.3
Below zero indicates
(0.008 - 0.012) Less than 0
that inner end is higher
(Outer end is higher More than 0.5 (0.020)
than outer end
than inner end.)

CL-3-9
 INSPECTION CL420

Flatness of contact surface

(Flywheel side)
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.15 (0.0059)

Thickness of contact surface

Unit: mm (in)
Maintenance standard Service limit Remarks
Wear limit on one side:
— 33.6 (1.323)
2 mm (0.08 in)

CLUTCH PRESSURE SPRING

Free length
Unit: mm (in)
Unit name Maintenance standard Service limit
Outer — 100.3 (3.949)
Inner — 103.6 (4.079)

Tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
759.1 - 839.5
719.8 When compressed to
Outer {77.4 - 85.6,
{73.4, 161.8} 58.2 mm (2.291 in)
170.7 - 188.7}
320.7 - 354.0
304.0 When compressed to
Inner {32.7 - 36.1,
{31.0, 68.4} 57.4 mm (2.260 in)
72.1 - 79.6}

Tilt
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Less than 3.7
Outer 5.5 (0.217)
(0.146)
Measure at free length
Less than 3.8
Inner 5.7 (0.224)
(0.150)

CL-3-10
 INSPECTION CL420

FLYWHEEL
Flatness of contact surface
Unit: mm (in)
Maintenance standard Service limit
Less than 0.1 (0.004) 0.15 (0.0059)

Decrease in thickness of contact surface

Unit: mm (in)
Item Maintenance standard Service limit
Thickness (A) — 51.5 (2.028)
Height (H) 91.3 - 91.5 (3.595 - 3.602) —

CLUTCH RELEASE MECHANISM

Release lever bushing inside diameter
Unit: mm (in)
Maintenance standard Service limit Remarks
Measure after bushing has
— 17.66 (0.6953) been pressed into release
lever

Lever pin and support pin outside diameter

Unit: mm (in)
Maintenance standard Service limit
— 12.5 (0.492)

Support inside diameter

Unit: mm (in)
Maintenance standard Service limit
— 12.9 (0.508)

CL-3-11
 INSPECTION CL420

Release shaft outside diameter

Unit: mm (in)
Maintenance standard Service limit
29.99 - 30.01 (1.1807 - 1.1815) –

Width of lever plate

Unit: mm (in)
Maintenance standard Service limit
6.9 - 7.1 (0.272 - 0.280) 6.4 (0.252)

CL-3-12
 REASSEMBLY CL420

REASSEMBLY
REASSEMBLY
CLUTCH COVER
Key point of reassembly
Before assembling, apply a coat of molybdenum disulfide grease to
all frictional surfaces.
z Sliding surfaces of release lever and support pin
z Sliding surfaces of release lever and lever pin
z Sliding surfaces of transmission main drive shaft and clutch
disc
25 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.
z Be sure to insert lever pin from the direction shown in the
figure.

20 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.
z Be sure to insert lever pin from the direction shown in
the figure.

14, 15 Pressure spring

Attach the spring seat and pressure spring to the pressure plate.
z Adjusting the pressure spring tension
If the pressure plate or intermediate plate is worn or the latter has
been machined, place plain adjustment washers between the pres-
sure plate and spring seat A in order to compensate for the total
amount of wear.
Since the pressure plate and intermediate plate cannot be ground
more than 2.0 mm (0.079 in) and 4.0 mm (0.157 in), respectively,
the adjustment range using plain washers should be within 6.0 mm
(0.236 in).
Use the following table as a guide in selecting the proper number of
plain adjustment washers t = 2.0 mm (0.079 in).

Total amount of wear No. of adjustment plain washers

Unit: mm (in) required
Less than 2.0 (0.079) None
2.0 - 4.0 (0.079 - 0.157) 1
4.0 - 6.0 (0.157 - 0.236) 2

CL-3-13
 REASSEMBLY CL420

12 Clutch cover
Attach the clutch cover to the pressure plate, using the guide bolt or
press.
NOTE
z Align the matching marks when reassembling the clutch
cover and pressure plate.

[Reassembly using the guide bolts]

z Screw the guide bolts into the pressure plate.
z Securely attach a wrench to the guide bolt, and then tighten
the nut until the support's threads can be seen on the clutch
cover. Then install the support nut.
NOTE
z Tighten the guide bolt nuts equally, one at a time.
z Compress the clutch cover so that the support's thread
area does not touch the clutch cover.

[Reassembly using the press]

z Compress the clutch cover with a guide bar until the sup-
port's threads can be seen on the upper surface of the
clutch cover and then install the support nut.
NOTE
z Do not allow the support's threads to touch the clutch
cover when compressing the latter.
z To prevent the clutch from accidentally disassembling
after it has been assembled, be sure to install the M10
setting bolt of 1.25 mm (0.0492 in) pitch, 75 mm (2.95 in)
bolt length and 26 mm (1.02 in) effective thread length
before loosening the press.

3 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.

CL-3-14
 REASSEMBLY CL420

2 Clutch disc
Install the clutch disc (Transmission side) to the intermediate plate.
NOTE
z The face of the lower boss of the clutch disc should
always be toward the pressure plate.
z Center the clutch disc and intermediate plate when
installing.

z Install the pressure plate to the intermediate plate.

NOTE
z Align the matching marks when reassembling the inter-
mediate plate and pressure plate.

z Temporarily tighten the lock washer, plain washer and strap

plates on the intermediate plate via reamer bolt C.

z Component parts at the location of the strap plate

z Strap plate retaining reamer bolt and plain washer.
Unit: mm (in)
Type of mounting bolt A B C
Overall length of the mounting bolt 47 (1.85) 42 (1.65) 51 (2.01)

Unit: mm (in)
Type of plain washer A B
Thickness of plain washer 1.0 (0.039) 2.5 (0.098)

z No. of strap plates required

Location of strap plate No. of strap plates
Between flywheel and intermedi-
4 per location (Total: 16)
ate plate
Between intermediate plate and
5 per location (Total: 20)
pressure plate

All of the strap plates are exactly the same in design.

CL-3-15
 REASSEMBLY CL420

z Component parts at the location of the strap plate.

Flywheel Intermediate plate Pressure plate
Reamer bolt A Reamer bolt C Reamer bolt B
Plain washer A (1) Plain washer A (1) Plain washer A (1)
— Plain washer B (2) Plain washer B (1)

z Adjusting the installed height of the strap plate

If a worn intermediate plate is used or if it has been remachined,
place plain adjustment washers between the strap plates at the
intermediate plate location to compensate for the total amount of
wear.
Use the following table as a guide in selecting the proper number of
plain washers t = 1 mm (0.04 in).
Total wear amount of intermediate No. of adjustment plain
plate and flywheel [mm (in)] washers required
Less than 0.5 (0.020) None
0.5 - 1.5 (0.020 - 0.059) 1
1.5 - 2.5 (0.059 - 0.098) 2
2.5 - 3.5 (0.098 - 0.138) 3
3.5 - 4.0 (0.138 - 0.157) 4

CLUTCH HOUSING
Key point of reassembly
12 MTS60, MTS70, MTP00 and 9 MRT20 release yoke
Insert the release shaft assembly into the clutch housing, fit the
release yoke onto the shaft, and then install the feather key, set bolt
and wire on 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 tool.
NOTE
z Clean the flywheel and intermediate plate prior to reas-
sembly.
z Ensure that the lower boss of the clutch disc (on the fly-
wheel side) faces the intermediate plate.
z Be sure to align the dowel pins when installing the clutch
cover assembly.

CL-3-16
 REASSEMBLY CL420

Setting tool

Transmission Setting tool

Setting shaft Setting sleeve
model assembly
Other than Fuller
99792 Z0060 99797 Z0061
transmission
99798 Z0008
For Fuller transmis-
99792 Z0068 99797 Z0069
sion

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 support nuts until the basic line on the setting shaft is
positioned at the point on the sleeve, as determined by the
previous measurement.
[When a new clutch disc is used]
Install the adjusting sleeve onto the setting shaft; turn the
four support nuts until the basic line on the setting shaft is at
point “N” on the sleeve.

3. After tightening the lock plate, remove the clutch disc set-
ting tool and tap on the lever plate several times with a
wooden mallet. Then insert the clutch disc setting tool again
and make sure that the reference line is aligned with posi-
tion “N”.

NOTE
z When reusing the clutch disc after it has been removed,
use the reference line which is verified during removal.
z If alignment is not made, readjust.

CL-3-17
 REASSEMBLY CL420

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-3-18
 ADJUSTMENT CL420

ADJUSTMENT
CLUTCH PEDAL PLAY
Depress the clutch pedal by hand until resistance is felt. While hold-
ing the clutch pedal in this position, measure the stroke length of
pedal play. If it is outside the specified range, adjust as follows:
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17) —

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 one 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

1. Remove the return spring.
2. Loosen the push rod lock nut.
3. Adjust the play of the outer lever by turning the push rod.
Unit: mm (in)
Item Maintenance standard
Clutch outer lever play 5.0 - 6.0 (0.197 - 0.236)

4. Tighten the lock nut.

5. Reinstall the return spring.

CL-3-19
 ADJUSTMENT CL420

CHECKING FOR WEAR ON THE CLUTCH DISC

To properly check for wear on the clutch disc in the vehicle, pro-
ceed as follows:
[Vehicles without clutch wear indicators]
1. Adjust free play of the outer lever and measure dimension
“L”. If “L” exceeds the wear limit specified in the table,
replace the clutch disc.
2. After installing a new clutch disc, be sure dimension “L” is
within the standard value.
If it is outside the standard value, check and adjust the
clutch itself.
Unit: mm (in)
Item Limit
Model with Fuller transmission 142 (5.59)
Dimension L Model with Nissan Diesel trans-
130 (5.12)
mission

[Vehicles with clutch wear indicators]

1. Adjust free play of the outer lever and check the position of
the indicator plate on the wear indicator. If the indicator
plate reaches the MIN. position, replace the clutch disc.
2. After installing a new clutch disc, be sure the clevis pin
points to the SET position. If it does not, measure dimen-
sion L (as outlined above) to make sure it is within the stan-
dard value.
If L is not outside the standard value, check and adjust the
clutch itself; if it is, proceed to the instructions under “Clutch
disc wear indicator installation and adjustment procedure”
below.

CLUTCH DISC WEAR INDICATOR INSTALLATION AND

ADJUSTMENT PROCEDURE
[After installing new clutch disc]
NOTE
z Be sure the clutch is properly adjusted.

1. Tighten the indicator stay to the clutch housing-to-flywheel

housing stud.
2. Adjust the outer lever play to the specified value.
3. Align the “SET” position of the indicator with the end of the
indicator plate, and secure the indicator. The clearance
between the indicator plate and the indicator must be 7.5
mm (0.295 in).

CL-3-20
 ADJUSTMENT CL420

NOTE
z To properly adjust the wear indicator, be sure dimension
“L” is within the standard value.

4. Fully depress the clutch pedal several times, then check to

be sure the end of the indicator plate is at the “SET” posi-
tion.

[After installing old clutch disc]

NOTE
z Do not loosen or remove the bolts which hold the clutch
wear indicator and stay.
z Be sure the clutch indicator is properly adjusted.
1. Tighten the indicator stay to the clutch housing-to-flywheel
housing stud.
2. Adjust the outer lever play to the specified value.
3. The clearance between the clevis pin and the indicator
must be 3 to 5 mm (0.12 to 0.20 in).
4. Check to make sure the clevis pin points to the mark previ-
ously chalked on the wear indicator.
5. Depress the clutch pedal several times before re-checking
the position of the clevis pin.

CL-3-21
 CONSTRUCTION CL535, 635, 640

= UNIT NAME CL535, 635, 640 =

CONSTRUCTION
CLUTCH COVER AND CLUTCH HOUSING ASSEMBLY

CL-4-1
 DISASSEMBLY CL535, 635, 640

DISASSEMBLY
REMOVAL
Key point of removal
<Removal of transmission equipped with pull type clutch>
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 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
z When the reference line is located to the left of gradua-
tion W on the setting sleeve, it is necessary to replace
the clutch disc.

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.

CL-4-2
 DISASSEMBLY CL535, 635, 640

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-4-3
 DISASSEMBLY CL535, 635, 640

DISASSEMBLY
CLUTCH COVER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Clutch disc 10. Spring cap (Except for CL535) 19. Lever pin A
2. Strap set bolt 11. Spring seat (lower) (for CL535) 20. Bushing
3. Lock plate bolt 12. Pressure spring (for CL535) , 21. Release lever
4. Lock plate 13. Spring seat (upper) (for CL535) 22. Return spring
5. Support nut 14. Cotter pin , 23. Lever support
+, 6. Clutch cover 15. Plain washer 24. Pressure plate
7. Spring cap 16. Lever pin B
8. Spring seat (Except for CL535) 17. Cotter pin
9. Pressure spring (Except for CL535) 18. Plain washer

Marks “+” and “,” indicate that the key points of operation are explained in the text.

CL-4-4
 DISASSEMBLY CL535, 635, 640

Key point of disassembly

Key point of disassembly
6. 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-4-5
 DISASSEMBLY CL535, 635, 640

CLUTCH HOUSING
Transmission model MPS60, MTS60, MTS70, MTP00

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Grease nipple 9. Release yoke set bolt 16. Air cleaner
2. Lock nut + 10. Feather key 17. Housing cover
3. Lock washer 11. Release shaft 18. Rubber seat
4. Grease hose , 12. Release yoke 19. Clutch housing
5. Spring 13. Bolt 20. Grease nipple
6. Release sleeve 14. Oil seal 21. Indicator stay (If so equipped)
7. Release bearing 15. Needle bearing 22. Indicator (If so equipped)
8. Wire
Marks“+” and “,” indicate that the key points of operation are explained in the text.

CL-4-6
 DISASSEMBLY CL535, 635, 640

Transmission model MRT20

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Grease nipple + 8. Feather key 15. Rubber seat
2. Grease hose , 9. Release yoke 16. Clutch housing (Front case)
3. Spring 10. Release yoke bearing 17. Grease nipple
4. Release sleeve 11. Oil seal 18. Plug
5. Release bearing 12. Needle bearing 19. Taper plug
6. Release yoke set bolt 13. Air cleaner 20. Gasket
7. Release shaft 14. Housing cover 21. Under cover
Marks“+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

10 MPS50, MTS60, 70, MTP00 and
8 MRT20 feather key
Remove the wires, set bolts and feather key.
NOTE
z Always remove the release yoke from the feather key
first, and then detach the key from the release shaft
assembly.

CL-4-7
 INSPECTION CL535, 635, 640

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has exceeded, repair or replace faulty parts.

CLUTCH DISC
Runout
Unit: mm (in)
Unit name Maintenance standard Service limit
CL535 Less than 1.0 (0.039) 1.4 (0.055)
CL635 — 1.4 (0.055)
CL640

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)
Unit name Maintenance standard Service limit
CL535 Less than 0.24 (0.0094) 0.5 (0.020)
CL635 Less than 0.27 (0.0106) 0.5 (0.020)
CL640

CL-4-8
 INSPECTION CL535, 635, 640

CLUTCH PRESSURE PLATE

Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
CL535 Less than 0.1 (0.004) 0.2 (0.008)
CL635 Less than 0.1 (0.004) 0.25 (0.0098)
CL640

Taper of contact face at outer section

Unit: mm (in)
Unit name Maintenance standard Service limit
0.05 - 0.15
CL535 —
(0.0020 - 0.0059)

Decrease in thickness of contact surface

Unit: mm (in)
Maintenance standard Service limit
59.7 - 59.9 (2.350 - 2.358) 57.8 (2.276)

CLUTCH PRESSURE SPRING

Free length
Unit: mm (in)
Unit name Maintenance standard Service limit
CL535 — 96.2 (3.787)
CL635 94.9 (3.736) 91.7 (3.610)
CL640 96.4 (3.795) 93.0 (3.661)

CL-4-9
 INSPECTION CL535, 635, 640

Tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
1,107.2 - 1,222.9
1,048.4
CL535 {112.9 - 124.7,
{106.9, 235.7}
249.0 - 275.0}
1,557.4 - 1,722.1
1,476.0 When compressed to
CL635 {158.8 - 175.6,
{150.5, 331.9} 63 mm (2.48 in)
350.2 - 387.2}
1,630.9 - 1,802.5
1,544.6
CL640 {166.3 - 183.8,
{157.5, 347.3}
366.7 - 405.3}

Tilt
Unit: mm (in)
Item Maintenance standard Service limit Remarks
CL535 Less than 3.5 (0.146) 5.2 (0.205)
Measure at free
CL635 Less than 3.3 (0.130) 5.0 (0.197)
length
CL640 Less than 3.4 (0.134) 5.0 (0.197)

FLYWHEEL
Flatness of contact surface
Unit: mm (in)
Maintenance standard Service limit
Less than 0.1 (0.004) 0.2 (0.008)

Decrease in thickness of contact surface

Unit: mm (in)
Unit name Maintenance standard Service limit Remarks
(A) — 48.5 (1.909) Rise toward outer
CL535 47.9 - 48.1 side
(H) — To flange end face
(1.886 - 1.894)
50.5 (1.988) 48.5 (1.909) P series engine
(A)
55.5 (2.185) 53.5 (2.106) R series engine
CL635
CL640 2.0 (0.079) Rise toward outer
47.9 - 48.1
(H) (Grinding side
(1.886 - 1.894)
depth) To flange end face

Thickness: (A), Height: (H)

CL-4-10
 INSPECTION CL535, 635, 640

CLUTCH RELEASE MECHANISM

Release lever bushing inside diameter
Unit: mm (in)
Maintenance standard Service limit Remarks
Measure after bushing has
12.7 (0.500) — been pressed into release
lever

Lever pin and support pin outside diameter

Unit: mm (in)
Maintenance standard Service limit
12.7 (0.500) 12.5 (0.492)

Support inside diameter

Unit: mm (in)
Maintenance standard Service limit
12.7 (0.500) 12.9 (0.508)

Release shaft outside diameter

Unit: mm (in)
Maintenance standard Service limit
29.99 - 30.01 (1.1807 - 1.1815) —

Release bearing wear

Unit: mm (in)
Maintenance standard Service limit Remarks
— 0.5 (0.020) Except for CL535

CL-4-11
 REASSEMBLY CL535, 635, 640

REASSEMBLY
REASSEMBLY
CLUTCH COVER
Key point of reassembly
Before assembling, apply a coat of molybdenum disulfide grease to
all frictional surfaces.
z Sliding surfaces of release lever and support pin
z Sliding surfaces of release lever and lever pin
z Sliding surfaces of transmission main drive shaft and clutch
disc
23 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.
21 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.

6 Clutch cover
Attach the clutch cover to the pressure plate, using the guide bolt or
press.
NOTE
z Align the matching marks when reassembling the clutch
cover and pressure plate.
z Using a round rod, correct the position of the pressure
spring.
[Reassembly using the guide bolts]
z Screw the guide bolts into the pressure plate.
z Securely attach a wrench to the guide bolt, and then tighten
the nut until the support's threads can be seen on the clutch
cover. Then install the support nut.
NOTE
z Tighten the guide bolt nuts equally, one at a time.
z Compress the clutch cover so that the support's thread
area does not touch the clutch cover.

CL-4-12
 REASSEMBLY CL535, 635, 640

[Reassembly using the press]

z Compress the clutch cover with a guide bar until the sup-
port's threads can be seen on the upper surface of the
clutch cover and then install the support nut.

NOTE
z Do not allow the support's threads to touch the clutch
cover when compressing the latter.

CLUTCH HOUSING
Key point of reassembly
12 MPS50, MTS60, MTS70, MTP00 and
9 MRT20 release yoke
Insert the release shaft assembly into the clutch housing, fit the
release yoke onto the shaft, and then install the feather key, set bolt
and wire on 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 tool.
NOTE
z Be sure to align the dowel pins when installing the clutch
cover assembly.
z Remove the guide to setting bolts after the clutch cover
has been installed on the flywheel.
z Clean the flywheel and pressure plate prior to reassem-
bly.
z Always install the clutch disc with the higher boss facing
the pressure plate.
Setting tool

Applicable engine Transmission model Setting tool assembly Setting shaft Setting sleeve
P series engine Other than Fuller trans- 99792 Z0016 99797 Z0017
R series engine mission 99792 Z0017 99797 Z0018
99797 Z0008
P and R series For Fuller transmis-
99792 Z0008 99797 Z0008
engine sion

CL-4-13
 REASSEMBLY CL535, 635, 640

2. Install the setting sleeve on the setting shaft and adjust the
height of the release lever's upper surfaces by turning the
support nut and lock nut with a support nut wrench so that
the reference line on the setting shaft is aligned with posi-
tion N on the sleeve.
NOTE
z When adjusting, turn the sleeve and make sure that the
reference line is aligned with position N around the entire
circumference.

z When reusing the clutch disc after it has been removed,

use the reference line which is verified during removal.
z Replace the clutch disc if the reference line is located to
the left of graduation W on the setting sleeve.
z If the release lever's surface is too high, turn the support
counterclockwise. If it is too low, turn it clockwise.
z One rotation of the support nut changes the height of the
release lever tip end by 8.5 mm (0.335 in).
3. After tightening the lock plate, remove the clutch disc set-
ting tool and tap on the lever plate several times with a
wooden mallet. Then insert the clutch disc setting tool again
and make sure that the reference line is aligned with posi-
tion N.
NOTE
z When reusing the clutch disc after it has been removed,
use the reference line which is verified during removal.
z If alignment is not made, readjust.

CL-4-14
 ADJUSTMENT CL535, 635, 640

ADJUSTMENT
CLUTCH PEDAL PLAY
Depress the clutch pedal by hand until resistance is felt. While hold-
ing the clutch pedal in this position, measure the stroke length of
pedal play. If it is outside the specified range, adjust as follows:
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17) —

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 one 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

1. Remove the return spring.
2. Loosen the push rod lock nut.
3. Adjust the play of the outer lever by turning the push rod.
Unit: mm (in)
Item Maintenance standard
Clutch outer lever play 5.0 - 7.0 (0.197 - 0.276)

4. Tighten the lock nut.

5. Reinstall the return spring.

[Vehicles without clutch wear indicators]

1. Adjust free play of the outer lever and measure dimension
“L”. If “L” exceeds the wear limit specified in the table,
replace the clutch disc.
2. After installing a new clutch disc, be sure dimension “L” is
within the standard value.
If it is outside the standard value, check and adjust the
clutch itself.

CL-4-15
 ADJUSTMENT CL535, 635, 640

CHECKING FOR WEAR ON THE CLUTCH DISC

To properly check for wear on the clutch disc in the vehicle, pro-
ceed as follows:
[Vehicles without clutch wear indicators]
1. Adjust free play of the outer lever and measure dimension
“L”. If “L” exceeds the wear limit specified in the table,
replace the clutch disc.
2. After installing a new clutch disc, be sure dimension “L” is
within the standard value.
If it is outside the standard value, check and adjust the
clutch itself.
Unit: mm (in)
Item Standard Limit
Model with Fuller transmission 137 (5.39) 117 (4.61)
CL535 106 (4.17) 130 (5.12)
Dimension L Model with Nissan
Diesel transmission Except for 75 (2.95) 100 (3.94)
CL535

[Vehicles with clutch wear indicators]

1. Adjust free play of the outer lever and check the position of
the clevis pin on the wear indicator. If the clevis pin reaches
the MIN. position, replace the clutch disc.
2. After installing a new clutch disc, be sure the clevis pin
points to the SET position. If it does not, measure dimen-
sion L (as outlined above) to make sure it is within the stan-
dard value.
If L is not outside the standard value, check and adjust the
clutch itself; if it is, proceed to the instructions under “Clutch
disc wear indicator installation and adjustment procedure”
below.

CLUTCH DISC WEAR INDICATOR INSTALLATION AND

ADJUSTMENT PROCEDURE
[After installing new clutch disc]
NOTE
z Be sure the clutch is properly adjusted.

1. Tighten the indicator stay to the clutch housing-to-flywheel

housing stud.
2. Adjust the outer lever play to the specified value.
3. Align the SET position of the indicator with the end of the
clevis pin, and secure the indicator. The clearance between
the clevis pin and the indicator must be 3 to 5 mm (0.12 to
0.20 in).

CL-4-16
 ADJUSTMENT CL535, 635, 640

NOTE
z To properly adjust the wear indicator, be sure dimension
“L” is within the standard value.

4. Fully depress the clutch pedal several times, then check to

be sure the end of the indicator plate is at the “SET” posi-
tion.

[After installing old clutch disc]

NOTE
z Do not loosen or remove the bolts which hold the clutch
wear indicator and stay.
z Be sure the clutch indicator is properly adjusted.
1. Tighten the indicator stay to the clutch housing-to-flywheel
housing stud.
2. Adjust the outer lever play to the specified value.
3. The clearance between the clevis pin and the indicator
must be 3 to 5 mm (0.12 to 0.20 in).
4. Check to make sure the clevis pin points to the mark previ-
ously chalked on the wear indicator.
5. Depress the clutch pedal several times before re-checking
the position of the clevis pin.

CL-4-17
 CLUTCH UNIT
(AIR SERVO TYPE)

CONTENTS
SERVICE DATA.................................. CL-1-1 = UNIT NAME 047, 048 AND 049 =
SPECIFICATIONS......................... CL-1-1 CONSTRUCTION .......................... CL-3-9
SERVICE DATA............................. CL-1-2 DISASSEMBLY ............................ CL-3-10
TIGHTENING TORQUE ................ CL-1-3 INSPECTION ............................... CL-3-12
SYSTEM DIAGRAM ...................... CL-1-4 REASSEMBLY ............................. CL-3-13
TOOLS................................................ CL-2-1 PERFORMANCE TEST ............... CL-3-14
CLUTCH BOOSTER .......................... CL-3-1 CLUTCH MASTER CYLINDER ......... CL-4-1
CONSTRUCTION .......................... CL-4-1
= UNIT NAME 037 =
DISASSEMBLY .............................. CL-4-2
CONSTRUCTION.......................... CL-3-1 INSPECTION ................................. CL-4-3
DISASSEMBLY ............................. CL-3-2 REASSEMBLY ............................... CL-4-4
INSPECTION................................. CL-3-4 ADJUSTMENT ............................... CL-4-4
REASSEMBLY .............................. CL-3-6
PERFORMANCE TEST ................ CL-3-7
 SERVICE DATA CLUTCH UNIT (AIR)

SERVICE DATA
SPECIFICATIONS
CLUTCH BOOSTER
Unit: mm (in)
Unit name 047 048 049
037
Item Type I Type II Type III Type I Type II Type I Type II
Type Air-servo
Power cylinder (cylinder shell) I.D. 90.0 (3.543)
22.2
Hydraulic cylinder I.D. —
(0.874)
Cylinder body (Hydraulic cylinder) 22.2 19.8 19.05 22.2 19.8
—
I.D. (0.874) (0.780) (0.750) (0.874) (0.780)
16.0
Valve piston O.D. —
(0.630)
16.0
Relay Liquid pressure side — 16.0 (0.630) 12.7 (0.500)
(0.630)
piston
O.D. 27.0
Atmospheric side — 23.5 (0.925) 27.0 (1.063)
(1.063)
27.0
Diaphragm effective diameter —
(1.063)
Push rod O.D. 8.0 (0.315)
60.0
Power piston stroke 35.8 (1.409)
(2.362)
3.5
Valve piston stroke —
(0.138)
Relay piston stroke — 3.6 (0.142)
Automatic clutch adjuster provided or
Yes No
not provided

* Identification of the clutch booster unit

The unit can be clearly identified by the number stamped on the power cylinder name plate.
Ex. 642-37FF (Refer to unit name 037)

CL-1-1
 SERVICE DATA CLUTCH UNIT (AIR)

SERVICE DATA
CLUTCH BOOSTER
Unit: mm (in)
Application
Maintenance 0 0 0 0
Item Service limit Remarks
standard 3 4 4 4
7 7 8 9
Clearance between power piston and cylin- 1.50
— O O O O
der shell (0.0591)
Clearance between hydraulic piston and 0.08
— O O O O
hydraulic cylinder (0.0031)
Clearance between valve piston and valve 0.11
— O – – –
fitting (0.0043)
Clearance 0.11
Liquid pressure side — – O O O
between (0.0043)
relay piston
and cylinder 0.30
Atmospheric side — – O O O
body (0.0118)

0.15
Bend of push rod — O O O O
(0.0059)
Piston return spring 86.8 (3.417) — – O O O
Valve spring 16.9 (0.665) — O – – –
Free length
Relay piston return spring 28.2 (1.110) — – O O O
Poppet spring 22.1 (0.870) — O O O O
When compressed
66.69
Piston return spring — to 59.9 mm (2.358 – O O O
{6.80, 14.99}
in)
When compressed
10.40
Valve spring — to 10.0 mm (0.394 O – – –
{1.06, 2.34}
Tension in)
N {kgf, lbf} When compressed
10.40
Relay piston return spring — to 13.1 mm (0.516 – O O O
{1.06, 2.34}
in)
When compressed
2.26
Poppet spring — to 13.0 mm (0.512 O O O O
{0.23, 0.51}
in)
0.25 - 0.60
Clearance between the push rod end and 1.0
(0.0098 - O – – –
inner lock (0.039)
0.0236)

CL-1-2
 SERVICE DATA CLUTCH UNIT (AIR)

CLUTCH PEDAL LINKAGE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.02 -0.19
Clearance between pedal shaft and bushing 0.5 (0.0020)
(0.0008 - 0.00075)
Play of clutch master cylinder push rod 1.0 (0.039) –
Play of clutch pedal 35 - 55 (1.38 - 2.17) –
Distance from clutch pedal to pedal stopper
50 (1.97) –
(When clutch pedal is released)
Protrusion of clutch switch 0 - 1.25 (0 - 0.0492) –
19.05 - 19.09
Clutch master cylinder I.D. 19.15 (0.7539)
(0.7500 - 0.7516)

TIGHTENING TORQUE
CLUTCH BOOSTER
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
037 047 048 049
Cylinder body and cylinder shell assem- 20 - 25 {2.0 - 2.5, 14 - 18} O – – –
bling bolt and nut 20 - 29 {2.0 - 3.0, 14 - 22} – O O O
Upper valve body mounting bolt 4 - 6 {0.4 - 0.6, 2.9 - 4.3} O O O O
Connector 20 - 29 {2.0 - 3.0, 14 - 22} O O O O
Piston plate mounting nut 20 - 29 {2.0 - 3.0, 14 - 22} O O O O
Air bleeder screw 7 - 13 {0.7 - 1.3, 5.1 - 9} O O O O
10 - 49 {1.0 - 5.0, 7 - 36} O – – –
Exhaust cover
15 - 20 {1.5 - 2.0, 11 - 14} – O O O
Elbow connector (Type II only) 15 - 167 {1.5 - 17.0, 11 - 123} – O O –
Valve fitting 15 - 25 {1.5 - 2.5, 11 - 18} O – – –
Bushing 8 - 10 {0.8 - 1.0, 5.8 - 7} O – – –
Hydraulic cylinder mounting bolt 29 - 39 {3.0 - 4.0, 22 - 29} O – – –
Switch assembly 25 - 34 {2.5 - 3.5, 18 - 25} O – – –
Push rod clevis nut
20 - 29 {2.0 - 3.0, 14 - 22} O – – –
(Automatic clutch adjuster only)

CLUTCH MASTER CYLINDER

Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
Clutch pedal shaft nut 16 - 22 {1.6 - 2.2, 12 - 16}
Clutch pedal bracket mounting bolt 11 - 14 {1.1 - 1.4, 8 - 10}
Clutch master cylinder stopper bolt 1.5 - 2.9 {0.15 - 0.30, 1.1 - 2.2}
Clutch master cylinder nipple 25 - 34 {2.5 - 3.5, 18 - 25}
Clutch master cylinder mounting bolt 54 - 69 {5.5 - 7.0, 40 - 51}

CL-1-3
 SERVICE DATA CLUTCH UNIT (AIR)

SYSTEM DIAGRAM

CL-1-4
 TOOLS CLUTCH UNIT (AIR)

TOOLS
CLUTCH BOOSTER
* * Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name Application
and number 0 0 0 0
Liquid pres- Atmospheric Description Shape
3 4 4 4
sure side side
7 7 8 9
Cup diameter
910-23280 910-23281 22.2 mm O O O –
(0.874 in)
Cup diameter Used to insert
910-23292 910-23293 19.8 mm (0.78 cup packing into – O O O
in) hydraulic piston
Cup diameter
Cup packing 910-23284 910-23285 19.05 mm – O – –
inserting (0.750 in)
guide
Cup diameter
910-24902 910-24905 16.0 mm – O – O
(0.630 in)
Used to insert
cup packing into
Cup diameter relay piston
910-24900 910-24903 12.7 mm – – O O
(0.500 in)

CL-2-1
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

CLUTCH BOOSTER
= UNIT NAME 037 =
CONSTRUCTION
<Clutch booster>

CL-3-1
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

<Automatic clutch adjuster>

DISASSEMBLY
REMOVAL
Key point of removal
1. Turn the key switch to the “OFF” position and chock the
wheels to be safe.
2. Do not separate the wear indicator and stay.
3. Cover the mounting position of the automatic clutch
adjuster so that it is protected from dirt or dust.
4. Do not depress the clutch pedal with the automatic clutch
adjuster removed.

CL-3-2
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

DISASSEMBLY
<Clutch booster>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Connector 18. Retaining ring 35. Retainer
2. Gasket , 19. Cup packing 36. Cup packing
3. Poppet spring , 20. Cup packing 37. Washer
4. Poppet valve 21. Hydraulic piston 38. Oil seal
5. Upper valve body + 22. Seat 39. Exhaust cover
6. Valve spring 23. Bushing 40. Air bleeder screw
7. Diaphragm assembly 24. Gasket 41. Eye bolt
8. Plate 25. Cylinder body 42. Gasket
9. Valve fitting 26. O-ring 43. Eye connector
10. Gasket 27. Power piston assembly 44. Gasket
11. Retaining ring 28. Nut 45. Switch assembly
12. Cup packing 29. Push rod 46. Gasket
13. Cup packing 30. O-ring 47. Rod
14. Valve piston 31. Cup packing 48. Guide
15. Hydraulic cylinder 32. Piston plate 49. O-ring
16. O-ring 33. Retaining ring 50. Cylinder shell
17. Straight pin 34. Washer
Marks“+” and “,” indicate that the key points of operation are explained in the text.

CL-3-3
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Key point of disassembly

22 Seat
When removing the piston assembly, use care as the seat may stay
in the hydraulic piston.

<Automatic clutch adjuster>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Clevis 2. Nut , 3. Clutch adjuster assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between power piston and cylinder shell
Unit: mm (in)
Maintenance standard Service limit
— 1.50 (0.0591)

CL-3-4
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Clearance between hydraulic piston and hydraulic cyl-

inder
Unit: mm (in)
Maintenance standard Service limit
— 0.08 (0.0031)

Clearance between valve piston and valve fitting

Unit: mm (in)
Maintenance
Service limit
standard
— 0.11 (0.0043)

Bend of push rod

Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)

Free length
Unit: mm (in)
Item Maintenance standard Service limit
Valve spring 16.9 (0.665) —
Poppet spring 22.1 (0.870) —

Tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
10.40 When compressed to
Valve spring —
1.06, 2.34 10.0 mm (0.394 in)
2.26 When compressed to
Poppet spring —
0.23, 0.51 13.0 mm (0.512 in)

CL-3-5
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

REASSEMBLY
<Clutch booster>
Key point of reassembly
19, 20 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
Item
Liquid pressure side Atmospheric side
Cup diameter
910-23280 910-23281
22.2 mm (0.874 in)

<Automatic clutch adjuster>

Key point of reassembly
3 Clutch adjuster assembly
Check each part for proper operation.
z Move the stopper and make sure that it moves smoothly.
z Using a press, etc., apply a load of move than 588 N {60
kgf, 132 lbf} in the axial direction of the adjuster and make
sure that the lock mechanism releases.
z With the adjuster locked, check clearance (A) between the
push rod end and inner lock.

Maintenance standard Service limit

0.25 - 0.60 (0.0098 - 0.0236) 1.0 (0.039)

1 Clevis
Screw the clevis in until the threaded end of the push rod is flush
with that of the clevis.
： 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22ft·lbf}

CL-3-6
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

INSTALLATION
Key point of installation
1. Using a press, etc., apply a load of more than 588 N {60
kgf, 132 lbf} in the axial direction of the adjuster and release
the lock mechanism. After that, move the outer lock to the
seat side as shown below and secure the outer lock in that
position.

2. Insert the inner lock side into the hydraulic piston.

3. Install the clevis on the outer lever.
4. Air bleed the fluid line. For this procedure, refer to the “MA”
section.

5. Depress the clutch pedal several times repeatedly until a

resistance is felt on the pedal. After that, make sure that the
adjuster stopper is in contact with the hydraulic cylinder
end.

6. Install the return spring. Then depress the clutch pedal sev-
eral times and make sure that the clutch pedal play is within
the specified values.

Unit: mm (in)
Item Maintenance standard Service limit
Play of clutch pedal 35 - 55 (1.38 - 2.17)

7. Install the boot on the clutch booster.

PERFORMANCE TEST
AIR TIGHTNESS TEST
With the clutch booster attached to the vehicle, raise the air pres-
sure to 588 kPa {6 kgf/cm 2, 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.
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

CL-3-7
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

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-3-8
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

= UNIT NAME 047, 048 AND 049 =

CONSTRUCTION

CL-3-9
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

DISASSEMBLY
REMOVAL
Key point of removal
1. Turn the key switch to the OFF position and chock the
wheels to be safe.
2. Do not separate the wear indicator and stay.

3. Plug the tube and hose to prevent dirt or dust from entering.

CL-3-10
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

01. Push rod assembly (Unit name 15. Piston return spring 30. Cup packing
047: Type III only) 16. Cylinder shell 31. Retainer assembly
02. Push rod assembly 17. Collar 32. Washer
03. Guard 18. O-ring 33. Retainer ring
04. Connector 19. Power piston assembly 34. Spring pin
05. Gasket 20. Nut 35. Elbow connector (Unit name
06. Poppet spring 21. Washer 047 and 048: Type II only)
07. Poppet valve 22. Push rod 36. Exhaust cover
08. Upper valve body 23. O-ring 37. Air bleeder screw
09. O-ring 24. Cup packing 38. Cylinder body
10. Relay piston return spring + 25. Piston plate 39. Eyebolt
11. O-ring 26. Hydraulic piston 40. Gasket
12. Relay piston assembly , 27. Cup packing 41. Eye connector
, 13. Cup packing , 28. Cup packing 42. Gasket
14. O-ring 29. Retainer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CL-3-11
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Key point of disassembly

25 Piston plate
Be sure to use the socket when placing the piston assembly in a
vise.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between power piston and cylinder shell
Unit: mm (in)
Maintenance standard Service limit
— 1.50 (0.0591)

Clearance between hydraulic piston and hydraulic cyl-

inder
Unit: mm (in)
Maintenance standard Service limit
— 0.08 (0.0031)

Clearance between relay piston and cylinder body

Unit: mm (in)
Item Maintenance standard Service limit
Liquid pressure side — 0.11 (0.0043)
Atmospheric side — 0.30 (0.0118)

CL-3-12
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Bend of push rod

Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)

Free length
Unit: mm (in)
Item Maintenance standard Service limit
Piston return spring 86.8 (3.417) —
Relay piston return
28.2 (1.110) —
spring
Poppet spring 22.1 (0.870) —

Tension
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Piston return 66.69 When compressed to
—
spring {6.80, 14.99} 59.9 mm (2.358 in)
Relay piston 10.40 When compressed to
—
return spring {1.06, 2.34} 13.1 mm (0.516 in)
2.26 When compressed to
Poppet spring —
{0.23, 0.51} 13.0 mm (0.512 in)

REASSEMBLY
Key point of reassembly
27, 28 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.

CL-3-13
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Cup packing inserting guide

Unit name
Liquid pressure side Atmospheric side
047 Cup diameter
910-23280 910-23281
048 22.2 mm (0.874 in)
047
Cup diameter
048 910-23292 910-23293
19.8 mm (0.780 in)
049
Cup diameter
047 910-23284 910-23285
19.05 mm (0.7500 in)

13 Cup packing
Using the cup packing inserting guide, install the cup packings to
the hydraulic piston.

Cup packing inserting guide

Unit name
Liquid pressure side Atmospheric side
047 Cup diameter
910-24902 910-24905
048 16.0 mm (0.630 in)
047
Cup diameter
048 910-24900 910-24903
12.7 mm (0.500 in)
049

PERFORMANCE TEST
AIR TIGHTNESS TEST
With the clutch booster attached to the vehicle, raise the air pres-
sure to 588 kPa {6 kgf/cm2, 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.
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.

CL-3-14
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

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-3-15
CLUTCH BOOSTER CLUTCH UNIT (AIR)

CL-3-16
CLUTCH BOOSTER CLUTCH UNIT (AIR)

CL-3-17
 CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)

CLUTCH MASTER CYLINDER

CONSTRUCTION

CL-4-1
 CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)

DISASSEMBLY
REMOVAL

1.Pedal bracket assembly 6.Clutch master cylinder assembly 10.Pedal bushing

2.Switch bracket 7.Pedal shaft 11.Pedal bushing
3.P.T.O switch assembly 8.Clutch pedal assembly 12.Stopper
4.Switch push- plate 9.Return spring 13.Stopper
5.Exhaust brake switch assembly
NOTE
z Numbers before part names do not indicate the disassembly sequence.

Key point of removal

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
 CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Push rod assembly 5.Stopper bolt 9.Spring
2.Dust cover 6.Gasket 10.Seat holder
3.Nipple 7.Circlip 11.Seat
4.Gasket , 8.Piston assembly 12.Cylinder
Marks “+” and “,” indicate that the key points of operation are explained in the text.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between pedal shaft and bushing
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.19 (0.0008 - 0.0075) 0.5 (0.020)

Clutch master cylinder inside diameter

Unit: mm (in)
Maintenance standard Service limit
19.05 - 19.09 (0.7500 - 0.7516) 19.15 (0.7539)

CL-4-3
 CLUTCH MASTER CYLINDER CLUTCH UNIT (AIR)

REASSEMBLY
REASSEMBLY
Key point of reassembly
8 Piston assembly
1. Apply a coat of rubber grease to the cup, cylinder and the
frictional surface of the piston.
2. Ensure the cup is installed with lip facing the valve.

INSTALLATION
Key point of installation
1. Apply grease to the shaft bushing and spring when install-
ing the clutch pedal assembly onto the pedal bracket
assembly.
2. If the clutch pedal has no free play when the clutch master
cylinder is installed onto the pedal assembly, loosen the
lock nut and turn the push rod clockwise to adjust the free
play.

ADJUSTMENT
Air bleeding the fluid line. For this procedure, refer to the “MA” sec-
tion.

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
protrudes 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 CONSTRUCTION............................... TM-5-1
SPECIFICATION ........................... TM-1-1 DISASSEMBLY .................................. TM-5-5
SERVICE DATA............................. TM-1-5 REMOVAL ..................................... TM-5-5
TIGHTENING TORQUE .............. TM-1-12 DISASSEMBLY ............................. TM-5-6
SYSTEM DIAGRAM .................... TM-1-14 INSPECTION.................................... TM-5-16
TOOLS................................................ TM-2-1 REASSEMBLY ................................. TM-5-22
REASSEMBLY ............................ TM-5-22
= UNIT NAME MPS50 = INSTALLATION ........................... TM-5-28
CONSTRUCTION ............................... TM-3-1
= UNIT NAME MTP00 =
DISASSEMBLY .................................. TM-3-3
REMOVAL ..................................... TM-3-3 CONSTRUCTION............................... TM-6-1
DISASSEMBLY ............................. TM-3-4 DISASSEMBLY .................................. TM-6-6
INSPECTION .................................... TM-3-15 REMOVAL ..................................... TM-6-6
REASSEMBLY ................................. TM-3-19 DISASSEMBLY ............................. TM-6-7
REASSEMBLY ............................ TM-3-19 INSPECTION.................................... TM-6-22
INSTALLATION............................ TM-3-26 REASSEMBLY ................................. TM-6-28
REASSEMBLY ............................ TM-6-28
= UNIT NAME MTS60 = INSTALLATION ........................... TM-6-35
CONSTRUCTION ............................... TM-4-1
= UNIT NAME MRT20 =
DISASSEMBLY .................................. TM-4-6
REMOVAL ..................................... TM-4-6 CONSTRUCTION............................... TM-7-1
DISASSEMBLY ............................. TM-4-7 DISASSEMBLY .................................. TM-7-4
INSPECTION .................................... TM-4-21 REMOVAL ..................................... TM-7-4
REASSEMBLY ................................. TM-4-27 DISASSEMBLY ............................. TM-7-5
REASSEMBLY ............................ TM-4-27 INSPECTION.................................... TM-7-22
INSTALLATION............................ TM-4-36 REASSEMBLY ................................. TM-7-28
REASSEMBLY ............................ TM-7-28
= UNIT NAME MTS70 = INSTALLATION ........................... TM-7-42
 SERVICE DATA T/M PROPER

SERVICE DATA
SPECIFICATION
UNIT NAME: MPS50, MTS60 AND MTS70
Unit name MPS50A MTS60A MTS60B MTS60D MTS70A
5 speeds for- 7 speeds for-
ward, 1 speed ward, 1 speed
reverse reverse
(Synchromesh 6 speeds forward, 1 speed reverse (Synchromesh
Transmission system type: 2-5 (Synchromesh type: 2-6 speeds type: 2-5
speeds Constant mesh type: 1 speed and reverse) speeds
Constant mesh Constant mesh
type: 1 speed type: 1 speed
and reverse) and reverse)
Operating system Remote control
1st and
Spur gear
Gear used reverse
2nd to 6th Helical gear
1st 5.445 6.736 6.736 6.326 6.736
2nd 3.148 4.164 4.164 4.139 4.164
3rd 1.743 2.545 2.315 2.326 2.315
4th 1.000 1.576 1.441 1.480 1.441
Gear ratio
5th 0.700 1.000 1.000 1.000 1.000
6th — 0.732 0.732 0.688 0.732
7th — — — — 0.633
Reverse 5.440 6.911 6.911 6.490 6.911
1st 37/11 47/12 47/12 47/12 47/12
2nd 35/18 46/19 46/19 41/16 46/19
3rd 28/26 37/25 35/26 36/25 35/26
4th Direct coupled 33/36 31/37 33/36 31/37
Number of gear 5th 16/37 Direct coupled
teeth 6th — 3/54 23/54 23/54 23/54
(Main/counter)
7th — — — — 21/57
Reverse 36/20 37/17 37/17 37/17 37/17
Reverse idler
28, 15 24, 13 24, 13 24, 13 24, 13
gear
Drive gear 21/34 25/43 25/43 26/42 25/43
Oil quantity W/O PTO 7.5 (6-5/8) 10.5 (9-1/4) 9.0 (7-7/8)
liter (Imp gl) W/PTO 8.0 (7) 11.0 (9-5/8) 9.5 (8-3/8)

TM-1-1
 SERVICE DATA T/M PROPER

UNIT NAME: MTP00

Unit name MTP00B MTP00C
10 speeds forward, 1 speed reverse
Transmission system (Synchromesh type: 3-10 speeds
Constant mesh type: 1, 2 speed and reverse)
Operating system Remote control
1st and reverse Spur gear
Gear used
2nd to 10th Helical gear
1st 7.979 6.630
2nd 6.176 5.132
3rd 4.171 3.831
4th 3.228 2.965
5th 2.328 2.131
6th 1.802 1.650
Gear ratio 7th 1.291 1.291
8th 1.000 1.000
9th 0.901 0.863
10th 0.697 0.668
Reverse 8.185 6.802
High 1.000 1.000
Low 1.291 1.291
1st 47/12 47/12
2nd 43/21 43/19
3rd 32/28 34/27
4th — —
Number of gear 5th 23/52 26/51
teeth
(Main/counter) Reverse 37/17 37/17
High 24/23 24/23
Low 26/21 26/21
Reverse idler gear 24, 13 24, 13
Drive gear 26/41 29/38
Oil quantity W/O PTO 10 (8-3/4)

liter (Imp gl) W/PTO 10.5 (9-1/4)

TM-1-2
 SERVICE DATA T/M PROPER

UNIT NAME: MRT20, MRT23

Unit name MRT20A MRT23B
12 speeds forward, 2 speed 12 speeds forward, 2 speed
reverse reverse
Transmission system
(Synchromesh type: 1-12 speeds (Synchromesh type: 1-12 speeds
Constant mesh type: reverse) Constant mesh type: reverse)
Operating system Remote control Remote control (Power shift)
Gear used 1st to 12th and reverse Helical gear Helical gear
1st 10.729 10.278
2nd 6.575 6.298
3rd 3.649 3.649
4th 2.236 2.236
Gear ratio 5th 1.464 1.464
6th 1.000 1.000
Reverse 9.563 9.160
High 0.811 0.811
Sub transmission
Low 1.000 1.000
1st 46/16 46/16
2nd 37/21 37/21
3rd 46/16 46/16
4th 37/21 37/21
5th 30/26 30/26
Number of gear 6th 33/26 26/33
teeth
(Main/counter) Reverse 41/16 41/16
Reverse idler gear 25 25
Range side sub High 26/24 26/24
transmission Low 38/14 39/15
Splitter side sub High 34/35 34/35
transmission Low 26/33 26/33
Oil quantity W/O PTO 12.8 (2-7/8) 10.8 (2-3/8)
liter (Imp gl) W/PTO 13.3 (2-7/8) 11.3 (2-1/2)

TM-1-3
 SERVICE DATA T/M PROPER

UNIT MODEL NAME

(Table 1) -Specifications
Synchro-
Main transmission
mesh
M R T 2 0 A
Classification of gear ratio: Sub-transmission Yes No
A - S: Overdrive type
T - Z: Direct drive type

No. of modifications No S C
No. of gearshift stages
4,5,6,...9 etc.
Greater than 10 stages:
Designated by the last digit

Main transmission
Splitter type P Q
(w/synchromesh or w/o
synchromesh) Sub-
transmission -> Refer to
Table 1. Range type R
Distance between main
shaft and counter shaft Yes
mm (in)
145(5.71)<“P”<150 (5.91)
155(6.10)<“R”<160 (6.30)
With range
165(6.50)<“T”<170 (6.70) T
splitter type

Transmission type
M: Manual

UNIT NO. LOCATION

The manufacturing number of each transmission is stamped on the
side of the transmission case. For the details, refer to the IDENTIFI-
CATION in the GENERAL chapter of this manual.

TM-1-4
 SERVICE DATA T/M PROPER

SERVICE DATA

UNIT NAME:MPS50A, MTS60A/B/D, MTS70A, MTP00B/C, MRT20A

Unit: mm (in)
Application
Maintenance MTS60A
Item Service limit Remarks MTP00B
standard MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
Clearance between
0.1 - 0.4 0.8
shift lever and select O O O O O
(0.004 - 0.016) (0.031)
lever
0.05 - 0.11
Radial play between O O O O
(0.0020 - 0.0043) 0.5
inner shaft and shift
0.02 - 0.08 (0.020)
lever splines O
(0.0008 - 0.0031)
Clearance between 0.1 - 0.4 1.0
O O O O
shift lever and shifters (0.004 - 0.016) (0.039)
Clearance between
0.74 - 0.96 1.5
shift lever and each O
(0.0291 - 0.0378) (0.059)
shifter/shift fork
Clearance between
0.1 - 0.4 1.0
locking lever and O
(0.004 - 0.016) (0.039)
shifter
0.03 - 0.08 0.2
O
(0.0012 - 0.0031) (0.008)
0.04 - 0.07
Reverse
(0.0016 - 0.0028)
0.07 - 0.10
Splitter
(0.0028 - 0.0039)
Clearance between
0.04 - 0.07 0.3
transmission cover and Range O
(0.0016 - 0.0028) (0.012)
shift fork shaft
0.07 - 0.17
1st - 2nd
(0.0028 - 0.067)
0.06 - 0.15
3rd - 4th
Trans- (0.0024 - 0.0059)
mission 0.13 - 0.18 0.3
O O
cover (0.0051 - 0.0071) (0.012)
Clearance between 0.03 - 0.08 0.2
transmission sub cover O
and shift fork shaft (0.0012 - 0.0031) (0.008)
Clearance between
transmission sub cover 0.07 - 0.16 0.2
and high-low cylinder (0.0028 - 0.0063) (0.008) O
piston
Except for
0.04 - 0.08 0.2 those indi- O O O O
Clearance between (0.0016 - 0.0031) (0.008)
locking lever and lever cated below
shaft 0.02 - 0.06 0.2 At 4th & 5th
(0.0008 - 0.0024) (0.008) shift fork O O
Clearance between 0.1 - 0.4 1.0
locking lever and lever O O O
(0.004 - 0.016) (0.039)
shifter
Clearance between
locking lever and shift 0.1 - 0.4 1.0 O
(0.004 - 0.016) (0.039)
shaft
Clearance between
each fork claw and 0.1 - 0.5 1.0 O
(0.004 - 0.020) (0.039)
synchronizer sleeve
Clearance between
each fork claw and shift 0.02 - 0.05 O
(0.0008 - 0.0020)
fork
0.07 - 0.10
(0.0028 - 0.0039) Splitter
Clearance between 0.3
cylinder and shift shaft (0.012) O
0.04 - 0.07
Range
(0.0016 - 0.0028)

TM-1-5
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance MTS60A
Item Service limit Remarks MTP00B
standard MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
41.0 - 44.0
O
(1.614 - 1.732)
42.5
O O O
(1.673)
Free 42.5 1st to 6th &
length (1.673) Reverse
35.0
Splitter O
(1.378)
34.5
Range
(1.358)
When com-
163.8 - 193.2
163.8 pressed to
{16.7 - 19.7, 36.8 - O
{16.7, 36.8} 26.9 mm
43.4}
(1.059 in)
When com-
Shift fork 127 - 157 157 pressed to
shaft O O O
{13 - 16, 29 - 35} {13, 29} 27 mm
locking (1.06 in)
spring
1st to 6th &
Reverse
137 - 167 When com-
Tension
{14 - 17, 31 - 37} pressed to
N {kgf,
29.0 mm
lbf}
Trans- (1.142 in)
mission Splitter
cover When com-
78 - 98 O
pressed to
8 - 10, 18 - 22
28 mm
(1.102 in)
Range
When com-
127 - 157
pressed to
13 - 16, 29 - 35
28 mm
(1.102 in)
0.10 - 0.24 1.0
(0.0039 - 0.0094) (0.039) O
Except for
0.10 - 0.24 1.0
those indi- O O O
(0.0039 - 0.0094) (0.039)
cated below
Clearance between
shift fork and sleeve At 5th & 6th
O
groove gears
0.10 - 0.29 1.0 At 4th & 5th
(0.0039 - 0.0114) (0.039) and 6th & O
7th gears
At 4th & 5th
O
gears
Clearance between
reverse shift fork and 0.10 - 0.24 1.0 O
reverse sleeve (0.0039 - 0.0094) (0.039)
groove

TM-1-6
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance Service Remar MTS60A
Item MTP00B
standard limit ks MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
0.10 - 0.24 0.5
(0.0039 - 0.0094) O O
Each main gear and counter (0.020)
gear backlash 0.15 - 0.25 0.5
(0.0059 - 0.0098) (0.020) O O O
0.30 - 0.50
O O
(0.0118 - 0.0197) 0.7
1st gear
0.20 - 0.40 (0.028)
O O O
(0.0079 - 0.0157)
0.30 - 0.50
(0.0118 - 0.0197) O O
0.7
2nd gear
0.20 - 0.40 (0.028)
O O O
(0.0079 - 0.0157)
0.30 - 0.50
O O
(0.0118 - 0.0197) 0.7
3rd gear
0.20 - 0.40 (0.028)
(0.0079 - 0.0157) O O O
0.30 - 0.50
O O
(0.0118 - 0.0197) 0.7
4th gear
Each main 0.20 - 0.40 (0.028)
O
gear end play (0.0079 - 0.0157)
0.35 - 0.55 0.7
5 th gear O
(0.0138 - 0.0217) (0.028)
0.35 - 0.55 0.7
6 th gear O
(0.0138 - 0.0217) (0.028)
0.30 - 0.50
Transmission (0.0118 - 0.0197) O O
proper 0.20 - 0.50 0.7
Reverse gear O O
(0.0079 - 0.0197) (0.028)
0.20 - 0.40
(0.0079 - 0.0157) O
0.20 - 0.40 0.7
Splitter gear (0.0079 - 0.0157) (0.028) O
Range low 0.20 - 0.40 0.7
gear (0.0079 - 0.0157) (0.028) O
0.30 - 0.50 0.7
Rear 6th gear O
(0.0118 - 0.0197) (0.028)
countershaft
gear end play 0.30 - 0.50 0.7
7th gear (0.0118 - 0.0197) (0.028) O
Sub countershaft low gear end 0.20 - 0.40 0.7
play (0.0079 - 0.0157) (0.028) O
0.30 - 0.60 1.0
(0.0118 - 0.0236) (0.039) O
0.30 - 0.80 1.0
(0.0118 - 0.0315) (0.039) O
Reverse idler gear end play
0.10 - 0.70 1.0
(0.0039 - 0.0276) (0.039) O O
0.30 - 0.50 1.0
(0.0118 - 0.0197) (0.039) O
Radial play of main shaft and 0.20 - 0.30 0.5
sleeve splines (0.0079 - 0.0118) (0.020) O O O
Radial play between hub and 0.20 - 0.30 0.5
sleeve splines (0.0079 - 0.0118) (0.020) O O O O O
Clearance between 5th bush- 0.10 - 0.14
ing and 5th gear (0.0039 - 0.0055) O

TM-1-7
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance Service Remar MTS60A
Item MTP00B
standard limit ks MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
0.40 - 0.50 1.0
(0.039) O O O O
(0.0157 - 0.0197)
1st gear
0.20 - 0.30 1.0 O
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
2nd gear (0.039) O O O O O
(0.0079 - 0.0118)
0.20 - 0.30 1.0
3rd gear O O O O O
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
Radial play 4th gear O O O O
(0.0079 - 0.0118) (0.039)
between
0.20 - 0.30 1.0
sleeves and 5th gear (0.039) O O
Transmission (0.0079 - 0.0118)
clutch gear
proper splines 0.20 - 0.30 1.0
6th gear O O
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
7th gear O
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
Splitter gear (0.039) O
(0.0079 - 0.0118)
Range low 0.20 - 0.30 1.0
O
gear (0.0079 - 0.0118) (0.039)
Reverse 0.40 - 0.50 1.0 O O O O O
gear (0.0157 - 0.0197) (0.039)
0.5
Ball bearing axial play O O O O O
(0.020)

TM-1-8
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance Service MTS60A
Item Remarks MTP00B
standard limit MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
Minus (-)
symbol
Alignment of synchronizer -0.2 - 0.4
Protrusion O O O O
rings with their discs (-0.008 - 0.016)
from the
Pin disc
type
0.3 - 1.5 4.0 Range
Height difference between (0.012 - 0.059) (0.157) high gear
synchronizer ring and syn- O
chronizer cone end surface 0.3 - 1.6 6.0 Range low
(0.012 - 0.063) (0.236) gear
1.6 - 2.5
O
Clearance between synchro- (0.063 - 0.098)
nizer ring and their cone 1.4 - 2.6
O
(0.055 - 0.102)
5.3 - 5.7
O
(0.209 - 0.224)
4.7 - 5.0
Tangential clearance between O
(0.185 - 0.197)
synchronizer ring and syn-
chronizer hub 6.3 - 6.7
1st to 4th
(0.248 - 0.264)
O
6.5 - 6.9
Splitter
(0.256 - 0.272)
0.05 - 0.35
Radial clearance between O
(0.0020 - 0.0138)
synchronizer hub and syn-
chronizer detent 0.1 - 0.3
O
(0.004 - 0.012)
1.4 - 1.8
1st - 2nd
(0.055 - 0.071)
Backlash between synchro- 1.5 - 1.9
0 3rd - 4th O
nizer ring and clutch gear (0.059 - 0.075)
1.4 - 1.6
Splitter
(0.055 - 0.063)
Synchro- 0.1 - 0.3
Axial clearance between syn- 1st to 4th
nizer (0.004 - 0.012)
system chronizer ring and synchro- O
nizer detent 1.3 - 1.5
Splitter
(0.051 - 0.059)
Lock 15
O
plunge (0.59)
r type 25.0
1st to 4th
(1.0)
Free length
26.0
Splitter O
(1.0)
50.0
Range
(2.0)
When
21.6 - 35.3 com-
{2.2 - 3.6, pressed to O
4.9 - 7.9} 12.0 mm
(0.472 in)
1st to 4th
Detent When
56.9 - 68.6
spring com-
{5.8 - 7.0,
pressed to
12.8 - 15.4}
18.0 mm
(0.709 in)
Tension N {kgf, lbf} Splitter
When
70.6 - 86.3
com-
{7.2 - 8.8, O
pressed to
15.9 - 19.4}
22.0 mm
(0.866 in)
Range
When
80.4 - 98.1
com-
{8.2 - 10.0,
pressed to
18.1 - 22.1}
35.0 mm
(1.378 in)

TM-1-9
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance Service MTS60A
Item Remarks MTP00B
standard limit MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
15
Outer
Free (0.59) O
length 13.5 (Set)
Inner
(0.531)
Lock
Detent 40.31 - 44.62 40.31
plunge When
spring Outer {4.11 - 4.55, {4.11,
r type Tension com-
9.06 - 10.03} 9.06} O
N {kgf, pressed to
lbf} 10.30 - 11.47 10.30 11.07 mm (Set)
Inner {1.05 - 1.17, {1.05, (0.4358 in)
2.32 - 2.58} 2.32}
Synchro- 1.5 - 2.7
nizer sys- 0 O
Clearance between synchro- (0.059 - 0.106)
tem
nizer ring and cone 1.0 - 3.0
0 O
(0.039 - 0.118)
4.49 - 4.85
O
Key Radial play between key and (0.1768 - 0.1909)
type synchronizer ring 4.9 - 5.4
O
(0.193 - 0.213)
0.04 - 0.19
(0.0016 - 0.0075) O
Radial play between key and
synchronizer hub 4.9 - 5.4
O
(0.193 - 0.213)
Clearance between drive shaft 0.06 - 0.09 0.2
and case (0.0024 - 0.0035) (0.0079)
Clearance between driven 0.06 - 0.09 0.2
shaft and case (0.0024 - 0.0035) (0.0079)
After tight-
ening bolts O O O
0.03 (0.0012), 0.7
Drive and driven gear end play to 20 N·m
min. (0.028)
{2 kgf·m,
Oil pump 14 lbf·ft}
Fit of drive shaft and front of 0.2 - 0.4 0.7
countershaft at notch location (0.008 - 0.016) (0.028)
0.05 - 0.09
Oil pump gear end play
(0.0020 - 0.0035)
Radial play between oil pump O
0 - 0.18
gear and counter shaft at
(0 - 0.0071)
splines

TM-1-10
 SERVICE DATA T/M PROPER

Unit: mm (in)
Application
Maintenance Service MTS70A MTS60B
Item Remarks
standard limit MTP00B MTS60A MTS60D
MTP00C MRT20A
Item No.
25.5
20
(1.004)
(Large)
Item No.
Free 23.6
30
length (0.929)
(Large)
Item No.
21.0
25
(0.827)
(Large)
When
Item No. com-
46.58 38.2
Type I 20 pressed to O O
{4.75, 10.47} {3.9, 8.6}
(Large) 15.05 mm
(0.5925 in)
When
Tension Item No. com-
13.82 11.8
N {kgf, 30 pressed to
{1.41, 3.11} {1.2, 2.6}
lbf} (Large) 15.05 mm
(0.5925 in)
When
Item No. com-
9.02 6.9
25 pressed to
Power {0.92, 2.03} {0.7, 1.5}
(Large) 13.0 mm
shift (0.512 in)
spring
Item No.
Power 18.1
16
shift (0.713)
(Large)
Item No.
Free 15.0
21
length (0.591)
(Large)
Item No.
21.0
25
(0.827)
(Large)
When
Type II Item No. 40.2 - 52.0 com- O O
47.1
16 {4.1 - 5.3, pressed to
{4.8, 10.6} 9.0 - 11.7}
(Large) 13.0 mm
(0.512 in)
Tension When com-
Item No. 15.7 - 20.6
N {kgf, 18.6 pressed to
21 {1.6 - 2.1,
lbf} {1.9, 4.2} 13.0 mm
(Large) 3.5 - 4.6}
(0.512 in)
When com-
Item No. 10.8 - 13.7
12.7 pressed to
26 {1.1 - 1.4,
{1.3, 2.9} 10.0 mm
(Large) 2.4 - 3.1}
(0.394 in)
0.15 (0.0059),
Valve seal dent depth O O O
max.
O
Distance between pipe retaining ring 80.5 - 81.1
O (Except
groove and cap end (3.169 - 3.193)
Type II)

NOTE
z Item Nos. indicate the disassembly sequence in the illustration.

TM-1-11
 SERVICE DATA T/M PROPER

UNIT NAME:MRT23B

Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Clearance between shift lever and select 0.1 - 0.4 0.8
lever (0.004 - 0.016) (0.031)
Radial play between shift shaft and shift 0.02 - 0.08 0.5
lever splines (0.0008 - 0.0031) (0.020)
Clearance between shift lever and each 0.74 - 0.96 1.5
shifter/shift fork (0.0291 - 0.0378) (0.059)
0.04 - 0.07
Reverse
(0.0016 - 0.0028)
0.07 - 0.10
Splitter
(0.0028 - 0.0039)
Clearance between transmission cover 0.04 - 0.07 0.3
Range
and shift fork shaft (0.0016 - 0.0028) (0.012)
0.07 - 0.17
1st & 2nd
(0.0028 - 0.0067)
0.06 - 0.15
3rd & 4th
(0.0024 - 0.0059)

Trans- Clearance between each fork claw and 0.1 - 0.5 1.0
mission synchronizer sleeve (0.004 - 0.020) (0.039)
cover Clearance between each fork claw and 0.02 - 0.05
–
shift fork (0.0008 - 0.0020)
0.07 - 0.10 0.3
Splitter
(0.0028 - 0.0039) (0.012)
Clearance between cylinder and shift shaft
0.04 - 0.07 0.3
Range
(0.0016 - 0.0028) (0.012)
42.5 (1.673) – 1st to 6th & Reverse
Free length 35.0 (1.378) – Splitter
34.5 (1.358) – Range

Shift fork shaft locking 137 - 167 When compressed to

–
spring {14 - 17, 31 - 37} 29.0 mm (1.142 in)
Tension 78 - 98 When compressed to
–
N {kgf, lbf} {8 - 10, 18 -22} 28.0 mm (1.102 in)
127 - 157 When compressed to
–
{13 - 16, 29 - 35} 28.0 mm (1.102 in)
Clearance between reverse shift fork and 0.10 - 0.24 1.0
reverse sleeve groove (0.0039 - 0.0094) (0.039)

TM-1-12
 SERVICE DATA T/M PROPER

Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Each main gear and counter gear back- 0.10 - 0.20 0.5
lash (0.0039 - 0.0079) (0.020)
0.20 - 0.40 0.7
1st gear
(0.0079 - 0.0157) (0.028)
0.20 - 0.40 0.7
2nd gear
(0.0079 - 0.0157) (0.028)
0.20 - 0.40 0.7
3rd gear
(0.0079 - 0.0157) (0.028)
Each main gear end play
0.20 - 0.40 0.7
Reverse gear
(0.0079 - 0.0157) (0.028)
0.20 - 0.40 0.7
Splitter gear
(0.0079 - 0.0157) (0.028)
Range low 0.20 - 0.40 0.7
gear (0.0079 - 0.0157) (0.028)
Trans- 0.30 - 0.50 1.0
Reverse idler gear end play
mission (0.0118 - 0.0197) (0.039)
proper Radial play between hub and sleeve 0.20 - 0.30 0.5
splines (0.0079 - 0.0118) (0.020)
0.20 - 0.30 1.0
1st gear
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
2nd gear
(0.0079 - 0.0118) (0.039)
0.20 - 0.30 1.0
Radial play between 3rd gear
(0.0079 - 0.0118) (0.039)
sleeves and clutch gear
splines 0.20 - 0.30 1.0
Splitter gear
(0.0079 - 0.0118) (0.039)
Range low 0.20 - 0.30 1.0
gear (0.0079 - 0.0118) (0.039)
0.40 - 0.50 1.0
Reverse gear
(0.0157 - 0.0197) (0.039)
Ball bearing axial play – 0.5 (0.020)

TM-1-13
 SERVICE DATA T/M PROPER

Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
1.4 - 1.8
0 2nd - 3rd
(0.055 - 0.071)
Clearance between synchro- 1.5 - 1.9
0 3rd - 4th
nizer ring and their cone (0.059 - 0.075)
1.4 - 1.6
0 Splitter
(0.055 - 0.063)
6.3 - 6.7
Tangential clearance between – 1st to 4th
(0.248 - 0.264)
synchronizer ring and synchro-
nizer hub 6.5 - 6.9
– Splitter
(0.256 - 0.272)
0.1 - 0.3
Axial clearance between syn- – 1st to 4th
(0.004 - 0.012)
chronizer ring and synchronizer
detent 1.3 - 1.5
– Splitter
Synchro- Lock (0.051 - 0.059)
nizer sys- plunger 25.0
tem type – 1st to 4th
(0.984)
26.0
Free length – Splitter
(1.024)
35.6
– Range
(1.402)

Detent 1st to 4th

56.9 - 68.6
spring – When compressed to
{5.8 - 7.0, 12.8 - 15.4}
18.0 mm (0.709 in)
Splitter
Tension 70.6 - 86.3
– When compressed to
N {kgf, lbf} {7.2 - 8.8, 15.9 - 19.4}
22.0 mm (0.866 in)
Range
153 - 169
– When compressed to
{15.6 - 17.2, 34 - 38}
29.0 mm (1.142 in)
Radial play between oil pump gear and 0 - 0.18
–
counter shaft at splines (0 - 0.0071)
Oil pump
0.05 - 0.09
Oil pump gear end play –
(0.0020 - 0.0035)
Item No.16 (Taper) 18.1 (0.713) –
Free
Item No.21 21.0 (0.827) –
length
Item No.26 (Taper) 15.0 (0.591) –
Power When compressed to
shift Item No.16 (Taper) 47.1 {4.8, 10.6} 40.2 {4.1, 9.0}
13.0 mm (0.512 in)
Power spring
shift Tension When compressed to
Item No.21 12.7 {1.3, 2.9} 10.8 {1.1, 2.4}
N {kgf, lbf} 10.0 mm (0.394 in)
When compressed to
Item No.26 (Taper) 18.6 {1.9, 4.2} 15.7 {1.6, 3.5}
13.0 mm (0.512 in)
0.15
Valve seal dent depth –
(0.0059), max.
NOTE
z Item Nos. indicate the disassembly sequence in the illustration.

TM-1-14
 SERVICE DATA T/M PROPER

TIGHTENING TORQUE

UNIT NAME:MPS50A, MTS60A/B/D, MTS70A, MTP00B/C, MRT20A

Unit: N·m {kgf·m, ft·lbf}
MTS60A
MTP00B
Item Tightening torque MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
186 - 235 {19 - 24, 137 - 174} O O M16
Clutch housing mounting bolt 58 - 77 {5.9 - 7.9, 43 - 57} O M12
142 - 186 {14.5 - 19.0, 105 - 137} O O
Transmission cover mounting 32 - 42 {3.3 - 4.3, 24 - 31} O O
bolt or nut 57 - 76 {5.8 - 7.7, 42 - 56} O O
19 - 25 {1.9 - 2.6, 14 - 19} O O
Control cover mounting bolt
32 - 42 {3.3 - 4.3, 24 - 31} O O O
Locking lever shaft mounting
89 - 118 {9.1 - 12, 66 - 87} O O O O
nut (on cover side)
Guide bolt 34 - 45 {3.5 - 4.6, 25 - 33} O O O O
34 - 39 {3.5 - 4.0, 25 - 29} O O O O
Switch
108 - 127 {11.0 - 13.0, 80 - 94} O
19 - 25 {1.9 - 2.6, 14 - 19} O O O O
Gear cover securing
6 TH 16 - 21 {1.6 - 2.1, 12 - 15} O
bolt
7 TH 19 - 25 {1.9 - 2.6, 14 - 19} O
Locking lever shaft mounting
89 - 118 {9.1 - 12, 66 - 87} O
nut (on case side)
Side cover mounting bolt 19 - 25 {1.9 - 2.6, 14 - 19} O O O O O
PTO gear box mounting bolt
32 - 42 {3.3 - 4.3, 24 - 31} O O O O O
and nut
Drain plug and level plug 118 - 137 {12 - 14, 87 - 101} O O O O O
Main drive gear bearing cap
32 - 42 {3.3 - 4.3, 24 - 31} O O O O O
mounting bolt
57 - 76 {5.8 - 7.7, 42 - 56} O O O
Bearing retainer Bolt 89 - 118 {9.1 - 12, 66 - 87} O O O
securing bolts and 127 - 167 {13 - 17, 94 - 123} O
nuts 89 - 118 {9.1 - 12, 66 - 87} O
Nut
137 - 186 {14 - 19, 101 - 137} O O O
Sub countershaft bearing
57 - 76 {5.8 - 7.7, 42 - 56} O
retainer securing bolts
18 - 22 {1.8 - 2.2, 13 - 16} O O O
Oil pump securing bolts
57 - 76 {5.8 - 7.7, 42 - 56} O
Oil filter securing bolts 32 - 42 {3.3 - 4.3, 24 - 31} O O O
598 - 745 {61 - 76, 441 - 550} O
Companion flange securing nut
686 - 981 {70 - 100, 506 - 723} O O O O
275 - 314 {28 - 32, 203 - 231} O
Main shaft lock nut 324 - 363 {33 - 37, 239 - 268} O O O
490 - 588 {50 - 60, 362 - 434} O
Countershaft lock nut 324 - 363 {33 - 37, 239 - 268} O
Counter shaft rear cover 57 - 76 {5.8 - 7.7, 42 - 56} O O
mounting bolt 127 - 167 {13 - 17, 94 - 123} O
34 - 45 {3.5 - 4.6, 25 - 33} O O
Shift fork and shifter securing
57 - 76 {5.8 - 7.7, 42 - 56} O
set screw
32 - 42 {3.3 - 4.3, 24 - 31} O O
Locking lever support securing
32 - 42 {3.3 - 4.3, 24 - 31} O
bolt
89 - 118 {9.1 - 12, 66 - 87} O
Rear case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56} O
137 - 186 {14 - 19, 101 - 137} O
Reverse idler gear shaft mount-
19 - 25 {1.9 - 2.6, 14 - 19} O
ing bolt
Speedometer gear support bolt 19 - 25 {1.9 - 2.6, 14 - 19} O

TM-1-15
 SERVICE DATA T/M PROPER

Unit: N·m {kgf·m, ft·lbf}

MTS60A
MTP00B
Item Tightening torque MPS50A MTS60B MTS70A MRT20A
MTP00C
MTS60D
Speedometer gear sleeve 34 - 44 {3.5 - 4.5, 25 - 33} O O
29 {3.0, 22} O O
Engine and transmission over-
25 - 34 {2.5 - 3.5, 18 - 25} O
run sensor
108 - 127 {11.0 - 13.0, 80 - 94} O
Oil catcher securing bolt 16 - 21 {1.6 - 2.1, 12 - 15} O
Plug 57 - 76 {5.8 - 7.7, 42 - 56} O
Oil strainer securing bolt 16 - 21 {1.6 - 2.1, 12 - 15} O
Sub main gear 82 - 108 {8.4 - 11, 61 - 80} O
Sub cover securing bolt 32 - 42 {3.3 - 4.3, 24 - 31} O
Middle case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56} O

High and low piston Splitter 57 - 76 {5.8 - 7.7, 42 - 56}

O
securing nuts Range 57 - 76 {5.8 - 7.7, 42 - 56}
Range high gear securing nut 686 - 981 {70.0 - 100, 506 - 723} O
Locking spring securing plugs 57 - 76 {5.8 - 7.7, 42 - 56} O
Shift shaft support securing
32 - 42 {3.3 - 4.3, 24 - 31} O
nuts
Range shift switch 34 - 49 {3.5 - 5.0, 25 - 36} O
Cylinder cap securing bolts 32 - 42 {3.3 - 4.3, 24 - 31} O
Control cover guide bolt 57 - 76 {5.8 - 7.7, 42 - 56} O
Cylinder cover securing bolts 8.6 - 12.7 {0.88 - 1.3, 6.4 - 9.4} O
Valve case securing bolt 16 - 21 {1.6 - 2.1, 12 - 15} O
Power shift assembly
78 - 98 {8.0 - 10.0, 58 - 72}
mounting bolt
Power shift cylinder 78 - 98 {8.0 - 10.0, 58 - 72}
Power shift cylinder
2.0 - 3.4 {0.2 - 0.35, 1.4 - 2.5}
screw O
Type I O O
Power shift striker nut 29 - 39 {3.0 - 4.0, 22 - 29} (MTS60A)

29 - 39 3.0 - 4.0, 22 -
8 - 12 {0.8 - 1.2, 5.8 - 8.7}
29
Power shift cylinder
59 - 69 {6.0 - 7.0, 43 - 51}
nut
Power shift assembly
21 - 23 {2.1 - 2.3, 15 - 17}
securing bolts
Power shift cylinder 98 - 118 {10.0 - 12.0, 72 - 87} O
Power shift cylinder (MTS60A)
Type II 2.0 - 3.4 {0.2 - 0.35, 1.4 - 2.5} O
screw (MTS60B)
Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7} (MTS60D)

Power shift cylinder

59 - 69 {6.0 - 7.0, 43 - 51}
nuts

TM-1-16
 SERVICE DATA T/M PROPER

UNIT NAME:MRT23B
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Front case Drain plug 118 - 137 {12.0 - 14.0, 87 - 101}
Main drive gear bearing cap mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
Plug 108 - 127 {11.0 - 13.0, 80 - 94}
Front side 32 - 42 {3.3 - 4.3, 24 - 31}
Gear cover mounting bolt
Rear side 32 - 42 {3.3 - 4.3, 24 - 31}
Middle case
Level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Middle case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Side cover mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
PTO gear box mounting bolt and nut 32 - 42 {3.3 - 4.3, 24 - 31}
Bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear case securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Drain plug and level plug 118 - 137 {12.0 - 14.0, 87 - 101}
Gear cover mounting bolt 32 - 42 {3.3 - 4.3, 24 - 31}
Rear case Sub countershaft bearing retainer securing bolts 57 - 76 {5.8 - 7.7, 42 - 56}
Rear bearing retainer securing Nut 137 - 186 {14.0 - 19.0, 101 - 137}
bolts and nut Bolt 89 - 118 {9.1 - 12.0, 66 - 87}
Switch 34 - 39 {3.5 - 4.0, 25 - 29}
Main shaft Main shaft lock nut (Left-hand thread) 412 - 471 {42.0 - 48.0, 304 - 347}
Sub main shaft and Companion flange securing nut 686 - 981 {70.0 - 100.0, 506 - 723}
countershaft Range high gear lock nut 686 - 981 {70.0 - 100.0, 506 - 723}
Shift fork and shifter securing set screw 32 - 42 {3.3 - 4.3, 24 - 31}
Shift fork assembly
Shift shaft support securing nuts 25 - 31 {2.5 - 3.2, 18 - 23}
Power shift assembly securing bolts 21 - 23 {2.1 - 2.3, 15 - 17}
Transmission control
Switch 108 - 127 {11.0 - 13.0, 80 - 94}
cover assembly
Cylinder cover securing 8.6 - 12.7 {0.88 - 1.3, 6.4 - 9.4}
Oil filter securing bolts 32 - 42 {3.3 - 4.3, 24 - 31}
Oil pump securing bolts 16 - 21 {1.6 - 2.1, 12 - 15}
Oil pump and oil filter
Valve case mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Connector 85 - 98 {8.7 - 10.0, 63 - 72}
Power shift cylinder 98 - 118 {10.0 - 12.0, 72 - 87}
Power shift cylinder screw 2.0 - 3.4 {0.20 - 0.35, 1.4 - 2.5}
Power shift assembly
Power shift connector 8 - 12 {0.8 - 1.2, 5.8 - 8.7}
Power shift cylinder nuts 59 - 69 {6.0 - 7.0, 43 - 51}

TM-1-17
 SERVICE DATA T/M PROPER

SYSTEM DIAGRAM
MTS70

MTP00

TM-1-18
 SERVICE DATA T/M PROPER

MRT20, MRT23

TM-1-19
 TOOLS T/M PROPER

TOOLS
Application
Tool name and number Description Shape MRT20
MPS50 MTS60 MTS70 MTP00
MRT23

Used together with the

Sliding hammer adapter to drive out the
o o o o o
99547 Z0000 reverse idler gear
shaft.

Used to remove main

Lock nut wrench shaft lock nut. Width
99809 Z0003 across flats = 54 mm
o — — — —
(2.13 in)
Used to remove main
Lock nut wrench shaft nut. Width
99809 Z0006 across flats = 60 mm
— o o o —
(2.36 in)
Used to remove/install
Socket wrench main shaft companion
99535 Z0003 flange. Width across
o — — — —
flats = 50 mm (1.97 in)
Used to install main
Socket wrench shaft lock nut. Width
o — — — —
99535 Z0014 across flats = 54 mm
(2.13 in)
Used to remove/install
main shaft companion
flange. Width across
— o o o —
flats = 58 mm (2.28 in)
Socket wrench
99535 Z0074 Used to remove/install
main shaft nuts or com-
panion flange. Width — — — — o
across flats = 58 mm
(2.28 in)
Used to install main
Socket wrench shaft lock nut. Width
99535 Z0075 across flats = 60 mm
— o o o —
(2.36 in)

Countershaft bearing Used to remove front

puller roller bearing outer — o o o —
99802 Z0000 race

TM-2-1
 TOOLS T/M PROPER

Application
Tool name and number Description Shape MRT20
MPS50 MTS60 MTS70 MTP00
MRT23

Pilot bearing replacer Used to press-fit main

99827 Z0070 shaft pilot bearing
— o — — —

Inner race replacer

Used to press-fit inner
1st 99827 Z0071
race on main shaft
— o — — —
4th 99827 Z0075

Inner race replacer Used to press-fit inner

2nd 99827 Z0073 race on main shaft
— o — — —

Inner race replacer

6th 99801 Z0004 Used to press-fit inner
1. 99827 Z0076 race on main shaft
— o — — —
2. 99827 Z0077

Attached to input shaft

Main drive shaft stop-
splines to prevent the
per
input shaft from rotat-
— — — — o
99803 Z0000
ing.

Used when lifting the

Gear hanger assem-
main shaft and
bly
countershaft assem-
— — — — o
99783 Z0002
blies as a unit.

TM-2-2
 TOOLS T/M PROPER

Application
Tool name and number Description Shape MRT20
MPS50 MTS60 MTS70 MTP00
MRT23

Used when removing

the main shaft rear nut
lock plate and the sub-
Lock plate replacer
99827 Z0069
main shaft bearing — — — — o
outer race as a unit.
(Used with sliding ham-
mer: 99547 Z0000)

Attached to the front

Gear shaft setting tool case when disassem-
99799 Z0003 bling/reassembling the
— — — — o
main shaft.

Attached to the main

Construction stand shaft rear splines when
99805 Z0000 installing the main
— — — — o
shaft tip end.

Bushing replacer
1st - 2nd Used when pressing
99801 Z0001 bushings into bores in
Bushing replacer the front and middle
3rd - 4th cases.
99801 Z0002
— — — — o
Used when pressing
Bushing replacer
the shift shaft bushing
At control lever
into the bore in the
99801 Z0003
control cover.

Used as a jig to mea-

sure the bearing-to-
Drive gear set tool bearing gap when
99806 Z0000 selecting shims suited
— — — — o
to the 4th gear bearing
preload.

Used when pressing

Bearing retainer
the bearing retainer
replacer
onto the main shaft
— — — — o
99827 Z0068
rear end.

TM-2-3
 TOOLS T/M PROPER

Application
Tool name and number Description Shape MRT20
MPS50 MTS60 MTS70 MTP00
MRT23

Oil seal replacer

Used when pressing oil
Range side
seals onto the range-
99807 Z0004
splitter select air cylin-
— — — — o
Splitter side
der.
99807 Z0005

Used to protect the

main shaft end from
Main shaft adapter damage when disas-
99804 Z0000 sembling the main
— — — — o
shaft using a gear
puller

Used when removing

Bearing remover the bearing from the
99800 Z0002 main shaft rear bearing
— — — — o
retainer.

Used when disassem-

bling and reassem-
bling the transmission.
Attachment
The attachment is used — — — — o
99555 Z0000
by installing it on the
engine stand (99550
96001).

Used when pull out the

Puller assembly o
910-11150 (JKC No.)
straight pin on power — — — o
(Type II)
shift striker.

Used when installing

Guide
910-24800 (JKC No.)
valve on power shift — o — — o
rod pipe.

TM-2-4
 TOOLS T/M PROPER

Used when installing

Tool insert
910-26500 (JKC No.)
snap ring on power — o — — o
shift rod pipe.

TM-2-5
 CONSTRUCTION MPS50

= UNIT NAME MPS50 =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-3-1
 CONSTRUCTION MPS50

MAIN SHAFT ASSEMBLY

COUNTERSHAFT ASSEMBLY

TM-3-2
 DISASSEMBLY MPS50

DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-3-3
 DISASSEMBLY MPS50

DISASSEMBLY
FRONT CASE, MIDDLE CASE AND REAR CASE ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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. Countershaft 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: , 24. Spacer
7. O-ring If so equipped) , 25. Ball bearing
8. Companion flange 17. Gasket ,+ 26. Countershaft assembly
+ 9. Bearing retainer 18. Lock plate 27. Transmission case
10. Gasket
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-3-4
 DISASSEMBLY MPS50

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Thrust washer +, 13. Detent 24. 2nd-3rd hub
2. 1st gear +, 14. 4th-5th synchronizer hub 25. 2nd gear
3. Needle bearing +, 15. 4th Synchronizer ring 26. Needle bearing
, 4. Retaining ring 16. 4th gear 27. Spacer
+ 5. Pilot bearing 17. Needle bearing 28. Needle bearing
, 6. Lock nut 18. 4th inner race 29. 2nd inner race
, 7. Lock washer , 19. Thrust washer , 30. Thrust washer
+, 8. Lock washer 20. 3rd gear , 31. Reverse gear
+, 9. 4th-5th synchronizer sleeve 21. Needle bearing 32. Needle bearing
+, 10. Lock plunger 22. 3rd inner race 33. 1st-reverse sleeve
+, 11. Synchronizer spring (Outer) +, 23. 2nd-3rd synchronizer assembly 34. Dowel pin
+, 12. Synchronizer spring (Inner) , 35. Main shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-3-5
 DISASSEMBLY MPS50

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 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. Countershaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-3-6
 DISASSEMBLY MPS50

TRANSMISSION COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. Locking 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. Reverse 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-3-7
 DISASSEMBLY MPS50

TRANSMISSION CONTROL COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Breather 8. Plug + 15. Oil seal
2. Shield plate 9. Spring 16. Bushing
3. Guide plate 10. Plunger 17. Gasket
4. Retaining ring + 11. Welch plug +, 18. Return spring
5. Thrust washer 12. Straight pin 19. Shift lever
6. Select lever +, 13. Inner shaft +, 20. Return spring
7. O-ring 14. Plate 21. Control cover
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-3-8
 DISASSEMBLY MPS50

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

z Measure and record the end play of each gear.

z Clearance between 4th gear and 4th-5th thrust washer
z Clearance between 3rd gear and 4th-5th thrust washer
z Clearance between 2nd gear and 2nd-3rd hub
z Clearance between the reverse gear and 1st-reverse hub
z Clearance between 1st gear and 1st thrust washer

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 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
Unlock the lock nut, and remove the lock nut using socket wrench
(99535 Z0003).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

NOTE
z Do not re-use the pinion nut after removal.

TM-3-9
 DISASSEMBLY MPS50

9 Bearing retainer
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.

13 Main drive gear

Be sure the cutout section of the synchronizer cone faces down-
ward when removing the main drive gear.
NOTE
z Attach a tag to the synchronizer ring for identification.

z Do not remove the ball bearing unless necessary.

15 Main shaft assembly

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
the transmission case.

TM-3-10
 DISASSEMBLY MPS50

19 Reverse idler shaft

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

20 Reverse idler gear

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

26 Countershaft assembly
While tilting the front of the countershaft assembly up using a hoist
and lifting wire, remove the countershaft assembly from the trans-
mission case.

MAIN SHAFT ASSEMBLY

Key point of disassembly
5 Pilot bearing
1. Place the main shaft on the work bench with the front facing
upward. Using the lock nut wrench (99809 Z0003), 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-3-11
 DISASSEMBLY MPS50

8 - 15 4th-5th synchronizer assembly

When disassembling the sleeve, be careful not to lose the detent,
plunger and synchronizer spring located between the hub and
sleeve.
1. Synchronizer ring 5. Synchronizer spring (Outer)
2. 4th-5th synchronizer hub 6. Lock plunger
3. Detent 7. 4th-5th synchronizer sleeve
4. Synchronizer spring (Inner) 8. Synchronizer ring
NOTE
z Attach tags to the synchronizer cone and synchronizer
ring for later identification.

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
z Attach tags to the synchronizer cone and synchronizer
ring for later identification.

COUNTERSHAFT ASSEMBLY
Key point of disassembly
The countershaft assembly need not be disassembled unless gears
are replaced due to wear or damage to gear teeth, etc.
3, 6, 7 Counter gear
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the countershaft on the
floor.

TRANSMISSION COVER ASSEMBLY

Key point of disassembly
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.

TM-3-12
 DISASSEMBLY MPS50

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.

9, 10 Welch plug
Make sure that the welch plug is driven out together with the shift
fork shaft.

TM-3-13
 DISASSEMBLY MPS50

TRANSMISSION CONTROL COVER ASSEMBLY

Key point of disassembly
11 Welch plug
Do not remove the cap plug unless necessary.

13 Inner shaft
Place an alignment mark on the shift lever and inner shaft before
removal.

15 Oil seal
Remove the oil seal only when oil leakage is noticed. Discard the
old oil seal and install a new one.

18, 20 Return spring

Tag the left and right resist springs for identification.

TM-3-14
 INSPECTION MPS50

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Radial play between inner shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Clearance between shift lever and shifters

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Clearance between locking lever and lever shaft

Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.08 (0.0016 - 0.0031) 0.2 (0.008)

TM-3-15
 INSPECTION MPS50

Clearance between locking lever and lever shifter

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Shift fork shaft locking spring

Unit: mm (in)
Item Maintenance standard Service limit Remarks
41.0 - 44.0
Free length —
(1.614 - 1.732)
163.8 - 193.2 When compressed
Tension 163.8
{16.7 - 19.7, to 26.9 mm
N {kgf, lbf} {16.7, 36.8}
36.8 - 43.4} (1.059 in)

Clearance between shift fork and sleeve groove

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)

NOTE
z Measure the clearance at the sleeve groove in at least
three points.

TRANSMISSION PROPER
Each main gears and counter gear backlashes
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.2 (0.0039 - 0.0079) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.50 (0.0118 - 0.0197) 0.7 (0.028)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.50 (0.0118 - 0.0197) 1.0 (0.039)

TM-3-16
 INSPECTION MPS50

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Clearance between 5th bushing and 5th gear

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.14
—
(0.0039 - 0.0055)

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Item Maintenance standard Service limit
2nd-5th 0.20 - 0.30 (0.0079 - 0.0118)
1.0 (0.039)
1st-Reverse 0.40 - 0.50 (0.0157 - 0.0197)

Ball bearing axial play

Unit: mm (in)
Maintenance standard Service limit
– 0.5 (0.020)

SYNCHRONIZER SYSTEM
<Pin type>
Alignment of synchronizer rings with their discs
Unit: mm (in)
Maintenance standard Service limit Remarks
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc

TM-3-17
 INSPECTION MPS50

NOTE
z Measure the value on the opposite side (180º apart) and
determine the mean value.

<Lock plunger type>

Clearance between synchronizer ring and their cone
Unit: mm (in)
Maintenance standard Service limit
1.6 - 2.5 (0.063 - 0.098) —

Tangential clearance between synchronizer ring and

synchronizer hub
Unit: mm (in)
Maintenance standard Service limit
5.3 - 5.7 (0.209 - 0.224) —

Radial clearance between synchronizer hub and syn-

chronizer detent
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.35 (0.0020 - 0.0138) —

DETENT SPRING
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Free Outer 15 (0.59) —
length Inner 13.5 (0.531) —
40.31 - 44.62
40.31
Outer {4.11 - 4.55,
{4.11, 9.06} When com-
Tension 9.06 - 10.03}
pressed to 11.07
N {kgf, lbf} 10.30 - 11.47
10.30 mm (0.4358 in)
Inner {1.05 - 1.17,
{1.05, 2.32}
2.32 - 2.58}

TM-3-18
 REASSEMBLY MPS50

REASSEMBLY
REASSEMBLY
z When assembling or installing parts, pay attention to the
direction of gears, thrust washers, etc.
z Do not confuse one type of needle bearing and spacer with
others.
z Apply a coat of clean gear oil to rotating parts.
z After installing gears, manually rotate to ensure smooth
rotation without noise.
z Use new oil seals and O-rings.

TRANSMISSION CONTROL COVER ASSEMBLY

Key point of reassembly
18, 20 Return spring
Do not confuse the left and right return springs.
Paint color:
Red: Right spring
Blue: Left spring

13 Inner shaft
Be sure to align the marks placed on the shift lever and inner shaft
during disassembly.

TRANSMISSION COVER ASSEMBLY

Key point of reassembly
14, 25 Interlock pin
Do not attempt to rotate the shaft if the interlock pin is already
installed. Be sure to install the steel ball and interlock pin in their
positions.
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.

TM-3-19
 REASSEMBLY MPS50

9, 10 Welch plug
Be careful not to damage the plug.

COUNTERSHAFT ASSEMBLY
Key point of reassembly
4, 8 Key
When installing a key, make sure that its large chamfered side is on
the side gear installation side.

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 countershaft.

3 Counter drive gear

Face the chamfered side of the counter drive gear (at the boss
location) toward the countershaft.

TM-3-20
 REASSEMBLY MPS50

1 Retaining ring
Make sure the retaining ring is fitted into the groove properly.

MAIN SHAFT ASSEMBLY

Key point of reassembly
35 Main shaft
Mount the main shaft on a mounting stand, or in a vise, with the
front of the shaft facing upward.

31 Reverse gear
Insert the reverse gear with the clutch gear section facing down-
ward.

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.

TM-3-21
 REASSEMBLY MPS50

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.

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.

TM-3-22
 REASSEMBLY MPS50

7 Lock washer
Install the lock washer in the groove of the main shaft with the pawl
facing down.

6 Lock nut
Tighten the lock nut with the socket wrench (99535 Z0014).

4 Retaining ring
1. Ensure that the retaining ring is fitted in the groove.
2. The retaining ring should be turned after it has been
installed.

1 Thrust washer
Drive the thrust washer into place with the large chamfered side
facing the rear of the main shaft assembly.
z Measure and record the end play of each gear.
NOTE
z Measure the end play of the 1st gear after installing the
main shaft assembly in the transmission case.

TRANSMISSION ASSEMBLY
Key point of reassembly
26 Countershaft assembly
Face the letter side of the outer race outward.

TM-3-23
 REASSEMBLY MPS50

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).
20 Reverse idler gear
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
4. Needle bearing 8. O-ring

15 Main shaft assembly

Using a hoist and lifting cable, lift the main shaft assembly into the
transmission case.

14 Ball bearing
Drive the ball bearing until it reaches the “butt-up”' point.

TM-3-24
 REASSEMBLY MPS50

13 Main drive gear

Face the cutout section of the synchronizer cone downward and
drive the gear assembly until it contacts the retaining ring.
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.

2. Lock the pinion nut so that two clinched points contact each
other.

4 Bearing cap
Align the oil hole in the transmission case with the oil groove in the
bearing cap and face the marked side upward when installing.

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.

TM-3-25
 REASSEMBLY MPS50

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle. Be sure to align the main drive shaft with the
clutch disc at their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-3-26
 CONSTRUCTION MTS60

= UNIT NAME MTS60 =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-4-1
 CONSTRUCTION MTS60

MAIN SHAFT ASSEMBLY

TM-4-2
 CONSTRUCTION MTS60

COUNTERSHAFT ASSEMBLY

TM-4-3
 CONSTRUCTION MTS60

POWER SHIFT ASSEMBLY

Type I

TM-4-4
 CONSTRUCTION MTS60

Type II

TM-4-5
 DISASSEMBLY MTS60

DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-4-6
 DISASSEMBLY MTS60

DISASSEMBLY
TRANSMISSION ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly + 14. Oil seal 27. Retaining ring
2. Side cover (PTO gear box: If so equipped) 15. Bearing cover , 28. Spacer
3. Gasket 16. Gasket + 29. Roller bearing
4. Overrun sensor ,+ 17. Bearing cap & oil seal + 30. Countershaft assembly
, 5. Transmission cover assembly 18. Gasket 31. Plug
,+ 6. Lock nut + 19. Main drive gear assembly 32. Spacer (Oil pump: If so equipped)
7. Washer 20. Ball bearing 33. O-ring (Oil pump: If so equipped)
8. O-ring + 21. Main shaft assembly 34. O-ring (Oil pump: If so equipped)
9. Companion flange 22. Set bolt 35. Gear cover
10. Bearing retainer 23. Welch plug 36. Oil catcher
11. Gasket + 24. Reverse idler shaft 37. Transmission case
12. Speedometer gear 25. Thrust washer
13. Speedometer driven gear assembly , 26. Reverse idler gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-7
 DISASSEMBLY MTS60

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Retaining ring 15. 5th & 6th gear 28. 1st gear
,+ 2. Pilot bearing , 16. Thrust washer 29. Needle bearing
, 3. Lock nut 17. Pin , 30. 1st gear inner race
, 4. Lock washer , 18. 4th gear inner race 31. 1st & 2nd hub
5. Synchronizer cone 19. Needle bearing 32. 1st & 2nd synchronizer assembly
6. Synchronizer ring 20. 4th gear 33. 2nd gear
+ 7. Spring ,+ 21. 3rd & 4th synchronizer assembly 34. Needle bearing
+ 8. 5th-6th sleeve 22. 3rd & 4th hub 35. Spacer
+ 9. Spring 23. 3rd gear , 36. 2nd gear inner race
+ 10. Key 24. Needle bearing , 37. Thrust washer
+ 11. 5th-6th hub 25. Spacer 38. Reverse gear
12. Synchronizer ring 26. Reverse sleeve 39. Needle bearing
, 13. 6th gear inner race , 27. Thrust washer 40. Spacer
14. Needle bearing 41. Main shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-8
 DISASSEMBLY MTS60

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Roller bearing inner race ,+ 5. 4th gear 9. Key
2. Retaining ring 6. Spacer 10. Key
,+ 3. counter drive gear ,+ 7. 3rd gear 11. Countershaft
,+ 4. 6th gear 8. Key 12. Roller bearing inner race
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-9
 DISASSEMBLY MTS60

TRANSMISSION COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Switch , 14. Shift fork (R) , 26. Shift fork (1st & 2nd)
, 2. Steel ball , 15. Interlock pin , 27. Steel ball
3. Switch , 16. Steel ball , 28. Interlock pin
, 4. Steel ball 17. Shift shaft 29. Shift shaft
5. Guide bolt 18. Setscrew 30. Setscrew
, 6. Welch plug , 19. Shift fork (5th & 6th) , 31. Shifter
7. Locking spring , 20. Shifter , 32. Shift fork (3rd & 4th)
, 8. Steel ball , 21. Steel ball 33. Shift shaft
9. Lever shaft , 22. Interlock pin 34. Setscrew
10. Bell crank 23. Shift shaft , 35. Setscrew
11. Self-locking nut 24. Setscrew , 36. Shifter
12. Setscrew , 25. Shifter 37. Shift shaft
, 13. Shifter
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-10
 DISASSEMBLY MTS60

TRANSMISSION CONTROL COVER ASSEMBLY

Type I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Breather 9. Check spring 17. Gasket
, 2. Lock plate (If so equipped) 10. Plunger 18. Return spring
3. Guide plate 11. Welch plug 19. Shift lever
4. Snap ring 12. Straight pin 20. Plain washer
5. Thrust washer 13. Inner shaft 21. Return spring
6. Select lever 14. Plate 22. Plain washer
7. O-ring 15. Oil seal 23. Control cover
8. Plug 16. Bushing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-11
 DISASSEMBLY MTS60

Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Control cover 11. Plug 21. Plate
2. Gasket 12. Check spring 22. Gasket
, 3. Power shift assembly 13. Steel ball 23. Plain washer
4. Gasket 14. Steel ball 24. Return spring
5. Guide plate 15. Plug 25. Shift lever
6. Retaining ring 16. Check spring 26. Return spring
7. Thrust washer 17. Plunger 27. Breather
8. Select lever 18. Spring pin 28. Plug
9. O-ring 19. Shift lever
10. Spring pin 20. Collar
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-12
 DISASSEMBLY MTS60

POWER SHIFT ASSEMBLY

Type I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Cylinder boots 21. Ring 41. Striker
2. Nut 22. Seat 42. Straight pin
3. Connector ,+ 23. Seat seal assembly 43. Ring
4. Cover 24. O-ring 44. Ring
5. Nut 25. Spring 45. O-ring
6. Ring 26. O-ring , 46. Piston packing
7. Plate ,+ 27. Seat seal assembly 47. Piston
8. Spring 28. Seat 48. Ring
9. Plug 29. Ring 49. Rod
10. Steel ball 30. Spring 50. O-ring
11. Bolt 31. Lifter 51. Boot
12. Filter 32. O-ring 52. Retainer
13. Tube 33. Pipe + 53. Cylinder packing
14. Ring 34. Filter 54. Bush
15. O-ring , 35. Rod cap assembly + 55. Cylinder packing
, 16. Tube ring , 36. Housing setscrew 56. Housing
17. Plate 37. Cylinder
18. Lifter 38. O-ring
19. O-ring 39. Oil seal
20. Spring 40. Ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-13
 DISASSEMBLY MTS60

Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-14
 DISASSEMBLY MTS60

OIL PUMP ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly 5. Spring 9. Dowel
2. Gasket 6. Steel ball 10. Drive gear
3. Plug 7. Case 11. Driven gear
4. Packing 8. Gasket 12. Housing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-4-15
 DISASSEMBLY MTS60

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

6 Lock nut
Unlock the lock nut, and remove the lock nut using socket wrench
(99535 Z0074).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

NOTE
z Do not re-use the pinion nut after removal.

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 the backlash at least three equally spaced
points for each gear.

z Measure and record the end play of each gear.

z Clearance between 1st gear and 1st & 2nd hub
z Clearance between 2nd gear and 1st & 2nd hub
z Clearance between reverse gear and hub
z Clearance between 3rd gear and hub
z Clearance between 4th gear and thrust washer
z Clearance between 5th (direct drive mechanism) or 6th
(over-drive mechanism) gear and thrust washer

14 Oil seal
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.

TM-4-16
 DISASSEMBLY MTS60

17 Bearing cap
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.

19 Main drive gear assembly

Do not remove the ball bearing unless necessary.

21 Main shaft assembly

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
the transmission case.

24 Reverse idler shaft

To remove the reverse idler gear shaft, remove the setscrew and
then use the sliding hammer (99547 Z0000).

TM-4-17
 DISASSEMBLY MTS60

29 Roller bearing
Drive the roller bearing out of the front of the countershaft using
countershaft bearing puller (99802 Z0000).
NOTE
z Do not remove the counter plug unless necessary. If the
countershaft bearing puller is not available, remove the
plug first. Do not re-use the plug after removal.

30 Countershaft assembly
While tilting the front of the countershaft assembly up using a hoist
and lifting wire, remove the counter shaft assembly from the trans-
mission case.

MAIN SHAFT ASSEMBLY

Key point of disassembly
2 Pilot bearing
1. Place the main shaft on the work bench with the front facing
upward. Using the lock nut wrench (99809 Z0006), 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.

7, 8, 9, 10, 11 5th-6th synchronizer assembly

Be careful not to lose parts located between the hub and sleeve
during disassembly.
1. Spring 4. Spring
2. 5th & 6th hub 5. 5th & 6th sleeve
3. Key

TM-4-18
 DISASSEMBLY MTS60

21 3rd-4th synchronizer assembly

Before removing the 3rd-4th synchronizer assembly, put an align-
ment mark on the side face of it.

COUNTERSHAFT ASSEMBLY
Key point of disassembly
z The countershaft assembly need not be disassembled
unless gears are replaced due to wear or damage to gear
teeth, etc.
3, 4, 5, 7 Counter gear
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the countershaft on the
floor.

TRANSMISSION COVER ASSEMBLY

Key point of disassembly
Remove the control cover assembly.
NOTE
z Be careful not to lose the locking spring and steel ball.

POWER SHIFT ASSEMBLY

Key point of disassembly
4 Retaining ring, 5 Retaining ring plate, 6 Straight pin /type II
Remove the snap ring and snap ring plate. Using the puller
assembly (910-11150 JKC NO.), pull out the straight pin.

TM-4-19
 DISASSEMBLY MTS60

23, 27 Type I, 19, 23 Type II seat seal assembly

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

53, 55 Type I, 36 Type II cylinder packing

Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.

TM-4-20
 INSPECTION MTS60

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Radial play between inner shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Clearance between shift lever and shifters

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Clearance between transmission cover and shift folk

shaft
Unit: mm (in)
Maintenance standard Service limit
0.03 - 0.08 (0.0012 - 0.0031) 0.2 (0.008)

TM-4-21
 INSPECTION MTS60

Clearance between locking lever and lever shaft

Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.08 (0.0016 - 0.0031) 0.2 (0.008)

Clearance between locking lever and lever shifter

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Shift fork shaft locking spring

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Free length 42.5 (1.673) —
When compressed
Tension 127 - 157 127
to 27 mm
N {kgf, lbf} {13 - 16, 29 - 35} {13, 29}
(1.06 in)

Clearance between shift fork and sleeve groove

Unit: mm (in)
Maintenance standard Service limit Remarks
Except for those indi-
0.10 - 0.24 (0.0039 - 0.0094)
1.0 (0.039) cated below
0.10 - 0.29 (0.0039 - 0.0114) At 5th & 6th gears

NOTE
z Measure the clearance at the sleeve groove in at least
three points.

TRANSMISSION PROPER
Each main gears and counter gear backlashes
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)

TM-4-22
 INSPECTION MTS60

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit Remarks
0.30 - 0.50
All except 6th gear
(0.0118 - 0.0194)
0.7 (0.028)
0.35 - 0.55
6th gear
(0.0138 - 0.0217)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.80 (0.0118 - 0.0315) 1.0 (0.039)

Radial play of mainshaft and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50
1st & reverse
(0.0157 - 0.0197)
1.0 (0.039)
0.20 - 0.30
Except for 1st & reverse
(0.0079 - 0.0118)

Ball bearing axial direction play

Unit: mm (in)
Maintenance standard Service limit
— 0.5 (0.020)

TM-4-23
 INSPECTION MTS60

SYNCHRONIZER SYSTEM
<Pin type>
Alignment of synchronizer rings with their discs
Unit: mm (in)
Maintenance standard Service limit Remarks
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc

NOTE
z Measure the value on the opposite side (180º apart) and
determine the mean value.

<KEY TYPE>
Clearance between synchronizer ring and cone
(Dimension B)
Unit: mm (in)
Maintenance standard Service limit
1.5 - 2.7 (0.059 - 0.106) 0

Radial play between key and synchronizer ring

(Dimension C)
Unit: mm (in)
Maintenance standard Service limit
4.49 - 4.85 (0.1768 - 0.1909) —

Radial play between key and synchronizer hub (Dimen-

sion D)
Unit: mm (in)
Maintenance standard Service limit
0.04 - 0.19 (0.0016 - 0.0075) —

TM-4-24
 INSPECTION MTS60

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Item No. 25.5
—
20 (1.004)
Free Item No. 23.6
—
length 30 (0.9291)
Item No. 21.0
—
25 (0.827)
When com-
Type I Item No. 46.58 38.2
pressed to 15.05
20 {4.75, 10.47} {3.9, 8.6}
mm (0.5925 in)
When com-
Tension Item No. 13.82 11.8
pressed to 15.05
N {kgf, lbf} 30 {1.41, 3.11} {1.2, 2.6}
mm (0.5925 in)
When com-
Item No. 9.02 6.9
pressed to 13.0
25 {0.92, 2.03} {0.7, 1.5}
mm (0.512 in)
Item No. 18.1
—
16 (0.713)
Free Item No. 15.0
—
length 21 (0.591)
Item No. 21.0
—
26 (0.827)

Type 40.2 - 52.0 When com-

Item No. 47.1
II {4.1 - 5.3, 9.0 - pressed to 13.0
16 {4.8, 10.6}
11.7} mm (0.512 in)
15.7 - 20.6 When com-
Tension Item No. 18.6
{1.6 - 2.1, 3.5 - pressed to 13.0
N {kgf, lbf} 21 {1.9, 4.2}
4.6} mm (0.512 in)
10.8 - 13.7 When com-
Item No. 12.7
{1.1 - 1.4, 2.4 - pressed to 10.0
26 {1.3, 2.9}
3.1} mm (0.394 in)

NOTE
z Item Nos. indicate the disassembly sequence.

Valve seal dent depth

Unit: mm (in)
Maintenance standard Service limit
Type I
0.15 (0.0059), max. —
Type II

TM-4-25
 INSPECTION MTS60

Distance between pipe retaining ring groove and cap end

face
Unit: mm (in)
Maintenance standard Service limit
Type I 80.5 - 81.1 (3.169 - 3.193) —

TM-4-26
 REASSEMBLY MTS60

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. 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.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during installa-
tion. Observe the following precautions during gasket application.

<Precautions during RTV liquid gasket application>

z Remove all traces of liquid gasket from the flanged surface
of parts using a scraper. Be careful not to scratch the
flanged surface and completely wipe away foreign particles
(grease, water, dust, etc.) using a clean cloth.
z Apply a continuous coat of liquid gasket to the inner edge of
the flange and the center of the bolt hole, as well as to the
outer edge of the flange and the area as close as possible
to the bolt holes. The gasket bead width must be 3 mm
(0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
z Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
z Install parts within 2 - 20 minutes of gasket application.
Leave parts unattended for approximately 2 hours, allowing
the gasket to completely harden.

POWER SHIFT ASSEMBLY

Key point of reassembly
46 Type I, 42 Type II piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.

TM-4-27
 REASSEMBLY MTS60

36 Type I, 33 Type II housing setscrew

Install the housing setscrew and clinch in two locations.

35 Type I, 32 Type II 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.

23, 27 Type I, 19, 23 Type II 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.

16 Type I, 12 Type II tube ring

1. Using the insert tool (910-26500 JKC No.) install the tube
ring.

TM-4-28
 REASSEMBLY MTS60

2. 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 Cylinder boots
Install the boot.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.

z Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve's sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift 59 N {6 kgf, 13 lbf}, max.
directions

TRANSMISSION CONTROL COVER ASSEMBLY

Key point of reassembly
<Type I>
2 Lock plate
Bend the lock plate to lock the plug.

TM-4-29
 REASSEMBLY MTS60

<Type II>
3 Power shift assembly
Install the power shift assembly.
NOTE
z Coat the external surface of the striker and connecting
portion to the shift lever with bearing grease.

TRANSMISSION COVER ASSEMBLY

Key point of reassembly
2, 4, 8, 15, 16, 21, 22, 27, 28 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.

13, 14, 19, 20, 25, 26, 31, 32, 35, 36 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.

6 Welch plug
Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.

COUNTERSHAFT ASSEMBLY
Key point of reassembly
7 3rd gear
1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.

TM-4-30
 REASSEMBLY MTS60

2. Press-fit the gear so that the side with protruding boss faces
the counter drive gear.

5 4th gear and 4 6th gear

1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.

2. Press-fit the gear so that the side with protruding boss faces
the counter drive gear.

3 Counter drive gear

1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.

2. Press-fit the gear so that the side with protruding boss faces
the counter drive gear.

TM-4-31
 REASSEMBLY MTS60

MAIN SHAFT ASSEMBLY

Key point of reassembly
37 Thrust washer
Install the thrust washer.
NOTE
z Face the large chamfered side of the thrust washer
toward the gear.

36 2nd gear inner race

Using the inner race replacer (99827 Z0073), press-fit the 2nd gear
inner race.

30 1st gear inner race

Using the inner race replacer (99827 Z0071), press-fit the 1st gear
inner race.

TM-4-32
 REASSEMBLY MTS60

27 Thrust washer
Install the thrust washer.
NOTE
z Face the large chamfered side of the thrust washer
toward the bearing.

21 3rd & 4th synchronizer assembly

Install the 3rd & 4th synchronizer assembly.
NOTE
z Align the alignment mark scribed during disassembly
when installing.
z When new parts are used, they can be installed in either
direction.

18 4th gear inner race

Using the inner race replacer (99827 Z0075), press-fit the 4th gear
inner race.

16 Thrust washer
Install the 5th or 6th washer.
NOTE
z Align the cutout portion of the 4th inner race with the 5th
or 6th washer pin.

TM-4-33
 REASSEMBLY MTS60

13 6th gear inner race

Using the inner race replacer (99801 Z0004), press-fit the 6th gear
inner race.
NOTE
z Insert the replacer 2. (99827 Z0077) into the tip of the
main shaft to use as a guide for the replacer 1. (99827
Z0076).

4 Lock washer and 3 Lock nut

Install the lock nut with the lock washer in place and tighten it with
the socket wrench (99535 Z0075).
: 324 - 363 N·m {33 - 37 kgf·m, 239 - 268 ft·lbf}
NOTE
z Bend the lock washer after installation.

2 Pilot bearing
Using the pilot bearing replacer (99827 Z0070), press-fit the main
shaft pilot bearing.

TM-4-34
 REASSEMBLY MTS60

z Measure the end play of each main shaft gear.

NOTE
z Be sure to measure the 1st gear end play after position-
ing the main shaft in the transmission case.

Unit: mm (in)
Item Maintenance standard Service limit
End play 0.3 - 0.5 (0.012 - 0.020) 0.7 (0.028)

TRANSMISSION ASSEMBLY
Key point of reassembly
28 Spacer
Select a 3.0 mm (0.118 in), 3.1 mm (0.122 in), 3.2 mm (0.126 in) or
3.3 mm (0.130 in) thickness spacer so that there is no clearance in
the countershaft groove and install it.

26 Reverse idler gear

Measure the end play of the reverse idler gear to ensure that it is
within maintenance standards.
Unit: mm (in)
Item Maintenance standard Service limit
End play 0.30 - 0.80 (0.0118 - 0.0315) 1.0 (0.039)
Backlash 0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)

17 Bearing cap
Align the oil groove in the bearing cap with the oil return hole in the
transmission case when installing.

6 Lock nut
1. Secure the transmission case to prevent it from turning
when tightening the lock nut and using a socket wrench
(99535 Z0074).
2. Lock the lock nut so that two clinched points contact each
other.

TM-4-35
 REASSEMBLY MTS60

5 Transmission cover assembly

1. Apply liquid gasket to the mating surface of the transmis-
sion cover.

2. With gears set in neutral, install the transmission cover

assembly.

: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle. Be sure to align the main drive shaft with the
clutch disc at their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-4-36
 CONSTRUCTION MTS70

= UNIT NAME MTS70 =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-5-1
 CONSTRUCTION MTS70

MAIN SHAFT ASSEMBLY

TM-5-2
 CONSTRUCTION MTS70

COUNTERSHAFT ASSEMBLY

TM-5-3
 CONSTRUCTION MTS70

POWER SHIFT ASSEMBLY

TM-5-4
 DISASSEMBLY MTS70

DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-5-5
 DISASSEMBLY MTS70

DISASSEMBLY
TRANSMISSION ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly 20. Lock washer 39. Roller bearing
2. Oil filter assembly 21. Roller bearing 40. Main shaft assembly
, 3. Transmission cover assembly 22. Washer 41. Set bolt
4. Overrun sensor 23. Counter 7th gear ,+ 42. Reverse idler gear shaft
,+ 5. Lock nut 24. Needle bearing 43. Reverse idler gear
6. Washer 25. Inner race 44. Inner race
7. O-ring 26. Drive gear 45. Roller bearing
8. Companion flange 27. Main 6th gear 46. Countershaft assembly
9. Side cover (PTO gear box: If so equipped) 28. 6th - 7th synchronizer assembly + 47. Roller bearing
10. Gasket 29. Counter 6th gear 48. Spacer
11. Rear case 30. Needle bearing 49. O-ring
12. Gasket 31. Gear cover (6th) 50. O-ring
13. Speedometer drive gear assembly 32. Bearing retainer 51. Gear cover
14. Roller bearing , 33. Main bearing cap 52. Transmission case
+ 15. Oil seal 34. Gasket
16. Gear cover (7th) 35. Packing
17. Inner case 36. Oil seal
18. Main 7th gear 37. Packing
19. Lock nut 38. Main drive gear assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-6
 DISASSEMBLY MTS70

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Synchronizer cone + 13. 4th-5th hub 25. Needle bearing
2. Synchronizer ring 14. 4th gear 26. Inner race
3. Clip 15. Needle bearing , 27. Thrust washer
+ 4. Pilot bearing 16. Inner race 28. Reverse gear
, 5. Lock nut , 17. Thrust washer 29. Needle bearing
, 6. Lock washer 18. Pin 30. 1st-reverse sleeve
+ 7. Synchronizer ring 19. 3rd gear , 31. Thrust washer
+ 8. 4th-5th sleeve 20. Needle bearing 32. 1st gear
+ 9. Detent 21. Inner race 33. Needle bearing
+ 10. Plunger +, 22. 2nd-3rd gear synchronizer assembly 34. Main shaft
+ 11. Spring (outer) 23. 2nd-3rd hub
+ 12. Spring (inner) 24. 2nd gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-7
 DISASSEMBLY MTS70

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Roller bearing inner race , 4. 4th gear 6. Key
2. Clip , 5. 3rd gear 7. Countershaft
, 3. Counter drive gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-8
 DISASSEMBLY MTS70

TRANSMISSION COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Gasket , 18. Shifter , 34. Shift folk
2. Neutral switch 19. Steel ball 35. Plug
3. Gasket 20. Lock pin 36. Plain washer
4. Steel ball , 21. Shift folk (2nd - 3rd) 37. Spring
5. Reverse switch 22. Setscrew 38. Steel ball
6. Gasket 23. Shift shaft 39. Self-locking nut
7. Steel ball , 24. Shift folk (4th - 5th) 40. Plain washer
8. Lock spring 25. Setscrew 41. Locking lever
9. Steel ball , 26. Shift shaft 42. Locking lever shaft
10. Setscrew , 27. Shifter 43. Setscrew
, 11. Welch plug , 28. Lever (6th - 7th) 44. Shift shaft
12. Shift shaft 29. Locking lever shaft , 45. Shifter
, 13. Shifter 30. Locking lever 46. Setscrew
14. Lock pin 31. Setscrew 47. Shift shaft
, 15. Lever shifter , 32. Welch plug , 48. Shift folk (6th - 7th)
16. Setscrew 33. Shift shaft 49. Transmission cover
17. Shift shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-9
 DISASSEMBLY MTS70

TRANSMISSION CONTROL COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Control cover 11. Plug 21. Plate
2. Gasket 12. Check spring 22. Gasket
, 3. Power shift assembly 13. Steel ball 23. Plain washer
4. Gasket 14. Steel ball 24. Return spring
5. Guide plate 15. Plug 25. Shift lever
6. Retaining ring 16. Check spring 26. Return spring
7. Thrust washer 17. Plunger 27. Breather
8. Select lever 18. Spring pin 28. Plug
9. O-ring 19. Shift lever
10. Spring pin 20. Collar
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-10
 DISASSEMBLY MTS70

POWER SHIFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Cylinder boots 21. Ring 41. Striker
2. Nut 22. Seat 42. Straight pin
3. Connector ,+ 23. Seat seal assembly 43. Ring
4. Cover 24. O-ring 44. Ring
5. Nut 25. Spring 45. O-ring
6. Ring 26. O-ring , 46. Piston packing
7. Plate ,+ 27. Seat seal assembly 47. Piston
8. Spring 28. Seat 48. Ring
9. Plug 29. Ring 49. Rod
10. Steel ball 30. Spring 50. O-ring
11. Bolt 31. Lifter 51. Boot
12. Filter 32. O-ring 52. Retainer
13. Tube 33. Pipe + 53. Cylinder packing
14. Ring 34. Filter 54. Bush
15. O-ring , 35. Rod cap assembly + 55. Cylinder packing
, 16. Tube ring , 36. Housing setscrew 56. Housing
17. Plate 37. Cylinder
18. Lifter 38. O-ring
19. O-ring 39. Oil seal
20. Spring 40. Ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-5-11
 DISASSEMBLY MTS70

OIL PUMP AND OIL FILTER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly 10. Spring 18. Cartridge assembly
2. Gasket 11. Steel ball 19. Cover assembly
3. Oil filter assembly 12. Case 20. Plug
4. Gasket 13. Gasket 21. Gasket
5. Connector assembly 14. Dowel 22. Spring
6. Gasket 15. Drive gear 23. Steel ball
7. Straight pin 16. Driven gear 24. Connector
8. Plug 17. Housing 25. Gasket
9. Packing

TM-5-12
 DISASSEMBLY MTS70

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

5 Lock nut
Unlock the lock nut, and remove the lock nut using socket wrench
(99535 Z0074).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

NOTE
z Do not re-use the pinion nut after removal.

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 the backlash at least three equally spaced
points for each gear.

z Measure and record the end play of each gear.

Main shaft
z Clearance between 1st gear and thrust washer
z Clearance between reverse gear and 1st & reverse hub
z Clearance between 2nd gear and 2nd & 3rd hub
z Clearance between 3rd gear and thrust washer
z Clearance between 4th gear and thrust washer
Countershaft
z Clearance between 6th gear and 6th & 7th hub
z Clearance between 7th gear and thrust washer
15 Oil seal
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.

TM-5-13
 DISASSEMBLY MTS70

42 Reverse idler gear shaft

To remove the reverse idler gear shaft, remove the setscrew and
then use the sliding hammer (99547 Z0000).

47 Roller bearing
Drive the roller bearing out of the front of the countershaft using
countershaft bearing puller (99802 Z0000).
NOTE
z Do not remove the counter plug unless necessary. If the
countershaft bearing puller is not available, remove the
plug first.
Do not re-use the plug after removal.

MAIN SHAFT ASSEMBLY

Key point of disassembly
4 Pilot bearing
1. Place the main shaft on the work bench with the front facing
upward. Using the lock nut wrench (99809 Z0006), 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-5-14
 DISASSEMBLY MTS70

7, 8, 9, 10, 11, 12, 13: 4th-5th gear synchronizer assembly

Be careful not to lose parts placed between the hub and synchro-
nizer when disassembly the sleeve.
1. 4th-5th sleeve 4. Detent
2. 4th-5th hub 5. Lock plunger
3. Spring 6. Synchronizer ring

22 2nd-3rd gear synchronizer assembly

Make an alignment mark on the side of the 2nd & 3rd synchronizer
assembly.

POWER SHIFT ASSEMBLY T

Key point of disassembly
23, 27 Seat seal assembly
Remove the valve assembly.
NOTE
z Be careful not to damage spring seat and lifter ring dur-
ing removal.

53, 55 Cylinder packing

Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.

TM-5-15
 INSPECTION MTS70

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Radial play between inner shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Clearance between shift lever and shifters

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Clearance between transmission cover and shift folk

shaft
Unit: mm (in)
Maintenance standard Service limit
0.13 - 0.18 (0.0051 - 0.0071) 0.3 (0.012)

TM-5-16
 INSPECTION MTS70

Clearance between locking lever and lever shaft

Unit: mm (in)
Maintenance standard Service limit Remarks
0.04 - 0.08 Except for those indi-
(0.0016 - 0.0039) 0.2 cated below
0.02 - 0.06 (0.008)
At 4th & 5th shift fork
(0.0008 - 0.0024)

Clearance between locking lever and lever shifter

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Clearance between locking lever and shift shaft

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

NOTE
z Measure the clearance at the sleeve groove in at least
three points.

Shift fork shaft locking spring

Unit: mm (in)
Item Maintenance standard Service limit Remarks
42.5
Free length —
(1.673)
When compressed
Tension 127 - 157 127
to 27 mm
N {kgf, lbf} {13 - 16, 29 - 35} {13, 29}
(1.06 in)

Clearance between shift fork and sleeve groove

Unit: mm (in)
Maintenance standard Service limit Remarks
Except for those indi-
0.10 - 0.24 (0.0039 - 0.0094)
cated below
1.0 (0.039)
At 4th & 5th and 6th &
0.10 - 0.29 (0.0039 - 0.0114)
7th gears

TM-5-17
 INSPECTION MTS70

NOTE
z Measure the clearance at the sleeve groove in at least
three points.

TRANSMISSION PROPER
Each main gears and counter gear backlashes
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit Remarks
0.20 - 0.40
(0.0079 - 0.0157)
0.7 (0.028)
0.35 - 0.55
Reverse gear
(0.0138 - 0.0217)

End play of rear counter shaft gears

Unit: mm (in)
Item Maintenance standard Service limit
6th gear 0.30 - 0.50
0.7 (0.028)
7th gear (0.0118 - 0.0194)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.70 (0.0039 - 0.0276) 1.0 (0.039)

Radial play of mainshaft and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

TM-5-18
 INSPECTION MTS70

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50
1st & reverse
(0.0157 - 0.0197) 1.0
0.20 - 0.30 (0.039)
Except for 1st & reverse
(0.0079 - 0.0118)

Ball bearing axial direction play

Unit: mm (in)
Maintenance standard Service limit
— 0.5 (0.020)

SYNCHRONIZER SYSTEM
<Pin type>
Alignment of synchronizer rings with their discs
Unit: mm (in)
Maintenance standard Service limit Remarks
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc

NOTE
z Measure the value on the opposite side (180º apart) and
determine the mean value.

<Lock plunger type>

Clearance between synchronizer ring and their cone
Unit: mm (in)
Maintenance standard Service limit
1.4 - 2.6 (0.055 - 0.102) —

TM-5-19
 INSPECTION MTS70

Tangential clearance between synchronizer ring and

synchronizer hub
Unit: mm (in)
Maintenance standard Service limit
4.7 - 5.0 (0.185 - 0.197) —

Radial clearance between synchronizer hub and syn-

chronizer detent
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.3 (0.004 - 0.012) —

Detent spring
Unit: mm (in)
Item Maintenance standard Service limit Remarks
15
Free length —
(0.59)
When com-
Tension 21.6 - 35.3
— pressed to 12 mm
N {kgf, lbf} {2.2 - 3.6, 4.9 - 7.9}
(0.472 in.)

OIL PUMP
Clearance between drive shaft and case
Unit: mm (in)
Maintenance standard Service limit
0.06 - 0.09 (0.0024 - 0.0035) 0.2 (0.0079)

Clearance between driven shaft and case

Unit: mm (in)
Maintenance standard Service limit
0.06 - 0.09 (0.0024 - 0.0035) 0.2 (0.0079)

Drive and driven gear end play

Unit: mm (in)
Maintenance standard Service limit Remarks
0.7 After tightening bolts to
0.03 (0.012), min.
(0.028) 20 N·m {2 kgf·m, 14 lbf·ft}

TM-5-20
 INSPECTION MTS70

Fit of drive shaft and front of countershaft at notch location

Unit: mm (in)
Maintenance standard Service limit
0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Item No. 25.5
—
20 (1.004)
Free Item No. 23.6
—
length 30 (0.9291)
Item No. 21.0
—
25 (0.827)
When com-
Item No. 46.58 38.2
pressed to 15.05
20 {4.75, 10.47} {3.9, 8.6}
mm (0.5925 in)
When com-
Tension Item No. 13.82 11.8
pressed to 15.05
N {kgf, lbf} 30 {1.41, 3.11} {1.2, 2.6}
mm (0.5925 in)
When com-
Item No. 9.02 6.9
pressed to 13.0
25 {0.92, 2.03} {0.7, 1.5}
mm (0.512 in)

NOTE
z Item Nos. indicate the disassembly sequence.

Valve seal dent depth

Unit: mm (in)
Maintenance standard Service limit
0.15 (0.0059), max. —

Distance between pipe retaining ring groove and cap end

face
Unit: mm (in)
Maintenance standard Service limit
80.5 - 81.1 (3.169 - 3.193) —

TM-5-21
 REASSEMBLY MTS70

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. 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.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during installa-
tion. Observe the following precautions during gasket application.

<Precautions during RTV liquid gasket application>

z Remove all traces of liquid gasket from the flanged surface
of parts using a scraper. Be careful not to scratch the
flanged surface and completely wipe away foreign particles
(grease, water, dust, etc.) using a clean cloth.
z Apply a continuous coat of liquid gasket to the inner edge of
the flange and the center of the bolt hole, as well as to the
outer edge of the flange and the area as close as possible
to the bolt holes. The gasket bead width must be 3 mm
(0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
z Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
z Install parts within 2 - 20 minutes of gasket application.
Leave parts unattended for approximately 2 hours, allowing
the gasket to completely harden.

POWER SHIFT ASSEMBLY

Key point of reassembly
46 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.

TM-5-22
 REASSEMBLY MTS70

36 Housing setscrew
Install the housing setscrew and clinch in two locations.

35 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.

23, 27 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 8.

NOTE
z Be sure to install the springs in the correct sequence.

16 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube
ring.

TM-5-23
 REASSEMBLY MTS70

2. 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. Cylinder boots
Install the boot.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.

z Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve's sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift 59 N {6 kgf, 13 lbf}, max.
directions

TRANSMISSION CONTROL COVER ASSEMBLY

Key point of reassembly
3 Power shift assembly
Install the power shift assembly.
NOTE
z Coat the external surface of the striker and connecting
portion to the shift lever with bearing grease.

TM-5-24
 REASSEMBLY MTS70

TRANSMISSION COVER ASSEMBLY

Key point of reassembly
26 Shift shaft
1. Do not rotate the shaft which has the interlock pin built into
it.

2. Insert each shift fork shaft into place with the shift lever
placed in Neutral.

13, 15, 18, 21, 24, 27, 28, 34, 45, 48 shift folk & shifter
Install and tighten the setscrew on each shift folk 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.

11, 32 Welch plug

Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.

COUNTERSHAFT ASSEMBLY
Key point of reassembly
4, 5 3rd, 4th gear
1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.

TM-5-25
 REASSEMBLY MTS70

2. Press-fit the 3rd, 4th gear so that the side with protruding
boss faces the counter drive gear.

3 Counter drive gear

1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.
2. Press-fit the counter drive gear so that the side with protrud-
ing boss faces 4th gear.

MAIN SHAFT ASSEMBLY

Key point of reassembly
31 Thrust washer
Install with the large chamfered side (outside dia.) facing the bear-
ing.

27 Thrust washer
Install with the large chamfered side (inside dia.) facing the reverse
gear.

22 2nd-3rd gear synchronizer assembly

1. Align the alignment mark scribed during disassembly before
reassembling.
2. The installation direction is not specified when installing
new parts.

TM-5-26
 REASSEMBLY MTS70

17 Thrust washer
Install with the large chamfered side (inside dia.) facing the reverse
gear.

5 Lock nut, 6 Lock washer

Install the lock nut with the lock washer in place and tighten it with
the socket wrench (99535 Z0075).
: 324 - 363 N·m {33 - 37 kgf·m, 239 - 268 ft·lbf}
NOTE
z Bend the lock washer after installation.

z Measure the end play of each main shaft gear.

NOTE
z Be sure to measure the 1st gear end play after position-
ing the main shaft in the transmission case.

Unit: mm (in)
Item Maintenance standard Service limit
End play 0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

TRANSMISSION ASSEMBLY
Key point of reassembly
42 Reverse idler gear shaft
Align the set bolt with the groove hole in the shaft when installing
the reverse idler gear shaft.
NOTE
z Make sure that the thread portion faces the lateral direc-
tion after installation.

33 Main bearing cap

Align the oil groove in the bearing cap with the oil return hole in the
transmission case when installing.

TM-5-27
 REASSEMBLY MTS70

5 Lock nut
1. Secure the transmission case to prevent it from turning
when tightening the lock nut and using a socket wrench
(99535 Z0075).
2. Lock the lock nut so that two clinched points contact each
other.

3 Transmission cover assembly

1. Apply liquid gasket to the mating surface of the transmis-
sion cover.

2. With gears set in neutral, install the transmission cover

assembly.

: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle. Be sure to align the main drive shaft with the
clutch disc at their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-5-28
 CONSTRUCTION MTP00

= UNIT NAME MTP00 =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-6-1
 CONSTRUCTION MTP00

MAIN SHAFT ASSEMBLY

TM-6-2
 CONSTRUCTION MTP00

COUNTERSHAFT ASSEMBLY

TM-6-3
 CONSTRUCTION MTP00

TRANSMISSION SUB COVER ASSEMBLY

TM-6-4
 CONSTRUCTION MTP00

POWER SHIFT ASSEMBLY

TM-6-5
 DISASSEMBLY MTP00

DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-6-6
 DISASSEMBLY MTP00

DISASSEMBLY
TRANSMISSION ASSEMBLY

TM-6-7
 DISASSEMBLY MTP00

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly 20. Ball bearing 39. Oil seal
2. Oil filter assembly 21. Roller bearing 40. Packing
, 3. Transmission cover assembly + 22. Counter gear (Low) ,+ 41. Main drive gear assembly
4. Transmission sub cover assembly 23. Sub main shaft assembly 42. Main shaft assembly
,+ 5. Lock nut 24. Lock washer ,+ 43. Reverse idler gear shaft
6. Washer 25. Washer 44. Reverse idler gear
7. O-ring 26. Shim 45. Clip
8. Companion flange 27. High gear 46. Spacer
9. Side cover (PTO gear box: If so equipped) 28. Oil connector 47. Roller bearing
10. Gasket 29. Sub counter shaft 48. Countershaft assembly
11. Bearing retainer 30. Strainer + 49. Roller bearing
12. Gasket 31. Bearing retainer 50. Spacer
13. Speedometer drive gear assembly 32. Ball bearing 51. O-ring
+ 14. Oil seal 33. Shim 52. O-ring
15. Drive gear 34. Counter rear cover 53. Gear cover assembly
16. Clip 35. Roller bearing 54. Straight pin
17. Spacer , 36. Main bearing cap 55. Screw plug
18. Transmission sub case 37. Gasket 56. Cup plug
19. Gasket 38. Packing 57. Transmission case
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-8
 DISASSEMBLY MTP00

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Synchronizer ring + 12. 4th-5th hub 23. Inner race
2. Spacer 13. Synchronizer ring ,+ 24. 2nd-3rd gear synchronizer assembly
3. 1st gear + 14. Spring 25. 2nd-3rd hub
4. Needle bearing + 15. Spring 26. 2nd gear
5. 1st-reverse sleeve 16. 5th gear 27. Needle bearing
6. Retaining ring 17. Needle bearing 28. Inner race
+ 7. Pilot bearing 18. Inner race , 29. Thrust washer
, 8. Lock nut , 19. Thrust washer 30. Reverse gear
, 9. Lock washer 20. Pin 31. Needle bearing
+ 10. 4th-5th sleeve 21. 3rd gear 32. Main shaft
+ 11. Key 22. Needle bearing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-9
 DISASSEMBLY MTP00

SUB MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Washer 4. Retaining ring ,+ 6. High - low synchronizer assembly
2. Low gear 5. Pilot bearing 7. Sub main shaft
3. Needle bearing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-10
 DISASSEMBLY MTP00

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Roller bearing inner race ,+ 4. 5th gear 6. Key
2. Retaining ring ,+ 5. 3rd gear 7. Countershaft
,+ 3. counter drive gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-11
 DISASSEMBLY MTP00

TRANSMISSION COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. 1st switch assembly 17. Steel ball , 32. Shift shaft
2. Gasket 18. Self-locking nut , 33. Lock pin
, 3. Steel ball 19. Locking lever shaft , 34. Steel ball
4. Reverse switch assembly 20. Locking lever 35. Self-locking nut
5. Gasket , 21. Spring pin 36. Locking lever shaft
, 6. Steel ball 22. Shifter 37. Locking lever
7. Neutral switch assembly , 23. Spring pin 38. Support
8. Gasket 24. Lever shifter 39. Set screw
, 9. Steel ball , 25. Shift shaft 40. 4th-5th shift fork
10. Guide bolt , 26. Lock pin , 41. Shift shaft
, 11. Welch plug , 27. Lock pin , 42. Spring pin
, 12. Welch plug , 28. Spring pin 43. 1st-reverse shift fork
, 13. Welch plug 29. Shifter , 44. Shift shaft
, 14. Welch plug , 30. Spring pin 45. Gasket
, 15. Welch plug 31. 2nd-3rd shift fork 46. Transmission cover
16. Lock spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-12
 DISASSEMBLY MTP00

TRANSMISSION SUB COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. High switch assembly 11. Cylinder cap 21. Gasket
2. Gasket 12. O-ring 22. Ring
3. Steel ball 13. Split pin 23. Pin
4. Low switch assembly 14. Slotted nut 24. Shift shaft
5. Gasket 15. Plain washer 25. High-low shift fork
6. Steel ball 16. O-ring 26. Air seal
7. Plug 17. Piston 27. Air orifice
8. Gasket 18. X-ring 28. Cap
9. Spring 19. Air orifice 29. Gasket
10. Steel ball 20. Plug 30. Sub cover

TM-6-13
 DISASSEMBLY MTP00

TRANSMISSION CONTROL COVER ASSEMBLY

Type I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Breather 8. Spring 15. Bushing
2. Guide plate 9. Plunger 16. Gasket
3. Retaining ring 10. Welch plug , 17. Return spring
4. Thrust washer 11. Straight pin 18. Shift lever
5. Select lever 12. Inner shaft , 19. Return spring
6. O-ring 13. Plate 20. Control cover
7. Plug 14. Oil seal
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-14
 DISASSEMBLY MTP00

Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Control cover 11. Plug 21. Plate
2. Gasket 12. Check spring 22. Gasket
, 3. Power shift assembly 13. Steel ball 23. Plain washer
4. Gasket 14. Steel ball 24. Return spring
5. Guide plate 15. Plug 25. Shift lever
6. Retaining ring 16. Check spring 26. Return spring
7. Thrust washer 17. Plunger 27. Breather
8. Select lever 18. Spring pin 28. Plug
9. O-ring 19. Shift lever
10. Spring pin 20. Collar
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-15
 DISASSEMBLY MTP00

POWER SHIFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Cylinder boots 21. Ring 41. Striker
2. Nut 22. Seat 42. Straight pin
3. Connector ,+ 23. Seat seal assembly 43. Ring
4. Cover 24. O-ring 44. Ring
5. Nut 25. Spring 45. O-ring
6. Ring 26. O-ring , 46. Piston packing
7. Plate ,+ 27. Seat seal assembly 47. Piston
8. Spring 28. Seat 48. Ring
9. Plug 29. Ring 49. Rod
10. Steel ball 30. Spring 50. O-ring
11. Bolt 31. Lifter 51. Boot
12. Filter 32. O-ring 52. Retainer
13. Tube 33. Pipe + 53. Cylinder packing
14. Ring 34. Filter 54. Bush
15. O-ring , 35. Rod cap assembly + 55. Cylinder packing
, 16. Tube ring , 36. Housing setscrew 56. Housing
17. Plate 37. Cylinder
18. Lifter 38. O-ring
19. O-ring 39. Oil seal
20. Spring 40. Ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-6-16
 DISASSEMBLY MTP00

OIL PUMP AND OIL FILTER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Oil pump assembly 10. Spring 18. Cartridge assembly
2. Gasket 11. Steel ball 19. Cover assembly
3. Oil filter assembly 12. Case 20. Plug
4. Gasket 13. Gasket 21. Gasket
5. Connector assembly 14. Dowel 22. Spring
6. Gasket 15. Drive gear 23. Steel ball
7. Straight pin 16. Driven gear 24. Connector
8. Plug 17. Housing 25. Gasket
9. Packing

TM-6-17
 DISASSEMBLY MTP00

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

5 Lock nut
Unlock the lock nut, and remove the lock nut using socket wrench
(99535 Z0075).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

NOTE
z Do not re-use the pinion nut after removal.

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 the backlash at least three equally spaced
points for each gear.

z Measure and record the end play of each gear.

Main shaft
z Clearance between 1st gear and thrust washer
z Clearance between reverse gear and 1st & reverse hub
z Clearance between 2nd gear and 2nd & 3rd hub
z Clearance between 3rd gear and thrust washer
z Clearance between 5th gear and thrust washer
Countershaft
z Clearance between high gear and high & low hub
z Clearance between low gear and thrust washer

14 Oil seal
Remove the oil seal only when leakage is noticed. Do not re-use it
after removal.

TM-6-18
 DISASSEMBLY MTP00

22 Counter gear (Low)

Remove the counter gear (low) while raising the sub main shaft.
NOTE
z While doing this, press the sub main shaft toward the
case occasionally to prevent the shaft or other parts from
falling down.

41 Main drive gear assembly

Remove the retaining ring and roller bearing.
NOTE
z Do this only when it is necessary.

43 Reverse idler shaft

To remove the reverse idler gear shaft, remove the setscrew and
then use the sliding hammer (99547 Z0000).

49 Roller bearing
Drive the roller bearing out of the front of the countershaft using
countershaft bearing puller (99802 Z0000).
NOTE
z Do not remove the counter plug unless necessary. If the
countershaft bearing puller is not available, remove the
plug first.
Do not re-use the plug after removal.

TM-6-19
 DISASSEMBLY MTP00

MAIN SHAFT ASSEMBLY

Key point of disassembly
7 Pilot bearing
1. Place the main shaft on the work bench with the front facing
upward. Using the lock nut wrench (99809 Z0006), 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.

10, 11, 12, 14, 15 Synchronizer assembly

Be careful not to lose parts located between the hub and sleeve
during disassembly.
1. 4th-5th sleeve 4. Spring
2. Key 5. Spring
3. 4th-5th hub 6.

24 2nd-3rd gear synchronizer assembly

Make an alignment mark on the side of the 2nd & 3rd synchronizer
assembly.

SUB MAIN SHAFT ASSEMBLY

Key point of disassembly
6 High-low synchronizer assembly
Make an alignment mark on the side of high-low synchronizer
assembly.

COUNTERSHAFT ASSEMBLY
Key point of disassembly
z The countershaft assembly need not be disassembled
unless gears are replaced due to wear or damage to gear
teeth, etc.

TM-6-20
 DISASSEMBLY MTP00

3, 4, 5 Counter gear
Using a hydraulic press, drive the counter gears out.
NOTE
z Be extremely careful not to drop the countershaft on the
floor.

TRANSMISSION COVER ASSEMBLY

Key point of disassembly
z Remove the control cover assembly.
NOTE
z Be careful not to lose the locking spring and steel ball.

POWER SHIFT ASSEMBLY T

Key point of disassembly
23, 27 Seat seal assembly
Remove the valve assembly.
NOTE
z Be careful not to damage spring seat and lifter ring dur-
ing removal.

53, 55 Cylinder packing

Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.

TM-6-21
 INSPECTION MTP00

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Item Maintenance standard Service limit
Shift lever
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)
Select lever

Radial play between inner shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.11 (0.0020 - 0.0043) 0.5 (0.020)

Clearance between shift lever and shifters

Unit: mm (in)
Item Maintenance standard Service limit
Shift lever
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
Select lever

Clearance between transmission cover and shift folk

shaft
Unit: mm (in)
Maintenance standard Service limit
0.13 - 0.18 (0.0051 - 0.0071) 0.3 (0.012)

TM-6-22
 INSPECTION MTP00

Clearance between transmission sub cover and shift

fork shaft
Unit: mm (in)
Maintenance standard Service limit
0.03 - 0.08 (0.0012 - 0.0031) 0.2 (0.008)

Clearance between transmission sub cover and high-

low cylinder piston
Unit: mm (in)
Maintenance standard Service limit
0.07 - 0.16 (0.0028 - 0.0063) 0.2 (0.008)

Clearance between locking lever and lever shaft

Unit: mm (in)
Maintenance standard Service limit Remarks
0.04 - 0.08 Except for those indi-
(0.0016 - 0.0039) 0.2 cated below
0.02 - 0.06 (0.008)
At 4th & 5th shift fork
(0.0008 - 0.0024)

Clearance between locking lever and lever shifter

Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)

Shift fork shaft locking spring

Unit: mm (in)
Item Maintenance standard Service limit Remarks
42.5
Free length —
(1.673)
127 - 157 When compressed
Tension 127
{13 - 16, to 27 mm
N {kgf, lbf} {13, 29}
29 - 35} (1.06 in)

TM-6-23
 INSPECTION MTP00

Clearance between shift fork and sleeve groove

Unit: mm (in)
Maintenance standard Service limit Remarks
Except for those indi-
0.10 - 0.24 (0.0039 - 0.0094)
1.0 (0.039) cated below
0.10 - 0.29 (0.0039 - 0.0114) At 4th & 5th gear

NOTE
z Measure the clearance at the sleeve groove in at least
three points.

TRANSMISSION PROPER
Each main gears and counter gear backlashes
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit Remarks
0.20 - 0.40
Except those indicated below
(0.0079 - 0.0157)
0.7 (0.028)
0.35 - 0.55
5th
(0.0138 - 0.0217)

Sub counter shaft low gear end play

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.70 (0.0039 - 0.0276) 1.0 (0.039)

Radial play of main shaft and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

TM-6-24
 INSPECTION MTP00

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50
1st & reverse
(0.0157 - 0.0197) 1.0
0.20 - 0.30 (0.039)
Except for 1st & reverse
(0.0079 - 0.0118)

Ball bearing axial direction play

Unit: mm (in)
Maintenance standard Service limit
— 0.5 (0.020)

SYNCHRONIZER SYSTEM
<Pin type>
Alignment of synchronizer rings with their discs
Unit: mm (in)
Maintenance standard Service limit Remarks
-0.2 to 0.4 Minus (-) symbol:
—
(-0.008 to 0.016) Protrusion from the disc

NOTE
z Measure the value on the opposite side (180º apart) and
determine the mean value.

<Key type>
Clearance between synchronizer ring and cone
(Dimension B)
Unit: mm (in)
Maintenance standard Service limit
1.0 - 3.0 (0.039 - 0.118) 0

TM-6-25
 INSPECTION MTP00

Radial play between key and synchronizer ring

(Dimension C)
Unit: mm (in)
Maintenance standard Service limit
4.9 - 5.4 (0.193 - 0.213) —

Radial play between key and synchronizer hub (Dimen-

sion D)
Unit: mm (in)
Maintenance standard Service limit
4.9 - 5.4 (0.193 - 0.213) —

OIL PUMP
Clearance between drive shaft and case
Unit: mm (in)
Maintenance standard Service limit
0.06 - 0.09 (0.0024 - 0.0035) 0.2 (0.0079)

Clearance between driven shaft and case

Unit: mm (in)
Maintenance standard Service limit
0.06 - 0.09 (0.0024 - 0.0035) 0.2 (0.0079)

Drive and driven gear end play

Unit: mm (in)
Maintenance standard Service limit Remarks
0.7 After tightening bolts to
0.03 (0.012), min.
(0.028) 20 N·m {2 kgf·m, 14 lbf·ft}

Fit of drive shaft and front of countershaft at notch location

Unit: mm (in)
Maintenance standard Service limit
0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

TM-6-26
 INSPECTION MTP00

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Item No. 25.5
—
16 (1.004)
Free Item No. 23.6
—
length 21 (0.9291)
Item No. 21.0
—
26 (0.827)
When com-
Item No. 46.58 38.2
pressed to 15.05
16 {4.75, 10.47} {3.9, 8.6}
mm (0.5925 in)
When com-
Tension Item No. 13.82 11.8
pressed to 15.05
N {kgf, lbf} 21 {1.41, 3.11} {1.2, 2.6}
mm (0.5925 in)
When com-
Item No. 9.02 6.9
pressed to 13.0
26 {0.92, 2.03} {0.7, 1.5}
mm (0.512 in)

NOTE
z Item Nos. indicate the disassembly sequence.

Valve seal dent depth

Unit: mm (in)
Maintenance standard Service limit
0.15 (0.0059), max. —

Distance between pipe retaining ring groove and cap end

face
Unit: mm (in)
Maintenance standard Service limit
80.5 - 81.1 (3.169 - 3.193) —

TM-6-27
 REASSEMBLY MTP00

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. 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.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during installa-
tion. Observe the following precautions during gasket application.

<Precautions during RTV liquid gasket application>

z Remove all traces of liquid gasket from the flanged surface
of parts using a scraper. Be careful not to scratch the
flanged surface and completely wipe away foreign particles
(grease, water, dust, etc.) using a clean cloth.
z Apply a continuous coat of liquid gasket to the inner edge of
the flange and the center of the bolt hole, as well as to the
outer edge of the flange and the area as close as possible
to the bolt holes. The gasket bead width must be 3 mm
(0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
z Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
z Install parts within 2 - 20 minutes of gasket application.
Leave parts unattended for approximately 2 hours, allowing
the gasket to completely harden.

POWER SHIFT ASSEMBLY

Key point of reassembly
46 Piston packing
Install the piston packing and piston O-ring on the piston, and the
piston assembly and retaining ring on the shifter rod.

TM-6-28
 REASSEMBLY MTP00

36 Housing setscrew
Install the housing setscrew and clinch in two locations.

35 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.

23, 27 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 8.

NOTE
z Be sure to install the springs in the correct sequence.

16 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube
ring.

TM-6-29
 REASSEMBLY MTP00

2. 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 Cylinder boots
Install the boot.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.

z Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve's sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift 59 N {6 kgf, 13 lbf}, max.
directions

TRANSMISSION CONTROL COVER ASSEMBLY

Key point of reassembly
<Type I>
17, 19 Return spring
Do not confuse the left and right return springs.
Paint color:
Red: Right spring
Blue: Left spring

TM-6-30
 REASSEMBLY MTP00

<Type II>
3 Power shift assembly
Install the power shift assembly.
NOTE
z Coat the external surface of the striker and connecting
portion to the shift lever with bearing grease.

TRANSMISSION COVER ASSEMBLY

Key point of reassembly
3, 6, 9, 25, 26, 27, 32, 33, 34, 41, 44 Steel ball & shift shaft
1. Do not rotate the shaft which has the interlock pin built into
it.

2. Insert each shift fork shaft into place with the shift lever
placed in Neutral.

21, 23, 28, 30, 42 Spring pin

Point the spring pin groove in the axial direction of the shaft when
driving the spring pin into the shift fork and shifter. The outer and
inner spring pin grooves should face in the opposite direction to
each other.

11, 12, 13, 14, 15 Welch plug

Drive the welch plugs into the cover.
NOTE
z Be careful not to burr the plug.

TM-6-31
 REASSEMBLY MTP00

COUNTERSHAFT ASSEMBLY
Key point of reassembly
4, 5 3rd, 5th gear
1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.

2. Press-fit the 3rd, 5th gear so that the side with protruding
boss faces the counter drive gear.

3. Counter drive gear

1. Install the key so that the side with the larger chamfer faces
the side on which the gear is installed.
2. Press-fit the counter drive gear so that the side with protrud-
ing boss faces 4th gear.

SUB MAIN SHAFT ASSEMBLY

Key point of reassembly
6 High-low synchronizer assembly
1. Align the alignment marks made during disassembly before
reassembly.
2. Installation direction is not specified when installing new
parts.

MAIN SHAFT ASSEMBLY

Key point of reassembly
29 Thrust washer
Install with the large chamfered side (outside dia.) facing the bear-
ing.

TM-6-32
 REASSEMBLY MTP00

24 2nd-3rd gear synchronizer assembly

1. Align the alignment mark marked during disassembly
before reassembling.
2. The installation direction is not specified when installing
new parts.

19 Thrust washer
Install with the large chamfered side (inside dia.) facing the reverse
gear.

8 Lock nut, 9 Lock washer

Install the lock nut with the lock washer in place and tighten it with
the socket wrench (99535 Z0075).
: 324 - 363 N·m {33 - 37 kgf·m, 239 - 268 ft·lbf}
NOTE
z Bend the lock washer after installation.

z Measure the end play of each main shaft gear.

NOTE
z Be sure to measure the 1st gear end play after position-
ing the main shaft in the transmission case.

Unit: mm (in)
Item Maintenance standard Service limit
End play 0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

TRANSMISSION ASSEMBLY
Key point of reassembly
43 Reverse idler gear shaft
Align the set bolt with the groove hole in the shaft when installing
the reverse idler gear shaft.
NOTE
z Make sure that the thread portion faces the lateral direc-
tion after installation.

TM-6-33
 REASSEMBLY MTP00

41 Main drive gear assembly

Remove the main drive gear assembly with the synchronizer cone
cutout set in the lower position.

36 Main bearing cap

Align the oil groove in the bearing cap with the oil return hole in the
transmission case when installing.

5 Lock nut
1. Secure the transmission case to prevent it from turning
when tightening the lock nut and using a socket wrench
(99535 Z0074).
2. Lock the lock nut so that two clinched points contact each
other.

3 Transmission cover assembly

1. Apply liquid gasket to the mating surface of the transmis-
sion cover.

2. With gears set in neutral, install the transmission cover

assembly.

: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}

TM-6-34
 REASSEMBLY MTP00

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle. Be sure to align the main drive shaft with the
clutch disc at their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-6-35
 CONSTRUCTION MRT20

= UNIT NAME MRT20 =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-7-1
 CONSTRUCTION MRT20

MAIN SHAFT ASSEMBLY

COUNTERSHAFT ASSEMBLY

TM-7-2
 CONSTRUCTION MRT20

POWER SHIFT ASSEMBLY

TM-7-3
 DISASSEMBLY MRT20

DISASSEMBLY
REMOVAL
KEY POINT OF REMOVAL
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-7-4
 DISASSEMBLY MRT20

DISASSEMBLY
MIDDLE CASE AND REAR CASE ASSEMBLY

TM-7-5
 DISASSEMBLY MRT20

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Rear bearing retainer ,+ 9. Rear case , 17. Reverse idler gear assembly
2. Gasket 10. Gear cover ,+ 18. Middle case
3. Oil seal ,+ 11. Bearing retainer 19. Gear cover
4. Speedometer driven gear assembly 12. Oil seal ring 20. Bearing cap
, 5. Speedometer drive gear + 13. Gear cover 21. Oil seal
6. Anti-overrun sensor 14. Anti-overrun sensor 22. O-ring
+ 7. Sub countershaft bearing retainer + 15. Neutral detection switch
8. Adjusting shim , 16. side cover
(PTO gear box: If equipped)
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-6
 DISASSEMBLY MRT20

FRONT CASE ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Top cover 9. Release sleeve 17. Needle bearing
2. Rubber seat 10. Release bearing 18. Oil seal
3. Air cleaner case (Upper) 11. Set bolt 19. Grease nipple
4. Air cleaner element 12. Release sleeve 20. Plug
5. Air cleaner case (lower) 13. Key 21. Taper plug
6. Grease nipple 14. Release sleeve 22. Under cover
7. Hose 15. Release sleeve 23. Rubber seat
8. Spring 16. Oil seal 24. Front case
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-7
 DISASSEMBLY MRT20

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Tapered bearing 17. Detent spring , 33. Detent spring
2. Reverse gear 18. 2nd double synchro assembly , 34. 3rd-4th synchro sleeve
3. Reverse sleeve 19. 2nd gear , 35. 3rd synchro ring
4. Needle bearing 20. Needle bearing 36. 3rd gear
5. Reverse gear bearing inner race ,+ 21. Lock nut (LH thread) 37. Needle bearing
6. Reverse hub 22. Tapered bearing 38. Main shaft
7. 1st gear 23. Thrust washer 39. Adjusting shim
8. Needle bearing 24. Tapered bearing 40. Detent
9. Spacer 25. Synchro ring 41. Detent spring
10. Needle bearing 26. Drive gear assembly + 42. Clip
11. 1st gear bearing inner race 27. Synchro ring + 43. Tapered bearing
12. 1st double synchro assembly , 28. Adjusting spacer 44. Splitter synchro ring
13. 1st-2nd synchro sleeve 29. Tapered bearing + 45. Splitter gear
14. 1st-2nd synchro hub , 30. 3rd-4th synchro hub + 46. Splitter synchro ring
15. Detent , 31. Detent + 47. Needle bearing
16. Synchro plunger , 32. Synchro plunger + 48. Input shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-8
 DISASSEMBLY MRT20

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Adjusting shim 4. Clip 7. Key
2. Tapered bearing* 5. Splitter counter gear 8. Countershaft
3. Tapered bearing* 6. Counter drive gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.
*: Do not reuse parts after removal

TM-7-9
 DISASSEMBLY MRT20

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Lock nut + 7. Range low gear + 12. Sub countershaft assembly
2. O-ring 8. Needle bearing + 13. Tapered bearing
3. Companion flange 9. Output shaft , 14. Lock washer
4. Dust shield 10. Spring pin ,+ 15. Range high gear lock nut
5. Ball bearing + 11. Range high-low synchro assembly 16. Range high gear
6. Thrust washer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-10
 DISASSEMBLY MRT20

SHIFT FORK ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cylinder cap 15. Setscrew 29. Setscrew
2. O-ring 16. Clip 30. 1st-2nd shifter
3. O-ring 17. Spacer 31. Setscrew
4. O-ring 18. Range shift fork 32. Reverse shift fork
5. Piston packing 19. Fork claw 33. Setscrew
6. Splitter piston 20. Range shift fork 34. Ring
7. O-ring 21. Setscrew 35. Reverse shifter
8. Piston packing 22. 3rd-4th shift fork 36. Reverse shift shaft
9. Range piston 23. Fork claw 37. Shift support
, 10. Air cylinder 24. 3rd-4th shift shaft 38. Setscrew
11. Air/oil seal 25. Setscrew 39. Splitter shift fork
12. Air/oil seal 26. 1st-2nd shift shaft 40. Fork claw
13. Pin 27. Fork claw 41. Splitter shift shaft
14. Gasket 28. 1st-2nd shift shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-11
 DISASSEMBLY MRT20

TRANSMISSION CONTROL COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Plug 13. Oil seal 24. O-ring
2. Spring 14. Straight pin 25. Cylinder cover
3. Steel ball (larger) 15. Spring pin 26. Needle bearing
4. Steel ball (small) 16. Shift lever 27. Oil seal
5. Range shift switch 17. Select lever 28. Shift shaft
6. Gasket 18. Bushing 29. Washer
7. Plunger 19. Shift shaft 30. Spring
8. Plug 20. Collar 31. Plug
9. Spring 21. Spring 32. Retaining ring
10. Plunger 22. Packing 33. Gasket
11. Guide bolt 23. Piston 34. Power shift assembly
12. Lever cap 35. Joint
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-12
 DISASSEMBLY MRT20

POWER SHIFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. Cylinder boots 18. Lifter ring 34. Cylinder
2. Connector nut ,+ 19. Seat seal assembly 35. Cylinder O-ring
3. Cylinder connector 20. O-ring + 36. Cylinder packing
4. Retaining ring 21. Seal spring 37. Rod plate
5. Retaining ring plate 22. O-ring 38. Cap packing
+ 6. Straight pin ,+ 23. Seat seal assembly 39. Striker
7. Tube filter 24. Spring seat 40. Piston ring
8. Tube collar 25. Lifter ring 41. Piston
9. Tube 26. Lifter spring , 42. Piston packing
10. Lifter ring 27. Lifter 43. Piston O-ring
11. O-ring 28. Lifter O-ring 44. Piston ring
, 12. Tube ring 29. Tube 45. Rod pipe
13. Rod pipe plate 30. Lifter ring 46. Housing hose clamp
14. Lifter 31. Rod pipe 47. Housing hose
15. Lifter O-ring , 32. Rod cap assembly 48. Housing boot clamp
16. Lifter spring , 33. Housing setscrew 49. Housing boot
17. Spring seat 50. Housing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-7-13
 DISASSEMBLY MRT20

OIL PUMP AND OIL FILTER

TM-7-14
 DISASSEMBLY MRT20

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

z Using a bolt (M10 x 1.5), remove the center brake drum

from the companion flange (if so equipped).

z Attach the main drive shaft stopper (99803 Z0000) to input

shaft splines.

z Install the transmission assembly to the attachment (99555

Z0000).

SUB MAIN SHAFT AND COUNTERSHAFT ASSEMBLY

Key point of disassembly
1 Lock nut
Unlock the lock nut, and remove the lock nut using socket wrench
(99535 Z0074).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

TM-7-15
 DISASSEMBLY MRT20

NOTE
z Do not re-use the pinion nut after removal.

7 Range low gear

Tilt the sub countershaft outward and remove the range low gear.
NOTE
z If the sub countershaft is hard to tilt, the notch of the syn-
chro cone may be misaligned with the countershaft. Re-
align if necessary.

11 Range high-low synchro assembly

Remove the range shift shaft assembly and range high and low
synchro assembly.
NOTE
z The range shift shaft and fork are clinched at the set-
screw. Do not separate the two unless necessary.

12 Sub countershaft assembly

Remove the sub countershaft assembly.
NOTE
z Tilt the sub countershaft inward before removing.

13 Tapered bearing
Using the sliding hammer (99547 Z0000) and lock plate replacer
(99827 Z0069), remove the tapered bearing outer race and lock
washer.

15 Range high gear lock nut

Remove the range high gear lock nut.
NOTE
z Before removing the lock nut, check to ensure that the
input shaft splines and shift shaft are clinched properly.

TM-7-16
 DISASSEMBLY MRT20

MIDDLE CASE AND REAR CASE ASSEMBLY

Key point of disassembly
7 Sub countershaft bearing retainer
Remove the sub countershaft bearing retainer, shim and O-ring.
NOTE
z Attach a tag to the shim for identification purposes.

9 Rear case
Lift the rear case vertically.
NOTE
z Take time to work on the rear case, being careful not to
damage the range and splitter shafts.
z Attach lifting cables to retainer mounting stud bolts, then
lift the rear case.

11 Bearing retainer
1. Remove the bolt securing the middle case bearing retainer,
then remove the range high gear and middle case bearing
retainer assembly using a gear puller and main shaft
adapter (99804 Z0000).

2. Using a hydraulic press and bearing remover (99800

Z0002), disassemble the middle case bearing retainer
assembly.

13 Gear cover
Remove the gear cover.
NOTE
z Do not remove the gear cover unless necessary.

TM-7-17
 DISASSEMBLY MRT20

15 Neutral detection switch

Remove the neutral detection (sensor) switch.
NOTE
z Ensure the shift fork is set to neutral so that the sensor
pin will not come out of position during switch removal.

18 Middle case
Lift the middle case until it is moved away from the various shift
shafts and splitter shafts.
NOTE
z Set the middle case as level as possible during lifting. Do
not apply undue stress to shift shafts.

SHIFT FORK ASSEMBLY

Key point of disassembly
1. Install the mainshaft rear nuts to secure the gear hanger
assembly (99783 Z0002), mainshaft, countershaft and the
various shift shafts.

2. Attach the gear shaft setting tool (99799 Z0003) to top of

the front case, then lower the gear shaft assembly to the
floor.

3. Remove the gear hanger assembly.

4. Remove the reverse, 1st-2nd and 3rd-4th shift shaft assem-
blies.
NOTE
z The shafts and forks are clinched at the setscrews. Do
not separate the shafts and forks unless necessary.

TM-7-18
 DISASSEMBLY MRT20

5. Remove the splitter shift shaft assembly.

NOTE
z The shaft and fork are clinched at the setscrews. Do not
separate the shaft and fork unless necessary.

MAIN SHAFT ASSEMBLY

Key point of disassembly
1. Using the gear hanger assembly (99783 Z0002), remove
the main shaft sub assembly from the input shaft assembly.

2. Attach the main shaft sub assembly to the construction

stand (99805 Z0000).
Remove the gear hanger assembly.

21 Lock nut
Unlock and remove the nut located at the end of the main shaft.
NOTE
z The nut is left-hand threaded.

42, 43, 45, 46, 47, 48 Input shaft assembly

Remove the clip from the input shaft. Using a hydraulic press,
remove the input shaft, tapered bearing, splitter gear, needle bear-
ing and splitter synchro ring.
NOTE
z Remove the detent and detent spring in advance.

TM-7-19
 DISASSEMBLY MRT20

1. Clip 4. Splitter synchro ring

2. Tapered bearing 5. Needle bearing
3. Splitter gear 6. Input shaft

OIL PUMP AND OIL FILTER ASSEMBLY

Key point of disassembly
Valve assembly
Remove the valve assembly.
NOTE
z Do not remove the valve assembly unless necessary.

POWER SHIFT ASSEMBLY T

Key point of disassembly
6 Straight pin
Remove the retaining ring and retaining ring plate.
Using the puller assembly (910-11150 JKC NO.), pull out the
straight pin.

19, 23 Seat seal assembly

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

TM-7-20
 DISASSEMBLY MRT20

36 Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.

TM-7-21
 INSPECTION MRT20

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Radial play between inner shift shaft and shift lever

splines
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.08 (0.0008 - 0.0031) 0.5 (0.020)

Clearance between shift lever and each shifter/shift

fork
Unit: mm (in)
Maintenance standard Service limit
0.74 - 0.96 (0.0291 - 0.0378) 1.5 (0.059)

Clearance between transmission cover and shift folk

shaft
Unit: mm (in)
Service
Maintenance standard Remarks
limit
0.04 - 0.07 (0.0016 - 0.0028) Reverse
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.04 - 0.07 (0.0016 - 0.0028) 0.3 (0.012) Range
0.07 - 0.17 (0.0028 - 0.0067) 1st-2nd
0.06 - 0.15 (0.0024 - 0.0059) 3rd-4th

TM-7-22
 INSPECTION MRT20

Clearance between each fork claw and synchronizer

sleeve
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.5 (0.004 - 0.020) 1.0 (0.039)

Clearance between each fork claw and shift fork

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.05 (0.0008 - 0.0020) —

Clearance between cylinder and shift shaft

Unit: mm (in)
Maintenance standard Service limit Remarks
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.3 (0.012)
0.04 - 0.07 (0.0016 - 0.0028) Range

Shift fork shaft locking spring

Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
42.5 (1.7) — 1st to 6th & Reverse
Free length 35.0 (1.4) — Splitter
34.5 (1.4) — Range
137 - 167 1st to 6th & Reverse
— {14 - 17, When compressed to
31 - 37} 29.0 mm (1.142 in)
78 - 98 Splitter When com-
Tension
— {8 - 10, pressed to 28.0 mm
N {kgf, lbf}
18 - 22} (1.102 in)
127 - 157 Range When com-
— {13 - 16, pressed to 28.0 mm
29 - 35} (1.102 in)

TM-7-23
 INSPECTION MRT20

Clearance between reverse shift fork and reverse

sleeve groove
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)

TRANSMISSION PROPER
Each main gears and counter gear backlashes
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.2 (0.004 - 0.008) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.40
0.7 (0.028)
(0.0079 - 0.0157)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.50 (0.0118 - 0.0197) 1.0 (0.039)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between sleeve and clutch gear at splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50
Reverse
(0.0157 - 0.0197) 1.0
0.20 - 0.30 (0.039)
Except for reverse
(0.0079 - 0.0118)

TM-7-24
 INSPECTION MRT20

Ball bearing axial play

Unit: mm (in)
Maintenance standard Service limit
— 0.5 (0.020)

SYNCHRONIZER SYSTEM
<Pin type>
Height difference between synchronizer ring and syn-
chronizer cone end surface
Unit: mm (in)
Maintenance standard Service limit Remarks
0.3 - 1.5 (0.012 - 0.059) 4.0 (0.157) Range high gear
0.3 - 1.6 (0.012 - 0.063) 6.0 (0.236) Range low gear

<Lock plunger type>

Tangential clearance between synchronizer ring and
synchronizer hub
Unit: mm (in)
Maintenance standard Service limit Remarks
6.3 - 6.7 (0.248 - 0.264) 1st to 4th
—
6.5 - 6.9 (0.256 - 0.272) Splitter

Backlash between synchronizer ring and clutch gear

Unit: mm (in)
Maintenance standard Service limit Remarks
1.4 - 1.8 (0.055 - 0.071) 1st-2nd
1.5 - 1.9 (0.059 - 0.075) 0 3rd-4th
1.4 - 1.6 (0.055 - 0.063) Splitter

TM-7-25
 INSPECTION MRT20

Axial clearance between synchronizer ring and syn-

chronizer detent
Unit: mm (in)
Maintenance standard Service limit Remarks
0.1 - 0.3 (0.004 - 0.012) 1st to 4th
—
1.3 - 1.5 (0.051 - 0.059) Splitter

Detent spring
Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
25.0 (1.0) 1st to 4th
Free length 26.0 (1.0) — Splitter
50.0 (2.0) Range
56.9 - 68.6 1st to 4th When com-
{5.8 - 7.0, pressed to 18.0 mm
12.8 - 15.4} (0.709 in)
70.6 - 86.3 Splitter When com-
Tension
— {7.2 - 8.8, pressed to 22.0 mm
N {kgf, lbf}
15.9 - 19.4} (0.866 in)
80.4 - 98.1 Range When com-
{8.2 - 10.0, pressed to 35.0 mm
18.1 - 22.1} (1.378 in)

OIL PUMP
Oil pump gear end play
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.09 (0.0020 - 0.0035) —

Radial play between oil pump gear and counter shaft at

splines
Unit: mm (in)
Maintenance standard Service limit
0 - 0.18 (0 - 0.0071) —

TM-7-26
 INSPECTION MRT20

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Item No. 18.1
—
16 (0.713)
Free Item No. 15.0
—
length 21 (0.591)
Item No. 21.0
—
26 (0.827)
40.2 - 52.0 When com-
Item No. 47.1
{4.1 - 5.3, pressed to 13.0
16 {4.8, 10.6}
9.0 - 11.7} mm (0.512 in)
15.7 - 20.6 When com-
Tension Item No. 18.6
{1.6 - 2.1, pressed to 13.0
N {kgf, lbf} 21 {1.9, 4.2}
3.5 - 4.6} mm (0.512 in)
10.8 - 13.7 When com-
Item No. 12.7
{1.1 - 1.4, pressed to 10.0
26 {1.3, 2.9}
2.4 - 3.1} mm (0.394 in)

NOTE
z Item Nos. indicate the disassembly sequence.

Valve seal dent depth

Unit: mm (in)
Maintenance standard Service limit
0.15 (0.0059), max. —

TM-7-27
 REASSEMBLY MRT20

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. 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.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond #1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during installa-
tion. Observe the following precautions during gasket application.

<Precautions during RTV liquid gasket application>

z Remove all traces of liquid gasket from the flanged surface
of parts using a scraper. Be careful not to scratch the
flanged surface and completely wipe away foreign particles
(grease, water, dust, etc.) using a clean cloth.
z Apply a continuous coat of liquid gasket to the inner edge of
the flange and the center of the bolt hole, as well as to the
outer edge of the flange and the area as close as possible
to the bolt holes. The gasket bead width must be 3 mm
(0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
z Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
z Install parts within 2 - 20 minutes of gasket application.
Leave parts unattended for approximately 2 hours, allowing
the gasket to completely harden.

FRONT CASE ASSEMBLY

Key point of reassembly
Bearing cap
Install the bearing cap (without the oil seal), adjusting shim and
bearing outer race in the front case as a unit.
NOTE
z Do not install the oil seal and O-ring.

TM-7-28
 REASSEMBLY MRT20

Bushing
Press the bushing into the bore in the front case with the clinch set
at a right angle to the left when viewed from the press-in direction
(horizontal when viewed from the transmission installation direc-
tion).
NOTE
z Use a bushing replacer to install the bushing.
1st-2nd 99801 Z0001
3rd-4th 99801 Z0002

POWER SHIFT ASSEMBLY

Key point of reassembly
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 8.

NOTE
z Be sure to install the springs in the correct sequence.

TM-7-29
 REASSEMBLY MRT20

12 Tube ring
1. Using the insert tool (910-26500 JKC No.) install the tube
ring.

2. 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 Cylinder boots
Install the boot.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.

z Functional check
After assembling, apply 736 kPa {7.5 kgf/cm2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve's sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift 59 N {6 kgf, 13 lbf}, max.
directions

TM-7-30
 REASSEMBLY MRT20

MAIN SHAFT ASSEMBLY

Key point of reassembly
z Heat each gear and the following parts in an oil bath and
then assemble them. [Oil temperature: 200ºC (392ºF)]
z Thrust washer
z Tapered bearing
z 1st-2nd synchro hub
z Inner race
z Securely attach the main shaft to the construction stand
(99805 Z0000).
NOTE
z Make sure that the construction stand is securely fixed in
place.

30 - 35 3rd-4th gear synchronizer assembly

1. Install the spring, detent and lock plunger on the synchro
hub.
NOTE
z Install the detent while pushing the lock plunger using a
screwdriver.

2. Install the 3rd gear sleeve.

NOTE
z When installing the sleeve, push the detent using a
screwdriver.
z Align the detent with the notch in the sleeve. (The syn-
chro sleeve must face the specified direction, so the
alignment should be done carefully.)

3. Install the synchro ring.

NOTE
z Ensure the synchro hub is fitted in the groove.

TM-7-31
 REASSEMBLY MRT20

28 Adjusting spacer
1. Install the tapered bearings into the bore in the drive gear
assembly, then tighten with the drive gear set tool (99806
Z0000).
: 7 N·m {0.7 kgf·m, 5.1 ft·lbf}
2. Measure the bearing-to-bearing end surface distances at
two places in the opposite direction, then determine the
mean value “A” of the two distance measurements.
NOTE
z Before distance measurements, turn the drive gear
assembly two or three complete rotations, then retighten
to 7 N·m {0.7 kgf·m, 5.1 ft·lbf}.

3. Install the tapered bearing and adjusting spacer [21.70 mm

(0.8543 in) thick] to the drive gear setting jig. Measure the
bearing-to-bearing end surface distances at two places in
the opposite direction, then determine the mean value “B”
of the two distance measurements.
: 7 N·m {0.7 kgf·m, 5.1 ft·lbf}

4. Determine the required adjusting spacer thickness “X1”

using the following equation.
X1 = A - B + 21.861
Select the suitable adjusting spacer which is suited to the
thickness “X1” from the following chart.
Unit: mm (in)
Spacer thickness 21.45 (0.8445) 21.50 (0.8465) 21.55 (0.8484)
Applicable 21.425 - 21.475 21.476 - 21.525 21.526 - 21.575
X1 range (0.8435 - 0.8455) (0.8455 - 0.8474) (0.8475 - 0.8494)

Unit: mm (in)
Spacer thickness 21.60 (0.8504) 21.65 (0.8524) 21.70 (0.8543)
Applicable 21.576 - 21.625 21.626 - 21.675 21.676 - 21.725
X1 range (0.8494 - 0.8514) (0.8514 - 0.8533) (0.8534 - 0.8553)

z Measure the main shaft gear end play.

Unit: mm (in)
Item Maintenance standard Service limit
End play 0.03 - 0.09 (0.001 - 0.004)

NOTE
z Before measuring the main shaft gear end play, turn the
drive gear two or three rotations.
z A certain amount of end play is allowed for the drive gear
tapered bearing. Check to ensure that the specified
amount of end play is maintained since excessive pre-
load may create a problem.

TM-7-32
 REASSEMBLY MRT20

21 Lock nut
Align the lock nut with the groove on the end of the main shaft, then
clinch securely.

z Reassembling the main shaft sub assembly

1. Install the front case on the transmission rotation block and
set the gear shaft setting plate (99799 Z0003) on the upper
surface of the front case.

2. Using the gear hanger assembly (99783 Z0002), install the

main shaft subassembly on the input shaft.
NOTE
z Carefully raise or lower the main shaft subassembly dur-
ing installation.

z Adjusting the main drive shaft end play.

NOTE
z Whenever any of the bearings or gears are replaced,
adjust the main drive shaft end play as described below.
z If disassembly does not require replacement of any com-
ponents, install the original shim used before disassem-
bly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the main drive shaft bearing outer race.

TM-7-33
 REASSEMBLY MRT20

2. Install the bearing cap by tightening it at three places as

shown by “+'' in the figure at right.
: 6 N·m {0.6 kgf·m, 4.3 ft·lbf}
NOTE
z After turning the main drive shaft two or three complete
rotations, again tighten the bolts to the specified torque.
z Do not tighten the bolts in excess of the specified torque
under any circumstances

3. Measure the bearing cap-to-mating surface clearance (at

three places) near the bolt location, and determine the
mean value “E” of the three measurements.
NOTE
z The clearance should be measured with the O-ring
removed.

4. Determine the required shim thickness “X4” using the fol-

lowing equation, and select a shim whose thickness is
closer to the measured value from those listed in the follow-
ing chart.
Equation: X4 = 3.384 - E
Unit: mm (in)
Shim thickness 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
1.670 - 1.730 1.731 - 1.790 1.791 - 1.850 1.851 - 1.910
Applicable “X4” range
(0.0657 - 0.0681) (0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752)

Unit: mm (in)
Shim thickness 1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
1.911 - 1.970 1.971 - 2.030 2.031 - 2.090 2.091 - 2.150
Applicable “X4” range
(0.0752 - 0.0776) (0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846)

Unit: mm (in)
Shim thickness 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929)
2.151 - 2.210 2.211 - 2.270 2.271 - 2.330 2.331 - 2.390
Applicable “X4” range
(0.0847 - 0.0870) (0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941)

Unit: mm (in)
Shim thickness 2.42 (0.0953) 2.48 (0.0976)
2.391 - 2.450 2.451 - 2.510
Applicable “X4” range
(0.0941 - 0.0965) (0.0965 - 0.0988)

TM-7-34
 REASSEMBLY MRT20

z Install the oil seal on the bearing cap, then install the bear-
ing cap, the selected shim and O-ring on the transmission
body as a unit.
: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}
NOTE
z Use liquid gestated bolts for those marked with “O'' in
the figure at right.
z The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will increase
the preload value, resulting in damage to the bearing.

COUNTERSHAFT ASSEMBLY
Key point of reassembly
z Install the counter splitter gear, counter drive gear, keys, clip
and tapered bearings onto the countershaft.
NOTE
z Heat the gears and bearings in an oil bath before installa-
tion.
Oil bath temperature: Pyrex. 200ºC (392ºF)

z Adjusting the countershaft end play

NOTE
z Whenever any of the bearings or gears are replaced,
adjust the countershaft end play as described below.
z If the disassembly does not require replacement of the
components, reuse the original shims which are
removed during disassembly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the countershaft rear bearing outer race.

2. Install the oil pump by tightening the bolts (three places).

: 6 N·m {0.6 kgf·m, 4.3 ft·lbf}
NOTE
z After turning the countershaft two or three complete rota-
tions, again tighten the bolts to the specified torque.
z Do not tighten the bolts in excess of the specified torque
under any circumstances.

TM-7-35
 REASSEMBLY MRT20

3. Using a thickness gauge, measure the oil pump end sur-

face-to-mating surface clearance near the bolt location at
three points. Determine the mean value “C” of the three
measurements.
4. Determine the required shim thickness “X2” using the fol-
lowing equation, then select the suitable shim from those
listed in the following charts.
Equation: X2 = 3.617 - C

Unit: mm (in)
Shim thickness 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
1.670 - 1.730 1.731 - 1.790 1.791 - 1.850 1.851 - 1.910
Applicable “X2” range
(0.0657 - 0.0681) (0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752)

Unit: mm (in)
Shim thickness 1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
1.911 - 1.970 1.971 - 2.030 2.031 - 2.090 2.091 - 2.150
Applicable “X2” range
(0.0752 - 0.0776) (0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846)

Unit: mm (in)
Shim thickness 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929)
2.151 - 2.210 2.211 - 2.270 2.271 - 2.330 2.331 - 2.390
Applicable “X2” range
(0.0847 - 0.0870) (0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941)

z Install the selected shim, oil strainer and oil pump.

: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
NOTE
z The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will inevitably
increase the preload value as the oil temperature
increases, resulting in malfunctioning parts.

SHIFT FORK ASSEMBLY

Key point of reassembly
z Install the fork and shifter to the shift shaft.
NOTE
z Be careful not to confuse the front of the shift fork with
the rear.
z Ensure the setscrew is fitted in the shaft groove, then
clinch at three points.

TM-7-36
 REASSEMBLY MRT20

z Lift the gear assembly using the gear hanger assembly

(99783 Z0002) and hoist, remove the shaft setting tool, then
lower the gear assembly to the inside of the front case.
NOTE
z Be careful not to damage the input shaft oil seal while
raising or lowering the gear assembly.

10 Air cylinder
1. Install the air/oil seal on the air cylinder.
NOTE
z Note the installation direction of the air/oil seal.
z Use an oil seal replacer to install the air/oil seal.
Range side 99807 Z0004
Splitter side 99807 Z0005

2. Install the air cylinder via gasket and a pin.

NOTE
z Using a copper hammer, lightly drive the air cylinder into
place.

3. Install the range piston, splitter piston, packing and O-ring.

NOTE
z Apply grease to the mating surfaces of the piston, O-ring
and packing before installation.
z Note the direction of the packing during installation.
4. Install the piston assembly on the range and splitter air cyl-
inders, then tighten the nuts using washers.
: Range side:
137 - 186 N·m {14.0 - 19.0 kgf·m, 101 - 137 ft·lbf}
: Splitter side:
57 - 76 N·m {5.8 - 7.7 ·m, 42 - 56 ft·lbf}
NOTE
z Apply grease to the air cylinder inner wall in advance.

5. Install the cylinder cap using the O-ring.

: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}
NOTE
z Use liquid gasketed bolts for those indicated in the figure
at right.

TM-7-37
 REASSEMBLY MRT20

MIDDLE CASE AND REAR CASE ASSEMBLY

Key point of reassembly
18 Middle case
1. Apply liquid gasket to the mating surface of the front and
middle cases.

2. Lower the middle case until it is in contact with the front

case.
NOTE
z Set the middle case as level as possible while lowering.
Do not allow guide bushings to catch shift shafts.

3. Tighten the middle case mounting bolts.

: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
NOTE
z Use liquid gasketed bolts for those marked with “O'' and
tighten from the front case side.

17 Reverse idler gear assembly

Apply liquid gasket to setscrews, then tighten the setscrews. When-
ever any of the bearings or gears are replaced, adjust the counter-
shaft end play as described below.
NOTE
z If the disassembly does not require replacement of the
components, reuse the original shims which are
removed during disassembly.

16 Side cover
1. Apply liquid gasket to the mounting surface of the transmis-
sion case side cover.

TM-7-38
 REASSEMBLY MRT20

2. Install the PTO gear assembly (if so equipped) or the side

cover using gasket.
: 32 - 42 N·m {3.3 - 4.3 kgf·m, 24 - 31 ft·lbf}

11 Bearing retainer
Press the middle case bearing retainer assembly into place using
the bearing retainer replacer (99827 Z0068).
: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}

9 Rear case
1. Apply liquid gasket to the mating surface of the middle and
rear cases.

2. Install the rear case.

: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}

z Tighten the rear case mounting bolts.

Bolt N·m Liter:

Remarks
No. {kgf·m, ft·lbf} mm (in)
A 85 (3.35) —
B 45 (1.77) —
57 - 76
{5.8 - 7.7, 42 - 56} Use liquid gasketed
C 45 (1.77)
bolts
D 95 (3.74) —

z Adjusting the sub countershaft end play

TM-7-39
 REASSEMBLY MRT20

NOTE
z If disassembly does not require replacement of bearings
or gears, use the original shims installed prior to disas-
sembly.
z Whenever any of the bearings or gears are replaced,
adjust the sub countershaft end play as described below.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the sub countershaft rear bearing outer
race.

2. Secure the sub countershaft bearing retainer at three points

as shown in the figure at right.
: 6 N·m {0.6 kgf·m, 4.3 ft·lbf}
NOTE
z After installing the sub countershaft bearing retainer,
turn the sub countershaft by turning the output shaft two
or three rotations, then tighten the retainer bolts again to
the specified torque.
z Do not tighten the bolts in excess of the specified torque.

3. Measure the retainer-to-mating surface clearance (at three

places) near the bolt locations, and determine the mean
value “D” of the three measurements.
NOTE
z The clearance should be measured with the O-ring
removed.

4. Determine the required shim thickness “X3” using the fol-

lowing equation, then select a shim whose thickness is
closer to the value calculated.
Equation: X3 = 3.709 - D
Unit: mm (in)
Shim thickness 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764) 2.00 (0.0787)

Applicable “X3” range

1.790 - 1.850 1.851 - 1.910 1.911 - 1.970 1.971 - 2.030
(0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776) (0.0776 - 0.0799)

Unit: mm (in)
Shim thickness 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858) 2.24 (0.0882)

Applicable “X3” range

2.031 - 2.090 2.091 - 2.150 2.151 - 2.210 2.211 - 2.270
(0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870) (0.0870 - 0.0894)

TM-7-40
 REASSEMBLY MRT20

Unit: mm (in)
Shim thickness 2.30 (0.0906) 2.36 (0.0929)

Applicable “X3” range

2.271 - 2.330 2.331 - 2.390
(0.0894 - 0.0917) (0.0918 - 0.0941)

z Install a selected shim and the O-ring, then install the sub
countershaft bearing retainer.
: 57 - 76 N·m {5.8 - 7.7 kgf·m, 42 - 56 ft·lbf}
NOTE
z The specified end play of the tapered bearing (when cold)
is 0.05 to 0.15 mm (0.0020 to 0.0059 in). Application of
preload to a cold tapered bearing will inevitably increase
the preload value as the oil temperature increases, which
results in damage to the bearing.

5 Speedometer drive gear

Install the speedometer drive gear onto the output shaft.
NOTE
z Note the installation direction of the drive gear.

SUB MAINSHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
Key point of reassembly
15 Range high gear lock nut
Tighten the range high lock nuts.
: 686 - 981 N·m {70 - 100 kgf·m, 506 - 723 ft·lbf}
NOTE
z Clinch the lock nuts in the same way as they were before
disassembly.

14 Lock washer
Align lock washers with lock bolt holes.
NOTE
z If the lock washer is not aligned with the bolt hole, turn
its topside down or move it to left or right, as required.
z If it is still hard to align, align it while turning the nut in
the direction that tightens.

TM-7-41
 REASSEMBLY MRT20

1 Lock nut
Install and tighten the companion flange nut.
: 686 - 981 N·m {70 - 100 kgf·m, 506 - 723 ft·lbf}
NOTE
z Lock the companion flange nut in the same way as it was
before disassembly.

z Align the companion flange nut flat surfaces with the

grooves on the shaft, then clinch the nut.

CONTROL COVER ASSEMBLY

Key point of reassembly
Bushing
Press the bushing into the bore in the control cover with the clinch
facing downward.
NOTE
z Use a bushing replacer to install the bushing.
99801 Z0003

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle. Be sure to align the main drive shaft with the
clutch disc at their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-7-42
 CONSTRUCTION MRT23B

= UNIT NAME MRT23B =

CONSTRUCTION
TRANSMISSION ASSEMBLY

TM-8-1
 CONSTRUCTION MRT23B

MAIN SHAFT ASSEMBLY

COUNTERSHAFT ASSEMBLY

TM-8-2
 CONSTRUCTION MRT23B

POWER SHIFT ASSEMBLY

TM-8-3
 DISASSEMBLY MRT23B

DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the transmission assembly, turn the key
switch to the “OFF” position and chock the wheels to be
safe.
2. Remove the drain plug and drain transmission gear oil from
the transmission case.
3. Remove/disengage the propeller shaft, transmission link-
age, cable, wiring, PTO (when equipped), etc., from around
the transmission case.
4. Remove the transmission from the flywheel housing. Sup-
port the transmission with a jack or lifting wires to prevent it
from dropping, and remove it from the flywheel housing.
NOTE
z Do not separate the wear indicator and stay.

TM-8-4
 DISASSEMBLY MRT23B

DISASSEMBLY
MIDDLE CASE ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Bearing retainer 5.Side cover 8.Gear cover
2.Oil seal ring (PTO gear box: if so equipped) 9.Bear cap
3.Gear cover 6.Reverse idler gear assembly 10.Oil seal
4.Neutral detection switch 7.Middle case 11.O-ring
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

TM-8-5
 DISASSEMBLY MRT23B

REAR CASE ASSEMBLY

TM-8-6
 DISASSEMBLY MRT23B

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Rear bearing retainer 9.Cylinder cap 17.Range piston
2.Gasket 10.O-ring 18.Air cylinder
3.Oil seal 11.O-ring 19.Air/oil seal
4.Speedometer driven gear assembly 12.O-ring 20.Air/oil seal
5.Speedometer drive gear 13.Piston packing 21 Pin
6.Anti-overrun sensor 14.Splitter piston 22.Gasket
7.Sub countershaft bearing retainer 15.O-ring 23.Rear case
8.Adjusting shim 16.Piston packing 24 Rear cover
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

TM-8-7
 DISASSEMBLY MRT23B

FRONT CASE ASSEMBLY

1.Top cover 9.Release sleeve 17.Needle bearing

2.Rubber seat 10.Release bearing 18.Oil seal
3.Air cleaner case (upper) 11.Set bolt 19.Grease nipple
4.Air cleaner element 12.Release shaft 20.Plug
5.Air cleaner case (lower) 13.Key 21.Taper plug
6.Grease nipple 14.Release yoke 22.Under cover
7.Hose 15.Release yoke bearing 23.Rubber seat
8.Spring 16.Oil seal 24.Front case
NOTE
z Numbers before part names do not indicate the disassembly sequence.

TM-8-8
 DISASSEMBLY MRT23B

OIL PUMP AND OIL FILTER ASSEMBLY

TM-8-9
 DISASSEMBLY MRT23B

MAIN SHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Tapered bearing 17.Detent spring 33.Detent spring
2.Reverse gear 18.2nd double synchro assembly 34.3rd-4th synchro sleeve
3.Reverse sleeve 19.2nd gear 35.3rd synchro ring
4.Needle bearing 20.Needle bearing 36.3rd gear
5.Reverse gear bearing inner race 21.Lock nut (LH thread) 37.Needle bearing
6.Reverse hub 22.Tapered bearing 38.Main shaft
7.1st gear 23.Thrust washer 39.Adjusting shim
8.Needle bearing 24.Tapered bearing 40.Detent
9.Spacer 25.Synchro ring 41.Detent spring
10.Needle bearing 26.Drive gear assembly 42.Clip
11.1st gear bearing inner race 27.Synchro ring 43.Tapered bearing
12.1st double synchro assembly 28.Adjusting spacer 44.Splitter synchro sleeve
13.1st-2nd synchro sleeve 29.Tapered bearing 45.Splitter gear
14.1st-2nd synchro hub 30.3rd-4th synchro hub 46.Splitter synchro ring
15.Detent 31.Detent 47.Needle bearing
16.Synchro plunger 32.Synchro plunger 48.Input shaft
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

TM-8-10
 DISASSEMBLY MRT23B

COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Adjusting shim 4.Clip 7.Key
2. apered bearing* 5.Splitter counter gear 8.Countershaft
3.Tapered bearing* 6.Counter drive gear
*: Do not reuse parts after removal.

TM-8-11
 DISASSEMBLY MRT23B

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Lock nut 8.Needle bearing 15.Synchro cone
2.O-ring 9.Range synchro sleeve 16.Sub countershaft assembly
3.Companion flange 10.Detent 17.Tapered bearing
4.Dust shield 11.Detent spring 18.Lock washer
5.Ball bearing 12.Range double synchro assembly 19.Range high gear lock nut
6.Thrust washer 13.Output shaft 20.Range high gear
7.Range low gear 14.Synchro ring
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

TM-8-12
 DISASSEMBLY MRT23B

SHIFT FORK ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Pin 10.3rd-4th shift shaft 19.Setscrew
2.Ring 11.Setscrew 20.Ring
3.Clip 12.1st-2nd shift shaft 21.Reverse shifter
4.Range shift fork 13.Fork claw 22.Reverse shift shaft
5.Fork claw 14.1st-2nd shift shaft 23.Shift support
6.Range shift shaft 15.Setscrew 24.Setscrew
7.Setscrew 16.1st-2nd shifter 25.Splitter shift fork
8.3rd-4th shift fork 17.Setscrew 26.Fork claw
9.Fork claw 18.Reverse shift fork 27.Splitter shift shaft

TM-8-13
 DISASSEMBLY MRT23B

TRANSMISSION CONTROL COVER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Plug 13.Oil seal 25.Cylinder cover
2.Spring 14.Straight pin 26.Needle bearing
3.Steel ball (large) 15.Spring pin 27.Oil seal
4.Steel ball (small) 16.Shift lever 28.Shift shaft
5.Range shift switch 17.Select lever 29.Washer
6.Gasket 18.Bushing 30.Spring
7.Plunger 19.Shift shaft 31.Plug
8.Plug 20.Collar 32.Retaining ring
9.Spring 21.Spring 33.Gasket
10.Plunger 22.Packing 34.Power shift assembly
11.Guide bolt 23.Piston 35.Joint
12.Lever cap 24.O-ring

TM-8-14
 DISASSEMBLY MRT23B

POWER SHIFT ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

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
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

TM-8-15
 DISASSEMBLY MRT23B

TRANSMISSION ASSEMBLY
Key point of disassembly
z Place the transmission on a work bench. Before starting to
disassemble, secure it so that it does not fall.

z Install the transmission assembly to the attachment (99555

Z0000).

z Attach the main drive shaft stopper (99803 Z0000) to input

shaft splines.

z When the control cover is removed, attach the stopper and

push the shift shaft with a screwdriver to engage gears (to
enter shifted condition).

Unlock the lock nut, and remove the lock nut using
socket wrench (99535 Z0074).
CAUTION
z Before removing the lock nut, make sure the transmis-
sion case is securely fixed.

NOTE
z Do not re-use the lock nut after removal.

TM-8-16
 DISASSEMBLY MRT23B

REAR CASE ASSEMBLY

Key point of disassembly
7.Sub countershaft bearing retainer
Remove the sub countershaft bearing retainer, shim and O-ring.
NOTE
z Attach a tag to the shim for identification purposes.

23.Rear case
1. Remove the nuts and washers securing the splitter and
range pistons.

2. While holding the end of the shaft by hand, apply com-

pressed air to the cylinder to push out the range and splitter
pistons.

3. Lightly tap the points (indicated by the arrows in the figure

at right), then remove the air cylinder.

4. Remove the splitter shift shaft locking plug.

TM-8-17
 DISASSEMBLY MRT23B

5. Remove the transmission anti-overrun sensor.

6. Install and tighten rear case mounting bolts in bolt holes on

the rear case flange. These bolts are used as pull bolts.

7. Lift the rear case vertically.

NOTE
z Take time to work on the rear case, being careful not to
damage the range and splitter shafts.
z Attach lifting cables to retainer mounting stud bolts, then
lift the rear case.

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
Key point of disassembly
7.Range low gear
Tilt the sub countershaft outward and remove the range low gear.
NOTE
z If the sub countershaft is hard to tilt, the notch of the
synchro cone may be misaligned with the countershaft.
Re-align if necessary.

16.Sub countershaft assembly

Remove the sub countershaft assembly.
NOTE
z Tilt the sub countershaft inward before removing.

TM-8-18
 DISASSEMBLY MRT23B

17.Tapered bearing
Using the sliding hammer (99547 Z0000) and lock plate replacer
(99827 Z0069), remove the tapered bearing outer race and lock
washer.

20.Range high gear

1. Remove the lock nut using socket wrench (99535 Z0074).
NOTE
z Before removing the lock nut, check to ensure that the
input shaft splines and shift shaft are clinched properly.

2. Remove the bolt securing the bearing retainer, then remove

the range high gear and bearing retainer assembly using a
gear puller and main shaft adapter (99804 Z0000).

3. Using a hydraulic press and bearing remover (99800

Z0002), disassemble the bearing retainer assembly.

MIDDLE CASE ASSEMBLY

Key point of disassembly
z Remove the valve assembly.
NOTE
z Do not remove the valve assembly unless necessary.

TM-8-19
 DISASSEMBLY MRT23B

3.Gear cover
Remove the gear cover.
NOTE
z Do not remove the gear cover unless necessary.

4.Neutral detection switch

Remove the neutral detection (sensor) switch.
NOTE
z Ensure the shift fork is set to neutral so that the sensor
pin will not come out of position during switch removal.

7.Middle case
Lift the middle case until it is moved away from the various
shift shafts and splitter shafts.
NOTE
z Set the middle case as level as possible during lifting. Do
not apply undue stress to shift shafts.

SHIFT FORK ASSEMBLY

Key point of disassembly
1. Install the main shaft rear nuts to secure the gear hanger
assembly (99783 Z0002), main shaft, countershaft and the
various shift shafts.

2. Attach the gear shaft setting tool (99799 Z0003) to top of

the front case, then lower the gear shaft assembly to the
floor.

TM-8-20
 DISASSEMBLY MRT23B

3. Remove the gear hanger assembly.

4. Remove the reverse, 1st-2nd and 3rd-4th shift shaft assem-
blies.
NOTE
z The shafts and forks are clinched at the setscrews. Do
not separate the shafts and forks unless necessary.

5.Remove the splitter shift shaft assembly.

NOTE
z The shaft and fork are clinched at the setscrews. Do not
separate the shaft and fork unless necessary.

MAIN SHAFT ASSEMBLY

Key point of disassembly
1. Using the gear hanger assembly (99783 Z0002), remove
the main shaft sub assembly from the input shaft assembly.

2. Attach the main shaft sub assembly to the construction

stand (99805 Z0000).
Remove the gear hanger assembly.

21.Lock nut (LH thread)

Unlock and lock nut, and remove the lock nut using socket wrench
(99535 Z0074).

TM-8-21
 DISASSEMBLY MRT23B

42, 43, 45, 46, 47, 48.Input shaft assembly

Remove the clip from the input shaft. Using a hydraulic press,
remove the input shaft, tapered bearing, splitter gear, needle bear-
ing and splitter synchro ring.
NOTE
z Remove the detent and detent spring in advance.

1.Clip 4.Splitter synchro ring

2.Tapered bearing 5.Needle bearing
3.Splitter gear 6.Input shaft

POWER SHIFT ASSEMBLY

Key point of disassembly
6.Straight pin
Remove the retaining ring and retaining ring plate.
Using the puller assembly (910-11150), pull out the straight pin.

19, 23.Seat seal assembly

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

TM-8-22
 DISASSEMBLY MRT23B

36.Cylinder packing
Remove the cylinder packing and cap packing.
NOTE
z These parts need not be removed unless damaged.

TM-8-23
 INSPECTION MRT23B

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

TRANSMISSION COVER
Clearance between shift lever and select lever
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.4 (0.004 - 0.016) 0.8 (0.031)

Radial play between shift shaft and shift lever splines

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.08 (0.0008 - 0.0031) 0.5 (0.020)

Clearance between shift lever and each shifter/shift

fork
Unit: mm (in)
Maintenance standard Service limit
0.74 - 0.96 (0.0291 - 0.0378) 1.5 (0.059)

Clearance between transmission cover and shift fork

shaft
Unit: mm (in)
Maintenance standard Service limit Remarks
0.04 - 0.07 (0.0016 - 0.0028) Reverse
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.04 - 0.07 (0.0016 - 0.0028) 0.3 (0.012) Range
0.07 - 0.17 (0.0028 - 0.0067) 1st-2nd
0.06 - 0.15 (0.0024 - 0.0059) 3rd-4th

TM-8-24
 INSPECTION MRT23B

Clearance between each fork claw and synchronizer

sleeve
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.5 (0.004 - 0.020) 1.0 (0.039)

Clearance between each fork claw and shift fork

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.05 (0.0008 - 0.0020) –

Clearance between cylinder and shift shaft

Unit: mm (in)
Maintenance standard Service limit Remarks
0.07 - 0.10 (0.0028 - 0.0039) Splitter
0.3 (0.012)
0.04 - 0.07 (0.0016 - 0.0028) Range

Shift fork shaft locking spring

Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
42.5 (1.673) – 1st to 6th & Reverse
Free length 35.0 (1.378) – Splitter
34.5 (1.358) – Range
1st to 6th & Reverse
137 - 167
– When compressed to
{14 - 17, 31 - 37}
29.0 mm (1.142 in)
Splitter
Tension 78 - 98
– When compressed to
N {kgf, lbf} {8 - 10, 18 - 22}
28.0 mm (1.102 in)
Range
127 - 157
– When compressed to
{13 - 16, 29 - 35}
28.0 mm (1.102 in)

TM-8-25
 INSPECTION MRT23B

Clearance between reverse shift fork and reverse

sleeve groove
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)

TRANSMISSION PROPER
Each main gear and counter gear backlash
Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)

Each main gear end play

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Reverse idler gear end play

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.50 (0.0118 - 0.0197) 1.0 (0.039)

Radial play between hub and sleeve splines

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between sleeve and clutch gear splines

Unit: mm (in)
Maintenance standard Service limit Remarks
0.40 - 0.50 (0.0157 - 0.0197) Reverse
1.0 (0.039)
0.20 - 0.30 (0.0079 - 0.0118) Except for reverse

Ball bearing axial play

Unit: mm (in)
Maintenance standard Service limit
– 0.5 (0.020)

TM-8-26
 INSPECTION MRT23B

SYNCHRONIZER SYSTEM
<Lock plunger type>
Tangential clearance between synchronizer ring and
synchronizer hub
Unit: mm (in)
Maintenance standard Service limit Remarks
6.3 - 6.7 (0.248 - 0.264) 1st to 4th
–
6.5 - 6.9 (0.256 - 0.272) Splitter

Clearance between synchronizer ring and clutch gear

Unit: mm (in)
Maintenance standard Service limit Remarks
1.4 - 1.8 (0.055 - 0.071) 1st - 2nd
1.5 - 1.9 (0.059 - 0.075) 0 (0) 3rd - 4th
1.4 - 1.6 (0.055 - 0.063) Splitter

Axial clearance between synchronizer ring and syn-

chronizer detent
Unit: mm (in)
Maintenance standard Service limit Remarks
0.1 - 0.3 (0.004 - 0.012) 1st to 4th
–
1.3 - 1.5 (0.051 - 0.059) Splitter

Detent spring
Unit: mm (in)
Nominal Maintenance
Item Remarks
dimension standard
25.0 (0.984) – 1st to 4th
Free length 26.0 (1.024) – Splitter
35.6 (1.402) – Range
56.9 - 68.6 1st to 4th
– {5.8 - 7.0, When compressed to
12.8 - 15.4} 18.0 mm (0.709 in)
70.6 - 86.3 Splitter
Tension
– {7.2 - 8.8, When compressed to
N {kgf, lbf}
15.9 - 19.4} 22.0 mm (0.866 in)
153 - 169 Range
– {15.6 - 17.2, When compressed to
34 - 38} 29.0 mm (1.142 in)

TM-8-27
 INSPECTION MRT23B

OIL PUMP
Clearance between drive shaft and case
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.09 (0.0024 - 0.0035) –

Radial play between oil pump gear and counter shaft at

splines
Unit: mm (in)
Maintenance standard Service limit
0 - 0.18 (0 - 0.0071) –

POWER SHIFT
Power shift spring
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
Item No. 18.1
–
16 (0.713)
Free Item No. 21.0
–
length 21 (0.827)
Item No. 15.0
–
26 (0.591)
Item No. 47.1 40.2 When compressed to
16 {4.8, 10.6} {4.1, 9.0} 13.0 mm (0.512 in)
Tension Item No. 12.7 10.8 When compressed to
N {kgf, lbf} 21 {1.3, 2.9} {1.1, 2.4} 10.0 mm (0.394 in)
Item No. 18.6 15.7 When compressed to
26 {1.9, 4.2} {1.6, 3.5} 13.0 mm (0.512 in)

NOTE
z Item Nos. indicate the disassembly sequence.

Valve seal dent depth

Unit: mm (in)
Maintenance standard Service limit
0.15 (0.0059), max. –

TM-8-28
 REASSEMBLY MRT23B

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.
Apply a coat of RTV (Room Temperature Vulcanizing) liquid gasket
(Three Bond No.1215 or equivalent) to the mating surfaces of the
middle case, rear case, side cover and control cover during installa-
tion. Observe the following precautions during gasket application.
<Precautions during RTV liquid gasket application>
z Remove all traces of liquid gasket from the flanged surface
of parts using a scraper. Be careful not to scratch the
flanged surface and completely wipe away foreign particles
(grease, water, dust, etc.) using a clean cloth.
z Apply a continuous coat of liquid gasket to the inner edge of
the flange and the center of the bolt hole, as well as to the
outer edge of the flange and the area as close as possible
to the bolt holes. The gasket bead width must be 3 mm
(0.12 in).
For detailed information concerning the gasket application, refer to
the gasket application drawing in the text.
z Also apply an equal and continuous bead of liquid gasket to
areas where the flanged surface is narrow (due to cutouts,
etc.); do not apply an excess coat to the gasket.
z Install parts within 2 - 20 minutes of gasket application.
Leave parts unattended for approximately 2 hours, allowing
the gasket to completely harden.

FRONT CASE ASSEMBLY

Key point of reassembly
Bearing cap
Install the bearing cap (without the oil seal), adjusting shim and
bearing outer race in the front case as a unit.
NOTE
•Do not install the oil seal and O-ring.

Bushing
Press the bushing into the bore in the front case with the clinch set
at a right angle to the left when viewed from the press-in direction
(horizontal when viewed from the transmission installation direc-
tion).
NOTE
z Use a bushing replacer to install the bushing.
1st-2nd 99801 Z0001
3rd-4th 99801 Z0002

TM-8-29
 REASSEMBLY MRT23B

POWER SHIFT ASSEMBLY

Key point of reassembly
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-8-30
 REASSEMBLY MRT23B

12.Tube ring
1. Using the insert tool (910-26500) install the tube ring.

2. Using the guide (910-24800) 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.Cylinder boot
Install the boots.
NOTE
z Ensure that the drain hole in the boot faces downward
during installation.

• Functional check
After assembling, apply 736 kPa {7.5 kgf/cm 2, 107 psi} of com-
pressed air to the power shift assembly to ensure that the valve
moves in both the pull and push directions, as well as to the neutral
position. Also check that valve is air-tight. Check the valve's sliding
resistance in the push and pull directions.
Item Specifications
Air-tightness inspection 10 kPa {0.1 kgf/cm 2, 1 psi}, max.
(during non-operation) (pressure drop for 15 seconds)
Air-tightness inspection 49 kPa {0.5 kgf/cm 2, 7 psi}, max.
(during operation) (pressure drop for 15 seconds)
Sliding resistance in shift directions 59 N {6 kgf, 13 lbf}, max.

TM-8-31
 REASSEMBLY MRT23B

MAIN SHAFT ASSEMBLY

Key point of reassembly
z Heat each gear and the following parts in an oil bath and
then assemble them. [Oil temperature: 200 °C (392 °F)]
•Thrust washer
•Tapered bearing
•1st-2nd synchro hub
•Inner race
z Securely attach the main shaft to the construction stand
(99805 Z0000).
NOTE
z Make sure that the construction stand is securely fixed in
place.

30 - 35.3rd-4th gear synchronizer assembly

1. Install the spring, detent and lock plunger on the synchro
hub.
NOTE
z Install the detent while pushing the lock plunger using a
screwdriver.

2. Install the 3rd gear sleeve.

NOTE
z When installing the sleeve, push the detent using a
screwdriver.
z Align the detent with the notch in the sleeve.
(The synchro sleeve must face the specified direction, so
the alignment should be done carefully.)

3. Install the synchro ring.

NOTE
z Ensure the synchro hub is fitted in the groove.

TM-8-32
 REASSEMBLY MRT23B

28.Adjusting spacer
1. Install the tapered bearings into the bore in the drive gear
assembly, then tighten with the drive gear set tool (99806
Z0000).
: 7 N•m {0.7 kgf•m, 5.1 ft•lbf}

2. Measure the bearing-to-bearing end surface distances at

two places in the opposite direction, then determine the
mean value “A” of the two distance measurements.
NOTE
z Before distance measurements, turn the drive gear
assembly two or three complete rotations, then retighten
to 7 N•m {0.7 kgf•m, 5.1 ft•lbf}.

3. Install the tapered bearing and adjusting spacer [21.70 mm

(0.8543 in) thick] to the drive gear setting jig. Measure the
bearing-to-bearing end surface distances at two places in
the opposite direction, then determine the mean value “B”
of the two distance measurements.
: 7 N•m {0.7 kgf•m, 5.1 ft•lbf}

4. Determine the required adjusting spacer thickness “X1”

using the following equation.
X1 = A – B + 21.861
Select the suitable adjusting spacer which is suited to the thick-
ness “X1” from the following chart.
Unit: mm (in)
Spacer thickness 21.45 (0.8445) 21.50 (0.8465) 21.55 (0.8484)
Applicable 21.425 - 21.475 21.476 - 21.525 21.526 - 21.575
X1 range (0.8435 - 0.8455) (0.8455 - 0.8474) (0.8475 - 0.8494)

Unit: mm (in)
Spacer thickness 21.60 (0.8504) 21.65 (0.8524) 21.70 (0.8543)
Applicable 21.576 - 21.625 21.626 - 21.675 21.676 - 21.725
X1 range (0.8494 - 0.8514) (0.8514 - 0.8533) (0.8534 - 0.8553)

TM-8-33
 REASSEMBLY MRT23B

z Measure the main shaft gear end play.

Unit: mm (in)
Maintenance standard Service limit
0.2 - 0.4 (0.008 - 0.016) 0.7 (0.028)

NOTE
z Before measuring the main shaft gear end play, turn the
drive gear two or three rotations.
z A certain amount of end play is allowed for the drive gear
tapered bearing. Check to ensure that the specified
amount of end play is maintained since excessive pre-
load may create a problem.

21.Lock nut (LH thread)

Align the lock nut with the groove on the end of the main shaft, then
clinch securely.

z Reassembling the main shaft sub assembly

1. Install the front case on the transmission rotation block and
set the gear shaft setting plate (99799 Z0003) on the upper
surface of the front case.

2. Using the gear hanger assembly (99783 Z0002), install the

main shaft subassembly on the input shaft.
NOTE
z Carefully raise or lower the main shaft subassembly dur-
ing installation.

TM-8-34
 REASSEMBLY MRT23B

z Adjusting the main drive shaft end play.

NOTE
z Whenever any of the bearings or gears are replaced,
adjust the main drive shaft end play as described below.
z If disassembly does not require replacement of any com-
ponents, install the original shim used before disassem-
bly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the main drive shaft bearing outer race.

2. Install the bearing cap by tightening it at three places as

shown by “ ” in the figure at right.
: 6 N•m {0.6 kgf•m, 4.3 ft•lbf}
NOTE
z After turning the main drive shaft two or three complete
rotations, again tighten the bolts to the specified torque.
z Do not tighten the bolts in excess of the specified torque
under any circumstances.

3. Measure the bearing cap-to-mating surface clearance (at

three places) near the bolt location, and determine the
mean value “E” of the three measurements.
NOTE
z The clearance should be measured with the O-ring
removed.

TM-8-35
 REASSEMBLY MRT23B

4. Determine the required shim thickness “X4” using the fol-

lowing equation, and select a shim whose thickness is
closer to the measured value from those listed in the follow-
ing chart.
Equation: X4 = 3.444 – E
Unit: mm (in)
Shim thickness 1.70 (0.0669) 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740)
1.670 - 1.730 1.731 - 1.790 1.791 - 1.850 1.851 - 1.910
Applicable X4 range
(0.0657 - 0.0681) (0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752)

Unit: mm (in)
Shim thickness 1.94 (0.0764) 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835)
1.911 - 1.970 1.971 - 2.030 2.031 - 2.090 2.091 - 2.150
Applicable X4 range
(0.0752 - 0.0776) (0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846)

Unit: mm (in)
Shim thickness 2.18 (0.0858) 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929)
2.151 - 2.210 2.211 - 2.270 2.271 - 2.330 2.331 - 2.390
Applicable X4 range
(0.0847 - 0.0870) (0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941)

Unit: mm (in)
Shim thickness 2.42 (0.0953) 2.48 (0.0976)
2.391 - 2.450 2.451 - 2.510
Applicable X4 range
(0.0941 - 0.0965) (0.0965 - 0.0988)

z Install the oil seal on the bearing cap, then install the bear-
ing cap, the selected shim and O-ring on the transmission
body as a unit.
: 32 - 42 N•m {3.3 - 4.3 kgf•m, 24 - 31 ft•lbf}
NOTE
z Use liquid gasketed bolts for those marked with “ ” in
the figure at right.
z The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will increase
the preload value, resulting in damage to the bearing.

COUNTERSHAFT ASSEMBLY
Key point of reassembly
z Install the counter splitter gear, counter drive gear, keys,
clip and tapered bearings onto the countershaft.
NOTE
z Heat the gears and bearings in an oil bath before installa-
tion.
Oil bath temperature: Approx. 200°C (392°F)

TM-8-36
 REASSEMBLY MRT23B

SHIFT FORK ASSEMBLY

Key point of reassembly
z Install the fork and shifter to the shift shaft.
NOTE
z Be careful not to confuse the front of the shift fork with
the rear.
z Ensure the setscrew is fitted in the shaft groove, then
clinch at three points.

z Lift the gear assembly using the gear hanger assembly

(99783 Z0002) and hoist, remove the shaft setting tool, then
lower the gear assembly to the inside of the front case.
NOTE
z Be careful not to damage the input shaft oil seal while
raising or lowering the gear assembly.

MIDDLE CASE ASSEMBLY

Key point of reassembly
7.Middle case
1. Apply liquid gasket to the mating surface of the front and
middle cases.

2. Lower the middle case until it is in contact with the front

case.
NOTE
z Set the middle case as level as possible while lowering.
Do not allow guide bushings to catch shift shafts.

3. Tighten the middle case mounting bolts.

: 57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}
NOTE
z Use liquid gasketed bolts for those marked with “ ”
and tighten from the front case side.

TM-8-37
 REASSEMBLY MRT23B

6 Reverse idler gear assembly

Apply liquid gasket to setscrews, then tighten the setscrews.
Whenever any of the bearings or gears are replaced, adjust the
countershaft end play as described below.
NOTE
z If the disassembly does not require replacement of the
components, reuse the original shims which are
removed during disassembly.

5.Side cover
1. Apply liquid gasket to the mounting surface of the transmis-
sion case side cover.

2. Install the PTO gear assembly (if so equipped) or the side

cover.
PTO gear assembly
: 32 - 42 N•m {3.3 - 4.3 kgf•m, 24 - 31 ft•lbf}
Side cover
: 19 - 25 N•m {1.9 - 2.6 kgf•m, 14 - 19 ft•lbf}

•Adjusting the countershaft end play

NOTE
z Whenever any of the bearings or gears are replaced,
adjust the countershaft end play as described below.
z If the disassembly does not require replacement of the
components, reuse the original shims which are
removed during disassembly.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the countershaft rear bearing outer race.

TM-8-38
 REASSEMBLY MRT23B

2. Install the oil pump by tightening the bolts (three places).

: 6 N•m {0.6 kgf•m, 4.3 ft•lbf}
NOTE
z After turning the countershaft two or three complete
rotations, again tighten the bolts to the specified torque.
z Do not tighten the bolts in excess of the specified torque
under any circumstances.

3. Using a thickness gauge, measure the oil pump end sur-

face-to-mating surface clearance near the bolt location at
three points. Determine the mean value “C” of the three
measurements.

4. Determine the required shim thickness “X2” using the fol-

lowing equation, then select the suitable shim from those
listed in the following charts.
Equation: X2 = 3.595 – C
Unit: mm (in)
Shim thickness 1.58 (0.0622) 1.64 (0.0646) 1.70 (0.0669) 1.76 (0.0693)
1.550 - 1.610 1.611 - 1.670 1.670 - 1.730 1.731 - 1.790
Applicable X2 range
(0.0610 - 0.0634) (0.0634 - 0.0657) (0.0657 - 0.0681) (0.0681 - 0.0705)

Unit: mm (in)
Shim thickness 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764) 2.00 (0.0787)
1.791 - 1.850 1.851 - 1.910 1.911 - 1.970 1.971 - 2.030
Applicable X2 range
(0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776) (0.0776 - 0.0799)

Unit: mm (in)
Shim thickness 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858) 2.24 (0.0882)
2.031 - 2.090 2.091 - 2.150 2.151 - 2.210 2.211 - 2.270
Applicable X2 range
(0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870) (0.0870 - 0.0894)

Unit: mm (in)
Shim thickness 2.30 (0.0906) 2.36 (0.0929)
2.271 - 2.330 2.331 - 2.390
Applicable X2 range
(0.0894 - 0.0917) (0.0918 - 0.0941)

TM-8-39
 REASSEMBLY MRT23B

z Install the selected shim, oil strainer and oil pump.

: 57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}
NOTE
z The specified end play of the tapered bearing (when cold)
is 0.20 to 0.30 mm (0.0079 to 0.0118 in). Application of
preload to the tapered bearing (when cold) will inevitably
increase the preload value as the oil temperature
increases, resulting in malfunctioning parts.

1.Bearing retainer
Press the middle case bearing retainer assembly into place
using the bearing retainer replacer (99827 Z0068).
: 57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}

SUB MAIN SHAFT AND SUB COUNTERSHAFT ASSEM-

BLY
Key point of reassembly
20.Range high gear
Tighten the lock nut using the socket wrench (99535 Z0074).
: 686 - 981 N•m {70.0 - 100.0 kgf•m, 506 - 723 ft•lbf}
NOTE
z Lock the lock nuts in the same way as it was before dis-
assembly.
18.Lock washer
Align lock washers with lock bolt holes.
NOTE
z If the lock washer is not aligned with the bolt hole, turn
its top side down or move it to left or right, as required.
z If it is still hard to align, align it while turning the nut in
the direction that tightens.

REAR CASE ASSEMBLY

Key point of reassembly
23.Rear case
1. Apply liquid gasket to the mating surface of the middle and
rear cases.

TM-8-40
 REASSEMBLY MRT23B

2. Install the rear case.

: 57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}

z Tighten the rear case mounting bolts.

Bolt No. : N•m {kgf•m, ft•lbf} mm (in) Remarks
A 85 (3.35)
B 45 (1.77)
57 - 76
{5.8 - 7.7, 42 - 56} Use liquid gasketed
C 45 (1.77)
bolts.
D 95 (3.74)

18 Air cylinder
1. Install the air/oil seal on the air cylinder.
NOTE
z Note the installation direction of the air/oil seal.
z Use an oil seal replacer to install the air/oil seal.
Range side: 99807 Z0004
Splitter side: 99807 Z0005

2. Install the air cylinder via gasket and a pin.

NOTE
z Using a copper hammer, lightly drive the air cylinder into
place.

3. Install the range piston, splitter piston, packing and O-ring.

NOTE
z Apply grease to the mating surfaces of the piston, O-ring
and packing before installation.
z Note the direction of the packing during installation.
4. Install the piston assembly on the range and splitter air cyl-
inders, then tighten the nuts using washers.
: Range side:
137 - 186 N•m {14.0 - 19.0 kgf•m, 101 - 137 ft•lbf}
: Splitter side:
57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}

TM-8-41
 REASSEMBLY MRT23B

NOTE
z Apply grease to the air cylinder inner wall in advance.

5. Install the cylinder cap using the O-ring.

: 32 - 42 N•m {3.3 - 4.3 kgf•m, 24 - 31 ft•lbf}
NOTE
z Use liquid gasketed bolts for those indicated in the figure
at right.

z Adjusting the sub countershaft end play

NOTE
z If disassembly does not require replacement of bearings
or gears, use the original shims installed prior to disas-
sembly.
z Whenever any of the bearings or gears are replaced,
adjust the sub countershaft end play as described below.

<End play adjustment procedure>

1. Install two 2.00 mm (0.0787 in) thick master shims which
are suitable for the sub countershaft rear bearing outer
race.

2. Secure the sub countershaft bearing retainer at three points

as shown in the figure at right.
: 6 N•m {0.6 kgf•m, 4.3 ft•lbf}
NOTE
z After installing the sub countershaft bearing retainer,
turn the sub countershaft by turning the output shaft two
or three rotations, then tighten the retainer bolts again to
the specified torque.
z Do not tighten the bolts in excess of the specified torque.

3. Measure the retainer-to-mating surface clearance (at three

places) near the bolt locations, and determine the mean
value “D” of the three measurements.
NOTE
z The clearance should be measured with the O-ring
removed.
4. Determine the required shim thickness “X3” using the fol-
lowing equation, then select a shim whose thickness is
closer to the value calculated.
Equation: X3 = 3.814 – D

TM-8-42
 REASSEMBLY MRT23B

Unit: mm (in)
Shim thickness 1.76 (0.0693) 1.82 (0.0717) 1.88 (0.0740) 1.94 (0.0764)
1.731 - 1.790 1.791 - 1.850 1.851 - 1.910 1.911 - 1.970
Applicable X3 range
(0.0681 - 0.0705) (0.0705 - 0.0728) (0.0729 - 0.0752) (0.0752 - 0.0776)

Unit: mm (in)
Shim thickness 2.00 (0.0787) 2.06 (0.0811) 2.12 (0.0835) 2.18 (0.0858)
1.971 - 2.030 2.031 - 2.090 2.091 - 2.150 2.151 - 2.210
Applicable X3 range
(0.0776 - 0.0799) (0.0800 - 0.0823) (0.0823 - 0.0846) (0.0847 - 0.0870)

Unit: mm (in)
Shim thickness 2.24 (0.0882) 2.30 (0.0906) 2.36 (0.0929) 2.40 (0.0945)
2.211 - 2.270 2.271 - 2.330 2.331 - 2.390 2.391 - 2.450
Applicable X3 range
(0.0870 - 0.0894) (0.0894 - 0.0917) (0.0918 - 0.0941) (0.0941 - 0.0965)

z Install a selected shim and the O-ring, then install the sub
countershaft bearing retainer.
: 57 - 76 N•m {5.8 - 7.7 kgf•m, 42 - 56 ft•lbf}
NOTE
z The specified end play of the tapered bearing (when cold)
is 0.05 to 0.15 mm (0.0020 to 0.0059 in). Application of
preload to a cold tapered bearing will inevitably increase
the preload value as the oil temperature increases, which
results in damage to the bearing.

5. Speedometer drive gear

Install the speedometer drive gear onto the output shaft.
NOTE
z Note the installation direction of the drive gear.

TRANSMISSION ASSEMBLY
Key point of reassembly
z Press the bushing into the bore in the control cover with the
clinch facing downward.
NOTE
z Use a bushing replacer (99801 Z0003) to install the bush-
ing.

TM-8-43
 REASSEMBLY MRT23B

z Tighten the lock nut using the socket wrench (99535

Z0074).
: 686 - 981 N•m {70.0 - 100.0 kgf•m, 506 - 723 ft•lbf}
NOTE
z Lock the lock nut in the same way as it was before disas-
sembly.

z Align the lock nut flat surfaces with the grooves on the
shaft, then clinch the nut.

INSTALLATION
Key point of installation
1. Using a transmission jack and wire, install the transmission
in the vehicle.
Be sure to align the main drive shaft with the clutch disc at
their splines.
2. Install the propeller shaft transmission linkage, cable, wir-
ing, PTO (when equipped), clutch booster, etc., in their orig-
inal positions.

TM-8-44
 TRANSMISSION PTO

CONTENTS
SERVICE DATA.................................... TM- 1 REMOVAL ........................................TM- 6
SPECIFICATIONS............................ TM- 1 DISASSEMBLY.................................TM- 6
SERVICE DATA................................ TM- 2 INSPECTION ....................................... TM-10
TIGHTENING TORQUE ................... TM- 3 REASSEMBLY .................................... TM-13
SYSTEM DIAGRAM ......................... TM- 3 REASSEMBLY.................................TM-13
CONSTRUCTION ................................. TM- 4 INSTALLATION................................TM-13
DISASSEMBLY .................................... TM- 6
 SERVICE DATA PTO

SERVICE DATA
SPECIFICATIONS
PTO output torque/Engine speed Number of gear teeth Transmission
Type PTO ratio
N·m {kgf·m, ft·lbf} /rpm a b c d e model
l 1.133 21 34 20 28 14 MPS50A
MTS60A,
1.214 25 43
II MTS60B
1.140 26 42 MTS60D
17 24 12
Air shift 294 {30, 217} /1,000 1.214 25 43 MTS70A
III 1.113 26 41 MTP00B
0.924 29 38 MTP00C
High 0.965 34 35
IV 16 25 15 MRT23B
Low 1.189 26 33

PTO IN OPERATION

TM-1
 SERVICE DATA PTO

SERVICE DATA
Unit: mm (in)
Service Application
Item Maintenance standard Remarks
limit l ll III IV
0.15 - 0.25 0.5
O O O —
Gear Idler gear - (0.0059 - 0.0098) (0.020)
backlash PTO gear 0.10 - 0.20 0.5
— — — O
(0.0039 - 0.0079) (0.020)
0.20 - 0.40 0.7
PTO gear end play — — — O
(0.0079 - 0.0157) (0.028)
Clearance between air cylin- 0.08 - 0.15 0.2
O O O —
der and piston (0.0031 - 0.0059) (0.008)
Radial play between PTO 0.07 - 0.14 0.3
O O O —
shaft and PTO gear spline (0.0028 - 0.0055) (0.012)
Radial play between PTO 0.20 - 0.30 0.5
— — — O
shaft and sleeve spline (0.0079 - 0.0118) (0.020)
Radial play between clutch
0.40 - 0.50 1.0
gear (PTO gear) and sleeve — — — O
(0.0157 - 0.0197) (0.039)
spline
0.02 - 0.07 0.2
O O O —
Clearance between PTO (0.0008 - 0.0028) (0.008)
case and shift shaft 0.04 - 0.10 0.2
— — — O
(0.0016 - 0.0039) (0.008)
Clearance between shift fork 0 - 0.05 0.2
O O O —
and shift shaft (0 - 0.0020) (0.008)
Clearance between shift fork 0.10 - 0.30 1.0
O O O —
and PTO gear (0.0039 - 0.0118) (0.039)
Clearance between shift fork 0.10 - 0.30 1.0
— — — O
and sleeve (0.0039 - 0.0118) (0.039)
80.0
Free length —
(3.150)
When com- O O O —
Tension 186 - 226 147
pressed to 39
N {kgf, lbf} {19 - 23, 42 - 51} {15, 33}
Return mm (1.54 in)
spring 78.5
Free length —
(3.091)
When com- — — — O
Tension 111.8 - 137.3
— pressed to 37
N {kgf, lbf} {11.4 - 14.0, 25.1 - 30.9}
mm (1.46 in)
Ball bearing axial direction 0.5
— One side O O O —
play (0.020)

TM-2
 SERVICE DATA PTO

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
l ll III IV
46 - 62 {4.7 - 6.3, 34 - 46} O O O —
PTO gear box mounting bolt
32 - 42 {3.3 - 4.3, 24 - 31} — — — O
Companion flange mounting nut 98 - 147 {10.0 - 15.0, 72 - 108} O O O O
Front bearing cover mounting bolts 16 - 21 {1.6 - 2.1, 12 - 15} O O O —
Rear bearing cover mounting bolts 16 - 21 {1.6 - 2.1, 12 - 15} O O O —
Support mounting bolts 16 - 21 {1.6 - 2.1, 12 - 15} — — — O
Air cylinder mounting bolts 4.0 - 5.4 {0.41 - 0.55, 3.0 - 4.0} O O O —
Shift fork setscrew 57 - 76 {5.8 - 7.7, 42 - 56} O O O —
Oil catcher mounting bolts 11 - 13 {1.1 - 1.3, 8 - 9} — — — O
Switch 34 - 39 {3.5 - 4.0, 25 - 29} O O O O

SYSTEM DIAGRAM

TM-3
 CONSTRUCTION PTO

CONSTRUCTION
Type I

Type II

TM-4
 CONSTRUCTION PTO

Type III

Type IV

TM-5
 DISASSEMBLY PTO

DISASSEMBLY
REMOVAL
Key point of removal
z Measure and record the backlash of the reverse idler gear
and PTO gear.

DISASSEMBLY
Type I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Switch 10. Oil seal 19. Gasket
2. Steel ball 11. Front bearing cover 20. Cylinder
3. Flange nut 12. Gasket 21. Piston
4. Lock washer 13. Rear ball bearing 22. X-ring
5. Tab 14. Front ball bearing 23. Set screw
6. Companion flange 15. PTO gear 24. Shift folk
7. Key 16. PTO shaft 25. Shift shaft
8. Rear bearing cover 17. Plug 26. Return spring
9. Gasket 18. Cylinder cap 27. PTO case

TM-6
 DISASSEMBLY PTO

Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Switch 11. Front bearing cover 20. Gasket
2.Steel ball 12. Gasket 21. Cylinder
3.Flange nut 13. Bearing 22. Piston
4.Lock washer 14. Washer 23. X-ring
5.Tab 15. Bearing 24. Set screw
6.Companion flange 16. PTO gear 25. Shift folk
7.Key 17. PTO shaft 26. Shift shaft
8.Rear bearing cover 18. Plug 27. Return spring
9.Gasket 19. Cylinder cap 28. PTO case
10.Oil seal

TM-7
 DISASSEMBLY PTO

Type III

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Switch 11.Support 21.Cylinder cap
2.Steel ball 12.Gasket 22.Gasket
3.Flange nut 13.Front bearing cover 23.Piston
4.Lock washer 14.Gasket 24.X-ring
5.Tab 15.Bearing 25.Cylinder
6.Companion flange 16.Washer 26.Set screw
7.Key 17.Bearing 27.Shift folk
8.Oil seal 18.PTO gear 28.Return spring
9.Retaining ring 19.PTO shaft 29.Shift shaft
10.Bearing 20.Plug 30.PTO case

TM-8
 DISASSEMBLY PTO

Type IV

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Switch 12. O-ring 23. PTO gear
2. Steel ball 13. Plug 24. Needle bearing
3. Flange nut 14. Shift shaft 25. Spacer
4. Lock washer 15. Spring guide 26. Needle bearing
5. Tab 16. Return spring 27. PTO shaft
6. Companion flange 17. Shift folk 28. Bearing outer race
7. Key 18. Air seal 29. Bearing outer race
8. Bearing retainer 19. Bearing inner race 30. Oil seal
9. O-ring 20. Sleeve 31. Oil catcher
10. O-ring 21. Bearing inner race 32. PTO case
, 11. Shim 22. Cone
Marks “+” and “,” indicate that the key points of operation are explained in the text.

TM-9
 INSPECTION PTO

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Gear backlash (Idler gear - PTO gear)

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)
Type III
Type IV 0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)

PTO gear end play

Unit: mm (in)
Item Maintenance standard Service limit
Type IV 0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

Clearance between air cylinder and piston

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type lI 0.08 - 0.15 (0.0031 - 0.0059) 0.2 (0.008)
Type III

Radial play between PTO shaft and PTO gear spline

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type lI 0.07 - 0.14 (0.0028 - 0.0055) 0.3 (0.012)
Type III

TM-10
 INSPECTION PTO

Radial play between PTO shaft and sleeve spline

Unit: mm (in)
Item Maintenance standard Service limit
Type IV 0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Radial play between clutch gear (PTO gear) and sleeve

spline
Unit: mm (in)
Item Maintenance standard Service limit
Type IV 0.40 - 0.50 (0.0157 - 0.0197) 1.0 (0.039)

Clearance between PTO case and shift shaft

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 0.02 - 0.07 (0.0008 - 0.0028) 0.2 (0.008)
Type III
Type IV 0.04 - 0.10 (0.0016 - 0.0039) 0.2 (0.008)

Clearance between shift fork and shift shaft

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 0 - 0.05 (0 - 0.0020) 0.2 (0.008)
Type III

Clearance between shift fork and PTO gear

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 0.10 - 0.30 (0.0039 - 0.0118) 1.0 (0.039)
Type III

TM-11
 INSPECTION PTO

Clearance between shift fork and sleeve

Unit: mm (in)
Item Maintenance standard Service limit
Type IV 0.10 - 0.30 (0.0039 - 0.0118) 1.0 (0.039)

Return spring free length

Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 80.0 (3.150) —
Type III
Type IV 78.5 (3.091) —

Return spring tension

Unit: N {kgf, lbf}
Item Maintenance standard Service limit Remarks
Type I
186 - 226 When compressed to
Type II 147 {15, 33}
{19 - 23, 42 - 51} 39 mm (1.54 in)
Type III
111.8 - 137.3 When compressed to
Type IV —
{11.4 - 14.0, 25.1 - 30.9} 37 mm (1.46 in)

Ball bearing axial direction play

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Type I
Type II — 0.5 (0.020) One side
Type III

TM-12
 REASSEMBLY PTO

REASSEMBLY
REASSEMBLY
Key point of reassembly
11 Shim (Type lV)
Select the shims and install them so that they protrude beyond the
PTO case end surface by 0.19 to 0.33 mm (0.0075 to 0.0130 in).
The thickness of the shims are 1.4, 1.5, 1.6 and 1.7 mm (0.055,
0.059, 0.063 and 0.067 in).
z Measure the PTO gear end play. (Type IV only)
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.40 (0.0079 - 0.0157) 0.7 (0.028)

INSTALLATION
Key point of installation
z Measure and record the backlash of the reverse idler gear
and PTO gear.
Unit: mm (in)
Item Maintenance standard Service limit
Type I
Type II 0.15 - 0.25 (0.0059 - 0.0098) 0.5 (0.020)
Type III
Type IV 0.10 - 0.20 (0.0039 - 0.0079) 0.5 (0.020)

z Test air tightness and operating load. Pour soapy water

over the connections of the air cylinder. Apply an air pres-
sure of 490 to 785 kPa {5.0 to 8.0 kgf/cm2, 71 to 114 psi} to
the connections to check for signs of leakage. Also check
the air shift mechanism for smooth movement.
NOTE
z Perform this test 30 minutes or more after the air cylinder
has been installed.

TM-13
 TRANSMISSION CONTROL LINKAGE

CONTENTS
SERVICE DATA..................................... TM-1 REASSEMBLY ...................................... TM-1
TIGHTENING TORQUE .................... TM-1 INSTALLATION..................................TM-1
SYSTEM DIAGRAM .......................... TM-1
DISASSEMBLY ..................................... TM-1
REMOVAL ......................................... TM-1
 SERVICE DATA T/M LINKAGE

SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Self-locking nut 34 {3.5, 25}
Shift lever mounting nut 93 {9.5, 69}

SYSTEM DIAGRAM
TRANSMISSION CONTROL SYSTEM
R.H.D. model

TM-1
 SERVICE DATA T/M LINKAGE

L.H.D. model

TM-2
 DISASSEMBLY T/M LINKAGE

DISASSEMBLY
REMOVAL
FRONT SIDE LINKAGE
R.H.D. model

1.Shift knob , 7.Shift rod assembly (No.1) 13.Shift lever assembly (No.1)
2.Boot 8.Return spring 14.Self-locking nut
3.Boot 9.Self-locking nut 15.Self-locking nut
4.Boot base 10.Self-locking nut 16.Select rod assembly (No.2)
5.Self-locking nut , 11.Select rod assembly (No.1) 17.Select lever assembly (No.1)
6.Self-locking nut 12.Lever complete 18.Select lever assembly (No.2)
Marks “+” and “,” indicate that the key points of operation are explained in the text.
NOTE

z Numbers before part names do not indicate the disassembly sequence

TM-3
 DISASSEMBLY T/M LINKAGE

L.H.D model

1.Shift knob 8.Self-locking nut 15.Self-locking nut

2.Boot 9.Shift lever bracket assembly 16.Self-locking nut
3.Boot 10.Journal assembly , 17.Select rod assembly (No.1)
4.Boot base 11.Boot 18.Select lever assembly (No.1)
5.Self-locking nut 12.Ball seat 19.Control lever assembly
6.Self-locking nut 13.Shift lever assembly (No.1) 20.Control lever
7.Shift rod assembly (No.1) 14.Return spring 21.Ball joint assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.
NOTE

z Numbers before part names do not indicate the disassembly sequence

TM-4
 DISASSEMBLY T/M LINKAGE

REAR SIDE LINKAGE

1.Self-locking nut 11.Self-locking nut 18.Select lever assembly

2.Self-locking nut 12.Self-locking nut (No.4 or No.3)
, 3.Shift rod assembly (No.2) , 13.Select rod assembly 19.Self-locking nut
4.Self-locking nut (No.4 or No.3) 20.Select lever
5.Self-locking nut 14.Select lever assembly 21.Self-locking nut
, 6.Shift rod assembly (No.3) (No.3 or No.2) 22.Self-locking nut
7.Shift lever assembly (No.2) 15.Self-locking nut , 23.Shift rod assembly (No.4)
8.Self-locking nut 16.Self-locking nut 24.Shift lever assembly (No.3)
9.Self-locking nut 17.Select rod assembly 25.Self-locking nut
10.Select rod assembly (No. 5 or No.4) 26.Push joint
(No.3 or No.2)
Marks“  ” and “  ” indicate that the key points of operation are explained in the text.
NOTE

z Numbers before part names do not indicate the disassembly sequence

TM-5
 DISASSEMBLY T/M LINKAGE

SHIFT LEVER ASSEMBLY (NO. 3)

1.Clamp 6.Clamp 10.Ball stud

2.Ball seat boot 7.Retaining ring 11.Ball seat
3.Ball stud 8.Cross bracket 12.Retaining ring
4.Ball seat 9.Ball seat boot 13.Control lever
5.Clip

NOTE

z Numbers before part names do not indicate the disassembly sequence

TM-6
 REASSEMBLY T/M LINKAGE

REASSEMBLY
INSTALLATION
LENGTH OF CONTROL RODS
R.H.D. model
Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4 5
585
MTS60A (23.03)
414.5 θ=-135° 1,437 255.5
(16.32) (56.57) (10.06)
MTP00B 578
θ=90° θ=180° θ=90°
(22.76)
MTP00C
θ=-135°
550 1,852 446
Fuller RTX11609A 475 370.5 1,245 (21.65) 520 374 (72.91) (17.56)
CKB450 θ=90° θ=180° θ=180°
(18.70) (14.59) (49.02) (20.47) (14.72)
BTNA
MTS60A with power θ=-90° θ=0° θ=-90° θ=0° θ=90°
shift 585
MTS70A with power (23.03)
shift 290.5 θ=-135° 1,437 255.5
(11.42) (56.57) (10.06)
MTP00B with power
θ=90° θ=180° θ=90°
shift
MTP00C with power
shift
360
MTS60A (14.17)
1,437 239
θ=90°
(56.57) (9.41)
475 370.5 1,245 235.5 585 520 374
CKB450 MTS60A with power θ=180° θ=90°
(18.70) (14.59) (49.02) (9.27) (23.03) (20.47) (14.72)
BTNT shift
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90°
Fuller RTX11609A 544.5 1,852 446
(21.44) (72.91) (17.56)
Fuller RTX11715
θ=90° θ=180° θ=180°
Fuller RT011613 475 370.5 1,245 550 585 520 374 1,852 446
CKB450
(18.70) (14.59) (49.02) (21.65) (23.03) (20.47) (14.72) (72.91) (17.56)
CTNA Fuller RT11609A
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
Fuller RT011613 475 370.5 1,245 544.5 585 520 374 1,852 446
CKB450
(18.70) (14.59) (49.02) (21.44) (23.03) (20.47) (14.72) (72.91) (17.56)
CTNT Fuller RT11609A θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
360
MTS60A (14.17)
475 370.5 1,240 585 520 374 1,437 239
CKB450 θ=90°
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (56.57) (9.41)
EDN 235.5
MTS60A with power θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=90°
(9.27)
shift
θ=90°
405
MTS60A (15.94)
475 370.5 1,240 585 520 374 1,482 239
CKB450 θ=90°
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (58.35) (9.41)
EMN 280.5
MTS60A with power θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=90°
(11.04)
shift
θ=90°
350.5 578
MPS50A (13.80) (22.76)
CKB450 θ=90° θ=-135°
FHN 475 370.5 1,240 360 520 374 1,437 239
FLN MTS60A (18.70) (14.59) (48.82) (14.17) (20.47) (14.72) (56.57) (9.41)
585
LHN θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=90°
NHH (23.03)
235.5 θ=-135°
MTS60A with power
(9.27)
shift
θ=90°

TM-7
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4 5
475 370.5 1,245 380 585 520 374 1,470 389
CKB453 MRT20A with power
(18.70) (14.59) (49.02) (14.96) (23.03) (20.47) (14.72) (57.87) (15.31)
BTNB shift
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=90°
377
MTS60A (14.84)
θ=110°
256 1,188 234.5
MTS60A with power (46.77) (9.23)
(10.07)
shift 475 370.5 985 585 520 374
θ=110° θ=180° θ=90°
CKB520BTN (18.70) (14.59) (38.78) (23.03) (20.47) (14.72)
θ=-90° θ=0° θ=-90° 260.5 θ=-135° θ=0° θ=90°
MTS70A with power
(10.26)
shift
θ=110°
561.5 1,597.5 446
Fuller RTX11609A (22.11) (62.89) (17.56)
θ=110° θ=180° θ=180°
377
MTS60A (14.84)
θ=110° 1,188 234.5
(46.77) (9.23)
475 370.5 985 256 585 520 374 θ=180° θ=90°
MTS60A with power
CKB533BTN (18.70) (14.59) (38.78) (10.07) (23.03) (20.47) (14.72)
shift
θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90°
398 1,217 389
MRT20A with power
(15.67) (47.91) (15.31)
shift
θ=110° θ=180° θ=90°
360
CWB450 MTS60A (14.17)
HDNT θ=90° 1,437 239
PHNT (56.57) (9.41)
475 370.5 1,240 235.5 585 520 374
PLNT MTS60A with power θ=180° θ=90°
(18.70) (14.59) (48.82) (9.27) (23.03) (20.47) (14.72)
SHNT shift
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90°
HDNA
PHNA Fuller RTX11609A 544.5 1,846.5 446
SHNA (21.44) (72.70) (17.56)
Fuller RTX11609B
θ=90° θ=180° θ=180°
405
MTS60A (15.94)
θ=90° 1,482 239
(58.35) (9.41)
CWB450 475 370.5 1,240 280.5 585 520 374
MTS60A with power θ=180° θ=90°
HMNT (18.70) (14.59) (48.82) (11.04) (23.03) (20.47) (14.72)
shift
HMNA θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90°
Fuller RTX11609A 589 1,891 446
(23.19) (74.45) (17.56)
Fuller RTX11609B
θ=90° θ=180° θ=180°
380 1,463 389
MRT20A with power
(14.96) (57.60) (15.31)
shift 475 370.5 1,240 585 520 374
CWB450 θ=90° θ=180° θ=90°
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72)
HTNB Fuller RTX11609B 550 1,846.5 446
θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90°
(21.65) (72.70) (17.56)
Fuller RT11715
θ=90° θ=180° θ=180°
Fuller RT11715 475 370.5 1,240 544.5 585 520 374 1,846.5 446
CWB450
(18.70) (14.59) (48.82) (21.44) (23.03) (20.47) (14.72) (72.70) (17.56)
KTNB Fuller RTO11613 θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
Fuller RTX11609B 475 370.5 1,240 550 585 520 374 1,846.5 446
CWB450
(18.70) (14.59) (48.82) (21.65) (23.03) (20.47) (14.72) (72.70) (17.56)
PPNA Fuller RT11715
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
475 370.5 1,240 550 585 520 374 1,846.5 446
CWB450
Fuller RT11715 (18.70) (14.59) (48.82) (21.65) (23.03) (20.47) (14.72) (72.70) (17.56)
PPNB
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°

TM-8
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4 5
Fuller RTX11609A 544.5 1,846.5
Fuller RTO11613 (21.44) (72.70)
Fuller RT11715 θ=90° θ=180°
CWB450 Fuller RT11609A 475 370.5 1,240 585 520 374 446
KTNT with engine rear PTO (18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (17.56)
KTNA θ=-90° θ=0° θ=-90° 589 θ=-135° θ=0° θ=90° 1,891 θ=180°
Fuller RTO11613
(23.19) (74.45)
with engine rear PTO
θ=90° θ=180°
Fuller RT11715
with engine rear PTO
CWB450 Fuller RTX11609B
475 370.5 1,240 544.5 585 520 374 1,846.5 446
PPNT
(18.70) (14.59) (48.82) (21.44) (23.03) (20.47) (14.72) (72.70) (17.56)
HTNT Fuller RT11715
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
HTNA
550
Fuller RT11715 (21.65)
475 370.5 1,240 θ=90° 585 520 374 1,846.5 446
CWB451
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (72.70) (17.56)
KTNB 594
Fuller RT11715 θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=180°
(23.39)
with engine rear PTO
θ=90°
544.5
Fuller RT11715 (21.44)
475 370.5 1,240 585 520 374 1,846.5 446
CWB451 θ=90°
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (72.70) (17.56)
KTNT 589
Fuller RT11715 θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=180°
(23.19)
with engine rear PTO
θ=90°
Fuller RT11715 475 370.5 1,240 544.5 585 520 374 1,846.5 446
CWB452
Fuller RTO11613 (18.70) (14.59) (48.82) (21.44) (23.03) (20.47) (14.72) (72.70) (17.56)
HTNB
Fuller RT11609A θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=180°
Fuller RTX11609A 544.5 1,846.5
Fuller RTO11613 (21.44) (72.70)
Fuller RT11715 θ=90° θ=180°
Fuller RT11609A 475 370.5 1,240 585 520 374 446
CWB452
with engine rear PTO (18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (17.56)
HTNT 589 1,891
Fuller RTO11613 θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180°
(23.19) (74.45)
with engine rear PTO
θ=90° θ=180°
Fuller RT11715
with engine rear PTO
475 370.5 1,240 380 585 520 374 1,463 389
CWB453 MRT20A
(18.70) (14.59) (48.82) (14.96) (23.03) (20.47) (14.72) (57.60) (15.31)
HTNB with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=-135° θ=0° θ=90° θ=180° θ=90°
377
MTS60A (14.84)
CWB520 985 1,188 234.5
θ=110°
HDN (38.78) (46.77) (9.23)
475 370.5 256 585 520 374
HMN MTS60A θ=-90° θ=180° θ=90°
(18.70) (14.59) (10.08) (23.03) (20.47) (14.72)
PHN with power shift
θ=-90° θ=0° θ=110° θ=-135° θ=0° θ=90°
PLN
SHN 981.5 561.5 1,597.5 446
Fuller RTX11609A (38.64) (22.11) (62.89) (17.56)
θ=-90° θ=110° θ=180° θ=180°
985 260.5 578 1,188 234.5
MTP00B
(38.78) (10.26) (22.76) (46.77) (9.23)
with power shift 475 370.5 520 374
CWB520 θ=-90° θ=110° θ=-135° θ=180° θ=90°
(18.70) (14.59) (20.47) (14.72)
HTN Fuller RTX11609A 981.5 561.5 585 1,597.5 446
θ=-90° θ=0° θ=0° θ=90°
(38.64) (22.11) (23.03) (62.89) (17.56)
Fuller RTX11609B θ=-90° θ=110° θ=-135° θ=180° θ=180°
Fuller RTX11609B 475 370.5 981.5 561.5 585 520 374 1,597.5 446
CWB520
(18.70) (14.59) (38.64) (22.11) (23.03) (20.47) (14.72) (62.89) (17.56)
PPN Fuller RT11715
θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90° θ=180° θ=180°

TM-9
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4 5
377
MTS60A (14.84)
CWB520 475 370.5 985 585 520 374 1,188 234.5
θ=110°
LDN (18.70) (14.59) (38.78) (23.03) (20.47) (14.72) (46.77) (9.23)
LMN θ=-90° θ=0° θ=-90° 256 θ=-135° θ=0° θ=90° θ=180° θ=90°
MTS60A
(10.08)
with power shift
θ=110°
398 1,217 389
MRT20A
(15.67) (47.91) (15.31)
with power shift 475 370.5 981.5 585 520 374
CWB533 θ=110° θ=180° θ=90°
(18.70) (14.59) (38.64) (23.03) (20.47) (14.72)
HTN 561.5 1,597.5 446
θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90°
Fuller RTX11609B (22.11) (62.89) (17.56)
θ=110° θ=180° θ=180°
377
CWB533 MTS60A (14.84)
475 370.5 981.5 585 520 374 1,188 234.5
LDN θ=110°
(18.70) (14.59) (38.64) (23.03) (20.47) (14.72) (46.77) (9.23)
LMN 256
MTS60A θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=90°
PHN (10.08)
with power shift
θ=110°
Fuller RT11609A 544.5 1,846.5
(21.44) (72.70)
Fuller RTO11613
CGB450 475 370.5 1,240 θ=90° 585 520 374 θ=180° 446
THNA Fuller RT11609A (18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (17.56)
UHNA with engine rear PTO θ=-90° θ=0° θ=-90° 589 θ=-135° θ=0° θ=90° 1,891 θ=180°
(23.19) (74.45)
Fuller RTO11613
θ=90° θ=180°
with engine rear PTO
550
Fuller RT11715 (21.65)
475 370.5 1,240 θ=90° 585 520 374 1,846.5 446
CGB450
(18.70) (14.59) (48.82) (23.03) (20.47) (14.72) (72.70) (17.56)
TPNB 594
Fuller RT11715 θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=180°
(23.39)
with engine rear PTO
θ=90°
475 370.5 981.5 561.5 585 520 374 1,597.5 446
CGB520
Fuller RT11609A (18.70) (14.59) (38.64) (22.11) (23.03) (20.47) (14.72) (62.89) (17.56)
UHN
θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90° θ=180° θ=180°
Fuller RTX11609B 475 370.5 981.5 561.5 585 520 374 1,597.5 446
CGB520
(18.70) (14.59) (38.64) (22.11) (23.03) (20.47) (14.72) (62.89) (17.56)
UPN Fuller RT11715 θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90° θ=180° θ=180°
382
MTP00B (15.04)
475 370.5 985 θ=110° 578 520 374 1,188 234.5
CGB520
(18.70) (14.59) (38.78) (22.76) (20.47) (14.72) (46.77) (9.23)
SMN 260.5
MTP00B θ=-90° θ=0° θ=-90° θ=-135° θ=0° θ=90° θ=180° θ=90°
(10.26)
with power shift
θ=110°
398 1,217 389
MRT20A
(15.67) (47.91) (15.31)
with power shift
θ=110° θ=180° θ=90°
475 370.5 981.5 377 585 520 374
CGB533
MTS60A (18.70) (14.59) (38.64) (14.84) (23.03) (20.47) (14.72)
SMN 1,188 234.5
θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90°
(46.77) (9.23)
256 θ=180° θ=90°
MTS60A
(10.08)
with power shift
θ=110°

TM-10
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4 5
382
MTP00B (15.04)
985 578 1,188 234.5
θ=110°
(38.78) (22.76) (46.77) (9.23)
475 370.5 260.5 520 374
CGB520 MTP00B θ=-90° θ=-135° θ=180° θ=90°
(18.70) (14.59) (10.26) (20.47) (14.72)
THN with power shift
θ=-90° θ=0° θ=110° θ=0° θ=90°
981.5 561.5 585 1,597.5 446
Fuller RTX11609A (38.64) (22.11) (23.03) (62.89) (17.56)
θ=-90° θ=110° θ=-135° θ=180° θ=180°
475 370.5 981.5 398 585 520 374 1,217 389
CGB533 MRT20A
(18.70) (14.59) (38.64) (15.67) (23.03) (20.47) (14.72) (47.91) (15.31)
THN with power shift
θ=-90° θ=0° θ=-90° θ=110° θ=-135° θ=0° θ=90° θ=180° θ=90°

TM-11
 REASSEMBLY T/M LINKAGE

L.H.D. model
Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4
MTS60D
290.5 1,437 255.5
with power shift
(11.42) (56.57) (10.06)
MTS70A 475 370.5 1,245 θ=90° 520 374 θ=180° θ=90°
CKB450 with power shift (18.70) (14.59) (49.02) (20.47) (14.72)
BTLB
θ=-90° θ=0° θ=-90° 380 θ=0° θ=90° 1,470 389
MRT20A
(14.96) (57.87) (15.31)
with power shift
θ=90° θ=180° θ=90°
256
MTS60B
(10.07)
with power shift 1,188 234.5
θ=110°
(46.77) (9.23)
475 370.5 985 260.5 520 374 θ=180° θ=90°
CKA530 MTS70A
(18.70) (14.59) (38.78) (10.26) (20.47) (14.72)
BTL with power shift
θ=-90° θ=0° θ=-90° θ=110° θ=0° θ=90°
398 1,217 389
MRT20A
(15.67) (47.91) (15.31)
with power shift
θ=110° θ=180° θ=90°
360
MTS60A (14.17)
1,437 255.5
θ=90°
(56.57) (10.06)
475 370.5 1,245 290.5 520 374
CKB450 MTS60A θ=180° θ=90°
(18.70) (14.59) (49.02) (11.42) (20.47) (14.72)
BTLA with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
544.5 1,852 446
Fuller RTX11609A (21.44) (72.91) (17.56)
θ=90° θ=180° θ=180°
360
MTS60A (14.17)
1,437 239
θ=90°
(56.57) (9.41)
475 370.5 1,245 235.5 520 374
CKB450 MTS60A θ=180° θ=90°
(18.70) (14.59) (49.02) (9.27) (20.47) (14.72)
BTLT with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
544.5 1,852 446
Fuller RTX11609A (21.44) (72.91) (17.56)
θ=90° θ=180° θ=180°
360
MTS60A (14.17)
475 370.5 1,240 520 374 1,437 239
CKB450 θ=90°
(18.70) (14.59) (48.82) (20.47) (14.72) (56.57) (9.41)
EDL 235.5
MTS60A θ=-90° θ=0° θ=-90° θ=0° θ=90° θ=180° θ=90°
(9.27)
with power shift
θ=90°
405
MTS60A (15.94)
475 370.5 1,240 520 374 1,482 239
CKB450 θ=90°
(18.70) (14.59) (48.82) (20.47) (14.72) (58.35) (9.41)
EML 280.5
MTS60A θ=-90° θ=0° θ=-90° θ=0° θ=90° θ=180° θ=90°
(11.04)
with power shift
θ=90°
350.5
MPS50A (13.80)
θ=90°
360 1,437 239
MTS60A (14.17) (56.57) (9.41)
CKB450 475 370.5 1,240 θ=90° 520 374 θ=180° θ=90°
FHL (18.70) (14.59) (48.82) (20.47) (14.72)
235.5
FLL MTS60A θ=-90° θ=0° θ=-90° θ=0° θ=90°
(9.27)
with power shift
θ=90°
544.5 1,846.5 446
Fuller RTX11609B (21.44) (72.70) (17.56)
θ=90° θ=180° θ=180°

TM-12
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4
350.5
MPS50A (13.80)
θ=90°
CKB450 475 370.5 1,240 360 520 374 1,437 239
LHL MTS60A (18.70) (14.59) (48.82) (14.17) (20.47) (14.72) (56.57) (9.41)
NHL θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=90°
235.5
MTS60A
(9.27)
with power shift
θ=90°
475 370.5 1,240 544.5 520 374 1,846.5 446
CKB450
Fuller RTX11609A (18.70) (14.59) (48.82) (21.44) (20.47) (14.72) (72.70) (17.56)
LPL
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=180°
475 370.5 1,240 550 520 374 1,852 446
CKB450
Fuller RTX11609A (18.70) (14.59) (48.82) (21.65) (20.47) (14.72) (72.91) (17.56)
LPLA
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=180°
377
MTS60A (14.84)
θ=110° 1,188 234.5
(46.77) (9.23)
475 370.5 985 256 520 374
CKB520 MTS60A θ=180° θ=90°
(18.70) (14.59) (38.78) (10.07) (20.47) (14.72)
BTL with power shift
θ=-90° θ=0° θ=-90° θ=110° θ=0° θ=90°
561.5 1,597.5 446
Fuller RTX11609A (22.11) (62.89) (17.56)
θ=110° θ=180° θ=180°
414.5
MTS60A (16.32)
1,482 255.5
θ=90°
(58.35) (10.06)
475 370.5 1,240 290.5 520 374 θ=180° θ=90°
CKC450 MTS60A
(18.70) (14.59) (48.82) (11.42) (20.47) (14.72)
DTLA with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
544.5 1,846.5 446
Fuller RTX11609A (21.44) (72.70) (17.56)
θ=90° θ=180° θ=180°
360
MTS60A (14.17)
1,482 239
θ=90°
(58.35) (9.41)
CKC450 475 370.5 1,240 235.5 520 374 θ=180° θ=90°
MTS60A
FDLT (18.70) (14.59) (48.82) (9.27) (20.47) (14.72)
with power shift
NHLT θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
544.5 1,846.5 446
Fuller RTX11609A (21.44) (72.70) (17.56)
θ=90° θ=180° θ=180°
235.5
MTS60B
(9.27)
CDA450 with power shift 475 370.5 1,240 520 374 1,437 239
θ=90°
RHHA (18.70) (14.59) (48.82) (20.47) (14.72) (56.57) (9.41)
240.5
THHA MTS70A θ=-90° θ=0° θ=-90° θ=0° θ=90° θ=180° θ=90°
(9.45)
with power shift
θ=90°
377
CWA520 MTS60A (14.84)
HDM 475 370.5 981.5 θ=110° 520 374 1,188 234.5
HMH (18.70) (14.59) (38.64) (20.47) (14.72) (46.77) (9.23)
PHH θ=-90° θ=0° θ=-90° 256 θ=0° θ=90° θ=180° θ=90°
MTS60A
VHH (10.07)
with power shift
θ=110°
CWA530
HDH 475 370.5 981.5 256 520 374 1,188 234.5
MTS60A
HMH (18.70) (14.59) (38.64) (10.07) (20.47) (14.72) (46.77) (9.23)
with power shift
PHH θ=-90° θ=0° θ=-90° θ=110° θ=0° θ=90° θ=180° θ=90°
SHH

TM-13
 REASSEMBLY T/M LINKAGE

Unit: mm (in)
Shift Select
Model Transmission model Remarks
1 2 3 4 1 2 3 4
360
CWB450 MTS60A (14.17)
HDLT 1,437 239
θ=90°
PHLT (56.57) (9.41)
475 370.5 1,240 233.5 520 374
PLLT MTS60A θ=180° θ=90°
(18.70) (14.59) (48.82) (9.27) (20.47) (14.72)
SHLT with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
HDLA
Fuller RTX11609A 544.5 1,846.5 446
PHLA
SHLA (21.44) (72.70) (17.56)
Fuller RTX11609B θ=90° θ=180° θ=180°
405
MTS60A (15.94)
θ=90° 1,482 239
(58.35) (9.41)
CWB450 475 370.5 1,240 280.5 520 374
MTS60A θ=180° θ=90°
HMLT (18.70) (14.59) (48.82) (11.04) (20.47) (14.72)
with power shift
HMLA θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
Fuller RTX11609A 589 1,891 446
(23.19) (74.45) (17.56)
Fuller RTX11609B
θ=90° θ=180° θ=180°
CWB450 Fuller RTX11609B
HTLT 475 370.5 1,240 544.5 520 374 1,846.5 446
PPLT (18.70) (14.59) (48.82) (21.44) (20.47) (14.72) (72.70) (17.56)
HTLA Fuller RT11715 θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=180°
PPLA
377
MTS60A (14.84)
CWB520 1,188 234.5
θ=110°
HDL (46.77) (9.23)
475 370.5 981.5 256 520 374 θ=180° θ=90°
HML MTS60A
(18.70) (14.59) (38.64) (10.08) (20.47) (14.72)
PHL with power shift
θ=-90° θ=0° θ=-90° θ=110° θ=0° θ=90°
PLL
SHL 589 1,597.5 446
Fuller RTX11609A (23.19) (62.89) (17.56)
θ=90° θ=180° θ=180°
CWB520 Fuller RTX11609B 475 370.5 981.5 561.5 520 374 1,597.5 446
HTL (18.70) (14.59) (38.64) (22.11) (20.47) (14.72) (62.89) (17.56)
PPL Fuller RT11715 θ=-90° θ=0° θ=-90° θ=110° θ=0° θ=90° θ=180° θ=180°
Fuller RTX11609B 475 370.5 1,240 544.5 520 374 1,846.5 446
CWB520
(18.70) (14.59) (48.82) (21.44) (20.47) (14.72) (72.70) (17.56)
KTLA Fuller RT11715
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=180°
360
MTS60A (14.17)
1,437 239
θ=90°
CWC450 (56.57) (9.41)
475 370.5 1,240 233.5 520 374
LDLA MTS60A θ=180° θ=90°
(18.70) (14.59) (48.82) (9.27) (20.47) (14.72)
PHLA with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
SHLA
544.5 1,846.5 446
Fuller RTX11609A (21.44) (72.70) (17.56)
θ=90° θ=180° θ=180°
405
MTS60A (15.94)
1,437 239
θ=90°
(56.57) (9.41)
475 370.5 1,240 280.5 520 374 θ=180° θ=90°
CWC450 MTS60A
(18.70) (14.59) (48.82) (11.04) (20.47) (14.72)
LMLA with power shift
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90°
589 1,846.5 446
Fuller RTX11609A (23.19) (72.70) (17.56)
θ=90° θ=180° θ=180°
475 370.5 1,160.5 589 520 374 1,803.5 446
CWC610
Fuller RT11715 (18.70) (14.59) (45.69) (23.19) (20.47) (14.72) (71.00) (17.56)
KTL
θ=-90° θ=0° θ=-90° θ=90° θ=0° θ=90° θ=180° θ=180°

TM-14
 REASSEMBLY T/M LINKAGE

z The length of control rods refers to the distance between

the centers of the joint ball studs.

z The direction of the ball stud (indicated by “θ” in the table) is

z determined by angle “θ” shown in the figure below.

Key point of installation

Shift and select rod assembly
Be sure to insert the square section of the shaft into the mounting hole when installing the ball joint assembly.

TM-15
 PROPELLER SHAFT

CONTENTS
SERVICE DATA.................................. PS-1-1 = PS430, 43S, 431, 480, 520, 580, 590 =
SPECIFICATIONS......................... PS-1-1 PS
CONSTRUCTION................................PS-2-1
IDENTIFYING THE TYPE OF DISASSEMBLY ...................................PS-2-3
PROPELLER SHAFT .................... PS-1-2 REMOVAL ..................................... PS-2-3
PROPELLER SHAFT SHAPE DISASSEMBLY ............................. PS-2-4
AND COMBINATION..................... PS-1-2
INSPECTION.......................................PS-2-9
SERVICE DATA............................. PS-1-2 REASSEMBLY ..................................PS-2-11
TIGHTENING TORQUE ................ PS-1-3 REASSEMBLY ............................. PS-2-11
INSTALLATION ........................... PS-2-15
 SERVICE DATA PROPELLER SHAFT

SERVICE DATA
SPECIFICATIONS
Unit: mm (in)
PS43S &
Item PS430 PS480 PS520 PS580 PS590
PS431 *1
Propeller shaft tube O.D. 90 (3.45) 80 (3.15) 101.6 (4.000) 107 (4.21)
Universal joint journal A 126 (4.96) 153 (6.02) 152 (5.98)

52.0
B 36.5 (1.437) 45.4 (1.787)
(2.047)
36.2
C 26.5 (1.043) 31 (1.22)
(1.425)

43.2
D 30.019 (1.1818) 38.11 (1.5004)
(1.701)

Bearing assembly 4.0 x

Needle
28.8 - 37
O.D. x 3.5 x 20.8 - 30 4.0 x 24.8 - 33
(0.157 x
length - (0.138 x 0.819 - 30) (0.157 x 0.976 - 33)
1.134 -
number
37)
63.5
E 43 (1.69) 55 (2.17)
(2.500)
44.5
F 33.6 (1.323) 37.8 (1.488)
(1.752)

G 25 (0.98) 26 (1.02) 30 (1.18)

Flange yoke H 136 (5.35) 164 (6.46)

I 68 (2.68) 90 (3.54) 68 (2.68) 75 (2.95) 85 (3.35)

63.5
J 43 (1.69) 55 (2.17)
(2.500)

K 104.6 (4.118)

PCD 200 (7.87)

L 134 (5.28)

Type SAE

Number
Involute spline 16 18
of teeth

Diameter 53.2 (2.094) 59.6 (2.346)

*1 Differential to differential PS43S: CWA, CWB, CGB series PS431: CWC series

PS-1-1
 SERVICE DATA PROPELLER SHAFT

IDENTIFYING THE TYPE OF PROPELLER

SHAFT
The propeller shaft is identified by the outside diameter (ØD) of
the tube and yoke span (H).
Unit: mm (in)
Tube outside
Yoke span Number of flange
diameter
Dimension H securing bolts
Dimension D
PS430 90 (3.543) 136 (5.35) 4
PS480 101.6 (4.000) 136 (5.35) 4
PS520 101.6 (4.000) 164 (6.46) 4
PS580 107.0 (4.213) 164 (6.46) 6
PS590 107.0 (4.213) 164 (6.46) 6

PROPELLER SHAFT SHAPE AND COMBINATION

Differential to
Combination (No.) No. Shape
differential
2
PS430 1+2 —
1+1+2
PS480 1+2 —
1
2
—
1+2
PS520
2
3*1
1+2
2
PS580 1+2 3*1
1+1+2
PS590 2 3*1
2
*1 PS430 (except CWC series) or PS431 (CWC series)

PS-1-2
 SERVICE DATA PROPELLER SHAFT

SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Less than
Propeller shaft runout 0.9 (0.035)
0.7 (0.028)
0.11 - 0.20
Spline rotational direction play 0.5 (0.020)
(0.0043 - 0.0079)
0.03 - 0.07
Journal to journal bearing clearance 0.25 (0.0098)
(0.0012 - 0.0028)
End play of journal and bearing 0 (0) —
1.0 - 2.3
PS430, PS480 —
{0.10 - 0.23, 0.7 - 1.7}
Swing torque of journal 1.0 - 3.6 Adjust with side plate
PS520, PS580 —
N·m {kgf·m, ft·lbf} {0.10 - 0.37, 0.7 - 2.7}
1.5 - 4.4
PS590 —
{0.15 - 0.45, 1.1 - 3.3}
PS430, PS480 0.18 - 0.25
Center ball bearing 0.25 (0.0098)
PS520 (0.0071 - 0.0094)
axial play
PS580 — 0.5 (0.020)

Data for the propeller shaft between the differentials is the same as that for the PS430 model.

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Companion flange bolts and nuts 211 - 240 {21.5 - 24.5, 156 - 177}
Companion flange mounting PS430, PS480, PS520 343 - 402 {35 - 41, 253 - 297}
nuts PS580 343 - 441 {35 - 45, 253 - 325}
Companion flange plain washer bolts (PS580 only) 34 - 46 {3.5 - 4.7, 25 - 34}
PS430, PS480, PS520, PS580 25 - 31 {2.5 - 3.2, 18 - 23}
Side plate mounting bolts
PS590 51 - 65 {5.2 - 6.6, 38 - 48}
Center bearing assembly bolts and nuts (PS580 only) 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Center bearing retainer mounting bolts and nuts (PS520, PS580) 98 - 127 {10 - 13, 72 - 94}

PS-1-3
 CONSTRUCTION PS430, 43S, 431, 480, 520, 580, 590

= PS430, 43S, 431, 480, 520, 580, 590 =

CONSTRUCTION
Unit name PS430, 480, 520

Unit name PS580

PS-2-1
 CONSTRUCTION PS430, 43S, 431, 480, 520, 580, 590

Unit name PS590

Unit name PS43S, 431 (Differential to differential)

PS-2-2
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

DISASSEMBLY
REMOVAL
Key point of removal
1. Always chock both the front and rear wheels.
2. Engage gear (1st or reverse) to lock the propeller shaft.
3. Place a stand under the propeller shaft or support the shaft
with a
4. fitting cable to prevent it from dropping when removed.
5. Ensure that the splined yoke and shaft have alignment
marks. If they do not, scribe an alignment mark.

PS-2-3
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

DISASSEMBLY
Unit name PS430, 480, 520

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Bolt , 8. Journal 15. Slinger (PS520 only)
2. Lock nut + 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 washer , 12. Castellated nut , 19. Dust cap
6. Seal 13. Washer 20. Felt washer
7. Dust shield ,+ 14. Companion flange
Marks “+” and “,” indicate that the key points of operation are explained in the text.

PS-2-4
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

Unit name PS580

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Bolt , 9. Castellated nut 16. Oil seal
2. Lock nut 10. Bolt ,+ 17. Center bearing
, 3. Side plate 11. Plain washer 18. Center bearing front case
4. Bearing ,+ 12. Companion flange 19. Oil seal
, 5. Journal 13. Cushion rubber 20. Propeller shaft
+ 6. Flange yoke 14. Bolt , 21. Dust cap
7. Grease nipple 15. Center bearing rear case 22. Felt washer
8. Cotter pin
Marks “+” and “,” indicate that the key points of operation are explained in the text.

PS-2-5
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

Unit name PS590

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Bolt , 5.Journal , 9.Dust cap
2.Lock plate + 6.Flange yoke 10.Felt washer
, 3.Side plate 7.Spline shaft yoke 11.Relief valve
4.Bearing 8.Spline yoke 12.Grease nipple
Marks “+” and “,” indicate that the key points of operation are explained in the text.

PS-2-6
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

Unit name PS43S, 431 (Differential to differential)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Bolt , 5.Journal 8.Spline shaft yoke
2.Lock plate + 6.Flange yoke 9.Relief valve
, 3.Side plate 7.Spline yoke 10.Grease nipple
4.Bearing
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

9 PS430, 480, 520 6 PS43S, 431, 580, 590 flange yoke
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-2-7
 DISASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

14 PS430, 480, 520 and 12 PS580 companion flange

1.Retainer 5.Castellated nut

2.Slinger (PS520 only) 6.Cotter pin
3.Companion flange 7.Propeller shaft
4.Washer 8.Center bearing assembly

1.Center bearing 4.Castellated nut

2.Companion flange 5.Cotter pin
3.Plain washer 6.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 (PS430, 480 and 520)

1.Propeller shaft 3.Center bearing assembly
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.
3. Do not remove the slinger unless it is to be replaced with a
new one. (PS520 only)

17 Center bearing (PS580)

1.Oil seal 5.Retainer
2.Front case 6.Rear case
3.Bearing 7.Oil seal
4.Cushion rubber 8.Grease nipple
1. Remove the grease nipple.
2. Remove the rubber cushion.
3. Remove the bolts and nuts.
4. Insert a chisel or similar tool between the front and rear
cases and separate them from the ball bearing.
5. Remove the oil seal from each case.

PS-2-8
 INSPECTION PS430, 43S, 431, 480, 520, 580, 590

INSPECTION
z Clean all disassembled parts in cleaning solvent. Carefully
check for scratches, deformity or damage. Replace faulty
parts.
z If measurement indicates that parts exceed the specified
service limit, repair or replace faulty parts.

Propeller shaft runout

Unit: mm (in)
Maintenance standard Service limit
Less than 0.7 (0.028) 0.9 (0.035)

Spline rotational direction play

Unit: mm (in)
Maintenance standard Service limit
0.11 - 0.20 (0.0043 - 0.0079) 0.5 (0.020)

Journal-to-journal bearing clearance

Unit: mm (in)
Maintenance standard Service limit
0.03 - 0.07 (0.0012 - 0.0028) 0.25 (0.0098)

Center ball bearing axial play

Unit: mm (in)
Unit name Maintenance standard Service limit
PS430
0.18 - 0.25
PS480 0.25 (0.0098)
(0.0071 - 0.0098)
PS520
PS580 — 0.5 (0.020)

PS-2-9
 INSPECTION PS430, 43S, 431, 480, 520, 580, 590

NOTE (PS430, 480 and 520)

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-
ion rubber. Replace if damage or cracking is found.

PS-2-10
 REASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

REASSEMBLY
REASSEMBLY
Key point of reassembly
19 PS430, 480, 520, 21 PS580 and 9 PS590 dust cap
Fit the dust cap onto the splined yoke fully and caulk at 2 points at
180-degree intervals with a center punch, on the scribed line on the
outside periphery of the dust cap.

16 PS430, 480, 520 center bearing

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.

17 PS580 center bearing

1.Cushion rubber 5.Oil seal
2.Grease nipple 6.Rear case
3.Front case 7.Retainer
4.Oil seal
1. Pack the ball bearing with grease and drive the bearing into
the rear center bearing case using a bearing insert.
2. Align with the protrusion of the rubber cushion and fit the
rear case to the rubber cushion.
3. Insert the bolt into the rear case, and using the bolt as a
guide for the front case, fit the grease nipple into the ball
bearing with its mounting hole facing the upper right (as
viewed from the front of the case).
NOTE
z The front case can be distinguished from the rear case
by the presence of a grease nipple hole in it.

4. Tighten the nuts uniformly. The front case is fitted to the ball
bearing by this tightening.

PS-2-11
 REASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

: 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 lb·ft}

5. Drive the oil seals into each case.
6. Install the grease nipple in the front case.

14 PS430, 480, 520 and 12 PS580 companion flange

1. Ensure that the slinger is new and free from defects.
(PS520 only)

2. Ensure that the alignment marks (to indicate “phase”) are

aligned.

12 PS430, 480, 520 and 9 PS580 castellated nut

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}
(PS430, 480, 520)
343 - 441 N·m {35 - 45 kgf·m, 253 - 325 ft·lbf}
(PS580)

8 PS430, 480, 520 and 5 PS580, 590, 43S, 431 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.

PS-2-12
 REASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

NOTE
z Ensure that the grease nipple is at a 450° angle to the
axis of the journal arm.

3 Side plate
1. Install a side plate (size A) on one side of the propeller shaft
yoke and apply pressure to the other end to remove any
free play. Then, measure the end play of the bearing.
Unit: mm (in)
Maintenance standard Service limit
Bearing end play
0 (0) —

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}

(PS430, 480, 520, 580)
51 - 65 N·m {5.2 - 6.6 kgf·m, 38 - 48 ft·lbf}
(PS590)
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)

PS-2-13
 REASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

3. Measure the swing torque of the journal (on the flange yoke
and propeller shaft yoke sides). If it is outside maintenance
standards, replace the side plates and readjust.
Unit: N·m {kgf·m, ft·lbf}
Model Maintenance standard Service limit
1.0 - 2.3
PS420, 430 –
Swing {0.10 - 0.23, 0.7 - 1.7}
torque of 1.0 - 3.6
journal PS520, 580 –
{0.10 - 0.37, 0.7 - 2.7}
1.5 - 4.4
PS590 –
{0.15 - 0.45, 1.1 - 3.3}

4. Bend the lock plate to lock the bolt.

PS-2-14
 REASSEMBLY PS430, 43S, 431, 480, 520, 580, 590

INSTALLATION

Key point of 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 lbf·ft}

PS-2-15
 DIFFERENTIAL

CONTENTS
SERVICE DATA................................. DF-1- 1 REASSEMBLY.............................. DF-4-10
SPECIFICATIONS......................... DF-1- 1 INSTALLATION............................. DF-4-16
SERVICE DATA............................. DF-1- 3
= UNIT NAME SRHQ-2 =
TIGHTENING TORQUE ................ DF-1- 5 DF
TOOLS............................................... DF-2- 1 CONSTRUCTION .............................. DF-5- 1
DISASSEMBLY ................................. DF-5- 2
= UNIT NAME SRSP-1 =
REMOVAL ..................................... DF-5- 2
CONSTRUCTION .............................. DF-3- 1 DISASSEMBLY.............................. DF-5- 4
DISASSEMBLY ................................. DF-3- 2 INSPECTION ..................................... DF-5- 7
REMOVAL ..................................... DF-3- 2 REASSEMBLY .................................. DF-5- 8
DISASSEMBLY ............................. DF-3- 4 REASSEMBLY............................... DF-5- 8
INSPECTION ..................................... DF-3- 7 INSTALLATION............................. DF-5-14
REASSEMBLY .................................. DF-3- 8
= UNIT NAME IPHM, IPHM-2 =
REASSEMBLY .............................. DF-3- 8
INSTALLATION............................. DF-3-14 CONSTRUCTION .............................. DF-6- 1
DISASSEMBLY ................................. DF-6- 2
= UNIT NAME SRHM, SRHM-2, SRHP-1 =
REMOVAL ..................................... DF-6- 2
CONSTRUCTION .............................. DF-4- 1 DISASSEMBLY.............................. DF-6- 4
DISASSEMBLY ................................. DF-4- 3 INSPECTION ..................................... DF-6- 9
REMOVAL ..................................... DF-4- 3 REASSEMBLY ................................. DF-6-12
DISASSEMBLY ............................. DF-4- 5 REASSEMBLY.............................. DF-6-12
INSPECTION ..................................... DF-4- 8 INSTALLATION............................ DF-6-20
REASSEMBLY ................................. DF-4-10
 SERVICE DATA DIFFERENTIAL

SERVICE DATA
SPECIFICATIONS
Unit name SRSP-1 SRHM SRHM-2 SRHP-1 SRHQ-2
Type Single reduction
Spiral bevel
Type of reduction gear Hypoid gear
gear
Gear ratio
Number of teeth Refer to the table below
Drive gear diameter mm (in)
Pinion offset mm (in) — 35 (1.38) 28 (1.10)
Type and number of differential gears Straight bevel gear: Large 2, Small 4
17 (3-3/4)
Gear oil capacity (Imp gal) 11 (2-3/8) 12 (2-5/8) 14 (3-1/8) 15 (3-1/4)
*1 15 (3-1/4)

Unit name IPHM IPHM-2

Type In-line tandem
Type of reduction gear Hypoid gear
Gear ratio
Number of teeth Refer to the table below
Drive gear diameter mm (in)
Pinion offset mm (in) 35 (1.38)
Type and number of differential gears and inter-
Straight bevel gear: Large 2, Small 4
mediate axle
*2 15.5 (3-3/8)
Gear oil capacity (Imp gal) 18 (4)
*3 18 (4)

NOTE
z *1 For AUSTRALIA and HONG KONG
z *2 Except tractor
z *3 Tractor

Gear ratio and number of teeth

Gear ratio 3.545 3.727 3.900 4.111 4.333 4.625 4.875 5.143 5.428 5.571 5.857 6.166 6.500 6.833 7.400
Number of teeth 39/11 41/11 39/10 37/9 39/9 37/8 39/8 36/7 38/7 39/7 41/7 37/6 39/6 41/6 37/5
SRSP-1 — — — — O O O O O — — — — — —
SRHM — O — O — O — O — O O O O O O

SRHM-2 O O — O — O — O — O O O O O —
Unit
SRHP-1 — — — — O O O O — O — O — O —
name
SRHQ-2 — — O O O O O O — O O — — — —
IPHM — O — O — O — O — O O O O O O

IPHM-2 O O — O — O — O — O O O O O —

DF-1-1
 SERVICE DATA DIFFERENTIAL

Drive gear diameter

Unit name SRSP-1 SRHM SRHM-2 SRHP-1 SRHQ-2
Diameter 448 440 434 428 425 440 428 425 448 476
mm (in) (17.64) (17.32) (17.09) (16.85) (16.73) (17.32) (16.85) (16.73) (17.64) (18.74)
4.333 7.400 5.143 4.111 3.727 5.143 3.545 3.727 4.333 3.900
4.625 4.625 5.571 4.111 4.625 4.111
4.875 5.571 5.857 4.625 4.875 4.333
5.143 5.857 6.166 5.143 4.625
Gear ratio
5.428 6.166 6.500 5.571 4.875
6.500 6.833 6.166 5.143
6.833 6.833 5.571
5.857

Unit name IPHM IPHM-2

Diameter 440 434 428 425 440 428 425
mm (in) (17.32) (17.09) (16.85) (16.73) (17.32) (16.85) (16.73)
7.400 5.143 4.111 3.727 5.143 3.545 3.727
4.625 5.571 4.111
5.571 5.857 4.625
Gear ratio 5.857 6.166
6.166 6.500
6.500 6.833
6.833

UNIT NAME

SR S P -1

Type Type of main Outside diameter of

reduction gear Model No.
axle housing mm (in)
SR Single reduction S Spiral bevel M 500 (19.69)

ln-line Tandem H Hypoid P 520 (20.47)

IP (Equipped with
oil pump) Q 550 (21.65)

DF-1-2
 SERVICE DATA DIFFERENTIAL

UNIT IDENTUFICATION NUMBER

SERVICE DATA
Unit: mm (in)
Application
S S S S S I I
Maintenance R R R R R P P
Item Service limit Remarks S H H H H H H
standard
P M M P Q M M
I I I I
2 1 2 2
0.30 - 0.40
Drive gear backlash 0.6 (0.024) O O O O O O O
(0.0118 - 0.0157)
0.20 - 0.35
0.5 (0.020) O O O O — O O
Side gear and differential pinion gear (0.0079 - 0.0138)
backlash 0.20 - 0.30
0.5 (0.020) — — — — O — —
(0.0079 - 0.0118)
Helical gears' backlash 0.15 - 0.25
— — — — — — O O
(Divider gear and pinion gear) (0.0059 - 0.0098)
Intermediate axle differential gear back- 0.20 - 0.28
— — — — — — O O
lash (0.0079 - 0.0110)
23.5 - 46.1
Drive pinion With new bearing —
{2.4 - 4.7, 5.3 - 10.4} Starting preload
bearing preload O O O O — — —
14.7 - 30.4 (With oil seal)
N {kgf, lbf} With reused bearing —
{1.5 - 3.1, 3.3 - 6.8}

DF-1-3
 SERVICE DATA DIFFERENTIAL

Application
S S S S S I I
Maintenance R R R R R P P
Item Service limit Remarks S H H H H H H
standard
P M M P Q M M
I I I I
2 1 2 2
With new 52.0 - 74.5
—
Type 520 bearing {5.3 - 7.6, 11.7 - 16.8}
flange With reused 33.3 - 48.1
—
bearing {3.4 - 4.9, 7.5 - 10.8} Starting preload
— — — — O — —
With new 44.1 - 63.7 (With oil seal)
Drive pinion —
Type 580 bearing {4.5 - 6.5, 9.9 - 14.3}
bearing preload
flange With reused 28.4 - 41.2
N {kgf, lbf} —
bearing {2.9 - 4.2, 6.4 - 9.3}
20.6 - 40.2 Starting preload
With new bearing —
{2.1 - 4.1, 4.6 - 9.0} (With oil seal)
— — — — — O O
12.7 - 26.5 Measure at perimeter
With reused bearing — of pinion drive gear
{1.3 - 2.7, 2.9 - 6.0}
29.4 - 39.2
With new bearing —
{3.0 - 4.0, 6.6 - 8.8}
O O O O O — —
18.6 - 25.5
Differential side With reused bearing {1.9 - 2.6, 4.2 - 5.7}
—
Measure at drive gear
bearing preload
43.2 - 64.7 bolt location
N {kgf, lbf} With new bearing —
{4.4 - 6.6, 9.7 - 14.6}
— — — — — O O
29.4 - 37.3
With reused bearing —
{3.0 - 3.8, 6.6 - 8.4}
Clearance between pinion gear and pin- 0.10 - 0.14
0.25 (0.0098) O O O O O O O
ion shaft (0.0039 - 0.0055)
Clearance between side gear boss and 0.21 - 0.31
0.5 (0.020) O O O O O O O
differential case (0.0083 - 0.0122)
Clearance between shift fork and sliding 0.10 - 0.24
1.0 (0.039) — — — — — O O
clutch (0.0039 - 0.0094)
Clearance between divider gear and 0.06 - 0.13
0.3 (0.012) — — — — — O O
input shaft (0.0024 - 0.0051)
Clearance between intermediate axle dif- 0.07 - 0.14
0.3 (0.012) — — — — — O O
ferential output gear and input shaft (0.0028 - 0.0055)
Clearance between intermediate axle dif- 0.12 - 0.16
0.3 (0.012) — — — — — O O
ferential pinion gear and pinion shaft (0.0047 - 0.0063)
0.13 - 0.20
Divider gear play in axial direction — — — — — — O O
(0.0051 - 0.0079)
245.5 At a length of 60 mm
Shift fork return When set in position 25.0, 55.1
—
(2.36 in)
spring tension — — — — — O O
N {kgf, lbf} When in operation 612.9 At a length of 45 mm
—
62.5, 137.8 (1.77 in)
17.26 - 21.18
Oil filter spring tension At a length of 15.5 mm
{1.76 - 2.16, — — — — — — O O
N {kgf, lbf} (0.610 in)
3.88 - 4.76}
Return spring tension (With Non-spin dif- 384.4 304.0 At a length of 23.2 mm
— O O — — — —
ferential only) N {kgf, lbf} {39.2, 86.4} {31.0, 68.4} (0.913 in)

DF-1-4
 SERVICE DATA DIFFERENTIAL

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Application
S S S S S I I
R R R R R P P
Item Tightening torque S H H H H H H
P M M P Q M M
I I I I
2 1 2 2
Carrier cover 88 - 118 {9.0 - 12.0, 65 - 87} — — — — — O O
Level plug
Axle housing 127 - 147 {13.0 - 15.0, 94 - 108} O O O O O — —
Carrier cover 29 - 39 {3.0 - 4.0, 22 - 29} — — — — — O —
Drain plug
Axle housing 127 - 147 {13.0 - 15.0, 94 - 108} O O O O O O O
Except hub reduction type
147 - 167 {15.0 - 17.0,108 - 123} O O O O O O O
Axle shaft bolt R/A
Hub reduction type R/A 196 - 216 {20.0 - 22.0, 145 - 159} — O O O — O O
Propeller shaft bolt and nut 211 - 240 {21.5 - 24.5, 156 - 177} O O O O O O O
127 - 147 {13.0 - 15.0, 94 - 108} O O O O — O O
Differential carrier bolt and nut
196 - 216 {20.0 - 22.0, 145 - 159} — — — — O — —
Bearing cover bolt (Through shaft) 59 - 69 {6.0 - 7.0, 43 - 51} — — — — — O O
Companion flange nut 392 - 539 {40.0 - 55.0, 289 - 398} O O O O O — —
Companion flange bolt 118 - 137 {12.0 - 14.0, 87 - 101} — — — — — O O
Bearing sleeve bolt 118 - 137 {12.0 - 14.0, 87 - 101} O O O O O — —
Bearing retainer bolt (Input shaft) 118 - 137 {12.0 - 14.0, 87 - 101} — — — — — O O
Cylinder bolt 34 - 44 {3.5 - 4.5, 25 - 33} — — — — — O O
Oil pump mounting bolt 14 - 18 {1.4 - 1.8, 10 - 13} — — — — — O O
Oil filter plug 216 - 255 {22.0 - 26.0,159 - 188} — — — — — O O
Carrier cover bolt 118 - 137 {12.0 - 14.0, 87 - 101} — — — — — O O
Oil jet 78 - 98 {8.0 - 10.0, 58 - 72} — — — — — O O
Intermediate axle differential case 49 - 59 {5.0 - 6.0, 36 - 43} — — — — — O O
Oil shelter bolt 9 - 13 {0.9 - 1.3, 6.5 - 9} — — — — — O O
Adjusting nut lock plate bolt 19 - 21 {1.9 - 2.1, 14 - 15} O O O O O O O
Bearing cap bolt 441 - 490 {45.0 - 50.0, 325 - 362} O O O O O O O
Differential case bolt 216 - 275 {22.0 - 28.0, 159 - 203} O O O O O O O
Drive gear bolt 588 - 686 {60.0 - 70.0, 434 - 506} O O O O — O O
Drive gear nut 490 - 588 {50.0 - 60.0, 362 - 434} — — — — O — —
Drive pinion nut 637 - 834 {65.0 - 85.0, 470 - 615} — — — — — O O
Bearing retainer bolt (Drive pinion) 118 - 137 {12.0 - 14.0, 87 - 101} — — — — — O O
Pilot bearing lock plate bolt 78 - 88 {8.0 - 9.0, 58 - 65} O O O O — O O
Oil catcher bolt 9 - 13 {0.9 - 1.3, 6.5 - 9} — — — — — O O

DF-1-5
 TOOLS DIFFERENTIAL

TOOLS
Application
S S S S S I I
R R R R R P P
Tool name and number Description Shape S H H H H H H
P M M P Q M M
I I I I
2 1 2 2

Differential jack Used when disassembling and assem-

O O O O O O O
99890 Z0000 bling the differential carrier

Used for disassembling and reassembling

Attachment the differential carrier.
— — — — O — —
99823 Z0007 This attachment is used by installing it on
the engine stand (99550 96001).

Differential wrench
Used for turning the adjusting nut O O O O O O O
99826 Z0000

Socket wrench Used for turning the companion flange nut

O O O O O — —
99535 Z0003 Width across flats: 50 mm (1.97 in)

Socket wrench Used for turning the drive pinion nut

— — — — — O O
99535 Z0076 Width across flats: 65 mm (2.56 in)

Oil seal replacer Used when installing the oil seal into the
— — — — O — —
99828 Z0019 bearing sleeve

DF-2-1
 TOOLS DIFFERENTIAL

Application
S S S S S I I
R R R R R P P
Tool name and number Description Shape S H H H H H H
P M M P Q M M
I I I I
2 1 2 2

Dust shield replacer Used when driving the dust shield into the
— — — — O — —
99828 Z0060 companion flange

DF-2-2
 CONSTRUCTION

= UNIT NAME SRSP-1 =

CONSTRUCTION

DF-3-1
 DISASSEMBLY

DISASSEMBLY
REMOVAL
Key point of removal
z Chock the wheels.
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 50°C (122°F) to prevent scalding.

NOTE
z Drain the oil into a container having a capacity of at least
11 liters (2-3/8 Imp gal).
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-3-2
 DISASSEMBLY

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 the differen-

tial jack (99890 Z0000) and lever block.

7. Install the differential carrier assembly on the differential

attachment.

DF-3-3
 DISASSEMBLY

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Lock plate 13Pinion shaft + 24.Dust shield
+ 2.Adjusting nut 14.Thrust washer , 25.Retaining ring
, 3.Side bearing cap ,+ 15.Pinion gear 26.Pilot bearing inner race
,+ 4.Differential case assembly 16.Side gear 27.Drive pinion
,+ 5.Drive pinion assembly , 17.Thrust washer 28.Washer
6.Adjusting shim , 18.Differential case (LH) 29.Bearing spacer
7.O-ring 19.Drive gear , 30.Bearing
8.Lock plate 20.Bearing 31.Oil seal
9.Pilot bearing outer race ,+ 21.Companion flange nut , 32.Bearing
, 10.Differential case (RH) 22.O-ring 33.Bearing sleeve
, 11.Thrust washer 23.Companion flange 34.Differential carrier
12.Side gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

DF-3-4
 DISASSEMBLY

Key point of disassembly

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 (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 Differential case assembly

Remove the differential case assembly.
NOTE
z Do not allow the side bearing outer race to drop into the
case assembly.

DF-3-5
 DISASSEMBLY

5 Drive pinion assembly

Before disassembling the drive pinion assembly, measure and
record the preload.
NOTE
z Record the thickness of the removed shim(s).

15 Pinion gear
Measure the backlash of the side gear and differential pinion gear,
and record the results.
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

21 Companion flange nut

Secure the drive pinion assembly in a vise and using the wrench
socket (99535 Z0003), 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.

24 Dust shield
Do not remove the dust shield unless it is faulty.

DF-3-6
 INSPECTION

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the service limit 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)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

Side gear and differential pinion gear backlash

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
thrust washer is worn.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

Clearance between pinion gear and pinion shaft

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)

Clearance between side gear boss and differential

case
NOTE
z Always replace the left and right differential cases as a
unit.

Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)

DF-3-7
 REASSEMBLY

REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.

REASSEMBLY
Key point of reassembly
30, 32 Bearing (outer)
Press the bearing outer races in.

25 Retaining ring
Drive the pilot bearing assembly and secure it with the retaining
ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.

z Measure the drive pinion bearing preload as follows:

1. Install the companion flange, then tighten it using the com-
panion flange nut.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}

2. Secure the bearing sleeve in place and hook a spring scale

on the companion flange. Then measure the preload.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks
Drive pinion New (*) 23.5 - 46.1 {2.4 - 4.7, 5.3 - 10.}
Starting prload
bearing pre-
Old (*) 14.7 - 30.4 {1.5 - 3.1, 3.3 - 6.8} (With oil seal)
load

If the preload is not within the specified range, add or remove

adjusting washer(s) until it is.

DF-3-8
 REASSEMBLY

NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 29 washers in 0.0125 mm (0.0005 in) incre-
ments in the 2.2500 to 2.6000 mm (0.0886 to 0.1024 in)
range.

21 Companion flange nut

After adjusting preload, tighten the companion flange nut using the
socket wrench (99535 Z0003) and stake the nut towards the drive
pinion groove in 2 places.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}
NOTE
z No breakages should exist in the staked portions.

18 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
specified torque.
: 588 - 686 N·m {60.0 - 70.0 kgf·m, 434 - 506 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the drive gear side when installing.

17, 11 Thrust washer

Install the thrust washer so that the side with the oil groove faces
the side gear.

DF-3-9
 REASSEMBLY

15 Pinion gear
Make sure that the backlash of the side gear and differential pinion
gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

10 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.
: 216 - 275 N·m {22.0 - 28.0 kgf·m, 159 - 203 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the differential case attaching bolts.

5 Drive pinion assembly

Fit the adjusting shim(s) and O-ring at the outside periphery of the
bearing sleeve and install the bearing sleeve assembly.
NOTE
z Do not install the O-ring in the wrong sequence. Install
the O-ring so that it is not twisted.
z To prevent oil leaks, attach a thicker adjusting shim on
the O-ring side.
z Do not attach a thinner or split type adjusting shim on
this O-ring side.

4 Differential case assembly

Install the differential case assembly.
NOTE
z Be careful not to drop the side bearing outer race into the
case assembly.

DF-3-10
 REASSEMBLY

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 differential wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the backlash
by tightening the right side adjusting nut.
Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

2) After the backlash has been adjusted, equally tighten both the
left and right adjusting nuts while adjusting the preload until it
is within maintenance standards.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks
Differential New (*) 29.4 - 39.2 {3.0 - 4.0, 6.6 - 8.8}
Measure at drive
side bearing
Old (*) 18.6 - 25.5 {1.9 - 2.6, 4.2 - 5.7} gear bolt location.
preload

NOTE
z The “New” refers to new bearings and the “Old” refers to
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 neces-
sary amount of shims between the bearing retainer and differential
carrier until the specified gear contact pattern is obtained.

DF-3-11
 REASSEMBLY

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.
z Tighten bolts in the order shown in the figure to the spec-
ified torque. Finally, retighten the bolt which was tight-
ened first.
: 118 - 137 N·m {12.0 - 14.0 kgf·m, 87 - 101 ft·lbf}
Adjusting shims thickness
Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
Split type 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)

DF-3-12
 REASSEMBLY

Tooth contact pattern Adjustment procedure

Tooth contact pattern is equally

1. distributed over the tooth.
— Adjustment is not required.

Increase backlash by loosening

Tooth contact pattern is toward
2. the “toe” of the tooth.
the left adjusting nut and tight-
ening the right one.

Decrease backlash by loosen-

Tooth contact pattern is toward
3. the “heel” of the tooth.
ing the right adjusting nut and
tightening the left one.

Move the pinion closer to the

Tooth contact pattern is high
4. on the tooth.
drive gear using a thinner
adjusting shim.

Tooth contact pattern is low on Move the pinion away from the
5. the tooth. drive gear using a 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-3-13
 REASSEMBLY

INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.

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 out-
side 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 with-
out any gaps [bead width more than 3 mm (0.12 in)].

DF-3-14
 REASSEMBLY

3) The bead should not be too thin, broken or protruding in por-

tions where the width of the flange is narrow due to a cutout.

3. Install the differential carrier assembly using the differential

jack (99890 Z0000) or lever block.
: 127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 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.

: 147 - 167 N·m {15.0 - 17.0 kgf·m, 108 - 123 ft·lbf}

5. Align matching marks when installing the propeller shaft.

: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}

DF-3-15
 REASSEMBLY

6. Remove the level plug and pour the specified amount of

gear oil into the plug hole. After that, tighten the level plug.
: 127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 ft·lbf}
Oil capacity: Approximately 11 liters (2-3/8 Imp gal)
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-3-16
 CONSTRUCTION SRHM, SRHM-2, SRHP-1

= UNIT NAME SRHM, SRHM-2, SRHP-1 =

CONSTRUCTION
UNIT NAME SRHM AND SRHM-2

DF-4-1
 CONSTRUCTION SRHM, SRHM-2, SRHP-1

UNIT NAME SRHP-1

DF-4-2
 DISASSEMBLY SRHM, SRHM-2, SRHP-1

DISASSEMBLY
REMOVAL
Key point of removal
z Chock the wheels.
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 50°C (122°F) to prevent scalding.

NOTE
z Drain the oil into a container having a capacity of at least
15 liters (3-1/4 Imp gal).
z The drain plug has a built-in magnet. Remove metal fill-
ings from the drain plug when reinstalling.

2. Remove the axle shaft.

NOTE
z Be careful not to scratch the oil seal when removing the
axle shaft.

DF-4-3
 DISASSEMBLY SRHM, SRHM-2, SRHP-1

3. Scribe matching marks on the splined section of the propel-

ler shaft.

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 the differen-

tial jack (99890 Z0000) and lever block.

7. Install the differential carrier assembly on the differential

attachment.

DF-4-4
 DISASSEMBLY SRHM, SRHM-2, SRHP-1

DISASSEMBLY
UNIT NAME SRHM, SRHM-2 AND SRHP-1

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Lock plate 13Pinion shaft 24.Companion flange
+ 2.Adjusting nut 14.Thrust washer + 25.Dust shield
, 3.Side bearing cap ,+ 15.Pinion gear , 26.Retaining ring
,+ 4.Differential case assembly 16.Side gear 27.Pilot bearing inner race
,+ 5.Drive pinion assembly , .17.Thrust washer 28.Drive pinion
6.Adjusting shim 18.Non-spin differential assembly 29.Washer
7.O-ring (SRHM and SRHM-2 only) 30.Bearing spacer
8.Lock plate , 19. Differential case , 31.Bearing
9.Pilot bearing outer race 20.Drive gear 32Oil seal
, 10.Differential case (RH) 21.Bearing , 33.Bearing
, 11.Thrust washer ,+ 22.Companion flange nut 34.Bearing sleeve
12.Side gear 23.O-ring 35.Differential carrier
Marks “+” and “,” indicate that the key points of operation are explained in the text.

DF-4-5
 DISASSEMBLY SRHM, SRHM-2, SRHP-1

Key point of disassembly

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 (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 Differential case assembly

Remove the differential case assembly.
NOTE
z Do not allow the side bearing outer race to drop into the
case assembly.

DF-4-6
 DISASSEMBLY SRHM, SRHM-2, SRHP-1

5 Drive pinion assembly

Before disassembling the drive pinion assembly, measure and
record the preload.
NOTE
z Record the thickness of the removed shim(s).

15 Pinion gear
Measure the backlash of the side gear and differential pinion gear,
and record the results.
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

22 Companion flange nut

Secure the drive pinion assembly in a vise and using the wrench
socket (99535 Z0003), 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.

25 Dust shield
Do not remove the dust shield unless it is faulty.

DF-4-7
 INSPECTION SRHM, SRHM-2, SRHP-1

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the service limit 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)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

Side gear and differential pinion gear backlash

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
thrust washer is worn.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

Clearance between pinion gear and pinion shaft

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)

Clearance between side gear boss and differential

case
NOTE
z Always replace the left and right differential cases as a
unit.

Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)

DF-4-8
 INSPECTION SRHM, SRHM-2, SRHP-1

Return spring tension

(With Non-spin differential only)
Unit: N {kgf, lbf}
Maintenance standard Service limit Remarks
At a length of
384.4 {39.2, 86.4} 304 {31.0 68.4}
23.2 (0.913 in)

DF-4-9
 REASSEMBLY SRHM, SRHM-2, SRHP-1

REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.

REASSEMBLY
Key point of reassembly
31, 33 Bearing (outer)
Press the bearing outer races in.

26 Retaining ring
Drive the pilot bearing assembly and secure it with the retaining
ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.

z Measure the drive pinion bearing preload as follows:

1. Install the companion flange, then tighten it using the com-
panion flange nut.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}

2. Secure the bearing sleeve in place and hook a spring scale

on the companion flange. Then measure the preload.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks

Drive pinion bear- New (*) 23.5 - 46.1 {2.4 - 4.7, 5.3 - 10.4} Starting preload
ing preload Old (*) 14.7 - 30.4 {1.5 - 3.1, 3.3 - 6.8} (With oil seal)

If the preload is not within the specified range, add or remove

adjusting washer(s) until it is.

DF-4-10
 REASSEMBLY SRHM, SRHM-2, SRHP-1

NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 29 washers in 0.0125 mm (0.0005 in) incre-
ments in the 2.2500 to 2.6000 mm (0.0886 to 0.1024 in)
range.

22 Companion flange nut

After adjusting preload, tighten the companion flange nut using the
socket wrench (99535 Z0003) and stake the nut towards the drive
pinion groove in 2 places.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}
NOTE
z No breakages should exist in the staked portions.

19 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
specified torque.
: 588 - 686 N·m {60.0 - 70.0 kgf·m, 434 - 506 ft·lb}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the drive gear side when installing.

17, 11 Thrust washer

Install the thrust washer so that the side with the oil groove faces
the side gear.

DF-4-11
 REASSEMBLY SRHM, SRHM-2, SRHP-1

15 Pinion gear
Make sure that the backlash of the side gear and differential pinion
gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

10 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.
: 216 - 275 N·m {22.0 - 28.0 kgf·m, 159 - 203 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the differential case attaching bolts.

5 Drive pinion assembly

Fit the shims and O-ring at the outside periphery of the bearing
sleeve and install the bearing sleeve assembly.
NOTE
z Do not install the O-ring in the wrong sequence. Install
the O-ring so that it is not twisted.
z To prevent oil leaks, attach a thicker adjusting shim on
the O-ring side.
z Do not attach a thinner or split type adjusting shim on
this O-ring side.

4 Differential case assembly

Install the differential case assembly.
NOTE
z Be careful not to drop the side bearing outer race into the
case assembly.

DF-4-12
 REASSEMBLY SRHM, SRHM-2, SRHP-1

3 Side bearing cap

1. Install the adjusting nuts and temporarily tighten the bearing
cap bolt.

Unit: N {kgf, lbf}

Type Temporary tightening torque
SRHM, SRHM-2, SRHP-1 196 {20, 150}

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 differential wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the backlash
by tightening the right side adjusting nut.
Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

2) For reference, when the specified preload has been applied to

the differential side bearings, starting force at the drive gear
bolt is as shown below.
Unit: N {kgf, lbf}
Bearings Maintenance standard Remarks
New (*) 20 - 49 {2.0 - 5.0, 15 - 36} Measure at drive gear bolt
Old (*) 20 - 32 {2.0 - 3.3, 15 - 24} location.

NOTE
z Measure the preload (starting force) within the drive gear
and drive pinion backlash range.
z The “New” refers to new bearings and the “Old” refers to
used bearings.

DF-4-13
 REASSEMBLY SRHM, SRHM-2, SRHP-1

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 differ-
ential carrier until the specified gear contact pattern is obtained.

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.
z Tighten bearing retainer bolts in the order shown in the
figure to the specified torque. Finally, retighten the bolt
which was tightened first.
: 118 - 137 N·m {12 - 14 kgf·m, 87 - 100 ft·lbf}

Adjusting shims thickness

Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
Split type 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)

DF-4-14
 REASSEMBLY SRHM, SRHM-2, SRHP-1

Tooth contact pattern Adjustment procedure

Tooth contact pattern is

1. equally distributed over the Adjustment is not required.
tooth.

Increase backlash by loosening

Tooth contact pattern is
2. toward the “toe” of the tooth.
the left adjusting nut and tight-
ening the right one.

Decrease backlash by loosen-

Tooth contact pattern is
3. toward the “heel” of the tooth.
ing the right adjusting nut and
tightening the left one.

Move the pinion closer to the

Tooth contact pattern is high
4. on the tooth.
drive gear using a thinner
adjusting shim.

Tooth contact pattern is low on Move the pinion away from the
5. the tooth. drive gear using a 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.

3) Tighten the side bearing cap bolts to the specified torque.

: 442 - 490 N·m {45 - 50 kgf·m, 320 - 360 ft·lbf}

DF-4-15
 REASSEMBLY SRHM, SRHM-2, SRHP-1

INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.

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-4-16
 REASSEMBLY SRHM, SRHM-2, SRHP-1

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 the differential

jack (99890 Z0000) or lever block.
: 127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 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.

: Except hub reduction type rear axle

147 - 167 N·m {15.0 - 17.0 kgf·m, 108 - 123 ft·lbf}
Hub reduction type rear axle
196 - 216 N·m {20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}

DF-4-17
 REASSEMBLY SRHM, SRHM-2, SRHP-1

5. Align matching marks when installing the propeller shaft.

: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}

6. Remove the level plug and pour the specified amount of

gear oil into the plug hole. After that, tighten the level plug.
: 127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 ft·lbf}
Unit: liter (Imp gal)
Unit name Oil capacity (Approximately)
SRHM 12 (2-5/8)
SRHM-2 14 (3-1/8)
SRHP-1 15 (3-1/4)

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-4-18
 CONSTRUCTION SRHQ-2

= UNIT NAME SRHQ-2 =

CONSTRUCTION

DF-5-1
 DISASSEMBLY SRHQ-2

DISASSEMBLY
REMOVAL
Key point of removal
z Chock the wheels.
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 50°C (122°F) to prevent scalding.

NOTE
z Drain the oil into a container having a capacity of at least
17 liters (3-3/4 Imp gal).
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-5-2
 DISASSEMBLY SRHQ-2

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 the differen-

tial jack (99890 Z0000) and lever block.

7. Attach the differential attachment (99823 Z0007) to the

engine stand (99550 96001) and then secure the differential
carrier to the attachment.

DF-5-3
 DISASSEMBLY SRHQ-2

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Lock plate 13Pinion shaft ,+ 24.Dust shield
+ 2.Adjusting nut 14.Thrust washer , 25.Retaining ring
, 3.Side bearing cap ,+ 15.Pinion gear 26.Pilot bearing inner race
,+ 4.Differential case assembly 16.Side gear 27.Drive pinion
,+ 5.Drive pinion assembly , 17.Thrust washer 28.Washer
6.Adjusting shim , 18.Differential case (LH) 29.Bearing spacer
7.O-ring 19.Drive gear , 30.Bearing
8.Lock plate 20.Bearing , 31.Oil seal
9.Pilot bearing outer race ,+ 21.Companion flange nut , 32.Bearing
, 10.Differential case (RH) 22.O-ring 33.Bearing sleeve
, 11.Thrust washer 23.Companion flange 34.Differential carrier
12.Side gear
Marks “+” and “,” indicate that the key points of operation are explained in the text.

DF-5-4
 DISASSEMBLY SRHQ-2

Key point of disassembly

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 (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 Differential case assembly

Remove the differential case assembly.
NOTE
z Do not allow the side bearing outer race to drop into the
case assembly.

DF-5-5
 DISASSEMBLY SRHQ-2

5 Drive pinion assembly

Before disassembling the drive pinion assembly, measure and
record the preload.
NOTE
z Record the thickness of the removed shim(s).

15 Pinion gear
Measure the backlash of the side gear and differential pinion gear,
and record the results.
NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

21 Companion flange nut

Secure the drive pinion assembly in a vise and using the wrench
socket (99535 Z0003), 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.

24 Dust shield
Do not remove the dust shield unless it is faulty.

DF-5-6
 INSPECTION SRHQ-2

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the service limit 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)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

Side gear and differential pinion gear backlash

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
thrust washer is worn.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

Clearance between pinion gear and pinion shaft

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)

Clearance between side gear boss and differential

case
NOTE
z Always replace the left and right differential cases as a
unit.

Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)

DF-5-7
 REASSEMBLY SRHQ-2

REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.

REASSEMBLY
Key point of reassembly
32, 30 Bearing (outer)
Press the bearing outer races in.

31 Oil seal
Install oil seal to the bearing sleeve using the oil seal replacer
(99828 Z0019).

25 Retaining ring
Drive the pilot bearing assembly and secure it with the retaining
ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.

24 Dust shield
Press-fit a new dust shield (if the old shield is removed) to the
companion flange using the dust shield replacer (99828 Z0060).
Measure the drive pinion bearing preload as follows:
1. Install the companion flange, then tighten it using the com-
panion flange nut.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}

DF-5-8
 REASSEMBLY SRHQ-2

2. Secure the bearing sleeve in place and hook a spring scale

on the companion flange. Then measure the preload.
Unit: N {kgf, lbf}
Item Maintenance standard Remarks
52.0 - 74.5
New (*)
Type 520 {5.3 - 7.6, 11.7 - 16.8}
flange 33.3 - 48.1
Drive pinion Old (*)
{3.4 - 4.9, 7.5 - 10.8} Starting preload
bearing pre-
44.1 - 63.7 (With oil seal)
load New (*)
Type 580 {4.5 - 6.5, 9.9 - 14.3}
flange 28.4 - 41.2
Old (*)
{2.9 - 4.2, 6.4 - 9.3}

If the preload is not within the specified range, add or remove

adjusting washer(s) until it is.
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 32 washers in 0.0125 mm (0.0005 in) incre-
ments in the 1.9125 to 2.3000 mm (0.0753 to 0.0906 in)
range.

21 Companion flange nut

After adjusting preload, tighten the companion flange nut using the
socket wrench (99535 Z0003) and stake the nut towards the drive
pinion groove in 2 places.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}
NOTE
z No breakages should exist in the staked portions.

18 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
specified torque.
: 490 - 588 N·m {50.0 - 60.0 kgf·m, 362 - 434 ft·lb}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the drive gear side when installing.

DF-5-9
 REASSEMBLY SRHQ-2

17, 11 Thrust washer

Install the thrust washer so that the side with the oil groove faces
the side gear.

15 Pinion gear
Make sure that the backlash of the side gear and differential pinion
gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.5 (0.020)

NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

10 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.
: 216 - 275 N·m {22.0 - 28.0 kgf·m, 159 - 203 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the differential case attaching bolts.

DF-5-10
 REASSEMBLY SRHQ-2

5 Drive pinion assembly

Fit the shims and O-ring at the outside periphery of the bearing
sleeve and install the bearing sleeve assembly.
NOTE
z Do not install the O-ring in the wrong sequence. Install
the O-ring so that it is not twisted.
z To prevent oil leaks, attach a thicker adjusting shim on
the O-ring side.
z Do not attach a thinner or split type adjusting shim on
this O-ring side.

4 Differential case assembly

Install the differential case assembly.
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 bolts.
Unit: N {kgf, lbf}
Type Temporary tightening torque
SRHM, SRHM-2, SRHP-1 196 {20, 150}

NOTE
z Observe the matching marks made prior to disassembly,
making sure that the original positioning of the cap is
maintained.

DF-5-11
 REASSEMBLY SRHQ-2

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 differential wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the backlash
by tightening the right side adjusting nut.
Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

2) For reference, when the specified preload has been applied to

the differential side bearings, starting force at the drive gear
bolt is as shown below.
Unit: N {kgf, lbf}
Bearings Maintenance standard Remarks
New (*) 20 - 49 {2.0 - 5.0, 15 - 36} Measure at drive gear bolt
Old (*) 20 - 32 {2.0 - 3.3, 15 - 24} location.

NOTE
z Measure the preload (starting force) within the drive gear
and drive pinion backlash range.
z The “New” refers to new bearings and the “Old” refers to
used bearings.

DF-5-12
 REASSEMBLY SRHQ-2

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 dif-
ferential carrier until the specified gear contact pattern is obtained.

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.
z Tighten bearing retainer bolts in the order shown in the
figure to the specified torque. Finally, retighten the bolt
which was tightened first.
: 118 - 137 N·m {12.0 - 14.0 kgf·m, 87 - 101 ft·lbf}

Adjusting shims thickness

Unit: mm (in)
Type Thickness
One-piece type 0.5 (0.020), 1.0 (0.039)
Split type 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020)

DF-5-13
 REASSEMBLY SRHQ-2

Tooth contact pattern Adjustment procedure

Tooth contact pattern is

1. equally distributed over the Adjustment is not required.
tooth.

Increase backlash by loosening

Tooth contact pattern is
2. toward the “toe” of the tooth.
the left adjusting nut and tight-
ening the right one.

Decrease backlash by loosen-

Tooth contact pattern is
3. toward the “heel” of the tooth.
ing the right adjusting nut and
tightening the left one.

Move the pinion closer to the

Tooth contact pattern is high
4. on the tooth.
drive gear using a thinner
adjusting shim.

Tooth contact pattern is low Move the pinion away from the
5. on the tooth. drive gear using a 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.

3) Tighten the side bearing cap bolts to the specified torque.

: 442 - 490 N·m {45 - 50 kgf·m, 320 - 360 ft·lbf}

DF-5-14
 REASSEMBLY SRHQ-2

INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.

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-5-15
 REASSEMBLY SRHQ-2

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 the differential

jack (99890 Z0000) or lever block.
: 196 - 216 N·m {20.0 - 22.0 kgf·m, 145 - 159 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.

: 147 - 167 N·m {15.0 - 17.0 kgf·m, 108 - 123 ft·lbf}

5. Align matching marks when installing the propeller shaft.

: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}

DF-5-16
 REASSEMBLY SRHQ-2

6. Remove the level plug and pour the specified amount of

gear oil into the plug hole. After that, tighten the level plug.
: 127 - 147 N·m {13 - 15 kgf·m, 94 - 110 ft·lbf}
Unit: liter (Imp gal)
Oil capacity
Remarks
(Approximately)
17 (3-3/4) Except AUSTRALIA and HONG KONG
15 (3-1/4) For AUSTRALIA and HONG KONG

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-5-17
 CONSTRUCTION IPHM, IPHM-2

= UNIT NAME IPHM, IPHM-2 =

CONSTRUCTION

DF-6-1
 DISASSEMBLY IPHM, IPHM-2

DISASSEMBLY
REMOVAL
Key point of removal
z Chock the wheels.
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 plugs [A (IPHM only) and B] 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 50°C (122°F) to prevent scalding.

NOTE
z Drain the oil into a container having a capacity of at least
18 liters (4 Imp gal).
z The drain plug has a built-in magnet. Remove metal fill-
ings from the drain plug when reinstalling.

2. Remove the axle shaft.

NOTE
z Be careful not to scratch the oil seal when removing the
axle shaft.

DF-6-2
 DISASSEMBLY IPHM, IPHM-2

3. Scribe matching marks on the splined section of the propel-

ler shaft.

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 the differen-

tial jack (99890 Z0000) and lever block.
7. Install the differential carrier assembly on the differential
attachment.

DF-6-3
 DISASSEMBLY IPHM, IPHM-2

DISASSEMBLY

DF-6-4
 DISASSEMBLY IPHM, IPHM-2

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Flange washer 24.Seal ring ,+ 47.Pinion gear
+ 2.Companion flange 25.Sliding clutch 48.Side gear
+ 3.Dust shield 26.Shift fork , 49.Thrust washer
4.Oil seal , 27.Oil jet 50.Drive gear
, 5.Bearing retainer , 28.Lock washer , 51.Differential case (RH)
6.Adjusting shim 29.Thrust washer 52.Side bearing
7.O-ring ,+ 30.Divider gear ,+ 53.Drive pinion assembly
8.Cylinder 31.Intermediate axle differential case ,+ 54.Nut
9.Piston 32.Thrust washer 55.Pinion drive gear
10.X-ring ,+ 33.Pinion gear , 56.Taper roller bearing (Outer)
, 11.Oil pump assembly 34.Pinion shaft 57.Washer
12.Plug 35.Oil shelter 58.Bearing retainer
13.Gasket 36.Intermediate axle differential output gear 59.Adjusting shim
14.Spring 37.Taper roller bearing 60.Bearing spacer
15.Washer 38.Lock plate , 61.Taper roller bearing (Outer)
16.Filter cap + 39.Adjusting nut 62.Drive pinion
17.Oil filter , 40.Side bearing cap , 63.Retaining ring
+ 18.Input shaft & Intermediate axle ,+ 41.Differential case assembly 64.Pilot bearing inner race
differential assembly , 42.Differential case (LH) 65.Lock plate
,+ 19.Carrier cover 43.Side gear 66.Pilot bearing outer race
20.Shift shaft , 44.Thrust washer 67.Oil catcher
21.Return spring 45.Pinion shaft 68.Oil catcher shim
22.Taper roller bearing 46.Thrust washer 69.Oil strainer
23.Input shaft 70.Differential carrier
Marks “+” and “,” indicate that the key points of operation are explained in the text.

DF-6-5
 DISASSEMBLY IPHM, IPHM-2

Key point of disassembly

2 Companion flange
Measure and record the divider gear play in the axial direction
before disassembling.

3 Dust shield
Do not remove the dust shield unless it is damaged.

18 Input shaft & Intermediate axle differential assembly,

19 Carrier cover
1. To remove the carrier cover, tap the protrusion in the flange
with a copper hammer.

2. Remove the carrier cover.

NOTE
z The input shaft, tapered roller bearing and sliding clutch
can be removed as a set with the carrier cover. (The
intermediate axle differential assembly is left in the car-
rier case.)

3. Remove the input shaft from the carrier cover using a press.

DF-6-6
 DISASSEMBLY IPHM, IPHM-2

30 Divider gear
Measure and record the backlash of the helical gears (divider gear
and pinion gear). Insert the input shaft into the bore in the divider
gear in advance.

33 Pinion gear
Measure and record the backlash of the intermediate axle differen-
tial gear.
Insert the input shaft into the bore in the pinion shaft in advance.

39 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 (99826
Z0000).

DF-6-7
 DISASSEMBLY IPHM, IPHM-2

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.

41 Differential case assembly

Remove the differential case assembly.
NOTE
z Do not allow the side bearing outer race to drop into the
case assembly.

47 Pinion gear
Measure the backlash of the side gear and differential pinion gear,
and record the results.
NOTE
z Always measure the backlash while holding the pinion
shaft in position.

53 Drive pinion assembly

Remove the pinion drive gear and drive pinion assembly.
NOTE
z Record the thickness of the removed shim(s).

54 Nut
Secure the drive pinion assembly in a vise and remove the nut
using the wrench socket (99535 Z0076).
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-6-8
 INSPECTION IPHM, IPHM-2

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks of damage and replace faulty parts.
z If measurement indicates that the service limit 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)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

Side gear and differential pinion gear backlash

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
thrust washer is worn.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

Helical gears' backlash (Divider gear and pinion gear)

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)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) —

Intermediate axle differential gear backlash

If the backlash that was measured during disassembly exceeds the
service limit, check the gear contact pattern and also see if any
thrust washer is worn.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.28 (0.0079 - 0.0110) —

DF-6-9
 INSPECTION IPHM, IPHM-2

Clearance between pinion gear and pinion shaft

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.14 (0.0039 - 0.0055) 0.25 (0.0098)

Clearance between side gear boss and differential

case
NOTE
z Always replace the left and right differential cases as a
unit.

Unit: mm (in)
Maintenance standard Service limit
0.21 - 0.31 (0.0083 - 0.0122) 0.5 (0.020)

Clearance between shift fork and sliding clutch

Unit: mm (in)
Maintenance standard Service limit
0.10 - 0.24 (0.0039 - 0.0094) 1.0 (0.039)

Clearance between divider gear and input shaft

Unit: mm (in)
Maintenance standard Service limit
0.06 - 0.13 (0.0024 - 0.0051) 0.3 (0.012)

Clearance between intermediate axle differential out-

put gear and input shaft
Unit: mm (in)
Maintenance standard Service limit
0.07 - 0.14 (0.0028 - 0.0055) 0.3 (0.012)

Clearance between intermediate axle differential pin-

ion gear and pinion shaft
Unit: mm (in)
Maintenance standard Service limit
0.12 - 0.16 (0.0047 - 0.0063) 0.3 (0.012)

DF-6-10
 INSPECTION IPHM, IPHM-2

Divider gear play in axial direction

Unit: mm (in)
Maintenance standard Service limit
0.13 - 0.20 (0.0051 - 0.0079) —

Shift fork return spring tension

Unit: N {kgf, lbf}
Item Maintenance standard Service limit Service limit
When set in posi- At a length of 60 mm
245.5 {25.0, 55.1} —
tion (2.36 in)
At a length of 45 mm
When in operation 612.9 {62.5, 137.8} —
(1.77 in)

Oil filter spring tension

Unit: N {kgf, lbf}
Maintenance standard Service limit Service limit
17.26 - 21.18 At a length of 15.5 mm (0.610
—
{1.76 - 2.16, 3.88 - 4.76} in)

DF-6-11
 REASSEMBLY IPHM, IPHM-2

REASSEMBLY
NOTE
z Before reassembling the differential carrier, coat all fric-
tional surfaces with gear oil.

REASSEMBLY
Key point of reassembly
63 Retaining ring
Drive the pilot bearing assembly and secure it with the retaining
ring.
NOTE
z Always drive the pilot bearing in with its part number fac-
ing the retaining ring.

61, 56 Taper roller bearing (outer)

Press the bearing outer races in.

z Measure the drive pinion bearing preload as follows:

1. Install the companion flange, then tighten it using the com-
panion flange nut.

DF-6-12
 REASSEMBLY IPHM, IPHM-2

2. Secure the bearing sleeve in place and hook a spring scale

on the companion flange. Then measure the preload.
Unit: N {kgf, lbf}
Item Maintenance standard

Drive pinion bear- New (*) 20.6 - 27.5 {2.1 - 2.8, 4.6 - 6.2}
ing preload Old (*) 10.8 - 17.7 {1.1 - 1.8, 2.4 - 4.0}

If the preload is not within the specified range, add or remove

adjusting washer(s) until it is.
NOTE
z The “New” refers to new bearings and the “Old” refers to
used bearings.
z There are 32 washers in 0.0250 mm (0.0010 in) incre-
ments in the 1.9125 to 2.3000 mm (0.0753 to 0.0906 in)
range.

54 Nut
After adjusting preload, tighten the nut using the socket wrench
(99535 Z0076) and stake the nut towards the drive pinion groove in
2 places.
: 637 - 834 N·m {65.0 - 85.0 kgf·m, 470 - 615 ft·lbf}
NOTE
z No breakages should exist in the staked portions.

53 Drive pinion assembly

Install the drive pinion assembly using adjusting shim(s).
: 118 - 137 N·m {12.0 - 14.0 kgf·m, 87 - 101 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.

51 Differential case (RH) 3

5
Install the left differential case on the drive gear.
Hold it with a pressing tool and tighten ring gear bolts to the
specified torque.
: 588 - 686 N·m {60.0 - 70.0 kgf·m, 434 - 506 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the drive gear side when installing.

DF-6-13
 REASSEMBLY IPHM, IPHM-2

49, 44 Thrust washer

Install the thrust washer so that the side with the oil groove faces
the side gear.

47 Pinion gear
Make sure that the backlash of the side gear and differential pinion
gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

NOTE
z Measure the backlash while pushing the pinion shaft
against the differential case.

42 Differential case (LH)

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.
: 216 - 275 N·m {22.0 - 28.0 kgf·m, 159 - 203 ft·lbf}
NOTE
z Apply a coat of “THREE BOND #1382” or “Loctite No.
271” to the differential case attaching bolts.

41 Differential case assembly

Install the differential case assembly.
NOTE
z Be careful not to drop the side bearing outer race into the
case assembly.

DF-6-14
 REASSEMBLY IPHM, IPHM-2

40 Side bearing cap

1. Install the adjusting nuts and temporarily tighten the bearing
cap.
Unit: N {kgf, lbf}
Type Temporary tightening torque
IPHM, IPHM-2 196 {20, 150}

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 differential wrench (99826 Z0000).
Then loosen the left side adjusting nut and adjust the backlash
by tightening the right side adjusting nut.
Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.40 (0.0118 - 0.0157) 0.6 (0.024)

2) For reference, when the specified preload has been applied to

the differential side bearings, starting force at the drive gear
bolt is as shown below.
Unit: N {kgf, lbf}
Bearings Maintenance standard Remarks
New (*) 20 - 49 {2.0 - 5.0, 15 - 36} Measure at drive gear bolt
Old (*) 20 - 32 {2.0 - 3.3, 15 - 24} location.

NOTE
z Measure the preload (starting force) within the drive gear
and drive pinion backlash range.
z The “New” refers to new bearings and the “Old” refers to
used bearings.

DF-6-15
 REASSEMBLY IPHM, IPHM-2

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 dif-
ferential carrier until the specified gear contact pattern is obtained.
NOTE
z Tighten bearing retainer bolts in the order shown in the
figure to the specified torque. Finally, retighten the bolt
which was tightened first.
z Insert the split shim into the gap between the sleeve and
one-piece type shim.
: 118 - 137 N·m {12 - 14 kgf·m, 87 - 100 ft·lbf}

Adjusting shims thickness

Unit: mm (in)
Type Thickness
Single 0.5 (0.020)
Split 0.1 (0.004), 0.15 (0.0059), 0.5 (0.020) (R.H., L.H.)

DF-6-16
 REASSEMBLY IPHM, IPHM-2

Tooth contact pattern Adjustment procedure

Tooth contact pattern is

1. equally distributed over the Adjustment is not required.
tooth.

Increase backlash by loosening

Tooth contact pattern is
2. toward the “toe” of the tooth.
the left adjusting nut and tight-
ening the right one.

Decrease backlash by loosen-

Tooth contact pattern is
3. toward the “heel” of the tooth.
ing the right adjusting nut and
tightening the left one.

Move the pinion closer to the

Tooth contact pattern is high
4. on the tooth.
drive gear using a thinner
adjusting shim.

Tooth contact pattern is low Move the pinion away from the
5. on the tooth. drive gear using a 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.

3) Tighten the side bearing cap bolts to the specified torque.

: 442 - 490 N·m {45 - 50 kgf·m, 320 - 360 ft·lbf}

DF-6-17
 REASSEMBLY IPHM, IPHM-2

2. Position the case assembly on the intermediate axle differ-

ential output gear, and insert the input shaft.
Measure the backlash of the intermediate axle differential
gear, and make sure the measured value is within the main-
tenance standard.
NOTE
z After measuring the backlash, apply a coat of “THREE
BOND #1382” or “Loctite No. 271” to the bolt threads and
tighten the bolts to the specified torque.

: 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.28 (0.0079 - 0.0110) —

30 Divider gear
Measure the backlash of the helical gears (divider gear and pinion
gear). Temporarily insert the input shaft into the bore in the divider
gear in advance.
Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) —

28 Lock washer, 27 Oil jet

Apply a coat of “THREE BOND #1382” or “Loctite No. 271” to the
oil jet threads and then tighten to secure the carrier cover. Bend the
lock washer to lock the oil jet.
: 78 - 98 N·m {8.0 - 10.0 kgf·m, 58 - 72 ft·lbf}

19 Carrier cover
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).

DF-6-18
 REASSEMBLY IPHM, IPHM-2

[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 con-
tinuously to line the bolt center as shown above. (Inside of the
center line is better than outside it)

[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.
: 118 - 137 N·m {12.0 - 14.0 kgf·m, 87 - 101 ft·lbf}
z Pouring gear oil into the differential carrier should be
done approximately 2 hours after installation.

11 Oil pump assembly

Install the RTV (Room Temperature Vulcanizing) liquid gasket
(THREE BOND #1215 or equivalent) using the following proce-
dures.
1. Remove any foreign material (dust, dirt, water, etc.) from
the surface of the carrier cover to be coated. It is not neces-
sary to remove oil. Apply the liquid gasket to the entire cir-
cumference of the bolt holes.
Apply the liquid gasket so that it will partially come out of the
outer periphery of the coated surface when the cover is
assembled.
2. Leave the liquid gasket for 1 to 3 minutes after applying and
install the cover within 20 minutes.
: 14 - 18 N·m {1.4 - 1.8 kgf·m, 10 - 13 ft·lbf}
3. After installing, do not allow the RTV liquid gasket to touch
oil for at least 2 hours, until the gasket hardens.

DF-6-19
 REASSEMBLY IPHM, IPHM-2

5 Bearing retainer
Position the bearing in the bearing retainer, install the O-ring and
adjusting shim(s) on the perimeter of the bearing retainer, and
install the cover.
Install the companion flange and measure the divider gear play in
the axial direction.
Unit: mm (in)
Maintenance standard Service limit
0.13 - 0.20 (0.0051 - 0.0079) —

: 118 - 137 N·m {12.0 - 14.0 kgf·m, 87 - 101 ft·lbf}

NOTE
z Be careful not to twist the O-ring during installation.
z Be sure to install the shims with the thicker one on the O-
ring side. If a thin or split-type shim is installed instead,
oil may leak.

INSTALLATION
Key point of installation
1. Thoroughly remove liquid gasket from the flange surfaces
of the differential carrier and axle housing. Deoil and clean
both the flange surfaces and thoroughly wipe oil, moisture
and other dirt away.
NOTE
z When removing the coated liquid gasket from the flange
surfaces, use a scraper blade, etc. so as not to damage
the flange surfaces.

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.

DF-6-20
 REASSEMBLY IPHM, IPHM-2

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)].

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 the differential

jack (99890 Z0000) or lever block.
: 127 - 147 N·m {13.0 - 15.0 kgf·m, 94 - 108 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

DF-6-21
 REASSEMBLY IPHM, IPHM-2

(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.

: Except hub reduction type rear axle

147 - 167 N·m {15.0 - 17.0 kgf·m, 108 - 123 ft·lbf}
Hub reduction type rear axle
196 - 216 N·m {20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}

5. Align matching marks when installing the propeller shaft.

: 211 - 240 N·m {21.5 - 24.5 kgf·m, 156 - 177 ft·lbf}

DF-6-22
 REASSEMBLY IPHM, IPHM-2

6. Remove the level plug and pour the specified amount of

gear oil into the plug hole. After that, tighten the level plug.
: 392 - 539 N·m {40.0 - 55.0 kgf·m, 289 - 398 ft·lbf}
Unit: liter (Imp gal)
Oil capacity
Unit Remarks
(Approximately)
15.5 (3-3/8) Except tractor
IPHM
18 (4) Tractor
IPHM-2 18 (4)

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-6-23
 REAR AXLE

REAR AXLE AND SUSPENSION

HUB REDUCTION

RA
 REAR AXLE AND SUSPENSION

CONTENTS
SERVICE DATA................................. RA-1- 1 REPAIR AND REPLACEMENT ....RA-4-10
SPECIFICATIONS......................... RA-1- 1 REASSEMBLY.............................. RA-4-11
SERVICE DATA............................. RA-1- 5
TIGHTENING TORQUE ................ RA-1- 6 = UNIT NAME RD1A, RD60, RW1A =
TOOLS .............................................. RA-2- 1
REAR AXLE ...................................... RA-5- 1
= UNIT NAME RS1A, RS1B, RS1D = CONSTRUCTION..........................RA-5- 1
DISASSEMBLY..............................RA-5- 5
REAR AXLE ...................................... RA-3- 1 INSPECTION................................RA-5-13
CONSTRUCTION.......................... RA-3- 1 REPAIR AND REPLACEMENT ....RA-5-13
DISASSEMBLY ............................. RA-3- 4 REASSEMBLY..............................RA-5-20
INSPECTION................................ RA-3-12 SUSPENSION.................................... RA-6- 1
REPAIR AND REPLACEMENT ... RA-3-12 CONSTRUCTION..........................RA-6- 1
REASSEMBLY ............................. RA-3-17 DISASSEMBLY............................. RA-6- 3
SUSPENSION ................................... RA-4- 1 INSPECTION.................................RA-6- 8
CONSTRUCTION.......................... RA-4- 1 REPAIR AND REPLACEMENT .... RA-6- 9
DISASSEMBLY ............................. RA-4- 2 REASSEMBLY............................. RA-6-11
INSPECTION................................. RA-4- 9
 SERVICE DATA REAR AXLE & SUSPENSION

SERVICE DATA
SPECIFICATIONS

REAR AXLE
Unit name RS1A RS1B RS1D
Type of rear axle Full-floating, axle tube type
Type of axle housing Pressed, banjo type Cast steel banjo type
Axle shaft diameter
55.5 (2.19) 52.5 (2.067) 52.5 (2.067)
mm (in)
Type of brake drum installation Inboard type Outboard type
Oil capacity
Refer to the “DIFFERENTIAL” section.
liter (Imp qt)
Hub bolt number 8 10 10 10

Unit name RD1A RD60 RW1A

Type of rear axle Full-floating, axle tube type Dead axle type Full-floating, axle tube type
Type of axle housing Pressed, banjo type — Pressed, banjo type
Pressed tube
Type of axle tube — —
type
Axle shaft diameter 50.0 (1.696)
52.5 (2.067) —
mm (in) 52.5 (2.067)
Inboard type
Type of brake drum installation Inboard type
Outboard type
Oil capacity
Refer to the “DIFFERENTIAL” section.
liter (Imp qt)
Hub bolt number 8 8 8 10

Type of brake drum installation

RA-1-1
 SERVICE DATA REAR AXLE & SUSPENSION

Unit name

R S 1A

UNIT CLASSIFICATION APPLICABLE MODEL NOMINAL WEIGHT ON

AXLE(S)
R REAR AXLE S REAR SINGLE SHAFT TRUCK 1A 10.0 ton
1B 11.0 ton
W REAR DOUBLE SHAFT TRUCK (2-axle drive)
1D 13.0 ton
D REAR DOUBLE SHAFT TRUCK (1-axle drive) 60 6.0 ton

Unit identification number

Unit identification numbers of rear axles are stamped on the right
rear section of the axle housing.

RA-1-2
 SERVICE DATA REAR AXLE & SUSPENSION

SUSPENSION
LEAF SPRING TYPE
Item RS1A RS1B RS1D
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)
Stabilizer type — — Torsion bar system

Item RD1A RD60 RW1A

Type of suspension Rigid axle type
Type of spring Semi-elliptic leaf spring (trunnion type)
Type of shock absorber
— —
(if so equipped)
Stabilizer type — —

RA-1-3
 SERVICE DATA REAR AXLE & SUSPENSION

SPRING SPECIFICATIONS
Axle type Vehicle model Length x width x thickness-Number of leaves mm (in)
13-2 0.51-2
Main: 1600 x 90 x 14-4 (62.99 x 3.54 x 0.55-4)
13-2 0.51-2
13-2 0.51-2
CKA450 Helper: 1170 x 90 x 14-3 (46.06 x 3.54 x 0.55-3)
CKA530
13-2 0.51-2
13-2 0.51-2
RS1A Main: 1600 x 90 x 14-3 (62.99 x 3.54 x 0.55-3)
CKB450
CKB453 13-1 0.51-1
CKB520 Helper: 1,170 x 90 x 13-5 (46.06 x 3.54 x 0.51-5)
CKB533
13-2 0.51-2
Main: 1600 x 90 x 14-4 (62.99 x 3.54 x 0.55-4)
13-2 0.51-2
Helper: 1,170 x 90 x 13-5 (46.06 x 3.54 x 0.51-5)
Main: 1,600 x 90 x 13-9 (62.99 x 3.54 x 0.51-9)
Helper: 1,100 x 90 x 12-9 (43.31 x 3.54 x 0.47-9)
RS1B CKB450
Main: 1,600 x 90 x 13-10 (62.99 x 3.54 x 0.51-10)
Helper: 1,100 x 90 x 12-10 (43.31 x 3.54 x 0.47-10)
13-3 0.55-3
Main: 1800 x 90 x 18-6 (70.87 x 3.54 x 0.71-6)
RS1D CKC450 14-2 0.55-2
Helper: 1,330 x 90 x 18-6 (52.36 x 3.54 x 0.71-6)
RD1A
CDA450 1,300 x 90 x 14-11 (51.18 x 3.54 x 0.55-11)
RD60
1,300 x 90 x 20-11 (51.18 x 3.54 x 0.79-11)
CWA530
1,300 x 90 x 20-12 (51.18 x 3.54 x 0.79-12)
CWB450 20-3 0.79-3
CWB451 1300 x 90 x 22-3 (51.18 x 3.54 x 0.87-3)
CWB452 20-3 0.79-3
CWB453
CWB520
RWIA
CWB530
CWB533 1300 x 90 x20-9 (51.18 x 3.54 x 0.79-9)
CGB520
CGB533
1,400 x 90 x 20-12 (55.12 x 3.54 x 0.79-12)
CWC450
CWC610 1400 x 90 x 20-3 (55.12 x 3.54 x 0.79-3 )
22-10 0.87-10

RA-1-4
 SERVICE DATA REAR AXLE & SUSPENSION

SERVICE DATA
REAR AXLE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Measure the runout at 205 mm
Axle shaft flange surface runout 0.1 (0.004), max. 0.5 (0.020)
(8.07 in) dia. point of flange surface.
29.4 - 63.7
Conventional type hub —
{3.0 - 6.5, 6.6 - 14.3}
Hub bearing preload Conventional type with hub 30.4 - 66.7 Measure the preload at hub bolt loca-
—
N {kgf, lbf} reduction {3.1 - 6.8, 6.8 - 15.0} tion.
24.5 - 53.9
Trilex wheel —
{2.5 - 5.5, 5.5 - 12.1}

SUSPENSION
Unit: mm (in)
Maintenance stan-
Item Service limit Remarks
dard
34.98 - 35.00
Spring pin and shackle pin O.D. 34.5 (1.358)
(1.3772 - 1.3780)
35.0 - 35.1
Spring pin and shackle pin bushing I.D. 36.0 (1.417)
(1.378 - 1.382)
0 - 0.12
Clearance between spring (shackle) pin and bushing 1.0 (0.039)
(0 - 0.0047)
0.05 - 0.30
Clearance between shackle and spring bracket — Adjust with shim
(0.0020 - 0.0118)
0.05 - 0.65
Clearance between shackle and spring — Adjust with shim
(0.0020 - 0.0256)
99.93 - 99.98
Trunnion shaft O.D. 99.40 (3.9134)
(3.9342 - 3.9362)
100.17 - 100.22
Trunnion shaft bushing I.D. 100.60 (3.9606)
(3.9437 - 3.9457)
0.19 - 0.29
Clearance between trunnion shaft and bushing 1.0 (0.039)
(0.0075 - 0.0114)
4.95 - 5.05
Steel — Without oil groove
(0.1949 - 0.1988)
Thrust washer thickness
4.95 - 5.05
Bearing metal 4.70 (0.185) With oil groove
(0.1949 - 0.1988)
0.1 - 0.2
Clearance between side plate and thrust washer —
(0.004 - 0.008)
Leaf wear — 15% of nominal thickness

RA-1-5
 SERVICE DATA REAR AXLE & SUSPENSION

TIGHTENING TORQUE
REAR AXLE
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
RS1A RS1B RS1D RD1A RD60 RW1A
196 - 216 {20 - 22, 145 - 159} *O *O
Axle shaft bolt
147 - 167 {15 - 17, 108 - 123} O O O O
Hub cap bolt (Dead axle) 59 - 69 {6 - 7, 43 - 51} O
Hub bolt and nut 294 - 412 {30 - 42, 217 - 304} O O O O O O
Axle housing side 127 - 147 {13 - 15, 94 - 108} O O O O O O
Drain plug
D/F side (IPHM type) 29 - 39 {3 - 4, 22 - 29} O
Axle housing side 127 - 147 {13 - 15, 94 - 108} O O O O O O
Level plug
D/F side (IPHM type) 88 - 118 {9 - 12, 65 - 87} O

Conventional SAE type 540 - 590 {55 - 60, 398 - 435} O O O O O

Wheel nut (Both inner and type hub ISO type 590 - 630 {60 - 65, 435 - 465} O O O
outer)
Trilex wheel 343 - 412 {35 - 42, 253 - 304} O O O O
Clamp nut Trilex wheel 265 - 294 {27 - 30, 195 - 217} O O O O
M16 216 - 284 {22 - 29, 159 - 210} O
BHL41
M22 490 - 588 {50 - 60, 362 - 434} O
Brake assembly mounting
BLL41 216 - 294 {22 - 30, 159 - 217} O O
bolt and nut
RB41 216 - 265 {22 - 27, 159 - 195} O
BPL41 216 - 294 {22 - 30, 159 - 217} O O O
Differential carrier mounting bolt and nut 127 - 147 {13 - 15, 94 - 108} O O O O O O
211 - 240
Propeller shaft mounting bolt and nut O O O O O O
{21.5 - 24.5, 156 - 177}
Lock plate mounting bolt 6.9 - 8.8 {0.7 - 0.9, 5.1 - 6.5} O O O O O O
69 {7, 51} O
Spring contact seat mounting bolt
88 - 108 {9 - 11, 65 - 80} O O
Torque rod mounting bolt and nut 196 - 265 {20 - 27, 145 - 195} O O O

NOTE
z Mark * is for hub reduction type only.

RA-1-6
 SERVICE DATA REAR AXLE & SUSPENSION

SUSPENSION
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
RS1A RS1B RS1D RD1A RD60 RW1A
Spring center bolt 167 - 196 {17 - 20, 123 - 145} O O O O O O
588 - 637 {60 - 65, 434 - 470} O O — — — —
U-bolt nut
716 - 843 {73 - 86, 528 - 622} — — O O* O* O*
Clip bolt 49 - 59 {5 - 6, 36 - 43} O O O O O O
Spring pin lock bolt and nut 64 - 78 {6.5 - 8.0, 47 - 58} O O O — — —
Trunnion bracket mounting bolt 216 - 275 {22 - 28, 159 - 203} — — — O O O
Torque rod mounting bolt and nut 196 - 265 {20 - 27, 145 - 195} — — — O O O
Trunnion shaft side plate mounting bolt 216 - 235 {22 - 24, 159 - 174} — — — O O O
Trunnion shaft spring seat mounting bolt 157 - 245 {16 - 25, 116 - 181} — — — — — O
Trunnion shaft cover mounting bolt 17 - 23 {1.7 - 2.3, 12 - 17} — — — O O O
255 - 343
Trunnion shaft knock bolt and nut {26 - 35, 188 - 253} (bolt) — — — O O O
333 - 441 {34 - 45, 246 - 325}

*: Apply engine oil or grease (wet) to the nut thread, nut seat, U-bolt thread and spring seat and tighten the
nut.

RA-1-7
 TOOLS REAR AXLE & SUSPENSION

TOOLS
REAR AXLE
Application
Part name and number Description Shape
RS1A RS1B RS1D RD1A RD60 RW1A

99820 Z0005
1 99829 Z0004 — — O — — O
2 99540 Z0000
Adjusting nut Used to install/
wrench remove adjusting nut
99820 Z0009
1 99829 Z0008 O O — O O O
2 99540 Z0000

99840 Z0013 Used to remove the hub

1 99848 Z0011 1 Puller body
2 99849 Z0003 2 Puller seat — — *O — — *O
3 99532 Z0010 3 Puller bolt
4 99531 Z0004 4 Bolt (M16 x 1.5)
Rear hub puller 99840 Z0019
1 Puller body
1 99848 Z0011
2 Puller seat
2 99849 Z0004
Straight pin) O O — O O O
(15-22 04224)
3 Puller bolt
3 99532 Z0010
4 Bolt (M14 x 1.5)
4 80-54402-1A

Used to drive oil seal into

the hub
99828 Z0006 O O — — O O
(Inside and outside)

Oil seal
replacer

Used to drive oil seal into

99828 Z0007 — — *O — — *O
axle tube

NOTE
z Mark * is for Hub reduction type only.

RA-2-1
 TOOLS REAR AXLE & SUSPENSION

Application
Part name and number Description Shape
RS1A RS1B RS1D RD1A RD60 RW1A

Used to install the inner

99827 Z0062 — — — — O O
hub bearing inner races

99827 Z0007 — — *O — — *O

Used to install the outer

hub bearing inner races

Hub bearing
99827 Z0062 O O — O O O
replacer

2 99843 Z5006 Used to install the inner

O O — O O O
3 99844 Z5000 hub bearing outer races

1 99843 Z5005 Used to install the outer

O O — O O O
3 99844 Z5000 hub bearing outer races

Used when simulta-

Hub inner neously removing the
bearing puller 99843 Z0005 inner bearing and the oil O O — O O O
attachment seal retainer of the rear
axle.

Oil seal Used to install the oil seal

retainer 99827 Z0061 retainer of inner hub O O — O O O
replacer bearing

NOTE
z Mark * is for Hub reduction type only.

RA-2-2
 TOOLS REAR AXLE & SUSPENSION

Application
Part name and number Description Shape
RS1A RS1B RS1D RD1A RD60 RW1A

Used for press fitting the

inner race of the inner
99827 Z0064 — — — — — O
and outer bearings onto
the shaft.

Final through
shaft bearing
replacer

Used for press fitting the

outer race of the inner
99827 Z0065 — — — — — O
and outer bearings onto
the shaft.

RA-2-3
 TOOLS REAR AXLE & SUSPENSION

SUSPENSION
Application
Part name and number Description Shape
RS1A RS1B RS1D RD1A RD60 RW1A

Used when replacing the

Bushing
99888 Z0012 spring (shackle) pin bush- O O O — — —
replacer
ing

Used when removing the

T-type socket 99535 Z0005 O O O O O O
spring clip bolt

Used to remove and

Replacing tool 99888 Z0065 install the torque rod — — — O O O
bushing

Bushing Used to remove the

99896 Z0005 — — — O O O
remover spring seat bushing

99883 Z0006
1 99888 Z0060
Used to replace the — — — O O —
2 99894 Z0001
3 81-14055-1A spring seat (trunnion
Bushing shaft) bushing
replacer 1 Replacer
99883 Z0007 2 Attachment
1 99888 Z0061 3 Bolt — — — — — O
2 99894 Z0001
3 81-14055-1A

RA-2-4
 REAR AXLE RS1A, RS1B, RS1D

=UNIT NAME RS1A, RS1B, RS1D=

REAR AXLE
CONSTRUCTION
RS1A and RS1B model (Inboard type)

RA-3-1
 REAR AXLE RS1A, RS1B, RS1D

RS1A and RS1B model (Outboard type)

RA-3-2
 REAR AXLE RS1A, RS1B, RS1D

RS1D (With hub reduction)

Trilex wheel
[Type 20”]

RA-3-3
 REAR AXLE RS1A, RS1B, RS1D

DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the front wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE
type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Trilex wheel nuts are right-hand threaded on the right and
left sides. (Wheel clamp nuts have right-hand threads both
on the right and left sides.)
6. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.

7. 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.

8. When removing the tire, be careful not to damage the hub

bolt threads.
9. Because the wheel is heavy, take care not to allow it to fall
toward you.
Refer to the “DISASSEMBLY” section for the disassembled view.
10. Remove the drain plug, and drain the gear oil.
NOTE
z Use an oil container which is larger in proportion to the
required amount.

RA-3-4
 REAR AXLE RS1A, RS1B, RS1D

11. When removing brake hose and tube, have a tray on hand
for the parts to be removed.

RA-3-5
 REAR AXLE RS1A, RS1B, RS1D

DISASSEMBLY

RS1A AND RS1B MODELS

RA-3-6
 REAR AXLE RS1A, RS1B, RS1D

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Trilex wheel
I Clamp 1. Level plug 4. Gasket
II Wheel nut 2. Gasket 5. Axle shaft
III Adapter 3. Drain plug

Inboard type Outboard type

+ 6. Oil seal + 6. Oil seal ,+ 19. Brake assembly
7. Lock washer 7. Brake drum 20. Bolt
,+ 8. Adjusting nut 8. Lock washer 21. Nut
9. Thrust washer ,+ 9. Adjusting nut 22. Air breather
, 10. Outer bearing inner race 10. Thrust washer ,+ 23. Axle housing
11. Brake drum , 11. Outer bearing inner race
+ 12. Hub + 12. Hub
,+ 13. Inner bearing inner race ,+ 13. Inner bearing inner race
,+ 14. Oil seal retainer ,+ 14. Oil seal retainer
15. Oil seal 15. Oil seal
16. Outer bearing outer race 16. Outer bearing outer race
17. Inner bearing outer race 17. Inner bearing outer race
18. Hub bolt 18. Hub bolt (Serration type)
Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-3-7
 REAR AXLE RS1A, RS1B, RS1D

RS1D

RA-3-8
 REAR AXLE RS1A, RS1B, RS1D

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

NOTE
z For disassembly and assembly of the hub reduction, refer to “Hub reduction”.

Trilex wheel 1. Level plug 14. Brake drum

I Clamp 2. Gasket , 15. Oil slinger
II Wheel nut 3. Drain plug 16. Oil seal
III Adapter 4. Gasket 17. Outer bearing outer race
,+ 5. Axle shaft 18. Inner bearing outer race
6. O-ring 19. Hub bolt (Serration type)
7. Lock plate ,+ 20. Brake assembly
,+ 8. Adjusting nut 21. Bolt
9. Oil seal 22. Nut
, 10. Outer bearing inner race 23. Air breather
+ 11. Hub ,+ 24. Axle housing
12. Inner bearing inner race
13. Oil seal retainer

Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

5 Axle shaft
1. Be careful not to scratch the oil seal when removing the
axle shaft.

5 Axle shaft (RS1D model with Hub reduction type only)

1. Remove the ring gear and axle shaft.
2. Be careful not to scratch the oil seal when removing the
axle shaft.
3. The axle shaft cannot easily be withdrawn as a shingle unit.

RA-3-9
 REAR AXLE RS1A, RS1B, RS1D

6 Oil seal (Except RS1D Hub reduction type model)

1. When removing the oil seal, pinch the protrusion with pliers.
Do not pry the oil seal with a screwdriver or other tool.

8 RS1A, RS1B (Inboard type), RS1D model

9 RS1A, RS1B (Outboard type) } Adjusting
nut
Remove the adjusting nut with the adjusting nut wrench.

Models Adjusting nut wrench

RS1A, RS1B 99820 Z0009
RS1D 99820 Z0005

11 RS1D
12 RS1A, RS1B
}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.

Models Adjusting nut wrench

RS1D 99840 Z0013
RS1A and RS1B 99840 Z0019

RA-3-10
 REAR AXLE RS1A, RS1B, RS1D

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.
13 Inner bearing inner race
14 Oil seal retainer } Eexcept RS1D hub reduc-
tion type
Using a bearing puller attachment, remove the inner bearing inner
race together with the oil seal retainer.

Models Bearing puller attachment

RS1A, RS1B 99843 Z0005

19 RS1A, RS1B
20 RS1D
}Brake assembly
For disassembly procedure of the brake assembly, refer to the “BR”
section.

23 RS1A, RS1B
24 RS1D
} Axle housing
Carefully lower the jack and extract the axle housing.
CAUTION
z Be careful not to drop the axle housing.

RA-3-11
 REAR AXLE RS1A, RS1B, RS1D

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Axle shaft flange surface runout

Unit: mm (in)
Mainte-
Service
Models nance Remarks
limit
standard
RS1A Measure the runout at
RS1B 0.1 (0.004) 0.5 (0.020) 205 mm (8.07 in) dia.
RS1D point of flange surface.

REPAIR AND REPLACEMENT

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.

RA-3-12
 REAR AXLE RS1A, RS1B, RS1D

3. Clinch the heads of the hub bolts (on the nut sides) at three
places.

<ISO>

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.
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 Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
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.

RA-3-13
 REAR AXLE RS1A, RS1B, RS1D

z Do not allow foreign matter to get into the bearing or hub

grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

Removal and installation using hammer

If hub bolts need to be replaced in emergencies, such as when
trouble occurs, etc., proceed as follows:
1. Remove hub bolts from the hub.
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

z Be careful not to scratch the hub, brake drum, and adja-

cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.

2. Press new hub bolts into the hub.

RA-3-14
 REAR AXLE RS1A, RS1B, RS1D

<Pressing hub bolts into a new hub>

z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Align hub bolt serrations with hub bolt hole serrations.
z Lightly tap hub bolt heads to properly mesh with the mating
serrations.
z Using a hammer (10 N {1 kgf, 2 lbf} weight, min.) and pad,
drive hub bolts straight into place.
NOTE
z Be careful not to scratch the hub or brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure hub bolts are flush and pressed properly.
z Wipe off oil seepage.

HUB BEARING
1. Remove the oil seal and the outer races of the inner and
outer bearings from the hub.
NOTE
z When removing the outer race of the outer bearing, use a
puller and other appropriate tools for the notches in the
grease collector and then remove.
z When changing the hub bearing, the inner and outer
races are changed as a set. Better results will also be

RA-3-15
 REAR AXLE RS1A, RS1B, RS1D

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)
Model Tool number Bearing outside diameter
RS1A
99843 Z5005 150 (5.91)
RS1B
RS1A
99843 Z5006 160 (6.30)
RS1B

OIL SEAL
Hub portion oil seal (RS1A and RS1B)
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.

Axle housing tube portion oil seal (RS1D only)

1. Remove the oil seal from the end of the axle housing tube.
2. Drive a new oil seal into place with the oil seal replacer
(99828 Z0007).
NOTE
z Apply grease to the lip portion before putting on the oil
seal.

RA-3-16
 REAR AXLE RS1A, RS1B, RS1D

GREASE
All markedly soiled deposits of grease should be removed from the
inner hub and bearings and replaced with new grease.
Rear hub greasing procedure

REASSEMBLY
REASSEMBLY
Key point of reassembly
23 RS1A, RS1B
24 RS1D
} Axle housing
Install the axle housing. Install the upper pad above the leaf spring.
Tighten the pad with U-bolts.
CAUTION
z Support the axle housing with a jack and proceed very
carefully with work.
z Face the lower pad with the arrow mark down and point
the arrow toward the front.

U-bolt nut
Unit: N·m {kgf·m, ft·lbf}
Models Tightening torque
RS1A, RS1B 588 - 637 {60 - 65, 434 - 470}
RS1D 716 - 843 {73 - 86, 528 - 622}

RA-3-17
 REAR AXLE RS1A, RS1B, RS1D

19 RS1A, RS1B
20 RS1D } Brake assembly
For installation procedure of the brake assembly, refer to the “BR”
section.

15 Oil slinger (RS1D hub reduction type only)

Apply RTV (Room Temperature Vulcanizing) liquid gasket (THREE
BOND #1215 or equivalent) to the oil slinger before installing it on
the hub.
NOTE
z Before installing the oil slinger, ensure that its and the
hub's surfaces are clean and free of dust.

14 Oil seal retainer (Except RS1D Hub reduction type

model)
Drive the oil seal retainer into the axle housing tube with the oil seal
retainer replacer.
Models Oil seal retainer replacer
RS1A
99827 Z0061
RS1B

13 Inner bearing inner race

(Except RS1D Hub reduction type model)
Drive the inner race of the housing tube with the inner hub bearing
replacer.
Models Oil seal retainer replacer
RS1A, RS1B 99827 Z0062

NOTE
z Remove all excess grease from the perimeter of the bear-
ing.

RA-3-18
 REAR AXLE RS1A, RS1B, RS1D

10 RS1A, RS1B (Inboard type), RS1D Outer bearing

11 RS1A, RS1B (Outboard type) }inner race
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 Oil seal retainer replacer

RS1D 99827 Z0007

Models Oil seal retainer replacer

RS1A and RS1B 99827 Z0062

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 RS1A, RS1B (Inboard type), RS1D Adjusting nut
9 RS1A, RS1B (Outboard type)
1. Attach adjusting nut and tighten with adjusting nut wrench.

Models Adjusting nut wrench

RS1D 99820 Z0005
RS1A
99820 Z0009
RS1B

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 60~ 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.

RA-3-19
 REAR AXLE RS1A, RS1B, RS1D

Preload
Unit: N {kgf, lb}
Maintenance standard
Item
(At hub bolt location)
Conventional type hub 29.4 - 63.7 {3.0 - 6.5, 6.6 - 14.3}
Conventional type with hub
30.4 - 66.7 {3.1 - 6.8, 6.8 - 15.0}
reduction
Trilex wheel 24.5 - 53.9 {2.5 - 5.5, 5.5 - 12.1}

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
z RS1A and RS1B model
1. Insert a new gasket and insert it on the axle shaft.
z RS1D model (Hub reduction type)
Apply a coat of “LOCTITE” (10127 90002) to the bolts before
installing.

WARNING
WARNING
z Be careful not to pinch your fingers.

CAUTION
z Be careful not to damage the oil seal.

RA-3-20
 REAR AXLE RS1A, RS1B, RS1D

2. Tighten the axle shaft bolts.

Unit: N·m {kgf·m, ft·lbf}
Models Tightening torque
RS1A
147 - 167 {15 - 17, 108 - 123}
RS1B
RS1D (with hub reduc-
196 - 216 {20 - 22, 145 - 159}
tion)

INSTALLATION
<SAE type and ISO type>
Key point of installation
Connect the brake hose with the connector on the axle housing.
CAUTION
z Apply a coat of Three Bond #1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.

NOTE
z Be careful not to twist the air hose.

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
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
washers (the tapered portion). Wipe away any excess
with a clean wastecloth. Do not apply any oil to the work-
RA-3-21
 REAR AXLE RS1A, RS1B, RS1D

ing face of the wheel disc and wheel nuts. Do not use
molybdenum grease for this purpose.

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.

3. 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}
： 590 - 630 N·m {60 - 65 kgf·m, 435 - 465 ft·lbf}
CAUTION
z Tighten the wheel nuts diagonally as shown at right.
Tighten to the specified torque in several steps.

<Trilex wheel>
Key point of installation
1. Align the concave portion of the adapter with the projections
of the inner wheel rim at each side of the tire valve, and
place the tire far back in the rim and adapter.

2. Place the spacer so that its stopper is positioned at the tire

valve location of the inner wheel rim.

RA-3-22
 REAR AXLE RS1A, RS1B, RS1D

3. Install the outer wheel rim so that the projections (one on

each side of the tire valve for inner and outer wheel rims)
are positioned in a symmetrical location.
4. Install clamps and nuts on the upper and lower sides of the
adapter at two places, tighten the nuts temporarily and cen-
ter the rims.
5. Install the remaining clamps and nuts, and slightly tighten
the nuts, one at a time, circumferentially, until the specified
torque is reached.
： 265 - 294 N·m {27 - 30 kgf·m, 195 - 217 ft·lbf}

NOTE
z Do not tighten the nuts diagonally, or in a criss-cross
fashion.
z Ensure the rim touches the entire tapered seat surface of
the adapter.
z After installing the wheels on the vehicle, drive the vehi-
cle about 100 km (62 miles) and check the tightening
torque of the nuts. Re-tighten the nuts if needed.
z If the rim and the tapered seat surface of the adapter do
not come into close contact (this often occurs when the
tire is new and its bead is still hard) although the nuts are
tightened to the specified torque setting, decrease the
tire pressure, attach the rims to the adapter and then
reinflate the tire.
6. Adjust the brake lining-to-drum clearance. Refer to the BR
section for procedures.

RA-3-23
 SUSPENSION RS1A, RS1B, RS1D

SUSPENSION
CONSTRUCTION
SUSPENSION
Type I

Type II

NOTE
z Rear suspensions Type I and Type II are applicable to the following truck models.

Type I: RS1A and RS1B models

Type II: RS1D model

RA-4-1
 SUSPENSION RS1A, RS1B, RS1D

STABILIZER

DISASSEMBLY
REMOVAL
Key point of removal
Chock the front wheels and remove mud and grease from the sus-
pension system before dismounting.

1. Jack up the rear axle and place a safety stand under the
frame at the rear of the spring. The stand should be such
that the rear wheels are 10 to 20 mm (0.39 to 0.79 in) off the
ground when the spring is free.
WARNING
WARNING
z In order to prevent a serious injury or accident, never get
under the vehicle while jacking it up.

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)

RA-4-2
 SUSPENSION RS1A, RS1B, RS1D

DISASSEMBLY
<SUSPENSION>
Type I

RA-4-3
 SUSPENSION RS1A, RS1B, RS1D

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cotter pin 13. Washer , 25. Lock bolt
2. Castellated nut 14. Shock absorber + 26. Spring pin
3. Washer 15. Shock absorber pin 27. Shim
4. Rubber bushing , 16. U-bolt nut , 28. Shackle
5. Rubber bushing 17. Lower pad , 29. Grease nipple
6. Washer 18. U-bolt , 30. Lock bolt
7. Nut 19. Upper pad ,+ 31. Spring pin
8. Washer , 20. Grease nipple 32. Shim
9. Rubber cushion , 21. Lock bolt + 33. Spring assembly
10. Washer ,+ 22. Shackle pin 34. Contact seat
11. Washer 23. Shim
12. Rubber cushion , 24. Grease nipple
Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-4-4
 SUSPENSION RS1A, RS1B, RS1D

Type II

RA-4-5
 SUSPENSION RS1A, RS1B, RS1D

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

, 1. U-bolt nut 8. Shim , 15. Lock bolt
2. Lower pad 9. Grease nipple ,+ 16. Spring pin
3. U-bolt , 10. Lock bolt 17. Shim
4. Upper pad + 11. Spring pin + 18. Spring assembly
5. Grease nipple 12. Shim 19. Contact seat
, 6. Lock bolt , 13. Shackle
,+ 7. Shackle pin 14. Grease nipple

Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-4-6
 SUSPENSION RS1A, RS1B, RS1D

<STABILIZER>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Nut , 8. Stabilizer cap 15. Stabilizer link rod
2. Bolt , 9. Bushing 16. Bushing
3. Grease nipple 10. Stabilizer bar 17. Lock nut
+ 4. Pin 11. Bushing 18. Lock washer
5. Nut 12. Lock nut 19. Bolt
6. Wave washer 13. Washer 20. Stabilizer bracket
7. Bolt 14. Stabilizer pin 21.

Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-4-7
 SUSPENSION RS1A, RS1B, RS1D

<SUSPENSION>
Key point of disassembly
22 Type I and 7 Type II shackle pin

1. Measure and record the clearances between the shackle

and spring bracket, and between the shackle and spring.
2. Remove the grease nipple and bolt.
Be sure to remove the shackle and spring assembly as a
unit.
NOTE
z Use a copper rod when removing the shackle pin.
z Record the thickness of the shims after removal.

26 Type I and 11 Type II spring pin (Shackle)

Remove the grease nipple and bolt.
NOTE
z Use a copper rod when removing the spring pin.
z Record the thickness of the shims after removal.

31 Type I and 16 Type II spring pin

Remove the grease nipple and bolt.
NOTE
z Use a copper hammer when removing the spring pin.

33 Type I and 18 type II spring assembly

Be sure to secure the spring assembly to a suitable attachment so
that it will not drop when separated.

RA-4-8
 SUSPENSION RS1A, RS1B, RS1D

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Spring pin and shackle pin outside diameter
Unit: mm (in)
Maintenance standard Service limit
34.98 - 35.00 (1.3772 - 1.3780) 34.5 (1.358)

Spring pin and shackle pin bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
35.0 - 35.1 (1.378 - 1.382) 36.0 (1.417)

Clearance between spring (shackle) pin and bushing

Unit: mm (in)
Maintenance standard Service limit
0 - 0.12 (0 - 0.0047) 1.0 (0.039)

Clearance between shackle and spring bracket (L1)

Unit: mm (in)
Maintenance standard Remarks
Adjust with shim
0.05 - 0.30 (0.0020 - 0.0118) Thickness of shims:
1.8, 2.0, 2.3 (0.071, 0.079, 0.091)

Clearance between shackle and spring (L2)

Unit: mm (in)
Maintenance standard Remarks
Adjust with shim
0.05 - 0.65 (0.002 - 0.026) Thickness of shims:
1.8, 2.0, 2.3 (0.071, 0.079, 0.091)

RA-4-9
 SUSPENSION RS1A, RS1B, RS1D

REPAIR AND REPLACEMENT

<SUSPENSION>
Leaf spring
1. Remove the clip bolt with the T-type socket (99535 Z0005).

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.
4. 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.

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}

Bushing
1. Remove the bushing using bushing replacer (99888
Z0012).

RA-4-10
 SUSPENSION RS1A, RS1B, RS1D

2. Attach a new bushing to the bushing replacer (99888

Z0012) and install.

<STABILIZER>
Key point of disassembly
4 Pin
Use a copper hammer when removing the pin.

REASSEMBLY
<SUSPENSION>
Apply a coat of bearing grease to the sliding sections of the various
parts before installation.

Key point of reassembly

31 Type I and 16 Type II spring pin
Using a garage jack, support the spring assembly. Connect the
front of the spring assembly to the bracket with a spring pin. Align
the cutout section for the spring pin lock bolt with the bracket when
driving in the spring pin.
NOTE
z Use a copper hammer when driving in the spring pin.

30 Type I and 15 Type II lock bolt

Insert the lock bolt from the front.

RA-4-11
 SUSPENSION RS1A, RS1B, RS1D

29, 24, 20 Grease nipple (Type I only)

1. Install the front side grease nipple so that it faces the vehi-
cle front, and install the rear side grease nipple facing the
vehicle rear.
2. Apply grease to service points through the grease fittings.

28 Type I and 13 Type II shackle

1. Select suitable shims so that the clearance between the

bracket and shackle is within the specified range.
Unit: mm (in)
Maintenance standard Thickness of shims
0.05 - 0.30 (0.0020 - 0.0118) 1.8, 2.0, 2.3 (0.071, 0.079, 0.091)

2. Align the cutout section for the spring pin lock bolt with the
shackle before driving the spring pin into place.
NOTE
z Use a copper hammer when driving in the spring pin.

25 Type I and 10 Type II lock bolt

Be sure to insert the lock bolt from the front.

22 Type I and 7 Type II shackle pin

1. Using a shackle pin, connect the shackle (located at the
rear of the spring) to the spring bracket with shims placed
on both sides of the shackle.
2. Select suitable shims so that the clearance between the
bracket and shackle is within the specified range.
Unit: mm (in)
Maintenance standard Thickness of shims
0.05 - 0.65 (0.0020 - 0.0256) 1.8, 2.0, 2.3 (0.071, 0.079, 0.091)

RA-4-12
 SUSPENSION RS1A, RS1B, RS1D

3. Align the cutout section for the shackle pin lock bolt with the
bracket before installing the shackle pin.
NOTE
z Use a copper hammer when driving in the shackle pin.

21 Type I and 6 Type II lock bolt

Insert the lock bolt from the front.

16 Type I and 1 Type II U-bolt nut

When securing the spring, jack up the vehicle until the rear axle
contacts the spring.
： Type I 588 - 637 N·m {60 - 65 kgf·m, 434 - 470 ft·lbf}
Type II 716 - 843 N·m {73 - 86 kgf·m, 528 - 622 ft·lbf}

<STABILIZER>
Key point of reassembly
9 Bushing
Be sure to install the bushing with the protruded portion facing the
direction shown in the figure below.

8 Stabilizer cap
1. Temporarily install the stabilizer bar on the stabilizer link rod
using the bushing and cap.
2. Tighten the stabilizer cap securely after installing the stabi-
lizer bar on the stabilizer bracket.

RA-4-13
 REAR AXLE RD1A, RD60, RW1A

=UNIT NAME RD1A, RD60, RW1A=

REAR AXLE
CONSTRUCTION
RD1A and RW1A model (Inboard type)

RA-5-1
 REAR AXLE RD1A, RD60, RW1A

RW1A model (Outboard type)

RA-5-2
 REAR AXLE RD1A, RD60, RW1A

RD60

RA-5-3
 REAR AXLE RD1A, RD60, RW1A

Trilex wheel
[Type 20”]

[Type 24”]

RA-5-4
 REAR AXLE RD1A, RD60, RW1A

DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the front wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE
type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Trilex wheel nuts are right-hand threaded on the right and
left sides. (Wheel clamp nuts have right-hand threads both
on the right and left sides.)
6. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.

7. 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.

8. When removing the tire, be careful not to damage the hub

bolt threads.
9. Because the wheel is heavy, take care not to allow it to fall
toward you.
Refer to the “DISASSEMBLY” section for the disassembled view.
10. Remove the drain plug, and drain the gear oil.
NOTE
z Use an oil container which is larger in proportion to the
required amount.

RA-5-5
 REAR AXLE RD1A, RD60, RW1A

11. When removing brake hose and tube, have a tray on hand
for the parts to be removed.

NOTE (AOH) type

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.

RA-5-6
 REAR AXLE RD1A, RD60, RW1A

DISASSEMBLY
RD1A and RD60 models

RA-5-7
 REAR AXLE RD1A, RD60, RW1A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Level plug ,+ 8. Adjusting nut 17. Inner bearing outer race
2. Gasket 9. Thrust washer 18. Hub bolt
3. Drain plug , 10. Outer bearing inner race ,+ 19. Brake assembly
4. Gasket 11. Brake drum 20. Bolt
,+ 5. Axle shaft (except RD60 model) + 12. Hub 20-1. Axle tube (Dead axle RD60 only)
5-1. Hub cap (RD60 only) ,+ 13. Inner bearing inner race 21. Nut
+ 6. Oil seal ,+ 14. Oil seal retainer 22. Air breather
6-1. Gasket (RD60 only) 15. Oil seal ,+ 23. Axle housing
7. Lock plate 16. Outer bearing outer race
Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-5-8
 REAR AXLE RD1A, RD60, RW1A

RW1A model

RA-5-9
 REAR AXLE RD1A, RD60, RW1A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Trilex wheel 1. Level plug
I Clamp 2. Gasket
II Wheel nut 3. Drain plug
III Adapter 4. Gasket
,+ 5. Axle shaft
,+ 5-1. Axle shaft (hub reduction type only)

Hub reduction type Outboard type Inboard type

6. O-ring + 6. Oil seal + 6. Oil seal
7. Lock plate , 7. Brake drum 7. Lock plate
,+ 8. Adjusting nut 8. Lock plate ,+ 8. Adjusting nut
8-1. Oil seal ,+ 9. Adjusting nut 9. Thrust washer
9. Outer bearing inner race 10. Thrust washer , 10. Outer bearing inner race
+ 10. Hub , 11. Outer bearing inner race 11. Brake drum
11. Inner bearing inner race + 12. Hub + 12. Hub
12. Oil seal retainer ,+ 13. Inner bearing inner race ,+ 13. Inner bearing inner race
, 13. Brake drum ,+ 14. Oil seal retainer ,+ 14. Oil seal retainer
14. Oil slinger 15. Oil seal 15. Oil seal
15. Oil seal 16. Outer bearing outer race 16. Outer bearing outer race
16. Outer bearing outer race 17. Inner bearing outer race 17. Inner bearing outer race
17. Inner bearing outer race 18. Hub bolt (Serration type) 18. Hub bolt
18. Hub bolt (Serration type)

Through shaft assembly

,+ 19. Brake assembly 29. Bolt
20. Pinion nut 30. Spring contact seat
21. Companion flange 31. Bolt
22. Dust cover 32. Nut
23. Oil seal 33. Air breather
24. Snap ring ,+ 34. Axle housing
, 25. Bearing
26. Spacer
27. Bearing retainer
28. Through shaft
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

5 Axle shaft {RD1A and RW1A (except hub reduction type)}
1. Be careful not to scratch the oil seal when removing the
axle shaft.

RA-5-10
 REAR AXLE RD1A, RD60, RW1A

5-1 Axle shaft (RW1A hub reduction type only)

1. Remove the ring gear and axle shaft.
2. Be careful not to scratch the oil seal when removing the
axle shaft.
3. The axle shaft cannot easily be withdrawn as a shingle unit.

6 Oil seal (RD1A and RW1A (except hub reduction type))

1. When removing the oil seal, pinch the protrusion with pliers.
Do not pry the oil seal with a screwdriver or other tool.

8 RD1A, RD60, RW1A (hub reduction type and inboard type)

and 9 RW1A (outboard type) adjusting nut
Remove the adjusting nut with the adjusting nut wrench.

Models Adjusting nut wrench

RS1A, RS1B 99820 Z0009
RS1D 99820 Z0005

10 RW1A (Hub reduction type), 12 RD1A, RD60 and RW1A

(except hub reduction type) 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.

Models Adjusting nut wrench

RS1D 99840 Z0013
RS1A and RS1B 99840 Z0019

RA-5-11
 REAR AXLE RD1A, RD60, RW1A

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.

13 Inner bearing inner race and 14 Oil seal retainer

Using a bearing puller attachment, remove the inner bearing inner
race together with the oil seal retainer.

Models Bearing puller attachment

RD1A, RD60 and RW1A
(Except hub reduction 99843 Z0005
type)

19 Brake assembly
For disassembly procedure of the brake assembly, refer to the “BR”
section.

23 RD1A, 34 RW1A axle housing

1. Remove the axle housing.
CAUTION
z Be careful not to drop the axle housing.

2. Support the axle housing (second rear axle) with a wire,

and support the axle housing (first rear axle) with a jack.

RA-5-12
 REAR AXLE RD1A, RD60, RW1A

NOTE
z Secure the spring assembly to prevent it from turning.

3. Remove the spring contact seat.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Rear axle shaft flange surface runout

Unit: mm (in)
Maintenance standard Service limit Remarks
Measure the runout at 205 mm
0.1 (0.004) max. 0.5 (0.020) (8.07 in) dia. point of flange sur-
face.

REPAIR AND REPLACEMENT

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.
Contact seat mounting bolt and nut.
Unit: N·m {kgf·m, ft·lbf}
Models Tightening torque
RD60 69 {7, 51 }
RD1A and RW1A 88 - 108 {9 - 11, 65 - 80}

RA-5-13
 REAR AXLE RD1A, RD60, RW1A

z Connect the axle housing (second 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 (first rear axle) with the torque
rod; and then remove the wire used to suspend the axle
housing (second rear axle).
： 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}

HUB AND HUB BOLT

<SAE type>
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 (Inboard
type only).
： 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. Align the flange of the hub bolt with the groove in the hub,
and tighten the bolt with the hub nut (Outboard type only).
： 294 - 412 N·m {30 - 42 kgf·m, 217 - 304 ft·lbf}
NOTE
z The left and right hub bolts have the same design.
z Ensure that the more rounded hub bolt end faces the out-
side of the vehicle.

RA-5-14
 REAR AXLE RD1A, RD60, RW1A

3. After tightening the hub bolt, clinch the thread end 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.
NOTE
z Be careful not to scratch the hub, brake drum and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.

2. Press bolts into the hub.

RA-5-15
 REAR AXLE RD1A, RD60, RW1A

<Pressing hub bolts into a new hub>

z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
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.

z Do not allow foreign matter to get into the bearing or hub

grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

Removal and installation using hammer

If hub bolts need to be replaced in emergencies, such as when
trouble occurs, etc., proceed as follows:
1. Remove hub bolts from the hub.
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.

RA-5-16
 REAR AXLE RD1A, RD60, RW1A

NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.

2. Press new hub bolts into the hub.

<Pressing hub bolts into a new hub>

z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Align hub bolt serrations with hub bolt hole serrations.
z Lightly tap hub bolt heads to properly mesh with the mating
serrations.
z Using a hammer (10 N {1 kgf, 2 lbf} weight, min.) and pad,
drive hub bolts straight into place.
NOTE
z Be careful not to scratch the hub or brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.
z Ensure hub bolts are flush and pressed properly.
z Wipe off oil seepage.

RA-5-17
 REAR AXLE RD1A, RD60, RW1A

HUB BEARING
Use a hub bearing replacer.
[as a set including the brace rod (99844 Z5000)].
Unit: mm (in)
Tool number Bearing outside diameter
99843 Z5005 (Inner) 150 (5.91)
99843 Z5006 (Outer) 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 Z0007) to install the oil seal.

RA-5-18
 REAR AXLE RD1A, RD60, RW1A

GREASE
Pack the hub assembly with grease.
Rear hub greasing procedure
<Drive axle type>

<Dead axle type>

RA-5-19
 REAR AXLE RD1A, RD60, RW1A

REASSEMBLY
REASSEMBLY
Key point of reassembly
23 RD1A, 34 RW1A axle housing
1. Connect the axle housing (first rear axle) with the torque
rod; and then remove the wire used to suspend the axle
housing (second rear axle).
： 196 - 265 N·m {20 - 27 kgf·m, 145 - 195 ft·lbf}

NOTE
z Free the spring assembly so that it can rotate.

2. Install the axle housing. Install the spring pad above the leaf
spring. Tighten the pad with U-bolts.
CAUTION
z Support the axle housing with a jack and proceed very
carefully with work.

U-bolt nut
Unit: N·m {kgf·m, ft·lbf}
Models Tightening torque
RS1D 716 - 843 {73 - 86, 528 - 622}

*:Apply engine oil or grease (wet) to the nut thread, nut seat, U-bolt
thread and spring seat and tighten the nut.

25 Bearing (RW1A only)

Using a bearing replacer, drive the bearing into the final through
shaft.
Item Bearing replacer
Inner race 99827 Z0064
Outer race 99827 Z0065

19 Brake assembly
For installation procedure of the brake assembly, refer to the “BR”
section.

RA-5-20
 REAR AXLE RD1A, RD60, RW1A

14 Oil seal retainer

Use an oil seal retainer replacer (99827 Z0061) to install the oil seal
retainer.

13 Inner bearing inner race

Use a bearing replacer (99827 Z0062) to install the bearing.

13 RW1A (Hub reduction type) and 7 RW1A (Outboard type)

brake drum
Be sure that the screw head does not protrude from the surface of
the brake drum. (Outboard type only)

11 RW1A (outboard), 10 RD1A, RD60, and RW1A (inboard

type) outer bearing inner race
Use an bearing replacer (99827 Z0062) to install the bearing.

9 RW1A (outboard type), 8 RD1A, RD60 and RW1A (inboard

type) 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.

RA-5-21
 REAR AXLE RD1A, RD60, RW1A

Preload
Unit: N kgf, lbf
Maintenance standard
Item Service limit
(At hub bolt location)
29.4 - 63.7
Conventional type hub —
{3.0 - 6.5, 6.6 - 14.3}
Conventional type hub 30.4 - 66.7
—
with hub reduction {3.1 - 6.8, 6.8 - 15.0}
24.5 - 53.9
Trilex wheel —
{2.5 - 5.5, 5.5 - 12.1}

1. Turn the brake drum more than 90~ and read the average
valve.
2. If the preload is not within maintenance standards, adjust
using the adjusting nut.
3. 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.

5 Axle shaft (Except RW1A hub reduction type)

Install the axle shaft.

WARNING
WARNING
z Be careful not to pinch your fingers.

CAUTION
z Be careful not to damage the oil seal.

5-1 Axle shaft (RW1A hub reduction type only)

Apply a coat of “LOCTITE” (10127 90002) to the bolts before
installing.
WARNING
WARNING
z Be careful not to pinch your fingers.

CAUTION
z Be careful not to damage the oil seal.

RA-5-22
 REAR AXLE RD1A, RD60, RW1A

Axle shaft bolt

Unit: N·m {kgf·m, ft·lbf}
Models Tightening torque
RD1A, RD60 and RW1A 147 - 167 {15 - 17, 108 - 123}
RW1A (Hub reduction
196 - 216 {20 - 22, 145 - 159}
type)

INSTALLATION
<SAE type and ISO type>
Key point of installation
Connect the brake hose with the connector on the axle housing.
CAUTION
z Apply a coat of Three Bond #1104 (or equivalent) to the
flared section of the air hose and piping before connect-
ing. Be careful that sealant does not get into the hose
and tube.

NOTE
z Be careful not to twist the air hose.

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
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
washers (the tapered portion). Wipe away any excess
with a clean wastecloth. Do not apply any oil to the work-

RA-5-23
 REAR AXLE RD1A, RD60, RW1A

ing face of the wheel disc and wheel nuts. Do not use
molybdenum grease for this purpose.

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.

3. 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}
： 590 - 630 N·m {60 - 65 kgf·m, 435 - 465 ft·lbf}
CAUTION
z Tighten the wheel nuts diagonally as shown at right.
Tighten to the specified torque in several steps.

<Trilex wheel>
Key point of installation
1. Align the concave portion of the adapter with the projections
of the inner wheel rim at each side of the tire valve, and
place the tire far back in the rim and adapter.

2. Place the spacer so that its stopper is positioned at the tire

valve location of the inner wheel rim.

RA-5-24
 REAR AXLE RD1A, RD60, RW1A

3. Install the outer wheel rim so that the projections (one on

each side of the tire valve for inner and outer wheel rims)
are positioned in a symmetrical location.
4. Install clamps and nuts on the upper and lower sides of the
adapter at two places, tighten the nuts temporarily and cen-
ter the rims.
5. Install the remaining clamps and nuts, and slightly tighten
the nuts, one at a time, circumferentially, until the specified
torque is reached.
： 265 - 294 N·m {27 - 30 kgf·m, 195 - 217 ft·lbf}

NOTE
z Do not tighten the nuts diagonally, or in a criss-cross
fashion.
z Ensure the rim touches the entire tapered seat surface of
the adapter.
z After installing the wheels on the vehicle, drive the vehi-
cle about 100 km (62 miles) and check the tightening
torque of the nuts. Re-tighten the nuts if needed.
z If the rim and the tapered seat surface of the adapter do
not come into close contact (this often occurs when the
tire is new and its bead is still hard) although the nuts are
tightened to the specified torque setting, decrease the
tire pressure, attach the rims to the adapter and then
reinflate the tire.
6. Adjust the brake lining-to-drum clearance. Refer to the BR
section for procedures.

RA-5-25
 SUSPENSION RD1A, RD60, RW1A

SUSPENSION
CONSTRUCTION
Type I
[Rear 1-axle drive model]

RA-6-1
 SUSPENSION RD1A, RD60, RW1A

Type II
[Rear 2-axle drive model]

RA-6-2
 SUSPENSION RD1A, RD60, RW1A

DISASSEMBLY
REMOVAL
Key point of removal
Chock the front wheels and remove mud and grease from the sus-
pension system before dismounting.

1. Jack up the rear axle and place a safety stand under the
frame at the rear of the spring. The stand should be such
that the rear wheels are 10 to 20 mm (0.39 to 0.79 in) off the
ground when the spring is free.
WARNING
WARNING
z In order to prevent a serious injury or accident, never get
under the vehicle while jacking it up.

RA-6-3
 SUSPENSION RD1A, RD60, RW1A

DISASSEMBLY
Type I
[Rear 1-axle drive model]

RA-6-4
 SUSPENSION RD1A, RD60, RW1A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. U-bolt 12. Spring seat ,+ 24. Torque rod (Front upper)
2. Spring pad 13. Thrust washer ,+ 25. Torque rod (Front lower)
+ 3. Spring assembly 14. Dowel pin ,+ 26. Torque rod (Rear lower)
4. Spacer 15. Oil seal 27. Torque rod bushing
5. Clip 16. Bushing 28. Torque rod bracket
6. Grease nipple , 17. Thrust washer 29. Knock bolt and nut
7. Cover 18. Dowel pin ,+ 30. Trunnion bracket
8. Side plate 19. O-ring 31. Trunnion shaft
, 9. Shim 20. Relief valve
10. Thrust washer 21. Bumper rubber
11. Dowel pin 22. Spacer
,+ 23. Torque rod (Rear upper)
Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-6-5
 SUSPENSION RD1A, RD60, RW1A

Type II
[Rear 2-axle drive model]

RA-6-6
 SUSPENSION RD1A, RD60, RW1A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. U-bolt 13. Thrust washer ,+ 25. Torque rod (Front upper)
2. Spring pad 14. Dowel pin ,+ 26. Torque rod (Front lower)
+ 3. Spring assembly 15. Oil seal ,+ 27. Torque rod (Rear lower)
4. Spacer 16. Bushing 28. Torque rod bushing
5. Clip , 17. Thrust washer 29. Torque rod bracket
6. Grease nipple 18. Dowel pin 30. Knock bolt and nut
7. Cover 19. O-ring ,+ 31. Trunnion bracket
8. Side plate 20. Relief valve 32. Trunnion shaft
, 9. Shim 21. Bumper rubber
10. Thrust washer 21-1. Bumper rubber (CWC series only)
11. Dowel pin 22. Spacer
12. Spring seat 23. Spacer
,+ 24. Torque rod (Rear upper)
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

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.

23, 24, 25, 26 TYPE I and 24, 25, 26, 27 TYPE II 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.

RA-6-7
 SUSPENSION RD1A, RD60, RW1A

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.

30 TYPE I and 31 TYPE II trunnion bracket

Place a jack under the trunnion shaft when removing the trunnion
bracket.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.
Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.

Trunnion shaft outside diameter

Unit: mm (in)
Maintenance standard Service limit
99.93 - 99.98 (3.9342 - 3.9362) 99.4 (3.913)

RA-6-8
 SUSPENSION RD1A, RD60, RW1A

Trunnion shaft bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
100.17 - 100.22 (3.9437 - 3.9457) 100.60 (3.9606)

Clearance between trunnion shaft and bushing

Unit: mm (in)
Maintenance standard Service limit
0.19 - 0.29 (0.0075 - 0.0114) 1.0 (0.039)

Thickness of thrust washer

Unit: mm (in)
Item Maintenance standard Service limit
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)

REPAIR AND REPLACEMENT

Leaf spring
1. Remove the clip bolt with the T-type socket (99535 Z0005).

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.
4. 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.

RA-6-9
 SUSPENSION RD1A, RD60, RW1A

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}

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.

RA-6-10
 SUSPENSION RD1A, RD60, RW1A

2. Place the spring seat on a press, set the replacing tool

(TYPE I: 99883 Z0006, TYPE II: 99883 Z0007) and press fit
the bushing until the bushing and spring seat top surface
are matched at the spring seat.

REASSEMBLY
Key point of reassembly
30 Type I and 31 Type II 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.

26, 25, 24, 23 Type I and 27, 26, 25, 24 type II torque rod
1. 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}

17 Thrust washer
Drive the dowel pin into the trunnion bracket and install the oil seal
and thrust washer (without oil groove).

RA-6-11
 SUSPENSION RD1A, RD60, RW1A

9 Shim
1. Measure dimension L shown in the figure at right, rounding
off results to 0.1 mm (0.004 in) increments.
2. Select shim(s) which is (are) 0.1 to 0.2 mm (0.004 to 0.008
in) thicker than dimension L.

Unit: mm (in)
Dimension L Shim thickness
0.5 (0.020) 0.6 (0.024)
0.4 (0.016) 0.6 (0.024)
0.3 (0.012) 0.4 (0.016)
0.2 (0.008) 0.4 (0.016)
0.1 (0.004) 0.2 (0.008)
0 (0) 0.2 (0.008)
-0.1 (-0.004) No shims required

RA-6-12
 HUB REDUCTION

CONTENTS
SERVICE DATA.................................... RA- 1 DISASSEMBLY .................................... RA- 5
SPECIFICATIONS............................ RA- 1 DISASSEMBLY ................................ RA- 5
SERVICE DATA................................ RA- 2 INSPECTION ........................................ RA- 8
TIGHTENING TORQUE ................... RA- 2 REASSEMBLY .................................... RA-10
TOOLS ................................................. RA- 3 REASSEMBLY ................................ RA-10
CONSTRUCTION ................................. RA- 4
RA
NOTE
z In this manual, only the hub reduction is described. For removal and installation of the road
wheel, rear axle and hub assembly, refer to the “REAR AXLE AND SUSPENSION” section.
 SERVICE DATA HRPD

SERVICE DATA
SPECIFICATIONS

Unit name HRPD (ISO type)

Type Full-floating, axle tube type
Oil capacity liter liter (Imp qt) 1 (7/8)
Gear ratio (Hub reduction) 1.523
Sun gear 20
Number of gear teeth Pinion gear 15
Ring gear 63
Applicable rear axle unit RS1DA, RW1AA

Unit name

HR P D

Type Main reduction gear type Classification

HR Hub reduction P Planetary D High-speed type hub reduction

RA-1
 SERVICE DATA HRPD

SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.38 - 0.92
Pinion gear end play 1.4 (0.055)
(0.0150 - 0.0362)
Pinion gear and ring gear back- 0.20 - 0.45
0.8 (0.031)
lash (0.0079 - 0.0177)
Sun gear and pinion gear back- 0.15 - 0.25
0.6 (0.024)
lash (0.0059 - 0.0098)
0.30 - 0.45
Plate gear and ring gear backlash 0.8 (0.031)
(0.0118 - 0.0177)
0.20 - 0.30
Sun gear and tube end backlash 0.6 (0.024)
(0.0079 - 0.0118)
Less than Measure at 205 mm (8.07 in) dia.
Rear axle shaft bend 0.5 (0.020)
0.1 (0.004) point of flange surface
30.4 - 66.7 Measure the preload at hub bolt
Hub bearing preload N {kgf, lbf} —
{3.1 - 6.8, 6.8 - 15.0} location

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Hub cover mounting bolt (A) 29 - 39 {3.0 - 4.0, 22 - 29}
Hub cover mounting bolt (B) 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
Rear axle shaft mounting bolt 235 - 265 {24.0 - 27.0, 174 - 195}
Cross shaft mounting bolt 8 - 10 {0.8 - 1.0, 5.8 - 7.2}
Planetary carrier mounting bolt 196 - 216 {20.0 - 22.0, 145 - 159}
Planetary carrier washer mounting bolt 4 - 5 {0.4 - 0.5, 2.9 - 3.6}
Pinion shaft lock bolt 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Level plug 69 - 88 {7.0 - 9.0, 51 - 65}
Drain plug 9 - 12 {0.9 - 1.2, 6.5 - 8.7}
Center plug 9 - 12 {0.9 - 1.2, 6.5 - 8.7}

RA-2
 TOOLS HRPD

TOOLS

Tool name and number Description Shape

Puller bolt
Used to remove the hub cover
99532 95001

RA-3
 CONSTRUCTION HRPD

CONSTRUCTION

RA-4
 DISASSEMBLY HRPD

DISASSEMBLY
DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1.Drain plug ,+ 11.Ring gear 21.Roller
2.Gasket 12.Washer 22.Spacer
, 3.Level plug 13.Plate gear 23.Roller
4.Gasket 14.Washer 24.Pinion gear
5.Center plug ,+ 15.Planetary carrier 25.Thrust washer
6.Gasket 16.Clip 26.O-ring
7.Hub cover bolt (A) 17.Sun gear
8.Hub cover bolt (B) , 18.Cross shaft
,+ 9.Hub cover ,+ 19.Pinion shaft
,+ 10.Rear axle shaft 20.Thrust washer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

RA-5
 DISASSEMBLY HRPD

Key point of disassembly

Key point of disassembly
1 Drain plug
Remove the drain plug and drain the gear oil completely.
NOTE
z After draining a little of the oil, remove the level plug.
(This will facilitate draining of the oil.)

9 Hub cover
Remove the hub cover bolts (B), then remove the center plug.
Screw the puller bolt (99532 95001) into the hole previously occu-
pied by the center plug to drive the hub cover out.
NOTE
z Be careful not to damage the oil seal which is at the
wheel hub.

10 Rear axle shaft, 11 Ring gear

1. Remove the ring gear and rear axle shaft.
NOTE
z When removing the rear axle shaft, be careful not to dam-
age the oil seal.
z The rear axle shaft cannot be easily withdrawn as a sin-
gle unit.
2. Measure the plate gear and ring gear backlash. If the mea-
sured value is more than 0.8 mm (0.031 in), replace the
plate gear and ring gear with new ones.

15 Planetary carrier
Before disassembling the planetary carrier assembly, measure the
backlash and end play of each gear.
1. Measure the pinion gear and ring gear backlash.
z Attach a fuse on the pinion gear using grease and install the
ring gear to the planetary carrier assembly.
NOTE
z Be careful not to move the fuses.
z Simultaneously measure the backlash at four points.
z Turn the ring gear a half turn.
z Remove the fuse and measure the thinnest part of the
fuse. If the measured value is more than 0.8 mm (0.031
in), replace the ring gear and pinion gear with new ones.
NOTE
z Take an average of the four measurements.

RA-6
 DISASSEMBLY HRPD

2. Measure the sun gear and pinion gear backlash.

z Attach a fuse to the pinion gear.
NOTE
z Be careful not to move the fuses.
z Simultaneously measure the backlash at four points.
z Turn the ring gear a half turn.
z Remove the fuse and measure the thinnest part of the
fuse. If the measured value is more than 0.6 mm (0.024
in), replace the sun gear and pinion gear with new ones.
NOTE
z Take an average of the four measurements.

3. Measure the sun gear and tube end backlash.

z Insert a fuse between the sun gear and tube end.
z Remove the fuse and measure the thinnest part of the fuse.
If the measured value is more than 0.6 mm (0.024 in),
replace the sun gear and rear axle housing with new ones.

4. Measure the end play of the pinion gear with a feeler

gauge. If it is more than 1.4 mm (0.055 in), replace the
thrust washer with a new one.

19 Pinion shaft
Remove the lock bolt and drive out the pinion shaft.
NOTE
z Be careful not to lose the roller found inside the pinion
gear.

RA-7
 INSPECTION HRPD

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Pinion gear end play

Unit: mm (in)
Maintenance standard Service limit
0.38 - 0.92 (0.0150 - 0.0362) 1.4 (0.055)

Pinion gear and ring gear backlash

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.45 (0.0079 - 0.0177) 0.8 (0.031)

Sun gear and pinion gear backlash

Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.6 (0.024)

Plate gear and ring gear backlash

Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.45 (0.0118 - 0.0177) 0.8 (0.031)

RA-8
 INSPECTION HRPD

Sun gear and tube end backlash

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.6 (0.024)

Plate gear and ring gear backlash

Unit: mm (in)
Maintenance standard Service limit Remarks
Measure at 205 mm
Less than
0.5 (0.020) (8.07 in) dia. point of
0.1 (0.004)
flange surface

RA-9
 REASSEMBLY HRPD

REASSEMBLY
REASSEMBLY
Key point of reassembly
z Apply a thin coat of bearing grease to various parts.
z Apply a thin coat of grease to the roller and spacer before
installing them on the pinion gear.

19 Pinion shaft
Install the thrust washer, pinion gear and thrust washer, in that
order, on the planetary carrier and insert the pinion shaft.
： 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}
NOTE
z Before installing the pinion shaft, be sure to align it with
the planetary carrier at the lock bolt holes.

18 Cross shaft
After installing the cross shaft, measure the pinion gear end play to
make sure it is within the maintenance standard.
： 8 - 10 N·m {0.8 - 1.0 kgf·m, 5.8 - 7.2 ft·lbf}
Unit: mm (in)
Maintenance standard Service limit
0.38 - 0.92 (0.0150 - 0.0362) 1.4 (0.055)

15 Planetary carrier
After installing the planetary carrier assembly, measure the back-
lash of each gear to make sure it is within the maintenance stan-
dard.
1. Measure the sun gear and tube end backlash.
Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.30 (0.0079 - 0.0118) 0.6 (0.024)

2. Measure the sun gear and pinion gear backlash.

Unit: mm (in)
Maintenance standard Service limit
0.15 - 0.25 (0.0059 - 0.0098) 0.6 (0.024)

3. Measure the pinion gear and ring gear backlash.

Unit: mm (in)
Maintenance standard Service limit
0.20 - 0.45 (0.0079 - 0.0177) 0.8 (0.031)

RA-10
 REASSEMBLY HRPD

11 Ring gear
Measure the backlash of the plate gear and ring gear to make sure
it is within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.30 - 0.45 (0.0118 - 0.0177) 0.8 (0.031)

10 Rear axle shaft

Insert the rear axle shaft into the axle tube.
NOTE
z Be careful not to damage the oil seal on the end of the
axle tube and the shaft splines.

9 Hub cover
Position the O-ring in the groove on the hub, and install the hub
cover with hub cover bolts (B).
： 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
NOTE
z Be careful not to damage the O-ring when installing the
hub cover.

3 Level plug
Pour oil through the level plug with its opening turned up.

Amount of oil
1 liter (7/8 Imp qt)
： 69 - 88 N·m {7.0 - 9.0 kgf·m, 51 - 65 ft·lbf}
NOTE
z When pouring oil, the drain plug must be turned up and
the oil must be added until it runs out of the level plug
hole.

RA-11
 FRONT AXLE AND SUSPENSION

CONTENTS
SERVICE DATA..................................FA-1- 1 FRONT AXLE (FA60) ....................... FA-4- 1
SPECIFICATIONS..........................FA-1- 1 CONSTRUCTION .......................... FA-4- 1
SERVICE DATA..............................FA-1- 5 DISASSEMBLY.............................. FA-4- 3
TIGHTENING TORQUE .................FA-1- 6 INSPECTION ................................. FA-4- 9
TOOLS................................................FA-2- 1 REPAIR AND REPLACEMENT .... FA-4-11
FRONT AXLE .................................FA-2- 1 REASSEMBLY.............................. FA-4-18
SUSPENSION ................................FA-2- 4 FRONT WHEEL ALIGNMENT...... FA-4-27
SUSPENSION................................. FA-5- 1
= UNIT NAME FA50, FA60 = CONSTRUCTION .......................... FA-5- 1
DISASSEMBLY.............................. FA-5- 3 FA
FRONT AXLE (FA50) ........................FA-3- 1 INSPECTION ............................... FA-5-13
CONSTRUCTION...........................FA-3- 1 REPAIR AND REPLACEMENT .... FA-5-14
DISASSEMBLY ..............................FA-3- 3 REASSEMBLY.............................. FA-5-16
INSPECTION.................................FA-3-13
REPAIR AND REPLACEMENT .....FA-3-15
REASSEMBLY ..............................FA-3-23
FRONT WHEEL ALIGNMENT ......FA-3-33
 SERVICE DATA FRONT AXLE & SUSPENSION

SERVICE DATA
SPECIFICATIONS

FRONT AXLE
Item FA50*1 FA50*2 FA60
Type of front axle Drop forged steel I cross section beam
Type of steering knuckle Reverse-Elliot
Kingpin O.D. mm (in) 47 (1.85) 55 (2.17)
0 - 2 (0 - 0.08) STD tire
Toe-in mm (in)
0 (0) Radial tire
Wheel alignment Camber 1°00’
Caster 3°20’
Kingpin inclination angle 7°00’
42º x 33º Conven-
tional wheel type
Maximum turning angle (Inside) x (Outside) 50º x 38º
40º x 32º Trilex wheel
type
Type of brake drum installation Inboard Outboard Outboard

NOTE
z *1 and *2 indicate respectively the inboard type and out-
board type installation methods of the brake drum.

FA-1-1
 SERVICE DATA FRONT AXLE & SUSPENSION

UNIT NAME

F A 50

Unit classification Axle shape Nominal weight on axle

F Front axle A I-section 50 5 ton

60 6 ton

UNIT IDENTIFICATION NUMBER

The unit identification number of the front axle is stamped on its
front right side.

SUSPENSION
Item FA50 FA60
Type of suspension Rigid axle type
Type of spring Semi-elliptic, leaf spring (shackle type)
Type of shock absorber Cylindrical double-action or single-action
Type of stabilizer (if so equipped) Torsion bar

FA-1-2
 SERVICE DATA FRONT AXLE & SUSPENSION

Spring specifications
Unit: mm
Axle type Vehicle model Length x width x thickness - number of leaves Spring type
1,550 x 90 x 13 - 7
CKA450, 530
1,550 x 90 x 13 - 8
CKB453, 533
1,550 x 90 x 13 - 9
1,550 x 90 x 13 - 7
1,550 x 90 x 13 - 8
CKB450 1,550 x 90 x 13 - 9 I
1,550 x 90 x 13 - 10
1,550 x 90 x 12 - 2, 13 - 7
1,550 x 90 x 13 - 7
1,550 x 90 x 13 - 8
CKB450BT 1,550 x 90 x 13 - 9
1,800 x 90 x 23 - 1, 25 - 2
III
1,800 x 90 x 23 - 1, 25 - 2, 19 - 1
FA50 1,550 x 90 x 13 - 7
CKB520BT 1,550 x 90 x 13 - 8
1,550 x 90 x 13 - 9
1,550 x 90 x 13 - 8 +
CWA530 1,550 x 90 x 13 - 9 +
1,550 x 90 x 13 - 10 +
I
CWB450, 451, 452, 453, 1,550 x 90 x 13 - 9 +
520, 530, 533 1,550 x 90 x 13 - 10 +
1,550 x 90 x 14 - 1, 15 - 4, 13 - 1
CDA450
1,550 x 90 x 14 - 1, 15 - 5, 13 - 1
1,550 x 90 x 13 - 8 *A
CGB450
1,550 x 90 x 13 - 8 *B
1,550 x 90 x 13 - 9 *C
CGB520, 533 II
1,550 x 90 x 13 - 9 *D
FA60 CKC450, CWC450, 610 1,550 x 90 x 13 - 10 I

NOTE
z + indicates a non-spacer type.
z *A: Used for front/front side. No. 8 leaf spring also serves as a shock absorber bracket.
z *B: Used for front/rear side. No. 7 leaf spring also serves as a shock absorber bracket.
z *C: Used for front/front side. No. 9 leaf spring also serves as a shock absorber bracket.
z *D: Used for front/rear side. No. 10 leaf spring also serves as a shock absorber bracket.

FA-1-3
 SERVICE DATA FRONT AXLE & SUSPENSION

Spring type

FA-1-4
 SERVICE DATA FRONT AXLE & SUSPENSION

SERVICE DATA
FRONT AXLE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
46.98 - 47.00
FA50 46.9 (1.846)
(1.8496 - 1.8504)
Kingpin O.D.
54.98 - 55.00
FA60 54.9 (2.161)
(2.1646 - 2.1654)
Clearance between kingpin and FA50 0.01 - 0.10
0.2 (0.008)
bushing FA60 (0.0004 - 0.0039)
0 - 0.04
FA50 0.15 (0.0059)
Clearance between front axle (0 - 0.0016)
hole and kingpin 0 - 0.05
FA60 0.15 (0.0059)
(0 - 0.0020)
19.6 - 53.9 {2.0 - 5.5, 4.4 -
Conven- FA50 —
12.1}
tional type
Preload of front hub wheel 29.4 - 47.1
FA60 —
N {kgf, lbf} {3.0 - 4.8, 6.6 - 10.6}
25.5 - 40.2
Trilex wheel —
{2.6 - 4.1, 5.7 - 9.0}
Starting force of steering knuckle Spring balance reading
Less than 9.8 {1.0, 2.2} —
N {kgf, lbf} taken at end knuckle
Clearance between steering knuckle and Measure with shims in
Less than 0.1 (0.004) —
axle place.
Kingpin angle 7º±10’ —

SUSPENSION
Unit: mm (in)
Item Maintenance standard Service limit
FA50
Spring pin and shackle pin OD 30.0 (1.181) 29.5 (1.161)
FA60
Spring pin and shackle pin bushing FA50
30.0 (1.181) 31.0 (1.220)
ID FA60
Clearance between spring FA50 0.02 - 0.14
1.0 (0.039)
(shackle) pin and bushing FA60 (0.0008 - 0.0055)
Leaf wear — 15% of nominal thickness

FA-1-5
 SERVICE DATA FRONT AXLE & SUSPENSION

TIGHTENING TORQUE
FRONT AXLE
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
FA50 FA60
U-bolt 490 - 539 {50 - 55, 362 - 398} O O
SAE type 540 - 590 {55 - 60, 398 - 435} O —
Conventional type hub
Wheel nut ISO type 590 - 630 {60 - 65, 435 - 465} O O
Trilex wheel 343 - 412 {35 - 42, 253 - 304} O O
Wheel clamp nut Trilex wheel 265 - 294 {27 - 30, 195 - 217} O O
Lock pin nut of kingpin 25 - 39 {2.5 - 4.0, 18 - 29} O O
Knuckle stopper bolt lock nut 137 - 167 {14 - 17, 101 - 123} O O
Steering arm mounting nut 490 - 588 {50 - 60, 362 - 434} O O
Tie-rod arm mounting nut 490 - 588 {50 - 60, 362 - 434} O O
Connecting nut for tie-rod arm and tie-rod ball stud 245 - 304 {25 - 31, 181 - 224} O O
Tie-rod clamp bolt nut 59 - 78 {6 - 8, 43 - 58} O O
Hub bolt nut 294 - 412 {30 - 42, 217 - 304} O O
Brake chamber bracket mounting bolt 69 - 88 {7 - 9, 51 - 65} O O
Brake chamber Chamber size $23$20 81 - 108 {8.3 - 11.0, 60 - 80} O O
mounting nut Chamber size $23$24 167 - 186 {17 - 19, 123 - 137} — O
Bolt 216 - 294 {22 - 30, 159 - 217} O O
Brake assembly mounting bolt or nut Castel-
490 - 588 {50 - 60, 362 - 434} O —
lated nut
Hub cap mounting bolt 8 - 13 {0.8 - 1.3, 5.8 - 9.4} O O
Kingpin plug 59 - 78 {6 - 8, 43 - 58} O O
Dust cover mounting bolt 10 - 20 {1 - 2, 7 - 14} — O
Lock plate mounting screw 7 - 9 {0.7 - 0.9, 5.1 - 6.5} O —
Outboard
Brake drum mounting screw 8 - 13 {0.8 - 1.3, 5.8 - 9.4} O O
type

SUSPENSION
Unit: N·m {kgf·m, ft·lbf}
Application
Item Tightening torque
FA50 FA60
Spring center bolt 108 - 127 {11 - 13, 80 - 94} O O
U-bolt nut 490 - 539 {50 - 55, 362 - 398} O O
Clip bolt 49 - 59 {5 - 6, 36 - 43} O O
Pin nut 118 - 177 {12 - 18, 87 - 130} O O
Stabilizer
Bracket mounting bolt 137 {14, 101} O O

FA-1-6
 TOOLS FRONT AXLE & SUSPENSION

TOOLS
FRONT AXLE

Application
Tool name and number Description Shape
FA50 FA60

Used to remove
Lock plate bolt
99545 Z0003 and install the lock O —
wrench socket
plate bolt

99820 Z0002 O —
Used to tighten and
Adjusting remove the nut fas-
nut wrench tening front hub
bearing
99820 Z5001 — O

99840 Z0018 — O

Front hub Used to remove the

puller hub

99840 Z0009 O —

FA-2-1
 TOOLS FRONT AXLE & SUSPENSION

Application
Tool name and number Description Shape
FA50 FA60

Used to remove the

Puller bolt 99532 Z0060 inner race from the O O
inner hub bearing

Used to remove and

install the kingpin bush-
99831 Z0003 ing

1 99833 Z0000 1 Replacer bar

2 99834 Z0002 2 Bushing replacer
3 99834 Z0003 (upper or lower)
— O
4 99835 Z0003 3 Bushing replacer
5 99847 Z0001 (upper or lower)
6 89-11144-1A 4 Replacer guide
5 Bushing remover
6 Nut (M14 x 1.5)
Kingpin bushing
tool Used to remove and
install the kingpin bush-
99831 Z0008 ing

1 99833 Z0003 1 Replacer bar

2 99834 Z0012 2 Bushing replacer
3 99834 Z0013 (Upper) O —
4 99834 Z0009 3 Bushing replacer
5 99835 Z0004 (Lower)
6 89-11144-1A 4 Oil seal replacer
7 99847 Z0003 5 Replacer guide
6 Nut (M14 x 1.5)
7 Bushing remover

Used to install the oil

Oil seal replacer 99828 Z0006
seal
O O

FA-2-2
 TOOLS FRONT AXLE & SUSPENSION

Application
Tool name and number Description Shape
FA50 FA60

1 99843 Z5002 O —

Bearing race
2 99843 Z5004 Used to install the inner O O
replacer hub bearing outer race

{Used with brace rod

(99844 Z5000) as a
3 99843 Z5006 set}
1. Bearing race replacer: Bearing OD for 120 mm
(4.72 in)
2. Bearing race replacer: Bearing OD for 140 mm — O
(5.51 in)
Brace rod 4 99844 Z5000 3. Bearing race replacer: Bearing O.D. for 160
mm (6.30 in)
4. Brace rod

99827 Z0011 O —
Oil seal retainer Used to install the oil
replacer seal retainer
99827 Z0103 — O

Used to install the inner

and outer hub bearing
inner races
99827 Z0014
(For unit FA60, outer
O O
hub bearing inner races
only)

Hub bearing
replacer

Used to install the inner

99827 Z0063
hub bearing inner races
— O

FA-2-3
 TOOLS FRONT AXLE & SUSPENSION

SUSPENSION

Application
Tool name and number Description Shape
FA50 FA60

Used when replac-

Bushing ing the spring
99888 Z0003 O O
replacer (shackle) pin bush-
ing.

Used when remov-

T-type socket 99535 Z0005 ing the spring clip O O
bolt.

Used together with

the socket wrench
Extension bar 99535 Z0012 O O
to remove the U-
bolt nut.

Used to turning the

Wrench socket 99535 Z0008 O O
U-bolt nut.

FA-2-4
 FRONT AXLE (FA50) FA50

=UNIT NAME FA50, FA60=

FRONT AXLE (FA50)
CONSTRUCTION

FA-3-1
 FRONT AXLE (FA50) FA50

TRILEX WHEEL (TYPE 20”)

FA-3-2
 FRONT AXLE (FA50) FA50

DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE
type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Trilex wheel nuts are right-hand threaded on the right and
left sides. (Wheel clamp nuts have right-hand threads both
on the right and left sides.)
6. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.

7. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.

8. When removing the tire, be careful not to damage the hub

bolt threads.
9. Because the wheel is heavy, take care not to allow it to fall
toward you.
Refer to the “DISASSEMBLY” section for the disassembled view.

FA-3-3
 FRONT AXLE (FA50) FA50

10. 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.

11. 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.

12. Remove the screws, and then remove the brake drum (Out-
board type only).
WARNING
WARNING
z Because the brake drum is heavy, use a lifting cable and
hoist to move it. To assure safety, this operation should
be performed by more than two men. Be careful not to
drop the drum onto your feet.

FA-3-4
 FRONT AXLE (FA50) FA50

DISASSEMBLY
[Front 1-axle model]

FA-3-5
 FRONT AXLE (FA50) FA50

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

I Trilex wheel nut Outboard type Inboard type
II Wheel clamp nut 1. Brake drum ,+ 1. Hub cap
III Wheel clamp ,+ 2. Hub cap 2. Gasket
IV Adapter 3. Gasket ,+ 3. Lock plate
,+ 4. Lock plate ,+ 4. Adjusting nut
,+ 5. Adjusting nut 5. Knuckle washer
6. Knuckle washer 6. Hub bolt
,+ 7. Hub 7. Brake drum
8. Outer bearing inner race ,+ 8. Hub
9. Oil seal 9. Outer bearing inner race
10. Outer bearing outer race 10. Oil seal
11. Inner bearing outer race 11. Outer bearing outer race
12. Hub bolt 12. Inner bearing outer race

13. Plug 24. Cotter pin 33. Gasket

+ 14. Stopper bolt 25. Castellated nut ,+ 34. Kingpin plug
, 15. Lock nut , 26. Tie-rod arm 35. Kingpin cap
, 16.Inner bearing inner race ,+ 27. Brake assembly mounting bolt , 36. Lock pin
, 17. Oil seal retainer 28. Cotter pin 37. Kingpin
18. Cotter pin 29. Castellated nut , 38. Shim
+ 19. Castellated nut ,+ 30. Steering arm , 39. Thrust bearing
20. Dust cover 31. Grease nipple 40. Oil seal
+ 21. Tie-rod clamp bolt 32. Kingpin cap 41. Kingpin bushing
, 22. Tie-rod end 32-1. Brake chamber bracket , 42. Steering knuckle
23. Tie-rod tube (Air brake type) ,+ 43.Front axle

Marks “+” and “,” indicate that the key points of operation are explained in the text.

FA-3-6
 FRONT AXLE (FA50) FA50

[Front 2-axle model]

Type I

FA-3-7
 FRONT AXLE (FA50) FA50

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Hub cap , 16.Inner bearing 31.Grease nipple
2.Gasket , 17.Oil seal retainer 32-1.Brake chamber bracket
,+ 3.Lock plate 18.Cotter pin 33.Gasket
,+ 4.Adjusting nut + 19.Castellated nut ,+ 34.Kingpin plug
5.Knuckle washer 20.Dust cover 35.Kingpin cap
6.Hub bolt + 21.Tie-rod clamp bolt , 36.Lock pin
7.Brake drum , 22.Tie-rod end 37.Kingpin
,+ 8.Hub 23.Tie-rod tube , 38.Shim
9.Outer bearing 24.Cotter pin , 39.Thrust bearing
10.Oil seal 25.Castellated nut 40.Oil seal
11.Outer bearing outer race 26.Tie-rod arm 41. Kingpin bushing
12.Inner bearing outer race ,+ 27.Brake bracket , 42.Steering knuckle
13.Plug 28.Cotter pin ,+ 43.Front axle
+ 14.Stopper bolt 29.Castellated nut
, 15.Lock nut ,+ 30.Steering arm
Marks “+” and “,” indicate that the key points of operation are explained in the text.

FA-3-8
 FRONT AXLE (FA50) FA50

[Front 2-axle model]

Type II

FA-3-9
 FRONT AXLE (FA50) FA50

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Hub cap , 16.Inner bearing 31.Grease nipple
2.Gasket , 17.Oil seal retainer 32-1.Brake chamber bracket
,+ 3.Lock plate 18.Cotter pin 33.Gasket
,+ 4.Adjusting nut + 19.Castellated nut ,+ 34.Kingpin plug
5.Knuckle washer 20.Dust cover 35.Kingpin cap
6.Hub bolt + 21.Tie-rod clamp bolt , 36.Lock pin
7.Brake drum , 22.Tie-rod end 37.Kingpin
,+ 8.Hub 23.Tie-rod tube , 38.Shim
9.Outer bearing inner race 24.Cotter pin , 39.Thrust bearing
10.Oil seal 25.Castellated nut 40.Oil seal
11.Outer bearing outer race 26.Tie-rod arm 41. Kingpin bushing
12.Inner bearing outer race ,+ 27.Brake assembly mounting bolt , 42.Steering knuckle
13.Plug 28.Cotter pin ,+ 43.Front axle
+ 14.Stopper bolt 29.Castellated nut
, 15.Lock nut ,+ 30.Steering arm
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

1 Inboard type
2 Outboard type }Hub cap
1. 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.
2. Be sure to discard the old gasket.

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 }
Adjusting nut
Using the adjusting nut socket (99820 Z0002), remove the adjust-
ing nut.

FA-3-10
 FRONT AXLE (FA50) FA50

8 Inboard type
7 Outboard type } Front hub
Using the front hub puller (99840 Z0009), remove the hub (with the
outer hub bearing and inner hub bearing outer race attached).
WARNING
WARNING
z Because the hub (with the brake drum attached) is heavy,
use a lifting cable and hoist to move it. To assure safety,
this operation should be performed by more than two
men. Be careful not to drop the hub and drum onto your
feet.

14 Stopper bolt
Remove the plug and stopper bolt from the back of the knuckle, and
insert the puller bolts (99532 Z0060) into those holes. Turn the
puller bolts alternately to remove the inner hub bearing inner race
and oil seal retainer.

19 Castellated nut
1. If the ball stud and tie-rod are hard to remove, use a puller.
Do not tap with a hammer.
2. Only the dust cover of the tie-rod assembly can be singly
replaced. For replacement procedures, refer to the instruc-
tions under the “REPAIR AND REPLACEMENT” section.

21 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-3-11
 FRONT AXLE (FA50) FA50

27 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.

30 Steering arm
Do not tap the ball stud of the drag link with a hammer. Use a puller
if necessary.

34 Kingpin plug
The grease seal and kingpin cap should not be reused.
1. Grease nipple 6. Washer
2. Bolt 7. Kingpin cap
3. Lock washer 8. Kingpin plug
4. Kingpin cap 9. Grease nipple
5. Gasket

NOTE
z In air brake vehicles, part 4 is the brake chamber bracket.

43 Front axle
Place a jack under the front axle and remove the nuts from the U-
bolts.
WARNING
WARNING
z Be sure to perform this operation with a jack placed
under the front axle.

FA-3-12
 FRONT AXLE (FA50) FA50

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Kingpin outside diameter

Unit: mm (in)
Maintenance standard Service limit
46.98 - 47.00 (1.8496 - 1.8504) 46.9 (1.846)

Clearance between kingpin and bushing

Unit: mm (in)
Maintenance standard Service limit
0.01 - 0.10 (0.0004 - 0.0039) 0.2 (0.008)

Clearance between front axle hole and kingpin

Unit: mm (in)
Maintenance standard Service limit
0 - 0.04 (0 - 0.0016) 0.15 (0.0059)

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.

FA-3-13
 FRONT AXLE (FA50) FA50

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 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. If there is even
the slightest difference in the left and right centering 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: 7° ± 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.

FA-3-14
 FRONT AXLE (FA50) FA50

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.

REPAIR AND REPLACEMENT

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 steering knuckle and the lower bush-
ing 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” 45°toward the
outer rear side of the vehicle.
z The upper bushing is shorter than the lower bushing.

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-3-15
 FRONT AXLE (FA50) FA50

CAUTION
z The upper bushing is shorter than the lower bushing.
Install the upper bushing with its oil groove facing
upward.
z When installing the bushings, press-fit with the clinch
faced 45°inward to the front of the vehicle.

BRAKE DRUM AND HUB

SAE type
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
z Use hub bolts stamped “L” for the left-hand hub and
those without any stamp for the right-hand hub. The hub
bolts must be installed with the shorter flange portion
facing outward.

ISO type
Type I
1. Loosen the hub bolt nuts.
2. Remove the hub bolts from the hub.
3. Align the flanged portion of each hub bolt with the groove in
the hub, and tighten the bolt with the hub nut.
: 294 - 412 N·m {30 - 42 kgf·m, 217 - 304 ft·lbf}
NOTE
z The left and right hub bolts have the same design.
z Ensure that the hub bolt's flanged end, which is more
rounded than the other, faces the outside of the vehicle.

FA-3-16
 FRONT AXLE (FA50) FA50

4. After tightening the hub bolt, clinch the thread end at three
places.

Type II (Serration hub bolts)

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.

[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.
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 hub bolts into the hub.

<Pressing hub bolts into a new hub>
z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.

FA-3-17
 FRONT AXLE (FA50) FA50

z Using a press and pad, press hub bolts into the hub with a
force of approximately 5 to 6 tons.
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure all hub bolts are flush and pressed equally.

z Wipe off oil seepage.
<Pressing hub bolts into an old hub>
z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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.

z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

[Pressing hub bolts using a hammer]

If hub bolts need to be replaced in emergencies, such as when
trouble occurs, etc., proceed as follows:
1. Remove hub bolts from the hub.
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 2-lb or greater weight.
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.

FA-3-18
 FRONT AXLE (FA50) FA50

2. Press new hub bolts into the hub.

<Pressing hub bolts into a new hub>
z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Using a hammer (2-lb weight, min.) and pad, drive hub bolts
straight into hub holes. The hub bolt will be properly driven
into place by hammering them approximately 20 times.
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure all hub bolts are flush and pressed equally.

z Wipe off oil seepage.
<Pressing hub bolts into an old hub>
z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Align hub bolt serrations with hub bolt hole serrations.
z Lightly tap hub bolt heads to properly mesh with the mating
serrations.

z Using a hammer (2-lb weight, min.) and pad, drive hub bolts
straight into place.
NOTE
z Be careful not to scratch the hub or brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure hub bolts are flush and pressed properly.

z Wipe off oil seepage.

HUB BEARING
1. Remove the outer hub bearing outer race by striking with a
hammer and a suitable bar. When removing the inner hub
bearing outer race, insert a suitable bar into the notch on
the grease sump and strike the bar.
NOTE
z The oil seal is also removed when the outer race is
removed. The oil seal must not be reused. Always
replace it with a new one.

FA-3-19
 FRONT AXLE (FA50) FA50

2. After cleaning the contact surfaces of the outer race, 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 Z5002 3.99844 Z5000

2.99843 Z5004

3. Drive in the oil seal using an oil seal replacer (99828

Z0006).
NOTE
z Apply grease to the oil seal lips before installation.

FA-3-20
 FRONT AXLE (FA50) FA50

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-3-21
 FRONT AXLE (FA50) FA50

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 20 g (0.71
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. Press the dust cover into place using special tool (99853
Z0001) and 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.

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 it immediately.

FA-3-22
 FRONT AXLE (FA50) FA50

REASSEMBLY
REASSEMBLY
Key point of reassembly
43 Front axle
1. Put the front axle under the leaf spring, with the knuckle
stopper side facing the rear of the vehicle.

2. Insert a caster shim between the front axle and leaf spring,
with the center bolt holes aligned.
CAUTION
z Insert the caster shim with the thick side facing the rear
of the vehicle.

： 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}

42 Steering knuckle
1. After selecting the shim, extract the kingpin, being careful
not to damage the dust seal. Then remove the temporarily
installed steering knuckle.
WARNING
WARNING
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during installation.

NOTE
z Do not drop the thrust bearing during installation.

FA-3-23
 FRONT AXLE (FA50) FA50

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
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during removal and installa-
tion.

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.

39 Thrust bearing
Install the thrust bearing on the lower part of the front axle. Using
the kingpin or a similar bar, temporarily install the steering knuckle.
NOTE
z Before installing the thrust bearing, apply bearing grease
to it until grease oozes out.
z When the thrust bearing is an O-ring type, face the O-ring
upward when installing.

FA-3-24
 FRONT AXLE (FA50) FA50

38 Shim
Measure the clearance between the steering knuckle and front
axle. Select the shim so that clearance corresponds to the mainte-
nance standard.
CAUTION
z When installing the shim and bearing do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.

Type of shim
8 types from 2.1 to 2.8 mm (0.083 to 0.110 in) at intervals of
0.1 mm (0.004 in)

36 Lock pin
Align the groove in the kingpin with the lock pin bore in the front
axle, and drive in the kingpin.
Insert the lock pin from the rear of the front axle with the cut surface
facing the kingpin.
： 25 - 39 N·m {2.5 - 4.0 kgf·m, 18 - 29 ft·lb}
Hang a spring balance from the steering knuckle spindle, as shown
in the figure below. 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, lb}

Maintenance standard Service limit
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)

FA-3-25
 FRONT AXLE (FA50) FA50

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.Lock washer 8.Kingpin plug
4.Kingpin cap 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 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.

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.
： 216 - 343 N·m {22 - 35 kgf·m, 159 - 253 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
： 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 490 - 588 N·m {50 - 60 kgf·m, 362 - 434 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.

FA-3-26
 FRONT AXLE (FA50) FA50

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.

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.

FA-3-27
 FRONT AXLE (FA50) FA50

3. Insert the tie-rod end clamp bolt and tighten it temporarily.

Tighten the clamp bolt after properly adjusting the toe-in.
Refer to th “Wheel Alignment” section for the toe-in adjust-
ment procedure.

17 Oil seal retainer

Install the oil seal retainer onto the steering knuckle with the oil
seal retainer replacer (99827 Z0011).

16 Inner bearing inner race

Install the inner hub bearing on the steering knuckle, using a
replacer (99827 Z0014).
NOTE
z After installing the hub bearing, remove any grease that
has been forced out.

15 Lock nut
Screw the plug into the front of the kingpin and temporarily tighten
the stopper and lock nut on the rear of the kingpin. The stopper bolt
should be tightened to the specified torque after installing the wheel
and adjusting steer-angle. For adjusting the steering angle, refer to
the “FRONT WHEEL ALIGNMENT” section.
Knuckle stopper bolt lock nut
： 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}

8 Inboard type
7 Outboard type }Hub
1. Charge the grease sump of the hub with bearing grease so
that grease properly lubricates the hub bearing.
Approximately amount of grease:
600 g (21.16 oz)

FA-3-28
 FRONT AXLE (FA50) FA50

2. Install the hub with the drum attached (inboard type only) to
the steering knuckle, and install the outer hub bearing inner
race with an installer (99827 Z0014).
WARNING
WARNING
z Because the hub (with the brake drum attached) is heavy,
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 adjusting nut.
： 196 N·m {20 kgf·m, 145 ft·lbf}
4. Pull the spring balance horizontally until the hub rotates at
least 90°, 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
Conventional type wheel
{2.0 - 5.5 kgf, 4.4 - 12.1 lbf}
25.5 - 40.2 N
Trilex wheel
{2.6 - 4.1 kgf, 5.7 - 9.0 lbf}

NOTE
z The method of measuring the preload and its measuring
position are the same both for conventional type wheels
and Trilex wheels.

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 10°).
2. Turn the hub 2 or 3 turns and then make sure the preload is
correct.

19.6 - 53.9 N
Conventional type wheel
{2.0 - 5.5 kgf, 4.4 - 12.1 lbf}
25.5 - 40.2 N
Trilex wheel
{2.6 - 4.1 kgf, 5.7 - 9.0 lbf}

FA-3-29
 FRONT AXLE (FA50) FA50

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.

3 Inboard
4 Outboard type } Lock plate
Install the lock plate and tighten the screw using the special wrench
socket (99543 Z0003).
： 7 - 9 N·m {0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf}

1 Inboard type
2 Outboard type } Hub cap
Install the new gasket and hub cap.
： 8 - 13 N·m {0.8 - 1.3 kgf·m, 5.8 - 9.4 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-3-16.

1.Bolt 3.Hub cap

2.Lock washer 4.Gasket

INSTALLATION
Key point of installation
Align the tire so that the hub bolts are in the middle of the disc
wheel bolt holes, and tighten the wheel nuts temporarily.
CAUTION
z If the wheel mounting section is dirty, the wheel nuts
may loosen. Clean with a wire brush and rag.

NOTE
<SAE type>
z The right-hand wheel nuts have right-hand threads and
the left-hand nuts have left-hand threads. The left-hand
wheel nuts are stamped with an “L”.
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
FA-3-30
 FRONT AXLE (FA50) FA50

washers (the tapered portion).

Wipe away any excess with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.

Position a garage jack under the front axle and raise the front of
vehicle. Remove the right and left trestles from the front of the
frame, and slowly lower the vehicle.
WARNING
WARNING
z Apply the jack at the jacking-up point accurately.

Tighten the wheel nuts so that disc closely contacts the neck of
each bolt.
： 540 - 590 N·m {55 - 60 kgf·m, 398 - 435 ft·lbf}
(SAE type)
： 590 - 630 N·m {60 - 65 kgf·m, 435 - 465 ft·lbf}
(ISO type)

CAUTION
z Tighten the wheel nuts diagonally as shown at right,
tighten to the specified torque in several steps.

FA-3-31
 FRONT AXLE (FA50) FA50

<Trilex wheel>
Key point of installation
1. Align the projections (on each side of the tire valve) at the
rim location with the concave portion (20”) or with flat area
(of the outer periphery) (24”) except for unit FA50 between
the spokes of the adapter, and attach the rim to the adapter.
2. Install the clamps and nuts at two places on the upper and
lower sides of the adapter. Tighten the nuts temporarily and
center the rims.
3. Install the remaining clamps and nuts, and slightly tighten
the nuts, one at a time, circumferentially, until the specified
torque is reached.
: 265 - 294 N·m {27 - 30 kgf·m, 195 - 217 ft·lbf}
NOTE
z Do not tighten the nuts diagonally, or in a criss-cross
fashion.
z When tightening the nut, ensure the boss of the clamp
touches the seating surface of the adapter.
z Also ensure the rim touches the entire tapered seat sur-
face of the adapter.
z After installing the wheels on the vehicle, drive the vehi-
cle about 100 km and check the tightening torque of the
nuts. Re-tighten the nuts if needed.
z If the rim and the tapered seat surface of the adapter do
not come into close contact (this often occurs when the
tire is new and its bead is still hard) although the nuts are
tightened to the specified torque setting, decrease the
tire pressure, attach the rims to the adapter and then
reinflate the tire.

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.

FA-3-32
 FRONT AXLE (FA50) FA50

MEASURING AND ADJUSTING TOE-IN

CAUTION
z When adjusting the toe-in, make sure that the tires are on
the ground.

<Single front axle vehicle>

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”.

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.

FA-3-33
 FRONT AXLE (FA50) FA50

Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the rear, 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.

<Dual front axle vehicle>

Measure procedure
1. Orient the front tires so that they face straight ahead.
2. On the front of the left and right tires on the 1st and 2nd
axles, 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 respective sets of 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” for the 1st axle and “A'” for the 2nd
axle.

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.

FA-3-34
 FRONT AXLE (FA50) FA50

5. Place the toe-in gauge behind the respective axles. Follow-

ing the same procedure as in step 3, read the distance
between the marks. Assume this dimension to be “B” for the
1st axle and “B'” for the 2nd axle.

6. The toe-in of the 1st axle is determined by subtracting “A”

from “B”, while the toe-in of the 2nd axle is determined by
subtracting “A'” from “B'”. Confirm that the values meet the
prescribed standard. If the prescribed standard is not met,
adjust with the tie-rod and pitman link.

Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the rear, 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.

3. Separate the pitman link.

4. Check tire directions using a straight bar [approx. 3,800 mm

(110 in) long]. If necessary, adjust them to C=C' and/or
D=D'.
5. After toe-in has been properly adjusted in step 4. above,
check the alignment of the pin hole in the pitman arm with
the hole in the pitman link. If it is not aligned, lengthen or
shorten the pitman link until correct alignment is obtained.
The clevis pin should be smoothly inserted into the aligned
holes.
NOTE
z Do not move the idler arm when adjusting the length of
the pitman link.

6. Tighten the turnbuckle bolt.

FA-3-35
 FRONT AXLE (FA50) FA50

1. Rear drag link 3. Idler arm 5. Front drag link

2. Power cylinder 4. Pitman link 6. Pitman arm

MEASURING CAMBER
A: Camber
B: Kingpin inclination
Use a flat area to measure camber. If a flat area is not available,
select a place that is as flat as possible.
1. Place the rear wheels on stands that are the same height as
the turning radius gauge.
2. Raise the front wheels with jacks and point them straighta-
head.
3. Slowly lower the jacks, making sure that the center of the
turning radius gauge is aligned with the center contacting
surface of the tire. At this point, set the gauge to zero.
4. Carefully attach the camber-caster-kingpin inclination
gauge horizontally to the hub.
5. Camber is determined by reading the center of the air bub-
ble in the camber scale.
6. If the measured value is in excess of specifications, check
the kingpin and bushing for wear, hub bearing for play, and
front axle for bending. Correct faulty part(s) as required.
Camber 1°00“
Kingpin inclination angle 7°00”

FA-3-36
 FRONT AXLE (FA50) FA50

MEASURING THE CASTER AND KINGPIN INCLINA-

TION
C: Caster
1. After measuring the camber, slowly turn the steering wheel
with the turning radius gauge set at zero, until the wheels
turn 20°. 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 20°, 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
20° from the straight forward position. Caster and kingpin
inclination are now determined by reading the center of the
air bubbles of both the caster and kingpin 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 adding 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 misalign-
ment and eliminate the problem.
Caster 3°20’

ADJUSTING MAXIMUM STEERING ANGLE

NOTE
z Adjust the maximum steering angle after completing
wheel alignment.

<Single front axle vehicle>

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-3-37
 FRONT AXLE (FA50) FA50

2. Turn the steering wheel fully to the right, and adjust the right
wheel (inner wheel) angle to the specified range with the
knuckle screw located on the steering knuckle.
Item Maximum turning angle
Inside 50°
Outside 38°

NOTE
z Keep the power steering oil pump operating.

3. Lock the knuckle screw.

： 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}
<Dual front axle vehicle>
1. Using the method described for the single front axle vehicle,
place the road wheels for the 1st and 2nd axles on a turn-
able equipped with a turning radius gauge.
2. Unscrew the knuckle screw on the 2nd axle 2/3 of the way
out.
3. Adjust the knuckle screw on the 1st axle in a manner similar
to that used for the single front axle vehicle. The steering
wheel should be turned fully to the right.
4. Turn the knuckle screw on the 2nd axle until it lightly
touches the front axle stopper, and lock it securely. In this
manner the steering angle will be governed by the 1st axle.
Item Maximum turning angle
Inside 50°
Outside 38°

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-3-38
 FRONT AXLE (FA60) FA60

FRONT AXLE (FA60)

CONSTRUCTION

FA-4-1
 FRONT AXLE (FA60) FA60

TRILEX WHEEL (TYPE 20”)

(TYPE 24”)

FA-4-2
 FRONT AXLE (FA60) FA60

DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels.
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE
type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Trilex wheel nuts are right-hand threaded on the right and
left sides. (Wheel clamp nuts have right-hand threads both
on the right and left sides.)
6. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.

7. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.

8. When removing the tire, be careful not to damage the hub

bolt threads.
9. Because the wheel is heavy, take care not to allow it to fall
toward you.
Refer to the “DISASSEMBLY” section for the disassembled view.

FA-4-3
 FRONT AXLE (FA60) FA60

10. Disconnect joints of the air chamber push rod and slack
adjuster.

11. 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.

12. 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.

FA-4-4
 FRONT AXLE (FA60) FA60

DISASSEMBLY

FA-4-5
 FRONT AXLE (FA60) FA60

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

I Trilex wheel nut
II Wheel clamp nut
III Wheel clamp
IV Adapter

1. Brake drum , 16.Inner bearing inner race

,+ 2. Hub cap , 17. Oil seal retainer
3. Gasket , 18. Dowel pin ,+ 31. Steering arm
4. Lock plate 19. Cotter pin 32. Grease nipple
,+ 5. Adjusting nut + 20. Castellated nut + 33. Brake chamber bracket
6. Knuckle washer 21. Dust cover 34. Gasket
,+ 7. Hub + 22. Tie-rod clamp bolt , 35. Dust cover
8. Outer bearing inner race , 23. Tie-rod end , 36. Lock pin
9. Oil seal 24. Tie-rod tube 37. Kingpin
10. Outer bearing outer race 25. Cotter pin , 38. Shim
11. Inner bearing outer race 26. Castellated nut , 39. Thrust bearing
12. Hub bolt 27. Tie-rod arm 40. Oil seal
13. Plug ,+ 28. Brake assembly mounting bolt 41. Kingpin bushing
+ 14. Stopper bolt 29. Cotter pin , 42. Steering knuckle
, 15. Lock nut 30. Castellated nut ,+ 43.Front axle
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

2 Hub cap
1. 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.
2. Be sure to discard the old gasket.
5 Adjusting nut
Using the adjusting nut socket (99820 Z5001), remove the adjust-
ing nut.

FA-4-6
 FRONT AXLE (FA60) FA60

7 Hub
Using the front hub puller (99840 Z0018), remove the hub (with the
outer hub bearing and inner hub bearing outer race attached).
WARNING
WARNING
z Because the hub is heavy, use a lifting cable and hoist to
move it. To assure safety, this operation should be per-
formed by more than two men. Be careful not to drop the
hub and drum onto your feet.

14 Stopper bolt
Remove the plug and stopper bolt from the back of the knuckle, and
insert the puller bolts (99532 Z0060) into those holes. Turn the
puller bolts alternately to remove the inner hub bearing inner race,
dowel pin and oil seal retainer.

20 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.

22 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.

28 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 grease.

31 Steering arm
Do not tap the ball stud of the drag link with a hammer. Use a puller
if necessary.

FA-4-7
 FRONT AXLE (FA60) FA60

33 Brake chamber bracket

Remove the chamber bracket from the steering knuckle.

43 Front axle
Place a jack under the front axle and remove the nuts from the U-
bolts.
WARNING
WARNING
z Be sure to perform this operation with a jack placed
under the front axle.

FA-4-8
 FRONT AXLE (FA60) FA60

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Kingpin outside diameter

Unit: mm (in)
Maintenance standard Service limit
54.98 - 55.00 (2.1646 - 2.1654) 54.9 (2.161)

Clearance between kingpin and bushing

Unit: mm (in)
Maintenance standard Service limit
0.01 - 0.10 (0.0004 - 0.0039) 0.2 (0.008)

Clearance between front axle hole and kingpin

Unit: mm (in)
Maintenance standard Service limit
0 - 0.05 (0 - 0.0020) 0.15 (0.0059)

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.

FA-4-9
 FRONT AXLE (FA60) FA60

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 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. If there is even
the slightest difference in the left and right centering 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: 7° ± 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.

FA-4-10
 FRONT AXLE (FA60) FA60

Brake drum
For inspection of the brake drum, refer to the “BRAKE” section.

REPAIR AND REPLACEMENT

KINGPIN BUSHING
1. Use the kingpin bushing tool (99831 Z0003) 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” 45° toward the
outer rear side of the vehicle.
z The upper bushing is shorter than the lower bushing.

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-4-11
 FRONT AXLE (FA60) FA60

CAUTION
z The upper bushing is shorter than the lower bushing.
Install the upper bushing with its oil groove facing
upward.
z When installing the bushings, press-fit with the clinch
faced 45° inward to the front of the vehicle.

BRAKE DRUM AND HUB

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.

[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.
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.

FA-4-12
 FRONT AXLE (FA60) FA60

2. Press hub bolts into the hub.

<Pressing hub bolts into a new hub>
z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
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 5 to 6 tons.
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure all hub bolts are flush and pressed equally.

z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a workbench to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
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.

z Ensure all hub bolts are flush and pressed equally.
z Wipe off oil seepage.

FA-4-13
 FRONT AXLE (FA60) FA60

[Pressing hub bolts using a hammer]

If hub bolts need to be replaced in emergencies, such as when
trouble occurs, etc., proceed as follows:
1. Remove hub bolts from the hub.
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 2-lb or greater weight.
NOTE
z Be careful not to scratch the hub, brake drum, and adja-
cent parts.
z Do not allow foreign matter to get into the bearing or hub
grease.

2. Press new hub bolts into the hub.

<Pressing hub bolts into a new hub>
z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Using a hammer (2-lb weight, min.) and pad, drive hub bolts
straight into hub holes. The hub bolt will be properly driven
into place by hammering them approximately 20 times.
NOTE
z Be careful not to scratch the hub and brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure all hub bolts are flush and pressed equally.

z Wipe off oil seepage.

<Pressing hub bolts into an old hub>

z Place the hub and brake drum on a firm mount to prevent
them from becoming deformed.
z Apply engine/gear oil to the entire perimeter of serrations.
z Align hub bolt serrations with hub bolt hole serrations.
z Lightly tap hub bolt heads to properly mesh with the mating
serrations.
NOTE
z Be careful not to scratch the hub or brake drum.
z Do not allow foreign matter to get into the bearing or hub
grease.

z Ensure hub bolts are flush and pressed properly.

z Wipe off oil seepage.

FA-4-14
 FRONT AXLE (FA60) FA60

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 Z5004 3.99844 Z5000

2.99843 Z5006

4. Drive in the oil seal using an oil seal replacer (99828

Z0006).
NOTE
z Apply grease to the oil seal lips before installation.

FA-4-15
 FRONT AXLE (FA60) FA60

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-4-16
 FRONT AXLE (FA60) FA60

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 20 g (0.71
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. Press the dust cover into place using special tool (99853
Z0001) and 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.

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 it immediately.

FA-4-17
 FRONT AXLE (FA60) FA60

REASSEMBLY
REASSEMBLY
Key point of reassembly
43 Front axle
1. Put the front axle under the leaf spring, with the knuckle
stopper side facing the rear of the vehicle.

2. Insert a caster shim between the front axle and leaf spring,
with the center bolt holes aligned.
CAUTION
z Insert the caster shim with the thick side facing the rear
of the vehicle.

： 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}

42 Steering knuckle
1. After selecting the shim, extract the kingpin, being careful
not to damage the dust seal. Then remove the temporarily
installed steering knuckle.
WARNING
WARNING
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during installation.

NOTE
z Do not drop the thrust bearing during installation.

FA-4-18
 FRONT AXLE (FA60) FA60

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
z Be careful not to pinch your fingers between the steering
knuckle and the front axle during removal and installa-
tion.

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.

39 Thrust bearing
Install the thrust bearing on the lower part of the front axle. Using
the kingpin or a similar bar, temporarily install the steering knuckle.
NOTE
z Before installing the thrust bearing, apply bearing grease
to it until grease oozes out.
z When the thrust bearing is an O-ring type, face the O-ring
upward when installing.

FA-4-19
 FRONT AXLE (FA60) FA60

38 Shim
Measure the clearance between the steering knuckle and front
axle. Select the shim so that clearance corresponds to the mainte-
nance standard.
CAUTION
z When installing the shim and bearing do not strike with a
hammer.
z Use only one shim. Install the shim after adjusting the
clearance.

Type of shim
10 types from 2.1 to 3.0 mm (0.083 to 0.118 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·lb}
Hang a spring balance from the steering knuckle spindle, as shown
in the figure below. 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, lb}

Maintenance standard Service limit
Less than 9.8 {1.0, 2.2} —

35 Dust cover
Dust cover mounting bolt
: 10 - 20 N·m {1.0 - 2.0 kgf·m, 7 - 14 ft·lbf}

1 Dust cover 2 Bolt

FA-4-20
 FRONT AXLE (FA60) FA60

31 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 {500 - 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.

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.
： 216 - 343 N·m 22 - 35 kgf·m, 159 - 253 ft·lbf
CAUTION
z If the cotter pin mounting holes are not aligned, loosen
and align to the nearest hole.

28 Brake assembly mounting bolt

1. Fit the brake assembly. Install the upper two mounting bolts
through a spring washer. Insert the lower two bolts through
the lock plate.
： 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.

NOTE
z Be careful not to wet the brake linings with oil or grease.

FA-4-21
 FRONT AXLE (FA60) FA60

23 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.

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.

3. Insert the tie-rod end clamp bolt and tighten it temporarily.

Tighten the clamp bolt after properly adjusting the toe-in.
Refer to th “Wheel Alignment” section for the toe-in adjust-
ment procedure.

18 Dowel pin and 17 Oil seal retainer

1. Drive in the dowel pin for the oil seal retainer.
2. Align the pin hole of steering knuckle and dowel pin and
install the oil seal retainer.

FA-4-22
 FRONT AXLE (FA60) FA60

16 Inner bearing inner race

Install the inner hub bearing on the steering knuckle, using a
replacer (99827 Z0063).
NOTE
z After installing the hub bearing, remove any grease that
has been forced out.

15 Lock nut
Screw the plug into the front of the kingpin and temporarily tighten
the stopper and lock nut on the rear of the kingpin. The stopper bolt
should be tightened to the specified torque after installing the wheel
and adjusting steer-angle. For adjusting the steering angle, refer to
the “FRONT WHEEL ALIGNMENT” section.
Knuckle stopper bolt lock nut
： 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 ft·lbf}

7 Hub
1. Charge the grease sump of the hub with bearing grease so
that grease properly lubricates the hub bearing.
Approximately amount of grease:
900 g (31.74 oz)
2. Install the hub to the steering knuckle, and install the outer
hub bearing inner race with an installer (99827 Z0014).
WARNING
WARNING
z Because the hub is heavy, 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. Install the brake drum.

: 8 - 13 N·m {0.8 - 1.3 kgf·m, 5.8 - 9.4 ft·lbf}
4. Apply grease to the threads on the steering knuckle and
knuckle washer. Install the knuckle washer and tighten with
the adjusting nut.
: 196 N·m {20 kgf·m, 145 ft·lbf}
5. Pull the spring balance horizontally until the hub rotates at
least 90~, and measure the preload by reading the mean
value of the spring balance indication.

FA-4-23
 FRONT AXLE (FA60) FA60

NOTE
z Ensure that the brake linings are not in contact with the
drum.

Preload
29.4 - 47.1 N
Conventional type wheel
{3.0 - 4.8 kgf, 6.6 - 10.6 lbf}
25.5 - 40.2 N
Trilex wheel
{2.6 - 4.1 kgf, 5.7 - 9.0 lbf}

NOTE
z The method of measuring the preload and its measuring
position are the same both for conventional type wheels
and Trilex wheel.

5 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
29.4 - 47.1 N
Conventional type wheel
{3.0 - 4.8 kgf, 6.6 - 10.6 lbf}
25.5 - 40.2 N
Trilex wheel
{2.6 - 4.1 kgf, 5.7 - 9.0 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.

2 Hub cap
Install the new gasket and hub cap.
: 8 - 13 N·m {0.8 - 1.3 kgf·m, 5.8 - 9.4 ft·lbf}

NOTE
z Before installing the hub cap, pack it with the specified
amount of grease. For details, refer to “Rear hub greas-
ing procedure” section.

1. Bolt 3. Hub cap

2. Lock washer 4. Gasket

FA-4-24
 FRONT AXLE (FA60) FA60

INSTALLATION
<ISO TYPE>
Key point of installation
Align the tire so that the hub bolts are in the middle of the disc
wheel bolt holes, and tighten the wheel nuts temporarily.
CAUTION
z If the wheel mounting section is dirty, the wheel nuts
may loosen. Clean with a wire brush and rag.

NOTE
<ISO type>
z The left and right wheel nuts have right-hand threads.
z Be careful not to damage the thread of the hub bolt with
the disc wheel.
z Remove any foreign material from the tapered portion
between the wheel nuts and washers using compressed
air so that the wheel nuts and washers rotate smoothly. If
they do not rotate smoothly, replace them with new ones.
z Apply two drops of engine oil or gear oil to the threaded
portions of the wheel nuts and between the nuts and
washers (the tapered portion).
Wipe away any excess with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.

Position a garage jack under the front axle and raise the front of
vehicle. Remove the right and left trestles from the front of the
frame, and slowly lower the vehicle.
WARNING
WARNING
z Apply the jack at the jacking-up point accurately.

Tighten the wheel nuts so that disc closely contacts the neck of
each bolt.
：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-4-25
 FRONT AXLE (FA60) FA60

<Trilex wheel>
Key point of installation
1. Align the projections (on each side of the tire valve) at the
rim location with the concave portion (20”) or with flat area
(of the outer periphery) (24”) except for unit FA50 between
the spokes of the adapter, and attach the rim to the adapter.
2. Install the clamps and nuts at two places on the upper and
lower sides of the adapter. Tighten the nuts temporarily and
center the rims.
3. Install the remaining clamps and nuts, and slightly tighten
the nuts, one at a time, circumferentially, until the specified
torque is reached.
: 265 - 294 N·m {27 - 30 kgf·m, 195 - 217 ft·lbf}
NOTE
z Do not tighten the nuts diagonally, or in a criss-cross
fashion.
z When tightening the nut, ensure the boss of the clamp
touches the seating surface of the adapter.
z Also ensure the rim touches the entire tapered seat sur-
face of the adapter.
z After installing the wheels on the vehicle, drive the vehi-
cle about 100 km and check the tightening torque of the
nuts. Re-tighten the nuts if needed.
z If the rim and the tapered seat surface of the adapter do
not come into close contact (this often occurs when the
tire is new and its bead is still hard) although the nuts are
tightened to the specified torque setting, decrease the
tire pressure, attach the rims to the adapter and then
reinflate the tire.

FA-4-26
 FRONT AXLE (FA60) FA60

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.

<Single front axle vehicle>

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.

FA-4-27
 FRONT AXLE (FA60) FA60

CAUTION
z Do not rotate the tires more than 180 degrees. If you
rotate them more than that, repeat the procedure from
step 1.

5. Place the toe-in gauge behind the axle. Following the same
procedure as in step 3, read the distance between the
marks. Assume this dimension to be “B”.

6. The toe-in is determined by subtracting “A” from “B”. Con-

firm that the value meets the prescribed standard. If the pre-
scribed standard is not met, adjust with the tie-rod.

Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
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 rear, 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.

<Dual front axle vehicle>

Measure procedure
1. Orient the front tires so that they face straight ahead.

FA-4-28
 FRONT AXLE (FA60) FA60

2. On the front of the left and right tires on the 1st and 2nd
axles, 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 respective sets of 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” for the 1st axle and “A'” for the 2nd
axle.

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 respective axles. Follow-

ing the same procedure as in step 3, read the distance
between the marks. Assume this dimension to be “B” for the
1st axle and “B'” for the 2nd axle.

6. The toe-in of the 1st axle is determined by subtracting “A”

from “B”, while the toe-in of the 2nd axle is determined by
subtracting “A'” from “B'”. Confirm that the values meet the
prescribed standard. If the prescribed standard is not met,
adjust with the tie-rod and pitman link.

FA-4-29
 FRONT AXLE (FA60) FA60

Adjustment procedure
1. Loosen the tie-rod end clamp bolt. Then turn the tie-rod (as
shown by the arrow) to adjust.
NOTE
z Turn the tie-rod toward the front to shorten, and toward
the rear to lengthen.
z Attach the tie-rod end clamp on the underside of the
vehicle. Then insert the bolt from the rear, 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.

3. Separate the pitman link.

4. Check tire directions using a straight bar [approx. 3,800 mm

(110 in) long]. If necessary, adjust them to C=C' and/or
D=D'.
5. After toe-in has been properly adjusted in step 4. above,
check the alignment of the pin hole in the pitman arm with
the hole in the pitman link. If it is not aligned, lengthen or
shorten the pitman link until correct alignment is obtained.
The clevis pin should be smoothly inserted into the aligned
holes.
NOTE
z Do not move the idler arm when adjusting the length of
the pitman link.

6. Tighten the turnbuckle bolt.

FA-4-30
 FRONT AXLE (FA60) FA60

1. Rear drag link 3. Idler arm 5. Front drag link

2. Power cylinder 4. Pitman link 6. Pitman arm

MEASURING CAMBER
A: Camber
B: Kingpin inclination
Use a flat area to measure camber. If a flat area is not available,
select a place that is as flat as possible.
1. Place the rear wheels on stands that are the same height as
the turning radius gauge.
2. Raise the front wheels with jacks and point them straighta-
head.
3. Slowly lower the jacks, making sure that the center of the
turning radius gauge is aligned with the center contacting
surface of the tire. At this point, set the gauge to zero.
4. Carefully attach the camber-caster-kingpin inclination
gauge horizontally to the hub.
5. Camber is determined by reading the center of the air bub-
ble in the camber scale.
6. If the measured value is in excess of specifications, check
the kingpin and bushing for wear, hub bearing for play, and
front axle for bending. Correct faulty part(s) as required.
Camber 1°00“
Kingpin inclination angle 7°00”

FA-4-31
 FRONT AXLE (FA60) FA60

MEASURING THE CASTER AND KINGPIN INCLINA-

TION
C: Caster
1. After measuring the camber, slowly turn the steering wheel
with the turning radius gauge set at zero, until the wheels
turn 20°. 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 20°, 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
20° from the straight forward position. Caster and kingpin
inclination are now determined by reading the center of the
air bubbles of both the caster and kingpin 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 adding 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 misalign-
ment and eliminate the problem.
Caster 3°20’

ADJUSTING MAXIMUM STEERING ANGLE

NOTE
z Adjust the maximum steering angle after completing
wheel alignment.

<Single front axle vehicle>

1. Place the left and right front road wheels in the center of a
turntable equipped with a turning radius gauge, and set the
steering wheel at the straight forward position.
2. Turn the steering wheel fully to the right, and adjust the right
wheel (inner wheel) angle to the specified range with the
knuckle screw located on the steering knuckle.
Item Maximum turning angle
42º Conventional wheel type
Inside
40º Trilex wheel type
33º Conventional wheel type
Outside
32º Trilex wheel type

FA-4-32
 FRONT AXLE (FA60) FA60

NOTE
z Keep the power steering oil pump operating.

3. Lock the knuckle screw.

: 137 - 167 N·m {14 - 17 kgf·m, 101 - 123 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-4-33
 SUSPENSION FA50, FA60

SUSPENSION
CONSTRUCTION
[Front 1-axle model]

[Front 2-axle model]

Type I

FA-5-1
 SUSPENSION FA50, FA60

[Front 2-axle model]

Type II

Stabilizer

FA-5-2
 SUSPENSION FA50, FA60

DISASSEMBLY
REMOVAL
Key point of removal
1. Apply chocks to the rear wheels
2. The wheel nuts on the right side of the vehicle have right-
hand threads and those on the left side have left-hand
threads. (SAE type)
3. The left-hand wheel nuts are marked with an “L”. (SAE
type)
4. The left and right ISO-type wheel nuts have the same right-
hand threads.
5. Trilex wheel nuts are right-hand threaded on the right and
left sides. (Wheel clamp nuts have right-hand threads both
on the right and left sides.)
6. Apply a small amount of grease to the threads of the hub
bolts and wheel nuts.

7. Place a jack under the front axle and raise the front of the
vehicle. For safety's sake, place a safety stand under each
side of the front of the frame.
WARNING
WARNING
z Use safety stands which have sufficient strength and sta-
bility.

8. When removing the tire, be careful not to damage the hub

bolt threads.
9. Because the wheel is heavy, take care not to allow it to fall
toward you.

FA-5-3
 SUSPENSION FA50, FA60

10. Remove the the front stabilizer. (Models equipped with front
stabilizer).
Refer to the “FRONT STABILIZER” section for procedures.
Refer to the “DISASSEMBLY” section for the disassembled view.

FA-5-4
 SUSPENSION FA50, FA60

DISASSEMBLY
<Suspension>
[Front 1-axle model]

FA-5-5
 SUSPENSION FA50, FA60

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Nut 13.Nut , 25.Shackle pin
2.Washer 14.Shock absorber pin 26.Shim
3.Rubber bushing ,+ 15.U-bolt nut + 27.Shackle
4.Rubber bushing 16.U-bolt , 28.Grease nipple
5.Washer 17.Pad , 29.Lock bolt
6.Washer 18.Rubber bumper , 30.Spring pin
7.Rubber cushion , 19.Grease nipple + 31.Spring assembly
8.Washer , 20.Lock bolt 32.Shock absorber bracket
9.Washer ,+ 21.Spring pin , 33.Spacer (Except CWA and CWB vehi-
10.Rubber cushion 22.Shim cle models)
11.Washer , 23.Grease nipple
12.Shock absorber , 24.Lock bolt
Marks “+” and “,” indicate that the key points of operation are explained in the text.
*O Install only one spacer 33 at right in right-hand drive vehicles and at left in left-hand drive vehi-
cles. (Except CWA and CWB series model vehicles)

FA-5-6
 SUSPENSION FA50, FA60

[Front 2-axle model]

Type I

FA-5-7
 SUSPENSION FA50, FA60

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Nut 12.Shock absorber , 23.Grease nipple
2.Washer 13.Nut , 24.Lock bolt
3.Rubber bushing 14.Shock absorber pin , 25.Shackle pin
4.Rubber bushing ,+ 15.U-bolt nut 26.Shim
5.Washer 16.U-bolt + 27.Shackle
6.Washer 17.Pad , 28.Grease nipple
7.Rubber cushion 18.Rubber bumper , 29.Lock bolt
8.Washer , 19.Grease nipple , 30.Spring pin
9.Washer , 20.Lock bolt + 31.Spring assembly
10.Rubber cushion ,+ 21.Spring pin 32.Shock absorber bracket
11.Washer 22.Shim
Marks “+” and “,” indicate that the key points of operation are explained in the text.
NOTE
z The rear side is the same as the front side except for the caster shim and spacer. Disassembly
is the same as that for the front side.

FA-5-8
 SUSPENSION FA50, FA60

[Front 2-axle model]

Type II

FA-5-9
 SUSPENSION FA50, FA60

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Nut ,+ 21.Spring pin + 36. Shackle
2.Washer 22.Shim + 37. Spring assembly
3.Rubber bushing , 23.Grease nipple (straight type) 38. Radius rod bracket
4.Rubber bushing , 23-1. Grease nipple , 39. Grease nipple
5.Washer , 24.Lock bolt , 40. Lock plate
6.Washer , 25.Shackle pin 41. Washer
7.Rubber cushion 26.Shim 42. Radius rod assembly
8.Washer + 27.Shackle 43. Rubber bushing
9.Washer , 28.Grease nipple , 44. Lock plate
10.Rubber cushion , 28-1. Grease nipple 45. Washer
11.Washer , 29.Lock bolt 46. Pin
12.Shock absorber , 29-1.Lock bolt 47. Thrust washer
13.Nut , 30.Spring pin 48. Equalizer beam assembly
14.Shock absorber pin ,+ 30-1. Spring pin 49. Thrust washer
15.Bolt + 31.Spring assembly 50. Spring seat
,+ 16.U-bolt nut , 31-1. Shim 51. Bracket assembly
17.U-bolt 32.Shock absorber bracket 52. Rubber bumper assembly
18.Bumper rubber assembly , 32-1. Grease nipple 53. Bumper spacer
, 19.Grease nipple (straight type) , 33-1.Lock bolt 54. Bumper spacer
, 19-1.Grease nipple , 34. Shackle pin 55. Rubber bumper assembly
, 20.Lock bolt 35. Shim 56. Bumper spacer
Marks “+” and “,” indicate that the key points of operation are explained in the text.
NOTE
z Operation No. 1 to 30-1 are the same both for the front side spring and rear side spring.

FA-5-10
 SUSPENSION FA50, FA60

<Stabilizer>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Nut , 9. Stabilizer clamp 16. Washer
+ 2. Pin , 10. Stabilizer clamp 17. Rubber cushion
3. Bushing 11. Stabilizer bar 18. Washer
4. Nut 12. Self-locking nut 19. Link rod
5. Bolt 13. Washer 20. Nut
6. Nut 14. Rubber cushion 21. Bolt
7. Bolt 15. Washer 22. Bolt
, 8. Bushing 23. Stabilizer bracket
Marks “+” and “,” indicate that the key points of operation are explained in the text.

FA-5-11
 SUSPENSION FA50, FA60

<Suspension>
Key point of disassembly
15 1-axle, 2-axle model type I and 16 2-axle model type II 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.

21 1-axle, 2-axle model type I, type II and 30-1 2-axle model

type II (Rear/Front side only) spring pin
1. Measure and record the clearances between the shackle
and spring bracket, and between the shackle and spring.
2. Remove the grease nipple and bolt.
NOTE
z Use a copper rod when removing the spring pin.
z Record the thickness of the shims after removal.

27 1-axle, 2-axle model type I, type II and 36 2-axle model

(Type II Rear/Front side only) shackle
Remove the grease nipple and bolt.
NOTE
z Use a copper rod when removing the shackle pin. If the
rod is not available, use a sliding hammer.

z Record the thickness of the shims after removal.

31 1-axle, 2-axle model type I, type II (Front side) and 37 2-

axle model type II (rear side) spring assembly
1. Lower the jack. Place the rear of the spring assembly on the
floor while supporting the front with wire.
2. Remove the grease nipple and bolt.
NOTE
z Use a copper rod when removing the spring pin.

3. While supporting the spring assembly with a garage jack,

dismount the spring assembly.

<Stabilizer>
(Models equipped with front stabilizer)
Apply a coat of bearing grease to the sliding sections of the various
parts before installation.
Key point of disassembly
2 Pin
Use a copper hammer when removing the pin.

FA-5-12
 SUSPENSION FA50, FA60

INSPECTION
<Suspension>
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Leaf spring
Measure wear on the leaf. If it is worn more than 15% of its nominal
thickness, replace it.
Spring pin and shackle pin outside diameter
Unit: mm (in)
Maintenance standard Service limit
30.0 (1.181) 29.5 (1.161)

Spring pin and shackle pin bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
30.0 (1.181) 31.0 (1.220)

Clearance between spring (shackle) pin and bushing

Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.14 (0.0008 - 0.0055) 1.0 (0.039)

FA-5-13
 SUSPENSION FA50, FA60

Clearance between shackle and spring bracket

Unit: mm (in)
Maintenance standard Service limit Remarks
Adjust with shim
0.05 - 0.70 Thickness of shims:
—
(0.0020 - 0.0276) 1.8, 2.0, 2.3 (0.071, 0.079,
0.091)

Clearance between shackle and spring

Unit: mm (in)
Maintenance standard Service limit Remarks
Adjust with shim
0.05 - 0.70 Thickness of shims:
—
(0.0020 - 0.0276) 1.8, 2.0, 2.3 (0.071, 0.079,
0.091)

REPAIR AND REPLACEMENT

<Suspension>
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 C-clamp and

tighten with the center bolt and nut.
： 108 - 127 N·m {11 - 13 kgf·m, 80 - 94 ft·lbf}

FA-5-14
 SUSPENSION FA50, FA60

7. Remove the C-clamp from the spring assembly.

8. Install the clip bolt with the T-type socket (99535 Z0005).
9. After tightening the clip bolt, stake the threaded end of the
clip bolt with the punch so that it is locked.
： 49 - 59 N·m {5 - 6 kgf·m, 36 - 43 ft·lbf}

Bushing
1. Remove the bushing with the bushing replacer (99888
Z0003).

2. Attach a new bushing to the bushing replacer (99888

Z0003) and install it.

FA-5-15
 SUSPENSION FA50, FA60

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.

Key point of reassembly

44, 40 Lock plate (2-axle model type II only)
After tightening with the bolt, securely bend the lock plate in 3
places to prevent the bolt from loosening.

39 Grease nipple (2-axle model type II only)

After installing the equalizer beam and radius rod, apply an ample
amount of grease to the grease nipple so that grease flows out from
between the equalizer beam center and thrust washer (or bracket).

33 Spacer (1-axle model only)

Install the spacer between the front axle and shock absorber
bracket with the center bolt holes aligned.
NOTE
z Install one spacer only at right in right-hand drive vehi-
cles and at left in left-hand drive vehicles. (Except CWA
and CWB series model vehicles)

34 2-axle model type II (Rear/Front side only)

and 25 1-axle, 2-axle model type I, type II shackle pin
1. Select suitable shims so that the clearance between the
spring bracket and shackle is within the specified range.
Unit: mm (in)
Maintenance standard Service limit Thickness of shims
0.05 - 0.70 1.8, 2.0, 2.3
—
(0.0020 - 0.0276) (0.071, 0.079, 0.091)

FA-5-16
 SUSPENSION FA50, FA60

2. Align the bracket with the cutout section of the shackle pin
lock bolt when driving the shackle pin into place.
NOTE
z Use a copper hammer when driving in the shackle pin.

33-1 2-axle model type II (Rear/Front side only) and

24 1-axle, 2-axle model type I, type II lock bolt
Bolt 33-1 for the 2-axle model type II (Rear/Front sides) should be
inserted from behind the vehicle towards the front of the vehicle,
and bolt 24 should be inserted from the front of the vehicle towards
the rear of the vehicle.

32-1, 28-1, 28, 23-1 / 23, 19, 19-1 2-axle model type II and
28, 23, 19 1-axle, 2-axle model type I grease nipple
1. Install the front side grease nipple so that it faces the vehi-
cle front, and install the rear side grease facing the vehicle
rear.
2. Apply grease to service points through grease fittings.

NOTE
z Parts 23 and 19 for the 2-axle model type II should be
straight type grease nipples.Grease nipples
z 32-1 and 28-1 for the 2-axle model type II should be
installed inside the vehicle and the other grease nipples
should be installed outside the vehicle.

FA-5-17
 SUSPENSION FA50, FA60

30 1-axle, 2-axle model type I and 2-axle model type II

(Front/Front side) spring pin
Using a garage jack, support the spring assembly. Connect the
front of the spring assembly to the bracket with spring pin.
Align the bracket with the cutout section of the spring pin lock bolt
when driving the spring pin into place.
NOTE
z Use a copper hammer when driving in the spring pin.

30-1 2-axle model type II (Rear/Front side only) and

21 1-axle, 2-axle model type I, type II spring pin
1. Raise the rear of the spring assembly with a garage jack,
secure the shackle using a spring pin with shims placed on
each side of the spring.
2. Select suitable shims so that the clearance between the
spring bracket and shackle is within the specified range.

Unit: mm (in)
Maintenance standard Service limit Thickness of shims
0.05 - 0.70 1.8, 2.0, 2.3
—
(0.0020 - 0.0276) (0.071, 0.079, 0.091)

3. Align the bracket with the cutout section of the spring pin
lock bolt when driving the spring pin into place.
NOTE
z Use a copper hammer when driving in the spring pin.

29-1 2-axle model type II (Rear/Front side only) and

24 20 1-axle, 2-axle model type I, type II lock bolt
Bolt 29-1 for the 2-axle model type II (Rear/Front sides) should be
inserted from behind the vehicle towards the front of the vehicle,
and bolts 24 and 20 should be inserted from the front of the vehicle
towards the rear of the vehicle.
： 34 - 49 N·m {3.5 - 5.0 kgf·m, 25 - 36 ft·lbf}

16 2-axle model type II and

15 1-axle, 2-axle model type I u-bolt nut
When securing the spring, jack up the vehicle until the front axle
contacts the spring.
： 490 - 539 N·m {50 - 55 kgf·m, 362 - 398 ft·lbf}

FA-5-18
 SUSPENSION FA50, FA60

<Stabilizer>
Key point of reassembly
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-5-19
 TIRES AND WHEELS

CONTENTS
SERVICE DATA....................................TW- 1 DISASSEMBLY................................ TW- 8
SPECIFICATIONS............................TW- 1 INSPECTION ...................................... TW-13
SERVICE DATA................................TW- 3 REASSEMBLY.................................... TW-15
TIGHTENING TORQUE ...................TW- 4 REASSEMBLY................................ TW-15
DISASSEMBLY ....................................TW- 5 INSTALLATION ............................... TW-19
REMOVAL ........................................TW- 5

TW
 SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Item Vehicle model
Tire Wheel CKA, CKB,
CKB-CT
CKC, CWC CWA CDA, CGB,
CWB-KT
Size Construction Size Mounting Series Series CWB
Series
Series
20 x 7.00T-162
10.00-20-14 PR B 10 O
20 x 7.50V-165
20 x 7.00T-162
10.00-20-16 PR B 8, 10 O O
20 x 7.50V-165
20 x 7.50V-165
11.00-20-14 PR B 8, 10 O O
20 x 7.50 (TRILEX)
20 x 7.50V-165
11.00-20-16 PR B 8, 10 O O
20 x 7.50 (TRILEX)
20 x 8.50V-180
12.00-20-16 PR B 10 O
20 x 8.50 (TRILEX)
12.00-20-18 PR B 20 x 8.50V-180 10 O
22.5 x 7.50-162
11R22.5-14 PR V R 8, 10 O O
22.5 x 8.25-165
22.5 x 7.50-162
11R22.5-16 PR V R 8, 10 O O O
22.5 x 8.25-165
12R22.5-14 PR V R 22.5 x 8.25-165 8, 10 O O

12R22.5-16 PR V R 22.5 x 8.25-165 8, 10 O O

20 x 7.00T-162
10.00R-20-14 PR R 8, 10 O O
20 x 7.50V-165
20 x 7.00T-162
10.00R-20-16 PR R 8, 10 O O O
20 x 7.50V-165
20 x 7.50V-165
11.00R-20-14 PR R 8, 10 O O
20 x 7.50 (TRILEX)
20 x 7.50V-165
11.00R-20-16 PR R 8, 10 O O
20 x 7.50 (TRILEX)
20 x 8.50V-180
12.00R-20-16 PR R 10 O
20 x 8.50 (TRILEX)
20 x 8.50V-180
12.00R-20-18 PR R 10 O
20 x 8.50 (TRILEX)
12.00R-24-18 PR R 24 x 8.50 (TRILEX) 10 O

NOTE
z Tire construction V: Tubeless, B: Bias, R: Radial
z Wheel mounting 8: 8 studs, 10: 10 studs

TW-1
 SERVICE DATA

Please note that the sizes in the below chart are examples of typi-
cal tire sizes and not necessarily apply to your vehicle.

TIRE SIZE DESIGNATION

Truck type radial

10.00 R - 20 - H (16PR)
Load range
Rim diameter in inches
Indicates radial construction
Nominal section width in inches

11 R 22.5 H (16PR)
Load range
Rim diameter in inches
Indicates radial construction
Nominal section width in inches

Truck type bias

10.00 - 20 - H (16PR)
Load range

Rim diameter in inches

Nominal section width in inches

WHEEL SIZE DESIGNATION

22.5 x 9.00 - 155

Offset (in mm)

Rim width (in inches)

Rim diameter (in inches)

TW-2
 SERVICE DATA

SERVICE DATA
TIRE SIZES AND TIRE INFLATION PRESSURES

Standard air pressure kPa {kgf/cm2, psi}

Tire size designation 638 662 687 711 736 760 785
{6.50, 92} {6.75, 96} {7.00, 100} {7.25, 103} {7.50, 107} {7.75, 110} {8.00, 114}
10.00-20-14 PR O
10.00-20-16 PR O
11.00-20-14 PR O
11.00-20-16 PR O
12.00-20-16 PR O
12.00-20-18 PR O
11R22.5-14 PR O
11R22.5-16 PR O
12R22.5-14 PR O
12R22.5-16 PR O
10.00R-20-14 PR O
10.00R-20-16 PR O
11.00R-20-14 PR O
11.00R-20-16 PR O
12.00R-20-16 PR O
12.00R-20-18 PR O
12.00R-24-18 PR O

TW-3
 SERVICE DATA

WHEEL SERVICE DATA

Unit: mm (in)
Mainte-
Service
Item nance stan-
limit
dard
Horizontal 2.0 (0.079) —
20 x 7.50V-165
Vertical 1.8 (0.071) —
Horizontal —
Disc 20 x 7.00T-162 Type I 1.8 (0.071)
Vertical —
wheel
runout Horizontal —
20 x 8.50V-180 2.4 (0.094)
Vertical —
22.5 x 7.50-162 Horizontal 2.0 (0.079) —
Type II
22.5 x 8.25-165 Vertical 1.8 (0.071) —
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
Unit: N·m {kgf·m, ft·Ibf}
Item Tightening torque
SAE type 540 - 590 {55 - 60, 398 - 435}
Wheel nut
ISO type 590 - 630 {60 - 65, 435 - 465}

TW-4
 DISASSEMBLY

DISASSEMBLY
REMOVAL
<CONVENTIONAL WHEEL TYPE>
Key point of 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 thread-
ing.

ISO type
Type I (outboard type)
The left and right whell nuts have the same right-hand thread
designs.

TW-5
 DISASSEMBLY

Type II (Inboard type)

<TRILEX WHEEL TYPE>

Key point of removal

1. Chock the rear road wheels at the front and rear.

2. Loosen all clamp nuts.

NOTE
z Lightly coat the threaded portion of the clamp bolt or
stud and clamp nut with grease.

3. Jack up the axle.

NOTE
z Plate the jack at the axle below the spring seat.

4. Remove the clamp nuts, and remove the road wheel.

NOTE
z When removing the road wheel, be careful not to damage
the threaded portion of the clamp bolt or stud.
z When removing the left and right wheels simultaneously,
support the front axle or frame with a rack.

TW-6
 DISASSEMBLY

z 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.

z 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
assembly which does not fit together properly resulting in
premature 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.

TW-7
 DISASSEMBLY

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.

DISASSEMBLY
<CONVENTIONAL WHEEL, WITH TUBE TYPE>
Key point of disassembly
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.

TW-8
 DISASSEMBLY

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.

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.

TW-9
 DISASSEMBLY

<CONVENTIONAL WHEEL, TUBELESS TYPE>

Key point of disassembly
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.
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.

TW-10
 DISASSEMBLY

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.

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.

<TRILEX WHEEL TYPE>

Key point of disassembly
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-11
 DISASSEMBLY

2. Insert the lever into the end gap of the side ring. Push it
down to the point where the lever groove is visible.

TW-12
 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-13
 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-14
 REASSEMBLY

REASSEMBLY
REASSEMBLY
<CONVENTIONAL WHEEL, WITH TUBE TYPE>
Key point of reassembly
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.

TW-15
 REASSEMBLY

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 90° from the valve so
it is evenly spaced between the disc ornamental holes.

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 clearance.
Unit: mm (in)
Maintenance standard Service limit
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.

TW-16
 REASSEMBLY

10. Coat the valve core with soapy water and check for air leak-
age. After that, install the valve cap.

<CONVENTIONAL WHEEL, TUBELESS TYPE>

Key point of reassembly
1. Spread lubricant or soapy water on the entire circumference
of tire bead and rim flange.

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.
TW-17
 REASSEMBLY

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.

<TRILEX WHEEL TYPE>

Key point of reassembly
1. Place the tire so that the valve faces upward. Install rim No.
1 over the convex portion facing up.
NOTE
z Be careful not to damage the valve.
2. Install rim No. 2.

3. Position rim No. 3 over the inner side of the tire.

4. Move rims No. 2 and No. 3 along the inner side of the tire.
NOTE
z Ensure the valve is at the right side of the through-hole.

5. Install rim No. 3 over the inner side of the tire using the
small end of the lever.
NOTE
z Ensure rim No. 3 fits to the inner side of the tire.

TW-18
 REASSEMBLY

6. Inflate the tire tube to the specified pressure.

INSTALLATION
<CONVENTIONAL WHEEL TYPE>
Key point of installation
z Procedures for mounting tires differ between the SAE type
and ISO type. When installing tires, be sure to observe pre-
cautions for each tire.
SAE type
1. Clean the wheel mounting surfaces with a wire brush and a
clean waste cloth. Dirty mounting surfaces may cause the
wheel nuts to loosen.
2. Apply two drops of engine oil or gear oil to the threaded por-
tions of the wheel nuts and between the nuts and washers
(the tapered portion). Wipe away any excess with a clean
wastecloth. Do not apply any oil to the working face of the
wheel disc and wheel nuts. Do not use molybdenum grease
for this purpose.
3. The wheel nuts on the right side of the vehicle have right-
handed threading; the left side wheel nuts have left-handed
threading.
4. Tighten the wheel nuts in the sequence shown in the figure
little by little to the specified torque.
： 540 - 590 N·m {55 - 60 kgf·m, 398 - 435 ft·Ibf}

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-19
 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).
Wipe away any excess with a clean wastecloth.
Do not apply any oil to the working face of the wheel disc
and wheel nuts. Do not use molybdenum grease for this
purpose.
5. Wheel nut tightening sequence and procedures are the
same as those for the SAE type.
： 590 - 630 N·m {60 - 65 kgf·m, 435 - 465 ft·Ibf}
NOTE
z Do not tighten the wheel nuts excessively.

<TRILEX WHEEL TYPE>

Key point of reassembly
1. Align the concave portion of the adapter with the projections
of the inner wheel rim at each side of the tire valve, and
place the tire far back in the rim and adapter.

2. Place the spacer so that its stopper is positioned at the tire

valve location of the inner wheel rim.

TW-20
 REASSEMBLY

3. Install the outer wheel rim so that the projections (one on

each side of the tire valve for inner and outer wheel rims)
are positioned in a symmetrical location.

4. Install clamps and nuts on the upper and lower sides of the
adapter at two places, tighten the nuts temporarily and cen-
ter the rims.

5. Install the remaining clamps and nuts, and slightly tighten

the nuts, one at a time, circumferentially, until the specified
torque is reached.
： 265 - 294 N·m {27 - 30 kgf·m, 195 - 217 ft·Ibf}

NOTE
z Do not tighten the nuts diagonally, or in a criss-cross
fashion.
z Ensure the rim touches the entire tapered seat surface of
the adapter.
z After installing the wheels on the vehicle, drive the vehi-
cle about 100 km and check the tightening torque of the
nuts. Re-tighten the nuts if needed.
z If the rim and the tapered seat surface of the adapter do
not come into close contact (this often occurs when the
tire is new and its bead is still hard) although the nuts are
tightened to the specified torque setting, decrease the
tire pressure, attach the rims to the adapter and then
reinflate the tire.
6. Adjust the brake lining-to-drum clearance. Refer to the BR
section for procedures.

TW-21
 STEERING SYSTEM

STEERING GEAR BOX AND HYDRAULIC PUMP

STEERING LINKAGE

ST
 STEERING GEAR BOX AND
HYDRAULIC PUMP

CONTENTS
SERVICE DATA..................................ST-1- 1 = HYDRAULIC PUMP
SPECIFICATIONS..........................ST-1- 1 (UNIT NAME PV123 AND PV132) =
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 DISASSEMBLY.............................. ST-5- 3
(UNIT NAME PSI-Y100) = INSPECTION ..................................... ST-5- 5
REASSEMBLY................................... ST-5- 6
CONSTRUCTION ...............................ST-3- 1 REASSEMBLY............................... ST-5- 6
DISASSEMBLY ..................................ST-3- 2 INSTALLATION .............................. ST-5- 8
REMOVAL ......................................ST-3- 2 INSPECTING RELIEF
DISASSEMBLY ..............................ST-3- 5 VALVE PRESSURE ....................... ST-5- 8
INSPECTION ......................................ST-3- 9
REASSEMBLY .................................. ST-3-11 = HYDRAULIC PUMP
REASSEMBLY ..............................ST-3-11 (UNIT NAME 475) =
INSTALLATION..............................ST-3-15
CONSTRUCTION .............................. ST-6- 1
= STEERING GEAR BOX DISASSEMBLY.................................. ST-6- 2
(UNIT NAME 446) = REMOVAL...................................... ST-6- 2
DISASSEMBLY.............................. ST-6- 3
CONSTRUCTION ...............................ST-4- 1 INSPECTION ..................................... ST-6- 5
DISASSEMBLY ..................................ST-4- 2 REASSEMBLY................................... ST-6- 6
REMOVAL ......................................ST-4- 2 REASSEMBLY............................... ST-6- 6
DISASSEMBLY ..............................ST-4- 5 INSTALLATION .............................. ST-6- 8
INSPECTION .....................................ST-4-10 INSPECTING RELIEF
REASSEMBLY ..................................ST-4-12 VALVE PRESSURE ....................... ST-6- 8
REASSEMBLY ..............................ST-4-12 BLEEDING AIR FROM THE POWER
INSTALLATION..............................ST-4-18 STEERING SYSTEM ......................... ST-7- 1
PERFORMANCE CHECKS...............ST-4-20
 SERVICE DATA GEAR BOX AND HYD PUMP

SERVICE DATA
SPECIFICATIONS
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Unit: mm (in)
Unit: name PSI-Y100-21 PSI-Y100-26 PSI-Y100-36
O.D. of steering wheel 480 (18.90)
Type Integral
Gear ratio 22.76

Operating angle of sector shaft +2º

2 x 48º 0º
Center-to-center distance between sector shaft and ball screw 93 (3.66)
Type of sector shaft Gear
Type Straight ball groove
Dia. of piston 100 (3.94)
Ball screw Torsional direction of ball screw Left Right
Number of balls 35
Lead 14.288(0.5625)

Made by JIDOSHA KIKI Co., Ltd.

Unit: mm (in)
Unit: name 446-02563 446-02560 446-02586
O.D. of steering wheel 480 (18.90)
Type Integral
Gear ratio 22.42

Operating angle of sector shaft 2 x 48º +2.5º

0º
Center-to-center distance between sector shaft and ball screw 91 (3.58)
Type of sector shaft Gear
Type Straight ball groove
Dia. of piston 100 (3.94)
Ball screw Torsional direction of ball screw Left Right
Number of balls 32
Lead 14.288 (0.5625)

NOTE
z On the following pages, PSI-Y100-21, PSI-Y100-26 and PSI-Y100-36 are combined under PSI-
Y100, and 446-02563, 446-02560 and 446-02586 are combined under 446.

ST-1-1
 SERVICE DATA GEAR BOX AND HYD PUMP

HYDRAULIC PUMP
Made by NIPPON POWER STEERING Co., Ltd.
Item PV123-35-13 PV123-35-15 PV132-25-46 PV132-25-49 PV132-25-52
Type Vane type
Drive Gear driven
Operating speed
500 - 4,500 500 - 3,600
rpm
Reliefsetpressure
13,240 {135, 1,920} 12,259 {125, 1,778}
kPa {kgf/cm2, psi}

Made by JIDOSHA KIKI Co., Ltd.

Item 475-03260 475-03282
Type Vane type (1 rotor)
Drive Gear driven
Operating speed
500 - 3,750 500 - 3,600
rpm
Reliefsetpressure
13,240 {135, 1,920}
kPa {kgf/cm2, psi}

STEERING GEAR BOX AND CORRESPONDING HYDRAULIC PUMP

Vehicle model
CKA450 CKB453
Item CKA530
CKC450 CKB450 CWB451 CKB520 CWA520 CKB533
CGB450 CGB520 CWA530 CGB533
CDA450 CWB450 CWB452 CWB520 CWC610 CWB533
CWB530
CWC450 CWB453
PSI-Y100-26 O O O O
446-02560 O O O O
R.H.D.
Steering gear PSI-Y100-36 O
box 446-02586 O O O
PSI-Y100-21 O O O O O O
L.H.D.
446-02563 O O O O O O
PV123-35-13 O O O
PV123-35-15 O O
PV132-25-46 O
Hydraulic pump PV132-25-49 O
PV132-25-52 O
475-03260 O O O
475-03282 O O

NOTE
z On the following pages, PV123-35-13 and PV123-35-15 are combined under PV123, and PV132-
25-46, PV132-25-49 and PV132-25-52 are combined under PV132, and 475-03260 and 475-03282
are combined under 475.

ST-1-2
 SERVICE DATA GEAR BOX AND HYD PUMP

SERVICE DATA
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Clearance between gear case and ball 0.03 - 0.095
0.15 (0.0059)
screw assembly (0.0012 - 0.0037)
Less than
Axial play of ball screw 0.04 (0.0016)
0.02 (0.0008)
Measure at end of pitman arm
Backlash between sector gear and ball 0.06 - 0.30
— 300 mm (11.81 in) with gears in
screw assembly (0.024 - 0.0118)
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)
Adjusting bolt
50.00 (1.9685) 49.95 (1.9665)
side
Wear of sector shaft O.D.
Pitman arm
57.12 (2.2488) 57.07 (2.2468)
side
Less than
Axial play of adjusting bolt —
0.10 (0.0039)

Made by JIDOSHA KIKI Co., Ltd.

Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Clearance between gear case and ball
— 0.15 (0.0059)
screw assembly
Axial play of ball screw — 0.04 (0.0016)
Measure at end of pitman arm
Backlash between sector gear and ball 0.2 - 0.4
— 300 mm (11.81 in) with gears in
screw assembly (0.008 - 0.016)
Neutral.
Less than
—
0.5 (0.020)
Adjusting bolt
47.975 (1.8888) 47.93 (1.8870)
side
Wear of sector shaft O.D.
Pitman arm
57.975 (2.2875) 57.93 (2.2807)
side
0.01 - 0.10
Axial play of adjusting bolt —
(0.0004 - 0.0039)

ST-1-3
 SERVICE DATA GEAR BOX AND HYD PUMP

HYDRAULIC PUMP
Made by NIPPON POWER STEERING Co., Ltd.
Unit: mm (in)
Item Maintenance standard Service limit Remarks
PV123-35-13 12,994 - 13,730
—
PV123-35-15 {132.5 - 140, 1,884 - 1,991}
Adjusted pressure
PV132-25-46
kPa {kgf/cm2, psi} 12,014 - 12,749
PV132-25-49 —
{122.5 - 130, 1,742 - 1,849}
PV132-25-52
Side plate indentation — 0.03 (0.0012)
Clearance between the relief valve outside diameter and 0.013 - 0.0020
0.03 (0.0012)
body inside diameter (0.00051 - 0.000079)
Decrease in shaft oil seal lip outside diameter — 0.05 (0.0020)

Made by JIDOSHA KIKI Co., Ltd.

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Adjusted pressure 475-03260 12,994 - 13,730
—
kPa {kgf/cm2, psi} 475-03282 {132.5 - 140, 1,884 - 1,991}
Clearance between the relief valve outside diameter and
— 0.03 (0.0012)
body inside diameter
Ball bearing play — 0.04 (0.0016)

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}
0.2 (0.008) Approx. 520 {5.3, 75}
475-03260
0.5 (0.020) Approx. 1,304 {13.3, 189}
13,240 {135, 1,920}
0.2 (0.008) Approx. 245 {2.5, 36}
475-03282
0.5 (0.020) Approx. 608 {6.2, 88}

ST-1-4
 SERVICE DATA GEAR BOX AND HYD PUMP

TIGHTENING TORQUE
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Valve housing mounting bolt 127 - 157 {13 - 16, 94 - 116}
Side cover mounting bolt 78 - 103 {8.0 - 10.5, 58 - 76}
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 186 {19, 137}
Pitman arm mounting nut 441 - 490 {45 - 50, 325 - 362}

Made by JIDOSHA KIKI Co., Ltd.

Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Valve housing mounting bolt 118 - 127 {12 - 13, 87 - 94}
Adjusting screw lock nut 118 - 127 {12 - 13, 87 - 94}
Side cover mounting bolt 54 - 64 {5.5 - 6.5, 40 - 47}
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.
Plug 9 - 13 {0.9 - 1.3, 6.5 - 9}
Gear box mounting bolt 186 {19, 137}
Pitman arm mounting nut 441 - 490 {45 - 50, 325 - 362}

HYDRAULIC PUMP
Made by NIPPON POWER STEERING Co., Ltd.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Relief valve plug 69 - 98 {7.0 - 10.0, 51 - 72}

Made by JIDOSHA KIKI Co., Ltd.

Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Pump body mounting bolt 69 - 88 {7.0 - 9.0, 51 - 65}
Pressure plate mounting screw 6 - 9 {0.6 - 0.9, 4.3 - 6.5}
Relief valve plug 49 - 59 {5.0 - 6.0, 36 - 43}
Relief valve 10 - 14 {1.0 - 1.4, 7 - 10}

ST-1-5
 TOOLS GEAR BOX AND HYD PUMP

TOOLS
STEERING GEAR BOX
Made by NIPPON POWER STEERING Co., Ltd.
Tool name and number Description Shape

Pitman arm puller

Used when removing pitman arm
99850 Z0001

Tightening tool
Used to tighten front cover
PSJIG-00183-2

Torque cap
Used to measure torque
PSJIG-00184-5

Lock nut tool

Used to tighten lock nut
PSJIG-00174

Used to remove and install pin

Block
which connects worm shaft and tor-
PSJIG-00184-1
sion bar

Pin remover
Used to drive out pin
PSJIG-00184-2

ST-2-1
 TOOLS GEAR BOX AND HYD PUMP

Insert tool Used to press-fit oil seal into gear

PSJIG-00184-3 case

Insert tool
Used to press-fit oil seal into plug
PSJIG-00184-4

*Hydraulic circuit
Used to test performance of
measuring tool
hydraulic lines
915-00082

* The hydraulic circuit measuring tool (915-00082) is of JKC make.

Made by JIDOSHA KIKI Co., Ltd.
Tool name and number Description Shape

Pitman arm puller

99850 Z0001 Used when removing pitman arm

Tool assembly
Used to install the thrust bearing
910-10611

ST-2-2
 TOOLS GEAR BOX AND HYD PUMP

Guide tool Used together with bearing installa-

910-23033 tion guide 910-10611

Attachment assembly
Used to secure the valve housing
910-10671

Wrench assembly Used to remove/install the adjusting

910-10743 plug

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

ST-2-3
 TOOLS GEAR BOX AND HYD PUMP

Needle Used to remove the O-ring, seal,

910-21200 ring, etc.

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

Hydraulic circuit measuring

Used to test performance of
tool
hydraulic lines
915-00082

ST-2-4
 TOOLS GEAR BOX AND HYD PUMP

HYDRAULIC PUMP
Made by JIDOSHA KIKI Co., Ltd.
Tool name and number Description Shape
Stick Used to drain oil from oil pan.
910-21630

Pliers Used to remove/install retaining

910-21632 ring.

Pliers Used to remove/install retaining

910-22570 ring.

Press fit tool Used to install oil seal.

910-22959

Press fit tool Used to remove/install needle

910-22956 bearing.

Press fit tool Used to install ball bearing.

910-22955

ST-2-5
 CONSTRUCTION PSI-Y100

= STEERING GEAR BOX (UNIT NAME PSI-Y100) =

CONSTRUCTION

ST-3-1
 DISASSEMBLY PSI-Y100

DISASSEMBLY
REMOVAL
Key point of removal
z Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.

<Model CK, CD and CW series>

1. Remove the nut and lock washer from the pitman arm.
2. 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.

3. Remove the dust cover.

4. Disconnect the inlet and outlet pipe connectors and turn the
steering wheel completely to the left and right to discharge
fluid from the steering gear box.
NOTE
z Before disconnecting the pipe connectors, wipe clean to
prevent foreign particles from getting into the ports.
z After draining steering fluid, plug the opening to prevent
the entry of foreign particles at the pipe connections.

ST-3-2
 DISASSEMBLY PSI-Y100

5. Separate the steering column and steering gear box.

6. Dismount the steering gear box from the vehicle.

<Model CG series>
1. Disconnect the inlet and outlet pipe connectors and turn the
steering wheel completely to the left and right to discharge
fluid from the steering gear box.
NOTE
z Before disconnecting the pipe connectors, wipe clean to
prevent foreign particles from getting into the ports.
z After draining steering fluid, plug the opening to prevent
the entry of foreign particles at the pipe connections.
2. Separate the steering column and steering gear box.
3. Remove the steering gear box together with the pitman arm
from the vehicle.
4. Prepare a jig, install the steering gear box onto it, and
remove the nuts and lock washers.

5. Remove the pitman arm, using a pitman arm puller (99850

Z0001).
NOTE
z Before removing the pitman arm, place a punch mark on
the serration groove at the end of the pitman arm and
sector shaft.

6. Remove the dust cover.

ST-3-3
DISASSEMBLY PSI-Y100

ST-3-4
 DISASSEMBLY PSI-Y100

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Side cover and sector shaft , 13.Oil seal 27.O-ring
assembly 14.Thrust bearing 28.Spool
2.Side cover ,+ 15.Plug 29.Seal ring
3.O-ring 16.Thrust race 30.O-ring
,+ 4.Sector shaft 17.Thrust bearing 31.O-ring
5.Needle bearing 18.Seal ring 32.O-ring
6.U-packing 19.O-ring 33.Seal ring
,+ 7.Lock nut 20.Thrust bearing 34.O-ring
,+ 8.Valve housing and ball screw 21.Worm shaft 35.Piston cap
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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-3-5
 DISASSEMBLY PSI-Y100

Key point of disassembly

CAUTION
z The integral power steering system is designated as a
“security” part and is precisely adjusted and tested
before installation.
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 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.

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.
NOTE
z The needle bearing need not be removed unless neces-
sary.

4 Sector shaft
Using a chisel, unlock the clinched portion of the adjuster of the
sector shaft assembly. Remove the adjuster by turning it counter-
clockwise.

ST-3-6
 DISASSEMBLY PSI-Y100

7 Lock nut
Using the Wrench (PSJIG-00174), remove the lock nut.

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 Tightening 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).

ST-3-7
 DISASSEMBLY PSI-Y100

37 U-packing
Remove the U-packing and oil seal from the case assembly.
NOTE
z Do not remove the needle bearing unless it is damaged.

ST-3-8
 INSPECTION PSI-Y100

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Clearance between gear case and ball screw assembly

Unit: mm (in)
Maintenance standard Service limit
0.03 - 0.095 (0.0012 - 0.0037) 0.15 (0.0059)

Axial play of ball screw

Unit: mm (in)
Maintenance standard Service limit
Less than 0.02 (0.0008) 0.04 (0.0016)

Backlash between ball screw assembly and sector

gear
Unit: mm (in)
Maintenance
Service limit Remarks
standard
0.06 - 0.30 Measure at end of pitman arm 300
—
(0.0024 - 0.0118) mm (11.81 in) with gears in Neutral.

Clearance between sleeve and spool

Unit: mm (in)
Maintenance standard Service limit
— 0.02 (0.0008)

Clearance between groove in sleeve and straight pin

Unit: mm (in)
Maintenance standard Service limit
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)
Item Maintenance standard Service limit
Adjusting screw side 50.00 (1.9685) 49.95 (1.9665)
Pitman arm side 57.12 (2.2488) 57.07 (2.2468)

ST-3-9
 INSPECTION PSI-Y100

Axial play of adjusting screw

Unit: mm (in)
Maintenance standard Service limit
— Less than 0.10 (0.0039)

ST-3-10
 REASSEMBLY PSI-Y100

REASSEMBLY
REASSEMBLY
Key point of reassembly
39 Oil seal
Using the Tool (PSJIG-00184-3) and a press, press the oil seal into
the gear case.
NOTE
z Be careful not to scratch the inner perimeter of the U-
packing.

38 Tapered plug
When installing the taper plug, wind seal tape around the thread.

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 Outside diameter of
pin new straight pin

4.5 (0.177) dia. 0 0

4.6 – 0.005 (0.181– 0.0002 ) dia.

0
4.6 (0.181) dia. 4.7 0 (0.185– 0.0002 ) dia.
– 0.005

0
4.7 (0.185) dia. 4.8 0 (0.189– 0.0002 ) dia.
– 0.005

ST-3-11
 REASSEMBLY PSI-Y100

If the outside diameter of the old straight pin exceeds [4.8 mm

(0.189 in)], replace the ball screw and stub shaft assemblies.
3. Using a reamer, ream the straight pin hole and remove
burrs.
Unit: mm (in)
Outside diameter of the new Diameter of straight pin hole
straight pin (after reaming)
0 0 – 0.013 – 0.0005
4.6 – 0.005 (0.181– 0.0002 ) dia. 4.6 – 0.028 (0.181– 0.0011 ) dia.

0 0 – 0.013 – 0.0005
4.7 – 0.005 (0.185– 0.0002 ) dia. 4.7 – 0.028 (0.185– 0.0011 ) dia.

0 0 – 0.013 – 0.0005
4.8 – 0.005 (0.189– 0.0002 ) dia. 4.8 – 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.
Stub shaft rotating torque
: 20 - 49 N·m {2 - 5 kgf·m, 14 - 36 ft·lbf}

13 Oil seal
Using the Tool (PSJIG-00184-4) and a press, press the oil seal into
the plug.

11 Ball screw assembly

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.

ST-3-12
 REASSEMBLY PSI-Y100

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}

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.

ST-3-13
 REASSEMBLY PSI-Y100

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}

4 Sector shaft
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.

1 Side cover and sector shaft assembly

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.

ST-3-14
 REASSEMBLY PSI-Y100

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
z 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
Key point of installation
<Model CK, CD and CW series>
1. After making sure the vehicle wheels are in the straightedge
direction, install the steering gear box.
: 186 N·m {19 kgf·m, 137 ft·lbf}

2. Connect the inlet and outlet connectors to the gear box.

NOTE
z Be careful to connect piping correctly. If incorrect, the
steering wheel will abruptly rotate when the oil pump
starts.

3. Fill the dust cover with grease and install it onto the sector
shaft.
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.

ST-3-15
 REASSEMBLY PSI-Y100

4. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.

: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

z After completing installation, carry out performance check.

Refer to page ST-4-20 for check procedures.

<Model CG series>
1. Install the steering gear box onto a jig.
2. Fill the dust cover with grease and install it onto the sector
shaft.
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.

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.

: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

4. Install the steering gear box assembly (with pitman arm) in

the vehicle.
: 186 N·m {19 kgf·m, 137 ft·lbf}

ST-3-16
 REASSEMBLY PSI-Y100

5. Connect the inlet and outlet connectors to the gear box.

NOTE
z Be careful to connect piping correctly. If incorrect, the
steering wheel will abruptly rotate when the oil pump
starts.

z After completing installation, carry out performance check.

Refer to page ST-4-20 for check procedures.

ST-3-17
 CONSTRUCTION 446

= STEERING GEAR BOX (UNIT NAME 446) =

CONSTRUCTION

ST-4-1
 DISASSEMBLY 446

DISASSEMBLY
REMOVAL
Key point of removal
z Before removing the steering gear box assembly from the
vehicle, turn the starter switch to “OFF” and chock the
wheels.

<Model CK, CD and CW series>

1. Remove the nut and lock washer from the pitman arm.
2. 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.

3. Remove the dust cover.

4. Disconnect the inlet and outlet pipe connectors and turn the
steering wheel completely to the left and right to discharge
fluid from the steering gear box.
NOTE
z Before disconnecting the pipe connectors, wipe clean to
prevent foreign particles from getting into the ports.
z After draining steering fluid, plug the opening to prevent
the entry of foreign particles at the pipe connections.

ST-4-2
 DISASSEMBLY 446

5. Separate the steering column and steering gear box.

6. Dismount the steering gear box from the vehicle.

<Model CG series>
1. Disconnect the inlet and outlet pipe connectors and turn the
steering wheel completely to the left and right to discharge
fluid from the steering gear box.
NOTE
z Before disconnecting the pipe connectors, wipe clean to
prevent foreign particles from getting into the ports.
z After draining steering fluid, plug the opening to prevent
the entry of foreign particles at the pipe connections.
2. Separate the steering column and steering gear box.
3. Remove the steering gear box together with the pitman arm
from the vehicle.
4. Prepare a jig, install the steering gear box onto it, and
remove the nuts and lock washers.

5. Remove the pitman arm, using a pitman arm puller (99850

Z0001).
NOTE
z Before removing the pitman arm, place a punch mark on
the serration groove at the end of the pitman arm and
sector shaft.

6. Remove the dust cover.

ST-4-3
DISASSEMBLY 446

ST-4-4
 DISASSEMBLY 446

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Side cover and sector shaft 13.O-ring ,+ 27.O-ring
,+
assembly 14.O-ring 28.Ball tube clip
2.O-ring 15.Adjusting plug , 29.Ball tube
3.Back-up ring , 16.Y-packing 30.Needle bearing
4.Y-packing 17.Ball bearing ,+ 31.Back-up ring
5.Needle bearing 18.O-ring ,+ 32.Y-packing
,+ 6.Side cover ,+ 19.Thrust bearing ,+ 33.Oil seal
7.Retainer + 20.Seal ring 34.Gear case
8.Adjusting screw 21.Stub shaft
,+ 9.Sector shaft , 22.Worm shaft assembly
10.Dust cover ,+ 23.Seal ring
,+ 11.Ball screw and valve housing ,+ 24.O-ring
assembly 25.Piston
12.Valve housing ,+ 26.Seal ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-4-5
 DISASSEMBLY 446

Key point of disassembly

CAUTION
z The integral power steering system is designated as a
“security” part and is precisely adjusted and tested
before installation.
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 until gears are set in neutral, and place
the steering gear box in a vise.

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. 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.

ST-4-6
 DISASSEMBLY 446

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.

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
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.

ST-4-7
 DISASSEMBLY 446

19 Thrust bearing
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

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
Remove the screw from the clip portion of the ball tube and remove
the ball tube.
NOTE
z Be careful to prevent damage. Do not insert a screw-
driver or sharp pointed object between the ball tube and
piston.
z 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.

ST-4-8
 DISASSEMBLY 446

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.
NOTE
z Do not remove the needle bearing and tapered plug
unless they are damaged.

ST-4-9
 INSPECTION 446

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Clearance between gear case and ball screw assembly

Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)

Axial play of ball screw

Unit: mm (in)
Maintenance standard Service limit
— 0.04 (0.0016)

Backlash between ball screw assembly and sector

gear
Unit: mm (in)
Maintenance
Service limit Remarks
standard
0.2 - 0.4 Measure at end of pitman arm 300
—
(0.008 - 0.016) mm (11.81 in) with gears in Neutral.

End play of piston and worm shaft

Unit: mm (in)
Maintenance standard Service limit
Less than 0.5 (0.02) —

Wear of sector shaft O.D.

Measure the outside diameter of the sector shaft. Adjusting screw
side and pitman arm side.
Unit: mm (in)
Item Maintenance standard Service limit
Adjusting screw side 47.975 (1.8888) 47.93 (1.8870)
Pitman arm side 57.975 (2.2825) 57.93 (2.2807)

ST-4-10
 INSPECTION 446

Axial play of adjusting screw

Unit: mm (in)
Maintenance standard Service limit
0.01 - 0.10 (0.0004 - 0.0039) —

ST-4-11
 REASSEMBLY 446

REASSEMBLY
REASSEMBLY
Key point of reassembly
33 Oil seal
Using the Insert Tool Assembly (910-11001), press the oil seal into
the steering body. Be sure to apply grease to the oil seal before
installation.

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-4-12
 REASSEMBLY 446

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-4-13
 REASSEMBLY 446

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
housing 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.

6. Position the O-rings in the outer groove (which mates with

the steering body) and the graded portion at the oil pas-
sage.
NOTE
z Be careful not to deform the O-ring.

16 Y-packing
1. Using the Press-Fit Tool (910-20404), install the Y-packing
in the recess on the inner perimeter of the adjusting plug.
NOTE
z When installing the Y-packing, use a hand press.

ST-4-14
 REASSEMBLY 446

2. Apply grease to the Y-packing and install the ball bearing.

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.

ST-4-15
 REASSEMBLY 446

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}

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 180º.
Retighten to 39 N·m {4 kgf·m, 29 ft·lbf} and then back off 20º.
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

Assembly (910-11001) when reforming the back-up ring to
its original shape.

ST-4-16
 REASSEMBLY 446

1 Side cover and sector shaft assembly

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.

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.

: 54 - 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 180~ 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.

ST-4-17
 REASSEMBLY 446

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.

INSTALLATION
Key point of installation
<Model CK, CD and CW series>
1. Install the steering gear box assembly in the vehicle.
: 186 N·m {19 kgf·m, 137 ft·lbf}

2. Connect the inlet and outlet connectors to the gear box.

NOTE
z Be careful to connect piping correctly. If incorrect, the
steering wheel will abruptly rotate when the oil pump
starts.

3. Fill the dust cover with grease and install it onto the sector
shaft.
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.

4. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.

: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

z After completing installation, carry out performance check.

Refer to page ST-4-20 for check procedures.

ST-4-18
 REASSEMBLY 446

<Model CG series>
1. Install the steering gear box onto a jig.
2. Fill the dust cover with grease and install it onto the sector
shaft.
NOTE
z Install the dust cover so that the side with a larger diame-
ter faces the steering gear box.

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.

: 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

4. Install the steering gear box assembly (with pitman arm) in

the vehicle.
: 186 N·m {19 kgf·m, 137 ft·lbf}

5. Connect the inlet and outlet connectors to the gear box.

NOTE
z Be careful to connect piping correctly. If incorrect, the
steering wheel will abruptly rotate when the oil pump
starts.

z After completing installation, carry out performance check.

Refer to page ST-4-20 for check procedures.

ST-4-19
 PERFORMANCE CHECKS 446

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 pres-
sure 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
1. Connect the oil pressure gauge, valve and copper tube in
advance. (No. 1. through 9. parts)
2. Disconnect the inlet pipe 13. from the steering gear
box.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 connector12. 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-4-20
 PERFORMANCE CHECKS 446

No Part No. Description Remarks

1/4″–19 [19,614 kPa {200
1 1360-0007 Oil pressure gauge
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
6 1220-1024 Copper tube
7 915-20001 Valve
8 1202-0159 Connector M12 x 1.5, PT 1/2
9 1220-1024 Copper tube
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-4-21
 PERFORMANCE CHECKS 446

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 60°C (122 to 140°F)].

Checking the pressure

The normal pressure is below 490 kPa {5kgf/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 PV132>
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 PV123 and 475>
1. 12,994 - 13,730 kPa {132.5 - 140 kgf/cm2, 1,884 - 1,991
psi} ... Normal.
2. 13,730 kPa {140 kgf/cm2, 1,991 psi}, min. ... Malfunctioning
relief valve
3. 12,994 kPa {132.5 kgf/cm2, 1,884 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}.

ST-4-22
 PERFORMANCE CHECKS 446

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.

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
<Hydraulic pump PV132>
1. 12,014 - 12,749 kPa {122.5 - 130 kgf/cm2, 1,742 - 1,849
psi}... Normal
2. 12,014 kPa {122.5 kgf/cm2, 1,742 psi}, max. ... Faulty
power steering system
Repair or replace faulty parts.
<Hydraulic pump PV123 and 475>
1. 12,994 - 13,730 kPa {132.5 - 140 kgf/cm2, 1,884 - 1,991
psi} ... Normal
2. 12,994 kPa {132.5 kgf/cm2, 1,884 psi}, max. ... Faulty
power steering system
Repair or replace faulty parts.

ST-4-23
 PERFORMANCE CHECKS 446

CHECKING METHOD 2

(W/FRONT WHEELS ON GROUND)

Procedure
1. Lower the front wheels.
2. Fully open the cock.
3. Operate the engine at 1,000 to 1,500 rpm. Turn the steering
wheel to the extreme limits of travel until the oil pressure
gauge registers 4,904 kPa {50 kgf/cm2, 711 psi.} Then,
release the steering wheel and record the pressure drop.
Repeat this operation at least five times.
4. Change set pressure to 3,923, 2,942, 1,961, 981 kPa {40,
30, 20, 10 kgf/cm2, 569, 427, 284, 142 psi}, respectively,
and repeat tests as outlined in step 3. above.
Judgement
1. Returns to 490 kPa {5 kgf/cm2, 71 psi} (piping resistance)
quickly … Normal
2. Same pressure as when steering wheel is turned to its
travel limits … Faulty power steering system (if steering col-
umn and under-carriage system are in good condition)
3. Returns to pressure higher than 490 kPa{5 kgf/cm2, 71 psi}
(piping resistance) … Same as 2. above.
Repair or replace faulty parts.
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
<Hydraulic pump PV132>
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.
<Hydraulic pump PV123 and 475>
1. 12,994 - 13,730 kPa {132.5 - 140 kgf/cm2, 1,884 - 1,991
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-4-24
 CONSTRUCTION PV123, PV132

= HYDRAULIC PUMP (UNIT NAMES

PV123 AND PV132) =
CONSTRUCTION

ST-5-1
 DISASSEMBLY PV123, PV132

DISASSEMBLY
REMOVAL
Key point of removal
Be sure to work on a flat floor and chock the front and rear wheels.
z 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).

1. Disconnect the inlet and outlet tube connections.

2. Remove the hydraulic pump assembly.

ST-5-2
 DISASSEMBLY PV123, PV132

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Key 9. O-ring 17. Retaining ring
2. Plug , 10. Spring , 18. Shaft
3. O-ring , 11. Side plate B 19. Retaining ring
4. Valve spring ,+ 12. Vane , 20. Ball bearing
+ 5. Relief valve assembly ,+ 13. Rotor , 21. Oil seal
6. Rod ,+ 14. Cam ring 22. Bushing
, 7. Retaining ring , 15. Side plate A 23. Body
,+ 8. Cover , 16. Dowel pin
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-5-3
 DISASSEMBLY PV123, PV132

Key point of disassembly

5 Relief valve assembly
Remove the plug, then remove the relief valve assembly and
spring.
NOTE
z If the discharge pressure is not within the maintenance
standard, replace the relief valve assembly.

8 Cover
Clamp the hydraulic pump assembly in a vise. Remove the cover
using a screw driver while pressing the retaining ring by inserting a
pin into the small hole on the body.
NOTE
z Be careful not to damage the body I.D. section.

12 - 14. Cartridge assembly

Remove the cover and separate the spring, O-ring, side plate A,
side plate B, dowel pin and cartridge assembly.
NOTE
z Make matching marks on the outer peripheries of the
cam rings of side plates A and B so that they can be cor-
rectly reassembled.

ST-5-4
 INSPECTION PV123, PV132

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Decrease in shaft oil seal lip outside diameter

Unit: mm (in)
Maintenance standard Service limit
— 0.05 (0.0020)

Clearance between the relief valve outside diameter

and body inside diameter
Unit: mm (in)
Maintenance standard Service limit
0.013 - 0.020 (0.0005 - 0.0008) 0.03 (0.0012)

Side plate indentation

Unit: mm (in)
Maintenance standard Service limit
— 0.03 (0.0012)

ST-5-5
 REASSEMBLY PV123, PV132

REASSEMBLY
REASSEMBLY
Key point of reassembly
NOTE
z This section is not just a key points explanation, but
rather a full explanation.

21 Oil seal
Using a presser, press the oil seal into the body.

20 Ball bearing
Press the ball bearing into the shaft from the driving side of the
shaft using a presser, then install the retaining ring.

18 Shaft
Install the shaft assembly (with the ball bearing) into the body,
then install the snap ring.
NOTE
z If the shaft cannot be pressed in up to the specified posi-
tion by hand, gently press it in using a press tool.
z When installing the shaft, be careful not to scratch or
damage the sealing lip of the oil seal with the spline of
the shaft.

16 Dowel pin and 15 Side plate A

Fit the dowel pins to the body, then install the side plate A.
NOTE
z Be sure to apply a few drops of power steering oil to the
sliding surface of the side plate prior to installation.
z Be sure to install the side plate with the dowel pin oblong
hole facing toward the relief valve side.

ST-5-6
 REASSEMBLY PV123, PV132

14 Cam ring
Install the cam ring aligning it with the dowel pins.
NOTE
z Be sure to install the cam ring aligning it with the side
plate hole.

13 Rotor and 12 Vane

Install the rotor aligning it with the spline of the shaft, then fit the
vane into the rotor groove.
NOTE
z Be sure to install the rotor with the chamfered spline side
facing the side plate A.
z Be sure to install the vane with the rounded end face side
facing outward.

11 Side plate B and 10 Spring

Install the side plate B and spring.
NOTE
z Be sure to apply a few drops of power steering oil to the
sliding surface of the side plate prior to installation.
z Turn the shaft by hand and check to make sure that it
rotates smoothly.

8 Cover
Install the cover positioning it carefully so that the two lugs which
function as stoppers do not block the side plate port.

7 Retaining ring
Using a press, secure the cover and fix it with the retaining ring.
NOTE
z Be sure to install so that the disassembly hole with a
diameter of 3 mm (0.12 in) is located near the opening of
the retaining ring.

ST-5-7
 REASSEMBLY PV123, PV132

INSTALLATION
Key point of installation
1. Install the hydraulic pump assembly with the O-ring in
place.
2. Connect the inlet and outlet tubes.
3. Add the power steering oil and purge the excess air.
a. Jack up the front axle and chock the rear wheels.
b. Fill the reservoir with oil to the specified level.
c. Idle the engine and turn the steering wheel fully to the right
and left several times. Then check the level and add more
oil as needed.
d. Repeat the operation in step 3 until the oil level stabilizes at
the specified level.
e. Turn the steering wheel and check to make sure that both
right and left wheels move smoothly.
f. Lower the jack on the front axle, and check to make sure that
there is no oil leakage from the line or the connector.
g. Check to make sure that the specified amount of oil is con-
tained in the reservoir.

INSPECTING RELIEF VALVE PRESSURE

1. Cut the joint in two at an appropriate point between the oil
pump and the power steering, and install a stop valve there.
Also install a pressure gauge 19,614 kPa {200 kgf/cm2,
2,844 psi} between the oil pump and the stop valve. Then
remove the air in the piping after ensuring that there is no oil
leakage from the connecting portion and that the stop valve
is fully open.
NOTE
z Prior to inspection, idle the engine until the temperature
of the oil reaches 50 to 60°C (122 to 140°F).

2. While maintaining the engine speed at 1,000-1,500 rpm,

gradually close the stop valve, keeping an eye on the pres-
sure gauge dial at the same time. The dial reading will indi-
cate the relief valve adjustment pressure when the stop
valve has been completely shut.

ST-5-8
 REASSEMBLY PV123, PV132

Unit: kPa {kgf/cm2, psi}

Model PV123-35-13 PV132-25-46
PV123-35-15 PV132-25-49
PV132-25-52
Relief valve 12,994 - 13,730 12,014 - 12,749
adjusting pressure {132.5 - 140, {122.5 - 130,
1,884 - 1,991} 1,742 - 1,849}

If the oil pressure exceeds the adjustment pressure plus 981 kPa
{10 kgf/cm2, 142 psi}, the relief valve is not working correctly. If, on
the other hand, the oil pressure fails to increase, either the oil pump
is malfunctioning, or there is a permanent leak in the relief valve.
CAUTION
z During inspection, do not close the stop valve for more
than fifteen seconds.
z If the relief valve regulated pressure cannot be adjusted,
replace as a relief valve assembly.

ST-5-9
 CONSTRUCTION 475

= HYDRAULIC PUMP (UNIT NAMES 475) =

CONSTRUCTION

ST-6-1
 DISASSEMBLY 475

DISASSEMBLY
REMOVAL
Key point of removal
Be sure to work on a flat floor and chock the front and rear wheels.
z 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).

1. Disconnect the inlet and outlet tube connections.

2. Remove the hydraulic pump assembly.

ST-6-2
 DISASSEMBLY 475

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Key 11. Bolt , 21. Straight pin
2. Plug , 12. Rear body 22. Retaining ring
3. O-ring , 13. O-ring , 23. Retaining ring
4. Spring 14. O-ring , 24. Ball bearing
5. Flow control valve 15. Screw , 25. Retaining ring
+ 6. Relief valve , 16. Pressure plate 26. Retaining ring
7. Shim ,+ 17. Vane ,+ 27. Oil seal
8. Ball ,+ 18. Rotor ,+ 28. Needle bearing
9. Ball retainer ,+ 19. Cam ring 29. Shaft
10. Spring , 20. Side plate 30. Front body
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-6-3
 DISASSEMBLY 475

Key point of disassembly

6 Relief valve assembly
Remove the plug, then remove the relief valve assembly and
spring.

17 - 19 Cartridge assembly
Remove the screw and separate the pressure plate, cartridge
assembly, side plate and straight pin.

27 Oil seal
Using a stick (910-21630), remove the oil seal from the body.

28 Needle bearing
Using a press fit (910-22956), pull out the needle bearing from the
front body.

ST-6-4
 INSPECTION 475

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Clearance between the relief valve outside diameter

and body inside diameter
Unit: mm (in)
Maintenance standard Service limit
— 0.03 (0.0012)

Ball bearing play

Unit: mm (in)
Maintenance standard Service limit
— 0.04 (0.0016)

ST-6-5
 REASSEMBLY 475

REASSEMBLY
REASSEMBLY
Key point of reassembly
NOTE
z This section is not just a key points explanation, but
rather a full explanation.

28 Needle bearing
Using a press fit (910-22956), press the needle bearing into the
front body with a press.

27 Oil seal
Using a press fit (910-22959), press the oil seal into the front body
with a press.
NOTE
z Press the oil seal until it is flush with the body end face.

25 Retaining ring and 24 Ball bearing

Fit the ball bearing onto the shaft using a press fit (910-22955) and
a presser, then fix it with the retaining ring.
NOTE
z Always press the ball bearing from the drive side.

23 Retaining ring
Install the shaft assembly, then secure with retaining ring using pli-
ers (910-22570).
NOTE
z If the shaft is hard to insert up to the specified position
by hand, lightly tap with a wooden mallet.
z Do not allow shaft splines to scratch the oil seal lip dur-
ing shaft installation.

ST-6-6
 REASSEMBLY 475

21 Straight pin and 20 Side plate

Insert the straight pins into the front body, then install the side plate,
aligning it with the straight pins.
NOTE
z Be sure to install the side plate with its groove facing
upward (i.e. the driving side).

19 Cam ring
Install the cam aligning it with the straight pins.
NOTE
z Be sure to install the cam correctly aligning it with the
side plate hole.

18 Rotor and 17 Vane

Install the rotor aligning it with the spline of the shaft, then fit the
vane into the rotor groove.
NOTE
z Be sure to install the vane with the rounded end face side
facing outward.

16 Pressure plate
Install the pressure plate aligning it with the straight pins, then fas-
ten it with the screw.
: 6 - 9 N·m {0.6 - 0.9 kgf·m, 4.3 - 6.5 ft·lbf}

13 O-ring and 12 Rear body

Fit the O-ring into the front body and install the rear body.
NOTE
z Tighten the bolts diagonally.

: 69 - 88 N·m {7.0 - 9.0 kgf·m, 51 - 65 ft·lbf}

ST-6-7
 REASSEMBLY 475

INSTALLATION
Key point of installation
1. Install the hydraulic pump assembly with the O-ring in
place.
2. Connect the inlet and outlet tubes.
3. Add the power steering oil and purge the excess air.
a. Jack up the front axle and chock the rear wheels.
b. Fill the reservoir with oil to the specified level.
c. Idle the engine and turn the steering wheel fully to the right
and left several times. Then check the level and add more
oil as needed.
d. Repeat the operation in step 3 until the oil level stabilizes at
the specified level.
e. Turn the steering wheel and check to make sure that both
right and left wheels move smoothly.
f. Lower the jack on the front axle, and check to make sure that
there is no oil leakage from the line or the connector.
g. Check to make sure that the specified amount of oil is con-
tained in the reservoir.

INSPECTING RELIEF VALVE PRESSURE

1. Cut the joint in two at an appropriate point between the oil
pump and the power steering, and install a stop valve there.
Also install a pressure gauge 19,614 kPa {200 kgf/cm2,
2,844 psi} between the oil pump and the stop valve. Then
remove the air in the piping after ensuring that there is no oil
leakage from the connecting portion and that the stop valve
is fully open.
NOTE
z Prior to inspection, idle the engine until the temperature
of the oil reaches 50 to 60°C (122 to 140°F).

2. While maintaining the engine speed at 1,000-1,500 rpm,

gradually close the stop valve, keeping an eye on the pres-
sure gauge dial at the same time. The dial reading will indi-
cate the relief valve adjustment pressure when the stop
valve has been completely shut.
Relief valve regulated pressure
12,994 - 13,730 kPa {132.5 - 140 kgf/cm2, 1,884 - 1,991 psi}

If the oil pressure exceeds the adjustment pressure plus 981 kPa
{10 kgf/cm2, 142 psi}, the relief valve is not working correctly. If, on
the other hand, the oil pressure fails to increase, either the oil pump
is malfunctioning, or there is a permanent leak in the relief valve.
CAUTION
z During inspection, do not close the stop valve for more
than fifteen seconds.
z If the relief valve regulated pressure cannot be adjusted,
replace as a relief valve assembly.

ST-6-8
 REASSEMBLY 475

Relief set pressure Thickness of shim Change in pressure

Model
kPa {kgf/cm2, psi} mm (in) kPa {kgf/cm2, psi}
0.2 (0.008) Approx. 520 {5.3, 75}
475-03260
0.5 (0.020) Approx. 1,304 {13.3, 189}
13,240 {135, 1,920}
0.2 (0.008) Approx. 245 {2.5, 36}
475-03282
0.5 (0.020) Approx. 608 {6.2, 88}

ST-6-9
 BLEEDING AIR FROM THE POWER STEERING
SYSTEM
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-7-1
 STEERING LINKAGE

CONTENTS
SERVICE DATA..................................ST-1- 1 STEERING LINKAGE.........................ST-4- 1
SERVICE DATA..............................ST-1- 1 DISASSEMBLY.............................. ST-4- 1
TIGHTENING TORQUE .................ST-1- 1 INSPECTION................................. ST-4- 4
SYSTEM DIAGRAM .......................ST-1- 2 REPAIR AND REPLACEMENT ..... ST-4- 6
TOOLS................................................ST-2- 1 REASSEMBLY............................... ST-4- 8
STEERING COLUMN.........................ST-3- 1 POWER CYLINDER ...........................ST-5- 1
CONSTRUCTION...........................ST-3- 1 CONSTRUCTION.......................... ST-5- 1
DISASSEMBLY ..............................ST-3- 2 DISASSEMBLY.............................. ST-5- 2
INSPECTION..................................ST-3- 5 REASSEMBLY............................... ST-5- 3
REASSEMBLY ...............................ST-3- 6
 SERVICE DATA ST LINKAGE

SERVICE DATA
SERVICE DATA
STEERING COLUMN
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Axial play at journal locations Less than 0.2 (0.008) —
Free play at ball bearing locations Less than 0.05 (0.0020) —
Free play at steering wheel 30 - 50 (1.18 - 1.97) —

STEERING LINKAGE
Drag link
Unit: N {kgf, lbf}
Item Maintenance standard Service limit Remarks
Amount of grease g (oz) 12 - 22 (0.42 - 0.78) —
Dust cover pressing load 3,923 {400, 882} —
Free length of drag link buffer
83.0 (3.268) —
spring mm (in) CG series
When compressed only
Tension of drag link buffer spring 2,550 {260, 573} —
to 75 mm (2.95 in)

TIGHTENING TORQUE
STEERING COLUMN
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Steering wheel mounting nut 88 {9, 65}
Steering column mounting bolt and nut 20 {2, 14}
Tilt handle mounting bolt 10 {1, 7}
Steering column yoke mounting bolt 51 - 61 {5.2 - 6.2, 38 - 45}

STEERING LINKAGE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Pitman arm mounting nut 441 - 490 {45 - 50, 325 - 362}
CK, CD, CW series 245 - 304 {25 - 31, 181 - 224}
Drag link mounting nut
CG series 216 - 343 {22 - 35, 159 - 253}
Power cylinder mounting nut 216 - 343 {22 - 35, 159 - 253}
Idler arm mounting nut CG series 177 - 206 {18 - 21, 130 - 152}
Clevis pin mounting bolt 13 - 16 {1.3 - 1.6, 9.4 - 11.6}
Flange lock screw 2.9 - 3.9 {0.3 - 0.4, 2.2 - 2.9}
Power cylinder Piston rod assembly lock nut 88 - 108 {9 - 11, 65 - 80}
Ball socket assembly mounting bolt and nut 93 - 113 {9.5 - 11.5, 69 - 83}

ST-1-1
 SERVICE DATA ST LINKAGE

SYSTEM DIAGRAM
Model CK, CD and CW series

Model CG series

ST-1-2
 SERVICE DATA ST LINKAGE

POWER STEERING TUBING

ST-1-3
 TOOLS ST LINKAGE

TOOLS
Part name and number Description Shape
Used when removing steering wheel.

Steering wheel puller

99851 Z0002

Used when removing pitman arm.

Pitman arm puller

99850 Z0002

Used when driving dust cover into ball stud.

Dust cover inserter

99853 Z0001

ST-2-1
 STEERING COLUMN ST LINKAGE

STEERING COLUMN
CONSTRUCTION

ST-3-1
 STEERING COLUMN ST LINKAGE

DISASSEMBLY
REMOVAL

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

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
Marks“+” and “,” indicate that the key points of operation are explained in the text.

ST-3-2
 STEERING COLUMN ST LINKAGE

Key point of removal

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
 STEERING COLUMN ST LINKAGE

1. Punch the center of the self-shear type screw breaking sur-

face.
2. 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.
3. Drive the screw out by turning the Screw Extractor (special
service tool) counterclockwise. Remove the key switch
assembly.

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Sleeve yoke 4.Column assembly 7.O-ring
2.Spline yoke shaft assembly 5.Column shaft assembly 8.Retaining ring
3.Retaining ring 6.Retaining ring 9.Column shaft

ST-3-4
 STEERING COLUMN ST LINKAGE

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Axial play at journal locations

Unit: mm (in)
Maintenance standard Service limit
Less than 0.2 (0.008) —

Free play at ball bearing locations

Unit: mm (in)
Maintenance standard Service limit
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)
Maintenance standard Service limit
30 - 50 (1.18 - 1.97) —

ST-3-5
 STEERING COLUMN ST LINKAGE

REASSEMBLY
INSTALLATION
Key point of installation
12 Key switch assembly
Install the key switch assembly onto the steering column with the
lock pin protruding beyond the switch.
1. Temporarily tighten the key switch assembly using a new
self-shear type screw.
2. Ensure that the key switch locks properly.
3. 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 CK, CD and CW series

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Drag link ,+ 2.Pitman arm 3.Dust cover
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-4-1
 STEERING LINKAGE ST LINKAGE

Model CG series

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Clevis pin 15.Washer 29.Ball stud
2.Clevis pin 16.Bushing 30.Ball seat
, 3.Pitman link 17.Thrust washer 31.Buffer spring
4.Front drag link 18.Retaining ring 32.Stopper
5.Rear drag link 19.Bearing 33.Dust seal
6.Clevis pin 20.Thrust washer , 34.Grease nipple
7.Power cylinder assembly 21.Bushing , 35.End plug
,+ 8.Pitman arm 22.Booster end 36.Buffer spring
9.Cotter pin 23.Bracket 37.Ball seat
10.Shaft 24.Bracket 38.Ball stud
11.Sleeve 25.Dust cover 39.Ball seat
12.Idler arm 26.Dust cover 40.Dust seal
13.Thrust washer , 27.End plug , 41.Grease nipple
14.Bushing 28.Ball seat
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-4-2
 STEERING LINKAGE ST LINKAGE

Key point of removal

<CK, CD and CW series>
2 Pitman arm
Remove the pitman arm, using a pitman arm puller (99850 Z0002).
NOTE
z Before removing the pitman arm, align the mark on the
sector shaft with the punch mark on-the pitman arm.
z Do not remove the dust cover unless it is damaged.

<CG series>
8 Pitman arm
1. Disconnect the inlet and outlet pipe connectors and turn the
steering wheel completely to the left and right to discharge
fluid from the steering gear box.
NOTE
z Before disconnecting the pipe connectors, wipe clean to
prevent foreign particles from getting into the ports.
z After draining steering fluid, plug the opening to prevent
the entry of foreign particles at the pipe connections.

2. Separate the steering column and steering gear box.

3. Remove the steering gear box and pitman arm from the
vehicle as a unit.

4. Attach the steering gear box to a jig (shown in the figure)

and place the jig in a vise. Remove nuts and lock washers.

ST-4-3
 STEERING LINKAGE ST LINKAGE

5. Remove the pitman arm, using a pitman arm puller (99850

Z0002).
NOTE
z Before removing the pitman arm, place a punch mark on
the se ration groove at the end of the pitman arm and
sector shaft.
z Do not remove the dust cover unless it is damaged.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Dust cover
Clean foreign matter off the ball joint and check the following:
1. Dust cover for grease leaks. Replace the dust cover if nec-
essary.
2. Depress the dust cover to ensure that grease does not
come out at any point. If it does, replace the dust cover.
3. Ensure that the dust cover is not lower than the arm. If it is,
replace the dust cover.

ST-4-4
 STEERING LINKAGE ST LINKAGE

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.

ST-4-5
 STEERING LINKAGE ST LINKAGE

Free length of drag link buffer spring

(CG series only)
Unit: mm (in)
Maintenance standard Service limit
83.0 (3.268) —

Tension of drag link buffer spring

(CG series only)
Unit: N {kgf, lbf}
Maintenance standard Service limit Remarks
When compressed to
2,550 {260, 573} —
75 mm (2.95 in)

REPAIR AND REPLACEMENT

DUST COVER
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 grams (0.71 oz)

ST-4-6
 STEERING LINKAGE ST LINKAGE

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.

4. Dust cover installation Place the dust cover over the socket
as shown in the figure, and install using dust cover inserter
(99853 Z0001) and a press.
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.

ST-4-7
 STEERING LINKAGE ST LINKAGE

PAINTING
NOTE
z Do not paint the dust cover. If the frame at the rubber
part is painted, mask the dust cover in advance. Remove
paint if it comes in contact with the cover.

REASSEMBLY
INSTALLATION
Key point of installation
<CK, CD and CW series>
2 Pitman arm
1. 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.

2. Install the pitman arm on the sector shaft and then install
the lock washer and nut.
NOTE
z Align the mark on the sector shaft with the punch mark
on the pitman arm.

： 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

ST-4-8
 STEERING LINKAGE ST LINKAGE

<CG series>
41 Grease nipple
Ensure the grease nipple faces backward.
34 Grease nipple
Ensure that the grease nipple faces down when installed.
27, 35 End plug
Tighten the end plug fully, back it of 3 turns, and set the position
of the cotter pin for a range of 60°.

8 Pitman arm
1. Attach the steering gear box to the jig.
2. 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.

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.

： 441 - 490 N·m {45 - 50 kgf·m, 325 - 362 ft·lbf}

ST-4-9
 STEERING LINKAGE ST LINKAGE

4. Install the steering gear box assembly (with pitman arm) in

the vehicle.
： 186 N·m {19 kgf·m, 137 ft·lbf}

5. Install the steering column on the gear box assembly.

： 51 - 61 N·m {5.2 - 6.2 kgf·m, 38 - 45 ft·lbf}

6. Connect the inlet and outlet connectors to the gear box.

NOTE
z Be careful to connect piping correctly. If incorrect, the
steering wheel will abruptly rotate when the oil pump
starts.

7. Pour power steering fluid into the reservoir and bleed air
from the fluid line. For procedures, refer to the “STEERING
GEAR BOX AND HYDRAULIC PUMP” section.
8. Proceed to the “Performance Check” that follows.

3 Pitman link
Install the pitman link with the nut facing the rear of the vehicle.

ST-4-10
 POWER CYLINDER ST LINKAGE

POWER CYLINDER
CONSTRUCTION

ST-5-1
 POWER CYLINDER ST LINKAGE

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1.Ball socket assembly 5.Dust seal 9.Ring seal
2.Flange 6.Y-packing 10.O-ring
3.Dust boot 7.O-ring , 11.Cylinder assembly
4.Bearing + 8.Piston and rod assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

ST-5-2
 POWER CYLINDER ST LINKAGE

Key point of disassembly

1 Ball socket assembly
Remove the ball socket assembly from the cylinder assembly.
NOTE
z Be careful not to damage the dust boot.

8 Piston and rod assembly

Extract the piston and rod assembly from the cylinder.
NOTE
z Do not remove the piston from the rod.

REASSEMBLY
Key point of reassembly
11 Cylinder assembly
Install the bearing to the cylinder assembly.
NOTE
z Securely clinch the cylinder assembly and bearing.

ST-5-3
 BRAKE SYSTEM

BRAKE PROPER
BRAKE UNIT: AIR OVER HYDRAULIC (AOH) BRAKE UNIT
BRAKE UNIT: AIR BRAKE UNIT
PARKING BRAKE

BR
 BRAKE PROPER

CONTENTS
SERVICE DATA................................. BR-1- 1 REPAIR AND REPLACEMENT........ BR-3-21
SPECIFICATIONS......................... BR-1- 1 ADJUSTMENT.................................. BR-3-22
SERVICE DATA............................. BR-1- 3
TIGHTENING TORQUE ................ BR-1- 7 = BRAKE PROPER (UNIT NAME
TOOLS............................................... BR-2- 1 FB43, BAL41, RB41, BPL41) =

= BRAKE PROPER (UNIT NAME BHL41, FRONT BRAKE

BLL41, *BHL41) = (UNIT NAME FB43, BAL41)............ BR-4- 1
CONSTRUCTION......................... BR-4- 1
FRONT BRAKE DISASSEMBLY............................. BR-4- 3
(UNIT NAME BAL41) ........................ BR-3- 1 REASSEMBLY.............................. BR-4- 6
CONSTRUCTION.......................... BR-3- 1 REAR BRAKE
DISASSEMBLY ............................. BR-3- 2 (UNIT NAME RB41, BPL41) ........... BR-4- 9
REASSEMBL................................ BR-3- 5 CONSTRUCTION......................... BR-4- 9
REAR BRAKE DISASSEMBLY............................ BR-4-12
(UNIT NAME BLL41, *BHL41).......... BR-3- 7 REASSEMBLY............................. BR-4-17
CONSTRUCTION.......................... BR-3- 7 INSPECTION ................................... BR-4-21
DISASSEMBLY ............................ BR-3-10 REPAIR AND REPLACEMENT....... BR-4-27
REASSEMBLY ............................. BR-3-16 ADJUSTMENT................................. BR-4-30
INSPECTION .................................... BR-3-18
 SERVICE DATA BRAKE PROPER

SERVICE DATA
SPECIFICATIONS

FRONT WHEEL BRAKE

Unit name BHL41 FB43 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)
Brake lining Width 150 (5.91)
mm (in) 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) 50.80 (2.0000) —
Brake cam type — Involute
Brake lining clearance adjusting
— Slack adjuster
system

REAR WHEEL BRAKE

Unit name BLL41 *BHL41 RB41 BPL41
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)
Brake lining Width 220 (8.66) 150 (5.91) 220 (8.66)
mm (in) 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) 44.0 (1.7323) —
Brake cam type — Involute
Brake lining clearance adjusting
— Slack adjuster
system

NOTE
z *BHL41 is for rear dead axle. (This also applies to the following pages.)

BR-1-1
 SERVICE DATA BRAKE PROPER

UNIT NAME

FB 4 3

WHEEL BRAKE ABBREVIATION BRAKE OPERATING SYSTEM MODEL CLASSIFICATION

FB Front wheel brake 4 Air brake for large-sized vehicles
RB Rear wheel brake

B H L 41

UNIT CLASSIFICATION lDENTIFICATION OF THE TYPE CLASSIFICATION DRUM SIZE

FROT AND REAR (Decimal point rounded up)
B Brake L Leading-trailing
H Front or rear liquid 41 410 mm
pressure
ure
P Rear liquid pressure
A Front air pressure
P Rear air pressure

BR-1-2
 SERVICE DATA BRAKE PROPER

SERVICE DATA
Unit: mm (in)
Application
*
Maintenance Service B B B F B R B
Item Remarks H L H B A B P
standard limit
L L L 4 L 4 L
4 4 4 3 4 1 4
1 1 1 1 1
414
I.D. 410 (16.14) O O O O O O O
(16.30)
Brake
drum Difference between
Less than 0.20
Out-of-roundness max. and min. drum O O O O O O O
0.025 (0.0010) (0.0079)
diameters
Clearance between brake 0.3 - 0.4
— O O O — — — —
Brake drum and brake lining (0.012 - 0.016)
lining 16.0 (0.630) O O O — O — O
Brake lining thickness 5.0 (0.197) Remaining thickness
15.0 (0.591) — — — O — O —
29.85
30.0 (1.181) O O O — O — O
(1.1752)
29.80
Anchor pin O.D. 30.0 (1.181) — — — O — — —
(1.1732)
31.80
32.0 (1.260) — — — — — O —
(1.2520)
30.15
30.0 (1.181) O O O — O — O
(1.1870)
30.20
Brake shoe bushing I.D. 30.0 (1.181) — — — O — — —
(1.1890)
32.20
32.0 (1.260) — — — — — O —
(1.2677)
0.07 - 0.20 0.25
O O O — O — O
(0.0028 - 0.0079) (0.0098)
Brake Clearance between anchor 0.10 - 0.25 0.35
— — — O — — —
shoe pin and brake shoe bushing (0.0039 - 0.0098) (0.0138)
0.10 - 0.25 0.50
— — — — — O —
(0.0039 - 0.0098) (0.0197)
26.4
26.0 (1.024) — — — O — O —
(1.039)
Brake shoe roller I.D.
20.7
20.3 (0.799) — — — — O — O
(0.815)
56.6
57.0 (2.244) With oil seal — — — O — O —
(2.228)
Brake shoe roller O.D.
39.9
40.3 (1.587) — — — — O — O
(1.571)
25.6
26.0 (1.024) — — — O — O —
(1.008)
Brake shoe roller pin O.D.
19.6
20.0 (0.787) — — — — O — O
(0.772)

BR-1-3
 SERVICE DATA BRAKE PROPER

Application
*
Maintenance Service B B B F B R B
Item Remarks H L H B A B P
standard limit
L L L 4 L 4 L
4 4 4 3 4 1 4
1 1 1 1 1
0.09 - 0.15 0.40
Clearance between brake — — — O — O —
Brake (0.0035 - 0.0059) (0.0157)
shoe roller and brake shoe
shoe 0.20 - 0.43 0.80
roller pin — — — — O — O
(0.0079 - 0.0169) (0.0315)
0.120 - 0.234
O — — — — — —
(0.0047 - 0.0092)
Clearance between wheel cyl- 0.128 - 0.248 0.25
— O — — — — —
inder and piston (0.0050 - 0.0098) (0.0098)
0.104 - 0.205
Wheel — — O — — — —
(0.0041 - 0.0081)
cylin-
der 50.6 - 51.2 Wheel cylinder I.D.
— O — — — — — —
(1.992 - 2.016) 50.80 mm (2.0000 in)
Wheel cylinder piston cup (lip) 55.4 - 56.0 Wheel cylinder I.D.
— — O — — — — —
O.D. (2.181 - 2.205) 55.56 mm (2.1874 in)
43.8 - 44.4 Wheel cylinder I.D.
— — — O — — — —
(1.724 - 1.748) 44.00 mm (1.7323 in)
44.3
44.0 (1.732) — — — O — O —
(1.744)
Camshaft bushing I.D.
40.3
40.0 (1.575) — — — — O — O
(1.587)
43.7
44.0 (1.732) — — — O — O —
(1.720)
Camshaft O.D.
Cam 39.7
40.0 (1.575) — — — — O — O
shaft (1.563)
0.15 - 0.22
— — — O — — —
(0.0059 - 0.0087)
Clearance between camshaft 0.05 - 0.12 0.60
— — — — O — O
bushing and camshaft (0.0020 - 0.0047) (0.0236)
0.37 - 0.44
— — — — — O —
(0.0146 - 0.0173)
Free length 195.9 (7.71) —
549 - 637 Measure tension when O — — — — — —
Tension N {kgf, lbf} {56.0 - 65.0, — spring is set at 219.0
123 - 143} mm (8.62 in) in length
Brake Free length 192.0 (7.56) —
shoe 462.4 - 527.1 Measure tension when
Outer — O — — — — —
return Tension N {kgf, lbf} {47.15 - 53.75, — spring is set at 219.0
spring 104.0 - 118.5} mm (8.62 in) in length
Free length 243.9 (9.60) —

Inner 178.9 - 208.3 Measure tension when — O — — — — —

Tension N {kgf, lbf} {18.24 - 21.24, — spring is set at 257.7
40.2 - 46.8} mm (10.15 in) in length

BR-1-4
 SERVICE DATA BRAKE PROPER

Application
B B * F B R B
Maintenance Service H L B B A B P
Item Remarks L L H 4 L 4 L
standard limit
4 4 L 3 4 1 4
1 1 4 1 1
1
Free length 192.0 (7.56) —
462.4 - 527.1 Measure tension when — — O — — — —
Tension N {kgf, lbf} {47.15 - 53.75, — spring is set at 219.0
104.0 - 118.5} mm (8.62 in) in length
Free length 184.3 (7.26) —
548 - 646 Measure tension when — — — O — — —
Tension N {kgf, lbf} {55.9 - 65.9, — spring is set at 209.0
123 - 145} mm (8.23 in) in length
Free length 195.9 (7.71) —

*1 549 - 637 Measure tension when

Tension N {kgf, lbf} {56.0 - 65.0, — spring is set at 219.0
123 - 143} mm (8.62 in) in length
— — — — O — —
Free length 194.3 (7.65) —

*2 544 - 642 Measure tension when

Brake Tension N {kgf, lbf} {55.5 - 65.5, — spring is set at 219.0
shoe 122 - 144} mm (8.62 in) in length
return Free length 229.8 (9.05) —
spring
Measure tension when — — — — — O —
783.6
Tension N {kgf, lbf} — spring is set at 250.0
7{9.9, 176.2}
mm (9.84 in) in length
Free length 195.9 (7.71) —

Outer 549 - 637 Measure tension when

Tension N {kgf, lbf} {56.0 - 65.0, — spring is set at 219.0
123 - 143} mm (8.62 in) in length
*1
Free length 242.6 (9.55) —

Inner 198 - 233 Measure tension when — — — — — — O

Tension N {kgf, lbf} {20.2 - 23.8, — spring is set at 252.5
45 - 52} mm (9.94 in) in length
Free length 186.7 (7.35) —

*2 691 - 819 Measure tension when

Tension N {kgf, lbf} {70.5 - 83.5, — spring is set at 219.0
155 - 184} mm (8.62 in) in length
Brake 165 (6.50) 30 (1.18) 45 (1.77) — — — O O — —
cham- 125 (4.92) 24 (0.94) 40 (1.57) — — — — — — O
ber
*3
push
rod 150 (5.91) 30 (1.18) 45 (1.77) — — — — — O O
stroke

BR-1-5
 SERVICE DATA BRAKE PROPER

NOTE
z *1 and *2 indicate respectively the inboard type and out-
board type installation methods of the brake drum.

NOTE
z Referring to *3
165 mm (6.50 in), 125 mm (4.92 in) and 150 mm (5.91 in)
are dimensions (L) between the centers of holes in both
ends of the slack adjuster.

BR-1-6
 SERVICE DATA BRAKE PROPER

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Application
*
B B B F B R B
Item Tightening torque Remarks H L H B A B P
L L L 4 L 4 L
4 4 4 3 4 1 4
1 1 1 1 1
490 - 588 {50.0 - 60.0, 362 - 434} Castellated nut
O — — — O — —
216 - 294 {22.0 - 30.0, 159 - 217} Bolt
216 - 294 {22.0 - 30.0, 159 - 217} — O — — — — O
Brake bracket mounting bolt or nut 490 - 588 {50.0 - 60.0, 362 - 434} M22
— — O — — — —
216 - 294 {22.0 - 30.0, 159 - 217} M16
216 - 294 {22.0 - 30.0, 159 - 217} — — — O — — —
216 - 265 {22.0 - 27.0, 159 - 195} — — — — — O —
75 - 91 {7.6 - 9.3, 55 - 67} O — O — — — —
Wheel cylinder mounting bolt
113 - 157 {11.5 - 16.0, 83 - 116} — O — — — — —
Air bleeder screw 10 - 34 {1.0 - 3.5, 7 - 25} O O O — — — —
Anchor pin setscrew 21 - 34 {2.1 - 3.5, 15 - 25} O O O — O — O
Back plate mounting bolt 21 - 34 {2.1 - 3.5, 15 - 25} O O O O O O O
69 - 88 {7.0 - 9.0, 51 - 65} — — — — O — —
137 - 157 {14.0 - 16.0, 101 - 116} — — — — — — O
Brake chamber bracket mounting bolt
108 - 127 {11.0 - 13.0, 80 - 94} — — — O — — —
127 - 147 {13.0 - 15.0, 94 - 108} — — — — — O —
Chamber size No.
81 - 108 {8.3 - 11.0, 60 - 80} — — — — O — —
20
Chamber size No. 24 — — — O O — —
Brake chamber mounting nut Chamber size No. 30 — — — — — O —
167 - 186 {17.0 - 19.0, 123 - 137} Chamber size No. — — — — — — O
2430
Chamber size No.
3030
— — — — — O O

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
8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Steel Flared O.D.
brake nut mm 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
(in) O O O O O O O
tube 12.0 (0.472) 59 - 78 {6.0 - 8.0, 43 - 58}
joints
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-1-7
 TOOLS BRAKE PROPER

TOOLS
Application
*
B B B F B R B
Part name and number Description Shape H L H B A B P
L L L 4 L 4 L
4 4 4 3 4 1 4
1 1 1 1 1
Used to remove/
install return spring
NOTE
Return spring tool z For unit names * *
99867 Z0000 marked with * on O O O O O O O
the Application
column, this tool
is used only on
the outer side

Return spring tool assem- Used to remove/

bly install return spring
99867 Z0001 (inner side) — O — — — — —
1. 99868 Z0000 1. Handle
2. 99868 Z0001 2. Hanger

Return spring tool assem- Used to remove/

bly install return spring
99867 Z0002 (inner side)
— — — — — — O
1 99868 Z0000 1 Handle
2 99868 Z0002 2 Hanger
3 99524 Z0000 3 Spacer

Used to remove/
install brake shoe
Adjusting cam assembly clearance adjusting
spring tool mechanism, and O O O — — — —
99842 Z0000 cam spindle pin of
the adjusting cam
assembly

Use as a guide when

installing the piston cup
into the wheel cylinder
Piston cup guide Cup guide inside diame-
ter (D):
*1 99866 Z0006 *1 *2 *3
*1 50.8 mm — — — —
*2 99866 Z0008 (2.000 in)
O O O
*3 99866 Z0004 *2 55.56 mm
(2.1874 in)
*3 44.0 mm
(1.732 in)

BR-2-1
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

= BRAKE PROPER (UNIT NAME BHL41, BLL41, *BHL41) =

FRONT BRAKE (UNIT NAME BHL41)
CONSTRUCTION
<WHEEL BRAKE>

BR-3-1
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

<WHEEL CYLINDER>

DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels. (Refer to the “FRONT
AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly. (Refer to the
“FRONT AXLE” section for procedures.)

BR-3-2
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

DISASSEMBLY
<WHEEL BRAKE>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Return spring 9. Wheel cylinder cover , 17. Adjuster cam assembly
, 2. Lock washer 10. Wheel cylinder assembly 18. Brake bracket
3. Lock plate ,+ 11. Cam spindle pin
4. Anchor pin 12. Indicator
, 5. Brake shoe assembly 13. Cover
6. Return spring pin 14. Adjuster boots
7. Shoe guide pin 15. Adjuster spring
8. Back plate 16. Adjuster washer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-3
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

Key point of disassembly

1 Return spring assembly
Remove the return spring assembly by using a spring tool (99867
Z0000).
NOTE
z Attach a band or ring [410 mm (16.14 in) in inside diame-
ter] to the edge of the brake lining to prevent it from
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.

<WHEEL CYLINDER>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Boot , 4. Back-up ring 7. Bleeder screw
2. Push rod ,+ 5. Piston cup 8. Body
3. Piston 6. Spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.
Key point of disassembly
5 Piston cup
When removing piston cup from the piston, pay attention so as not
to scratch or damage the piston.

BR-3-4
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
5 Piston cup
Install the piston cup to the piston using piston cup guide (99866
Z0006).

4 Back-up ring
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.

<WHEEL BRAKE>
Key point of reassembly
17 Adjuster cam assembly
Apply bearing grease sparingly when installing.

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.

5 Brake shoe assembly

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
z After installing the brake shoe assembly, attach the band
or ring [410 mm (16.14 in) in inside diameter] to the edge
of the brake lining.

BR-3-5
 FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41

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}

1 Return spring assembly

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.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “FRONT AXLE” section for procedures.)
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.

4. Bleed the air from the brake line.

(For detailed information on bleeding the air from the brake
line, refer to the “BRAKE UNITS” section.
5. Install the front road wheel.
(Refer to the “FRONT AXLE” section for procedures.)

BR-3-6
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

REAR BRAKE (UNIT NAME BLL41, *BHL41)

CONSTRUCTION
<WHEEL BRAKE>
Unit name BLL41

BR-3-7
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

Unit name *BHL41

BR-3-8
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

<WHEEL CYLINDER>
Unit name BLL41

BR-3-9
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

Unit name *BHL41

DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the rear road wheels.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)

BR-3-10
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

DISASSEMBLY
<WHEEL BRAKE>
Unit name BLL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Return spring assembly 9.Shoe guide pin 17.Cover
2.Return spring pin 10.Return spring pin 18.Adjuster boots
3.Guide pin 11.Back plate 19.Adjuster spring
,+ 4.Return spring assembly 12.Shield cover (Upper) 20.Adjuster washer
, 5.Lock washer 13.Wheel cylinder cover , 21.Adjuster cam assembly
6.Lock plate 14.Shield cover (lower) 22.Brake bracket
7.Anchor pin 15.Cam spindle pin
, 8.Brake shoe assembly ,+ 16.Indicator
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-11
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

Unit name *BHL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Return spring assembly 9.Wheel cylinder cover , 17.Adjuster cam assembly
, 2.Lock washer 10.Wheel cylinder assembly 18.Brake bracket
3.Lock plate ,+ 11.Cam spindle pin
4.Anchor pin 12.Indicator
, 5.Brake shoe assembly 13.Cover
6.Return spring pin 14.Adjuster boots
7.Shoe guide pin 15.Adjuster spring
8.Back plate 16.Adjuster washer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

1 Return spring assembly (Unit names BLL41 and *BHL41
are explained jointly)
Remove the return spring using a 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.

BR-3-12
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

4 Return spring assembly (Unit name BLL41 only)

Remove the return spring using a spring tool (99867 Z0001).

15 Unit name BLL41 and

11 Unit name *BHL41 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-3-13
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

<WHEEL CYLINDER>
Unit name BLL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Boots , 4.Back-up ring 7.Bleeder
2.Push rod ,+ 5.Piston cup 8.Body
3.Piston 6.Spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-14
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

Unit name *BHL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Boot , 4.Back-up ring 7.Bleeder screw
2.Push rod ,+ 5.Piston cup 8.Body
3.Piston 6.Spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

5 Piston cup (Unit names BLL41 and *BHL41 are explained
jointly)
When removing the piston cap from the piston, use care not to
scratch the piston.

BR-3-15
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
5 Piston cup (Unit names BLL41 and BHL41 are explained
jointly)
Install the piston cup to the piston using piston cup guide.
Unit name Piston cup guide
BLL41 99866 Z0008
*BHL41 99866 Z0004

4 Back-up ring (Unit names BLL41 and BHL41 are explained

jointly)
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.

<WHEEL BRAKE>
Key point of reassembly
21 Unit name BLL41 and
17 Unit name *BHL41 adjuster cam assembly
Apply bearing grease sparingly when installing.

15 Unit name BLL41 and

11 Unit name *BHL41 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.

8 Unit name BLL41 and

5 Unit name *BHL41 brake shoe assembly
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
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-3-16
 REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41

5 Unit name BLL41 and

2 Unit name *BHL41 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 (Unit name BLL41 only)

Install the return spring using the spring tool (99867 Z0001).
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.

1 Return spring assembly (Unit names BLL41 and *BHL41

are explained jointly)
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.(Refer to the “REAR
AXLE” section for procedures.)
2. Adjust the preload.(Refer to the “REAR AXLE” section for
procedures.)
3. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.

4. Bleed the air from the brake line.(For detailed information

on bleeding the air from the brake line, refer to the “BRAKE
UNITS” section.)
5. Install the rear road wheel.(Refer to the “REAR AXLE” sec-
tion for procedures.)

BR-3-17
 INSPECTION BHL41, BLL41, *BHL41

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

BRAKE DRUM
Inside diameter
Unit: mm (in)
Maintenance standard Service limit
410 (16.14) 414 (16.30)

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)
Maintenance standard Service limit
Less than 0.025 (0.0010) 0.20 (0.0079)

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
Brake lining thickness
Unit: mm (in)
Maintenance
Service limit Remarks
standard
16.0 (0.630) 5.0 (0.197) Remaining thickness (H)

BR-3-18
 INSPECTION BHL41, BLL41, *BHL41

BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
Maintenance standard Service limit
30.0 (1.181) 29.85 (1.1752)

Brake shoe bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
30.0 (1.181) 30.15 (1.1870)

Clearance between anchor pin and brake shoe bush-

ing
Unit: mm (in)
Maintenance standard Service limit
0.07 - 0.20 (0028 - 0.0079) 0.25 (0.0098)

WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
0.120 - 0.234
BHL41
(0.0047 - 0.0092)
0.128 - 0.248
BLL41 0.25 (0.0098)
(0.0050 - 0.0098)
0.104 - 0.205
*BHL41
(0.0041 - 0.0081)

Wheel cylinder piston cup (lip) outside diameter

Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
50.6 - 51.2 Wheel cylinder I.D.
BHL41 —
(1.992 - 2.016) 50.80 mm (2.0000 in)
55.4 - 56.0 Wheel cylinder I.D.
BLL41 —
(2.181 - 2.205) 55.56 mm (2.1874 in)
43.8 - 44.4 Wheel cylinder I.D.
*BHL41
(1.724 - 1.748) 44.00 mm (1.7323 in)

BR-3-19
 INSPECTION BHL41, BLL41, *BHL41

BRAKE SHOE RETURN SPRING

Free length
Unit: mm (in)
Maintenance
Unit name Service limit
standard
BHL41 195.9 (7.71) —
Outer 192.0 (7.56) —
BLL41
Inner 243.9 (9.60) —
*BHL41 192.0 (7.56) —

Tension
Unit: N {kgf, lbf}
Maintenance Service
Unit name Remarks
standard limit
Measure tension
549 - 637
when spring is set at
BHL41 {56.0 - 65.0, —
219.0 mm (8.62 in) in
123 - 143}
length
Measure tension
462.4 - 527.1
when spring is set at
Outer {47.15 - 53.75, —
219.0 mm (8.62 in) in
104.0 - 118.5}
length
BLL41
Measure tension
178.9 - 208.3
when spring is set at
Inner {18.24 - 21.24, —
257.7 mm (10.15 in)
40.2 - 46.8}
in length
Measure tension
462.4 - 527.1
when spring is set at
*BHL41 {47.15 - 53.75, —
219.0 mm (8.62 in) in
104.0 - 118.5}
length

BR-3-20
 REPAIR AND REPLACEMENT BHL41, BLL41, *BHL41

REPAIR AND REPLACEMENT

BRAKE LINING
1. Drill away the rivet heads at the brake shoe, using a drilling
machine. Then remove the rivets and separate the lining.

2. Align the lining hole with the brake shoe hole, and attach
the lining to the shoe, as shown in the figure. Secure the
backing in a vice.
NOTE
z Start riveting the lining to the shoe at the center, and
work alternately outward to the ends.
Before riveting the lining, thoroughly remove any
scratches or irregularities from the platform of the shoe.

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-3-21
 ADJUSTMENT BHL41, BLL41, *BHL41

ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the back plate grommet, and insert a 0.3 to 0.4 mm
(0.012 to 0.016 in) feeler gauge.
3. Rotate the adjuster cam from the “START” position in the
direction of the arrow, until resistance is felt when pulling
out the feeler gauge.
Unit: mm (in)
Maintenance standard Service limit
0.3 - 0.4 (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-3-22
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

= BRAKE PROPER (UNIT NAME FB43, BAL41, RB41, BPL41) =

FRONT BRAKE (UNIT NAME FB43, BAL41)
CONSTRUCTION
Unit name FB43

BR-4-1
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

Unit name BAL41

BR-4-2
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels. (Refer to the “FRONT
AXLE” section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
z Do not twist the brake hose excessively when discon-
necting it.

4. Remove the hub (with drum) assembly. (Refer to the

“FRONT AXLE” section for procedures.)

BR-4-3
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

DISASSEMBLY
Unit name FB43

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Return spring assembly 9. Clevis pin 17. Camshaft
2. Setscrew 10. Shim 18. Oil seal
3. Anchor pin 11. Plain washer 19. Dust seal
, 4. Brake shoe assembly 12. Retaining ring 20. Back plate
5. Clip , 13. Wear indicator 21. Brake bracket
, 6. Roller pin 14. Camshaft spacer , 22. Brake chamber assembly
7. Roller + 15. Slack adjuster assembly
8. Cotter pin 16. Camshaft spacer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-4
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

Unit name BAL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Return spring assembly 9. Cotter pin 17. Camshaft
, 2. Lock washer 10. Clevis pin 18. Back plate
3. Lock plate 11. Retaining ring 19. Brake bracket
4. Anchor pin , 12. Wear indicator , 20. Brake chamber assembly
, 5. Brake shoe assembly 13. Camshaft spacer
6. Clip ,+ 14. Slack adjuster assembly
, 7. Roller pin 15. Camshaft spacer
8. Roller 16. Felt ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

1. Return spring assembly (Unit names FB43 and BAL41 are
explained jointly)
Remove the return spring assembly by using a spring tool (99867
Z0000).
NOTE
z Attach a band or ring [410 mm (16.14 in) in inside diame-
ter] to the edge of the brake lining to prevent it from
expanding.

BR-4-5
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

15 Unit name FB43 and

14 Unit name BAL41 slack adjuster assembly
If the slack adjuster assembly is hard to remove, take it off using a
puller.
NOTE
z To rotate the auto slack adjuster, remove the fitting, gas-
ket, spring and guide pawl. Take care not to lose the
removed parts. (Unit name BAL41 only)

REASSEMBLY
REASSEMBLY
Key point of reassembly
22 Unit name FB43 and
20 Unit name BAL41 brake chamber assembly
Before installing the brake chamber assembly, make sure dimen-
sion “L”.
Unit: mm (in)
Unit name Dimension “L”
FB43 163 (6.42)
BAL41 225 (8.86)

: 81 - 108 N·m {8.3 - 11.0 kgf·m, 60 - 80 ft·lbf}

(Chamber size #20)
167- 186 N·m {17 - 19 kgf·m, 123 - 137 ft·lbf}
(Chamber size #24)

14 Slack adjuster assembly (Unit name BAL41 only)

When rotating the auto slack adjuster to connect it with the brake
chamber assembly, remove the fitting, gasket, spring and guide.
Be careful not to lose the removed parts.

13 Unit name FB43 and

12 Unit name BAL41 wear indicator
Install the wear indicator by aligning it with the arrow mark on the
camshaft.

BR-4-6
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

6 Roller pin (Unit name FB43 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.

7 Roller pin (Unit name BAL41 only)

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.

4 Unit name FB43 and

5 Unit name BAL41 brake shoe assembly
When installing the brake shoe assembly to the brake bracket,
apply bearing grease sparingly to the inner groove of the bushing
and anchor pin grooves (two places).
NOTE
z After installing the brake shoe assembly, attach the band
or ring [410 mm (16.14 in) in inside diameter] to the edge
of the brake lining.

2 Lock washer (Unit name BAL41 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}

1 Return spring assembly (Unit names FB43 and BAL41 are

explained jointly)
1. Install the return spring assembly using 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.

BR-4-7
 FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41

INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “FRONT AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “FRONT AXLE” section for procedures.)
3. Install the brake hose on the wheel brake side. Then, install
the brake hose on the bracket side (frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.

4. Install the front road wheel.

(Refer to the “FRONT AXLE” section for procedures.)

BR-4-8
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

REAR BRAKE (UNIT NAME RB41, BPL41)

CONSTRUCTION
Unit name RB41

BR-4-9
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

Unit name BPL41

<Type I>

BR-4-10
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

<Type II>

BR-4-11
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the rear road wheels.
(Refer to the “REAR AXLE” section for procedures.)
3. Remove the brake hose or tube from the bracket side
(frame side). Then, remove the brake hose or tube from the
rear axle housing side.
NOTE
z Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
z Do not twist the brake hose excessively when discon-
necting it.
4. Remove the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)

BR-4-12
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

DISASSEMBLY
Unit name RB41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Return spring assembly 9.Clevis pin , 17.Brake chamber assembly
2.Setscrew 10.Plain washer , 18.Brake chamber bracket
3.Anchor pin 11.Shim 19.Brake bracket
, 4.Brake shoe assembly 12.Retaining ring
5.Clip + 13.Slack adjuster assembly
, 6.Roller pin 14.Camshaft spacer
7.Roller 15.Camshaft
8.Cotter pin 16.Back plate
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-13
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

Unit name BPL41

<Type I>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Return spring assembly , 9.Roller pin 17.Camshaft spacer
,+ 2.Return spring assembly 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.Back plate
6.Anchor pin , 14.Retaining ring , 22.Brake chamber assembly
, 7.Brake shoe assembly 15.Camshaft spacer , 23.Brake chamber bracket
8.Clip ,+ 16.Slack adjuster assembly 24.Brake bracket
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-14
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

<Type II>

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1.Return spring assembly 10.Roller 19.Camshaft spacer
,+ 2.Return spring assembly 11.Cotter pin 20.Clip
3.Return spring pin 12.Clevis pin 21.Camshaft
, 4.Lock washer 13.Retaining ring , 22.Camshaft bracket
5.Lock plate , 14.Wear indicator 23.Shim
6.Anchor pin 15.Camshaft spacer 24.Back plate
, 7.Brake shoe assembly ,+ 16.Slack adjuster assembly 25.Oil seal
8.Clip 17.Camshaft spacer 26.Brake bracket
, 9.Roller pin 18.Clip , 27.Brake chamber assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-15
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

Key point of disassembly

1 Return spring assembly (Unit names RB41 and BPL41 are
explained jointly)
Remove the return spring using a 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.

Figure CBR-019A on the right shows the removal procedure for the
unit name RB41.

2 Return spring assembly (Unit name BPL41 only)

1. Turn the adjusting screw of the slack adjuster assembly to
reduce the camshaft cam lift to the position shown in the fig-
ure (WBR023A) at right so that the brake shoe contracts
inwards.

2. Slightly insert the return spring tool assembly handle into

the position shown in the figure with the spacer in place.
3. Insert the hanger into the inside of the brake shoe and
press-fit the hexagonal part of the handle in the hexagonal
hole in the hanger.
Return spring tool assembly
99867 Z0002
1 99868 Z0000 (Handle)
2 99868 Z0002 (Hanger)
3 99524 Z0000 (Spacer)
4. Make sure the return spring tip is in the 5 mm (0.20 in)
diameter spot-faced hole in the hanger tip. After that, turn
the handle in the direction of the arrow to push the return
spring up and extract the return spring pin.

NOTE
z If the spring tip does not enter the 5 mm (0.20 in) diame-
ter spot-faced hole in the hanger tip, move the spring
towards the right and left so it may enter.

BR-4-16
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

13 UNIT NAME RB41 and

16 UNIT NAME BPL41 slack adjuster assembly
If the slack adjuster assembly is hard to remove by hand, use a
puller for removal.
NOTE
z To rotate the auto slack adjuster, remove the fitting, gas-
ket, spring and guide pawl. Take care not to lose the
removed parts. (Unit name BPL41 only)

REASSEMBLY
REASSEMBLY
Key point of reassembly
27 Brake chamber assembly [Unit name BPL41 (Type II)]
Before installing the brake chamber assembly, make sure dimen-
sion “L” is 360 mm (14.17 in).
: 167 - 186 N·m {17.0 - 19.0 kgf·m, 123 - 137 ft·lbf}

18 Unit name RB41 and

23 Unit name BPL41 (Type I) 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}

22 Camshaft bracket [Unit name BPL41 (Type II)]

After inserting the camshaft, check that the camshaft can be rotated
smoothly, then tighten the camshaft bracket.
If camshaft rotation has resistance, add or remove shim(s) so that
the camshaft rotates smoothly.
[There are 0.2 mm (0.008 in), 0.3 mm (0.012 in), 0.7 mm (0.028 in)
and 1.5 mm (0.059 in) thick shims; 4 types in all]

BR-4-17
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

17 Unit name RB41 and

22 Unit name BPL41 (Type I) 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}

16 Slack adjuster assembly (Unit name BPL41 only)

When rotating the auto slack adjuster to connect it with the brake
chamber assembly, remove the fitting, gasket, spring and guide
pawl in advance.
Take care not to lose the removed parts.

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.

BR-4-18
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

4 Unit name RB41 and

7 Unit name BPL41 brake shoe assembly
When installing the brake shoe assembly to the brake bracket,
apply bearing grease sparingly to the inside face (groove) of the
bushing and anchor pin grooves (two places).
NOTE
z After installing the brake shoe assembly, attach the band
or ring [410 mm (16.14 in) in inside diameter] to the edge
of the brake lining.

For unit name RB41, apply bearing grease to the bushing only. Do
not apply to the anchor pin.
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 (Unit name BPL41 only)

1. Install the return spring tool assembly (99867 Z0002) to the
brake shoe assembly in the same manner as removal.
2. Temporarily install the return spring.
3. Make sure the return spring tip is in the 5 mm (0.20 in)
diameter spot-faced hole in the hanger tip. After that, turn
the handle in the direction of the arrow to push the return
spring up and insert the return spring pin.

1 Return spring assembly (Unit names RB41 and BPL41 are

explained jointly)
1. Install the return spring assembly using 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.

BR-4-19
 REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41

INSTALLATION
1. Install the hub (with drum) assembly.
(Refer to the “REAR AXLE” section for procedures.)
2. Adjust the preload.
(Refer to the “REAR AXLE” section for procedures.)
3. Install the brake hose or tube onto the rear axle housing.
Then, install the brake hose or tube on the bracket side
(frame side).
NOTE
z Do not twist the brake hose excessively when reconnect-
ing it.

4. Install the rear road wheel.

(Refer to the “REAR AXLE” section for procedures.)

BR-4-20
 INSPECTION FB43, BAL41, RB41, BPL41

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

BRAKE DRUM
Inside diameter
Unit: mm (in)
Maintenance standard Service limit
410 (16.14) 414 (16.30)

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)
Maintenance standard Service limit
Less than 0.025 (0.0010) 0.20 (0.0079)

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
Brake lining thickness
Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
FB43, RB41 15.0 (0.591)
Remaining thickness
BAL41, 5.0 (0.197)
16.0 (0.630) (H)
BPL41

BR-4-21
 INSPECTION FB43, BAL41, RB41, BPL41

BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB43 30.0 (1.181) 29.80 (1.1732)
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)
Unit name Maintenance standard Service limit
FB43 30.0 (1.181) 30.20 (1.1890)
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 bush-

ing
Unit: mm (in)
Unit name Maintenance standard Service limit
0.10 - 0.25
FB43 0.35 (0.0138)
(0.0039 - 0.0098)
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)
Unit name Maintenance standard Service limit
FB43, RB41 26.0 (1.024) 26.4 (1.039)
BAL41, BPL41 20.3 (0.799) 20.7 (0.815)

BR-4-22
 INSPECTION FB43, BAL41, RB41, BPL41

Brake shoe roller outside diameter

Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
FB43, RB41 57.0 (2.244) 56.6 (2.228) With oil seal
BAL41,
40.3 (1.587) 39.9 (1.571)
BPL41

Brake shoe roller pin outside diameters

Unit: mm (in)
Unit name Maintenance standard Service limit
FB43, RB41 26.0 (1.024) 25.6 (1.008)
BAL41, BPL41 20.0 (0.787) 19.6 (0.772)

Clearance between brake shoe roller and brake shoe

roller pin
Unit: mm (in)
Unit name Maintenance standard Service limit
0.09 - 0.15
FB43, RB41 0.40 (0.0157)
(0.0035 - 0.0059)
0.20 - 0.43
BAL41, BPL41 0.80 (0.0315)
(0.0079 - 0.0169)

CAMSHAFT
Camshaft bushing inside diameter
Unit: mm (in)
Unit name Maintenance standard Service limit
FB43, RB41 44.0 (1.732) 44.3 (1.744)
BAL41, BPL41 40.0 (1.575) 40.3 (1.587)

BR-4-23
 INSPECTION FB43, BAL41, RB41, BPL41

Camshaft outside diameter

Unit: mm (in)
Unit name Maintenance standard Service limit
FB43, RB41 44.0 (1.732) 43.7 (1.720)
BAL41, BPL41 40.0 (1.575) 39.7 (1.563)

Clearance between camshaft bushing and camshaft

Unit: mm (in)
Unit name Maintenance standard Service limit
0.15 - 0.22
FB43
(0.0059 - 0.0087)
0.05 - 0.12
BAL41, BPL41 0.60 (0.0236)
(0.0020 - 0.0047)
0.37 - 0.44
RB41
(0.0146 - 0.0173)

BR-4-24
 INSPECTION FB43, BAL41, RB41, BPL41

BRAKE SHOE RETURN SPRING

Free length
Unit: mm (in)
Maintenance Service
Unit name Remarks
standard data
FB43 184.3 (7.26) —
Inboard type 195.9 (7.71) —
BAL41
Outboard type 194.3 (7.65) —
RB41 229.8 (9.05) —
Inboard Outer 195.9 (7.71) —
BPL41 type Inner 242.6 (9.55) —
Outboard type 186.7 (7.35) —

BR-4-25
 INSPECTION FB43, BAL41, RB41, BPL41

Tension
Unit: N {kgf, lbf}
Maintenance Ser-
Unit name standard vice Remarks
limit
Measure tension
548 - 646
when spring is set at
FB43 {55.9 - 65.9, —
209.0 mm (8.23 in) in
123 - 145}
length
Measure tension
549 - 637
when spring is set at
Inboard type {56.0 - 65.0, —
219.0 mm (8.62 in) in
123 - 143}
length
BAL41
Measure tension
544 - 642
Outboard when spring is set at
{55.5 - 65.5, —
type 219.0 mm (8.62 in) in
122 - 144}
length
Measure tension
783.6 when spring is set at
RB41 —
{79.9, 176.2} 250.0 mm (9.84 in) in
length
Measure tension
549 - 637
when spring is set at
Outer {56.0 - 65.0, —
219.0 mm (8.62 in) in
Inbo 123 - 143}
length
ard
type Measure tension
198 - 233
when spring is set at
BPL41 Inner {20.2 - 23.8, —
252.5 mm (9.94 in) in
45 - 52}
length
Measure tension
691 - 819
Outboard when spring is set at
{70.5 - 83.5, —
type 219.0 mm (8.62 in) in
155 - 184}
length

BR-4-26
 REPAIR AND REPLACEMENT FB43, BAL41, RB41, BPL41

REPAIR AND REPLACEMENT

BRAKE LINING
1. Drill away the rivet heads at the brake shoe, using a drilling
machine. Then remove the rivets and separate the lining.

2. Align the lining hole with the brake shoe hole, and attach
the lining to the shoe, as shown in the figure. Secure the
backing in a vice.
NOTE
z Start riveting the lining to the shoe at the center, and
work alternately outward to the ends.
Before riveting the lining, thoroughly remove any
scratches or irregularities from the platform of the shoe.

BRAKE SHOE BUSHING

<UNIT NAME BAL41 AND BPL41>
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.

<UNIT NAMES FB43 AND RB41>

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.
NOTE
z Do not coat the shoe bushing with grease or oil.

BR-4-27
 REPAIR AND REPLACEMENT FB43, BAL41, RB41, BPL41

CAMSHAFT BUSHING
<UNIT NAME FB43>
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.

<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 bushing 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>

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.

BR-4-28
 REPAIR AND REPLACEMENT FB43, BAL41, RB41, BPL41

<UNIT NAME BPL41>

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 bushing 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 and oil seal onto the brake
bracket.
After press-fitting the bushing, measure the bushing 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.

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-4-29
 ADJUSTMENT FB43, BAL41, RB41, BPL41

ADJUSTMENT
ADJUSTING THE BRAKE CHAMBER PUSH ROD
STROKE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Measure the push rod stroke when the brake pedal is
depressed with normal pressure.
Unit: mm (in)
Maintenance
Unit name Service data
standard
FB43,
*165 (6.50) 30 (1.18) 45 (1.77)
BAL41
Push rod
*125 (4.92) BPL41 24 (0.94) 40 (1.57)
stroke
RB41,
*150 (5.91) 30 (1.18) 45 (1.77)
BPL41

NOTE
z Referring to *
165 mm (6.50 in), 125 mm (4.92 in) and 150 mm (5.91 in)
are dimensions (L) between the centers of holes in both
ends of the slack adjuster.

3. Adjust the push rod stroke if it is outside the allowable limit.

z Check the installation length of the brake chamber push
rod.
Unit: mm (in)
Unit name Push rod set length “L” Remarks
FB43 163 (6.42)
BAL41 225 (8.86) Distance from the
RB41 chamber end face to the
60 (2.36) center of clevis pin hole
BPL41 (Type I)
BPL41 (Type II) 360 (14.17)

BR-4-30
 ADJUSTMENT FB43, BAL41, RB41, BPL41

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-4-31
 BRAKE UNIT
AIR OVER HYDRAULIC (AOH)
BRAKE UNIT

CONTENTS
SERVICE DATA................................. BR-1- 1 INSPECTION............................... BR-4- 5
SPECIFICATIONS......................... BR-1- 1 REASSEMBLY............................. BR-4- 6
SERVICE DATA............................. BR-1- 2 FUNCTIONAL CHECK ................ BR-4- 8
TIGHTENING TORQUE ................ BR-1- 5 AIR PRESSURE GOVERNOR ........ BR-5- 1
DIAGRAM OF PIPING................... BR-1- 6 CONSTRUCTION........................ BR-5- 1
TOOLS............................................... BR-2- 1 DISASSEMBLY AND
BRAKE VALVE................................ BR-3- 1 REASSEMBLY............................. BR-5- 2
FUNCTIONAL CHECK ................ BR-5- 3
= 241-02224 = AIR DRYER ..................................... BR-6- 1
CONSTRUCTION.......................... BR-3- 1 CONSTRUCTION........................ BR-6- 1
DISASSEMBLY ............................. BR-3- 2 DISASSEMBLY............................ BR-6- 2
INSPECTION............................... BR-3- 5 INSPECTION............................... BR-6- 3
REASSEMBL................................ BR-3- 7 REASSEMBLY............................. BR-6- 3
FUNCTIONAL CHECK ................ BR-3- 9 INSPECTION AFTER MOUNTING ON
VEHICLE .................................... BR-6- 4
= E6-H24 = BRAKE LOCK ................................. BR-7- 1
CONSTRUCTION....................... BR-3-10 BRAKE LOCK SYSTEM .............. BR-7- 1
DISASSEMBLY .......................... BR-3-11 CONSTRUCTION........................ BR-7- 2
INSPECTION.............................. BR-3-14 DISASSEMBLY AND
REASSEMBLY ........................... BR-3-16 REASSEMBLY............................. BR-7- 3
FUNCTIONAL CHECK ............... BR-3-17 CHECKING THE BRAKE LOCK
AIR BOOSTER .................................. BR-4- 1 SYSTEM ...................................... BR-7- 3
CONSTRUCTION.......................... BR-4- 1 BLEEDING AIR FROM THE BRAKE
DISASSEMBLY ............................. BR-4- 1 SYSTEM ......................................... BR-8- 1
 SERVICE DATA BRAKE UNIT (AOH)

SERVICE DATA
SPECIFICATIONS
Item Contents
Type Dual type
Brake valve 241-02224
Model
E6-H24
*1 Air booster Type Air servo type
Type Piston type
Air pressure
Pressure adjustment range Low 667 {6.8, 97}
governor
2
kPa {kgf/cm , psi} High 785 {8.0, 114}
Type Barrel type
Air dryer
Model DR-31
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}
kPa {kgf/cm2, psi} Service reservoir fitted 2.0 - 3.9 {0.02 - 0.04, 0.3 - 0.6}
Light ON pressure 422 - 481 {4.3 - 4.9, 61 - 70}
Type I
Light OFF pressure 422 - 530 {4.3 - 5.4, 61 - 77}
Light ON pressure 490 - 549 {5.0 - 5.6, 71 - 80}
Type II
*2 Air pressure switch Light OFF pressure 520 - 628 {5.3 - 6.4, 75 - 91}
kPa {kgf/cm2, psi} Light ON pressure 461 - 520 {4.7 - 5.3, 67 - 75}
Type III
Light OFF pressure 471 - 579 {4.8 - 5.9, 68 - 84}
Light ON pressure 490 - 549 {5.0 - 5.6, 71 - 80}
Type IV
Light OFF pressure 490 - 598 {5.0 - 6.1, 71 - 87}

*1 Air booster
Type I Type II Type III Type IV Type V
Model
(234-04116) (234-04114) (234-04200) 234-04669) (234-04797)

Cylinder shell I.D. 138 (5.43)

mm (in) Stroke 188 (7.40) 118 (4.65)

Hydraulic cylinder I.D. 29.1 (1.146) 26.7 (1.051) 29.1 (1.146) 26.7 (1.051)
mm (in) Stroke 185 (7.28) 115 (4.53)
Residual pressure kPa {kgf/cm2, psi} 59 - 157 {0.6 - 1.6, 9 - 23}

*2 Air pressure switch

z To identify the air pressure switch, confirm the identification
mark (operating pressure) stamped on the body.

Type Identification mark

I 4.5
II 5.5
III P52
IV P55

BR-1-1
 SERVICE DATA BRAKE UNIT (AOH)

SERVICE DATA
BRAKE VALVE
Model 241-02224
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Plunger O.D. 19.9 (0.783) 19.80 (0.7795)
Piston O.D. 52.1 (2.051) 51.95 (2.0453)
Relay piston O.D. 66.5 (2.618) 66.30 (2.6102)
Sleeve spring 13.7 (0.539) —
Piston spring (Large) 29.5 (1.161) —
Piston spring (Small) 20.0 (0.787) —
Piston return spring 60.5 (2.382) —
Spring free
length Primary inlet valve
41.6 (1.638) —
spring
Relay piston spring 46.4 (1.827) —
Secondary inlet valve
24.4 (0.961) —
spring
When compressed to 12.6
Sleeve spring 216 {22, 49} —
mm (0.496 in)
When compressed to 26.5
Piston spring (Large) 213.8 {21.8, 48.1} —
mm (1.043 in)
When compressed to 19.4
Piston spring (Small) 34.3 {3.5, 7.7} —
mm (0.764 in)
Spring ten-
When compressed to 17.0
sion Piston return spring 97.1 {9.9, 21.8} —
mm (0.669 in)
N {kgf, lbf}
Primary inlet valve When compressed to 14.3
37.3 {3.8, 8.4} —
spring mm (0.563 in)
When compressed to 12.8
Relay piston spring 33.3 {3.4, 7.5} —
mm (0.504 in)
Secondary inlet valve When compressed to 12.9
47.1 {4.8, 10.6} —
spring mm (0.508 in)
Pressure difference between primary
Less than 20 {0.2, 3} —
and secondary outlet kPa {kgf/cm2, psi}
12.0 - 18.0
Brake pedal free play —
(0.472 - 0.709)

BR-1-2
 SERVICE DATA BRAKE UNIT (AOH)

Model E6-H24
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pedal pin holes I.D. 10.0 (0.394) 10.25 (0.4035)
Roller pin O.D. 10.0 (0.394) 9.85 (0.3878)
I.D. 10.0 (0.394) 10.20 (0.4016)
Roller
O.D. 21.9 (0.862) 21.70 (0.8543)
Mounting plate bushing I.D. 26.5 (1.043) 26.70 (1.0512)
Plunger O.D. 26.5 (1.043) 26.20 (1.0315)
Main spring 28.4 (1.118)
Sub spring 23.2 (0.913)
Relay piston spring 39.5 (1.555)
Spring free
Piston return spring 61.6 (2.425)
length
Primary valve spring 32.1 (1.264)
Secondary valve spring 16.5 (0.650)
Stem spring 29.5 (1.161)
When compressed to 27.0
Main spring 210.9 {21.5, 47.4}
mm (1.063 in)
When compressed to 20.1
Sub spring 335.4 {34.2, 75.4}
mm (0.791 in)
When compressed to 12.1
Relay piston spring 46.1 {4.7, 10.4}
mm (0.476 in)
Spring ten-
When compressed to 14.6
sion Piston return spring 103.0 {10.5, 23.2}
mm (0.575 in)
N {kgf, lbf}
When compressed to 14.3
Primary valve spring 44.1 {4.5, 9.9}
mm (0.563 in)
When compressed to 11.0
Secondary valve spring 25.5 {2.6, 5.7}
mm (0.433 in)
When compressed to 19.9
Stem spring 73.6 {7.5, 16.5}
mm (0.783 in)
Pressure difference between primary
Less than 20 {0.2, 3}
and secondary outlet kPa {kgf/cm2, psi}
12.0 - 18.0
Brake pedal free play
(0.472 - 0.709)

AIR BOOSTER
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Clearance between cylinder shell and power
— 1.8 (0.071)
piston
Push rod run-out — 1.2 (0.047)
Clearance between hydraulic cylinder and
— 0.15 (0.0059)
piston
Type I
When compressed to 245.2
Type II — 103.0 {10.5, 23.2}
Power piston spring tension mm (9.65 in)
Type III
N {kgf, lbf}
Type IV When compressed to 175.2
— 103.0 {10.5, 23.2}
Type V mm (6.90 in)

BR-1-3
 SERVICE DATA BRAKE UNIT (AOH)

AIR PRESSURE GOVERNOR

Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
Low 647 - 686
—
range {6.6 - 7.0, 94 - 100}
Pressure adjustment range
High 765 - 814
—
range {7.8 - 8.3, 111 - 118}

BR-1-4
 SERVICE DATA BRAKE UNIT (AOH)

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Sleeve screw 1 - 3 {0.1 - 0.3, 0.7 - 2.2}
Piston mounting bolt 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
Sleeve 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
241-02224
Cover assembly mounting bolt 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
Mounting plate assembly mounting bolt 12 - 19 {1.2 - 1.9, 9 - 14}
Brake valve
Pedal setscrew 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
Upper piston installing nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
E6-H24
Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
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}
Switch assembly 25 - 34 {2.5 - 3.5, 18 - 25}
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}
Air booster
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 0.7 - 1.3 {0.07 - 0.13, 0.5 - 0.9}
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}
Air dryer
Bracket tightening bolt 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Heater 23 - 29 {2.3 - 3.0, 17 - 22}
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. mm 8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut
(in) 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
Steel brake tube joints
12.0 (0.472) 59 - 78 {6.0 - 8.0, 43 - 58}
15.0 (0.591) 69 - 93 {7.0 - 9.5, 51 - 69}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}

BR-1-5
 SERVICE DATA BRAKE UNIT (AOH)

DIAGRAM OF PIPING
Model CW and CD series

BR-1-6
 TOOLS BRAKE UNIT (AOH)

TOOLS
BRAKE VALVE
z Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and number Description Shape

Needle
Used when removing O-rings.
910-21200

Insert tool
Used when installing the relay piston O-ring.
910-24461

Retainer
Used when inserting pistons into place.
910-24590

AIR BOOSTER
z Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and number Description Shape

Stand Used to disassemble/reassemble the air

910-00450 booster

Needle
Used when removing the cap or O-ring
910-21200

BR-2-1
 TOOLS BRAKE UNIT (AOH)

Cup insert guide

Used when inserting the hydraulic piston cup
910-23290

Holder Used when removing/installing the power

910-24831 piston.

BR-2-2
 BRAKE VALVE BRAKE UNIT (AOH)

BRAKE VALVE
= MODEL 241-02224 =
CONSTRUCTION

BR-3-1
 BRAKE VALVE BRAKE UNIT (AOH)

DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
3. Tilt the cab upward.
WARNING
WARNING
ELECTRIC TILT TYPE
z After tilting the cab upward, make sure the tilt cylinder tilt
stopper is securely locked.

WARNING
WARNING
MANUAL TILT TYPE
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.

BR-3-2
 BRAKE VALVE BRAKE UNIT (AOH)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Pedal cover 21. Relay piston spring 41. O-ring
2. Cotter pin ,+ 22. O-ring 42. O-ring
3. Washer + 23. O-ring 43. Retainer
4. Straight pin 24. Relay piston 44. Secondary inlet valve spring
5. L-pin + 25. O-ring 45. Valve retainer
6. Cotter pin 26. Bushing , 46. Secondary inlet valve
7. Washer ,+ 27. Bolt 47. Cover
8. Straight pin 28. Spring seat 48. Retaining ring
9. Roller 29. Piston spring (Small) 49. Retainer
10. Mounting plate assembly 30. Piston spring (Large) 50. O-ring
11. Boot + 31. O-ring 51. O-ring
12. Plunger 32. Piston 52. Washer
13. Mounting plate 33. Screw 53. Primary inlet valve spring
14. Cover assembly , 34. Sleeve 54. Washer
+ 15. O-ring 35. Washer , 55. Primary inlet valve
16. Retaining ring 36. Spring 56. Body
17. Sleeve spring 37. Spring
,+ 18. Piston assembly 38. Retaining ring
19. Piston return spring 39. Exhaust cover assembly
+ 20. Relay piston assembly 40. Washer

Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-3
 BRAKE VALVE BRAKE UNIT (AOH)

Key point of disassembly

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.

15 O-ring
Using the needle (910-21200), remove the O-ring from the cover
groove.

18 Piston assembly, 20 Relay piston assembly

Secure the body assembly with the socket wrench [width across
flats: 14 mm (0.55 in)] secured in a vise, loosen the screw, and
remove the piston assembly and relay piston assembly.
NOTE
z When loosening the body, be sure to hold the piston by
hand as it jumps out because of the spring pressure in
the body.

22, 23, 25 O-ring

Using the needle (910-21200), remove the O-ring from the groove
in the relay piston and bushing.

BR-3-4
 BRAKE VALVE BRAKE UNIT (AOH)

27 Bolt
Secure the piston assembly in a vise and disassemble the piston
assembly using the socket wrench [width across flats: 14 mm (0.55
in)].
NOTE
z When securing the piston assembly in a vise, do not
secure the valve seat. Be careful not to damage it.

31 O-ring
Using the needle (910-21200), remove the O-ring from the piston
groove.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Plunger outside diameter
Unit: mm (in)
Maintenance standard Service limit
19.9 (0.783) 19.80 (0.7795)

Piston outside diameter

Unit: mm (in)
Maintenance standard Service limit
52.1 (2.051) 51.95 (2.0453)

BR-3-5
 BRAKE VALVE BRAKE UNIT (AOH)

Relay piston outside diameter

Unit: mm (in)
Maintenance standard Service limit
66.5 (2.618) 66.30 (2.6102)

Spring free length

Unit: mm (in)
Item Maintenance standard Service limit
Sleeve spring 13.7 (0.539)
Piston spring (Large) 29.5 (1.161)
Piston spring (Small) 20.0 (0.787)
Piston return spring 60.5 (2.382)
Primary inlet valve spring 41.6 (1.638)
Relay piston spring 46.4 (1.827)
Secondary inlet valve spring 24.4 (0.961)

Spring tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
216 When compressed to
Sleeve spring —
{22, 49} 12.6 mm (0.496 in)
Piston spring 213.8 When compressed to
—
(Large) {21.8, 48.1} 26.5 mm (1.043 in)
Piston spring 34.3 When compressed to
—
(Small) {3.5, 7.7} 19.4 mm (0.764 in)
Piston return 97.1 When compressed to
—
spring {9.9, 21.8} 17.0 mm (0.669 in)
Primary inlet 37.3 When compressed to
—
valve spring {3.8, 8.4} 14.3 mm (0.563 in)
Relay piston 33.3 When compressed to
—
spring {3.4, 7.5} 12.8 mm (0.504 in)
Secondary 47.1
When compressed to
inlet valve {4.8, 10.6} —
12.9 mm (0.508 in)
spring

BR-3-6
 BRAKE VALVE BRAKE UNIT (AOH)

REASSEMBLY
REASSEMBLY
Key point of reassembly
z Align the alignment mark (scribed during disassembly)
when installing the cover assembly and mounting plate.

55 Primary inlet valve

When assembling the primary inlet valve, pay attention to the instal-
lation position of the washer and retainer.
NOTE
z After installing each part, make sure the retaining ring fits
correctly in the body groove.

46 Secondary inlet valve

When assembling the secondary inlet valve, pay attention to the
installation position of the washer.
NOTE
z After installing each part, make sure the retaining ring fits
correctly in the cover groove.

34 Sleeve
After assembling the sleeve assembly, apply silicone grease so that
the spring is just concealed.
: 1- 3 N·m {0.1 - 0.3 kgf·m, 0.7 - 2.2 ft·lbf}

27 Bolt
Secure the piston in a vise and assemble the piston assembly
using the socket wrench [width across flats: 14 mm (0.55 in)].
: 5- 8 N·m {0.5 - 0.8 kgf·m, 3.6 - 5.8 ft·lbf}
NOTE
z When securing the piston assembly in a vise, do not
secure the valve seat. Be careful not to damage it.

BR-3-7
 BRAKE VALVE BRAKE UNIT (AOH)

22 O-ring
Using the insert tool (910-24461), install the O-ring onto the relay
piston.

18 Piston assembly
Install the piston assembly onto the body and secure the piston
assembly with the retainer (910-24590).
NOTE
z Before removing the retainer (910-24590), remove retain-
ing ring 16.

BR-3-8
 BRAKE VALVE BRAKE UNIT (AOH)

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Connect air pressure gauges to air discharge lines on the
primary and secondary sides, as close to the brake valve as
possible. These gauges should be capable of registering
more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.

FUNCTIONAL TEST
1. Gradually depress the brake pedal while observing the
pressure gauge on the primary side. When the gauge regis-
ters the first pressure increase, measure the pedal angle to
the floor. The pedal angle is correct if it agrees with the
value indicated in the performance characteristic curve. If it
is outside the specified value, adjust the length of the push
rod or the pedal angle (by means of the stopper bolt located
below the pedal) to the specified value.
Pedal setscrew
: 5 - 8 N·m {0.5 - 0.8 kgf·m, 3.6 - 5.8 ft·lbf}
2. Next, depress the brake pedal further to determine a point
at which an abrupt pressure rise takes place. Beyond this
point, the air pressure will rise rapidly to the air reservoir
pressure. Also check to be sure that just before the brake
pedal is depressed fully, the air pressure reservoir pressure
is equal to the brake pressure and the brake pedal can still
be depressed further.
3. Check the air pressure gauge on the secondary side to
ensure that its indication always increases proportionally
within 20 kPa {0.2 kgf/cm2, 3 psi} of the gauge indication on
the primary side during the test.
4. Also check to see that all air is discharged smoothly from
the discharge line without residual air pressure.

BR-3-9
 BRAKE VALVE BRAKE UNIT (AOH)

= MODEL E6-H24 =
CONSTRUCTION

BR-3-10
 BRAKE VALVE BRAKE UNIT (AOH)

DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
3. Tilt the cab upward.
WARNING
WARNING
ELECTRIC TILT TYPE
z After tilting the cab upward, make sure the tilt cylinder tilt
stopper is securely locked.

WARNING
WARNING
MANUAL TILT TYPE
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.

BR-3-11
 BRAKE VALVE BRAKE UNIT (AOH)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Pedal assembly 21. Retaining ring 41. Retaining ring
2. Lower body assembly 22. Special washer 42. Special washer
,+ 3. E-ring 23. O-ring retainer 43. O-ring retainer
4. Stem plate 24. O-ring 44. O-ring
5. Stem spring 25. O-ring 45. O-ring
6. Upper body 26. Secondary valve spring 46. Primary valve spring
+ 7. Piston assembly 27. Valve retainer 47. Valve retainer
8. Bushing , 28. Lower valve , 48. Upper valve
9. O-ring 29. Retaining ring 49. Pedal
10. Piston return spring 30. Primary valve assembly 50. Cotter pin
11. Sleeve 31. Nut 51. Pin
12. Relay piston 32. Lock washer 52. Roller pin
13. O-ring 33. Special washer 53. Roller
14. O-ring 34. Stem 54. Boot
15. Relay piston spring 35. Spring seat 55. Plunger
16. Retaining washer 36. Sub spring seat 56. Mounting plate
17. Exhaust check 37. Main spring
18. Exhaust cover 38. Sub spring
19. Lower body , 39. Piston
20. O-ring 40. O-ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-12
 BRAKE VALVE BRAKE UNIT (AOH)

Key point of disassembly

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.

3 E-ring
Insert a Phillips screw driver fixed in a vise into the relay piston
exhaust passage until it contacts the stem portion, and remove the
E-ring.
NOTE
z When removing the E-ring, hold the piston by hand so
that it does not pop out.

7 Piston assembly
Place a standard screwdriver in the sleeve end groove to prevent
the sleeve from rotating while loosening the nut when disassem-
bling the piston assembly.

BR-3-13
 BRAKE VALVE BRAKE UNIT (AOH)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Pin hole inside diameter

Unit: mm (in)
Maintenance standard Service limit
10.0 (0.394) 10.25 (0.4035)

Roller pin outside diameter

Unit: mm (in)
Maintenance standard Service limit
10.0 (0.394) 9.85 (0.3878)

Roller
Unit: mm (in)
Item Maintenance standard Service limit
Inside diameter 10.0 (0.394) 10.20 (0.4016)
Outside diameter 21.9 (0.862) 21.70 (0.8543)

Mounting plate bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
26.5 (1.043) 26.70 (1.0512)

BR-3-14
 BRAKE VALVE BRAKE UNIT (AOH)

Plunger outside diameter

Unit: mm (in)
Maintenance standard Service limit
26.5 (1.043) 26.20 (1.0315)

Spring free length

Unit: mm (in)
Item Maintenance standard Service limit
Main spring 28.4 (1.118) —
Sub spring 23.2 (0.913) —
Relay piston spring 39.5 (1.555) —
Piston return spring 61.6 (2.425) —
Primary valve spring 32.1 (1.264) —
Secondary valve spring 16.5 (0.650) —
Stem spring 29.5 (1.161) —

Spring tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
210.9 When compressed to
Main spring —
{21.5, 47.4} 27.0 mm (1.063 in)
335.4 When compressed to
Sub spring —
{34.2, 75.4} 20.1 mm (0.791 in)
Relay piston 46.1 When compressed to
—
spring {4.7, 10.4} 12.1 mm (0.476 in)
Piston return 103.0 When compressed to
—
spring {10.5, 23.2} 14.6 mm (0.575 in)
Primary valve 44.1 When compressed to
—
spring {4.5, 9.9} 14.3 mm (0.563 in)
Secondary 25.5 When compressed to
—
valve spring {2.6, 5.7} 11.0 mm (0.433 in)
73.6 When compressed to
Stem spring —
{7.5, 16.5} 19.9 mm (0.783 in)

BR-3-15
 BRAKE VALVE BRAKE UNIT (AOH)

REASSEMBLY
REASSEMBLY
Key point of reassembly
z Apply lithium soap-base grease or equivalent to the sliding
surfaces of the inlet valve, body and relay piston.
z When assembling the O-ring, be sure to apply lithium soap-
base grease or equivalent to the O-ring. Fill the O-ring
groove with this grease.
z Apply molybdenum disulfide grease or equivalent to the
sliding surfaces (10-mm dia. pin and plunger) of pedal.
z After fitting each retaining ring, make sure it is securely
located in its groove.

z Align the alignment mark (scribed during disassembly)

when installing the cover assembly and mounting plate.

48 Upper valve
Assemble the primary valve assembly paying attention to the orien-
tation of O-ring retainer and special washer.
NOTE
z Check that the retaining ring is assembled securely.

39 Piston
Reassembling the piston complete.
Place the piston, main spring, sub spring, spring seat, special
washer, and spring washer, in that order, on the sleeve. Then
tighten the sleeve with the nut.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}
NOTE
z Place a standard screwdriver secured in a vise in the
sleeve end groove to prevent the sleeve from rotating,
then tighten the nut.

BR-3-16
 BRAKE VALVE BRAKE UNIT (AOH)

28 Lower valve
Assemble the secondary valve assembly paying attention to the O-
ring retainer and the special washer.
NOTE
z Check that the retaining ring is installed correctly.

3 E-ring
1. Holding the relay piston with one hand so that the spring will
not shoot it out, insert the stem into the relay piston. Then
put the upper body on a Phillips screwdriver so that the end
of the stem will touch the tip of the screwdriver.

2. Install the return spring, piston complete, stem spring, and

stem plate onto the upper body.Then, pushing down the
stem plate, insert the E-ring into the groove of the stem.

FUNCTIONAL CHECK
FUNCTIONAL TEST
To check brake valve performance, prepare a pressure gauge
capable of measuring a maximum pressure of 981 kPa {10 kgf/cm2,
142 psi} and its operating characteristic diagram.
First, install the pressure gauge onto the discharge side of upper
side. Gradually depress the brake pedal, and check that the pres-
sure gauge increases when brake pedal is depressed to an angle
of 2.8 to 3.5º.
Next, check the lower side pressure. Check that lower side pres-
sure increases smoothly following the pressure increase in the
upper side.

BR-3-17
 AIR BOOSTER BRAKE UNIT (AOH)

AIR BOOSTER
CONSTRUCTION

DISASSEMBLY
REMOVAL
Key point of removal
1. Before removing the brake booster, drain the brake fluid
from the air booster to remove dirt and dust.
2. Plug the connections to prevent dirt and dust from entering
the lines and prevent the brake fluid from flowing out.

BR-4-1
 AIR BOOSTER BRAKE UNIT (AOH)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Body assembly + 21. Piston ,+ 41. Cup packing
2. Collar 22. O-ring , 42. Power piston spring
3. O-ring 23. Retainer (cover) + 43. Retaining ring
4. O-ring 24. Spring 44. Straight pin
5. Pipe 25. Road ,+ 45. Hydraulic piston assembly
6. Cover assembly 26. Retaining ring ,+ 46. Retainer assembly
7. Exhaust cover 27. Retaining ring 47. Washer
8. Retaining ring , 28. Connector + 48. O-ring
9. Inlet valve assembly + 29. O-ring 49. Back-up ring
10. Spring 30. Spring retainer ,+ 50. Cup packing
11. Valve retainer 31. Spring 51. Retaining ring
12. O-ring 32. Valve 52. Spring
13. O-ring 33. Retainer 53. Valve
14. Valve guide 34. Cylinder shell assembly 54. Rod
15. Retaining ring 35. O-ring 55. Straight pin
16. Valve seat ,+ 36. Push rod nut 56. Switch assembly
17. Cover 37. Washer 57. Gasket
18. Cover 38. Washer 58. Air bleeder screw
19. Spring 39. O-ring 59. Cylinder
20. Cover 40. Power piston assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-2
 AIR BOOSTER BRAKE UNIT (AOH)

Key point of disassembly

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.
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.

41 Cup packing
Using the needle (910-21200), remove the cup packing from the
power piston assembly.

BR-4-3
 AIR BOOSTER BRAKE UNIT (AOH)

43 Retaining ring
Remove the retaining ring and then remove the back-up ring and
push rod together with the hydraulic piston assembly.

45 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.

46 Retainer assembly
Extract the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If extracted from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.

48 O-ring
Using the needle (910-21200), remove the O-ring from the retainer
assembly.

50 Cup packing
Using the needle (910-21200), remove the cup packing from the
hydraulic piston assembly.

BR-4-4
 AIR BOOSTER BRAKE UNIT (AOH)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Clearance between cylinder shell and power piston

Unit: mm (in)
Maintenance standard Service limit
— 1.8 (0.071)

Push rod run-out

Unit: mm (in)
Maintenance standard Service limit
— 1.2 (0.047)

Clearance between hydraulic cylinder and piston

Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)

Power piston spring tension

Unit: N {kgf, lbf}
Maintenance
Model Service limit Remarks
standard
Type I
103.0 When compressed to
Type II —
{10.5, 23.2} 245.2 mm (9.65 in)
Type III
Type IV 103.0 When compressed to
—
Type V {10.5, 23.2} 175.2 mm (6.90 in)

BR-4-5
 AIR BOOSTER BRAKE UNIT (AOH)

REASSEMBLY
REASSEMBLY
Key point of reassembly

50 Cup packing
Install the back-up ring in the hydraulic piston groove. Using the cup
insert guide (910-23290), install the cup packing.
NOTE
z Pay attention to the installation direction of the cup pack-
ing.

46 Retainer assembly
Install the retainer assembly from the hydraulic piston side of the
push rod.
NOTE
z If installed from the power piston side, the oil seal inside
the retainer assembly may be damaged by the push rod
thread resulting in oil leaks.

45 Hydraulic piston assembly

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.

BR-4-6
 AIR BOOSTER BRAKE UNIT (AOH)

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.

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.
2. Secure the power piston rib with the holder (910-24831)
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
180~ 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-4-7
 AIR BOOSTER BRAKE UNIT (AOH)

FUNCTIONAL CHECK
SIMPLE TEST
1. Prepare an air pressure gauge 785 kPa {8 kgf/cm2, 114
psi}, hydraulic pressure gauges 19,614 kPa {200 kgf/cm2,
2,844 psi}, pipes and joints.
2. Remove the hydraulic cylinder plug air bleeder screw and
install a hydraulic pressure gauge 19,614 kPa {200 kgf/cm2,
2,844 psi}.
3. Remove the power cylinder shell oil plug and install an air
pressure gauge 785 kPa {8 kgf/cm2, 114 psi}.
4. Remove the wheel cylinder air bleeder screw and install a
hydraulic pressure gauge 19,614 kPa {200 kgf/cm2, 2,844
psi}.

TEST PROCEDURE
1. Air tightness test without load.
z This test is to check air-tightness from air lines. At first, keep
air pressure at the specified value.
z Coat soapy water around air pipes and connectors and
observe if bubbles appear. If bubbles appear, it shows leak-
age. Repair or replace faulty parts.
z Coat soapy water on the exhaust cover. Any bubble shows
the air tightness imperfection of relay valve inlet valve
(atmosphere side). In this case, replace the inlet valve.
2. Operational test with load.
z Keep air pressure at the specified value.
z When the brake pedal is depressed until the air pressure
gauge shows 588 kPa {6 kgf/cm2, 85 psi}, the hydraulic
gauge on the hydraulic cylinder plug shows above 12,259
to 13,632 kPa {125 to 139 kgf/cm2, 1,778 to 1,977 psi}. If it
shows below 12,259 to 13,632 kPa {125 to 139 kgf/cm2,
1,778 to 1,977 psi}, repair since the brake fluid may leak
from the hydraulic piston (packing cup or ball) or air mixes
in hydraulic system.
z When the brake pedal is depressed slowly, the air pressure
gauge and hydraulic pressure gauge pointers should raise
up in proportion to the pedal stroke. When the air pressure
reaches to maximum point, release the brake pedal. At this
time, the pressure should be returned quickly.
z If this response is not smooth, inspect by following the test
procedure above. If the air booster is not returned to the
non-operating condition, the relay valve does not slide
smoothly.
3. Air-tightness test with load.
Raise the air pressure to the specified value, inspect air
leakage with the brake pedal depressed.
If the air pressure falls, the relay valve inlet valve (atmo-
sphere side), piston assembly, power piston leather packing
or control tube is faulty.
BR-4-8
 AIR BOOSTER BRAKE UNIT (AOH)

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.

z Performance curve.

z Test method and rated values

Unit: kPa {kgf/cm2, psi}
Test item Test method Rated values
Apply a hydraulic pressure of 11,768 {120, 1,706} to the
Hydraulic tightness test hydraulic system and measure the time required for the 10 seconds or more
pressure to drop 981 {10, 142} when blocked.
Apply 588 {6, 85} compressed air to the air booster and
Air tightness test without load block the compressed air source and measure the pres- 39 {0.4, 6} or less
sure drop over 15 seconds.
Supply a command pressure to the control valve by
gradually depressing the brake pedal and measure the
Operation start pressure test 98 {1.0, 14} or less
command pressure at which the wheel cylinder hydrau-
lic pressure begins to rise.
Hydraulic cylinder hydraulic pressure of command 588 12,259 - 13,632 {125 - 139,
Operation test with full load
{6, 85}. 1,778 - 1,977}
Block the command pressure and reservoir supply pres-
Air tightness test with full load sure and measure the pressure drop in 15 seconds from 59 {0.6, 9} or less
the full load operation state and confirm air tightness.
Measure the wheel cylinder hydraulic pressure when
Residual pressure test 59 - 157 {0.6 - 1.6, 9 - 23}
the brake pedal has been released.
Loosen the air bleeder of the plug and apply a pressure
of 196 to 294 {2 to 3, 28 to 43} to the air booster to oper-
Detector switch operation test Must operate
ate the power piston and confirm that the switch is oper-
ating properly, using an electric tester.

BR-4-9
 AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)

AIR PRESSURE GOVERNOR

CONSTRUCTION

BR-5-1
 AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-5-2
 AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)

REASSEMBLY
Key point of disassembly
z Prior to reassembly, apply a coat of silicone grease to the
inner wall of the body, the outer surface of the piston and
the O-ring groove, O-ring, spring guide and adjusting screw.

6 Piston
Position the O-ring in the groove at the piston stem hole. Install the
valve on the piston with the small spring diameter end facing the
valve, and push the large spring diameter end into the groove in the
piston.

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Disconnect the check valve from the air reservoir and con-
nect a 981 kPa {10 kgf/cm2, 142 psi} pressure gauge to it.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.

FUNCTIONAL TEST
1. Gradually increase air pressure. When the air pressure
increase is stopped, ensure that the air pressure is within
the specified high pressure range.
Next, gradually decrease the air pressure and ensure that it
is within the low pressure range when the “hissing” sound is
heard.
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit
Low range 647 - 686 {6.6 - 7.0, 94 - 100} —
High range 765 - 814 {7.8 - 8.3, 111 - 118} —

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.

BR-5-3
 AIR PRESSURE GOVERNOR BRAKE UNIT (AOH)

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
CONSTRUCTION

BR-6-1
 AIR DRYER BRAKE UNIT (AOH)

DISASSEMBLY
DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.
Key point of disassembly

BR-6-2
 AIR DRYER BRAKE UNIT (AOH)

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
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

REASSEMBLY
REASSEMBLY
Key point of reassembly
14 Oil filter
Install the oil filter with the bend section of the net facing down.

11, 7 Filter
Be sure to install the filter with the thick, soft layer side facing up.

10 Desiccant
1. The standard weight of the desiccant to be used is 480 g
(16.93 oz). In the case of desiccant being purchased as a
repair kit, use the full contents of one bag.

BR-6-3
 AIR DRYER BRAKE UNIT (AOH)

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
 BRAKE LOCK BRAKE UNIT (AOH)

BRAKE LOCK
BRAKE LOCK SYSTEM

BR-7-1
 BRAKE LOCK BRAKE UNIT (AOH)

CONSTRUCTION
BRAKE LOCK SENSOR ASSEMBLY

BRAKE LOCK VALVEL

BR-7-2
 BRAKE LOCK BRAKE UNIT (AOH)

DISASSEMBLY AND REASSEMBLY

BRAKE LOCK VALVE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Body assembly 9. O-ring 17. Guide
2. Gasket 10. Spring 18. Cap
3. Plate assembly 11. Piston 19. O-ring
4. Valve assembly 12. O-ring 20. Spring
5. Valve seat 13. Exhaust 21. Valve
6. O-ring 14. Retaining ring 22. Plug
7. O-ring 15. Cap 23. Spring
8. 16. Shuttle 24. Valve
Marks “+” and “,” indicate that the key points of operation are explained in the text.
NOTE
z Numbers before part names do not indicate the disas-
sembly sequence.

CHECKING THE BRAKE LOCK SYSTEM

CONFIRMATION OF BRAKE LOCK OPERATION
1. After starting the engine, make sure the air meter needle
points above 588 kPa {6kgf/cm2, 85 psi}.
2. Pull the parking brake lever all the way up.
3. Make sure the operation indicator light (green) comes on.
4. Push the operation switch ON. The pressure light (orange)
comes on and the brake lock operates.
CONFIRMATION OF BRAKE LOCK RELEASE
1. Push the operation switch OFF.
2. The brake lock is released. Make sure the pressure light
(orange) goes out at the same time.
3. Return the parking brake lever all the way. Make sure the
operation indicator light (green) goes out.

BR-7-3
 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.
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

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-8-1
 BRAKE UNIT
AIR BRAKE UNIT

CONTENTS
SERVICE DATA .......................................... BR-1- 1 DISASSEMBLY AND REASSEMBLY..........BR-6- 2
SPECIFICATIONS ...................................... BR-1- 1 INSPECTION AFTER MOUNTING
SERVICE DATA .......................................... BR-1- 3 ON VEHICLE...............................................BR-6- 3
TIGHTENING TORQUE ............................. BR-1- 8 PARKING BRAKE VALVE .......................BR-7- 1
DIAGRAM OF PIPING ............................... BR-1-10 CONSTRUCTION........................................BR-7- 1
TOOLS .......................................................... BR-2- 1 DISASSEMBLY............................................BR-7- 3
BRAKE VALVE ........................................... BR-3- 1 INSPECTION...............................................BR-7- 7
REASSEMBLY.............................................BR-7- 8
= 241- 02228 AND 241-02224 =
FUNCTIONAL CHECK ...............................BR-7-10
CONSTRUCTION ....................................... BR-3- 1
DISASSEMBLY ........................................... BR-3- 2 CAB CONTROL VALVE ...........................BR-8- 1
INSPECTION .............................................. BR-3- 5 CONSTRUCTION........................................BR-8- 1
REASSEMBLY ............................................ BR-3- 7 DISASSEMBLY AND REASSEMBLY..........BR-8- 2
FUNCTIONAL CHECK ............................... BR-3- 9 FUNCTIONAL CHECK ................................BR-8- 3
= E6-H28 AND E6-H24 = TRAILER BRAKE HAND
CONSTRUCTION ...................................... BR-3-10 CONTROL VALVE......................................BR-9- 1
DISASSEMBLY .......................................... BR-3-11 CONSTRUCTION........................................BR-9- 1
INSPECTION ............................................. BR-3-13 DISASSEMBLY............................................BR-9- 2
REASSEMBLY ........................................... BR-3-16 INSPECTION...............................................BR-9- 3
FUNCTIONAL CHECK .............................. BR-3-17 REASSEMBLY.............................................BR-9- 4
AIR PRESSURE GOVERNOR .............. BR-4- 1 FUNCTIONAL CHECK ................................BR-9- 5
CONSTRUCTION ....................................... BR-4- 1 QUICK RELEASE VALVE .....................BR-10- 1
DISASSEMBLY AND REASSEMBLY ......... BR-4- 2 CONSTRUCTION......................................BR-10- 1
FUNCTIONAL CHECK ............................... BR-4- 3 DISASSEMBLY AND REASSEMBLY........BR-10- 1
AIR DRYER.................................................. BR-5- 1 FUNCTIONAL CHECK ..............................BR-10- 2
CONSTRUCTION ....................................... BR-5- 1 DOUBLE CHECK VALVE ....................... BR-11-1
DISASSEMBLY ........................................... BR-5- 2 CONSTRUCTION.......................................BR-11-1
INSPECTION .............................................. BR-5- 3 DISASSEMBLY AND REASSEMBLY.........BR-11-1
REASSEMBLY ............................................ BR-5- 3 FUNCTIONAL CHECK
INSPECTION AFTER MOUNTING (TYPE I ONLY) .........................................BR-11- 2
ON VEHICLE .............................................. BR-5- 6 PROTECTION VALVE ...........................BR-12- 1
OIL MIST SEPARATOR ........................... BR-6- 1 CONSTRUCTION......................................BR-12- 1
CONSTRUCTION ....................................... BR-6- 1 DISASSEMBLY AND REASSEMBLY........BR-12- 1
 FUNCTIONAL CHECK ............................. BR-12- 2 CONSTRUCTION ..................................... BR-16- 1
AIR BRAKE CHAMBER ........................ BR-13- 1 DISASSEMBLY AND REASSEMBLY ....... BR-16- 2
= NO. 20 = FUNCTIONAL CHECK ............................. BR-16- 2
CONSTRUCTION ..................................... BR-13- 1 = JIDOSHA KIKI =
DISASSEMBLY ......................................... BR-13- 2 CONSTRUCTION ..................................... BR-16- 3
INSPECTION ............................................ BR-13- 3 DISASSEMBLY AND REASSEMBLY ....... BR-16- 4
REASSEMBLY .......................................... BR-13- 3 FUNCTIONAL CHECK ............................. BR-16- 4
FUNCTIONAL CHECK ............................. BR-13- 5 2-WAY RELAY VALVE ........................... BR-17- 1
= NO. 24 AND NO. 30 = CONSTRUCTION ..................................... BR-17- 1
CONSTRUCTION ..................................... BR-13- 6 DISASSEMBLY......................................... BR-17- 2
DISASSEMBLY ......................................... BR-13- 7 INSPECTION ............................................ BR-17- 3
INSPECTION ............................................ BR-13- 8 REASSEMBLY.......................................... BR-17- 3
REASSEMBLY .......................................... BR-13- 8 FUNCTIONAL CHECK ............................. BR-17- 3
FUNCTIONAL CHECK ............................. BR-13- 9 MULTI-RELAY VALVE ............................ BR-18- 1
SPRING BRAKE CHAMBER ................ BR-14-1 CONSTRUCTION ..................................... BR-18- 1
= ANCHORLOCK = DISASSEMBLY AND REASSEMBLY ....... BR-18- 2
CONSTRUCTION ...................................... BR-14-1 INSPECTION ............................................ BR-18- 3
DISASSEMBLY AND REASSEMBLY ........ BR-14-2 FUNCTIONAL CHECK ............................. BR-18- 3
= MGM (TR3030-T) = SYNCHRO VALVE................................... BR-19- 1
CONSTRUCTION ...................................... BR-14-9 CONSTRUCTION ..................................... BR-19- 1
DISASSEMBLY AND REASSEMBLY ........ BR-14-9 DISASSEMBLY......................................... BR-19- 2
INSPECTION ............................................ BR-19- 3
= SANWA SEIKI =
REASSEMBLY.......................................... BR-19- 3
CONSTRUCTION .................................... BR-14-14
FUNCTIONAL CHECK ............................. BR-19- 3
DISASSEMBLY ........................................ BR-14-14
INSPECTION ........................................... BR-14-16 PRESSURE REDUCING VALVE ........ BR-20- 1
REASSEMBLY ......................................... BR-14-17 CONSTRUCTION ..................................... BR-20- 1
DISASSEMBLY AND REASSEMBLY ....... BR-20- 2
LOAD SENSING
INSPECTION ............................................ BR-20- 3
PROPORTION VALVE .......................... BR-15- 1 FUNCTIONAL CHECK ............................. BR-20- 3
CONSTRUCTION .................................... BR-15- 1
SUPPLY DUMP VALVE ........................ BR-21- 1
DISASSEMBLY ........................................ BR-15- 1
CONSTRUCTION .................................... BR-21- 1
INSPECTION ........................................... BR-15- 3
DISASSEMBLY AND REASSEMBLY ...... BR-21- 2
REASSEMBLY ......................................... BR-15- 3
INSPECTION ........................................... BR-21- 3
FUNCTIONAL CHECK ............................ BR-15- 3
FUNCTIONAL CHECK ............................ BR-21- 3
RELAY VALVE .......................................... BR-16- 1 NYLON TUBING ...................................... BR-22- 1
= NABCO =
 SERVICE DATA BRAKE UNIT (AIR)

SERVICE DATA
SPECIFICATIONS
Item Contents
Type Dual type
241-02228 (R.H.D. model)
JIDOSHA KIKI
Brake valve 241-02224 (L.H.D. model)
Model
E6-H28 (R.H.D. model)
NABCO
E6-H24 (L.H.D. model)
Type Piston type
Air pressure governor Pressure adjustment Low 706 {7.2, 102}
range kPa {kgf/cm2, psi} High 834 {8.5, 121}
Type Barrel type
Air dryer
Model DR-5
Oil mist separator Model MS-1
Type I Cam type (without release knob)
Type II Cam type (with release knob)
Parking brake valve
Type III Cam type (with release knob and secondary valve)
Type IV Cam type (without release knob and secondary valve)
Cab control valve Model PP-1B
Trailer brake hand control valve Cam type
Quick release valve Diaphragm type
Double check valve —
Protection valve Single type
Type Diaphragm type
Front Rear
Model No. 20
Air brake chamber No. 24 No. 30
Type I Type II
70.0
Maximum stroke mm (in) 58.0 (2.283) 63.0 (2.480)
(2.756)
Diaphragm type
Type
(Mechanically-actuated release)
ANCHORLOK SANWA SEIKI MGM
Model
Spring brake chamber 2430 3030 S-3 (3030) TR3030-T
70.0 (2.760) Service
57.0 63.5 63.5
Maximum stroke mm (in) side 63.5 (2.500)
(2.244) (2.500) (2.500)
Emergency side
Load sensing proportion valve (LSPV) Diaphragm type
Relay valve Coil spring type
2-way relay valve Diaphragm type
Multi-relay valve Piston type
Synchro valve Piston type
Pressure reducing valve Diaphragm type
Supply dump valve Piston type
Safety valve opening pressure kPa {kgf/cm2, psi} 932 - 971 {9.5 - 9.9, 135 - 141}
Check valve opening Supply reservoir fitted Less than 29 0.3, 4
pressure
Service reservoir fitted 2.0 - 3.9 {0.02 - 0.04, 0.3 - 0.6}
kPa {kgf/cm2, psi}

BR-1-1
 SERVICE DATA BRAKE UNIT (AIR)

Item Contents
Light ON pressure 422 - 481 {4.3 - 4.9, 61 - 70}
Type I
Light OFF pressure 422 - 530 {4.3 - 5.4, 61 - 77}
Light ON pressure 490 - 549 {5.0 - 5.6, 71 - 80}
Type II
*Air pressure switch Light OFF pressure 520 - 628 {5.3 - 6.4, 75 - 91}
kPa {kgf/cm2, psi} Light ON pressure 461 - 520 {4.7 - 5.3, 67 - 75}
Type III
Light OFF pressure 471 - 579 {4.8 - 5.9, 68 - 84}
Light ON pressure 490 - 549 {5.0 - 5.6, 71 - 80}
Type IV
Light OFF pressure 490 - 598 {5.0 - 6.1, 71 - 87}

z To identify the air pressure switch, confirm the identification

mark (operating pressure) stamped on the body.
Type Identification mark
I 4.5
II 5.5
III P52
IV P55

ANCHORLOK: Made by LEAR SIEGLER, INC. ANCHORLOK DIVISION

SANWA SEIKI: Made by SANWA SEIKI MANUFACTURING CO., LTD.
JIDOSHA KIKI: Made by JIDOSHA KIKI CO., LTD.
NABCO: Made by NABCO Ltd.

BR-1-2
 SERVICE DATA BRAKE UNIT (AIR)

SERVICE DATA
BRAKE VALVE
Models 241-02228 and 241-02224
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Plunger O.D. 19.9 (0.783) 19.80 (0.7795)
Piston O.D. 52.1 (2.051) 51.95 (2.0453)
Relay piston O.D. 66.5 (2.618) 66.30 (2.6102)
241-02228 23.6 (0.929)
Sleeve spring
241-02224 13.7 (0.539)
Piston spring (Large) 29.5 (1.161)
Piston spring 241-02228 20.0 (0.787)
(Small) 241-02224 22.0 (0.866)
Spring free length
Piston return spring 60.5 (2.382)
Primary inlet valve spring 41.6 (1.638)
Relay piston 241-02228 36.7 (1.445)
spring 241-02224 46.4 (1.827)
Secondary inlet valve spring 24.4 (0.961)
342 When compressed to
241-02228
{34.9, 77} 21.3 mm (0.839 in)
Sleeve spring
216 When compressed to
241-02224
{22.0, 49} 12.6 mm (0.496 in)
214 When compressed to
Piston spring (Large)
{21.8, 48.1} 26.5 mm (1.043 in)
40 When compressed to
241-02228
Piston spring {4.1, 9} 19.1 mm (0.752 in)
(Small) 34 When compressed to
241-02224
Spring tension {3.5, 7} 19.4 mm (0.764 in)
N {kgf, lbf} 97 When compressed to
Piston return spring
{9.9, 22} 17.0 mm (0.669 in)
37 When compressed to
Primary inlet valve spring
{3.8, 8} 14.3 mm (0.563 in)
24 When compressed to
241-02228
Relay piston {2.4, 5} 12.8 mm (0.504 in)
spring 33 When compressed to
241-02224
{3.4, 7} 12.8 mm (0.504 in)
47 When compressed to
Secondary inlet valve spring
{4.8, 11} 12.9 mm (0.508 in)
Pressure difference between primary and
Less than 20 {0.2, 3}
secondary outlets kPa {kgf/cm2, psi}
12.0 - 18.0
Brake pedal free play
(0.472 - 0.709)

BR-1-3
 SERVICE DATA BRAKE UNIT (AIR)

Models E6-H28 and E6-H24

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pedal pin holes I.D. 10.0 (0.394) 10.25 (0.4035)
Roller pin O.D. 10.0 (0.394) 9.85 (0.3878)
I.D. 10.0 (0.394) 10.20 (0.4016)
Roller E6-H28 17.2 (0.677) 17.00 (0.6693)
O.D.
E6-H24 21.9 (0.862) 21.70 (0.8543)
Mounting plate bushing I.D. 26.5 (1.043) 26.70 (1.0512)
Plunger O.D. 26.5 (1.043) 26.20 (1.0315)
E6-H28 30.0 (1.181)
Main spring
E6-H24 28.4 (1.118)
E6-H28 22.6 (0.890)
Sub spring
E6-H24 23.2 (0.913)
Spring free length
Relay piston spring 39.5 (1.555)
Piston return spring 61.6 (2.425)
Primary valve spring 32.1 (1.264)
Secondary valve spring 16.5 (0.650)
Stem spring 29.5 (1.161)
235 When compressed to
E6-H28
{24.0, 53} 27.7 mm (1.091 in)
Main spring
211 When compressed to
E6-H24
{21.5, 47} 27.0 mm (1.063 in)
503 When compressed to
E6-H28
{51.3, 113} 19.4 mm (0.764 in)
Sub spring
335 When compressed to
E6-H24
{34.2, 75} 20.1 mm (0.791 in)
Spring tension
46 When compressed to
N {kgf, lbf} Relay piston spring
{4.7, 10} 12.1 mm (0.476 in)
103 When compressed to
Piston return spring
{10.5, 23} 14.6 mm (0.575 in)
44 When compressed to
Primary valve spring
{4.5, 10} 14.3 mm (0.563 in)
25 When compressed to
Secondary valve spring
{2.6, 6} 11.0 mm (0.433 in)
74 When compressed to
Stem spring
{7.5, 17} 19.9 mm (0.783 in)
Pressure difference between primary and Less than
secondary outlets kPa {kgf/cm2, psi} 20 {0.2, 3}
12.0 - 18.0
Brake pedal free play
(0.472 - 0.709)

BR-1-4
 SERVICE DATA BRAKE UNIT (AIR)

AIR PRESSURE GOVERNOR

Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
686 - 726
Low range
{7.0 - 7.4, 100 - 105}
Pressure adjustment range
814 - 863
High range
{8.3 - 8.8, 118 - 125}

PARKING BRAKE VALVE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
38.1 - 38.5
Distance from body end to cam holder assembly Use shims to adjust
(1.500 - 1.516)
Type I
31.4 (1.236) 30.4 (1.197)
Type II
Main spring
Type III
Free length 29.6 (1.165) 28.6 (1.126)
Type IV
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)

TRAILER BRAKE HAND CONTROL VALVE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Distance between body end and exhaust 38.3 - 38.7
Use shims to adjust
valve seat end (1.508 - 1.524)
Main spring 31.4 (1.236) 30.4 (1.197)
Free length Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)

AIR BRAKE CHAMBER

Unit: mm (in)
Item Maintenance standard Service limit Remarks
No.20 115.1 (4.531)
Front
No.24 170.0 (6.693)
Return spring free length No.30 170.0 (6.693)
Rear TR3030-T
222.3 (8.752)
(MGM)
137 When compressed to
No.20
{14.0, 31} 70.0 mm (2.756 in)
Front
Return spring tension 178 When compressed to
No.24
N {kgf, lbf} [18.2, 40} 89.0 mm (3.504 in)
178 When compressed to
Rear No.30
{18.2, 40} 89.0 mm (3.504 in)

BR-1-5
 SERVICE DATA BRAKE UNIT (AIR)

LOAD SENSING PROPORTION VALVE (LSPV)

Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
+30º 686 {7.0, 100}
Operat- 304 - 363
Pressure on brake chamber 0º
ing arm {3.1 - 3.7, 44 - 53}
side
angle 157 - 216
-30º
{1.6 - 2.2, 23 - 31}

2-WAY RELAY VALVE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
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 Less than
discharge pressure kPa {kgf/cm2, psi} 29 {0.3, 4}

MULTI-RELAY VALVE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Piston spring 52.5 (2.067) 49.0 (1.929)
Free length
Valve spring 23.5 (0.925) 21.0 (0.827)
When compressed to
Piston spring 20 {2.0, 4}
32.0 mm (1.260 in)
Tension N {kgf, lbf}
When compressed to
Valve spring 52 {5.3, 12}
13.0 mm (0.512 in)

SYNCHRO VALVE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
More than
Clearance between lower valve and valve guide
0.28 (0.011)
More than
Clearance between piston and body
0.28 (0.011)
Leakage amount to delivery Less than
Air leakage test and exhaust ports 30 (1.1)
m (Imp fl oz) Leakage amount from Less than
exhaust port 30 (1.1)
Pressure at which valve
432 - 490
opens and delivery pres-
{4.4 - 5.0, 63 - 71}
Operating test sure rises
kPa {kgf/cm2, psi} Supply and control pressure
when delivery pressure is 0 363 - 422
{3.7 - 4.3, 53 - 61}
kPa {0 kgf/cm2, 0 psi}

BR-1-6
 SERVICE DATA BRAKE UNIT (AIR)

PRESSURE REDUCING VALVE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Free length 32.0 (1.260)
Valve spring Tension When compressed to
121 {12.37, 27}
N {kgf, lbf} 28.5 mm (1.122 in)

SUPPLY DUMP VALVE

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Main spring 40.4 (1.591) 36.0 (1.417)
Free length
Valve spring 20.5 (0.807) 19.0 (0.748)
When compressed to
Main spring 167 {17.0, 37}
29.0 mm (1.142 in)
Tension N {kgf, lbf}
When compressed to
Valve spring 34 {3.5, 8}
13.5 mm (0.531 in)

BR-1-7
 SERVICE DATA BRAKE UNIT (AIR)

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Sleeve screw 1 - 3 {0.1 - 0.3, 0.7 - 2.2}
Piston mounting bolt 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
241- Sleeve 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
02228,241-
02224 Cover assembly mounting bolt 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
Plate assembly mounting bolt 12 - 19 {1.2 - 1.9, 9 - 14}
Brake valve
Pedal setscrew 5 - 8 {0.5 - 0.8, 3.6 - 5.8}
Mounting plate mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10.1}
E6- Upper piston installing nut 6 - 8 {0.6 - 0.8, 4.3 - 5.8}
H28,E6-
H24 Lower body mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Taper plug 29 - 39 {3.0 - 4.0, 22 - 29}
Air pressure governor Lock nut 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Case 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}
Air dryer
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}
Piston mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Cartridge mounting bolt 2 - 4 {0.2 - 0.4, 1.4 - 2.9}
Oil mist separator Purge chamber mounting bolt 9 - 14 {0.9 - 1.4, 6.5 - 10}
Thermostat clamp mounting screw 1.5 - 2.5 {0.15 - 0.25, 1.1 - 1.8}
Heater 20 - 29 {2.0 - 3.0, 14 - 22}
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}
Sealing nut 25 - 34 {2.5 - 3.5, 18 - 25}
Cab control valve Tighten to 2 {0.2, 1.4} and then locate,
Castellated nut
keeping torque below 4.4 {0.45, 3}.
Trailer brake hand control Handle head mounting screw 3.4 - 4.9 {0.35 - 0.50, 2.5 - 3.6}
valve Cover mounting screw 5.4 - 7.4 {0.55 - 0.75, 4.0 - 5.4}
Double check valve (Type I only) Nipple 34 - 44 {3.5 - 4.5, 25 - 33}
Brake chamber mounting nut 81 - 108 {8.3 - 11.0, 60 - 80}
No. 20 Clamp band mounting nut and bolt 15 - 20 {1.5 - 2.0, 11 - 14}
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
Air brake chamber
Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
No. 24
Clamp band mounting nut and bolt 20 - 25 {2.0 - 2.6, 14 - 19}
No. 30
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
ANCHOR-
Spring brake chamber Clamp band mounting nut 25 - 33 {2.5 - 3.4, 18 - 25}
LOK
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}

BR-1-8
 SERVICE DATA BRAKE UNIT (AIR)

Unit: N·m {kgf·m, ft·lbf}

Item Tightening torque
Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
SANWA Screw 2.3 {0.23, 1.7}
(S-3) Clamp band mounting nut 20 - 25 {2.0 - 2.6, 14 - 19}
Clevis lock nut 39 - 59 {4.0 - 6.0, 29 - 43}
Spring brake Brake chamber mounting nut 167 - 186 {17.0 - 19.0, 123 - 137}
chamber
Clamp band mounting nut 27 - 34 {2.8 - 3.5, 20 - 25}
MGM Clevis lock nut 44 - 54 {4.5 - 5.5, 33 - 40}
TR3030-T
Release stud nut
(When install the release stud and nut in the car- 13.7 {1.4, 10}
rying pocket)
Cover mounting bolt 4 - 7 {0.4 - 0.7, 2.9 - 5.1}
Relay valve (NABCO only)
Exhaust check mounting screw 3 - 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}
Multi-relay valve Cover and lower body 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}
Supply dump valve Cover mounting bolt 10 - 20 {1.0 - 2.0, 7 - 14}
4.76 (0.1874) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
Tube O.D. 8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut
Steel brake mm (in) 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
tube joints 12.0 (0.472) 59 - 78 {6.0 - 8.0, 43 - 58}
15.0 (0.591) 69 - 93 {7.0 - 9.5, 51 - 69}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}

BR-1-9
 SERVICE DATA BRAKE UNIT (AIR)

DIAGRAM OF PIPING
Model CK series

Model CK tractor (For TAIWAN)

BR-1-10
 SERVICE DATA BRAKE UNIT (AIR)

Model CK tractor

Model CK tractor (For HONG KONG)

BR-1-11
 SERVICE DATA BRAKE UNIT (AIR)

Model CK tractor (For AUSTRALIA)

Model CKC series

BR-1-12
 SERVICE DATA BRAKE UNIT (AIR)

Model CKC tractor

Model CW series

BR-1-13
 SERVICE DATA BRAKE UNIT (AIR)

Model CW series (For HONG KONG)

Model CW tractor

BR-1-14
 SERVICE DATA BRAKE UNIT (AIR)

Model CG series

Model CG series (For AUSTRALIA)

BR-1-15
 SERVICE DATA BRAKE UNIT (AIR)

Model CG series (For HONG KONG)

BR-1-16
 TOOLS BRAKE UNIT (AIR)

TOOLS
BRAKE VALVE
Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and
Description Shape
number

Needle
Used when removing O-rings.
910-21200

Insert tool
Used when installing the relay piston O-ring.
910-24461

Retainer
Used when inserting pistons into place.
910-24590

BR-2-1
 BRAKE VALVE BRAKE UNIT (AIR)

BRAKE VALVE
= 241-02228 AND 241-02224 =
CONSTRUCTION

BR-3-1
 BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.

3. Tilt the cab upward.

WARNING
WARNING
ELECTRIC TILT TYPE
z After tilting the cab upward, make sure the tilt cylinder tilt
stopper is securely locked.

WARNING
WARNING
MANUAL TILT TYPE
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.

BR-3-2
 BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Pedal cover + 20. Relay piston assembly 39. Exhaust cover assembly
2. Cotter pin 21. Relay piston spring 40. Washer
3. Washer ,+ 22. O-ring 41. O-ring
4. Straight pin + 23. O-ring 42. O-ring
5. L-pin 24. Relay piston 43. Retainer
6. Cotter pin + 25. O-ring 44. Secondary inlet valve spring
7. Washer 26. O-ring 45. Valve retainer
8. Straight pin ,+ 27. Bolt , 46. Secondary inlet valve
9. Roller 28. Spring seat 47. Cover
10. Mounting plate assembly 29. Piston spring (Small) 48. Retaining ring
11. Boot 30. Piston spring (Large) 49. Retainer
12. Plunger + 31. O-ring 50. O-ring
13. Mounting plate 32. Piston 51. O-ring
14. Cover assembly 33. Screw 52. Washer
+ 15. O-ring , 34. Sleeve 53. Primary inlet valve spring
16. Retaining ring 35. Washer 54. Washer
17. Sleeve spring 36. Spring , 55. Primary inlet valve
,+ 18. Piston assembly 37. Spring 56. Body
19. Piston return spring 38. Retaining ring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-3
 BRAKE VALVE BRAKE UNIT (AIR)

Key point of disassembly

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.

15 O-ring
Using the needle (910-21200), remove the O-ring from the cover
groove.

18 Piston assembly, 20 Relay piston assembly

Secure the body assembly with the socket wrench [width across
flats: 14 mm (0.55 in)] secured in a vise, loosen the screw, and
remove the piston assembly and relay piston assembly.
NOTE
z When loosening the body, be sure to hold the piston by
hand as it jumps out because of the spring pressure in
the body.

22, 23, 25 O-ring

Using the needle (910-21200), remove the O-ring from the groove
in the primary piston and secondary piston.

BR-3-4
 BRAKE VALVE BRAKE UNIT (AIR)

27 Bolt
Secure the piston assembly in a vise and disassemble the piston
assembly using the socket wrench [width across flats: 14 mm (0.55
in)].
NOTE
z When securing the piston assembly in a vise, do not
secure the valve seat. Be careful not to damage it.

31 O-ring
Using the needle (910-21200), remove the O-ring from the piston
groove.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Plunger outside diameter

Unit: mm (in)
Maintenance standard Service limit
19.9 (0.783) 19.80 (0.7795)

Piston outside diameter

Unit: mm (in)
Maintenance standard Service limit
52.1 (2.051) 51.95 (2.0453)

BR-3-5
 BRAKE VALVE BRAKE UNIT (AIR)

Relay piston outside diameter

Unit: mm (in)
Maintenance standard Service limit
66.5 (2.618) 66.30 (2.6102)

Spring free length

Unit: mm (in)
Maintenance stan-
Item Service limit
dard
241-02228 23.6 (0.929)
Sleeve spring
241-02224 13.7 (0.539)
Piston spring (Large) 29.5 (1.161)
Piston spring 241-02228 20.0 (0.787)
(Small) 241-02224 22.0 (0.866)
Piston return spring 60.5 (2.382)
Primary inlet valve spring 41.6 (1.638)
Relay piston 241-02228 36.7 (1.445)
spring 241-02224 46.4 (1.827)
Secondary inlet valve spring 24.4 (0.961)

Spring tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
342 When compressed to
241-02228
Sleeve {34.9, 77} 21.3 mm (0.839 in)
spring 216 When compressed to
241-02224
{22.0, 49} 12.6 mm (0.496 in)
214 When compressed to
Piston spring (Large)
{21.8, 48.1} 26.5 mm (1.043 in)
40 When compressed to
Piston 241-02228
{4.1, 9} 19.1 mm (0.752 in)
spring
34 When compressed to
(Small) 241-02224
{3.5, 7} 19.4 mm (0.764 in)
97 When compressed to
Piston return spring
{9.9, 22} 17.0 mm (0.669 in)
Primary inlet valve 37 When compressed to
spring {3.8, 8} 14.3 mm (0.563 in)
24 When compressed to
241-02228
Relay pis- {2.4, 5} 12.8 mm (0.504 in)
ton spring 33 When compressed to
241-02224
{3.4, 7} 12.8 mm (0.504 in)
Secondary inlet valve 47 When compressed to
spring {4.8, 11} 12.9 mm (0.508 in)

BR-3-6
 BRAKE VALVE BRAKE UNIT (AIR)

REASSEMBLY
REASSEMBLY
Key point of reassembly
z Align the alignment mark (scribed during disassembly)
when installing the cover assembly and mounting plate.

55 Primary inlet valve

When assembling the primary inlet valve, pay attention to the instal-
lation position of the washer and retainer.
NOTE
z After installing each part, make sure the retaining ring
fits correctly in the body groove.

46 Secondary inlet valve

When assembling the secondary inlet valve, pay attention to the
installation position of the washer.
NOTE
z After installing each part, make sure the retaining ring
fits correctly in the cover groove.

34 Sleeve
After assembling the sleeve assembly, apply silicone grease so
that the spring is just concealed.
: 1 - 2.9 N·m {0.1 - 0.3 kgf·m, 0.7 - 2.2 ft·lbf}

27 Bolt
Secure the piston in a vise and assemble the piston assembly
using the socket wrench [width across flats: 14 mm (0.55 in)].
: 5 - 8 N·m {0.5 - 0.8 kgf·m, 3.6 - 5.8 ft·lbf}
NOTE
z When securing the piston assembly in a vise, do not
secure the valve seat. Be careful not to damage it.

BR-3-7
 BRAKE VALVE BRAKE UNIT (AIR)

22 O-ring
Using the insert tool (910-24461), install the O-ring onto the relay
piston.

18 Piston assembly
Install the primary piston assembly onto the body and secure the
piston assembly with the retainer (910-24590).
NOTE
z Before removing the retainer (910-24590), remove retain-
ing ring 17.

BR-3-8
 BRAKE VALVE BRAKE UNIT (AIR)

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Connect air pressure gauges to air discharge lines on the
primary and secondary sides, as close to the brake valve as
possible. These gauges should be capable of registering
more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.

FUNCTIONAL TEST
1. Gradually depress the brake pedal while observing the
pressure gauge on the primary side. When the gauge regis-
ters the first pressure increase, measure the pedal angle to
the floor. The pedal angle is correct if it agrees with the
value indicated in the performance characteristic curve. If it
is outside the specified value, adjust the length of the push
rod or the pedal angle (by means of the stopper bolt located
below the pedal) to the specified value.

Pedal setscrew
： 5 - 8 N·m {0.5 - 0.8 kgf·m, 3.6 - 5.8 ft·lbf}
2. Next, depress the brake pedal further to determine a point
at which an abrupt pressure rise takes place. Beyond this
point, the air pressure will rise rapidly to the air reservoir
pressure. Also check to be sure that just before the brake
pedal is depressed fully, the air pressure reservoir pressure
is equal to the brake pressure and the brake pedal can still
be depressed further.
3. Check the air pressure gauge on the secondary side to
ensure that its indication always increases proportionally
within less than 25 kPa {0.25 kgf/cm2, 4 psi} of the gauge
indication on the primary side during the test.
4. Also check to see that all air is discharged smoothly from
the discharge line without residual air pressure.

BR-3-9
 BRAKE VALVE BRAKE UNIT (AIR)

= E6-H28 AND E6-H24 =

CONSTRUCTION

BR-3-10
 BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY
REMOVAL
Key point of removal
1. Chock the front and rear road wheels.
2. Completely discharge compressed air from the air reservoir.
3. Tilt the cab upward.

WARNING
WARNING
ELECTRIC TILT TYPE
z After tilting the cab upward, make sure the tilt cylinder tilt
stopper is securely locked.

WARNING
WARNING
MANUAL TILT TYPE
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.

BR-3-11
 BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Pedal assembly 20. O-ring , 39. Piston
2. Lower body assembly 21. Retaining ring 40. O-ring
,+ 3. E-ring 22. Special washer 41. Retaining ring
4. Stem plate 23. O-ring retainer 42. Special washer
5. Stem spring 24. O-ring 43. O-ring retainer
6. Upper body 25. O-ring 44. O-ring
+ 7. Piston assembly 26. Secondary valve spring 45. O-ring
8. Bushing 27. Valve retainer 46. Primary valve spring
9. O-ring , 28. Lower valve 47. Valve retainer
10. Piston return spring 29. Retaining ring , 48. Upper valve
11. Sleeve 30. Primary valve assembly 49. Pedal
12. Relay piston 31. Nut 50. Cotter pin
13. O-ring 32. Lock washer 51. Pin
14. O-ring 33. Special washer 52. Roller pin
15. Relay piston spring 34. Stem 53. Roller
16. Retaining washer 35. Spring seat 54. Boot
17. Exhaust check 36. Sub spring seat 55. Plunger
18. Exhaust cover 37. Main spring 56. Mounting plate
19. Lower body 38. Sub spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-3-12
 BRAKE VALVE BRAKE UNIT (AIR)

Key point of reassembly

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.

3 E-ring
Insert a Phillips screw driver fixed in a vise into the relay piston
exhaust passage until it contacts the stem portion, and remove the
E-ring.
NOTE
z When removing the E-ring, hold the piston by hand so
that it does not pop out.

7 Piston assembly
Place a standard screwdriver in the sleeve end groove to prevent
the sleeve from rotating while loosening the nut when disassem-
bling the piston assembly.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Pedal pin hole inside diameter

Unit: mm (in)
Maintenance standard Service limit
10.0 (0.394) 10.25 (0.4035)

BR-3-13
 BRAKE VALVE BRAKE UNIT (AIR)

Roller pin outside diameter

Unit: mm (in)
Maintenance standard Service limit
10.0 (0.394) 9.85 (0.3878)

Roller
Unit: mm (in)
Maintenance stan-
Item Service limit
dard
Inside diameter 10.0 (0.394) 10.20 (0.4016)
E6-H28 17.2 (0.677) 17.00 (0.6693)
Outside diameter
E6-H24 21.9 (0.862) 21.70 (0.8543)

Mounting plate bushing inside diameter

Unit: mm (in)
Maintenance standard Service limit
26.5 (1.043) 26.70 (1.0512)

Plunger outside diameter

Unit: mm (in)
Maintenance standard Service limit
26.5 (1.043) 26.20 (1.0315)

BR-3-14
 BRAKE VALVE BRAKE UNIT (AIR)

Spring free length

Unit: mm (in)
Item Maintenance standard Service limit
E6-H28 30.0 (1.181)
Main spring
E6-H24 28.4 (1.118)
E6-H28 22.6 (0.890)
Sub spring
E6-H24 23.2 (0.913)
Relay piston spring 39.5 (1.555)
Piston return spring 61.6 (2.425)
Primary valve spring 32.1 (1.264)
Secondary valve spring 16.5 (0.650)
Stem spring 29.5 (1.161)

Spring tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
235 When compressed to
E6-H28
Main {24.0, 53} 27.7 mm (1.091 in)
spring 211 When compressed to
E6-H24
{21.5, 47} 27.0 mm (1.063 in)
503 When compressed to
E6-H28
{51.3, 113} 19.4 mm (0.764 in)
Sub spring
335 When compressed to
E6-H24
{34.2, 75} 20.1 mm (0.791 in)
46 When compressed to
Relay piston spring
{4.7, 10} 12.1 mm (0.476 in)
103 When compressed to
Piston return spring
{10.5, 23} 14.6 mm (0.575 in)
44 When compressed to
Primary valve spring
{4.5, 10} 14.3 mm (0.563 in)
Secondary valve 25 When compressed to
spring {2.6, 6} 11.0 mm (0.433 in)
74 When compressed to
Stem spring
{7.5, 17} 19.9 mm (0.783 in)

BR-3-15
 BRAKE VALVE BRAKE UNIT (AIR)

REASSEMBLY
REASSEMBLY
Key point of reassembly
z Apply lithium soap-base grease or equivalent to the sliding
surfaces of the inlet valve, body and relay piston.
z When assembling the O-ring, be sure to apply lithium soap-
base grease or equivalent to the O-ring. Fill the O-ring
groove with this grease.
z Apply molybdenum disulfide grease or equivalent to the
sliding surfaces (10-mm dia. pin and plunger) of pedal.
z After fitting each retaining ring, make sure it is securely
located in its groove.
z Align the alignment mark (scribed during disassembly)
when installing the cover assembly and mounting plate.

48 Upper valve
Assemble the primary valve assembly paying attention to the orien-
tation of O-ring retainer and special washer.
NOTE
z Check that the retaining ring is assembled securely.

39 Piston
Reassembling the piston complete.
Place the piston, main spring, sub spring, spring seat, special
washer, and spring washer, in that order, on the sleeve. Then
tighten the sleeve with the nut.
: 6 - 8 N·m {0.6 - 0.8 kgf·m, 4.3 - 5.8 ft·lbf}

NOTE
z Place a standard screwdriver secured in a vise in the
sleeve end groove to prevent the sleeve from rotating,
then tighten the nut.

28 Lower valve
Assemble the secondary valve assembly paying attention to the O-
ring retainer and the special washer.
NOTE
z Check that the retaining ring is installed correctly.

BR-3-16
 BRAKE VALVE BRAKE UNIT (AIR)

3 E-ring
1. Holding the relay piston with one hand so that the spring will
not shoot it out, insert the stem into the relay piston. Then
put the upper body on a Phillips screwdriver so that the end
of the stem will touch the tip of the screwdriver.

2. Install the return spring, piston complete, stem spring, and

stem plate onto the upper body.
Then, pushing down the stem plate, insert the E-ring into
the groove of the stem.

FUNCTIONAL CHECK

FUNCTIONAL TEST
To check brake valve performance, prepare a pressure gauge
capable of measuring a maximum pressure of 981 kPa {10 kgf/cm2,
142 psi} and its operating characteristic diagram. First, install the
pressure gauge onto the discharge side of upper side. Gradually
depress the brake pedal, and check that the pressure gauge
increases when brake pedal is depressed to an angle of 3.5 to 4.5º
(E6-H28) or 2.8 to 3.5º (E6-H24).
Next, check the lower side pressure. Check that lower side pres-
sure increases smoothly following the pressure increase in the
upper side.

BR-3-17
 AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)

AIR PRESSURE GOVERNOR

CONSTRUCTION

BR-4-1
 AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-4-2
 AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)

REASSEMBLY
Key point of disassembly
Prior to reassembly, apply a coat of silicone grease to the inner wall
of the body, the outer surface of the piston and the O-ring groove,
O-ring, spring guide and adjusting screw.

6 Piston
Position the O-ring in the groove at the piston stem hole. Install the
valve on the piston with the small spring diameter end facing the
valve, and push the large spring diameter end into the groove in the
piston.

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Disconnect the check valve from the air reservoir and con-
nect a 981 kPa {10 kgf/cm2, 142 psi} pressure gauge to it.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.

FUNCTIONAL TEST
1. Gradually increase air pressure. When the air pressure
increase is stopped, ensure that the air pressure is within
the specified high pressure range.
Next, gradually decrease the air pressure and ensure that it
is within the low pressure range when the “hissing” sound is
heard.
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit
Low range 686 - 726 {7.0 - 7.4, 100 - 105}
High range 814 - 863 {8.3 - 8.8, 118 - 125}

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.

BR-4-3
 AIR PRESSURE GOVERNOR BRAKE UNIT (AIR)

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-4-4
 AIR DRYER BRAKE UNIT (AIR)

AIR DRYER
CONSTRUCTION

BR-5-1
 AIR DRYER BRAKE UNIT (AIR)

DISASSEMBLY
DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-5-2
 AIR DRYER BRAKE UNIT (AIR)

Key point of disassembly

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
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

REASSEMBLY
REASSEMBLY
Key point of reassembly
26 Valve assembly
When inserting the valve assembly into the body, be careful not to allow the O-
ring to get caught in the cutout of the body.

BR-5-3
 AIR DRYER BRAKE UNIT (AIR)

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.

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-5-4
 AIR DRYER BRAKE UNIT (AIR)

11 Filter
With the softer layer of the filter facing downward, insert it into the
case.

7 Check valve
Push the raised portion in the center of the check valve to fit it in the
case cover.
NOTE
z Apply grease to the projecting portion of the check valve
to facilitate easy fitting.

6 Case cover
Place the filter plate and set spring in the case already containing
desiccant. After that, fit the case cover and push on with the special
tool and then secure with a bolt, spring washer and nut.
： 4 - 7 N·m {0.4 - 0.7 kgf·m, 2.9 - 5.1 ft·lbf}
WARNING
WARNING
z Be careful when installing as the set spring setting load
is almost 726 N {74 kgf, 163 lbf}.

3 Stopper ring
Lever the stopper ring into the groove by moving a flat-blade screw-
driver outward.

BR-5-5
 AIR DRYER BRAKE UNIT (AIR)

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-5-6
 OIL MIST SEPARATOR BRAKE UNIT (AIR)

OIL MIST SEPARATOR

CONSTRUCTION

BR-6-1
 OIL MIST SEPARATOR BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Purge chamber 8. Bolt 14. Retaining ring
2. O-ring 9. Lock washer 15. Valve body
3. Cartridge assembly 10. Piston 16. O-ring
4. O-ring 11. O-ring 17. Thermostat assembly
5. Gasket 12. Valve spring 18. Heater
6. Stop ring 13. Valve 19. Body
7. Exhaust cover
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-6-2
 OIL MIST SEPARATOR BRAKE UNIT (AIR)

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”.
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-6-3
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

PARKING BRAKE VALVE

CONSTRUCTION
Type I

Type II

BR-7-1
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

Type III

Type IV

BR-7-2
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY
Type I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. Handle assembly 10. Return spring 19. O-ring
2. Spring seat , 11. Cam holder assembly 20. Piston
, 3. Spring 12. Shim(s) , 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-7-3
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY
Type II

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-7-4
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

DISASSEMBLY
Type III

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. Handle assembly 14. Spring holder + 27. C-ring
2. Spring seat 15. O-ring , 28. Feed valve seat
, 3. Spring , 16. Valve spring 29. O-ring
4. Spring seat 17. C-ring 30. Feed valve
5. Cover 18. Feed valve 31. O-ring
6. Shim(s) 19. O-ring 32. Piston
7. Main spring 20. Valve holder , 33. Exhaust valve seat
, 8. Valve spring 21. O-ring , 34. Cam ring
9. Piston assembly , 22. Plunger 35. Guide
10. Return spring 23. O-ring 36. O-ring
, 11. Cam holder assembly 24. Boot 37. Holder
12. Shim(s) 25. O-ring 38. Pin
13. C-ring 26. C-ring 39. Body
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-7-5
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

Type IV

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+ 1. Handle assembly 14. Spring holder + 27. C-ring
2. Spring seat 15. O-ring , 28. Feed valve seat
, 3. Spring , 16. Valve spring 29. O-ring
4. Spring seat 17. C-ring 30. Feed valve
5. Cover 18. Feed valve 31. O-ring
6. Shim(s) 19. O-ring 32. Piston
7. Main spring 20. Valve holder , 33. Exhaust valve seat
, 8. Valve spring 21. O-ring , 34. Cam ring
9. Piston assembly , 22. Plunger 35. Guide
10. Return spring 23. O-ring 36. O-ring
, 11. Cam holder assembly 24. Boot 37. Holder
12. Shim(s) 25. O-ring 38. Pin
13. C-ring 26. C-ring 39. Body
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-7-6
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

Key point of removal

1 Handle assembly
The handle head is spring-loaded. When removing the screw, hold
the handle head by hand.

15 Type I, Type II C-ring

27 Type III and Type IV C-ring
Remove the piston assembly C-ring, and remove the feed valve
seat and the O-ring. Also remove the C-ring from the feed valve,
and remove the feed valve. Remove the O-ring from the piston
O.D. section.
NOTE
z When removing the C-ring from the feed valve, pay atten-
tion not to expand it excessively.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Spring free length

Unit: mm (in)
Maintenance
Item Service limit
standard
Type I
31.4 (1.236) 30.4 (1.197)
Type II
Main spring
Type III
29.6 (1.165) 28.6 (1.126)
Type IV
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)

BR-7-7
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

REASSEMBLY
Key point of reassembly
z Reassemble after greasing the O-ring groove, pin, shim,
and sliding sections.
22 Type I, Type II, 34 Type III, Type IV 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 Type I, Type II, 33 Type III, Type IV 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 Type I, Type II, 28 Type III, Type IV 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.

22 Plunger (Type III, Type IV only)

Apply grease abundantly to the secondary valve side ID surface of
the body, then install the plunger fitted with an O-ring, the feed
valve and valve holder, in that order.
NOTE
z The feed valve seating surface must be kept free from
dirt, etc.

BR-7-8
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

16 Valve spring (Type III, Type IV only)

Install the C-ring onto the feed valve, and install the valve spring
and the spring holder onto the feed valve in that order, then secure
by fitting a C-ring.
NOTE
z Pay attention not to expand the C-ring excessively when
fitting to the feed valve.
z Check that the valve spring is correctly placed on the C-
ring fitted to the feed valve.
1. Plunger 6. C-ring
2. O-ring 7. Valve spring
3. Feed valve 8. O-ring
4. O-ring 9. Spring holder
5. Valve holder 10. C-ring

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).

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.

BR-7-9
 PARKING BRAKE VALVE BRAKE UNIT (AIR)

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.

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-7-10
 CAB CONTROL VALVE BRAKE UNIT (AIR)

CAB CONTROL VALVE

CONSTRUCTION

BR-8-1
 CAB CONTROL VALVE BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY I

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cover 6. Valve 10. Plunger
2. Sealing ring 7. Sealing nut 11. Spring pin
3. Cotter pin 8. Plunger spring 12. Button
4. Nut 9. O-ring 13. Body
5. Washer
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-8-2
 CAB CONTROL VALVE BRAKE UNIT (AIR)

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL TESTS
1. Connect an air pressure gauge 981 kPa {10 kgf/cm2, 142
psi}, min. to the discharge line as close to the parking brake
valve as possible.
2. Increase air pressure inside the air reservoir to the specified
value.
3. Check all air lines for leakage. Repair the line if necessary.

AIR LEAKAGE TEST

1. Apply compressed air of 686 kPa {7 kgf/cm2, 100 psi} to the
air reservoir and keep pushing the button in. Apply soapy
water to the joint of the body and cover and the exhaust port
to check for leakage.
Standard: There should be no leakage from the joint. Leak-
age from the exhaust port should produce only soapy water
bubbles of less than 25 mm (0.98 in) diameter in 5 seconds.
2. Apply compressed air of 686 kPa {7 kgf/cm2, 100 psi} to the
air reservoir and keep the button pulled out. Apply soapy
water to the exhaust port to check for leakage.
Standard: Leakage from the exhaust port should produce
only soapy water bubbles of less than 25 mm (0.98 in)
diameter in 5 seconds.

FUNCTIONAL TEST
1. Apply compressed air of 686 kPa {7 kgf/cm2, 100 psi} to the
air reservoir and keep pushing the button in. After that,
close the cut valve and slowly open the drain cock to
reduce the air reservoir pressure. Using a pressure gauge
(1), check the pressure when the button pops out.
Standard: The button should automatically pop out at 235 to
314 kPa {2.4 to 3.2 kgf/cm2, 34 to 46 psi}.
2. Apply compressed air of 422 kPa {4.3 kgf/cm2, 61 psi} to
the air reservoir and push the button in. Check if the button
remains pushed in if the hand is released.
Standard: The button should remain pushed in at 422 kPa
{4.3 kgf/cm2, 61 psi}.

BR-8-3
 TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)

TRAILER BRAKE HAND CONTROL VALVE

CONSTRUCTION

BR-9-1
 TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-9-2
 TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)

Key point of disassembly

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
z When removing the C-ring from the feed valve, pay atten-
tion not to expand it excessively.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Free length
Unit: mm (in)
Maintenance stan-
Item Service limit
dard
Main spring 31.4 (1.236) 30.4 (1.197)
Return spring 29.0 (1.142) 26.0 (1.024)
Valve spring 28.5 (1.122) 27.0 (1.063)

BR-9-3
 TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)

REASSEMBLY
Key point of reassembly
z Reassemble after greasing the O-ring groove, pin, shim and
sliding sections.
20 Cam ring
Apply grease to the cam ring sliding surface, and install the cam
ring so that the pin is positioned as shown.

19 Exhaust valve seat

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.

BR-9-4
 TRAILER BRAKE HAND CONTROL VALVE BRAKE UNIT (AIR)

8 Valve spring
Install the valve spring by checking that it is correctly positioned on
the feed valve C-ring.

FUNCTIONAL TEST
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.

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-9-5
 QUICK RELEASE VALVE BRAKE UNIT (AIR)

QUICK RELEASE VALVE

CONSTRUCTION

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cover 3. Filter 5. Body
2. O-ring 4. Diaphragm

BR-10-1
 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-10-2
 DOUBLE CHECK VALVE BRAKE UNIT (AIR)

DOUBLE CHECK VALVE

CONSTRUCTION

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Nipple 3. Guide 5. Body
2. Packing 4. Valve

BR-11-1
 DOUBLE CHECK VALVE BRAKE UNIT (AIR)

FUNCTIONAL CHECK (TYPE I ONLY)

FUNCTIONAL TEST O
C
U
F
S
E
T
L
A
N
dr)(It.,f/il
y
9
0
P
k
4
3
8
5
m
c
7
2
1
p
A
B
n
a
s
w
tfl
u
o
h
e
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-11-2
 PROTECTION VALVE BRAKE UNIT (AIR)

PROTECTION VALVE
CONSTRUCTION

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Retaining ring 4. Shim(s) 6. O-ring
2. Plate 5. Piston 7. Body
3. Spring

BR-12-1
 PROTECTION VALVE BRAKE UNIT (AIR)

FUNCTIONAL CHECK

PREPARATIONS FOR FUNCTIONAL CHECKS

1. Connect air pressure gauges to the inlet and outlet of the
protection valve. Each pressure gauge should be capable
of registering more than 981 kPa {10 kgf/cm2, 142 psi}.
2. Increase air pressure to the specified level inside the air
reservoir.
3. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.

FUNCTIONAL TEST
Maintain both the inlet and outlet of the protection valve at a pres-
sure of 686 kPa {7 kgf/cm2, 100 psi}. Decrease the air pressure at
the outlet for the specified length of time.
The minimum holding pressure at the inlet should be in the range of
422 to 461 kPa {4.3 to 4.7 kgf/cm2, 61 to 67 psi} regardless of
decreases in the outlet air pressure.
Specified length of time:
z 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-12-2
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

AIR BRAKE CHAMBER

= NO. 20 =
CONSTRUCTION
Type I

Type II

BR-13-1
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY
Type I and Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Boot (Type II only) 4. Diaphragm + 7. Non-pressure plate
,+ 2. Clamp band 5. Push rod
3. Pressure plate 6. Return spring
Marks “+” and “,” indicate that the key points of operation are explained in the text.
Key point of disassembly
z Put matching marks on the pressure plate, non-pressure
plate, and clamp band.

2 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.

BR-13-2
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

7 Non-pressure plate
Place the push rod side downward on the work bench. Hold down
the non-pressure plate and remove the hand clamp.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Return spring
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
Free length 115.1 (4.531)
Tension N When compressed to
137 {14.0, 31}
{kgf, lbf} 70.0 mm (2.756 in)

BR-13-3
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

REASSEMBLY
Key point of reassembly
2 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}

BR-13-4
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

FUNCTIONAL CHECK
AIR LEAKAGE TEST
Supply to the inlet air at a pressure of 490 to 785 kPa {5 to 8 kgf/
cm2, 71 to 114 psi}. Apply soapy water over the entire pressure
plate, the clamp portion, and the area around the non-pressure
plate hole. Ensure that there is no leakage. If leakage exists, dis-
assemble the brake chamber and determine the cause.

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-13-5
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

= NO. 24 AND NO. 30 =

CONSTRUCTION

BR-13-6
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Clamp band 4. Push rod
, 2. Pressure plate 5. Return spring
, 3. Diaphragm 6. Non-pressure plate
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-13-7
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

Key point of disassembly

z Put matching marks on the pressure plate, non-pressure
plate, and clamp band.

1 Clamp band
The pressure plate is pushed up by the spring force of the return
spring.
Remove the clamp band while pressing the pressure plate against
the spring force.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Return spring
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
Free length 170.0 (6.693)
Tension When compressed to
178 {18.2, 40}
N {kgf, lbf} 89.0 mm (3.504 in)

REASSEMBLY
Key point of reassembly
3 Diaphragm
Assemble the diaphragm so that it is at the center of the non-pres-
sure plate.
2 Pressure plate
Assemble the pressure plate to the non-pressure plate by aligning
the match marks.
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}

BR-13-8
 AIR BRAKE CHAMBER BRAKE UNIT (AIR)

z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = No. 24
225 mm (8.858 in)
L = No. 30
60 mm (2.362 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-13-9
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

SPRING BRAKE CHAMBER

= ANCHORLOK =
CONSTRUCTION

BR-14-1
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY

REMOVAL
1. Shift the parking brake lever to the PARK position.

2. Chock the front and rear road wheels.

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-14-2
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

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-14-3
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

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
instructions may result in forceful release of the spring
chamber and its contents which could cause death,
severe personal 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 con-
tents which could cause death, severe personal injury
and/or properly damage. Remove complete spring
brake and replace with new unit.

BR-14-4
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

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
WARNING
WARNING
z If the recommended X dimension is not correct for cham-
ber size and torque value, the spring brake should be
replaced.

BR-14-5
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

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
sidewall 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. Dis-
assembly of the release tool from the chamber assem-
bly will result in the forceful release of the compression
spring and pressure plate and may result in severe per-
sonal injury or death.

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

BR-14-6
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

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
z First follow steps 1 through 9 for mechanical release.

1. Follow steps 1 through 9 for mechanical release of spring

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.
7. Check if diaphragm is properly seated between the 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.
8. Apply a maximum of 827 kPa {8.4 kgf/cm2, 120 psi} air
pressure to the service port and check diaphragm seal for

BR-14-7
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

leakage by applying a water and soap solution to the ser-

vice clamp area (no leakage allowed).
9. Uncage compression spring and reassemble release tool in
side pocket of adapter.
10. Replace dust plug in release tool keyhole in center of cham-
ber.
WARNING
WARNING
z After reassembly, check for proper emergency and ser-
vice operation.

z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
Model: 2340
L = 360 mm (14.173 in)
Model: 3030
L = 60 mm (2.362 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}

INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
INSTRUCTIONS FOR MECHANICAL RELEASE OF
SPRING BRAKE for details.)
z Check the position mark (R or L) on the chamber, which
was applied during dismounting, and install the assem-
bly on the same side it was dismounted from.
z After mounting, uncage compression spring and reas-
semble release tool in side pocket of adapter. Install dust
plug in release tool key hole in center of chamber.

BR-14-8
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

= MGM (MODEL TR3030-T) =

CONSTRUCTION

DISASSEMBLY
REMOVAL
1. Shift the parking brake lever to the “PARK” position.
2. Chock the front and rear road wheels.
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-14-9
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Breather tube 5. Service push rod 9. Nut
+, 2. Service clamp assembly 6. Service diaphragm 10. Washer
3. Service housing 7. Adapter assembly 11. Release stud
4. Service return spring 8. Weather seal plug
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-14-10
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

Key point of disassembly

z Make an alignment mark on the clamp band before
removal.

2 Service clamp assembly

When removing the clamp band, be sure to press the chamber in.

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check
for scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Return spring free length

Unit: mm (in)
Maintenance standard Service limit
222.3 (8.752) —

REASSEMBLY
REASSEMBLY
Key point of reassembly
2 Service clamp assembly
1. Apply an air pressure of 637 to 834 kPa {6.5 to 8.5 kgf/cm2, 92
to 121 psi} through the emergency port to deflect the main
spring.
2. Position the diaphragm, push rod, return spring and chamber on
the service side of the bulkhead in that order.
3. Install the clamp band while compressing it with a press.
: 27 - 34 N·m {2.8 - 3.5 kgf·m, 20 - 25 ft·lbf}

4. After tightening the clamp band, check for air leakage. Apply an
air pressure of 961 kPa {9.8 kgf/cm2, 139 psi} through the ser-
vice port to check for air leaks at or around the clamp. The emer-
gency port should be open to the atmosphere during leak tests.

BR-14-11
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 60 mm (2.362 in)
: 44 - 54 N·m {4.5 - 5.5 kgf·m, 33 - 40 ft·lbf}

INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
INSTRUCTION FOR MECHANICAL RELEASE OF SPRING
BRAKE for details.)
z Check the position mark (R or L) on the chamber, which
was applied during dismounting, and install the assem-
bly on the same side it was dismounted from.
z After mounting, uncage compression spring and reas-
semble release stud in carrying pocket. Install weather
seal plug in release stud key hole in center of chamber.

INSTRUCTION FOR MECHANICAL RELEASE

OF SPRING BRAKE
CAUTION
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 chamber and its contents which
could cause death, severe personal injury and/or prop-
erly damage. remove complete spring brake and replace
with new unit.

1. Block the wheels to prevent the vehicle from moving.

2. Remove the release stud and nut from the carrying pocket on
the brake chamber assembly.
3. Remove the weather seal plug from the end of the spring cham-
ber.

BR-14-12
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

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.
CAUTION
z Instruction 6 listed below only applies when spring brake
is not pressurized. If air pressure is used to compress
spring, do not tighten release stud nut more than finger
tight. Torquing the nut can cause pressure plate damage
resulting in sudden release of the spring causing death
or severe personal injury.

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 use INPACT WRENCH.)
: 67 N·m {6.8 kgf·m, 49 ft·lbf} max
Do not over torque release stud nut.

7. To ensure compression spring is fully caged, the stud length

beyond the nut (see “X” above) should measure: 82 mm (3.228
in) Minimum

Reset procedure
1. Unscrew and remove the release stud nut.
2. Reinstall the release stud and nut in the carrying pocket. Install
the weather seal plug in the housing opening.

BR-14-13
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

= SANWA SEIKI =
CONSTRUCTION

DISASSEMBLY
REMOVAL
1. Shift the parking brake lever to the PARK position.
2. Chock the front and rear road wheels.
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-14-14
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+ 1. Clamp band ,+ 8. Clamp band 14. Screw
2. Chamber assembly 9. End cap assembly 15. Spring locator
3. Diaphragm 10. Spring locator 16. O-ring
4. Push rod assembly 11. Main spring 17. Return spring
5. Push rod return spring 12. Spring support 18. Adapter rod
6. Screw 13. Diaphragm 19. Bulkhead
7. Adapter plate
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-14-15
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

Key point of disassembly

z Make an alignment mark on the clamp band before
removal.

1 Clamp band
When removing the clamp band, be sure to press the chamber in.

8 Clamp band
While pushing down on the end cap with a press, remove the clamp
band on the emergency side.
NOTE
z Be careful when working on the main spring since it has
a spring preload of approximately 5,786 N {590 kgf, 4,267
lbf} with a stroke length of approximately 90 mm (3.5 in).

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

BR-14-16
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

REASSEMBLY
REASSEMBLY
Key point of reassembly
8 Clamp band
1. While aligning the alignment mark and compressing the
chamber with a pressing tool, install the clamp band.
: 20 - 25 N·m {2.0 - 2.6 kgf·m, 14 - 18 ft·lbf}
NOTE
z Ensure that the diaphragm is located in the center.
z Tighten the clamp band by lightly tapping the perimeter
with a plastic hammer.
2. After tightening the clamp band, carry out the following
inspection.
z Apply an air pressure of 785 kPa {8 kgf/cm2, 114 psi}
through the emergency port to check for air leaks at or
around the clamp perimeter and the O-ring section of the
bulkhead.
z Repeatedly apply air pressure to, and discharge it from, the
emergency port several times to ensure that the adapter
rod operates properly. If it does not, disassemble and reas-
semble the adapter rod.
z Gradually increase air pressure until the adapter rod returns
to the original position. At this point, read the air pressure
on the indicator. The air pressure should be less than 637
kPa {6.5 kgf/cm2, 92 psi}.
1 Clamp band
1. Apply an air pressure of 637 to 834 kPa {6.5 to 8.5 kgf/cm2,
92 to 121 psi} through the emergency port to deflect the
main spring.
2. Position the diaphragm, push rod, return spring and cham-
ber on the service side of the bulkhead in that order.

3. Install the clamp band while compressing it with a press.

: 20 - 25 N·m {2.0 - 2.6 kgf·m, 14 - 18 ft·lbf}

4. After tightening the clamp band, check for air leakage.

Apply an air pressure of 785 kPa {8 kgf/cm2, 114 psi} through the
service port to check for air leaks at or around the clamp. The
emergency port should be open to the atmosphere during leak
tests.

BR-14-17
 SPRING BRAKE CHAMBER BRAKE UNIT (AIR)

z Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
L = 60 mm (2.362 in)
: 39 - 59 N·m {4.0 - 6.0 kgf·m, 29 - 43 ft·lbf}

INSTALLATION
Mount the spring brake chamber assembly.
NOTE
z Before mounting, release the spring brake. (Refer to
INSTRUCTIONS FOR MECHANICAL RELEASE OF
SPRING BRAKE for details.)
z Check the position mark (R or L) on the chamber, which
was applied during dismounting, and install the assem-
bly on the same side it was dismounted from.
z After mounting, uncage compression spring and reas-
semble release tool in side pocket of adapter. Install dust
plug in release tool key hole in center of chamber.

BR-14-18
 LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)

LOAD SENSING PROPORTION VALVE

CONSTRUCTION

DISASSEMBLY
REMOVAL
Key point of removal
z Remove any mud or dirt attached to the exteriors before
disassembling.
NOTE
z Before removing the load sensing proportion valve, mea-
sure the installation length of the wire and confirm that
the indicator is aligned with the alignment mark (under
no load conditions).

BR-15-1
 LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Pipe retainer 11. Diaphragm retainer 20. Connecting rod assembly
2. Pipe 12. Diaphragm 21. Oil seal
3. Cover 13. Diaphragm protector 22. Oil seal
4. Diaphragm guide 14. Retaining ring 23. Plunger
, 5. Retaining ring 15. Piston guide 24. O-ring
6. Piston 16. Cap 25. Plunger
7. Valve spring 17. Hexagon socket screw 26. O-ring
8. Valve 18. Exhaust check 27. Plunger return spring
9. Piston packing 19. Cam 28. Cap
10. Piston 29. Body
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-15-2
 LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

REASSEMBLY
Key point of reassembly
5 Retaining ring
When reassembling the piston assembly, install the valve, valve
spring and spring seat, and secure these parts with a retaining ring.

INSTALLATION
Key point of installation
Install the load sensing proportion valve in the vehicle and set the
wire length as follows:
1. Set the installation length of the wire so that the indicator is
aligned with the alignment mark on the body. Then fix the
wire.
2. Measure the installation length of the wire and make sure it
is equal with the length measured before removal.
NOTE
z The wire length should be set with the vehicle parked on
a level surface under no load conditions.

FUNCTIONAL CHECK
AIR LEAKAGE TEST
1. Close the brake chamber side (delivery port) and supply
pressurized air at 686 kPa {7 kgf/cm2, 100 psi} from the
brake valve side (supply port) to move the operating arm up
and down between MAX and MIN. Coat soapy water
around the body and check for air leakage.
2. Air leakage from the exhaust port must be below 25 mm
(0.98 in) in soapy water bubbles within 5 minutes after fixing
the operating arm in position.

BR-15-3
 LOAD SENSING PROPORTION VALVE BRAKE UNIT (AIR)

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.
Unit: kPa {kgf/cm2, psi}
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-15-4
 RELAY VALVE BRAKE UNIT (AIR)

RELAY VALVE
= NABCO =
CONSTRUCTION

BR-16-1
 RELAY VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

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-16-2
 RELAY VALVE BRAKE UNIT (AIR)

= JIDOSHA KIKI =
CONSTRUCTION

BR-16-3
 RELAY VALVE BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cover 7. Body 12. O-ring
2. O-ring 8. Retaining ring 11. O-ring
3. Relay valve 9. Exhaust cover 14. Spring
4. O-ring 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-16-4
 2-WAY RELAY VALVE BRAKE UNIT (AIR)

2-WAY RELAY VALVE

CONSTRUCTION

BR-17-1
 2-WAY RELAY VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-17-2
 2-WAY RELAY VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Valve spring
Maintenance Service
Item Remarks
standard limit
Free length
46.0 (1.811)
mm (in)
Tension When compressed to
59 {6.05, 13}
N {kgf, lbf} 30.0 mm (1.181 in)

REASSEMBLY
Key point of reassembly
8 Diaphragm
When installing the diaphragm, pay attention not to allow dirt and
dust to contact the cover and body surfaces.
: 12 - 15 N·m {1.2 - 1.5 kgf·m, 9 - 11 ft·lbf}

FUNCTIONAL CHECK
AIR LEAKAGE TEST
Allowable air leakage Test pressure
Part Remarks
mili liter (Imp fl oz)/min. kPa {kgf/cm2, psi}
0 - 294
10 (0.4)
{0 - 3, 0 - 43}
Feed valve Tank pressure
294 - 785
0 (0)
{3 - 8, 43 - 114}
0 - 294
10 (0.4)
{0 - 3, 0 - 43} Tank pressure: 785 kPa
Exhaust valve Signal pressure
294 - 785 {8 kgf/cm2, 114 psi}
0 (0)
{3 - 8, 43 - 114}
0 - 294
10 (0.4)
{0 - 3, 0 - 43}
Double check valve Signal pressure In both directions
294 - 785
0 (0)
{3 - 8, 43 - 114}
Each tightening sec-
0 (0) 785 {8, 114}
tion

BR-17-3
 2-WAY RELAY VALVE BRAKE UNIT (AIR)

AIR DIFFERENTIAL PRESSURE TEST

Confirm the difference between signal pressure (A or B) and dis-
charge pressure.
Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit
29 {0.3, 4} —

BR-17-4
 MULTI-RELAY VALVE BRAKE UNIT (AIR)

MULTI-RELAY VALVE
CONSTRUCTION

BR-18-1
 MULTI-RELAY VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Dust seal rubber 11. Valve spring 21. O-ring
2. C-ring 12. Valve retainer 22. O-ring
3. Dust seal rubber 13. Valve 23. O-ring
4. Body (B) 14. Piston (C) 24. Piston (B)
5. O-ring 15. O-ring 25. O-ring
6. C-ring 16. O-ring 26. O-ring
7. O-ring retainer 17. O-ring 27. Piston spring
8. O-ring 18. Cover 28. Body (A)
9. O-ring 19. O-ring
10. Valve holder plate 20. Piston (A)

BR-18-2
 MULTI-RELAY VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Free length
Unit: mm (in)
Item Maintenance standard Service limit
Piston spring 52.5 (2.067) 49.0 (1.929)
Valve spring 23.5 (0.925) 21.0 (0.827)

Tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
When compressed to
Piston spring 20 {2.0, 4}
32.0 mm (1.260 in)
When compressed to
Valve spring 52 {5.3, 12}
13.0 mm (0.512 in)

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL TESTS
1. Connect an air pressure gauge (min. indication: 981 kPa
{10 kgf/cm2, 142 psi}) in the line between the brake and
multi-relay valves and multi-relay and supply dump valves
(trailer brake service line), each.
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. With the IN (3) of the hand control lever maintained at a
pressure of 686 kPa {7 kgf/cm2, 100 psi}, change air pres-
sure on the IN (1) of the primary brake valve and the IN (2)
of the secondary brake valve from 0 to 686 kPa {0 to 7 kgf/
cm2, 0 to 100 psi}.
Air pressure between the multi-relay valve and supply dump
valve should conform to the characteristic curve (A) shown
in the performance characteristic diagram.
2. With the IN (1) of the primary brake valve and the IN (2) of
the secondary brake valve maintained at zero pressure,
change air pressure on the IN (3) of the hand control valve

BR-18-3
 MULTI-RELAY VALVE BRAKE UNIT (AIR)

(on the secondary valve side) from 686 to 0 kPa {7 to 0 kgf/

cm2, 100 to 0 psi}.
Air pressure between the multi-relay valve and supply dump
valve should conform to the characteristic curve (A) shown
in the performance characteristic diagram.
NOTE
z Before conducting functional tests, first stabilize air
pressure at approximately 0. This is necessary because
moving the hand control valve to the Parking position
may not cause a pressure drop at some valves (if the
secondary valve is equipped).

BR-18-4
 SYNCHRO VALVE BRAKE UNIT (AIR)

SYNCHRO VALVE
CONSTRUCTION

BR-19-1
 SYNCHRO VALVE BRAKE UNIT (AIR)

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

BR-19-2
 SYNCHRO VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Clearance between lower valve and valve guide
Unit: mm (in)
Maintenance standard Service limit
More than 0.28 (0.011)

Clearance between piston and body

Unit: mm (in)
Maintenance standard Service limit
More than 0.28 (0.011)

REASSEMBLY
Key point of reassembly
11 Valve guide
Assemble the lower valve assembly paying attention to the orienta-
tion of the valve guide.
NOTE
z After assembling, check that the retaining ring is
installed correctly.

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: mili liter (Imp fl oz)/min.
Maintenance standard Service limit
Less than 30 (1.1)

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: mili liter (Imp fl oz)/min.
Maintenance standard Service limit
Less than 30 (1.1)

BR-19-3
 SYNCHRO VALVE BRAKE UNIT (AIR)

OPERATING TEST
1. Verify the pressure at which the delivery pressure starts ris-
ing when pressure is applied to both the supply and control
ports at the same time. The pressure is gradually increased.
Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit
432 - 490 {4.4 - 5.0, 63 - 71}

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}.
Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit
363 - 422 {3.7 - 4.3, 53 - 61}

BR-19-4
 PRESSURE REDUCING VALVE BRAKE UNIT (AIR)

PRESSURE REDUCING VALVE

CONSTRUCTION

BR-20-1
 PRESSURE REDUCING VALVE BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cover 6. Nut 10. seal
2. Spring seat 7. Lock washer 11. Valve
3. Spring 8. Seat 12. Valve seat
4. Nut 9. Diaphragm 13. Body

BR-20-2
 PRESSURE REDUCING VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Valve spring
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
Free length 32.0 (1.260)
Tension When compressed to 28.5
121 12.37, 27
N {kgf, lbf} mm (1.122 in)

FUNCTIONAL CHECK
FUNCTIONAL TEST
Raise the inlet pressure gradually from 0 to 686 kPa {0 to 7 kgf/
cm2, 0 to 100 psi}, and check that the outlet pressure stabilizes at
736 kPa {7.5 kgf/cm2, 107 psi}.

BR-20-3
 SUPPLY DUMP VALVE BRAKE UNIT (AIR)

SUPPLY DUMP VALVE

CONSTRUCTION

BR-21-1
 SUPPLY DUMP VALVE BRAKE UNIT (AIR)

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Bracket 8. O-ring 14. O-ring
2. Cover 9. Dust seal rubber 15. Valve holder plate
3. O-ring 10. C-ring 16. Valve spring
4. Main spring 11. Dust seal plate 17. Valve retainer
5. Piston 12. Valve holder 18. Valve
6. O-ring 13. O-ring 19. Body
7. O-ring

BR-21-2
 SUPPLY DUMP VALVE BRAKE UNIT (AIR)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
Spring free length
Unit: mm (in)
Item Maintenance standard Service limit
Main spring 40.4 (1.591) 36.0 (1.417)
Valve spring 20.5 (0.807) 19.0 (0.748)

Spring tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
When compressed to
Main spring 167 {17.0, 37}
29.0 mm (1.142 in)
When compressed to
Valve spring 34 {3.5, 8}
13.5 mm (0.531 in)

FUNCTIONAL CHECK
PREPARATIONS FOR FUNCTIONAL CHECKS
1. Install an air pressure gauge (min. indication: 981 kPa {10
kgf/cm2, 142 psi}) and an air bleed valve as close to the ser-
vice port as possible.
2. Install an air pressure gauge (min. indication: 981 kPa {10
kgf/cm2, 142 psi}) as close to the emergency port as possi-
ble.
3. Increase air pressure to the specified level inside the air
reservoir.
4. Check all air lines to ensure that there is no leakage. Cor-
rect any faulty connection.
FUNCTIONAL CHECK
Gradually decrease air pressure at the service port. When it
reaches the specified value of 490 to 549 kPa {5 to 5.6 kgf/cm2, 71
to 80 psi}, air pressure at the emergency port should begin to dis-
charge.
AIR LEAKAGE TEST
1. When air pressure of 0 to 834 kPa {0 to 8.5 kgf/cm2, 0 to
121 psi} is applied to the service port, rear port and tank
port, no leakage should occur at the exhaust port.
2. When the rear port and tank port are operated at an air
pressure of 0 to 834 kPa {0 to 8.5 kgf/cm2, 0 to 121 psi}, no
leakage should occur at the exhaust port and service port.
3. When the service port is operated at an air pressure of 0 to
834 kPa {0 to 8.5 kgf/cm2, 0 to 121 psi}, no leakage should
occur at any point.

BR-21-3
 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 fitting 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.

BR-22-1
 NYLON TUBING BRAKE UNIT (AIR)

5. Protect nylon tubing from battery acid.

The service nylon tubing will be marked with name, number,
type, size and manufacturing code designations. This mark-
ing is intended to positively identify the tubing and prevent
substitution of inferior quality tubing.

BR-22-2
 PARKING BRAKE

CONTENTS
SERVICE DATA................................. BR-1- 1 REASSEMBLY ................................. BR-4- 6
SPECIFICATIONS......................... BR-1- 1 REASSEMBLY.............................. BR-4- 6
SERVICE DATA............................. BR-1- 2 INSTALLATION............................. BR-4- 7
TIGHTENING TORQUE ................ BR-1- 2 ADJUSTMENT.................................. BR-4- 8
TOOLS............................................... BR-2- 1
PARKING BRAKE CONTROL ......... BR-3- 1 = UNIT NAME CB31 =
DISASSEMBLY AND
REASSEMBLY ............................. BR-3- 1 CONSTRUCTION .............................. BR-5- 1
ADJUSTMENT ............................. BR-3- 2 DISASSEMBLY ................................ BR-5- 2
REMOVAL .................................... BR-5- 2
= UNIT NAME CB41 = DISASSEMBLY..............................BR-5- 3
INSPECTION ..................................... BR-5- 4
CONSTRUCTION .............................. BR-4- 1 REPAIR AND REPLACEMENT......... BR-5- 5
DISASSEMBLY ................................ BR-4- 2 REPLACING THE BRAKE
REMOVAL .................................... BR-4- 2 LINING.......................................... BR-5- 5
DISASSEMBLY ............................. BR-4- 3 REASSEMBLY ................................. BR-5- 6
INSPECTION ..................................... BR-4- 4 REASSEMBLY.............................. BR-5- 6
REPAIR AND REPLACEMENT ........ BR-4- 5 INSTALLATION............................. BR-5- 8
REPLACING THE BRAKE ADJUSTMENT.................................. BR-5- 9
LINING.......................................... BR-4- 5
 SERVICE DATA PARKING BRAKE

SERVICE DATA
SPECIFICATIONS
Unit name 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) 254 (10.00) 305 (12.00)
Width 60 (2.36) 75 (2.95)
Brake lining mm (in)
Thickness 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 1 INTERNAL EXPANSION DUO SERVO (AKEBONO BRAKE MAKE)
ABBREVIATION (Unit: in)

CB PARKING BRAKE
3 12
4 10

BR-1-1
 SERVICE DATA PARKING BRAKE

SERVICE DATA
Unit: mm (in)
Maintenance
Item Service limit Remarks
standard
When a pull at 196 N {20
Parking brake lever stroke 3 - 12 notches —
kgf, 44 lb} is applied
CB41 254 (10.00) 256 (10.08)
Brake drum I.D.
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.
CB41 5.7 (0.224) 3.1 (0.122) Thickness of remaining lin-
Brake lining thickness
CB31 6.1 (0.240) 3.7 (0.146) ing
0.2 - 0.3 Back up 8 notches from
CB41 —
Clearance between the brake (0.008 - 0.012) zero clearance.
drum and lining 0.2 - 0.3 Back up 8 to 9 notches from
CB31 —
(0.008 - 0.012) zero clearance.

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
CB41 17 - 23 {1.7 - 2.3, 12 - 17}
Brake lever mounting nut
CB31 15 - 23 {1.5 - 2.3, 11 - 17}
CB41 196 - 235 {20 - 24, 145 - 174}
Brake assembly mounting bolt
CB31 137 - 157 {14 - 16, 101 - 116}
CB41 686 - 981 {70 - 100, 506 - 723} Width across flats = 58 mm (2.28 in)
Companion flange nut
CB31 598 - 745 {61 - 76, 441 - 550} Width across flats = 50 mm (1.97 in)
Brake drum mounting bolt 118 - 137 {12 - 14, 87 - 101}
Propeller shaft mounting bolt 211 - 240 {21.5 - 24.5, 156 - 177}

BR-1-2
 TOOLS PARKING BRAKE

TOOLS
Tool name and number Description Shape

Return spring remover

Used to remove the brake shoe return
99878 Z0000
spring

Return spring replacer Used to install the brake shoe return

99879 Z0000 spring

Socket wrench
99535 Z0003 Used to remove/install main shaft com-
Width across flats = 50 mm panion flange
(1.97 in) NOTE
Socket wrench z Manual transmission model
99535 Z0074 only
Width across flats = 58 mm
(2.28 in)

BR-2-1
 PARKING BRAKE CONTROL PARKING BRAKE

PARKING BRAKE CONTROL

DISASSEMBLY AND REASSEMBLY

1. Parking brake cover 4. Wire bracket 6. Clevis pin

2. Parking brake switch 5. Parking brake wire 7. Brake lock sensor assembly
3. Parking brake lever assembly
NOTE
z Numbers before part names do not indicate the disassembly sequence.

BR-3-1
 PARKING BRAKE CONTROL PARKING BRAKE

ADJUSTMENT
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.
I
Item Maintenance standard Service limit
Lever stroke 3 - 12 notches —

z Also check for proper installation of the parking brake lever.

ADJUSTMENT OF PARKING BRAKE LEVER STROKE

Adjust the parking brake lever stroke after adjusting the brake lining
clearance. (For adjusting the brake lining clearance, refer to
“ADJUSTMENT” in the unit name CB41 and CB31 sections.)
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 12 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-3-2
 CB41

= UNIT NAME CB41 =

CONSTRUCTION

BR-4-1
 DISASSEMBLY CB41

DISASSEMBLY
z Chock the wheels so that the vehicle cannot move.
z Shift the gear into first or reverse so as not to turn the pro-
peller shaft.

REMOVAL
Key point of removal
1. Unlock the pinion nut, and remove the pinion nut using
socket wrench (99535 Z0074). Remove the companion
flange and O-ring.
NOTE
z When loosening the pinion nut, support the transmission
case securely so that it does not move.
z Do not re-use the pinion nut after removal.

BR-4-2
 DISASSEMBLY CB41

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

2 Return spring
Using the return spring remover (99878 Z0000), remove the brake
shoe return spring.

BR-4-3
 INSPECTION CB41

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

BRAKE DRUM
Inside diameter
Unit: mm (in)
Maintenance standard Service limit
254 (10.00) 256 (10.08)

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)
Maintenance standard Service limit
0.02 (0.0008) 0.2 (0.008)

BRAKE LINING THICKNESS

Unit: mm (in)
Maintenance
Service limit Remarks
standard
Thickness of remaining
5.7 (0.224) 3.1 (0.122)
lining

BR-4-4
 REPAIR AND REPLACEMENT CB41

REPAIR AND REPLACEMENT

REPLACING THE BRAKE LINING
1. Drill out rivet heads on the rear of the brake shoe assembly,
remove the rivets with a punch and detach the brake lining.
NOTE
z Do not drill the brake shoe.

1. Drill 3. Brake shoe

2. Rivet 4. Brake lining

2. Align the brake shoe with the lining at the rivet holes and
place in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining

BR-4-5
 REASSEMBLY CB41

REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate
When reassembling the hand brake, coat each of the following slid-
ing parts with heat resistant grease.
1. Camshaft and brake shoe contact parts 4. Brake shoe and support plate con-
tact surface
2. Camshaft and plate contact surface 5. Brake shoe and adjuster contact
surface
3. Camshaft and support plate contact sur- 6. Adjusting screw threads and socket
face

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-4-6
 REASSEMBLY CB41

INSTALLATION
Key point of installation
Install the companion flange, O-ring and pinion nut. Tighten the lock
nut using the socket wrench (99535 Z0074).
Socket wrench
: 686 - 981 N·m {70 - 100 kgf·m, 506 - 723 ft·lbf}
NOTE
z Lock the pinion nut so that two clinched points contact
each other.
z When tightening the pinion nut, support the transmission
case securely so that it does not move.

BR-4-7
 ADJUSTMENT CB41

ADJUSTMENT
BRAKE LINING CLEARANCE
Chock the front wheels and jack up the rear wheel to adjust the
brake lining clearance.
1. Remove the rubber plug attached to the adjusting hole in
the brake drum. Turn the drum by hand so that the adjusting
hole is located at the lower portion (where the adjuster can
be seen).
2. Using a flat-blade screwdriver, turn the adjuster in the direc-
tion which the shoe expands (moving the screwdriver from
the upper to the lower portion) so that the brake shoe
comes into slight contact with the drum (the clearance
between the lining and drum is zero).
3. Turn back the adjuster 8 turns (moving the screwdriver from
the lower to the upper portion). The clearance between the
lining and drum is 0.2 to 0.3 mm (0.008 to 0.012 in).
4. After adjustment, install the rubber plug on the adjusting
hole.

BR-4-8
 CONSTRUCTION CB31

= UNIT NAME CB31 =

CONSTRUCTION

BR-5-1
 DISASSEMBLY CB31

DISASSEMBLY
z Chock the wheels so that the vehicle cannot move.
z Shift the gear into first or reverse so as not to turn the pro-
peller shaft.

REMOVAL
Key point of removal
1. Unlock the pinion nut, and remove the pinion nut using
socket wrench (99535 Z0003). Remove the companion
flange and O-ring.
NOTE
z When loosening the pinion nut, support the transmission
case securely so that it does not move.
z Do not re-use the pinion nut after removal.

BR-5-2
 DISASSEMBLY CB31

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

2 Return spring
Using the return spring remover (99878 Z0000), remove the brake
shoe return spring.

BR-5-3
 INSPECTION CB31

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

BRAKE DRUM I.D.

Inside diameter
Unit: mm (in)
Maintenance standard Service limit
305 (12.00) 307 (12.09)

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)
Maintenance standard Service limit
0.02 (0.0008) 0.2 (0.008)

BRAKE LINING THICKNESS

Unit: mm (in)
Maintenance
Service limit Remarks
standard
Thickness of remaining
6.1 (0.240) 3.7 (0.146)
lining

BR-5-4
 REPAIR AND REPLACEMENT CB31

REPAIR AND REPLACEMENT

REPLACING THE BRAKE LINING
1. Drill out rivet heads on the rear of the brake shoe assembly,
remove the rivets with a punch and detach the brake lining.
NOTE
z Do not drill the brake shoe.

1. Drill 3. Brake shoe

2. Rivet 4. Brake lining

2. Align the brake shoe with the lining at the rivet holes and
place in a vise with pads attached.
NOTE
z Smooth the surface of the brake shoe, removing
scratches before fastening with rivets. Fasten the brake
shoe and lining with rivets, starting in the middle and
alternately moving outward.
1. Rivet guide punch 5. Backing
2. Brake shoe 6. Flaring punch
3. Rivet 7. Flattening punch
4. Brake lining

BR-5-5
 REASSEMBLY CB31

REASSEMBLY
REASSEMBLY
Key points of reassembly
15 Support plate
When reassembling the hand brake, coat each of the following slid-
ing parts with heat resistant grease.
1. Camshaft and brake shoe contact parts 4. Brake shoe and support plate con-
tact surface
2. Camshaft and plate contact surface 5. Brake shoe and adjuster contact
surface
3. Camshaft and support plate contact sur- 6. Adjusting screw threads and socket
face

12 Camshaft lever
Align the match mark on the camshaft lever with that on the cam-
shaft.

5 Adjusting screw assembly

Retract the adjusting screw fully and install it with its adjusting
wheel facing right.

BR-5-6
 REASSEMBLY CB31

2 Return spring
Install the brake shoe return spring using the return spring replacer
(99879 Z0000).
NOTE
z Make sure that the brake shoe return spring is installed
correctly.

BR-5-7
 REASSEMBLY CB31

INSTALLATION
Key point of installation
Install the companion flange, O-ring and pinion nut. Tighten the lock
nut using the socket wrench (99535 Z0003).
Socket wrench
: 598 - 745 N·m {61 - 76 kgf·m, 441 - 550 ft·lbf}
NOTE
z Lock the pinion nut so that two clinched points contact
each other.
z When tightening the pinion nut, support the transmission
case securely so that it does not move.

BR-5-8
 ADJUSTMENT CB31

ADJUSTMENT
BRAKE LINING CLEARANCE
Chock the front wheels and jack up the rear wheel to adjust the
brake lining clearance.
1. Remove the rubber plug attached to the adjusting hole in
the brake drum. Turn the drum by hand so that the adjusting
hole is located at the lower portion (where the adjuster can
be seen).
2. Using a flat-blade screwdriver, turn the adjuster in the direc-
tion which the shoe expands (moving the screwdriver from
the upper to the lower portion) so that the brake shoe
comes into slight contact with the drum (the clearance
between the lining and drum is zero).
3. Turn back the adjuster 8 turns (moving the screwdriver from
the lower to the upper portion). The clearance between the
lining and drum is 0.2 to 0.3 mm (0.008 to 0.012 in).
4. After adjustment, install the rubber plug on the adjusting
hole.

BR-5-9
 ELECTRICAL SYSTEM

CONTENTS
INTRODUCTION ...................................... EL-1- 1 HEADLIGHT............................................EL-10-1
HOW TO READ WIRING DIAGRAM .......EL-1- 1 LIGHTING SWITCH
ILLUSTRATION OF CONNECTORS ... EL-2- 1 (COMBINATION SWITCH) ....................EL-10-3
CONNECTORS........................................EL-2- 1 TAIL, FOG, CLEARANCE AND
SMJ..........................................................EL-2- 2 OTHER LIGHTS.....................................EL-10- 4
RELAY .....................................................EL-2- 3 OPERATION SYSTEM .......................... EL-11- 1
BATTERY AND CIRCUIT ACCESSORY SYSTEM ........................ EL-12- 1
PROTECTOR ............................................ EL-3- 1 WIRING DIAGRAM ................................ EL-13- 1
BATTERY.................................................EL-3- 1 POWER SUPPLY...................................EL-13- 1
FUSE .......................................................EL-3- 3 STARTING SYSTEM..............................EL-13- 5
FUSIBLE LINK .........................................EL-3- 4 MANUAL AIR HEATER SYSTEM ..........EL-13- 6
HARNESS LAYOUT ................................ EL-4- 1 AUTO AIR HEATER SYSTEM ...............EL-13- 7
SCHEMATIC DIAGRAM ..........................EL-4- 1 CHARGING SYSTEM ............................EL-13- 9
CAB HARNESS .......................................EL-4- 2 AIR DRYER........................................... EL-13-11
MAIN HARNESS......................................EL-4- 4 TRAILER AND SPRING BRAKE
CHASSIS HARNESS...............................EL-4- 8 INDICATOR LIGHT ...............................EL-13-12
ENGINE HARNESS................................EL-4-12 FUEL GAUGE .......................................EL-13-14
LOCATION OF ELECTRICAL UNIT .... EL-5- 1 TACHOMETER .....................................EL-13-16
SWITCH (CAB SIDE)...............................EL-5- 1 AIR PRESSURE WARNING LIGHT......EL-13-18
RELAY (CAB SIDE) .................................EL-5- 3 ENGINE COOLANT LEVEL AND
CONTROL UNIT (CAB SIDE)..................EL-5- 5 OVERHEAT WARNING LIGHT.............EL-13-20 EL
SUPER MULTIPLE JUNCTION (SMJ).....EL-5- 7 OIL PRESSURE AND OIL
FUSE .......................................................EL-5- 7 FILTER WARNING LIGHT ....................EL-13-22
FUSIBLE LINK .........................................EL-5- 7 CHARGE WARNING LIGHT .................EL-13-24
OIL FILTER WARNING LIGHT .............EL-13-26
EARTH POINT .......................................... EL-6- 1
AIR FILTER WARNING LIGHT .............EL-13-28
CHASSIS SIDE........................................EL-6- 1
BRAKE WARNING LIGHT ................... EL-13-30
CAB SIDE ................................................EL-6- 5
CLUTCH DISC WEAR WARNING
STARTING SYSTEM ............................... EL-7- 1 LIGHT................................................... EL-13-31
STARTER CIRCUIT .................................EL-7- 1 COUPLER LOCK WARNING............... EL-13-32
METER CLUSTER ................................... EL-8- 1 WARNING LIGHT BULB CHECK
WARNING SYSTEM ................................ EL-9- 1 SYSTEM .............................................. EL-13-34
LIGHTING SYSTEM ............................... EL-10-1 HEADLIGHT......................................... EL-13-36
FOG LIGHT.......................................... EL-13-39 THIRD DIFFERENTIAL LOCK
TURN SIGNAL, HAZARD AND SYSTEM.............................................. EL-13-79
CORNERING LIGHT ........................... EL-13-41 BRAKE LOCK CONTROL SYSTEM ... EL-13-81
TAIL AND STOP LIGHT....................... EL-13-49 WINDSHIELD WIPER ......................... EL-13-83
CLEARANCE LIGHT ........................... EL-13-57 CAB TILT SYSTEM ............................. EL-13-84
BACK-UP LIGHT ................................. EL-13-58 POWER WINDOW .............................. EL-13-85
ROOM, SPOT AND STEP LIGHTS ..... EL-13-60 2-WAY ELECTRIC HORN ................... EL-13-87
MARKER LIGHT .................................. EL-13-62 HORN AND CIGARETTE LIGHTER ... EL-13-89
SEARCH LIGHT .................................. EL-13-64 AIR CONDITIONER ............................ EL-13-91
ROTARY BEACON LIGHT................... EL-13-66 AUDIO ................................................. EL-13-95
BED ROOM LIGHT.............................. EL-13-67 TACHOGRAPH ................................... EL-13-97
ILLUMINATION LIGHT CONTROL ...... EL-13-68 SEAT BELT WARNING ....................... EL-13-98
EXHAUST BRAKE SYSTEM ............... EL-13-70 SPEED LIMITER SYSTEM ................. EL-13-99
TRANSMISSION PTO ......................... EL-13-72 CIRCUIT DIAGRAM ................................ EL-14- 1
TRANSMISSION HIGH-LOW CHANGE
SYSTEM .............................................. EL-13-76
 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, mm 2), 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 as shown in the figure.

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
figure 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 con-
ventional 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 position to
another, such as multi-position switches, are shown in the circuit
operation chart to clearly indicate the relationship of the connec-
tions.

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 connector
symbol) indicates “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 90° 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-13-1.
To trace a power supply, the leading wiring diagrams (pages EL13-1) should be referred to first and the
required power supply can be traced back from the applicable fuse.

EL-1-8
 ILLUSTRATION OF CONNECTORS

ILLUSTRATION OF CONNECTORS
CONNECTORS
The symbol of a connector in the wiring diagram indicates the number of poles, type, and male or female
shape of the terminal from which the connector of an electrical device can be checked.

EL-2-1
 ILLUSTRATION OF CONNECTORS

SMJ

EL-2-2
 ILLUSTRATION OF CONNECTORS

RELAY

EL-2-3
 BATTERY AND CIRCUIT PROTECTOR

BATTERY AND CIRCUIT PROTECTOR

BATTERY
Item Rated 5-hour 20-hour rate Charging
voltage ampere rate capacity current
Type [V] [AH] [AH] [A]
115E41R
12 88 110 11
(NS120)
115E41R-MF
12 88 110 11
(NS120)
115F51
12 96 120 12
(N120)
115F51-MF
12 96 120 12
(N120)
115F51-HB
12 96 120 12
(N120)
145F51
12 112 140 14
(NS150)
145F51-MF
12 112 140 14
(NS150)
145G51
12 120 150 15
(N150)
145G51-MF
12 120 150 15
(N150)
195G51
12 140 170 17
(NX300-15)

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 [20°C (68°F)].

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.

EL-3-1
 BATTERY AND CIRCUIT PROTECTOR

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.

2. Using a gravimeter, measure the specific gravity of the elec-

trolyte in each cell.
Maintenance standard
[Electrolyte temperature at 20°C (68°F)]
1.200 - 1.290
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 20°C (68°F) standard.

S 20 = St + 0.0007 (t - 20)
Where,
S 20 : Specific gravity of electrolyte at standard temperature
20°C (68°F)
St : Specific gravity measured at t°C
t : Temperature of measured electrolyte (°C)

EL-3-2
 BATTERY AND CIRCUIT PROTECTOR

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.

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 45°C (113°F).
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.

EL-3-3
 BATTERY AND CIRCUIT PROTECTOR

FUSIBLE LINK
CARTRIDGE TYPE
Specifications
Color Capacity current
Black 65A
Green 40A
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
 HARNESS LAYOUT

M-1 Chassis harness (C-1) M-41 Cigarette lighter

M-2 Chassis harness (C-2) M-42 Spare connector
M-3 Engine harness (E-1) M-43 Spare connector
M-5 Cab front harness (CF-1) M-44 Rotary beacon switch
M-6 Cab front harness (CF-2) M-45 Anti-jackknife switch
M-8 Diode M-46 Horn select switch
M-9 Wiper motor M-47 Exhaust temperature gauge
M-10 Door harness LH (DL-2) M-48 Junction block
M-11 Door harness LH (DL-1) M-49 Tachograph harness
M-12 Frame earth M-50 Floor upper harness (U-1)
M-13 Water level & overheat buzzer M-51 Clutch switch
M-14 Fuse block M-52 Clutch switch
M-15 Headlight relay No. 1 M-53 Meter cluster (Green)
M-16 Headlight relay No. 2 M-54 Meter cluster (Brown)
M-17 Accessory relay M-55 Meter cluster (White)
M-18 Tail light relay M-56 Meter cluster (Black)
M-19 Hazard unit M-57 Meter cluster (Blue)
M-20 Air dryer sensor M-58 Overspeed warning light
M-21 Intake actuator M-59 Combination switch
M-22 Blower motor M-60 Starter switch
M-23 Resistor M-61 Search light switch
M-24 Thermo amplifier M-62 Fog light switch
M-25 Air heater timer M-63 Accelerator switch
M-26 Intermittent wiper relay M-64 Low air buzzer
M-27 Stop light relay M-65 Frame earth
M-29 Anti-jackknife relay M-66 Door harness RH (DR-2)
M-30 Transmission PTO relay M-67 Door harness RH (DR-1)
M-31 Transmission relay No. 3 or headlight relay M-68 Body side harness (B-1)
M-32 Horn relay or transmission relay No. 2 M-69 Exhaust temperature buzzer
M-33 Air conditioner relay M-70 Speed limit control unit
M-34 Condenser fan relay M-74 12-speed transmission control unit
M-35 Radio M-75 Transmission relay No. 3
M-36 Controller M-77 Diode
M-37 Air conditioner harness M-81 Timer relay
M-38 Transmission PTO switch M-82 Air conditioner cut relay
M-39 Third differential lock switch M-89 Diode
M-40 Cigarette lighter

EL-4-5
 HARNESS LAYOUT

LHD model

EL-4-6
 HARNESS LAYOUT

M-1 Chassis harness (C-1) M-38 Transmission PTO switch

M-2 Chassis harness (C-2) M-39 Third differential lock switch
M-3 Engine harness (E-1) M-40 Cigarette lighter
M-4 Engine harness (E-29) M-41 Cigarette lighter
M-5 Cab front harness (CF-1) M-42 Spare connector
M-8 Diode M-43 Spare connector
M-9 wiper motor M-44 Rotary beacon switch
M-10 Door harness LH (DL-2) M-46 Horn select switch
M-11 Door harness LH (DL-1) M-49 Tachograph harness
M-12 Frame earth M-50 Floor upper harness (U-1)
M-13 Water level & overheat buzzer M-51 Clutch switch
M-14 Fuse block M-52 Clutch switch
M-15 Headlight relay No. 1 M-53 Meter cluster (Green)
M-16 Headlight relay No. 2 M-54 Meter cluster (Brown)
M-17 Accessory relay M-55 Meter cluster (White)
M-18 Tail light relay M-56 Meter cluster (Black)
M-19 Hazard unit M-57 Meter cluster (Blue)
M-20 Air dryer sensor M-59 Combination switch
M-21 Intake actuator M-60 Starter switch
M-22 Blower motor M-61 Search light switch
M-23 Resistor M-62 Fog light switch
M-24 Thermo amplifier M-63 Accelerator switch
M-26 Intermittent wiper relay M-64 Low air buzzer
M-27 Stop light relay M-65 Frame earth
M-30 Transmission PTO relay M-66 Door harness RH (DR-2)
M-33 Air conditioner relay M-67 Door harness RH (DR-1)
M-34 Condenser fan relay M-68 Body side harness (B-1)
M-36 Controller M-71 Spring brake switch No. 2
M-37 Air conditioner harness M-72 Receptacle

EL-4-7
 HARNESS LAYOUT

CHASSIS HARNESS AND TAIL HARNESS

RHD model

EL-4-8
 HARNESS LAYOUT

C-1 Main harness (M-1) C-37 Third differential lock magnetic valve
C-2 Main harness (M-2) C-38 Tail harness (T-1)
C-3 Engine harness (E-3) C-39 Sub harness (For tractor)
C-4 Engine harness (E-2) C-40 Sub harness (For tractor)
C-5 Dual switch C-41 Frame earth (For tractor)
C-6 Condenser fan motor C-42 Rear combination light (LH) (For tractor)
C-7 Cab earth C-43 License plate light (For tractor)
C-8 Frame earth C-44 Back buzzer (For tractor)
C-9 Fog light harness C-45 Rear combination light (RH) (For tractor)
C-10 Tilt stopper switch C-46 Back-up light (For tractor)
C-11 Cylinder stroke switch C-47 Air pressure switch
C-12 Tilt buzzer C-48 T/M High switch
C-13 T/M neutral switch C-49 T/M Low switch
C-14 Sub harness (T/M PTO pilot light switch) C-50 T/M High magnetic valve
C-15 Back-up light switch C-51 T/M Low magnetic valve
C-16 Fuel tank unit C-52 Spring brake switch
C-17 Frame earth C-53 Electric horn (horn high)
C-19 Sub harness (Air pressure switch) C-54 Electric horn (horn low)
C-20 Coupler switch (For tractor) C-55 T/M select switch (For 12-speed T/M)
C-21 Battery relay C-56 SPL high magnetic valve (For 12-speed T/M)
C-22 Battery relay C-57 SPL low magnetic valve (For 12-speed T/M)
Range high magnetic valve
C-23 Fusible link C-58
(For 12-speed T/M)
C-24 Fusible link C-59 Range low magnetic valve (For 12-speed T/M)
C-25 T/M PTO magnetic valve C-64 Speed sensor
C-26 Exhaust brake magnetic valve C-65 Actuator
C-27 Water level switch T-1 Chassis harness (C-38)
C-28 Sub harness (Starter relay) T-2 Frame earth
C-29 Sub harness (Tilt relay) T-3 Rear combination light (RH)
C-30 Sub harness (Tilt relay) T-4 Rear combination light (LH)
C-31 Tilt motor T-5 License plate light
C-32 Tilt motor T-6 Back-up light
C-33 Tilt switch T-7 Back buzzer
C-35 Frame earth T-8 Chassis harness (C-64) (Except for tractor)
C-36 Frame earth

EL-4-9
 HARNESS LAYOUT

LHD model

EL-4-10
 HARNESS LAYOUT

C-1 Main harness (M-1) C-31 Tilt motor

C-2 Main harness (M-2) C-32 Tilt motor
C-3 Engine harness (E-3) C-33 Tilt switch
C-4 Engine harness (E-2) C-34 Spare
C-5 Dual switch C-35 Frame earth
C-6 Condenser fan motor C-36 Frame earth
C-7 Cab earth C-37 Third differential lock magnetic valve
C-8 Frame earth C-38 Tail harness (T-1)
C-10 Tilt stopper switch C-39 Sub harness (Stop light switch)
C-11 Cylinder stroke switch C-40 Jumper cable
C-12 Tilt buzzer C-41 Frame earth
C-13 T/M neutral switch C-42 Rear combination light (LH) (For tractor)
C-14 Sub harness (T/M PTO pilot light switch) C-43 License plate light (For tractor)
C-15 Back-up light switch C-44 Back buzzer (For tractor)
C-16 Fuel tank unit C-45 Rear combination light (RH) (For tractor)
C-17 Frame earth C-46 Back-up light (For tractor)
C-18 Air dryer C-48 Brake fluid level switch (For tractor)
C-19 Sub harness (Air pressure switch) C-49 Air booster stroke switch No. 1 (For tractor)
C-20 Coupler switch (For tractor) C-50 Air booster stroke switch No. 2 (For tractor)
C-21 Battery relay C-53 Electric horn (horn high)
C-22 Battery relay C-54 Electric horn (horn low)
C-23 Fusible link T-1 Chassis harness (C-38)
C-24 Fusible link T-2 Frame earth
C-25 T/M PTO magnetic valve T-3 Rear combination light (RH)
C-26 Exhaust brake magnetic valve T-4 Rear combination light (LH)
C-27 Water level switch T-5 License plate light
C-28 Sub harness (Starter relay) T-6 Back-up light
C-29 Sub harness (Tilt relay) T-7 Back buzzer
C-30 Sub harness (Tilt relay)

EL-4-11
 HARNESS LAYOUT

ENGINE HARNESS
PF6 SERIES ENGINE (RHD MODEL)

EL-4-12
 HARNESS LAYOUT

PF6 SERIES ENGINE (LHD MODEL)

EL-4-13
 HARNESS LAYOUT

RF8 ENGINE (RHD MODEL)

EL-4-14
 HARNESS LAYOUT

RF8 ENGINE (LHD MODEL)

EL-4-15
 HARNESS LAYOUT

RG8 ENGINE (RHD MODEL)

EL-4-16
 HARNESS LAYOUT

RG8 ENGINE (LHD MODEL)

EL-4-17
 HARNESS LAYOUT

RE10 ENGINE

EL-4-18
 LOCATION OF ELECTRICAL UNIT

LOCATION OF ELECTRICAL UNIT

SWITCH (CAB SIDE)
RHD model

EL-5-1
 LOCATION OF ELECTRICAL UNIT

LHD model

EL-5-2
 LOCATION OF ELECTRICAL UNIT

RELAY (CAB SIDE)

RHD model

EL-5-3
 LOCATION OF ELECTRICAL UNIT

LHD model

EL-5-4
 LOCATION OF ELECTRICAL UNIT

CONTROL UNIT (CAB SIDE)

RHD model

EL-5-5
 LOCATION OF ELECTRICAL UNIT

LHD model

EL-5-6
 LOCATION OF ELECTRICAL UNIT

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-5-7
 EARTH POINT

EARTH POINT
CHASSIS SIDE
CD·CW series

EL-6-1
 EARTH POINT

CW-T SERIES

EL-6-2
 EARTH POINT

CK-series

EL-6-3
 EARTH POINT

CK-T series

EL-6-4
 EARTH POINT

CAB SIDE
RHD models

LHD models

EL-6-5
 STARTING SYSTEM

STARTING SYSTEM
STARTER CIRCUIT
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical units, be sure to turn the
ignition switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.

IGNITION SWITCH (KEY SWITCH)

Specifications
Rated voltage (V) 24
Voltage drop (V) 0.4 or less in 10 amperes

Auto-preheat specifications
Position 0 1 2 3 4 5
Mark
Terminal (LOCK) ACC ON HEAT ST

1 B O O O O
2 ACC O O
3 IGN O O O
4 H O O
5 S O
6 A O O O O O O
7 P1 O O O
8 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
Exciting current (A) 40 for 30 seconds
Voltage drop (V) 0.2 or less in 50 amperes

EL-7-1
 STARTING SYSTEM

Inspection
1. Check the continuity, operation and insulation of the starter
safety relay.

AIR HEATER RELAY

Specifications
Rated voltage (V) 12
40 sec. (220A)
Rated time
10 min. (110A)
Attraction voltage (V) 8 or less
Release voltage (V) (V) 4 or less at 12 volts
Voltage drop (V) 0.1 or less in 100 amperes
Inspection
1. Check the continuity, operation and insulation of the air
heater relay.

BATTERY RELAY
Specifications
Rated voltage (V) 24
Pull-in voltage (V) 20 or less
Holding voltage (V) (V) 9 or less
Exciting current (A) 0.5 or less
0.35 or less between M8 termi-
Voltage drop (V)
nals in 100 amperes

Inspection
1. Check the continuity between the terminals with a circuit
tester (ohm range).
2. Inspect the operation and insulation of the battery switch.

EL-7-2
 STARTING SYSTEM

ENGINE COOLANT TEMPERATURE SENSOR

Specifications
Temperature range -40 to 120ºC (-40 to 248ºF)
Rated resistance valve 1.011 - 1.411 kΩ

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
Voltage drop V 0.3 or less in 4 amperes
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
Terminal OFF ON

1
2

EL-7-4
 STARTING SYSTEM

AIR DRYER HEATER AND THERMOSTAT

Specifications
Heater 24V - 50W
ON 0 - 8°C (32 - 46°F)
Thermostat
OFF Less than 20°C (Less than 68°F)

Inspection
1. Check the continuity between the terminal and heater body
with a circuit tester (ohm range).

AIR HEATER TIMER

Inspection
Check the operation mode of the air heater timer.

EL-7-5
 STARTING SYSTEM

AIR HEATER
Inspection
Conduct continuity tests in air heater circuits.

EL-7-6
 METER CLUSTER

METER CLUSTER
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
Before servicing the electrical units, be sure to turn the ignition key to “OFF” and disconnect
the negative (-) cable from the battery to ensure safety.

RHD MODELS

EL-8-1
 METER CLUSTER

LHD MODELS

EL-8-2
 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 four screws mounting the cluster meter 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

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
meter cluster.
Inspection of tachograph
Check the tachograph. Replace as an assembly if bent recording
needle or any other faults are noted.

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”)

EL-8-3
 METER CLUSTER

THERMO SENDER
Specifications
Rated voltage (V) 24
Indication temperature range ºC (ºF) 50 - 130 (122 - 266)

Inspection
Check temperature versus resistance characteristics.

69.8 - 70.2 129.7 -

Temperature 110
(157.6 - 90 (194) 130.3 (265 150 (302) 170 (338)
ºC (ºF) (230)
158.4) - 267)
Resistance
83.5 - 101.5 50 27.4 15.0 - 17.6 10 6.7
(Ω)

FUEL 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) Resistance (Ω)
Type Type Type
Type I Type II Type III Type IV Type V
I - III IV V
385.2 427.6 460.2 304.8 526.8
A 9.5 - 11.0 9.5 - 11.0 9.5 - 11.0
(15.17) (16.83) (18.12) (12.00) (20.74)
288.9 320.7 345.2 228.6 395.1
B 19 19 23
(11.37) (12.63) (13.59) (9.00) (15.56)
192.6 213.8 230.1 152.4 263.4
C 29 - 35 29 - 35 30.5 - 36.5
(7.58) (8.42) (9.06) (6.00) (10.37)
96.3 106.9 115.0 76.2 131.7
D 49.5 49.5 47.5
(3.79) (4.21) (4.53) (3.00) (5.19)
E 0 (0) 0 (0) 0 (0) 0 (0) 0 (0) 82 - 92 82 - 92 82 - 92
236 257.5 274.1 185.7 308.3
L
(9.29) (10.14) (10.79) (7.31) (12.14)
235 261 281 186 322
R
(9.25) (10.28) (11.06) (7.32) (12.68)

TRAILER BRAKE SWITCH

Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).

EL-8-4
 METER CLUSTER

SPRING BRAKE SWITCH

Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).

SPEED SENSOR
Specifications
Rated voltage 24V - 32V
Revolution speed 180 km/h (112 MPH) (2,000 rpm)
Output current 30 mA (max.)
Output impedance About 200Ω

EL-8-5
 WARNING SYSTEM

WARNING SYSTEM
CAUTION
z PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
z Before servicing the electrical unit, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.

For warning system circuit diagrams, refer to “METER CLUSTER”.

ENGINE COOLANT LEVEL AND OVER HEAT WARN-

ING BUZZER

Check the continuity, insulation and operation of the buzzer.

ENGINE OVERRUN BUZZER

Inspection
Check the continuity, insulation and operation of the buzzer.
Rated voltage 24V

PARKING BRAKE SWITCH

Inspection
1. 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
Check the continuity, insulation and operation of the buzzer.
Rated voltage 24V

AIR PRESSURE SWITCH

Inspection
Using a circuit tester (ohm range), check the switch to see that it
makes (body earth) and breaks the circuit under the specified air
pressure.
Turn-on Type I 422 - 481 kPa {4.3 - 4.9 kgf/cm 2, 61 - 70 psi}
pressure Type II 49 - 69 kPa {0.5 - 0.7 kgf/cm 2, 7 - 10 psi}

Turn-off Type I 422 - 530 kPa {4.3 - 5.4 kgf/cm 2, 61 - 77 psi}

pressure Type II 49 - 98 kPa {0.5 - 1.0 kgf/cm 2, 7 - 14 psi}

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.

OVER HEAT SWITCH

Specifications
Rated voltage 12V
143 - 149
SWITCH CLOSED
Indication temperature (289 - 300)
ºC (ºF) 140 - 152
SWITCH OPEN
(284 - 306)
Inspection
Raise the temperature and check if the over heat switch operates
within the specifications.

EL-9-2
 WARNING SYSTEM

OIL FILTER SWITCH

Specifications
Rated voltage 24V
Turn-on pressure 98 - 137 kPa {1.0 - 1.4 kgf/cm 2, 14 - 20 psi}
73.6 - 137.3 kPa
Turn-off pressure
{0.75 - 1.4 kgf/cm 2, 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.
Specified negative pres- 5.9166 - 6.5383 kPa
{603.3 - 666.7 mmAq,
sure
23.752 - 26.248 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: mili liter (Imp fl oz)
Maintenance standard Service limit
292.5 (10.30) —

AIR BOOSTER STROKE SWITCH

Rated 4A
Voltage drop 0.1 V or less
Operating force 24.5 N {2.5 kgf, 5.5 lbf}

EL-9-3
 WARNING SYSTEM

Inspection
1. Check the continuity between the switch terminals and insu-
lation to the body.
2. Check the switch operation.
3. Check the spring free length and tension.

Item Maintenance standard

Spring free length 53 mm (2.09 in)
24.5 N {2.5 kgf, 5.5 lbf}
Spring tension
[When compressed to 48 mm (1.89 in)]

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
Check the continuity between the terminals with a circuit tester
(ohm range).

OIL PRESSURE SENDER

Inspection
Using a circuit tester (ohm range), check the switch to see that it
makes (body earth) and breaks the circuit under the specified oil
pressure.
Turn-on pressure 29 kPa {0.3 kgf/cm2, 4 psi} or less
Turn-off pressure 78 kPa {0.8 kgf/cm 2, 11 psi}

AIR DRYER SENSOR

Specifications
Rated voltage 12V
Operating temperature
-30 to 80ºC (-22 to 176ºF)
range
Resistance load 50 - 100W
0.5V or less [across terminals (1) and (2)]
Voltage drop 0.5V or less [across terminals (1) and (3)]

EL-9-4
 WARNING SYSTEM

Inspection
Check the continuity and insulation between the terminals.

EL-9-5
 LIGHTING SYSTEM

LIGHTING SYSTEM
HEADLIGHT
Specifications
Type
Semi-sealed beam 24V 75/70W
(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.
3. Remove the dust cover.
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.

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 MAIN DIM PASS
1 O O
2 O
3 O O
29 O
30 O
5 O O
6 O
7 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.

HEADLIGHT RELAY
Inspection
Check the circuit of the headlight relay.
Refer to “ILLUSTRATION OF CONNECTORS”.

EL-10-3
 LIGHTING SYSTEM

TAIL, FOG, CLEARANCE AND OTHER LIGHT

INTERIOR LIGHT
Circuit

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).
Termi- HAZARD
RH N LH
nal 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-10-4
 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 3.03A - 4.74A
(wire brake) Type I
(2.17A - 3.89A)
2.17A - 3.89A
Type II
(1.31A - 3.03A)
0.5V max. (between termi-
Voltage drop
nals 3 and 4, 3 and 5)

Inspection
Check the continuity, insulation and operation of the buzzer.

FRONT COMBINATION LIGHT

Specifications
Front turn signal
24V 25W
light
With cornering light
Clearance/corner-
24V 25W/10W
ing light
Front turn signal
Without cornering 24V 21W
light
light
Clearance light 24V 10W

SIDE TURN SIGNAL LIGHT

Specifications
Type I 24V/12W
Type II 24V/10W

EL-10-5
 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

TAIL LIGHT RELAY

Inspection
Check the circuit of the tail light relay. Refer to “ILLUSTRATION OF
CONNECTORS”.

BACK-UP LIGHT
Specifications
Type I 24V 25W
Type II 24V 21W

EL-10-6
 LIGHTING SYSTEM

BACK-UP LIGHT SWITCH

Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
L should be 23 to 24 mm (0.91 to 0.94 in) when the switch is off.

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/cm 2, 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.

FOG LIGHT
Specifications: 24V/55W

EL-10-7
 LIGHTING SYSTEM

FOG LIGHT SWITCH

Inspection
Turn the switch on and off and check for continuity.
OFF ON
1 O
2 O
3 O
4 O
5 O O
— 8 8
6 O O

STOP LIGHT RELAY

Inspection
Check the circuit of the stop light relay. Refer to “ILLUSTRATION
OF CONNECTORS”.
STEP LIGHT
Specifications: 24V 6W

ROTARY BEACON LIGHT

Specifications
Type I Type II
Nominal voltage 24V 24V
Conform to bulb 24V 60W 24V 60W
Times/minute 220/280 140/160

Inspection
Turn the rotary beacon light on and make sure it rotates.

EL-10-8
 LIGHTING SYSTEM

ROTARY BEACON SWITCH

Inspection
Turn the switch on and off and check for continuity.
OFF ON
1 O
2 O
3 O O
— 8 8
4 O O

BED ROOM LIGHT

Type: 24V 5W

SEARCH LIGHT

SEARCH LIGHT SWITCH

Inspection
Turn the switch on and off and check for continuity.

OFF ON
1 O
2 O
3 O O
— 8 8
4 O O

EL-10-9
 OPERATION SYSTEM

OPERATION SYSTEM
PRECAUTIONS FOR HANDLING ELECTRICAL UNITS
CAUTION
z Before servicing the electrical units, be sure to turn the
key switch to “OFF” and disconnect the negative (-)
cable from the battery to ensure safety.

EXHAUST BRAKE SWITCH

Removing the exhaust brake switch
Refer to the “LIGHTING SYSTEM” section.

Inspection
1. Check the continuity between the terminals with a circuit
tester (ohm range).

Terminal OFF ON
20 O
21 O

CLUTCH SWITCH
Inspection
1. Using a circuit tester (ohm range), check the continuity
between the terminals and check the insulation of the
switch.

Terminal OFF ON
1 O
2 O

EL-11-1
 OPERATION SYSTEM

ACCELERATOR SWITCH
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
Terminal OFF ON
1 O
2 O

EXHAUST BRAKE MAGNETIC VALVE

Inspection
1. 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.
Refer to “ILLUSTRATION OF CONNECTORS”.

TRANSMISSION PTO SWITCH

Rated voltage 24V

Rated load 100W

EL-11-2
 OPERATION SYSTEM

Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
OFF ON
1 O
2 O
3 O
4 O
5 O O
— 8 8
6 O O

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
Check the continuity between the terminals with a circuit tester
(ohm range).
OFF ON
1 O
2 O
3 O O
— 8 8
4 O O

EL-11-3
 OPERATION SYSTEM

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”.

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).
Terminal 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
LOW 37 - 45 rpm
Speed
HIGH 56 - 68 rpm
Starting voltage 16V or less
39.2 N·m
LOW
{400 kgf·cm, 347 in·lbf}
Torque
36.3 N·m
HIGH
{370 kgf·cm, 321 in·lbf}

EL-11-4
 OPERATION SYSTEM

Terminal 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 cir- onds after washer is turned on
cuit Wiper operates 2 to 3 times and then stops
after washer is turned off

Inspection
1. Using a circuit tester (ohm range), check the continuity
between the respective terminals and check the inspect
motor.
2.

EL-11-5
 OPERATION SYSTEM

WINDOW WASHER
Specifications
Rated voltage 24V
Discharge pressure 78 kPa {0.8 kgf/cm2, 11 psi}
Discharge flow rate 200 mili liter (7.0 Imp fl oz)/10 sec.
Minimum working voltage 16V or less
Inspection
Check the continuity, operation and insulation of the switch.

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)

EL-11-6
 OPERATION SYSTEM

Inspection
OPERA- OPERATION
TION
CONNECTED TO
TERMI- U N D
NAL NO.
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

POWER WINDOW MOTOR

Specifications
Rated voltage 27V
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
1. Using the circuit tester (ohm range), check the continuity
between the terminals and inspect the motor.
2. Check the operation of the motor (refer to the specifica-
tions).

POWER WINDOW UNIT

Inspection
Rated voltage 24V
Consumption current 0.5A or less

Specifications
MANUAL MODE
INPUT OUTPUT
Terminal Terminal Terminal Terminal Terminal
No. 1 No. 4 No. 5 No. 6 No. 7
MANUAL MANUAL MOTOR MOTOR
IGN SW (+) (R, L)
UP SW DOWN SW (L)
ON OFF + -
ON OFF ON - -
OFF OFF - -
OFF ON/OFF ON/OFF - -

EL-11-7
 OPERATION SYSTEM

AUTO MODE
INPUT OUTPUT
Terminal Terminal Terminal MOTOR Terminal Terminal
No. 1 No. 2 No. 3 REVOLVING No. 6 No. 7
AUTO UP AUTO CONDITION MOTOR
IGN SW (+) MOTOR (L) (R, L)
SW DOWN SW
DRIVE + -
ON OFF
STOP - -
DRIVE - +
ON OFF ON
STOP - -
DRIVE - -
OFF OFF
STOP - -
OFF ON/OFF ON/OFF STOP - -

POWER WINDOW RELAY

Inspection
Check the circuit of the power window relay. Refer to “ILLUSTRA-
TION OF CONNECTORS”.

CIRCUIT BREAKER
Inspection
Rated voltage 27V
Cycle 5 sec. (Action) - 1 sec. (Lock)

EL-11-8
 OPERATION SYSTEM

HIGH-LOW CHANGE SWITCH

10-SPEED TRANSMISSION RELAY

Inspection
Check the circuit of the 10-speed transmission relay. Refer to
“ILLUSTRATION OF CONNECTORS”.
HIGH & LOW MAGNETIC VALVE
Inspection
Check that the following circuit holds good when DC24V is applied
to shut off.
OFF ON
1 Inlet port O
2 Outlet port O O
3 Exhaust port O

EL-11-9
OPERATION SYSTEM

EL-11-10
 OPERATION SYSTEM

HIGH-LOW SWITCH
Inspection
Refer to “TRANSMISSION NEUTRAL SWITCH”.

12-SPEED TRANSMISSION RELAY

Inspection
Check the circuit of the 12-speed transmission relay. Refer to
“ILLUSTRATION OF CONNECTORS”.

HIGH & LOW MAGNETIC VALVE

Inspection
Check that the following circuit holds good when DC24V is applied
to shut off.

OFF ON
1 Inlet port O
2 Outlet port O O
3 Exhaust port O

EL-11-11
 OPERATION SYSTEM

HIGH-LOW SWITCH
Inspection
Check the continuity between the terminals with a circuit tester
(ohm range).
Terminal OFF ON
1 O
2 O

CLUTCH SWITCH
The clutch switch for the 12-speed transmission system is the same
as that for the exhaust brake system. For removal, installation and
inspection, refer to “EXHAUST BRAKE CLUTCH SWITCH”.

TILT LOCK SWITCH

Inspection
Rated voltage 10V - 28V
Rated load 60W
Voltage drop 0.2V or less

EL-11-12
 OPERATION SYSTEM

TILT RELAY
Inspection
Rated voltage 24V
Minimum action voltage 18V or less
Opening voltage 9V or less
Exciting current 0.4A or less
Voltage drop 0.2V or less (at 30A)

TILT STOPPER SWITCH

Inspection
Rated voltage 10V - 28V
Rated load 60W
Voltage drop 0.2V or less

EL-11-13
 OPERATION SYSTEM

TILT BUZZER
Inspection
Apply a rated voltage of 24 volts and make sure the buzzer oper-
ates.

EL-11-14
 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 (Air type)

Inspection
Connect a test circuit as shown in the figure and check the opera-
tion of the horn.

EL-12-1
 ACCESSORY SYSTEM

HORN (Electrical type)

HORN RELAY
Inspection
Check the circuit of the horn relay. Refer to “ILLUSTRATION OF
CONNECTORS”.

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

EL-12-2
 ACCESSORY SYSTEM

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 Speaker (LH) (-)
3 Speaker (RH) (+)
4 Speaker (RH) (-)
7 Illumination (+) 24V
8 Illumination (-)
9 Power source (Accessory) (+) 12V
10 Ground

SPEED SENSOR
Inspection
Rated voltage 24V - 32V
Revolution speed 180 km/h (112 MPH) (2,000 rpm)
Output current 30 mA (max.)
Output impedance About 200Ω

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

MANUAL AIR HEATER SYSTEM

EL-13-6
 WIRING DIAGRAM

AUTO AIR HEATER SYSTEM

RHD model

EL-13-7
 WIRING DIAGRAM

LHD model

EL-13-8
 WIRING DIAGRAM

CHARGING SYSTEM
RHD model

EL-13-9
 WIRING DIAGRAM

LHD model

EL-13-10
 WIRING DIAGRAM

AIR DRYER

EL-13-11
 WIRING DIAGRAM

TRAILER AND SPRING BRAKE INDICATOR LIGHT

RHD model

EL-13-12
 WIRING DIAGRAM

LHD model

EL-13-13
 WIRING DIAGRAM

FUEL GAUGE
RHD model

EL-13-14
 WIRING DIAGRAM

LHD model

EL-13-15
 WIRING DIAGRAM

TACHOMETER
RHD model

EL-13-16
 WIRING DIAGRAM

LHD model

EL-13-17
 WIRING DIAGRAM

AIR PRESSURE WARNING LIGHT

RHD model

EL-13-18
 WIRING DIAGRAM

LHD model

EL-13-19
 WIRING DIAGRAM

ENGINE COOLANT LEVEL AND OVERHEAT WARNING LIGHT

RHD model

EL-13-20
 WIRING DIAGRAM

LHD model

EL-13-21
 WIRING DIAGRAM

OIL PRESSURE WARNING LIGHT

RHD model

EL-13-22
 WIRING DIAGRAM

LHD model

EL-13-23
 WIRING DIAGRAM

CHARGE WARNING LIGHT

RHD model

EL-13-24
 WIRING DIAGRAM

LHD model

EL-13-25
 WIRING DIAGRAM

OIL FILTER WARNING LIGHT

RHD model

EL-13-26
 WIRING DIAGRAM

LHD model

EL-13-27
 WIRING DIAGRAM

AIR FILTER WARNING LIGHT

RHD model

EL-13-28
 WIRING DIAGRAM

LHD model

EL-13-29
 WIRING DIAGRAM

BRAKE WARNING LIGHT

A.O.H. brake vehicle only

EL-13-30
 WIRING DIAGRAM

CLUTCH DISC WEAR WARNING LIGHT

EL-13-31
 WIRING DIAGRAM

COUPLER LOCK WARNING

RHD model

EL-13-32
 WIRING DIAGRAM

LHD model

EL-13-33
 WIRING DIAGRAM

WARNING LIGHT BULB CHECK SYSTEM

RHD model

EL-13-34
 WIRING DIAGRAM

LHD model

EL-13-35
 WIRING DIAGRAM

HEADLIGHT
RHD model (Except for Australia)

EL-13-36
 WIRING DIAGRAM

RHD model (For Australia)

EL-13-37
 WIRING DIAGRAM

LHD model

EL-13-38
 WIRING DIAGRAM

FOG LIGHT
RHD model

EL-13-39
 WIRING DIAGRAM

LHD model

EL-13-40
 WIRING DIAGRAM

TURN SIGNAL, HAZARD AND CORNERING LIGHT

RHD model (Except tractor)

EL-13-41
WIRING DIAGRAM

EL-13-42
 WIRING DIAGRAM

RHD model (Tractor)

EL-13-43
WIRING DIAGRAM

EL-13-44
 WIRING DIAGRAM

LHD model (Except tractor)

EL-13-45
WIRING DIAGRAM

EL-13-46
 WIRING DIAGRAM

LHD model (Tractor)

EL-13-47
WIRING DIAGRAM

EL-13-48
 WIRING DIAGRAM

TAIL AND STOP LIGHT

RHD model (Except tractor)

EL-13-49
WIRING DIAGRAM

EL-13-50
 WIRING DIAGRAM

RHD model

EL-13-51
WIRING DIAGRAM

EL-13-52
 WIRING DIAGRAM

LHD model (Except tractor)

EL-13-53
WIRING DIAGRAM

EL-13-54
 WIRING DIAGRAM

LHD model (Tractor)

EL-13-55
WIRING DIAGRAM

EL-13-56
 WIRING DIAGRAM

CLEARANCE LIGHT

EL-13-57
 WIRING DIAGRAM

BACK-UP LIGHT
Except tractor

EL-13-58
 WIRING DIAGRAM

Tractor

EL-13-59
 WIRING DIAGRAM

ROOM, SPOT AND STEP LIGHTS

RHD model

EL-13-60
 WIRING DIAGRAM

LHD model

EL-13-61
 WIRING DIAGRAM

MARKER LIGHT
RHD model

EL-13-62
 WIRING DIAGRAM

LHD model

EL-13-63
 WIRING DIAGRAM

SEARCH LIGHT
RHD model

EL-13-64
 WIRING DIAGRAM

LHD model (Tractor only)

EL-13-65
 WIRING DIAGRAM

ROTARY BEACON LIGHT

EL-13-66
 WIRING DIAGRAM

BED ROOM LIGHT

EL-13-67
 WIRING DIAGRAM

ILLUMINATION LIGHT CONTROL

RHD model

EL-13-68
 WIRING DIAGRAM

LHD model

EL-13-69
 WIRING DIAGRAM

EXHAUST BRAKE SYSTEM

RHD model

EL-13-70
 WIRING DIAGRAM

LHD model

EL-13-71
 WIRING DIAGRAM

TRANSMISSION PTO
RHD model (Except 10-speed transmission)

EL-13-72
 WIRING DIAGRAM

RHD model (10-speed transmission)

EL-13-73
 WIRING DIAGRAM

LHD model (Except 12-speed transmission)

EL-13-74
 WIRING DIAGRAM

LHD model (12-speed transmission)

EL-13-75
 WIRING DIAGRAM

TRANSMISSION HIGH-LOW CHANGE SYSTEM

10-speed transmission

EL-13-76
 WIRING DIAGRAM

12-speed transmission

EL-13-77
WIRING DIAGRAM

EL-13-78
 WIRING DIAGRAM

THIRD DIFFERENTIAL LOCK SYSTEM

RHD model

EL-13-79
 WIRING DIAGRAM

LHD model

EL-13-80
 WIRING DIAGRAM

BRAKE LOCK CONTROL SYSTEM

EL-13-81
WIRING DIAGRAM

EL-13-82
 WIRING DIAGRAM

WINDSHIELD WIPER

EL-13-83
 WIRING DIAGRAM

CAB TILT SYSTEM

EL-13-84
 WIRING DIAGRAM

POWER WINDOW
RHD model

EL-13-85
 WIRING DIAGRAM

LHD model

EL-13-86
 WIRING DIAGRAM

2-WAY ELECTRIC HORN

RHD model

EL-13-87
 WIRING DIAGRAM

LHD model

EL-13-88
 WIRING DIAGRAM

HORN AND CIGARETTE LIGHTER

RHD model

EL-13-89
 WIRING DIAGRAM

LHD model

EL-13-90
 WIRING DIAGRAM

AIR CONDITIONER
RHD model

EL-13-91
WIRING DIAGRAM

EL-13-92
 WIRING DIAGRAM

LHD model

EL-13-93
WIRING DIAGRAM

EL-13-94
 WIRING DIAGRAM

AUDIO
RHD model

EL-13-95
 WIRING DIAGRAM

LHD model

EL-13-96
 WIRING DIAGRAM

TACHOGRAPH

EL-13-97
 WIRING DIAGRAM

SEAT BELT WARNING

EL-13-98
 WIRING DIAGRAM

SPEED LIMITER SYSTEM

EL-13-99
 CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

EL-14-1
CIRCUIT DIAGRAM

EL-14-2
CIRCUIT DIAGRAM

EL-14-3
 CAB BODY

CONTENTS
SERVICE DATA.................................... CB-1 DISASSEMBLY AND
SPECIFICATIONS............................ CB-1 REASSEMBLY ............................... CB-22
SERVICE DATA................................ CB-1 ELECTRIC TILT .................................. CB-28
TIGHTENING TORQUE ................... CB-2 CONSTRUCTION .......................... CB-28
TOOLS.................................................. CB-3 DISASSEMBLY ............................. CB-31
CAB ASSEMBLY ................................. CB-4 INSPECTION ................................. CB-33
REMOVAL ........................................ CB-4 REASSEMBLY ............................... CB-34
REPAIR AND REPLACEMENT ........ CB-7 GLASS ................................................ CB-36
INSTALLATION............................... CB-10 DISASSEMBLY .............................. CB-36
DOOR ................................................. CB-12 REASSEMBLY ............................... CB-37
DISASSEMBLY .............................. CB-12 INSTRUMENT PANEL ........................ CB-39
REASSEMBLY ............................... CB-18 DISASSEMBLY .............................. CB-39
CAB MOUNTING................................ CB-22 REASSEMBLY ............................... CB-43
REMOVAL AND INSTALLATION.... CB-22

CB
 SERVICE DATA CAB BODY

SERVICE DATA
SPECIFICATIONS
Type Forward control, all-steel welded construction tilting cab
Mounting type Fix cab Suspension cab
Model — CT-3020331-N10C
Type — Saw-teeth type
Tilt cylinder
Tilt capacity (Load on roof) — 250 kg (551 lb)
Tilt angle 50°
Electric tilt Model — PT-22E11H-N10A
Type — Electric
Hydraulic oil
Type of oil used — MIL-H-5606E or equivalent
pump
Total — 800 mili liter (28.2 Imp fl oz)
Oil quantity
Reservoir — 450 mili liter (15.8 Imp fl oz)
Front glass Laminated glass

SERVICE DATA
Unit: mm (in)
Maintenance Service
Item Shape & remarks
standard limit

Clearance (A) between upper 8.0 - 10.0

–
side of door and cab (0.315 - 0.394)

Clearance (B) between door 4.4 - 6.4

Cab and –
assembly and cab (0.173 - 0.252)
door

Alignment (C) of door with cab 0 (0) –

Electric Up 25sec., max. – Measure tilting speeds with a 200 kg (441 lb)
Tilting speed
tilt Down 11sec., max. – weight loaded on seat rack.

CB-1
 SERVICE DATA CAB BODY

TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Cab assembly SMJ (Super Multi Junction) connector bolt 2.9 - 4.9 {0.3 - 0.5, 2.2 - 3.6}
Door Hinge bolt 14 - 18 {1.4 - 1.8, 10 - 13}
Hinge bushing Electric tilt 78 - 98 {8 - 10, 58 - 72}
cap bolt Manual tilt 127 {13, 94}
Hinge bushing pin nut 275 - 343 {28 - 35, 203 - 253}
Front cab mount Tilt hinge support bolt 78 - 108 {8 - 11, 58 - 80}
Suspension link pin nut 235 - 324 {24 - 33, 174 - 239}
Link bracket bolt 177 - 235 {18 - 24, 130 - 174}
Spring bracket bolt 118 - 157 {12 - 16, 87 - 116}
Tilt lock pin bolt 49 - 69 {5 - 7, 36 - 51}
Suspension link bolt 78 - 108 {8 - 11, 58 - 80}
Rear cab mount Rubber cushion bolt 49 - 69 {5 - 7, 36 - 51}
Cab mounting lower bracket bolt 78 - 108 {8 - 11, 58 - 80}
Cab mounting upper bracket bolt 49 - 69 {5 - 7, 36 - 51}
Tilt lock assembly 37 {3.8, 27}
Cab lock system
Safety bracket 37 {3.8, 27}
Cylinder lower self-locking nut 47 - 64 {4.8 - 6.5, 35 - 47}
Electric tilt cylinder Cylinder upper bolt nut 78 - 108 {8 - 11, 58 - 80}
Tilt cylinder bracket bolt 78 - 108 {8 - 11, 58 - 80}
Side window Window glass hinge bolt 2 {0.2, 1.4}
Sleeve yoke lock bolt 51 - 61 {5.2 - 6.2, 38 - 45}
Steering
Steering wheel nut 88 {9, 65}

CB-2
 TOOLS CAB BODY

TOOLS
Tool name and number Description Shape
SMJ bolt tool Used when installing the stopper ring onto the Super
99782 Z0000 Multi-Junction (SMJ) bolt

SMJ bolt holder tool Used when removing the SMJ bolt holder
99781 Z0000

Steering wheel puller Used when removing the steering wheel

99851 Z0002

CB-3
 CAB ASSEMBLY CAB BODY

CAB ASSEMBLY
REMOVAL
Key point of removal
1. 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.

2. Stop the engine and turn the key switch “OFF”. (Disconnect
the negative (-) cable from the battery.)

3. Completely discharge air and refrigerant (if equipped with

air conditioner), and drain engine coolant and clutch fluid.

4. Disconnect the cable from the control lever on the dump

truck or mixer, and remove it and the grommet as a unit
from the compartment.

5. Remove the clevis pin which secures the cable to the hand
brake lever, and remove the cable and grommet from the
compartment (Mechanically-actuated type). Disconnect the
parking brake valve piping and harness connector, and
push them out of the vehicle (Air-actuated type).

CB-4
 CAB ASSEMBLY CAB BODY

6. Open the front lid, and disconnect the heater hoses.

7. Disconnect the air and clutch hoses.

NOTE
z Place a container under the clutch hose connection to
collect the clutch fluid.

8. Disconnect the speedometer and tachometer harness

(main harness).

9. Disconnect the accelerator control cable.

10. Disconnect the chassis harness and cab harness.

CB-5
 CAB ASSEMBLY CAB BODY

11. Place an alignment mark on the steering gear box and

sleeve yoke, and disconnect the steering column.

12. Disengage the transmission linkage.

13. Tilt the cab using a cable and hoist or crane.

14. Hold the cab in the tilt-up position.

15. Remove the nut and bolt which secure the sub-lever and
cab to the upper end of the tilt cylinder.
NOTE
z Be careful not to damage the cylinder piston rod.

Remove the tilt stopper bracket connected to the cab. (Manual tilt
type)

CB-6
 CAB ASSEMBLY CAB BODY

16. Lower the cab and attach it to the special suspending

equipment for cab removal and installation. Then hold the
cab level again.
17. Remove the hinge bracket cap.

18. Slightly raise the cab using a hoist. After ensuring all con-
nections are disconnected, slowly move the cab away from
the vehicle body and place it on a suitable workbench.
NOTE
z Never get under the cab while it is being raised.

REPAIR AND REPLACEMENT

EMBLEM
Pinch both sides of the clip on the inner side of the front lid, and
unfasten the clip.
NOTE
z Do not remove the emblem from the outside as it may get
damaged.

FRONT LID
1. Remove the ball joint located on the lower side of the gas
damper lid stay, and remove the front lid.

CB-7
 CAB ASSEMBLY CAB BODY

2. Remove the bolts securing the assist grips to both sides of

the front lid, and remove the front lid from 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 -
18 N·m {1.2 - 1.8 kgf·m, 9 - 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}

56-pin-SMJ connector bolt replacement

1. Separate the female and male connectors by prying apart
with a standard 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.

CB-8
 CAB ASSEMBLY CAB BODY

84-pin-SMJ connector bolt replacement

1. Insert BOLT HOLDER TOOL (99781 Z0000) into the four
slits on the male connector.

2. With BOLT HOLDER TOOL held in that position, pull the

bolt out by lifting the holder with your hand.
NOTE
z Always replace the bolt after removing the connector
cover.

3. Remove the bolt from the male connector while holding the
bolt with pliers and loosening the screw. Separate the
female and male connectors by pulling them in the direc-
tions shown by the arrows.
NOTE
z The female and male connectors need not be separated
when only replacing the bolt with a new one.

4. Install a new bolt and washer from the outside of the bolt
holder.

5. With the bolt holder (with the bolt attached) on a flat sur-
face, install the stopper ring onto the bolt from the inner
side.
6. Drive the stopper ring onto the bolt using the SMJ BOLT
TOOL (99782 Z0000), and assemble the bolt holder.

CB-9
 CAB ASSEMBLY CAB BODY

7. Install the bolt holder on the male connector with the con-
cave portion facing the harness grommet.
NOTE
z Ensure that the bolt holder is inserted into the male con-
nector until a “click” is heard (to indicate that the pawl is
securely engaged with the connector).

8. After connecting the SMJ connector, install the box cover

(used to keep air and water out).
NOTE
z Ensure that the water-proof grommet is properly seated
when installing the box cover.

INSTALLATION
Key point of installation
Move the vehicle to a safe, spacious location so that the cab can be
installed with a hoist or crane. Chock all wheels securely.
1. To install the cab assembly, reverse the order of removal.
Replace the parts which require replacement (rubber parts)
with new ones.
2. Install the hinge bracket cap.

NOTE
z Ensure that dimensions A and B (shown in the figure
right) are equal before installing the cab suspension link
cap.

: 78 - 98 N·m {8 - 10 kgf·m, 58 - 72 ft·lbf}

CB-10
 CAB ASSEMBLY CAB BODY

3. Install the steering yoke shaft on the sleeve yoke.

NOTE
z Ensure the alignment marks are aligned properly before
installation.

<MANUAL TILT TYPE>

1. When installing the torsion bar on the hinge bracket, make
sure that the rotating direction and right and left sides are
correct.

NOTE
z Align the cutout grooves in the torsion bar with the align-
ment marks on the tilt hinge brackets.

2. When installing the torsion arm on the torsion bar, the flat
part of both parts should join.

NOTE
z Align the white painted marks on the flat part when
installing.

CB-11
 DOOR CAB BODY

DOOR
DISASSEMBLY
R.H. DOOR

Inner R.H. door

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

CB-12
 DOOR CAB BODY

Outer R.H. door

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
NOTE
z The drawing shows the left-hand drive model equipped with safety window.

1.Cap 14.Finisher bracket , 25.Glass runner

2.Glass protector +, 15.Film 26.Center sash assembly
3.Pull handle cap 16.Relay bracket* 27.Door glass
4.Pull handle 17.Relay assembly* 28.Door glass holder
5.Ash tray 18.Step light assembly 29.Rear lower sash assembly
6 Ash tray bracket 19.Power window unit assembly* , 30.Door ventilator assembly
7.Handle escutcheon 31.Door lock knob
20.Power window breaker assembly*
+ 8.Power window switch assembly 32.Door lock assembly
9.Switch finisher* 21.Door moulding assembly 33.Door handle assembly
10.Door window handle , 22.Guide channel 34.Cylinder assembly
+ 11.Door lower finisher assembly +, 23.Power window motor (Regulator) 35.Side turn signal light assembly
12.Door upper finisher assembly assembly* 36.Wiring harness assembly*
13.Handle support +, 24.Regulator assembly ,37.Side view glass assembly*1
38.Door panel assembly
Parts with an asterisk (*) are only for vehicles with power window.
Parts with an asterisk (*1) are only for vehicles with side view glass.
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CB-13
 DOOR CAB BODY

Key point of disassembly

8 Power window switch finisher
Pry the power window switch finisher clips off using a flat-blade
screwdriver.

11 Door lower finisher assembly

Pry the door lower finisher assembly clips off using a standard
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.

23 Power window motor (Regulator) assembly

24 Regulator assembly
1. Remove the screws securing the guide channel, and sepa-
rate the power window motor (regulator) assembly or regu-
lator assembly from the door glass.

2. Remove the bolts securing the power window motor (regu-

lator) assembly or regulator assembly to the door, and
remove the motor assembly or regulator assembly through
the access hole in the door panel.

CB-14
 DOOR CAB BODY

L.H. DOOR

Inner L.H. door

CB-15
 DOOR CAB BODY

Outer L.H. door

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
NOTE
z The drawing shows the right-hand drive model equipped with safety window.

1. Cap , 15. Glass runner 28. Door lock assembly

2. Glass protector 16. Center sash assembly 29. Rubber seal
3. Ash tray , 17. Door ventilator assembly 30. Rear lower sash
4. Ash tray bracket 18. Finisher bracket , 31. Side view glass assembly*1
5. Handle finisher 19. Handle support 32. Door finisher
6. Handle escutcheon , 20. Film 33. Door handle
7. Door inner glass assembly , 21. Film 34. Door handle finisher
8. Door lock 22. Door glass 35. Cylinder assembly
9. Door hinge 23. Glass support 36. Door moulding assembly
10. Spacer 24. Power window breaker assembly* 37. Side turn signal light assembly
+, 11. Inner door glass weatherstrip*1 +, 25. Power window motor (Regulator) 38. Escutcheon
+ 12. Door finisher assembly assembly* 39. Wiring harness assembly*
13. Power window switch assembly* +, 26. Regulator assembly 40. Door panel assembly
14. Door window handle 27. Door lock knob
Parts with an asterisk (*) are only for vehicles with power window.
Parts with an asterisk (*1) are only for vehicles with side view glass.
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CB-16
 DOOR CAB BODY

Key point of disassembly

11 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.

12 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.
z Locate the screwdriver as close to the trim clip as possi-
ble before prying the clip off.

25 Power window motor (regulator) assembly

26 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-17
 DOOR CAB BODY

4. Remove the inner door glass weatherstrip and door finisher

assembly.
NOTE
z Refer to items 11 and 12.

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.

REASSEMBLY
R.H. DOOR
Key point of reassembly
37 Side view glass assembly
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.
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 outside, fit the weatherstrip over the
flange, pulling the string out inside the compartment.

CB-18
 DOOR CAB BODY

NOTE
z Do not tap any part of the glass except the middle portion
shown by hatches in the figure.
z Do not use a rubber-faced hammer. Use the palm of your
hand.
3. Evenly tap the glass with the palm of your hand until the
weatherstrip settles properly.

30 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.

25 Glass runner
Observe the following note before installing the glass runner.
NOTE
z Ensure that the weatherstrip is free of scratches or
cracks. Replace with a new one if necessary.

23 Power window motor (regulator) assembly

24 Regulator assembly
Insert the power window motor (regulator) assembly or regulator
assembly into the access hole in the door panel, and secure with
bolts.

22 Guide channel
Position the guide channel in the power window motor (regulator)
assembly or regulator assembly, and secure it to the glass holder
using screws.

CB-19
 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).

L.H. DOOR
Key point of reassembly
31 Side view glass
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.
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.

CB-20
 DOOR CAB BODY

25 Power window motor (regulator) assembly

26 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.

20, 21 Film
Before installing the waterproof film, observe the following note.
NOTE
z Ensure that the film is free of scratches, cuts or holes.
Replace with a new one if necessary.
z Always install the film on the butyl tape which has been
installed in advance.

17 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.
15 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.

11 Inner door glass weather strip

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.

CB-21
 CAB MOUNTING CAB BODY

CAB MOUNTING
REMOVAL AND INSTALLATION
Open the front lid, and remove and install the center lower grill assembly.

DISASSEMBLY AND REASSEMBLY

ELECTRIC TILT TYPE
FRONT

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cap 6. Pin 11. Spring

2. Pin 7. Cab suspension link assembly 12. Spring seat
3. Hinge bushing 8. Link bracket 13. Spring bracket
4. Tilt hinge support 9. Hinge bushing
5. Shock absorber 10. Bound stopper

CB-22
 CAB MOUNTING CAB BODY

REAR

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Tilt lock pin assembly 6. Spring seat 11. Cab mounting lower bracket
2. Suspension link assembly 7. Spring
3. Shock absorber 8. Bound stopper
4. Rubber cushion 9. Cab mounting upper bracket
5. Sub frame 10. Shock absorber bracket

CB-23
 CAB MOUNTING CAB BODY

LOCK SYSTEM

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Tilt lock assembly (R.H.) 3. Handle bracket assembly 5. Handle rod assembly
2. Tilt lock assembly (L.H.) 4. Rod assembly 6. Tilt switch assembly

CB-24
 CAB MOUNTING CAB BODY

MANUAL TILT TYPE

FRONT

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Cap 6.Contact rubber 11.Torsion bushing
2.Bolt 7.Torsion bar arm 12.Torsion bushing
3.Hinge bushing 8.Tilt hinge bracket
4.Tilt hinge support 9.Torsion bar (L.H. side)
5.Torsion clamp 10.Torsion bar (R.H. side)

CB-25
 CAB MOUNTING CAB BODY

REAR

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Cab mounting cushion 7.Hook 12.Bracket
2.Cushion 8.Sub hook rod 13.Rod guide
3.Spacer 9.Spring 14. Chain
4.Main hook pin 10.Safety hook 15. Pin
5.Cushion 11.Cab mounting bracket (Upper) 16. Cab mounting bracket (Lower)
6.Safety rod

CB-26
 CAB MOUNTING CAB BODY

LOCK SYSTEM

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Safety bracket 5.Tilt lock assembly (L.H.) 9.Spring rod
2.Tilt lock assembly (R.H.) 6.Rod 10.Bracket
3.Rod assembly 7.Tilt handle
4.Rod 8.Spring

CB-27
 ELECTRIC TILT CAB BODY

ELECTRIC TILT
CONSTRUCTION
<TILT CYLINDER>

<ELECTRIC OIL PUMP>

CB-28
 ELECTRIC TILT CAB BODY

HYDRAULIC SYSTEM

CB-29
 ELECTRIC TILT CAB BODY

WARNING CIRCUITS

CB-30
 ELECTRIC TILT CAB BODY

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly

+, 1.Fastener band 11.Hose support 21. Clamp
+, 2.Tilt wire assembly 12.Cover rivet 22. Spacer
+, 3.Oil hose assembly (Down) 13.Tilt cover 23. Tilt tube assembly (Down No. 2)
+, 4.Oil hose assembly (Up) 14.Tilt wire assembly 24. Tilt tube assembly (Up No. 2)
+, 5.Tilt cylinder assembly +, 15.Tilt pump assembly 25. Heat insulator
+, 6.Tilt stroke switch 16.Start switch 26. Clamp
+, 7.Tilt stopper-detection switch 17.Tilt lever assembly 27. Stay
8.Tilt cylinder bracket 18. Tilt pump bracket assembly 28. Tube clip
9.Tilt cylinder bracket 19. Straight union 29. Tilt tube assembly (Down No. 1)
10.Hose support 20. Straight union 30. Tilt tube assembly (Up No. 1)
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CB-31
 ELECTRIC TILT CAB BODY

Key point of removal

z Lower the cab to the standard position and chock the
wheels.

Key point of removal

1 Fastener band
Disconnect the stroke and stopper-detection switch connectors
from the tilt cylinder. Unfasten the fastener bands which secure the
electrical wiring.

2 Tilt wire assembly 2

Remove the cotter pin from the end of the tilt cylinder lock release
lever, and disconnect the lock release cable from the lever.

3, 4 Oil hose assembly

Disconnect the oil hose (on the tilt cylinder side) from the oil pump
tube (on the oil pump side).
NOTE
z Before disconnecting the oil hose, place a container
under the connection to catch the oil.

5 Tilt cylinder assembly

1. Remove the self lock nut which secures the lower end (on
the check valve side) of the tilt cylinder.
NOTE
z Do not reuse the self-locking nut.

CB-32
 ELECTRIC TILT CAB BODY

2. Remove the nuts and bolts which secure the upper side of
the tilt cylinder to the sub-lever and cab. Remove the tilt cyl-
inder assembly.

6, 7 Tilt stroke and stopper-detection switch

Remove the stroke and stopper detection switch from the tilt cylin-
der.

15 Tilt pump assembly

Disconnect the tube assembly from the tilt pump assembly, then
the pump assembly from the pump bracket assembly.
NOTE
z Place a container on the floor to catch oil before discon-
necting the tube assembly.

INSPECTION
Check the ensure no leakage exists at any part of the hydraulic sys-
tem.

ELECTRIC OIL PUMP FLUID

1. Check to ensure the oil level is even with the plug hole in
the reservoir when the cab is lowered.

Type of oil used MIL-H-5606E

Reservoir oil quantity 450 mili liter (15.8 Imp fl oz)

2. Operate the hydraulic oil pump, and raise and lower the
cab.
3. Re-check the oil level in the hydraulic oil pump as the oil
flows through the cylinder and piping during operation.
NOTE
z Ensure that the cab is properly lowered before checking
the oil level.

CB-33
 ELECTRIC TILT CAB BODY

TILTING SPEED
1. Tilt the cab up and down two or three times to ensure the
hydraulic oil pump properly operates as indicated below.
NOTE
z Ensure that a 200 kg (441 lb) weight is loaded on the seat
rack before measuring tilting speeds.

Item Maintenance standard Service limit

Tilt-up time 25sec., max. —
Tilt-down time 11sec., max. —

REASSEMBLY
Key point of reassembly
NOTE
z Lower the cab to the standard position and chock the
wheels.

15 Tilt pump assembly

Install the tilt pump assembly on the pump bracket assembly, then
connect the tube assembly to the tilt pump assembly.
6, 7 Tilt stroke and stopper-detection switch
Install the stroke and stopper-detection switch for the tilt cylinder.

5 Tilt cylinder assembly

1. Install the sub-lever (located on the upper end of the tilt cyl-
inder assembly), and secure with bolts and nuts.
: 78 - 118 N·m {8 - 11 kgf·m, 58 - 80 ft·lbf}

CB-34
 ELECTRIC TILT CAB BODY

2. Position the lower end of the tilt cylinder assembly in the

cylinder bracket, and secure with self-locking nuts.
NOTE
z Always use new self-locking nuts.

: 47 - 64 N·m {4.8 - 6.5 kgf·m, 35 - 47 ft·lbf}

3, 4 Oil hose assembly

Connect the oil hose assembly to the tilt cylinder assembly, then
the oil hose assembly to the tube assembly.
NOTE
z Apply sealing tape to the oil hose connector before con-
necting it to the tilt cylinder.

2 Tilt wire assembly

Connect the wire assembly to the end of the tilt cylinder lock
release lever, and secure with the pin and cotter pin.

1 Fastener band
Connect the switch wiring connector (located on the tilt cylinder
assembly) to the wiring harness, and secure with the fastener band.

CB-35
 GLASS CAB BODY

GLASS
DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of 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-36
 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
Key point of removal
1. Remove the wiper arm.

2. Using a spatula or a flat-blade screwdriver, remove the

windshield and weatherstrip.

REASSEMBLY
INSTALLATION
Key point of installation
1. Fit the weatherstrip to the edges of the windshield, and fit a
strong string [5 to 8 mm (0.20 to 0.31 in) dia. and 5 to 7 m
(16 to 23 ft) long] in the outer edge of the weatherstrip.
Passing the string through a copper pipe [8 mm (0.31 in),
inside dia.] and using the pipe as a guide facilitates the
installation of the weatherstrip.
NOTE
z Always install the weatherstrip with the water drain hole
facing downward.

2. While placing the end of the string inside the compartment,

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-37
 GLASS CAB BODY

NOTE
z Do not tap any part of the windshield except the middle
portion shown by hatches in the figure.
z Do not use a rubber-faced hammer. Use the palm of your
hand.

3. Evenly tap the windshield with the palm of your hand until
the weatherstrip settles properly.
4. Install the wiper arm.

CB-38
 INSTRUMENT PANEL CAB BODY

INSTRUMENT PANEL
DISASSEMBLY
R.H.D. VEHICLES

CB-39
 INSTRUMENT PANEL CAB BODY

1.Rod bracket + 14.Switch escutcheon 27.End finisher

2.Bushing +, 15.Escutcheon 28.Glove box bracket
3.Stopper rod +, 16.Escutcheon 29.Meter cover
4.Hinge +, 17.Cluster lid 30.Instrument upper panel assembly
5.Instrument pad assembly 18.Ventilator assembly +, 31.Instrument support
6.Instrument pad latch 19.End finisher +, 32.Instrument support
7.Grille assembly 20.Grille assembly +, 33.Instrument member assembly
8.Bracket +, 21.Unit bracket 34.Instrument center support
9.Ventilator assembly +, 22.Unit bracket 35.Stopper
10.Ash tray 23.Unit support assembly 36.Striker
11.Bracket 24.Glove box assembly 37.Stopper bracket
12.Instrument panel finisher 25.Lock assembly 38.Instrument pad striker
13.Box 26.Lower cover assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CB-40
 INSTRUMENT PANEL CAB BODY

L.H.D. VEHICLES

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

CB-41
 INSTRUMENT PANEL CAB BODY

1.Rod bracket c 14.Switch escutcheon 27.End finisher

2.Bushing +, 15.Escutcheon 28.Glove box bracket
3.Stopper rod +, 16.Escutcheon 29.Meter cover
4.Hinge +, 17.Cluster lid 30.Instrument upper panel assembly
5.Instrument pad assembly 18.Ventilator assembly +, 31.Instrument support
6.Instrument pad latch 19.End finisher +, 32.Instrument support
7.Grille assembly 20.Grille assembly +, 33.Instrument member assembly
8.Bracket +, 21.Unit bracket 34.Instrument center support
9.Ventilator assembly +, 22.Unit bracket 35.Stopper
10.Ash tray 23.Unit support assembly 36.Striker
11.Bracket 24.Glove box assembly 37.Stopper bracket
12.Instrument panel finisher 25.Lock assembly 38.Instrument pad striker
13.Box 26.Lower cover assembly
Marks “+” and “,” indicate that the key points of operation are explained in the text.

REMOVAL
1. Remove the horn pad. Using the steering wheel puller
(99851 Z0002), remove the steering wheel.
NOTE
z Scribe an alignment mark on the steering wheel before
removal.
z When removing the steering wheel, always use the des-
ignated puller. Do not strike the end of the shaft.

2. Remove the steering column cover.

3. Remove the combination switch.
NOTE
z Be careful not to bend the horn contact point.

Key point of disassembly

14 Switch escutcheon
Pry the switch escutcheon off using a standard screwdriver.
NOTE
z Be careful not to scratch the cluster lid.

15, 16 Escutcheon
Remove the knob and washer, and pry the escutcheon off using a
standard screwdriver.
NOTE
z Be careful not to scratch the cluster lid.

17 Cluster lid
Remove the six screws securing the combination meter assembly,
and remove the cluster lid. Remove the speedometer.
21, 22 Unit bracket
Remove the unit bracket, then the radio.
31, 32 Instrument support, 33 Instrument member assembly
Remove the four nuts securing the heater, air conditioner and
instrument center support. Remove the two screws securing each
side of the inner pillar, and remove the instrument member assem-
bly.

CB-42
 INSTRUMENT PANEL CAB BODY

REASSEMBLY
Key point of reassembly

31, 32 Instrument support, 33 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.
21, 22 Unit bracket
Install the unit bracket on the radio, then the radio on the unit sup-
port assembly.
17 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. Do not route
any harness close to the resistor located on the rear of
the cluster meter since it emits heat during operation.
15, 16 Escutcheon
Install the engine control and stop wire assembly on the instrument
member bracket, and secure with nuts. Position the escutcheon
and install the knob.

INSTALLATION
1. Install the combination switch.
NOTE
z Ensure that the contact point of the combination switch
horn is not deformed before installation. Also check that
the horn sounds properly at any point over the entire
travel range (360°, max.) of the steering wheel when acti-
vated after installation.

2. Install the steering column cover.

3. Install the steering wheel and the horn pad.
NOTE
z Align to the mark placed in advance on the steering
wheel.

: 88 N·m {9 kgf·m, 65 ft·lbf}

CB-43
 COUPLER

CONTENTS
SERVICE DATA................................. CP-1- 1 =UNIT NAME CP1300, JSK37A, J-18.5T-
SPECIFICATIONS......................... CP-1- 1 2(3.5) =
SERVICE DATA............................. CP-1- 2 CONSTRUCTION .............................. CP-2- 1
TIGHTENING TORQUE ................ CP-1- 3 DISASSEMBLY ................................. CP-2- 4
REMOVAL .....................................CP-2- 4
DISASSEMBLY..............................CP-2- 5
INSPECTION .................................... CP-2-11
REASSEMBLY ................................. CP-2-16
REASSEMBLY..............................CP-2-16
ADJUSTMENT.................................. CP-2-22

CP
 SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Unit: mm (in)
Unit name CP-1300 JSK37A J-18.5T-2 J-18.5T-3.5
Coupler type Rubber mounting One shaft Two shaft Two shaft
Vertical direction Rubber cushion Complete bolt Pitching shaft Pitching shaft
Buffer
Horizontal direction Rubber cushion – Rolling shaft Rolling shaft
Height of coupler unit (h)

177 - 217 185 296 296

(6.97 - 8.54) (7.28) (11.65) (11.65)

Pitch angle b, b‘ 15° 15° 14° 14°

Roll angle a, a‘ — — 4° 4°
Kingpin used

50.8 50.8 50.8 88.9

(2.000) (2.000) (2.000) (3.500)

Roll angle Pitch angle

CP-1-1
 SERVICE DATA

SERVICE DATA
UNIT NAME CP-1300
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Kingpin O.D. 50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961) —
Diameter of jaw at kingpin loca-
51.0 - 51.2 (2.008 - 2.016) 52.0 (2.047) —
tion
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 jaw
0.18 - 0.20 (0.0071 - 0.0079) 0.5 (0.020) —
pin
Clearance between jaw pin head
and upper surface of coupler 2.0 - 3.0 (0.079 - 0.118) 0.5 (0.020) —
base
Replace or remove shims
2 years or 200,000 km
Cushion rubber — according to wear on rubber
(120,000 miles)
cushion

UNIT NAME JSK37A

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Kingpin O.D. 50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961)
Lock jaw thickness 19.0 (0.748) 17.5 (0.689)
Wearing ring thickness 33.5 (1.319) 30.5 (1.201)
Clearance between inner ring
— 3.0 (0.118)
and outer ring

UNIT NAME J-18.5T-2, J-18.5T-3.5

Unit: mm (in)
Item Maintenance standard Service limit Remarks
J-18.5T-2 50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961)
Kingpin O.D.
J-18.5T-3.5 88.77 - 89.03 (3.4949 - 3.5051) 87.9 (3.461)
Diameter of jaw at J-18.5T-2 51.2 - 51.8 (2.016 - 2.039) 53.5 (2.106)
king-pin location J-18.5T-3.5 89.7 - 90.3 (3.531 - 3.555) 92.5 (3.642)
Clearance between J-18.5T-2 0.3 - 1.1 (0.012 - 0.043) 3.7 (0.146)
jaw and kingpin J-18.5T-3.5 0.67 - 1.53 (0.0264 - 0.0602) 4.6 (0.181)
Diameter of jaw pin hole 50.08 - 50.12 (1.9716 - 1.9732) 50.5 (1.988)
Jaw pin O.D. 50.03 - 50.05 (1.9697 - 1.9705) 49.7 (1.9567)
Engagement width of plunger and jaw 69.90 - 69.95 (2.7520 - 2.7539) 69.0 (2.717)
Not suitable for further
Bend of plunger shaft Less than 0.3 (0.012) 1.0 (0.039)
use if cracked
Clearance between jaw and jaw pin 0.03 - 0.09 (0.0012 - 0.0035) 0.5 (0.020)
Pitching shaft O.D. 69.94 - 69.97 (2.7535 - 2.7547) 69.7 (2.7441)

CP-1-2
 SERVICE DATA

Unit: mm (in)
Item Maintenance standard Service limit Remarks
Pitching shaft bushing I.D. 70.15 - 70.18 (2.7618 - 2.7630) 70.5 (2.7756)
Clearance between pitching shaft and
0.18 - 0.24 (0.0071 - 0.0094) 0.6 (0.024)
bushing
Rolling shaft O.D. 69.94 - 69.97 (2.7535 - 2.7547) 69.7 (2.744)
Rolling shaft bushing I.D. 70.15 - 70.18 (2.7618 - 2.7630) 70.5 (2.776)
Clearance between rolling shaft and
0.18 - 0.24 (0.0071 - 0.0094) 0.6 (0.024)
bushing
Clearance between working beam and
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
sub base (in direction of rolling shaft)
Clearance between coupler base and
working beam (in direction of pitching 0.2 - 0.8 (0.008 - 0.031) 1.5 (0.059)
shaft)
It is suitable for further
Wear on upper surface of coupler base
use if pin head does not
(or: clearance between jaw pin head 2.0 (0.079) 0.5 (0.020)
come into contact with
and upper surface of coupler base)
kingpin plate.

TIGHTENING TORQUE
UNIT NAME CP-1300
Unit: N·m {kgf·m, ft·lbf}
Item 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}

UNIT NAME JSK37A

Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Complete bolt 30 {3.1, 21}
Head bolt 140 {14.3, 100}
Coupler assembly mounting bolt 167 - 226 {17 - 23, 123 - 16}

UNIT NAME J-18.5T-2, J-18.5T-3.5

Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Sub base mounting bolt 108 {11, 80}
Plate mounting bolt 29 {3, 22}
Pitching shaft set bolt 29 {3, 22}
Latch nut 15 {1.5, 11}
Latch stud 44 {4.5, 33}
Adjusting wedge mounting bolt 108 {11, 80}
Coupler assembly mounting bolt 196 - 265 {20 - 27, 145 - 195}

CP-1-3
 CONSTRUCTION CP-1300, JSK37A, J-18.5T-2(3.5)

=UNIT NAME CP1300, JSK37A, J-18.5T-2(3.5) =

CONSTRUCTION
UNIT NAME CP-1300

CP-2-1
 CONSTRUCTION CP-1300, JSK37A, J-18.5T-2(3.5)

UNIT NAME JSK37A

CP-2-2
 CONSTRUCTION CP-1300, JSK37A, J-18.5T-2(3.5)

UNIT NAME J-18.5T-2, J-18.5T-3.5

CP-2-3
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

DISASSEMBLY
REMOVAL
Key point of removal
1. Use a crane or a hoist for disassembling. Remain safety
conscious. Before starting disassembly, clean each portion
of the assembly.

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)
Unit name Maintenance standard Service limit
CP-1300 2.0 - 3.0 (0.079 - 0.118) 0.5 (0.020)
J-18.5T-2
2.0 (0.079) 0.5 (0.020)
J-18.5T-3.5

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-1300 only)

CP-2-4
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

DISASSEMBLY
UNIT NAME CP-1300

CP-2-5
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Bolt 18.Plain washer 35.Limit switch
2.Nut 19.Roller 36.Limit dog
3.Earth wire 20.Cotter pin , 37.Adjusting nut
4.Sub base 21.Castellated nut 38.Plain washer
5.Bracket 22.Plain washer 39.Rubber
6.Base spring 23.Roller 40.Yoke spring
7.Bolt 24.Plain washer 41.Yoke shaft
8.Lock washer 25.Bolt 42.Yoke
9.Clamp 26.Lock spring 43.Snap pin
+ 10.Shim 27.Spring pin 44.Lock guard pin
+ 11. Cushion rubber , 28.Secondary lock 45.Lock guard spring
+ 12.Cushion rubber 29.Cam plate , 46.Lock guard
13.Lever spring 30.Plain washer 47.Cotter pin
14.Lever 31.Nut 48.Jaw pin
15.Bolt 32.Lock washer 49.Jaw spring
16.Square lock washer 33.Bolt 50.Jaw
17.Bolt 34.Switch bracket 51.Coupler base
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CP-2-6
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

UNIT NAME JSK37A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1.Bolt 10.Wearing ring 19.Grease nipple assembly
2.Pedestal 11.Eyebolt ,+20. Outer ring
3.Spring 12.Spring ,+21.Inner ring
4.Head bolt assembly 13.Pivot 22.Seal
, 5.Operating handle 14.Lock jaw 23.Pin
, 6.Lever 15.Adjusting screw 24.Spring hook
7.Locking bar bolt assembly 16.Nut 25.Coupler base
8.Locking bar 17.Guide
9.Head bolt 18.Grease nipple
Marks “+” and “,” indicate that the key points of operation are explained in the text.

CP-2-7
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

UNIT NAME J-18.5T-2, J-18.5T-3.5

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

CP-2-8
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

1.Bolt 20.Washer , 39.Jaw

2.Washer 21.Spacer 40.Washer
3.Nut 22.Washer 41.Coupler base
4.Washer , 23.Guide pin 42.Grease nipple
5.Pin 24. Pin 43.Bolt
6.Nut 25.Nut 44.Washer
7.Bolt 26.Washer 45.Plate
,+ 8.Pitching shaft 27.Latch ,+ 46.Rolling shaft
9.Bolt 28.Latch shaft , 47. Bushing
10.Lock washer 29.Washer 48.Working beam
11.Spring ,+ 30.Plunger 49.Plate
12.Stopper 31.Plunger , 50.Bushing
13.Grease nipple 32.Pin 51.Grease nipple
14.Pin 33.Washer 52.Bolt
15.Washer 34.Lever 53.Nut
16.Washer 35.Lever pin 54.Washer
, 17. Jaw pin , 36.Jaw spring (J-18.5T-2) 55.Wedge
18.Latch spring , 37.Jaw spring (J-18.5T-3.5) 56.Sub base
19.Pin 38.Hook (J-18.5T-3.5) 57.
Marks “+” and “,” indicate that the key points of operation are explained in the text.

Key point of disassembly

<Unit name CP-1300>
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.

<Unit name JSK37A>

Place the coupler assembly on a square work bench of 700 mm
(27.56 in) on which there is a 50.8 mm (2.000 in) kingpin in the cen-
ter. Lock the kingpin and coupler.
NOTE
z The kingpin should protrude by dimension (A) of 84 -1.5
mm (3.307 - 0.059 in).

CP-2-9
 DISASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

20 Outer ring
Remove the outer ring.

21 Inner ring
To remove the inner ring, tap it with a hammer. If necessary, also
remove the seal.

<Unit name J-18.5T-2, J-18.5T-3.5>

8 Pitching shaft
To remove the pitching shaft, remove the bolts which prevent it from
turning from both ends of the shaft. If the shaft is bent or seized,
use a press to extract the shaft as it is difficult to extract the shaft by
tapping with a hammer.

30 Plunger
With the lever pulled, fasten the latch to the plunger. Place a
wooden block between the hole in the plunger and the coupler base
to prevent the plunger from returning.
NOTE
z To prevent an accident, ensure that the plunger does not
return by spring tension.

46 Rolling shaft
Push down the working beam slightly using a jack, and drive out the
rolling shaft.

CP-2-10
 INSPECTION CP-1300, JSK37A, J-18.5T-2(3.5)

INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the repair limit or wear limit
has been exceeded, repair or replace faulty parts.

Kingpin O.D.
Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300
JSK37A 50.7 - 50.9 (1.996 - 2.004) 49.8 (1.961)
J-18.5T-2
J-18.5T-3.5 88.77 - 89.03 (3.4949 - 3.5051) 87.9 (3.461)

Diameter of jaw at kingpin location

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 51.0 - 51.2 (2.008 - 2.016) 52.0 (2.047)
JSK37A — —
J-18.5T-2 51.2 - 51.8 (2.016 - 2.039) 53.5 (2.106)
J-18.5T-3.5 89.7 - 90.3 (3.531 - 3.555) 92.5 (3.642)

Clearance between jaw and kingpin

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 0.1 - 0.5 (0.004 - 0.020) 2.0 (0.079)
JSK37A — —
J-18.5T-2 0.3 - 1.1 (0.012 - 0.043) 3.7 (0.146)
J-18.5T-3.5 0.67 - 1.53 (0.0264 - 0.0602) 4.6 (0.181)

Diameter of jaw pin hole

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 28.8 (1.134) 29.5 (1.161)
JSK37A — —
J-18.5T-2
50.08 - 50.12 (1.9716 - 1.9732) 50.5 (1.988)
J-18.5T-3.5

CP-2-11
 INSPECTION CP-1300, JSK37A, J-18.5T-2(3.5)

Jaw pin O.D.

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 28.6 (1.126) 28.3 (1.114)
JSK37A — —
J-18.5T-2
50.03 - 50.05 (1.9697 - 1.9705) 49.7 (1.9567)
J-18.5T-3.5

Engagement width of plunger and jaw

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
69.90 - 69.95 (2.7520 - 2.7539) 69.0 (2.717)
J-18.5T-3.5

Bend of plunger shaft

Unit: mm (in)
Maintenance stan-
Unit name Service limit Remarks
dard
CP-1300 — — —
JSK37A — — —
J-18.5T-2 Less than 0.3 Not suitable for further use
1.0 (0.039)
J-18.5T-3.5 (0.012) if cracked

Clearance between jaw and jaw pin

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 0.18 - 0.20 (0.0071 - 0.0079) 0.5 (0.020)
JSK37A — —
J-18.5T-2
0.03 - 0.09 (0.012 - 0.035) 0.5 (0.020)
J-18.5T-3.5

Cushion rubber
Maintenance
Unit name Service limit Remarks
standard
2 years or 200,000 Replace or remove
CP-1300 — km (120,000 shims according to wear
miles) on rubber cushion
JSK37A — — —
J-18.5T-2
— — —
J-18.5T-3.5

CP-2-12
 INSPECTION CP-1300, JSK37A, J-18.5T-2(3.5)

Lock jaw thickness

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A 19.0 (0.748) 17.5 (0.689)
J-18.5T-2
— —
J-18.5T-3.5

Wearing ring thickness

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A 33.5 (1.319) 30.5 (1.201)
J-18.5T-2
— —
J-18.5T-3.5

Clearance between inner ring and outer ring

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — 3.0 (0.118)
J-18.5T-2
— —
J-18.5T-3.5

Pitching shaft O.D.

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
69.94 - 69.97 (2.7535 - 2.7547) 69.7 (2.744)
J-18.5T-3.5

Pitching shaft bushing I.D.

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
70.15 - 70.18 (2.7618 - 2.7630) 70.5 (2.776)
J-18.5T-3.5

CP-2-13
 INSPECTION CP-1300, JSK37A, J-18.5T-2(3.5)

Clearance between pitching shaft and bushing

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
0.18 - 0.24 (0.0071 - 0.0094) 0.6 (0.024)
J-18.5T-3.5

Rolling shaft O.D.

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
69.94 - 69.97 (2.7535 - 2.7547) 69.7 (2.744)
J-18.5T-3.5

Rolling shaft bushing I.D.

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
70.15 - 70.18 (2.7618 - 2.7630) 70.5 (2.776)
J-18.5T-3.5

Clearance between rolling shaft and bushing

Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
0.18 - 0.24 (0.0071 - 0.0094) 0.6 (0.024)
J-18.5T-3.5

Clearance between working beam and subbase (in

direction of rolling shaft)
Unit: mm (in)
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
0.1 - 0.4 (0.004 - 0.016) 1.0 (0.039)
J-18.5T-3.5

CP-2-14
 INSPECTION CP-1300, JSK37A, J-18.5T-2(3.5)

Clearance between coupler base and working beam (in

direction of pitching shaft)
Unit: mm (in
Unit name Maintenance standard Service limit
CP-1300 — —
JSK37A — —
J-18.5T-2
0.2 - 0.8 (0.008 - 0.031) 1.5 (0.059)
J-18.5T-3.5

CP-2-15
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

REASSEMBLY
REASSEMBLY
Key point of reassembly
<Unit name CP-1300>
46 Lock guard and 28 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)
Maintenance standard Service limit
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.

CP-2-16
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

<Unit name JSK37A>

21 Inner ring
The cylinder pin of the bearing stud must project into the groove on
the inner bearing.

20 Outer ring
Grease hole on the outer ring must be facing in direction of upper
side of plate. After the outer ring has been hammered in it stands
about 2 to 3 mm (0.08 to 0.12 in) in from the outer edge of the seat.

6 Lever, 5 Operating handle

Install the lever and operating handle beforehand. Apply grease to
the bolt, tighten the nut and back it off by a half turn, then insert the
pin.

INSPECTION AFTER ASSEMBLY

1. The function of the automatic locking procedure of the fifth
wheelmechanism is checked as follows: When the operat-
ing handle is kept in the direction shown by the arrow with
the kingpin released, dimension “g” should be 6 mm (0.24
in). If it is less than 6 mm (0.24 in), check the lever, handle
and locking lever for deformation and wear.

2. Check the proper function of the safety mechanism: When

the handle is locked with the kingpin connected, dimension
“h” from the cutout end of the handle to the side face of the
coupler base is 10 mm (0.39 in) or more. If the dimension is
less than specified, check the locking parts, operating han-
dle and lever for deformation.

CP-2-17
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

3. Wear check in coupled-up position: The appropriate forward

and rearward play of a new kingpin and jaw mechanism is
0.3 mm (0.012 in).

If the second cutout notch of the handle is in contact with the cou-
pler base, check the wearing ring, lock jaw and kingpin. If the lever
bushing hits against the casting [dimension “i” in the illustration of
step 2 is 0 mm (0 in)], check dimension “h” shown in step 2.

<Unit name J-18.5T-2, J-18.5T-3.5>

Assembly of coupler base
39 Jaw
37 Jaw spring <J-18.5T-3.5>
36 Jaw spring <J-18.5T-2>
1. Place the base on the work bench with the sliding surface
face down.
2. Hook the jaw spring to the jaw. Hook one end of the jaw
spring to the pin on one of the jaws. (J-18.5T-2)Hook one
end of the jaw spring to the installation hole in the jaw. Do
this for both jaws. (J-18.5T-3.5)
3. Close the right and left jaws. With the sides hooked by the
jaw spring facing down, install the jaws so that the base
side holes align with the jaw pin holes.

30 Plunger
Place a wooden block between the hole in the plunger and the cou-
pler base to prevent the plunger from returning.
NOTE
z To prevent an accident, ensure that the plunger does not
return by spring tension.

CP-2-18
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

23 Guide pin
Insert a round bar into the hole in the base, jaw and washer. Turn
the bar to center the holes and remove the bar, then insert the
guide pin.
NOTE
z Be sure to use a round bar for centering. Do not use the
hand.

17 Jaw pin
1. Place the coupler base with the top face up.
2. Withdraw the guide bar and insert the jaw pin.
NOTE
z Apply grease to the jaw pin before installing it.
z Be sure to align the eccentric spot face of the coupler
base with the eccentric portion of the jaw pin before driv-
ing the pin into place.

Assembly of sub base assembly

50 Bushing
Drive the bushing into the working beam.
NOTE
z Be sure to align the grease hole in the bushing with the
grease nipple hole in the beam.

47 Bushing
Drive the bushing into the hole of the sub base.
NOTE
z Ensure that the slit on the bushing is to the side.

46 Rolling shaft
1. Place the 2 level springs on the spring seat on the sub base
so that the grease nipple side of the working beam is
located to the opposite side of the wedge installation side.
Place a weight of 50 to 60 kg (110 to 132 lb) on the working
beam and align the hole in the rolling shaft and working
beam.

CP-2-19
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

2. Apply grease to the rolling shaft, and install it with the

recess facing up.

Assembly of coupler assembly

8 Pitching shaft
1. Place the coupler base on the work bench with the top side
down and securely hold the base.
2. Upon completion of inspection of the sub base, apply
grease to the inner wall of the bushing for the working beam
pitching shaft.
3. Install the sub base to the coupler base with the wedge fac-
ing the rear of the coupler.
4. Drive the pitching shaft into the bore by properly aligning
the set bolt holes in the pitching shaft with the coupler base.

INSPECTION AFTER ASSEMBLY

1. Using a kingpin (dummy pin), make sure the jaw holds the
kingpin smoothly by repeating the holding operation several
times.

2. Make sure the latch engages the plunger securely when the
lever is pulled.

CP-2-20
 REASSEMBLY CP-1300, JSK37A, J-18.5T-2(3.5)

3. With the jaw closed, make sure the shaft tip of the lock
plunger goes into the inner side of the plunger stopper slid-
ing surface and the stopper closes securely.

4. When the jaw is ready to be connected (open), make sure

the shaft tip of the lock plunger protrudes the sliding surface
of the plunger stopper and prevents the stopper from clos-
ing.

CP-2-21
 ADJUSTMENT CP-1300, JSK37A, J-18.5T-2(3.5)

ADJUSTMENT
<Unit name CP-1300>
1. 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.

2. When rubber (A) or (B) wears, pushing impact or vibration

from the trailer becomes larger. Remove the shim and
install the clamp on the coupler base. If there is rattling,
replace rubber (A) and (B).

<Unit name JSK37A>

1. The king pin in the locking mechanism should have a longi-
tudinal movement of at least 0.3 mm (0.012 in). The adjust-
ment of the locking mechanism can be carried out with the
fifth wheel mounted on the tractive unit or on a mounting
bench. A properly dimensioned king pin (maximum wear
0.25 mm (0.098 in)) must be used.

2. Loosen nut of adjuster rod to screw out rod until it no longer

touches the top of the locking bar. Then strike operating
handle lightly so that the locking bar reaches its final posi-
tion. Screw in rod until any play between the levers is elimi-
nated and the locking bar can just move or couple up again.
Screw in rod 1.1/2 turns and check nut (1.1/2 turns means
0.3 mm (0.012 in) play).
z With the handle fully pushed in but not secured with the
spring hook screw in the rod until the handle begins to
move outwards.
z If play can still be felt when driving away with the trailer
brakes on then there is no further room for adjustment and
the wearing ring and lock jaw must be replaced.

CP-2-22
 ADJUSTMENT CP-1300, JSK37A, J-18.5T-2(3.5)

<Unit name J-18.5T-2, J-18.5T-3.5>

Slide on the sub base the wedge which adjusts the rolling angle to
provide more clearance between the working beam and wedge. By
doing this, it becomes possible to adjust the amount of rolling
between 0 and 4°.
Loosen the wedge mounting bolt and set the wedge so that the
clearance between the working beam and right and left wedges is
the same. Securely tighten the mounting bolt.

CP-2-23