LIGHT DUTY VEHICLE

(N**)
LABOR TIME GUIDE

FOREWORD
These Labor Time allowances are published by ISUZU for the purpose of imple-
menting the terms of the current Warranty Claim Processing Manual and are
intended for the purpose of computing the compensation payable by ISUZU
MOTORS LIMITED for the performance of warranty, policy and campaign adjust-
ments and other work authorized and performed for the account of ISUZU. The
use of these allowances for any other purposes will be at the discretion of each
dealer. All time allowances are subject to change at any time by ISUZU based on
time studies by ISUZU related to improved methods, techniques or equipment or
other advances in the industry.

ISUZU MOTORS LIMITED

Publication No. L4G-LE-99C3

Printed in Japan
 INTRODUCTION

This Labor Time Guide is designed for more POLICY CODES

convenient and accurate use. The guide is identi-
cal in page format to all Labor Time Guides pro- The policy codes applicable to any labor
duced by ISUZU. In addition to the uniform page operation(s) are noted under the major operation
layout, the Operation Description and Numbering description (if they apply to all operations) or to
System is now standard for all ISUZU vehicles. the left of a particular operation if the operations
listed under a major labor operation description
have different policy requirements. Each letter
PAGE LAYOUT indicates a policy as it applies to an Operation.
Below is a listing of the Policy Codes and
To aid in the use of the Time Guide, the Descriptions used in this publication.
layout has been structured in reading sequence.
Reading from left to right are the “Operation P– Power train
Description” and its qualifiers, followed by the A– Requires Authorization
“Operation Numbers”. On the right hand side of T– Towing Allowed
the page is an area designating the vehicles by E– Emission Related Operation
series with their appropriate times.

OPERATION DESCRIPTION

MAJOR OPERATIONS allowable on that component. These notations,

plus the description of same, are provided below:
Operations having a labor operation number
(A1234) are classified as Major Operations. A REPLACE (as a single action word)
major operation time allowance is sufficient to do The “REPLACE” notation is used when the
the work described as a single operation. part or an assembly is subject to replacement
only. A part is required on the warranty claim.
Operations within each section are generally
arranged in the following manner – Front to R&R (as a single action word)
Rear, Top to Bottom, Right to Left. Sitting in the “R&R” notation indicates the part or assem-
driver’s seat, Right-Hand components are to the bly is repairable and can be removed, repaired,
Driver’s Right, Left-Hand to the Driver’s Left. and reinstalled. All labor operations so noted are
followed by “ADD” statements which cover all
possible repair conditions. This can be a labor
ADD CONDITIONS only operation.
Additional time allowances which may be REPAIR
required for performing a Major Operation or sup- ALIGN (as a single action word)
plement a Major Operation are included in the ADJUST
“ADD” sections under vehicle designation. Each TIGHTEN
“add” is preceded by a letter designation (A, B, The above notation indicate the work (repair)
C, ~) which should be placed on the dealer repair to be performed. This can be a labor only opera-
order under the 5-Position Major Operation Num- tion.
ber if the “ADD” is performed. These letters are
not to appear on the Warranty Claim. REPAIR OR REPLACE
R&R OR REPLACE
The above notations indicate the part or
ACTION WORDS assembly can be repaired, aligned or adjusted on
the vehicle or removed, repaired, and/or
Each labor operation description has been reinstalled or replaced, depending on the extent
revised to clearly identify the repair that is of failure. This can be a labor only operation
when no part or assembly is required.
 RECONDITION Some repair operation time allowances are
When this term is used with a Major Opera- developed from data which indicates that most
tion, it means to remove an assembly from the repairs can be performed in the published time. It
vehicle, disassemble, clean and inspect all parts, is reasonable to assume that additional time may
rebuild the assembly with the same or new parts, be required when unusual conditions are encoun-
reinstall and adjust. When this term is used in an tered. An authorization is required for the addi-
ADD Operation, it does not include Remove and tional time.
Reinstall but only that work necessary to recondi-
tion an assembly once it is removed from the
vehicle. DIAGNOSIS TIME

“Repair diagnosis” time is included in all

INCLUDES established labor time operations where it is
required of the technician to perform the opera-
The Includes which follow some of the tion. It is the responsibility of qualified superviso-
descriptions are provided to assist in knowing ry personnel to assist technicians in “customer
whether or not certain items or functions are problem analysis” and “symptom diagnosis”.
included within the operation. These are not all Service personnel should be contacted for
encompassing because to place all such data in assistance in circumstances requiring extensive
the Guide would make it difficult to use. If there diagnosis. Time for extensive diagnosis will
are any questions as to whether something is require authorization if deemed allowable.
included or not, the Request for Review form may Following are definitions of the terms used in
be used to question or recommend changes. the preceding statement:
“Customer Problem Analysis” – The process
NOTES of translating the customer’s problems to a
symptom. Examples are: A/C insufficient cooling,
Throughout the Time Guide, various notes brakes pull, engine diesels, hesitates, surges, etc.
will be inserted to assist in the use of the Guide. It also includes those failures which are readily
apparent to the normal senses of sight, touch,
sound and smell. Defining these is the duty of the
TIME ALLOWANCES dealership service management and/or service
writer.
All time allowances as indicated in hours and “Symptom Diagnosis” – The process of
tenths of hours published in this guide (except finding the source of a problem based on a
for a few Repair Operations) are based on studies detailed symptom. Symptom diagnosis is com-
of the actual time required to complete the plete when the problem has been found.
operation. No connection with technicians’ “Repair Diagnosis” – The checks, tests and
wages is implied since they are dependent upon measurements needed in the repair to find the
the dealer technician pay plan in use. cause of failure, or identify faulty parts.
The time allowances published have been Examples Are:
determined by performing the operation a suffi-
cient number of times to establish an average ● cleaning and inspection of all parts such
time or to determine that a fair and equitable time as gears and clutch plates;
has been developed. Standard technicians’ hand ● use of common testers such as an ohm-
tools and dealer essential and available tools are meter, voltampere meter or timing light that are
used in performing time studies. No power oper- included in the service manual procedure.
ated wrenches are used for time studies. Pro-
cedures outlined in Service Manuals, other Ser-
vice Publications and good shop practices are
used as a guide when performing the work
necessary to establish time allowances.
The time allowance includes the actual time
required to perform the operation plus an addi-
tional allowance to provide for operating varia-
bles. Time allowances do not include time to
remove and replace special equipment other than
manufacturer options and accessories.
 REQUEST FOR REVIEW VEHICLES MODEL YEAR
Any questions relating to suggested new or Refer to below illustrations for vehicles model.
existing operations and/or time allowances in this
time guide should be submitted on a “Request
for Review” form. These forms can be found at
the end of this Manual. When completing this
form, it is important that vehicle identification '95CabModel
data affecting or influencing the operation in
question be provided. It is also important to sub-
mit a complete (detailed) description of the work
performed. The statement “followed Shop Manual
Procedure” is generally not a sufficient explana-
tion of the procedure followed. Generally, a tech-
nician performs the steps of an operation in a
sequence which is comfortable to him/her and it
is their procedure which we would like to review
and compare with ours. The “Request for
Review” form is primarily intended for your use
to inform us of a problem affecting the ability of
technicians to perform an operation within the
published time allowance. The request should be
forwarded to the address indicated on the form.
All inquiries received at the home office will
be acknowledged and reviewed. A review will be
conducted of the Labor Time Guide text and pro-
cedure as outlined by the model year service
manual and dealer bulletins, restudies will be
conducted as required.

'05CabModel '08CabModel
 VEHICLE AND ENGINE IDENTIFICATION

The Engine Code designation from the Ve-

hicle Identification Number (VIN) is used to iden-
tify the appropriate engine mechanical sections
within this publication. Refer to the VIN chart for
engine identification codes.

ABBREVIATIONS
Abbreviations will be used through the Labor Time Guide. Below is a list of
abbreviations and their meaning.

Abbrevia- Abbrevia-
Description Description
tions tions

A/C Air Conditioning EXC Except

ADD Addition INC Includes
ADJ Adjust I/P Instrument Panel
AIR Air Injector Reactor MAN Manual
ASSY Assembly NEC Necessary
AUTO Automatic OHC Overhead Camshaft
CONT’D Continued P/S Power Steering
CV-JOINT Constant Velosity R&R Remove and Reinstall
CYL Cylinder TRANS Transmission
D&C Disconnect And Connect TPS Throttle Position Sensor
DIFF Differential TURBO Turbocharger
DOHC Double Overhead Camshaft T.V. Throttle Valve
ECM Electronic Control Module VIN Vehicle Identification Number
EFE Early Fuel Evaporation W/ With
EGR Exhaust Gas Recirculation W/O Without
 REQUEST FOR REVIEW FORM
DEALERSHIP INFORMATION
A REVIEW OF LABOR OPERATION
FRANCHISE NAME:
NUMBER WITH A
ISUZU DEALER CODE:
OPERATION DESCRIPTION OF
SUBMITTED BY:

IS REQUESTED BECAUSE: SERVICE MGR. SIGNATURE:

A New Labor Operation description is recommended DISTRIBUTOR USE ONLY

(Record your suggestion in technicians comments)
Published Time is insufficient YES NO
(Completion of step by step labor description on Does the labor listed on the reverse side follow
reverse side is required) the Isuzu Service Manual?
Is the repairing technician Isuzu trained?
Operation Description is incorrect
(Record you suggestion in tech comments) Did you verify the availability/condition of the
essential tools required for this repair?
Other — (Describe in Technicians Comments section)
Did you review this request with both the
Technicians Comments: technician and service manager?
SIGNATURE

recommendation/comments:

SIGNATURE
LABOR OP #

OPERATION DESCRIPTION
STEP DESCRIPTION OF BASIC STEPS TIME
NO. IN MIN.

STEP DESCRIPTION OF BASIC STEPS TIME

NO. IN MIN.

The actual time required to perform this labor operation in our shop is hr.
Vehicle Information

VIN # Engine Family Trans #

Rear Axle # Body Type Special Equip.

Additional Comments:
 TROUBLE CODES
1 BROKEN 43 SHIFTS HARD
2 BROKEN WELD 44 SLIPS OUT OF GEAR
3 STRIPPED 45 WIND NOISE
4 TORN OR PUNCTURED 46 FLOODS
5 CRACKED 47 FLAT SPOT OR HESITATES
6 WORN 48 DISCOLORED
7 SCORED OR SCRATCHED 49 PITTED
8 POOR METAL FINISH 50 ELECTRICAL FAILURES
9 CHIPPED 51 NOT CONNECTED
10 SOILED OR STAINED 52 BINDS, STICKS
11 BENT 53 NOT DRILLED
12 FOREIGN MATERIAL 54 WRONG PART
13 OVERHEATED 55 POOR FIT
14 BURNED 56 INOPERATIVE
15 SEIZED 57 REGISTERS INCORRECTLY
16 PAINT - DIRT OR FOREIGN 58 PART IMPROPERLY INSTALLED
MATERIAL 59 PULLS
17 PAINT - DRY SPRAY, MOTTLING 60 ENGINE PING
SAGS, 61 INCORRECT PRESSURE
OFF-COLOR, ROUGH 62 IMPROPER CLEARANCE
18 PAINT - FILM MARRED OR 63 FADE OR HARD PEDAL
SCRATCHED 64 GLAZED
19 PAINT - THIN OR RUBBED THROUGH 65 SLIPS
20 PAINT - CORROSION, CRAZING, 66 COLLAPSED
CRACKING, CHALKING 67 EXCESSIVE LUBRICATION OR OIL
21 PAINT - POOR REPAIR SOAKED
22 PAINT - FILM SPOTTED 68 INSUFFICIENT LUBRICATION
23 PAINT - FINISH COMES OFF 69 POOR OIL MILEAGE
24 CHROME PLATING DEFECTIVE 70 POOR GASOLINE MILEAGE
25 MISALIGNED 71 PULLED LOOSE
26 MISADJUSTED 72 SPLIT SEAMS
27 LOOSE 73 IMPROPERLY PADDED
29 PART OMITTED 74 FUMES
30 POROSITY 75 RUSTED OR CORRODED
31 POOR MACHINING 76 WRINKLED
32 GLASS - POOR VISION 78 CARBON DEPOSIT
33 WEAK 79 POOR RELEASE
34 OUT OF BALANCE 81 HARD RIDE
35 OUT OF ROUND 82 SURGE
36 VIBRATES 83 HARD STARTING (COLD)
37 POOR ENGAGEMENT 84 HARD STARTING (HOT)
38 DOES NOT SEAT 85 SHEARED
39 GRABS 93 DISCHARGED
40 NOISY 95 SPECIAL POLICY
41 CHATTERS 96 CAMPAIGN
42 LEAKS
A PAINT A
A - 2 PAINT

PAINT EXTERIOR
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

NOTE: All paint operations are ST (straight time) operation which requires
time documentation as detailed in the claims processing manual.
Authorization request is required beyond 1.5 hours.

BUMPER, FRONT
COLOR COAT; ONE PIECE A0028 ST

PANEL, FRONT END

COLOR COAT; UPPER RIGHT CORNER A0142 ST
COLOR COAT; UPPER LEFT CORNER A0143 ST
COLOR COAT; LOWER RIGHT CORNER A0144 ST
COLOR COAT; LOWER LEFT CORNER A0145 ST
COLOR COAT; CENTER A0147 ST

GRILLE
INC: R&R grille, emblem and headlight bezels.
COLOR COAT A0260 ST

PILLAR, WINDSHIELD
COLOR COAT; RIGHT A0800 ST
COLOR COAT; LEFT A0801 ST

ROOF
POLICY: A
Except Spot Repair
COLOR COAT A0880 ST

PILLAR, CENTER
COLOR COAT; RIGHT A1020 ST
COLOR COAT; LEFT A1021 ST

FRAME, FRONT DOOR WINDOW

COLOR COAT; RIGHT A1100 ST
COLOR COAT; LEFT A1101 ST
 PAINT A - 3

PAINT EXTERIOR
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

DOOR, FRONT
INC: Door window frame, R&R mirror.
DOES NOT INC: Drivers vent. on aluminum tilt series,
use spot repair for vent.
COLOR COAT; RIGHT A1220 ST
COLOR COAT; LEFT A1221 ST

PANEL, CAB SIDE

COLOR COAT; RIGHT A1300 ST
COLOR COAT; LEFT A1301 ST

PANEL, CAB BACK

POLICY: A
Except Spot Repair
COLOR COAT A1360 ST

DOOR, REAR
COLOR COAT; RIGHT A1520 ST
COLOR COAT; LEFT A1521 ST

LOAD FLOOR
COLOR COAT A2410 ST

TAILGATE, COMPLETE
COLOR COAT A2920 ST

WHEELS
COLOR COAT; RIGHT FRONT A3300 ST
COLOR COAT; LEFT FRONT A3301 ST
COLOR COAT; RIGHT REAR A3320 ST
COLOR COAT; LEFT REAR A3321 ST

BOX, BATTERY
REFINISH A3450 ST
A - 4 PAINT

PAINT EXTERIOR
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SUPPORT, STEP, DOOR OPENING

COLOR COAT; RIGHT A7560 ST
COLOR COAT; LEFT A7561 ST
B BODY EXTERIOR
B
 BUMPERS, DOORS AND EXTERIOR TRIM B - 3

BUMPER AND FRONT END

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BUMPER ASSEMBLY, FRONT - REPLACE B0048 .5

BUMPER ASSEMBLY, FRONT - ALIGN B0260 .3

BAR, REAR BUMPER FACE - REPLACE B0800 .4

BUMPER ASSEMBLY, REAR - ALIGN B0860 .4

GRILLE ASSEMBLY - REPLACE

ONE PIECE B1308 .1
ADD:
A - '95 Cab Model................................................................................................................ .3

INSULATION, ENGINE HOOD - REPLACE B1510 .4

PANEL ASSEMBLY, (LID) FRONT CENTER - REPLACE B1770 .2

GUARD, MUD - REPLACE B1830 .3

ADD:
A - To Replace Both............................................................................................................ .2

FLAP, MUD GUARD - REPLACE B1831 .2

ADD:
A - To Replace Both............................................................................................................ .1

PLATE, FLAP - REPLACE B1832 .2

ADD:
A - To Replace Both............................................................................................................ .1

COVER, NOISE - R&R OR REPLACE

ENGINE & TRANSMISSION LOWER B1910 .5
TRANSMISSION RIGHT B1914 .8
TRANSMISSION LEFT B1915 .7
TRANSMISSION UPPER B1916 .4
CAB REAR B1919 .4
B - 4 BUMPERS, DOORS AND EXTERIOR TRIM

BUMPER AND FRONT END

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

STEP, CAB ASSIST - REPLACE

RIGHT UPPER B1920 .4
LEFT UPPER B1921 .4
 BUMPERS, DOORS AND EXTERIOR TRIM B - 5

DOORS AND REAR COMPARTMENT

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

DOOR ASSEMBLY, FRONT - ALIGN

RIGHT B4000 .5
LEFT B4001 .5

DOOR ASSEMBLY, FRONT - R&R

RIGHT B4005 .5
LEFT B4006 .5

HINGE, FRONT DOOR (BOLT ON) - REPLACE

INC: Adjust door lock striker plate and door assy. to door opening.
RIGHT UPPER B4012 .6
LEFT UPPER B4013 .6
RIGHT LOWER B4014 .6
LEFT LOWER B4015 .6

CHECK ASSEMBLY, FRONT DOOR - REPLACE

RIGHT B4070 .4
LEFT B4071 .4

HANDLE, FRONT DOOR OUTSIDE - REPLACE

RIGHT B4120 .6
LEFT B4121 .6

CYLINDER, FRONT DOOR LOCK - R&R OR REPLACE

RIGHT B4180 .5
LEFT B4181 .5
ADD:
A - '08 Cab Model................................................................................................................ .2

STRIKER, FRONT DOOR LOCK - REPLACE

DOES NOT INC: Aligning door assy. to door opening.
RIGHT B4240 .3
LEFT B4241 .3
B - 6 BUMPERS, DOORS AND EXTERIOR TRIM

DOORS AND REAR COMPARTMENT

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LOCK, FRONT DOOR - R&R OR REPLACE

RIGHT B4260 .7
LEFT B4261 .7

HANDLE, FRONT DOOR INSIDE OPENING - R&R OR REPLACE

RIGHT B4280 .3
LEFT B4281 .3
ADD:
A - EXC. '08 Cab Model....................................................................................................... .2

CONTROL, FRONT DOOR LOCK REMOTE - REPLACE

RIGHT B4290 .5
LEFT B4291 .5
ADD:
A - '08 Cab Model................................................................................................................ .4

KNOB, FRONT DOOR INSIDE LOCKING - REPLACE

RIGHT B4350 .6
LEFT B4351 .6

ROD, FRONT DOOR INSIDE LOCKING - R&R OR REPLACE

RIGHT B4360 .6
LEFT B4361 .6

CABLE, FRONT DOOR INSIDE LOCKING - REPLACE

RIGHT B4362 .8
LEFT B4363 .8

DOOR ASSEMBLY, REAR - ALIGN

RIGHT B4400 .5
LEFT B4401 .5

DOOR ASSEMBLY, REAR - R&R

RIGHT B4405 .5
LEFT B4406 .5
 BUMPERS, DOORS AND EXTERIOR TRIM B - 7

DOORS AND REAR COMPARTMENT

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HINGE, REAR DOOR - REPLACE

RIGHT UPPER B4412 .5
LEFT UPPER B4413 .5
RIGHT LOWER B4414 .5
LEFT LOWER B4415 .5

HANDLE, REAR DOOR OUTSIDE - REPLACE

RIGHT B4520 .5
LEFT B4521 .5

STRIKER, REAR DOOR LOCK - REPLACE

RIGHT B4640 .3
LEFT B4641 .3

LOCK, REAR DOOR - R&R OR REPLACE

RIGHT B4660 .5
LEFT B4661 .5

HANDLE, REAR DOOR INSIDE OPENING - R&R OR REPLACE

RIGHT B4680 .3
LEFT B4681 .3
ADD:
A - EXC. '08 Cab Model....................................................................................................... .2

RUBBER, BUMPER, SIDEGATE AND/OR TAILGATE - REPLACE

ONE OR ALL B5850 .3
B - 8 BUMPERS, DOORS AND EXTERIOR TRIM

EXTERIOR TRIM
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

EMBLEM, GRILLE - REPLACE B7100 .3

INC: R&R grille if nec.

PLATE, MODEL DESIGNATION - REPLACE

ONE B7390 .3
 BUMPERS, DOORS AND EXTERIOR TRIM B - 9

BODY
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BODY - REPAIR B9990 ST

POLICY: A
C BODY INTERIOR

C
 GLASS, INTERIOR TRIM AND SEATS C - 3

GLASS AND ATTACHING PARTS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

GLASS, WINDSHIELD - RESEAL C0020 .5

POLICY: A
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
INC: Water test.

GLASS, WINDSHIELD - REPLACE

POLICY: A
INC: Water test and extra man's assistance.
ONE PIECE C0034 2.0

MIRROR, INSIDE REAR VIEW - REPLACE C0040 .3

POLICY: A

SUPPORT, INSIDE REAR VIEW MIRROR - R&R OR REPLACE C0050 .3

POLICY: A
INC: Transfer or replacement of mirror to support.

GLASS, FRONT DOOR - ALIGN

POLICY: A
RIGHT C0100 .5
LEFT C0101 .5

GLASS, FRONT DOOR - R&R

POLICY: A
INC: Nec.lubrication and adjustments.
RIGHT C0110 .7
LEFT C0111 .7
ADD:
A - '95 Cab Model................................................................................................................ .7

GLASS, FRONT DOOR - REPLACE

POLICY: A
INC: Nec.lubrication and adjustments.
RIGHT C0114 .7
(CONTINUED)
C - 4 GLASS, INTERIOR TRIM AND SEATS

GLASS AND ATTACHING PARTS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
LEFT C0115 .7
ADD:
A - '95 Cab Model................................................................................................................ .7

CHANNEL, FRONT DOOR GLASS LOWER SASH - R&R OR REPLACE

RIGHT C0116 .5
LEFT C0117 .5
ADD:
A - EXC. '08 Cab Model....................................................................................................... .3

WAIST SEAL AND/OR RETAINER, FRONT DOOR WINDOW INNER -

R&R OR REPLACE
RIGHT C0120 .3
LEFT C0121 .3
ADD:
A - EXC. '08 Cab Model....................................................................................................... .3

WAIST SEAL, FRONT DOOR WINDOW OUTER - R&R OR REPLACE

RIGHT C0130 .1
LEFT C0131 .1
ADD:
A - EXC. '08 Cab Model....................................................................................................... .2

CHANNEL, FRONT DOOR WINDOW RUN - R&R OR REPLACE

INC: R&R door glass as nec.
RIGHT C0140 .6
LEFT C0141 .6

HANDLE, FRONT DOOR WINDOW REGULATOR - REPLACE

RIGHT C0170 .3
LEFT C0171 .3

COVER, FRONT DOOR WINDOW REGULATOR HANDLE - REPLACE

ONE OR ALL C0179 .3
 GLASS, INTERIOR TRIM AND SEATS C - 5

GLASS AND ATTACHING PARTS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

REGULATOR, FRONT DOOR WINDOW - R&R OR REPLACE

INC: D&C glass, prop in up position and transfer motor where nec.
MANUAL; RIGHT C0180 .6
MANUAL; LEFT C0181 .6
POWER; RIGHT C0182 .7
POWER; LEFT C0183 .7

GLASS, REAR DOOR - R&R

POLICY: A
RIGHT C0310 .5
LEFT C0311 .5

GLASS, REAR DOOR - REPLACE

POLICY: A
RIGHT C0314 .5
LEFT C0315 .5

HANDLE, REAR DOOR WINDOW REGULATOR - REPLACE

RIGHT C0370 .3
LEFT C0371 .3

REGULATOR, REAR DOOR WINDOW - R&R OR REPLACE

MANUAL; RIGHT C0380 .4
MANUAL; LEFT C0381 .4
POWER; RIGHT C0382 .4
POWER; LEFT C0383 .4

GLASS, BACK WINDOW - REPLACE C0660 .7

INC: R&R rubber channel where nec., water test and extra man's assistance.
C - 6 GLASS, INTERIOR TRIM AND SEATS

WEATHERSTRIPS AND FINISHER

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

WEATHERSTRIP - ALIGN OR REPLACE

FRONT DOOR; RIGHT C1060 .4
FRONT DOOR; LEFT C1061 .4
REAR DOOR; RIGHT C1120 .4
REAR DOOR; LEFT C1121 .4

FINISHER - ALIGN OR REPLACE

FRONT DOOR; RIGHT C1603 .4
FRONT DOOR; LEFT C1604 .4
REAR DOOR; RIGHT C1610 .4
REAR DOOR; LEFT C1611 .4
 GLASS, INTERIOR TRIM AND SEATS C - 7

INTERIOR TRIM
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SUNSHADE AND/OR SUPPORT - R&R OR REPLACE

RIGHT C2020 .3
LEFT C2021 .3

LOCK, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2100 .1

ADD:
A - To Code Cyl................................................................................................................... .4
B - EXC. '08 Cab Model....................................................................................................... .2

STRIKER, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2115 .2

HINGE AND/OR STRIKER, GLOVE COMPARTMENT INSTRUMENT C2120 .4

PANEL - ADJUST OR REPLACE

DOOR ASSEMBLY, GLOVE COMPARTMENT INSTRUMENT PANEL - C2140 .4

R&R OR REPLACE
INC: Align compartment door latch catch.

BOX, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2160 .4

INC: D&C door assy.
ADD:
A - '08 Cab Model................................................................................................................ 1.2

ASH TRAY, INSTRUMENT PANEL - R&R OR REPLACE C2200 .3

PAD, INSTRUMENT PANEL COVER - REPLACE C2475 1.6

ADD:
A - EXC. '08 Cab Model....................................................................................................... 1.0

PAD, INSTRUMENT PANEL COVER - REPAIR C2480 .5

NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.

INSTRUMENT PANEL ASSEMBLY - R&R C2500 2.6

NOTE: EXC. '08 Cab Model
C - 8 GLASS, INTERIOR TRIM AND SEATS

INTERIOR TRIM
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HEADLINING ASSEMBLY - REPAIR

ONE PIECE C3098 .6

HEADLINING ASSEMBLY - R&R OR REPLACE

ONE PIECE C3108 .6
ADD:
A - To Replace Headlining Equipped with Roof Ventilator and/or Header........................... .1
B - '95 Cab Model................................................................................................................ 3.5
C - '08 Cab Model................................................................................................................ .5
D - With Header Shelf.......................................................................................................... .3

HEADLINING ASSEMBLY, REAR END - R&R OR REPLACE C3130 .4

TRIM ASSEMBLY, FRONT DOOR - R&R OR REPLACE

RIGHT; ONE PIECE C3348 .4
LEFT; ONE PIECE C3358 .4

PLATE AND/OR INSERT, FRONT DOOR SILL - REPLACE

RIGHT C3360 .3
LEFT C3361 .3

TRIM ASSEMBLY, REAR DOOR - R&R OR REPLACE

RIGHT C3540 .3
LEFT C3541 .3
 GLASS, INTERIOR TRIM AND SEATS C - 9

SEATS AND SEAT TRIM

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SLIDE ADJUSTER ASSEMBLY, FRONT SEAT MANUAL - R&R OR REPLACE

BUCKET SEAT, ONE SIDE; DRIVER C6011 .4

SEAT ASSEMBLY, FRONT - REPLACE

BUCKET SEAT; PASSENGER C6820 .3
BUCKET SEAT; DRIVER C6821 .3
ADD:
A - '95 Cab Model................................................................................................................ .3

COVER AND/OR PAD, FRONT SEAT, CUSHION - R&R OR REPLACE

BUCKET SEAT; PASSENGER C6870 1.1
BUCKET SEAT; DRIVER C6871 1.1

COVER AND/OR PAD, FRONT SEAT, BACK - R&R OR REPLACE

BUCKET SEAT; PASSENGER C7050 1.1
BUCKET SEAT; DRIVER C7051 1.1

COVER AND/OR PAD, REAR SEAT, CUSHION - R&R OR REPLACE

CUSHION; 1 PIECE TYPE C7253 .7

COVER AND/OR PAD, REAR SEAT, BACK - R&R OR REPLACE

INC: Replace frame as nec.
BACK; 1 PIECE TYPE C7278 .8

SEAT BELT, FRONT BUCKLE SIDE - REPLACE

RIGHT C9020 .3
LEFT C9021 .3

SEAT BELT, FRONT RETRACTOR SIDE - R&R OR REPLACE

RIGHT C9040 .5
LEFT C9041 .5
BOTH C9047 .7

GUIDE AND/OR COVER, SEAT BELT - R&R OR REPLACE

RIGHT C9050 .3
LEFT C9051 .3
C - 10 GLASS, INTERIOR TRIM AND SEATS

SEATS AND SEAT TRIM

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SEAT BELT, FRONT CENTER - REPLACE C9100 .4

SEAT BELT, REAR (BACKLE SIDE) - REPLACE

RIGHT C9190 .4
LEFT C9191 .4

SEAT BELT, REAR (RETRACTOR SIDE) - REPLACE

RIGHT C9200 .6
LEFT C9201 .6

SAFETY BELT, REAR CENTER - REPLACE

BUCKLE SIDE C9206 .4
TONGUE SIDE C9207 .4

BOLTS, FASTENERS AND FITTINGS - TIGHTEN C9990 .4

NOTE: This operation is to be used on body items only. For Chassis
items refer to operation number E1990 of the Frame section.
D HEATING AND AIR CONDITIONING

D
 HEATING AND AIR CONDITIONING D - 3

HEATING AND AIR CONDITIONING

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

FOR THOSE OPERATIONS IN THIS SECTION WHICH HAVE AN "ADD"

FOR DISCHARGE/CHARGE OF THE A/C SYSTEM, THIS "ADD" CAN
ONLY BE USED ONCE PER REPAIR ORDER.

KNOB, CONTROL ASSEMBLY - REPLACE D0100 .3

INC: One or all.

BEZEL, CONTROL ASSEMBLY - REPLACE D0140 .3

SWITCH, A/C ON-OFF - REPLACE D0240 .3

CONTROL ASSEMBLY - REPLACE

HEATER ONLY D0360 .6
WITH A/C D0362 .6
AUTO A/C D0363 .4

CABLES, AIR DISTRIBUTION - R&R OR REPLACE

INC: Fabricate new cable and adjust.
HEATER (NON A/C) AIR INLET D0436 .7
HEATER (NON A/C) TEMPERATURE D0437 .7
HEATER (NON A/C) DEFROSTER D0438 .7
AIR CONDITIONING TEMPERATURE D0447 .7
AIR SOURCE SELECT D0448 .7
AIR SELECT D0449 .7

RESISTOR, BLOWER MOTOR - REPLACE

HEATER ONLY D1000 .4
WITH A/C D1002 .4

RELAY, A/C - REPLACE

A/C D1027 .3

SENSOR, SUN - REPLACE D1100 1.3

SWITCH, COMPRESSOR CUT-OFF - REPLACE

DUAL PRESSURE D1116 .3
(CONTINUED)
D - 4 HEATING AND AIR CONDITIONING

HEATING AND AIR CONDITIONING

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ADD:
A - Discharge/Charge A/C System...................................................................................... .6

SWITCH, THERMOSTATIC CONTROL - REPLACE D1140 .7

ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - '95 Cab Model................................................................................................................ .5

MOTOR AND/OR FAN - R&R OR REPLACE

BLOWER (HEATER ONLY) D1320 .4
BLOWER (WITH A/C) D1322 .4
ADD:
A - '95 Cab Model................................................................................................................ .3
B - '08 Cab Model................................................................................................................ .2

NOZZLE ASSEMBLY, DEFROSTER - REPLACE

RIGHT D1420 1.3
LEFT D1421 1.3
CENTER D1426 1.3
ADD:
A - '95 Cab Model (Center Only).......................................................................................... 1.2

DEFLECTOR (GRILLE), AIR - REPLACE

RIGHT D1440 .4
LEFT D1441 .4
RIGHT CENTER D1442 .4
LEFT CENTER D1443 .4
ADD:
A - '05 Cab Model (Right & Right Center Only).................................................................... .8

CASE, HEATER - REPLACE

INC: R&R instrument panel assy and cross beam.
HEATER ONLY D2220 1.7
ADD:
A - '95 Cab Model................................................................................................................ 1.2
 HEATING AND AIR CONDITIONING D - 5

HEATING AND AIR CONDITIONING

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CASE, EVAPORATOR - R&R OR REPLACE D2510 1.3

ADD:
A - '95 Cab Model................................................................................................................ .5
B - Discharge/Charge A/C System...................................................................................... .6

HOSES, HEATER (WITHOUT AIR CONDITIONING) - REPLACE

ONE D2746 .6
BOTH D2747 .7

HOSES, HEATER (WITH AIR CONDITIONING) - REPLACE

ALL HOSES D2787 .7

CORE, HEATER - R&R

HEATER ONLY D2800 1.8
WITH A/C D2802 1.8
ADD:
A - Discharge/Charge A/C System (EXC. '05 Cab Model)................................................... .6
B - '95 Cab Model................................................................................................................ 1.2

CORE, HEATER - REPLACE

HEATER ONLY D2820 1.8
WITH A/C D2822 1.8
ADD:
A - Discharge/Charge A/C System (EXC. '05 Cab Model)................................................... .6
B - '95 Cab Model................................................................................................................ 1.2

A/C SYSTEM - LEAK TEST DISCHARGED SYSTEM D3000 .4

NOTE: This labor operation to be used when necessary to partially
charge 1 lb. max. the A/C system to locate a leak. Other Labor Hours
not allowed with this labor operation. This operation may only be
claimed in conjunction with a failed part operation.
D - 6 HEATING AND AIR CONDITIONING

HEATING AND AIR CONDITIONING

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SEALS, REFRIGERANT O-RING - REPLACE

COMPRESSOR MANIFOLD D3040 .4
CONDENSER D3041 .3
CONDENSER OUTLET PIPE D3042 .3
EXPANSION VALVE D3043 1.0
EVAPORATOR D3044 .4
FILTER DRYER D3048 .3
ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - '95 Cab Model (Expansion Valve Only).......................................................................... .6
C - '08 Cab Model (Expansion Valve Only).......................................................................... .6

HOSES AND/OR LINES, REFRIGERANT - REPLACE

INC: Assemble service hose as nec.
CONDENSER INLET D3081 .4
COMPRESSOR DISCHARGE D3082 .4
EVAPORATOR OUTLET D3084 .4
COMPRESSOR SUCTION AND DISCHARGE HOSE ASSEMBLY D3088 .4
COMPRESSOR SUCTION D3089 .4
FILTER DRYER TO CONDENSER D3096 .4
FILTER DRYER OUTLET D3097 .4
ANY ONE PIPE EXPANSION VALVE INLET D3099 1.0
ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - '95 Cab Model (Expansion Valve Inlet Only).................................................................. .6
C - '08 Cab Model (Expansion Valve Inlet Only).................................................................. .6

CONDENSER - REPLACE D3140 .6

ADD:
A - Discharge/Charge A/C System...................................................................................... .6

VALVE, EXPANSION - REPLACE D3220 1.0

ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - '95 Cab Model................................................................................................................ .4
C - '08 Cab Model................................................................................................................ .6
 HEATING AND AIR CONDITIONING D - 7

HEATING AND AIR CONDITIONING

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

DRYER, IN-LINE FILTER - REPLACE D3250 .4

ADD:
A - Discharge/Charge A/C System...................................................................................... .6

CORE, EVAPORATOR - REPLACE D3320 .8

ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - '95 Cab Model................................................................................................................ .4
C - '08 Cab Model................................................................................................................ .9

PULLEY IDLER, A/C - R&R D4020 .4

ADD:
A - With Crew Cab............................................................................................................... 1.0

BRACKET (S) , COMPRESSOR MOUNTING - R&R OR REPLACE

ALL D4237 .6

CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR - REPLACE D4240 .8

INC. R&R compressor assembly.
ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - EXC.4HK1 Engines (Euro4 Specification) Fitted '05/'08 Cab Models............................ .6
C - 4JJ1 Engine................................................................................................................... .2

COMPRESSOR ASSEMBLY - REPLACE D4440 .4

ADD:
A - Discharge/Charge A/C System...................................................................................... .6
B - EXC.4HK1 Engines (Euro4 Specification) Fitted '05/'08 Cab Models............................ .6
C - 4JJ1 Engine................................................................................................................... .2
E WHEELS, SUSPENSION, STEERING

E
 STEERING, SUSPENSION, WHEELS AND TIRES E - 7

WHEELS AND TIRES

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

WHEEL - BALANCE
POLICY: A
INC: R&R wheel and tire.
ONE E0200 .6
TWO E0201 .8
THREE E0202 1.1
FOUR E0203 1.3

WHEEL OR TIRE - REPLACE

POLICY: A
NOTE: Include separate tire from wheel, and wheel balance (static).
ONE E0411 .7
TWO E0412 1.0
THREE E0413 1.2
FOUR E0414 1.4
FIVE E0415 1.6
SIX E0416 1.7

WHEEL W/TIRE - R&R OR REPLACE

POLICY: A
INC: R&R wheel to hub. Dual wheels are considered as one wheel on
dual wheeled models.
NOTE: Does not include wheel balance (static).
ONE E0420 .5
TWO E0421 .8
THREE E0422 1.1
FOUR E0423 1.3
FIVE E0424 1.6
SIX E0425 1.8

BOLT, WHEEL MOUNTING - REPLACE

RIGHT FRONT E0474 .7
LEFT FRONT E0475 .7
ADD:
A - To Replace Additional Two Bolts................................................................................... .3
B - To Replace Additional Four Bolts................................................................................... .5
(CONTINUED)
E - 8 STEERING, SUSPENSION, WHEELS AND TIRES

WHEELS AND TIRES

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - To Replace All Bolts....................................................................................................... .7
D - To Replace Additional Two Bolts (Disc Brake Type)..................................................... .1
E - To Replace Additional Four Bolts (Disc Brake Type)..................................................... .2
F - To Replace All Bolts (Disc Brake Type)......................................................................... .2
RIGHT REAR E0484 1.1
LEFT REAR E0485 1.1
ADD:
A - To Replace Additional Two Bolts................................................................................... .3
B - To Replace Additional Four Bolts................................................................................... .5
C - To Replace All Bolts....................................................................................................... .7
D - To Replace Additional Two Bolts (Disc Brake Type)..................................................... .1
E - To Replace Additional Four Bolts (Disc Brake Type)..................................................... .2
F - To Replace All Bolts (Disc Brake Type)......................................................................... .2

HANGER ASSY(HOLD DOWN), SPARE TIRE - R&R OR REPLACE E0600 .3

JACK AND/OR HANDLE - REPLACE E0620 .3

POLICY: A
 STEERING, SUSPENSION, WHEELS AND TIRES E - 9

FRAME
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

PAD AND/OR BOLT, BODY - R&R OR REPLACE E1040 .8

CUSHION, PAD AND/OR BOLT, BODY - R&R OR REPLACE

MOUNT POSITION ONE E1106 .8
ADD:
A - To Replace Additional Two Cushions............................................................................ .2
B - To Replace Additional Four Cushions............................................................................ .3
C - Replace All Cushions..................................................................................................... .4

LATCH, CAB HOLD DOWN - REPLACE E1300 .4

SUPPORT, CAB REAR - REPLACE E1330 .4

BAR, CAB TORSION - REPLACE

NOTE: R&R cab assy.
ONE PIECE E1358 1.8
ADD:
A - With A/C......................................................................................................................... .3
B - '08 Cab Model................................................................................................................ 1.4

HOOK, CAB REAR HOLD DOWN SAFETY - REPLACE E1400 .3

BUSHING, MOUNTING LEVER - REPLACE

RIGHT E1420 .8
LEFT E1421 .8
ADD:
A - '08 Cab Model................................................................................................................ 3.3

CROSSMEMBER, FRAME - REPAIR E1760 .5

NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
E - 10 STEERING, SUSPENSION, WHEELS AND TIRES

FRAME
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CROSSMEMBER, FRAME - REPLACE E1770 .5

NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.

FRAME ASSEMBLY - REPAIR E1860 .5

NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.

BOLTS, FASTENERS AND FITTINGS - TIGHTEN E1990 .6

NOTE: This operation is to be used on chassis items only. For body
items refer to operation C9990 of the seats section.
 STEERING, SUSPENSION, WHEELS AND TIRES E - 11

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

TOE-IN, FRONT SUSPENSION - ADJUST E2000 .5

FRONT SUSPENSION - CHECK AND/OR ALIGN E2020 1.6

INC: Adjust camber, caster, toe-in and trim height where applicable.

ROD, FRONT STRUT - REPLACE

POLICY: P
RIGHT E2100 .7
LEFT E2101 .7
BOTH E2107 1.1

BUSHINGS, FRONT STRUT ROD - REPLACE

RIGHT E2120 .7
LEFT E2121 .7
BOTH E2127 1.1

SHAFT, FRONT STABILIZER - REPLACE E2160 .5

POLICY: P
INC: R&R links and bushings.

NUT, FRONT WHEEL HUB - REPLACE E2200 .4

ADD:
A - To Replace Both............................................................................................................ .3

BEARING, FRONT WHEEL - ADJUST

RIGHT E2220 .5
LEFT E2221 .5
BOTH E2227 .7

CAP, FRONT WHEEL HUB DUST - REPLACE

RIGHT E2230 .3
LEFT E2231 .3
BOTH E2237 .3
E - 12 STEERING, SUSPENSION, WHEELS AND TIRES

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BEARING, FRONT WHEEL - REPLACE

POLICY: T, P
INC: R&R wheel, clean and pack inner and outer bearings,
replace seal, fill oiler cap.
NOTE: Maximum time not to exceed operation number E2267 & E2268.
INNER RIGHT (4 x 2) E2240 1.3
INNER LEFT (4 x 2) E2241 1.3
INNER RIGHT (4 x 4) E2242 1.4
INNER LEFT (4 x 4) E2243 1.4
INNER BOTH (4 x 2) E2247 2.4
INNER BOTH (4 x 4) E2248 2.6
OUTER RIGHT (4 x 2) E2250 1.3
OUTER LEFT (4 x 2) E2251 1.3
OUTER RIGHT (4 x 4) E2252 1.4
OUTER LEFT (4 x 4) E2253 1.4
OUTER BOTH (4 x2) E2257 2.4
OUTER BOTH (4 x 4) E2258 2.6
INNER AND OUTER RIGHT (4 x 2) E2260 1.3
INNER AND OUTER LEFT (4 x 2) E2261 1.3
INNER AND OUTER RIGHT (4 x 4) E2262 1.4
INNER AND OUTER LEFT (4 x 4) E2263 1.4
INNER AND OUTER BOTH (4 x 2) E2267 2.4
INNER AND OUTER BOTH (4 x 4) E2268 2.6

SEAL, FRONT WHEEL BEARING - REPLACE

POLICY: P
INC: Clean, inspect and repack inner and outer bearings. Replace
bearings as nec. (2001 and before models).
RIGHT (4 x 2) E2280 1.3
LEFT (4 x 2) E2281 1.3
RIGHT (4 x 4) E2282 1.1
LEFT (4 x 4) E2283 1.1
BOTH (4 x 2) E2287 2.4
BOTH (4 x 4) E2291 1.9
ADD:
A - To Clean Or Replace Brake Shoes One Wheel............................................................ .3
 STEERING, SUSPENSION, WHEELS AND TIRES E - 13

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HUB ASSEMBLY, FRONT WHEEL (DISC BRAKE TYPE) - REPLACE

ONE E2317 1.1
ADD:
A - To Replace Additional Hub Assembly (One).................................................................. .9

HUB ASSEMBLY, FRONT WHEEL - REPLACE

NOTE: If Problems are discovered inspection, the hub assembly
must be replaced (2002 Model).
INC: R&R wheel, clean and pack inner and outer bearings,
replace seal, fill oiler cap (2001 and before models).
RIGHT E2320 .8
ADD:
A - 4x4 Models..................................................................................................................... .3
LEFT E2321 .8
ADD:
A - 4x4 Models..................................................................................................................... .3
BOTH E2327 1.6
ADD:
A - 4x4 Models..................................................................................................................... .6

AUTO LOCKING HUB - REPLACE

RIGHT E2360 .6
LEFT E2361 .6
BOTH E2367 1.1

KNUCKLE ASSEMBLY, STEERING - REPLACE

POLICY: T
INC: R&R wheel, hub, steering knuckles, king pins and thrust bearings.
Adjust and lubricate front wheel bearings, adjust brakes and set toe-in
DOES NOT INC: Rebush steering knuckles.
RIGHT (4 x 2) E2520 2.2
LEFT (4 x 2) E2521 2.2
RIGHT (4 x 4) E2522 1.5
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 1.0

(CONTINUED)
E - 14 STEERING, SUSPENSION, WHEELS AND TIRES

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
LEFT (4 x 4) E2523 1.5
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 1.0
BOTH (4 x 2) E2527 3.1
BOTH (4 x 4) E2528 2.7
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 2.2

KNUCKLE OIL SEAL - REPLACE

RIGHT E2551 1.5
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 1.1
LEFT E2552 1.5
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 1.1
BOTH E2557 2.7
ADD:
A - Front Leaf Spring (4ｘ4)................................................................................................ 2.3

STOP, STEERING KNUCKLE - ADJUST OR REPLACE

RIGHT E2560 .4
LEFT E2561 .4
BOTH E2567 .6

BUSHINGS, STEERING KNUCKLE - REPLACE

INC: R&R wheels, hubs, steering knuckles, king pins and thrust bearings.
Replace bushings and fit pins. Adjust brakes, front wheel bearings and toe-in.
RIGHT E2760 2.4
LEFT E2761 2.4
BOTH E2767 4.3

BALL JOINT, CONTROL ARM - REPLACE

POLICY: T
UPPER RIGHT E2920 1.2
UPPER LEFT E2921 1.2
(CONTINUED)
 STEERING, SUSPENSION, WHEELS AND TIRES E - 15

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
UPPER BOTH E2927 2.2
LOWER RIGHT E2930 1.6
LOWER LEFT E2931 1.6
LOWER BOTH E2937 2.6

KING PINS AND THRUST BEARINGS - REPLACE

POLICY: T
INC: R&R wheel, hub, steering knuckles, king pins and thrust bearings.
Adjust and lubricate front wheel bearings, adjust brakes and set toe-in.
DOES NOT INC: Rebush steering knuckles.
RIGHT E2960 2.0
LEFT E2961 2.0
BOTH E2967 3.6
ADD:
A - To Replace Tie Rod End Each...................................................................................... .3
B - To Replace Wheel Cyl................................................................................................... .7
C - To Replace Front Brake Shoes Each Side................................................................... .3
D - To Rebush Steering Knuckle Each Side Brass Bushing Only.................................... .5
E - 4x4 Models (Right or Left Only)...................................................................................... .3
F - 4x4 Models (Both Only).................................................................................................. .6

BOLT, FRONT LEAF SPRING CENTER - REPLACE

POLICY: T
INC: R&R spring assy.
RIGHT E3100 1.8
LEFT E3101 1.8
BOTH E3107 3.4

SPRING ASSEMBLY, FRONT LEAF - R&R

RIGHT E3120 1.7
LEFT E3121 1.7
BOTH E3127 3.0
ADD:
A - To Replace Center Bolt Each........................................................................................ .4
B - To Rebush Front Spring Hanger Each.......................................................................... .5
(CONTINUED)
E - 16 STEERING, SUSPENSION, WHEELS AND TIRES

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - To Rebush Front Spring Eye-Hanger End Each........................................................... .4
D - To Rebush Front Spring Eye-Shackle End Each.......................................................... .5

SPRING ASSEMBLY, FRONT LEAF - REPLACE

POLICY: T
RIGHT E3130 1.7
LEFT E3131 1.7
BOTH E3137 3.0

LEAVES, FRONT SPRING - REPLACE

RIGHT E3140 1.9
LEFT E3141 1.9
BOTH E3147 3.6

BUSHING, FRONT SPRING EYE - REPLACE

INC: R&R spring assy.
FRONT RIGHT E3180 .8
FRONT LEFT E3181 .8
REAR RIGHT E3190 .8
REAR LEFT E3191 .8

SHACKLE AND/OR PIN, FRONT SPRING - REPLACE

POLICY: T
INC: Shackle end only.
RIGHT E3200 1.0
LEFT E3201 1.0

BOLT, FRONT SPRING EYE HANGER END - REPLACE

POLICY: T
RIGHT E3220 .6
LEFT E3221 .6
BOTH E3227 1.0
 STEERING, SUSPENSION, WHEELS AND TIRES E - 17

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

U-BOLT, FRONT SPRING - REPLACE

POLICY: T
INC: Both U-bolts.
RIGHT E3240 .6
LEFT E3241 .6

BAR, FRONT TORSION - ADJUST E3300 .7

NOTE: Use operation E2020 instead of this one, if front end alignment
is nec.

BAR, FRONT TORSION - REPLACE

INC: Adjust trim height.
RIGHT E3320 1.0
LEFT E3321 1.0
BOTH E3327 1.6

ARM, TORSION BAR PIVOT - REPLACE

INC: Adjust trim height.
RIGHT E3330 1.0
LEFT E3331 1.0
BOTH E3337 1.6

ARM ASSEMBLY, FRONT CONTROL - REPLACE

UPPER RIGHT E3520 1.2
UPPER LEFT E3521 1.2
UPPER BOTH E3527 2.0
LOWER RIGHT E3530 1.2
LOWER LEFT E3531 1.2
LOWER BOTH E3537 2.2

AXLE, I-BEAM - REPLACE E3600 4.6

POLICY: A, T
ADD:
A - To Replace Wheel Cyl. (One Side)................................................................................ .6
B - To Replace Wheel Cyl. (Both Side)............................................................................... .5
C - To Replace Front Brake Shoes One Side..................................................................... .3
(CONTINUED)
E - 18 STEERING, SUSPENSION, WHEELS AND TIRES

FRONT SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
D - To Replace Front Brake Shoes Both Side..................................................................... .5
E - To Rebush Steering Knuckles One Side........................................................................ .5
F - To Rebush Steering Knuckles Both Side....................................................................... 1.0

SHOCK ABSORBER, FRONT - REPLACE

POLICY: A
RIGHT E3800 .4
LEFT E3801 .4
BOTH E3807 .6
 STEERING, SUSPENSION, WHEELS AND TIRES E - 19

REAR SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BAR, REAR STABILIZER - REPLACE E4160 .6

INSULATOR AND/OR SUPPORT, REAR STABILIZER BAR - REPLACE

RIGHT E4180 .5
LEFT E4181 .5
BOTH E4187 .7

BEARINGS, REAR WHEEL - REPLACE

POLICY: T, P
INC: R&R wheel and hub as an assy. Clean, inspect, lubricate and
adjust bearings. Replace oil seal if nec.
DOES NOT INC: Replace bearing cups.
RIGHT E4240 2.4
LEFT E4241 2.4
ADD:
A - To Replace Inner Bearing Cup One Wheel................................................................... .3
B - To Replace Outer Bearing Cup One Wheel.................................................................. .3

SEAL, OIL, REAR WHEEL BEARING INNER (ONE WHEEL) - REPLACE

POLICY: P
INC: R&R wheel and hub as an assy. Clean, inspect, lubricate,
and adjust bearings. Clean brake shoes.
DOES NOT INC: Replace bearing cups.
RIGHT E4270 2.4
LEFT E4271 2.4
ADD:
A - To Replace Inner Bearing Cup One Wheel................................................................... .3
B - To Replace Outer Bearing Cup One Wheel.................................................................. .3
C - To Replace Or Reline Brake Shoes One Wheel........................................................... .7

HUB ASSEMBLY, REAR WHEEL (DISC BRAKE TYPE) - REPLACE

ONE E4367 1.4
ADD:
A - To Replace Additional Hub Assembly (One).................................................................. 1.0
E - 20 STEERING, SUSPENSION, WHEELS AND TIRES

REAR SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HUB ASSEMBLY, REAR WHEEL - REPLACE

POLICY: T, P
INC: R&R wheel, axle shaft, hub bearings, cups, oil seal and hub bolts.
Inspect, lubricate and adjust bearings.
RIGHT E4370 1.8
LEFT E4371 1.8

DUMPER, AXLE - REPLACE

RIGHT E4400 .3
LEFT E4401 .3
BOTH E4407 .4

BOLT, REAR LEAF SPRING CENTER - REPLACE

POLICY: T
INC: D&C spring to axle and align spring leaves.
DOES NOT INC: Rebushing.
RIGHT E5100 1.8
LEFT E5101 1.8
BOTH E5107 3.5

SPRING ASSEMBLY, REAR LEAF - REPLACE

POLICY: A, T
INC: D&C spring at both hangers and axle.
DOES NOT INC: Rebushing.
RIGHT E5130 1.6
LEFT E5131 1.6
BOTH E5137 2.9

LEAVES, REAR SPRING - REPLACE

INC: Remove, disassemble, clean, replace leaves as nec.
DOES NOT INC: Rebushing.
RIGHT E5140 2.2
LEFT E5141 2.2
BOTH E5147 4.1
 STEERING, SUSPENSION, WHEELS AND TIRES E - 21

REAR SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BUSHING, REAR LEAF SPRING EYE - REPLACE

RIGHT E5180 .8
LEFT E5181 .8
BOTH E5185 1.7

SHACKLE AND/OR BUSHING, REAR LEAF SPRING - REPLACE

POLICY: T
RIGHT E5200 .7
LEFT E5201 .7
BOTH E5207 1.3

SHACKLE PINS, REAR SPRING - REPLACE

POLICY: T
RIGHT E5210 .5
LEFT E5211 .5
BOTH E5217 .8

U-BOLT OR RETAINING BOLT, REAR LEAF SPRING - REPLACE

POLICY: T
INC: Both U-Bolts or Retaining Bolts.
RIGHT E5220 .8
LEFT E5221 .8
BOTH E5227 1.3

BOLT, REAR LEAF SPRING EYE OR LINK - REPLACE

POLICY: T
RIGHT E5240 .5
LEFT E5241 .5
BOTH E5247 .6

HELPER DAMPER,REAR LEAF SPRING - REPLACE E5650 .3

ADD:
A - To Replace Helper Damper (One)................................................................................. .1
B - To Replace Helper Damper (All).................................................................................... .2
E - 22 STEERING, SUSPENSION, WHEELS AND TIRES

REAR SUSPENSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SHOCK ABSORBER, REAR - REPLACE

POLICY: A
RIGHT E5800 .3
LEFT E5801 .3
BOTH E5807 .4
 STEERING, SUSPENSION, WHEELS AND TIRES E - 23

STEERING
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

EMBLEM AND/OR PAD, HORN BUTTON - REPLACE E7010 .3

INC: Transfer parts.

WHEEL, STEERING - REPLACE E7020 .3

LEVER, TURN SIGNAL - REPLACE E7050 .6

LEVER, TILT WHEEL - REPLACE E7080 .3

HORN CONTACT - REPLACE E7100 .6

CYLINDER, IGNITION LOCK - R&R OR REPLACE E7200 .6

POLICY: T
ADD:
A - With Imobilizer System.................................................................................................. .3

COVER, LOCK HOUSING - REPLACE E7220 .3

BEARING AND/OR BUSHING, UPPER - REPLACE

STANDARD E7320 .7
TILT E7321 1.0

SHAFT AND/OR SPHERE ASSEMBLY - REPLACE E7400 1.8

BEARING AND/OR BUSHING, STEERING SHAFT LOWER - REPLACE E7620 2.0

COLUMN ASSEMBLY, STEERING - R&R E7660 1.0

UNIVERSAL JOINT, STEERING SHAFT - R&R OR REPLACE

UPPER E7782 2.0
LOWER E7783 2.0

ARM, PITMAN - REPLACE E7900 .5

POLICY: T
E - 24 STEERING, SUSPENSION, WHEELS AND TIRES

STEERING
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LINK, DRAG - REPLACE E7940 .6

POLICY: T

ARM, STEERING IDLER - REPLACE E7960 .6

POLICY: T

BRACKET, IDLER ARM FRAME - REPLACE E7970 .6

POLICY: T

TIE ROD, INNER - REPLACE

POLICY: T
INC: Check and adjust toe-in R&R rack and pinion gear assy. as nec.
RIGHT E8040 .8
ADD:
A - Rack and Pinion Gear.................................................................................................... 2.1
LEFT E8041 .8
ADD:
A - Rack and Pinion Gear.................................................................................................... 2.1
BOTH E8047 1.2
ADD:
A - Rack and Pinion Gear.................................................................................................... 1.9

TIE ROD END AND/OR ADJUST SLEEVE - REPLACE

POLICY: T
INC: Check and adjust toe-in.
RIGHT E8060 1.0
LEFT E8061 1.0
BOTH E8067 1.4

TIE ROD ASSEMBLY - R&R OR REPLACE E8080 1.1

POLICY: T

TIE ROD, IDLER ARM - REPLACE E8090 .6

 STEERING, SUSPENSION, WHEELS AND TIRES E - 25

STEERING
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

ARM, STEERING KNUCKLE - REPLACE

POLICY: T
INC: Adjust toe-in. R&R wheel and hub assy. when nec.
DOES NOT INC: Check caster or camber.
RIGHT E8100 1.1
LEFT E8101 1.1

CAP, POWER STEERING PUMP RESERVOIR - REPLACE E8300 .3

PULLEY, POWER STEERING PUMP - REPLACE E8360 .4

POLICY: T

FILTER, POWER STEERING OIL - REPLACE E8420 .4

VALVE, POWER STEERING PUMP FLOW CONTROL - REPLACE E8440 .8

POLICY: T
ADD:
A - Diagnosis Time.............................................................................................................. .3

HOSES, POWER STEERING HYDRAULIC - REPLACE

POLICY: T
INC: Check and add fluid.
PRESSURE E8622 .6
RETURN E8623 .5

PUMP ASSEMBLY, POWER STEERING - R&R E9040 1.1

POLICY: T
INC: Bleed hydraulic system.
ADD:
A - To Replace Reservoir And/Or Hose............................................................................... .4
B - To Recondition Pump..................................................................................................... 1.0
C - Diagnosis Time.............................................................................................................. .3
D - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. .3
E - 4JJ1 Engine................................................................................................................... .9
E - 26 STEERING, SUSPENSION, WHEELS AND TIRES

STEERING
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

PUMP ASSEMBLY, POWER STEERING - REPLACE E9050 1.2

POLICY: T
INC: Bleed hydraulic system.
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .3
C - 4JJ1 Engine................................................................................................................... .9

PUMP ASSEMBLY, POWER STEERING & HYDRAULIC POWER E9060 1.8

BRAKE BOOSTER - R&R
INC: Air bleed power steering line & brake hydraulic system.
ADD:
A - Diagnosis Time.............................................................................................................. .3

RESERVOIR ASSEMBLY, POWER STEERING FLUID REMOTE - REPLACE E9100 .4

POLICY: T
INC: Bleed hydraulic system.
ADD:
A - With Crew Cab............................................................................................................... .5

GEAR ASSEMBLY, MANUAL STEERING - ADJUST E9600 .3

GEAR ASSEMBLY, MANUAL STEERING - R&R E9620 1.8

GEAR ASSEMBLY, MANUAL STEERING - REPLACE E9640 1.8

POLICY: T
ADD:
A - To Replace Drag Link.................................................................................................... .4

GEAR ASSEMBLY, POWER STEERING - ADJUST E9700 .4

 STEERING, SUSPENSION, WHEELS AND TIRES E - 27

STEERING
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

GEAR ASSEMBLY, POWER STEERING - R&R E9720 1.0

POLICY: T
INC: R&R steering gear assy., drain and refill, bleed hydraulic system.
ADD:
A - To Replace Side Cover And/Or O-Ring Seal................................................................. .5
B - To Replace End Cover And/Or O-Ring Seal.................................................................. .5
C - To R&R Pitman Shaft Or Bearing.................................................................................. .5
D - To Recondition Adjuster Plug Assembly........................................................................ .5
E - To Recondition Valve Body Assembly........................................................................... .7
F - To Recondition Rack Piston Assembly.......................................................................... .7
G - To Replace Housing...................................................................................................... 1.1
H - To Recondition P/S Gear (Complete)............................................................................ 1.6
I - Diagnosis Time................................................................................................................ .3
J - Rack and Pinion Gear..................................................................................................... 1.7
INC: All add conditions exc bench leak test.

GEAR ASSEMBLY, POWER STEERING - REPLACE E9740 1.0

POLICY: T
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - Rack and Pinion Gear.................................................................................................... 1.7

BELT, POWER STEERING PUMP DRIVE - REPLACE E9750 .3

F AXLE AND DIFFERENTIAL

F
 AXLE AND DIFFERENTIAL F - 3

AXLE AND DIFFERENTIAL

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BEARING, CENTER SUPPORT - REPLACE F0040 1.3

POLICY: T, P
INC: D&C front and intermediate universal joints. R&R center bearing support
to frame. R&R propeller shaft and hanger bearing to shaft.

UNIVERSAL JOINT, PROPELLER SHAFT - REPLACE

FRONT F1002 1.2
REAR F1003 1.2
INTERMEDIATE F1004 1.2

PROPELLER SHAFT ASSEMBLY - R&R OR REPLACE

POLICY: P, T
ONE PIECE TYPE F1280 .5
TWO PIECE TYPE; FRONT F1281 .7
TWO PIECE TYPE; REAR F1284 .7
FRONT DRIVE (4 x 4) F1288 .5

SHAFT, FRONT AXLE - REPLACE

RIGHT F1520 1.7
ADD:
A - Independent Suspension............................................................................................... 4.3
LEFT F1521 1.7
ADD:
A - Independent Suspension............................................................................................... 4.3
BOTH F1527 3.0
ADD:
A - Independent Suspension............................................................................................... 3.1

SHAFT, REAR AXLE - REPLACE

POLICY: P, T
RIGHT F1530 .7
LEFT F1531 .7
BOTH F1537 1.0
F - 4 AXLE AND DIFFERENTIAL

AXLE AND DIFFERENTIAL

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SEAL, AXLE SHAFT OIL - REPLACE

POLICY: P
FRONT AXLE; RIGHT F1600 2.7
ADD:
A - Independent Suspension............................................................................................... 3.3
FRONT AXLE; LEFT F1601 2.7
ADD:
A - Independent Suspension............................................................................................... 3.3
FRONT AXLE; BOTH F1607 5.2
ADD:
A - Independent Suspension............................................................................................... .9
REAR AXLE; RIGHT F1610 .6
REAR AXLE; LEFT F1611 .6
REAR AXLE; BOTH F1617 .8

BEARING, KING PIN (4x4 MODEL) - REPLACE

RIGHT F1630 2.3
LEFT F1631 2.3
BOTH F1637 4.3

BEARING, AXLE SHAFT - REPLACE

POLICY: P, T
REAR AXLE; RIGHT F1650 .7
REAR AXLE; LEFT F1651 .7
REAR AXLE; BOTH F1657 1.0

SEAL, PINION SHAFT OIL - REPLACE

POLICY: P
FRONT DIFFERENTIAL F2022 .7
REAR DIFFERENTIAL F2023 .7

FLANGE, PINION SHAFT - REPLACE

POLICY: P
INC: Reset bearing preload. Pinion seal and add lubricant.
FRONT DIFFERENTIAL F2042 .6
REAR DIFFERENTIAL F2043 .6
 AXLE AND DIFFERENTIAL F - 5

AXLE AND DIFFERENTIAL

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CARRIER ASSEMBLY, FRONT AXLE - R&R OR REPLACE F2122 4.2

POLICY: A, P, T
ADD:
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................ .6
B - To Replace Side Bearings............................................................................................. .5
C - To Replace Pinion Bearings.......................................................................................... .5
D - To Replace Ring Gear and Pinion................................................................................. .8
E - To Replace Case........................................................................................................... .6
F - To Replace Carrier......................................................................................................... 1.0
G - To Recondition Carrier Complete.................................................................................. 1.7
H - Independent Suspension............................................................................................... 3.1

CARRIER ASSEMBLY, REAR AXLE - R&R OR REPLACE F2123 2.8

POLICY: A, P, T
ADD:
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................ .6
B - To Replace Side Bearings (EXC.292/320mm Diff. Size)............................................... .5
C - To Replace Side Bearings; 292/320mm Diff. Size......................................................... .7
D - To Replace Pinion Bearings (EXC.292/320mm Diff. Size)............................................ .5
E - To Replace Pinion Bearings; 292/320mm Diff. Size...................................................... 1.0
F - To Replace Ring Gear and Pinion (EXC.292/320mm Diff. Size).................................... .8
G - To Replace Ring Gear and Pinion; 292/320mm Diff. Size............................................. 1.6
H - To Replace Case........................................................................................................... .6
I - To Replace Carrier (EXC.292/320mm Diff. Size)............................................................ 1.0
J - To Replace Carrier; 292/320mm Diff. Size..................................................................... .2
K - To Recondition Carrier Complete (EXC.292/320mm Diff. Size)..................................... 1.7
L - To Recondition Carrier Complete; 292/320mm Diff. Size............................................... 1.6

HOUSING ASSEMBLY, REAR AXLE - REPLACE F3023 6.0

POLICY: P, T
INC: R&R propeller shaft, transfer all parts, bleed brakes and make
all nec adjustments.

HOUSING ASSEMBLY, FRONT AXLE - REPLACE F3060 7.3

ADD:
A - Leaf Spring..................................................................................................................... 1.3
F - 6 AXLE AND DIFFERENTIAL

AXLE AND DIFFERENTIAL

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

VENTILATOR, AXLE - REPLACE F3270 .4

INC: Hose assy.
H BRAKES

H
H - 6 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BRAKE ASSEMBLY, FRONT - REPLACE

NOTE: Full air brake type.
RIGHT H0001 .8
LEFT H0002 .8
BOTH H0003 1.4

BRAKE ASSEMBLY, REAR - REPLACE

NOTE: Full air brake type.
RIGHT H0015 1.2
LEFT H0016 1.2
BOTH H0017 2.1

PADS, DISC BRAKE - R&R OR REPLACE

BOTH FRONT H0042 1.3
BOTH REAR H0043 1.0

CALIPER ASSEMBLY - R&R

POLICY: T
INC: R&R brake pads from caliper. Clean and inspect caliper
and bleed brakes.
FRONT RIGHT H0080 .7
FRONT LEFT H0081 .7
FRONT BOTH H0087 1.1
ADD:
A - To Recondition Caliper Assembly (One)........................................................................ .3
B - To Recondition Caliper Assembly (All)........................................................................... .5

CALIPER ASSEMBLY, REAR BRAKE - R&R H0098 .7

ADD:
A - To R&R Caliper Assembly (One Additional)................................................................... .4
B - To Recondition Caliper Assembly (One)........................................................................ .3
C - To Recondition Caliper Assembly (All).......................................................................... .5
 BRAKES H - 7

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CALIPER ASSEMBLY - REPLACE

POLICY: T
INC: R&R brake pads from caliper. Clean and inspect caliper
and bleed brakes.
FRONT RIGHT H0100 .7
FRONT LEFT H0101 .7
FRONT BOTH H0107 1.1

CALIPER ASSEMBLY, REAR BRAKE - REPLACE H0118 .7

ADD:
A - To Replace Caliper Assembly (One Additional)............................................................. .4

DISC ASSEMBLY - R&R OR REPLACE

INC: D&C caliper assy. and visually inspect. Check rotor lateral runout
and parallelism. Transfer seals, bearings and races. Clean and repack
wheel bearing as nec.
FRONT RIGHT (4 x 2) H0120 1.3
FRONT LEFT (4 x 2) H0121 1.3
FRONT BOTH (4 x 2) H0127 2.3
ADD:
A - To Reface Disc (One).................................................................................................... .5
B - To Reface Disc (Both).................................................................................................... .8
C - With Anti Lock Brake System (One).............................................................................. .4
D - With Anti Lock Brake System (Both).............................................................................. .6

DISC ASSEMBLY, REAR - R&R OR REPLACE H0138 1.0

ADD:
A - To Replace Disc Assembly (One Additional)................................................................. .7

DRUM, BRAKE - R&R OR REPLACE

INC: Adjust wheel bearings when nec. to remove hub, adjust brake shoes.
DOES NOT INC: Replace hub, bearings or oil seal. Adjust brake shoes on
opposite wheels.
FRONT RIGHT H0190 .5
FRONT LEFT H0191 .5
FRONT BOTH H0197 .7
(CONTINUED)
H - 8 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
REAR RIGHT H0200 .7
REAR LEFT H0201 .7
REAR BOTH H0207 1.0
ADD:
A - To Reface Drum (One)................................................................................................... .5
B - To Reface Drum (Two)................................................................................................... .8

SHOES AND LININGS, DRUM BRAKE - R&R OR REPLACE

INC: R&R wheel, hub, drum and brake shoes. Clean shoes and drum.
Clean and lubricate anchor pins and cam. Adjust wheel bearings
and brake shoes.
DOES NOT INC: Reline brake shoes.
FRONT RIGHT H0240 1.0
FRONT LEFT H0241 1.0
FRONT BOTH H0247 1.8
REAR RIGHT H0250 1.3
REAR LEFT H0251 1.3
REAR BOTH H0257 1.9
ADD:
A - Full Air Brake Type (Only H0257).................................................................................. .3

SPRINGS, BRAKE SHOE RETURN AND/OR HOLD DOWN - REPLACE

NOTE: Hydraulic brake type.
REAR RIGHT H0290 1.2
REAR LEFT H0291 1.2
REAR BOTH H0297 1.4

CYLINDER, BRAKE WHEEL - R&R OR REPLACE

POLICY: T
INC: Time to recondition, adjust bearings, bleed brakes.
FRONT RIGHT H0360 1.3
FRONT LEFT H0361 1.3
FRONT BOTH H0367 2.4
REAR RIGHT H0370 1.7
REAR LEFT H0371 1.7
(CONTINUED)
 BRAKES H - 9

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
REAR BOTH H0377 3.0

SHIELD, REAR BRAKE DUST - R&R OR REPLACE

NOTE: Hydraulic brake type.
DRUM, RIGHT H0400 1.9
DRUM, LEFT H0401 1.9
DRUM, BOTH H0407 3.6

CAMSHAFT, BRAKE - REPLACE

FRONT RIGHT H0460 .9
FRONT LEFT H0461 .9
FRONT BOTH H0467 1.6
REAR RIGHT H0470 1.1
REAR LEFT H0471 1.1
REAR BOTH H0477 1.9

ADJUSTER, BRAKE SLACK - REPLACE

FRONT RIGHT H0480 .5
FRONT LEFT H0481 .5
FRONT BOTH H0487 .8
REAR RIGHT H0490 1.1
REAR LEFT H0491 1.1
REAR BOTH H0497 1.9

CYLINDER ASSEMBLY, BRAKE MASTER - R&R H0620 .8

INC: Air bleed brake system.
ADD:
A - '95 Cab Model................................................................................................................ .8

CYLINDER ASSEMBLY, BRAKE MASTER - REPLACE H0640 .8

POLICY: T
INC: Air bleed brake system.
ADD:
A - '95 Cab Model................................................................................................................ .8
H - 10 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BRAKE SYSTEM - BLEED H0700 .6

HOSE, BRAKE - REPLACE

POLICY: T
INC: Air bleed brake system.
FRONT RIGHT H0720 .5
FRONT LEFT H0721 .5
FRONT BOTH H0727 .7

SWITCH, BRAKE SYSTEM FAILURE WARNING - REPLACE H0770 .2

VALVE, LOAD SENSING PROPORTIONING, BRAKE - R&R OR REPLACE H0775 2.3

VALVE, LOAD SENSING PROPORTIONING, BRAKE - ADJUST H0777 1.7

VALVE, BRAKE COMBINATION - REPLACE H0780 .6

VALVE, METERING - REPLACE H0782 .6

SENSOR, PRESSURE, BRAKE FLUID - REPLACE H0784 .4

SWITCH, LOW BRAKE FLUID WARNING - REPLACE H0785 .2

PIPE, BRAKE - REPLACE

POLICY: T
INC: Air bleed brake system.
MASTER CYL TO CONNECTOR H0800 .8
MASTER CYL TO METERING VALVE H0825 .7
HYDRAULIC BRAKE BOOSTER H0850 1.0
CONNECTOR TO FRONT WHEEL FLEX HOSE; RIGHT H0880 .8
CONNECTOR TO FRONT WHEEL FLEX HOSE; LEFT H0881 .8
AXLE HOUSING JUNCTION TO REAR WHEEL; RIGHT H0910 .6
AXLE HOUSING JUNCTION TO REAR WHEEL; LEFT H0911 .6

VACUUM TANK - REPLACE H0960 .5

 BRAKES H - 11

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BOOSTER ASSEMBLY, VACUUM POWER BRAKE - R&R OR REPLACE

POLICY: T
INC: Air bleed brake system.
MASTER VAC MODEL H1100 3.1
HYDRO MASTER MODEL H1110 1.1
ADD:
A - To Recondition Booster
( '05 Cab Model; Vacuum Booster Cannot Be Overhauled)..................................... ST

BOOSTER ASSEMBLY, VACUUM POWER BRAKE - REPLACE H1120 3.1

POLICY: T

BOOSTER ASSEMBLY, HYDRAULIC POWER BRAKE - R&R

H.B.B. MODEL H1130 4.0

BOOSTER ASSEMBLY, HYDRAULIC POWER BRAKE - REPLACE

H.B.B. MODEL H1135 4.1

ACCUMULATOR, HYDRAULIC POWER BRAKE BOOSTER OIL - REPLACE

H.B.B. MODEL H1140 1.1

RESERVOIR, HYDRAULIC POWER BRAKE BOOSTER OIL - REPLACE H1145 .8

VALVE, FILTER, HOSE AND/OR PIPE, VACUUM POWER BRAKE - REPLACE H1240 .3

HOSE, AIR BRAKE - REPLACE

FRONT RIGHT H1700 .4
FRONT LEFT H1701 .4
FRONT BOTH H1707 .5
REAR RIGHT H1708 .2
REAR LEFT H1709 .2
REAR BOTH H1711 .3
PARKING BRAKE H1718 .2
H - 12 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LINE, AIR BRAKE(ONE) - REPAIR OR REPLACE H1720 .5

NOTE: THIS IS A ST(STRAIGHT TIME)OPERATION WHICH REQUIRES TIME
DOCUMENTATION AS DETAILED IN THE CLAIMS PROCESSING MANUAL.
ZONE APPROVAL IS REQUIRED BEYOND .5 HOURS.

LINE, AIR BRAKE (UNDER DASH) - REPAIR OR REPLACE H1740 .5

NOTE: THIS IS A ST(STRAIGHT TIME)OPERATION WHICH REQUIRES TIME
DOCUMENTATION AS DETAILED IN THE CLAIMS PROCESSING MANUAL.
ZONE APPROVAL IS REQUIRED BEYOND .5 HOURS.

DRYER SYSTEM, AIR BRAKE - REPAIR H1750 .5

NOTE: THIS IS A ST (STRAIGHT TIME) OPERATION WHICH REQUIRES TIME
DOCUMENTATION AS DETAILED IN THE CLAIMS PROCESSING MANUAL.
ZONE APRROVAL IS REQUIRED BEYOND .5 HOURS.

DRYER SYSTEM ASSEMBLY, AIR BRAKE - R&R OR REPLACE H1753 .5

ADD:
A - To Recondition Dryer System Assembly........................................................................ .8

TANK, AIR - REPLACE H1760 1.3

ADD:
A - To Replace Additional Air Tank (One)............................................................................ .5

VALVE, BRAKE QUICK RELEASE - REPLACE

FRONT H1781 .5
REAR H1782 .5
PARKING BRAKE H1785 .4

VALVE, AIR TANK DRAIN - REPLACE H1830 .2

ADD:
A - To Replace Each Additional........................................................................................... .1

VALVE, SPRING BRAKE CONTROL - REPLACE H1900 .4

 BRAKES H - 13

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

VALVE, BRAKE SAFETY - REPLACE H2000 .2

ADD:
A - Hydraulic Brake Type..................................................................................................... .4

VALVE, DOUBLE CHECK - REPLACE H2020 .5

VALVE, PROTECTION, MALTI CONTROL - R&R OR REPLACE H2105 .5

COMPRESSOR, AIR - R&R

4H H2205 3.1
ADD:
A - To Recondition Compressor ......................................................................................... 1.6

COMPRESSOR, AIR - REPLACE

POLICY: A
4H H2225 3.1

HEAD, COMPRESSOR, AIR - R&R OR REPLACE

4H H2240 .8

VALVE ASSEMBLY, APPLICATION - R&R OR REPLACE

RHD H2320 .7
LHD H2321 .7
ADD:
A - To Recondition Application Valve.................................................................................. .8

CHAMBER, AIR, BRAKE - R&R OR REPLACE

FRONT RIGHT H2380 .5
FRONT LEFT H2381 .5
FRONT BOTH H2387 .7
REAR RIGHT H2390 .6
REAR LEFT H2391 .6
REAR BOTH H2397 .9
ADD:
A - To Recondition Air Chamber.......................................................................................... .2
H - 14 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

G - SENSOR - REPLACE H2408 .2

NOTE:Only 4x4
ADD:
A - Diagnosis Time.............................................................................................................. .3

SPEED SENSOR, ABS - R&R

FRONT RIGHT H2410 .4
FRONT LEFT H2411 .4
ADD:
A - Maximum Diagnosis Time Allowed................................................................................ .6
B - Full Air Brake Type......................................................................................................... .2
REAR RIGHT H2414 .8
REAR LEFT H2415 .8
ADD:
A - Maximum Diagnosis Time Allowed................................................................................ .6
B - Full Air Brake Type......................................................................................................... .1
REAR CENTER (IN DIFF.) H2419 .4
ADD:
A - Maximum Diagnosis Time Allowed................................................................................ .6

RING, EXCITOR, ABS - R&R

FRONT RIGHT H2450 .7
FRONT LEFT H2451 .7
REAR CENTER (IN DIFF.) H2452 2.9
REAR RIGHT H2453 .8
REAR LEFT H2454 .8
ADD:
A - 4x4 Models (H2450 and H2451 Only)............................................................................ .1
B - Maximum Diagnosis Time Allowed................................................................................ .6

HYDRAULIC UNIT, ABS - R&R H2480 1.3

INC: R&R battery, Time to bleed brakes.
ADD:
A - Diagnosis Time.............................................................................................................. .3
 BRAKES H - 15

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

MODULATOR, AIR, ABS, FRONT - R&R OR REPLACE H2485 .4

ADD:
A - To Replace Each Additional........................................................................................... .2
B - Diagnosis Time.............................................................................................................. .3

MODULATOR, AIR, ABS, REAR - R&R OR REPLACE H2487 .4

ADD:
A - To Replace Each Additional........................................................................................... .2
B - Diagnosis Time.............................................................................................................. .3

CONTROL UNIT, ABS - REPLACE H2490 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROL MODULE, ABS ELECTRONIC BRAKE - R&R H2506 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3

PEDAL AND/OR BUSHING, BRAKE - R&R OR REPLACE H2640 .5

ADD:
A - Hydraulic Brake Type..................................................................................................... .7

PAD, BRAKE PEDAL - REPLACE H2660 .3

SPRING, BRAKE PEDAL RETURN - REPLACE H2680 .3

ADD:
A - Full Air Brake Type......................................................................................................... .2

PARKING BRAKE - ADJUST H2800 .4

LEVER AND/OR SUPPORT, PARKING BRAKE ASSEMBLY - R&R H2860 .4

OR REPLACE
ADD:
A - '95 Cab Model................................................................................................................ .4
H - 16 BRAKES

BRAKES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CABLE, PARKING BRAKE - REPLACE

ONE PIECE TYPE H2881 1.1
REAR SECTION (2 PIECE) H2887 1.1
ADD:
A - With Crew Cab............................................................................................................... .5

SHOE AND/OR SUPPORT PLATE, PROPELLER SHAFT PARKING H3000 1.1

BRAKE DRUM TYPE INTERNAL - REPLACE
ADD:
A - Two Piece Type Propeller Shaft..................................................................................... .3

LEVER, PROPELLER SHAFT PARKING BRAKE SHOE - REPLACE H3010 1.0

DRUM, PROPELLER SHAFT BRAKE - REPLACE H3070 .5

ADD:
A - Two Piece Type Propeller Shaft..................................................................................... .3

DRUM, PARKING BRAKE (RETARDER) ASSEMBLY - R&R OR REPLACE H3300 ST

VALVE, HSA - R&R OR REPLACE H3500 1.1

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROL UNIT, HSA - REPLACE H3600 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
J ENGINE

J
J - 12 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

MANIFOLD AND/OR GASKET, EXHAUST - REPLACE

POLICY: P, E
4J J0103 .6
ADD:
A - 4JH1-T or TC Engine..................................................................................................... 1.6
B - With Crew Cab............................................................................................................... 1.0
4B J0104 1.6
ADD:
A - 4BD2-TC Engine............................................................................................................ .6
B - With Crew Cab............................................................................................................... 1.0
4H J0105 1.0
ADD:
A - 4HE1-TC Engine............................................................................................................ 1.1
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.8
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ 1.4
D - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>)................... .7
E - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .3
F - With Crew Cab............................................................................................................... 1.0
4JJ1 J0113 2.6
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .6
B - With Crew Cab............................................................................................................... 1.0

MANIFOLD AND/OR GASKET, INTAKE - REPLACE

POLICY: P
4J J0203 1.2
ADD:
A - 4JH1-T Engine............................................................................................................... 1.0
B - With Crew Cab............................................................................................................... 3.2
4B J0204 1.2
ADD:
A - 4BD1 Engine.................................................................................................................. .5
B - With Crew Cab............................................................................................................... 3.2
4H J0205 1.2
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.7
(CONTINUED)
 ENGINE J - 13

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
B - 4HK1 Engine Fitted '08 Cab Model................................................................................ 1.1
C - With Crew Cab............................................................................................................... 3.2
D - 4HV1 Engine.................................................................................................................. .2
4JJ1 J0213 1.7
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .4
B - With A/C......................................................................................................................... .4
C - With Crew Cab............................................................................................................... 3.2

CASE, INLET EGR - REPLACE J0230 1.7

ADD:
A - With Crew Cab............................................................................................................... 3.2

PUMP AND/OR GASKET, VACUUM - REPLACE J0240 .7

ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .3
B - With Crew Cab............................................................................................................... .7
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 1.7
D - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .7
E - 4HK1 Engine Fitted '08 Cab Model (EXC. Generator Tandem Type)............................ 1.4
F - 4JJ1 Engine Fitted '08 Cab Model.................................................................................. .4

FLEXIBLE PIPE, VACUUM PUMP - REPLACE

DIESEL J0245 .3
ADD:
A - With Crew Cab............................................................................................................... .7

COVER AND/OR GASKET, ROCKER - REPLACE

POLICY: P
4J J0303 .5
ADD:
A - 4JH1-T Engine............................................................................................................... .4
B - With Crew Cab............................................................................................................... 1.9

(CONTINUED)
J - 14 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4B J0304 .4
ADD:
A - With Crew Cab............................................................................................................... 1.9
4H J0305 .4
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .8
B - 4HK1 Engine Fitted '08 Cab Model................................................................................ .6
C - With Crew Cab............................................................................................................... 1.9
D - 4HV1 Engine.................................................................................................................. .1
4JJ1 J0313 .7
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .3
B - With Crew Cab............................................................................................................... 1.9

COVER AND/OR GASKET, PUSH ROD SIDE - REPLACE

POLICY: P
ONE 4J J0323 .5
ADD:
A - To Replace All Covers................................................................................................... .3
B - With Crew Cab............................................................................................................... 1.9
ONE 4B J0324 .5
ADD:
A - To Replace All Covers................................................................................................... .3
B - With Crew Cab............................................................................................................... 1.9

ROCKER ARM - REPLACE

POLICY: P, T
INC: R&R rocker cover and install new gasket.
4J J0353 .7
ADD:
A - With Crew Cab............................................................................................................... 1.9
4B J0354 .8
ADD:
A - With Crew Cab............................................................................................................... 1.9

(CONTINUED)
 ENGINE J - 15

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4H J0355 1.0
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.1
B - 4HK1 Engine Fitted '08 Cab Model................................................................................ .8
C - With Crew Cab............................................................................................................... 1.9
D - 4HV1 Engine.................................................................................................................. .1
4JJ1 J0363 2.3
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .5
B - With Crew Cab............................................................................................................... 1.9

VALVE LASH - ADJUST

4J J0423 .8
ADD:
A - 4JH1-TC or T Engine..................................................................................................... .4
B - With Crew Cab............................................................................................................... 1.9
4B J0424 .8
ADD:
A - With Crew Cab............................................................................................................... 1.9
4H J0425 .8
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.0
B - 4HK1 Engine Fitted '08 Cab Model................................................................................ .7
C - With Crew Cab............................................................................................................... 1.9
D - 4HV1 Engine.................................................................................................................. .2
4JJ1 J0433 1.1
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .3
B - With Crew Cab............................................................................................................... 1.9
J - 16 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

GASKET, CYLINDER HEAD - REPLACE

POLICY: P, T
INC: R&R rocker cover, loosen rocker arms and remove push rods.
D&C exhaust pipe and make all nec. adjustments.
4J J0503 3.5
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 5.1
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 3.6
C - With Turbocharger (4J** Engines, EXC. 4JJ1 Engine).................................................. 1.0
D - With EGR Cooler (4J** Engines, EXC. 4JJ1 Engine).................................................... .5
E - With A/C......................................................................................................................... .7
F - With A/C (4JJ1 Engine).................................................................................................. .5
G - With Crew Cab............................................................................................................... 3.4
4B J0504 4.2
ADD:
A - With Crew Cab............................................................................................................... 3.4
4H J0505 3.6
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ 2.6
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 4.8
D - 4HK1 Engine Fitted '08 Cab Model................................................................................ 3.1
E - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>)................... .7
F - With A/C (4HK1 Engine <Euro4 Specification> Fitted '05 Cab Model).......................... .4
G - With A/C (4HK1 Engine Fitted '08 Cab Model).............................................................. .2
H - With Crew Cab............................................................................................................... 3.4
J - To Replace Nozzle Sleeves (All).................................................................................... 1.4

HEAD, CYLINDER - REPLACE

POLICY: P, T
INC: R&R rocker cover, loosen rocker arms and remove push rods.
D&C exhaust pipe and make all nec. adjustments.
4J J0513 5.3
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 6.7
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 4.9
(CONTINUED)
 ENGINE J - 17

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - With Turbocharger (4J** Engines, EXC. 4JJ1 Engine).................................................. 1.0
D - With EGR Cooler (4J** Engines, EXC. 4JJ1 Engine).................................................... .5
E - With A/C......................................................................................................................... .7
F - With A/C (4JJ1 Engine).................................................................................................. .5
G - With Crew Cab............................................................................................................... 2.8
4B J0514 7.4
ADD:
A - With Crew Cab............................................................................................................... 2.8
4H J0515 5.4
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ 4.4
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 7.8
D - 4HK1 Engine Fitted '08 Cab Model................................................................................ 5.4
E - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>)................... .7
F - With A/C (4HK1 Engine <Euro4 Specification> Fitted '05 Cab Model).......................... .4
G - With A/C (4HK1 Engine) Fitted '08 Cab Model.............................................................. .2
H - With Crew Cab............................................................................................................... 2.8

VALVE - RECONDITION OR REPLACE

POLICY: P
INC: R&R rocker cover, rocker arms, push rods, cyl. head, recondition
valve seat and replace valve seal and make all nec. adjustments.
ONE CYL; 4J J0523 3.8
ADD:
A - To Recondition Valves One Additional Cyl..................................................................... .5
B - To Recondition All Valves.............................................................................................. 1.3
C- With Turbocharger.......................................................................................................... 1.0
D - With EGR Cooler........................................................................................................... .5
E - With A/C......................................................................................................................... .7
F - With Crew Cab............................................................................................................... 2.6
INC: Replace valves as nec. (Effective From Additional Code A and B)
ONE CYL; 4B J0524 4.6
ADD:
A - To Recondition Valves One Additional Cyl..................................................................... .5
(CONTINUED)
J - 18 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
B - To Recondition All Valves.............................................................................................. 1.3
C - With Crew Cab............................................................................................................... 2.6
INC: Replace valves as nec. (Effective From Additional Code A and B)
ONE CYL; 4H J0525 4.7
ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ 2.3
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 4.3
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ 2.7
D - To Recondition Valves One Additional Cyl. (EXC.4HK1 Engine)................................... .5
E - To Recondition Valves One Additional Cyl. (4HK1 Engine)........................................... 1.0
F - To Recondition All Valves (EXC.4HK1 Engine).............................................................. 1.3
G - To Recondition All Valves (4HK1 Engine)..................................................................... 2.6
H - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>)................... .7
J - With A/C (4HK1 Engine <Euro4 Specification> Fitted '05 Cab Model)........................... .4
K - With A/C (4HK1 Engine Fitted '08 Cab Model).............................................................. .2
L - With Crew Cab............................................................................................................... 2.6
INC: Replace valves as nec. (Effective From Additional Code D to G)
ONE CYL; 4JJ1 J0533 8.4
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.7
B - To Recondition Valves One Additional Cyl..................................................................... 1.1
C - To Recondition All Valves.............................................................................................. 3.2
D - With A/C......................................................................................................................... .5
E - With Crew Cab............................................................................................................... 2.6
INC: Replace valves as nec. (Effective From Additional Code B and C)

SPRING, CAP AND/OR SEAL, VALVE - REPLACE

POLICY: T, P
ONE CYL; 4J J0543 1.1
ADD:
A - To Replace Springs, Caps and/or Seals One Additional Cyl......................................... .4
B - To Replace Springs, Caps and/or Seals Two Additional Cyl......................................... .6
C - To Replace All Springs, Caps and/or Seals................................................................... .8
D - With Crew Cab............................................................................................................... 1.9

(CONTINUED)
 ENGINE J - 19

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ONE CYL; 4B J0544 1.1
ADD:
A - To Replace Springs, Caps and/or Seals One Additional Cyl......................................... .4
B - To Replace Springs, Caps and/or Seals Two Additional Cyl......................................... .6
C - To Replace All Springs, Caps and/or Seals................................................................... .8
D - With Crew Cab............................................................................................................... 1.9
ONE CYL; 4H J0545 1.6
ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .4
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .8
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ 1.9
D - To Replace Springs, Caps and/or Seals One Additional Cyl......................................... .4
E - To Replace Springs, Caps and/or Seals Two Additional Cyl. (EXC. 4HK1 Engine)....... .6
F - To Replace Springs, Caps and/or Seals Two Additional Cyl. (4HK1 Engine)................ 1.0
G - To Replace All Springs, Caps and/or Seals................................................................... .8
H - With Crew Cab............................................................................................................... 1.9
ONE CYL; 4JJ1 J0553 8.4
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.7
B - To Replace Springs, Caps and/or Seals One Additional Cyl......................................... .7
C - To Replace Springs, Caps and/or Seals Two Additional Cyl......................................... 1.3
D - To Replace All Springs, Caps and/or Seals................................................................... 1.9
E - With Crew Cab............................................................................................................... 1.9

PUSH ROD - REPLACE

POLICY: P, T
ONE CYL; 4J J0583 .7
ADD:
A - To Replace All Push Rods............................................................................................. .2
B - With Crew Cab............................................................................................................... 1.9
ONE CYL; 4B J0584 .8
ADD:
A - To Replace All Push Rods............................................................................................. .2
B - With Crew Cab............................................................................................................... 1.9
J - 20 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LIFTER, VALVE - REPLACE

POLICY: P, T
ONE CYL; 4J J0623 6.5
ADD:
A - With A/C......................................................................................................................... .5
B - To Replace All Lifters..................................................................................................... .2
C - With Crew Cab............................................................................................................... 1.9
D - With Noise Cover........................................................................................................... .6
ONE CYL; 4B J0624 5.3
ADD:
A - With A/C......................................................................................................................... .5
B - To Replace All Lifters..................................................................................................... .2
C - With Crew Cab............................................................................................................... 1.9
D - With Noise Cover........................................................................................................... .6

BELT, DRIVE - ADJUST

NOTE: Without serpentine type.
ONE; 4J J0653 .3
ADD:
A - To Adjust All Belts.......................................................................................................... .2
B - With Crew Cab............................................................................................................... .1
ONE; 4B J0654 .3
ADD:
A - To Adjust All Belts.......................................................................................................... .2
B - With Crew Cab............................................................................................................... .1
ONE; 4H J0655 .3
ADD:
A - To Adjust All Belts.......................................................................................................... .2
B - With Crew Cab............................................................................................................... .1

BELT, DRIVE - REPLACE

POLICY: T
A/C J0660 .4
ADD:
A - With Crew Cab............................................................................................................... .3

(CONTINUED)
 ENGINE J - 21

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
FAN GENERATOR J0663 .4
ADD:
A - 4JH1-T Engine............................................................................................................... .4
B - With Crew Cab............................................................................................................... .3

TENSIONER, DRIVE BELT - R&R OR REPLACE J0681 .3

ADD:
A - To Replace Bearing....................................................................................................... .1

PULLEY, CRANKSHAFT - REPLACE

POLICY: P, T
4J J0703 .7
ADD:
A - With Crew Cab............................................................................................................... 1.0
4B J0704 .7
ADD:
A - With Crew Cab............................................................................................................... 1.0
4H J0705 1.2
ADD:
A - With Crew Cab............................................................................................................... 1.0
4JJ1 J0713 1.6
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .4
B - With Crew Cab............................................................................................................... 1.0

SEAL, CRANKCASE FRONT COVER - REPLACE

4H J0745 1.3
ADD:
A - With A/C......................................................................................................................... .1

SEAL, TIMING COVER OIL - REPLACE (GEAR TYPE)

POLICY: P
INC: R&R harmonic balancer.

(CONTINUED)
J - 22 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4J J0753 .8
ADD:
A - With Crew Cab............................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6
4B J0754 1.0
ADD:
A - With Crew Cab............................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6
4JJ1 J0755 2.5
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .5
B - With Crew Cab............................................................................................................... 1.2
C - With Noise Cover........................................................................................................... .6

COVER (RETAINER) AND/OR GASKET, CRANKCASE FRONT - REPLACE

4H J0760 3.1
ADD:
A - With Crew Cab............................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6
C - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)...................................... 1.1
D - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. .7

COVER AND/OR GASKET, TIMING - REPLACE

POLICY: P
4J J0783 1.8
ADD:
A - With Crew Cab............................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6
4B J0784 1.9
ADD:
A - With Crew Cab............................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6
4JJ1 J0785 3.2
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .7
(CONTINUED)
 ENGINE J - 23

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
B - With Crew Cab............................................................................................................... 1.2
C - With Noise Cover........................................................................................................... .6

HOUSING AND/OR GASKET, TIMING PULLEY - REPLACE

4JJ1 J0790 13.0
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 2.6
B - To Replace Timing Gear................................................................................................ 2.6
C - With Crew Cab............................................................................................................... 1.2
D - With Noise Cover........................................................................................................... .6
4J J0793 2.4
ADD:
A - To Replace Timing Gear................................................................................................ 2.6
B - With Crew Cab............................................................................................................... 1.2
C - With Noise Cover........................................................................................................... .6
4B J0794 5.5
ADD:
A - To Replace Timing Gear................................................................................................ 2.6
B - With Crew Cab............................................................................................................... 1.2
C - With Noise Cover........................................................................................................... .6
4H J0795 3.8
ADD:
A - To Replace Timing Gear................................................................................................ 2.6
B - With Crew Cab............................................................................................................... 1.2
C - With Noise Cover........................................................................................................... .6

GEAR, IDLER TIMING - REPLACE

4JJ1 J0822 3.3
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .7
B - To Replace Idle Gear "B"............................................................................................... .2
C - With Crew Cab............................................................................................................... 2.2
D - With Noise Cover........................................................................................................... .6

(CONTINUED)
J - 24 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4J J0823 1.8
ADD:
A - To Replace Idle Gear "B"............................................................................................... .2
B - With Crew Cab............................................................................................................... 2.2
C - With Noise Cover........................................................................................................... .6
4B J0824 1.9
ADD:
A - To Replace Idle Gear "B"............................................................................................... .2
B - With Crew Cab............................................................................................................... 2.2
C - With Noise Cover........................................................................................................... .6
4H J0825 11.9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)....................................... .9
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .9
C - Automatic Transmission................................................................................................. .8
D - With Smoother............................................................................................................... 1.7
E - To Replace Idle Gear "B"............................................................................................... .2
F - With A/C......................................................................................................................... .8
G - With Crew Cab............................................................................................................... 2.2
H - With Noise Cover........................................................................................................... .6
J - 4x4 Models..................................................................................................................... 1.0

GEAR, CRANKSHAFT TIMING - REPLACE

POLICY: P, T
4J J0833 2.0
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 2.1
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 1.4
C - With Crew Cab............................................................................................................... 2.2
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... 1.0
4B J0834 2.0
ADD:
A - With Crew Cab............................................................................................................... 2.2
B - With Noise Cover........................................................................................................... .6
(CONTINUED)
 ENGINE J - 25

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - 4x4 Models..................................................................................................................... 1.0
4H J0835 16.3
ADD:
A - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)....................................... 1.3
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.3
C - With Smoother............................................................................................................... 1.7
D - With Crew Cab............................................................................................................... 2.2
E - With Noise Cover........................................................................................................... .6
F - 4x4 Models..................................................................................................................... 1.0

GEAR, CAMSHAFT TIMING - REPLACE

POLICY: P, T
NOTE: EXC. 4JJ1 Engine.
4J J0843 1.9
ADD:
A - With Crew Cab............................................................................................................... 1.9
B - With Noise Cover........................................................................................................... .6
4B J0844 2.2
ADD:
A - With Crew Cab............................................................................................................... 1.9
B - With Noise Cover........................................................................................................... .6
4H J0845 1.1
ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .4
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.1
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ .7
D - With Crew Cab............................................................................................................... 1.9
E - 4HV1 Engine.................................................................................................................. .4

CAMSHAFT - REPLACE
POLICY: P, T
INC: R&R radiator, harmonic balancer, cover and seal. Replace
camshaft gear if nec. Adjust valves.

(CONTINUED)
J - 26 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4J J0853 1.2
ADD:
A - 4J** Engines (EXC. 4JJ1 Engine).................................................................................. 4.9
B - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .3
C - To Replace All Valve Lifter............................................................................................. 1.2
D - To Replace One Additional............................................................................................ .5
E - With A/C (EXC. 4JJ1 Engine)........................................................................................ .6
F - With Crew Cab............................................................................................................... 1.9
G - With Noise Cover........................................................................................................... .6
4B J0854 4.8
ADD:
A - To Replace All Valve Lifter............................................................................................. 1.2
B - With A/C......................................................................................................................... .6
C - With Crew Cab............................................................................................................... 1.9
D - With Noise Cover........................................................................................................... .6
4H J0855 1.1
ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .4
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.1
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ .7
D - With A/C......................................................................................................................... .6
E - With Crew Cab............................................................................................................... 1.9
F - 4HV1 Engine.................................................................................................................. .4

TENSIONER ASSEMBLY, AND/OR GASKET TIMING CHAIN - REPLACE J0865 1.5

ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .3

CHAIN, TIMING - REPLACE J0866 2.8

ADD:
A - With A/C......................................................................................................................... .4
B - To Replace Sprocket (Supply Pump Side)..................................................................... .6
C - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .6
D - With Crew Cab............................................................................................................... 1.2
 ENGINE J - 27

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LEVER,TIMING CHAIN - REPLACE J0867 3.8

ADD:
A - With A/C......................................................................................................................... .4
B - To Replace Chain Guide................................................................................................ .3
C - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .8
D - With Crew Cab............................................................................................................... 1.2

CAP, OIL FILLER - REPLACE J0900 .3

TUBE, DIPSTICK - REPLACE J0930 .2

ADD:
A - Non Tilt Cab................................................................................................................... .6
B - 4JH1-T Engine............................................................................................................... .2
C - With Crew Cab............................................................................................................... .2

BEARINGS, CAMSHAFT - REPLACE J0945 1.0

NOTE: EXC. 4JJ1 Engine.
ADD:
A - 4JB*, 4JG* Engines........................................................................................................ 5.4
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ .3
C - With Crew Cab............................................................................................................... 1.9
D - With Noise Cover (EXC. 4H** Engines)......................................................................... .6
E - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 1.2
F - 4HK1 Engine Fitted '08 Cab Model................................................................................ .8
G - 4HV1 Engine.................................................................................................................. .4

FILTER, OIL - REPLACE

4J J0953 .4
ADD:
A - With Noise Cover........................................................................................................... .6
4B J0954 .4
ADD:
A - With Noise Cover........................................................................................................... .6
4H J0955 .5
ADD:
A - With Noise Cover........................................................................................................... .6
J - 28 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

ADAPTER, OIL FILTER - REPLACE J0961 .5

ADD:
A - With Crew Cab............................................................................................................... .5
B - With Noise Cover........................................................................................................... .6

OIL PIPE, COOLER TO FILTER - REPLACE

4BE1 J0962 .4

COVER, OIL PAN - REPLACE

4J J0985 1.4
ADD:
A - With Noise Cover........................................................................................................... .6

PAN AND/OR GASKET OIL - REPLACE

4J J0992 .9
ADD:
A - 4J** Engines (EXC. 4JH1-T Engine).............................................................................. .7
B - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .2
C - With Oil Pan Cover........................................................................................................ 1.2
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... .2
4B J0993 2.0
ADD:
A - With Oil Pan Cover........................................................................................................ 1.2
B - With Noise Cover........................................................................................................... .6
C - 4x4 Models..................................................................................................................... .2
4H J0997 .9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine)................................................................................ .2
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ .5
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. .2
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... .2
 ENGINE J - 29

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CRANKCASE OR MAIN PAN AND/OR GASKET, OIL - REPLACE

POLICY: P
INC: R&R engine assy. or front axle case assy.,
clean oil pump screen.
4JJ1 J1001 13.6
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 3.7
B - Automatic Transmission................................................................................................. .8
C - Manual Transmission..................................................................................................... .6
D - With A/C......................................................................................................................... .2
E - With Noise Cover........................................................................................................... .6
F - 4x4 Models..................................................................................................................... 1.0
4J J1003 6.5
ADD:
A - Automatic Transmission................................................................................................. .8
B - With Smoother............................................................................................................... 1.7
C - With A/C......................................................................................................................... .8
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... 1.0
4H J1005 15.7
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 3.3
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ .8
D - Automatic Transmission................................................................................................. .8
E - With Smoother (EXC. 4HK1 Engine Fitted '05/'08 Cab Models).................................... 1.7
F - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>) .................. .8
G - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)...................................................... .2
H - With Noise Cover........................................................................................................... .6
J - 4x4 Models..................................................................................................................... 1.0

GEAR, OIL PUMP DRIVE - R&R OR REPLACE

POLICY: P
4J J1013 3.8
ADD:
A - To Replace Pump Seal.................................................................................................. .2
(CONTINUED)
J - 30 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
B - With Noise Cover........................................................................................................... .6
C - 4J** Engines (EXC. 4JJ1 Engine).................................................................................. 3.3
4B J1014 2.3
ADD:
A - To Replace Pump Seal.................................................................................................. .2
B - With Noise Cover........................................................................................................... .6

PUMP, ENGINE OIL - REPLACE

POLICY: P, T
NOTE: 4H** engines, inc. R&R engine assy., R&R cyl. head assy.,
oil pan and flywheel housing.
4JJ1 J1022 3.1
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .7
B - With Crew Cab............................................................................................................... 2.2
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... 1.0
4J J1023 7.0
ADD:
A - With Smoother............................................................................................................... 1.7
B - With Crew Cab............................................................................................................... 2.2
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... 1.0
4B J1024 2.3
ADD:
A - With Smoother............................................................................................................... 1.7
B - With Crew Cab............................................................................................................... 2.2
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... 1.0
4H J1025 11.9
ADD:
A - 4HE1-TC Engine............................................................................................................ 1.0
B - 4H** Engines (EXC.4HE1-TC and 4HK1 Engines Fitted '05/'08 Cab Models)............... .3
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 1.6

(CONTINUED)
 ENGINE J - 31

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
D - Automatic Transmission
(4H** Engines, EXC. 4HK1 Engine Fitted '05/'08 Cab Models)...................................... .8
E - With Smoother (EXC. 4HK1 Engine) Fitted '05/'08 Cab Models.................................... 1.7
F - With A/C (4H** Engines <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>) .................. .8
G - With A/C (4HK1 Engine) Fitted '05/'08 Cab Models...................................................... .2
H - With Crew Cab............................................................................................................... 2.2
J - With Noise Cover............................................................................................................ .6
K - 4x4 Models..................................................................................................................... 1.0

STRAINER, OIL - REPLACE

4J J1034 6.6
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 10.8
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 7.9
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... .2
4H J1035 .9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)....................................... .4
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .4
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... .2

VALVE, RELIEF, OIL FILTER - REPLACE

4J J1060 .4
ADD:
A - With Noise Cover........................................................................................................... .6

SEALS, CRANKSHAFT REAR MAIN - REPLACE

POLICY: P
INC: R&R transmission.
4JJ1 J1119 3.0
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .6
B - Automatic Transmission................................................................................................. .8
(CONTINUED)
J - 32 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - With Noise Cover........................................................................................................... .6
D - 4x4 Models..................................................................................................................... 1.0
4J J1123 4.3
ADD:
A - 4x4 Models..................................................................................................................... 1.0
B - Automatic Transmission................................................................................................. .8
C - With Smoother............................................................................................................... 1.7
D - With Noise Cover........................................................................................................... .6
4B J1124 4.2
ADD:
A - 4x4 Models..................................................................................................................... 1.0
B - Automatic Transmission................................................................................................. .8
C - With Smoother............................................................................................................... 1.7
D - With Noise Cover........................................................................................................... .6
4H J1125 3.0
ADD:
A - 4H** Engines (EXC. 4HK1 Engine) Fitted '05/'08 Cab Models....................................... 1.4
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .6
C - 4x4 Models..................................................................................................................... 1.0
D - Automatic Transmission (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)..................... .8
E - With Smoother (EXC. 4HK1 Engine Fitted '05/'08 Cab Models).................................... 1.7
F - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models)................................... 1.2
G - With Noise Cover........................................................................................................... .6

BEARING, CRANKSHAFT MAIN - REPLACE

POLICY: P, T
INC; R&R engine assy., oil pan and flywheel housing,
plastic type gauge bearing.
ONE BEARING; 4JJ1 J1152 15.7
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 3.2
B - To Replace Main Bearings (One Additional).................................................................. .3
C - To Replace Main Bearings (Two Additional).................................................................. .5
D - To Replace All Main Bearings........................................................................................ 1.0
E - To Replace Connecting Rod Bearings (One Additional)................................................ .2
(CONTINUED)
 ENGINE J - 33

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
F - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
G - To Replace All Connecting Rod Bearings..................................................................... .6
H - Automatic Transmission................................................................................................. .8
J - Manual Transmission...................................................................................................... .6
K - With A/C......................................................................................................................... .5
L - With Crew Cab............................................................................................................... 3.7
M - With Noise Cover........................................................................................................... .6
N - 4x4 Models..................................................................................................................... 1.0
ONE BEARING; 4J J1153 8.0
ADD:
A - To Replace Main Bearings (One Additional).................................................................. .3
B - To Replace Main Bearings (Two Additional).................................................................. .5
C - To Replace All Main Bearings........................................................................................ 1.0
D - To Replace Connecting Rod Bearings (One Additional)................................................ .2
E - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
F - To Replace All Connecting Rod Bearings...................................................................... .6
G - Automatic Transmission................................................................................................ .8
H - With A/C (Engine Remove Work Only).......................................................................... .8
J - With Smoother................................................................................................................ 1.7
K - With Crew Cab............................................................................................................... 3.7
L - With Noise Cover........................................................................................................... .6
M - 4x4 Models.................................................................................................................... 1.0
ONE BEARING; 4B J1154 8.0
ADD:
A - To Replace Main Bearings (One Additional).................................................................. .3
B - To Replace Main Bearings (Two Additional).................................................................. .5
C - To Replace All Main Bearings........................................................................................ 1.0
D - To Replace Connecting Rod Bearings (One Additional)................................................ .2
E - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
F - To Replace All Connecting Rod Bearings...................................................................... .6
G - Automatic Transmission................................................................................................ .8
H - With A/C (Engine Remove Work Only).......................................................................... .8
J - With Smoother................................................................................................................ 1.7
K - With Crew Cab............................................................................................................... 3.7
L - With Noise Cover........................................................................................................... .6
(CONTINUED)
J - 34 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
M - 4x4 Models.................................................................................................................... 1.0
ONE BEARING; 4H J1155 16.6
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 3.0
C - To Replace Connecting Rod Bearings (One Additional)................................................ .2
D - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
E - To Replace All Connecting Rod Bearings...................................................................... .6
F - Automatic Transmission (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)...................... .8
G - With Smoother (EXC. 4HK1 Engine Fitted '05/'08 Cab Models).................................... 1.7
H - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models)................................... .6
J - With A/C
(Engine Remove Work Only, <EXC.4HK1 Engine Fitted '05/'08 Cab Models>)............. .8
K - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2
L - With Crew Cab............................................................................................................... 3.7
M - With Noise Cover........................................................................................................... .6
N - 4x4 Models..................................................................................................................... 1.0

BEARING, CONNECTING ROD - REPLACE

POLICY: P, T
INC: R&R oil pan, oil pump, plastic type gauge bearings ,
clean and inspect oil pump and pan.
ONE BEARING; 4J J1183 6.7
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 10.7
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 7.8
C - To Replace Connecting Rod Bearings (One Additional)................................................ .3
D - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
E - To Replace All Connecting Rod Bearings...................................................................... .6
F - With A/C......................................................................................................................... .5
G - With Crew Cab............................................................................................................... 2.6
H - With Noise Cover........................................................................................................... .6
J - 4x4 Models..................................................................................................................... .2

(CONTINUED)
 ENGINE J - 35

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ONE BEARING; 4B J1184 2.3
ADD:
A - To Replace Connecting Rod Bearings (One Additional)................................................ .3
B - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
C - To Replace All Connecting Rod Bearings...................................................................... .6
D - With A/C (Engine Remove Work only)........................................................................... .5
E - With Crew Cab............................................................................................................... 2.6
F - With Noise Cover........................................................................................................... .6
G - 4x4 Models..................................................................................................................... .2
ONE BEARING; 4H J1185 2.3
ADD:
A - To Replace Connecting Rod Bearings (One Additional)................................................ .3
B - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
C - To Replace All Connecting Rod Bearings...................................................................... .6
D - With A/C (Engine Remove Work only)........................................................................... .5
E - With Crew Cab............................................................................................................... 2.6
F - With Noise Cover........................................................................................................... .6
G - 4x4 Models..................................................................................................................... .2

CRANKSHAFT - REPLACE
POLICY: P, T
INC: R&R engine assy. R&R cyl. head assy, oil pan and flywheel
housing, plastic type gauge bearings.
NOTE: EXC. 4JJ1/4HK1 Engines Fitted '05/'08 cab models.
4J J1203 8.0
ADD:
A - To Replace Rod and/or Pin Only (One)......................................................................... .4
B - To Replace Rod and/or Pin Only (Two)......................................................................... .7
C - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
D - To Replace Cylinder Head............................................................................................. 2.5
E - To Recondition or Replace All Valve.............................................................................. 1.7
F - To Replace Piston, Rod and/or Rings (One).................................................................. .4
G - To Replace Piston, Rod and/or Rings (Two)................................................................. .7
H - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
J - To Replace Cylinder Liner (One).................................................................................... .6
(CONTINUED)
J - 36 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
K - To Replace Cylinder Liner (Two).................................................................................... 1.2
L - To Replace Cylinder Liner (All)....................................................................................... 1.9
M - Automatic Transmission................................................................................................ .8
N - With Smoother............................................................................................................... 1.7
O - With A/C........................................................................................................................ .8
P - With Crew Cab............................................................................................................... 3.7
Q - With Noise Cover........................................................................................................... .6
R - 4x4 Models..................................................................................................................... 1.0
4B J1204 8.0
ADD:
A - To Replace Rod and/or Pin Only (One)......................................................................... .4
B - To Replace Rod and/or Pin Only (Two)......................................................................... .7
C - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
D - To Replace Cylinder Head............................................................................................. 2.5
E - To Recondition or Replace All Valve.............................................................................. 1.7
F - To Replace Piston, Rod and/or Rings (One).................................................................. .4
G - To Replace Piston, Rod and/or Rings (Two)................................................................. .7
H - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
J - To Replace Cylinder Liner (One).................................................................................... .6
K - To Replace Cylinder Liner (Two).................................................................................... 1.2
L - To Replace Cylinder Liner (All)....................................................................................... 1.9
M - Automatic Transmission................................................................................................ .8
N - With Smoother............................................................................................................... 1.7
O - With A/C........................................................................................................................ .8
P - With Crew Cab............................................................................................................... 3.7
Q - With Noise Cover........................................................................................................... .6
R - 4x4 Models..................................................................................................................... 1.0
4H J1205 16.6
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - To Replace Rod and/or Pin Only (One)......................................................................... .4
C - To Replace Rod and/or Pin Only (Two)......................................................................... .7
D - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
E - To Replace Cylinder Head............................................................................................. 2.5
F - To Recondition or Replace All Valve.............................................................................. 1.7
(CONTINUED)
 ENGINE J - 37

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
G - To Replace Piston, Rod and/or Rings (One)................................................................. .4
H - To Replace Piston, Rod and/or Rings (Two).................................................................. .7
J - To Replace Piston, Rod and/or Rings (All)..................................................................... 1.1
K - To Replace Cylinder Liner (One).................................................................................... .3
L - To Replace Cylinder Liner (Two).................................................................................... .5
M - To Replace Cylinder Liner (All)...................................................................................... .8
N - Automatic Transmission................................................................................................. .8
O - With Smoother............................................................................................................... 1.7
P - With A/C......................................................................................................................... .8
Q - With Crew Cab............................................................................................................... 3.7
R - With Noise Cover........................................................................................................... .6
S - 4x4 Models..................................................................................................................... 1.0

CRANKSHAFT - R&R OR REPLACE

NOTE: 4JJ1/4HK1 engines fitted '05/'08 cab models only.
4JJ1 J1250 15.8
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 3.3
B - To Replace Cylinder Head............................................................................................. 3.7
C - To Recondition or Replace All Valves............................................................................ 3.9
D - To Replace Piston, Rod and/or Rings (One).................................................................. .3
E - To Replace Piston, Rod and/or Rings (Two).................................................................. .6
F - To Replace Piston, Rod and/or Rings (All)..................................................................... .9
G - Manual Transmission..................................................................................................... .6
H - With A/C......................................................................................................................... .5
J - With Crew Cab............................................................................................................... 3.7
K - 4x4 Models..................................................................................................................... 1.0
4HK1 J1251 16.3
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 3.3
B - To Replace Cylinder Head............................................................................................. 4.9
C - To Recondition or Replace All Valves............................................................................ 2.9
D - To Replace Piston, Rod and/or Rings (One).................................................................. .4
E - To Replace Piston, Rod and/or Rings (Two).................................................................. .7
F - To Replace Piston, Rod and/or Rings (All)..................................................................... 1.1
(CONTINUED)
J - 38 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
G - Manual Transmission..................................................................................................... .6
H - With A/C......................................................................................................................... .2
J - With Crew Cab............................................................................................................... 3.7
K - 4x4 Models..................................................................................................................... 1.0

PISTON, ROD AND/OR RINGS - REPLACE

POLICY: P, T
INC: R&R oil pan and cylinder head, R&R piston and rod assy.
ONE CYL; 4JJ1 J1302 14.6
ADD:
A - To Recondition or Replace All Valves............................................................................ 3.9
B - To Replace Piston, Rod and/or Rings (One Additional)................................................. .3
C - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .6
D - To Replace Piston, Rod and/or Rings (All).................................................................... .9
E - To Replace Cylinder Head............................................................................................. 3.7
F - With A/C......................................................................................................................... .5
G - With Crew Cab............................................................................................................... 2.6
H - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 3.0
J - 4x4 Models..................................................................................................................... 1.0
ONE CYL; 4J J1303 7.0
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - To Replace Piston, Rod and/or Rings (One Additional)................................................. .4
D - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
E - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
F - To Replace Cylinder Liner (One).................................................................................... .6
G - To Replace Cylinder Liner (Two)................................................................................... 1.2
H - To Replace Cylinder Liner (All)...................................................................................... 1.9
J - With Turbocharger (4J** Engines).................................................................................. 1.0
K - With EGR Cooler (4J** Engines).................................................................................... .5
L - With A/C......................................................................................................................... .7
M - With Crew Cab.............................................................................................................. 2.6
N - With Noise Cover........................................................................................................... .6
O - 4x4 Models..................................................................................................................... .2
(CONTINUED)
 ENGINE J - 39

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ONE CYL; 4B J1304 6.5
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - To Replace Piston, Rod and/or Rings (One Additional)................................................. .4
D - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
E - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
F - To Replace Cylinder Liner (One).................................................................................... .6
G - To Replace Cylinder Liner (Two)................................................................................... 1.2
H - To Replace Cylinder Liner (All)...................................................................................... 1.9
J - With A/C......................................................................................................................... .7
K - With Crew Cab............................................................................................................... 2.6
L - With Noise Cover........................................................................................................... .6
M - 4x4 Models.................................................................................................................... .2
ONE CYL; 4H J1305 5.3
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. 3.7
C - 4HK1 Engine Fitted '08 Cab Model................................................................................ 2.2
D - To Replace Cylinder Head
(INC. Add.F, <EXC. 4HK1 Engine Fitted '05/'08 Cab Models>)...................................... 2.5
E - To Replace Cylinder Head (4HK1 Engine Fitted '05/'08 Cab Models)........................... 4.9
F - To Recondition or Replace All Valves
(EXC. 4HK1 Engine Fitted '05/'08 Cab Models)............................................................. 1.7
G - To Recondition or Replace All Valves (4HK1 Engine Fitted '05/'08 Cab Models).......... 2.9
H - To Replace Piston, Rod and/or Rings (One Additional)................................................. .4
J - To Replace Piston, Rod and/or Rings (Two Additional).................................................. .7
K - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
L - To Replace Cylinder Liner (One).................................................................................... .3
M - To Replace Cylinder Liner (Two)................................................................................... .5
N - To Replace Cylinder Liner (All)...................................................................................... .8
O - With Smoother (EXC. 4HK1 Engine Fitted '05/'08 Cab Models).................................... .7
P - With A/C ........................................................................................................................ .2
Q - With Crew Cab............................................................................................................... 2.6
R - With Noise Cover........................................................................................................... .6
(CONTINUED)
J - 40 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
S - 4x4 Models..................................................................................................................... .2
T - With Crew Cab (4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model).................. 3.7
U - With Crew Cab (4HK1 Engine Fitted '08 Cab Model).................................................... 3.1

FLYWHEEL (AUTOMATIC TRANSMISSION) - REPLACE J1401 3.4

POLICY: P
ADD:
A - With Noise Cover........................................................................................................... .6
B - EXC. 4HK1 Engine Fitted '05/'08 Cab Models............................................................... .9

FLYWHEEL (MANUAL TRANSMISSION) - REPLACE

POLICY: P
INC: R&R transmission.
4J J1423 2.4
ADD:
A - To Replace Clutch Pilot Bearing.................................................................................... .3
B - To Replace Ring Gear................................................................................................... .6
C - With Smoother (EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models)......................... .6
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... 1.0
F - EXC. 4B** Engines and 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models........................ 1.8
G - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.8
4B J1424 4.0
ADD:
A - To Replace Clutch Pilot Bearing.................................................................................... .3
B - To Replace Ring Gear................................................................................................... .6
C - With Smoother (EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models)......................... .6
D - With Noise Cover........................................................................................................... .6
E - 4x4 Models..................................................................................................................... 1.0
4H J1425 2.4
ADD:
A - To Replace Clutch Pilot Bearing.................................................................................... .3
B - To Replace Ring Gear................................................................................................... .6
C - With Smoother (EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models)......................... .6
D - With Noise Cover........................................................................................................... .6
(CONTINUED)
 ENGINE J - 41

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
E - 4x4 Models..................................................................................................................... 1.0
F - EXC. 4B** Engines and 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models........................ 1.8
G - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 1.8

FLYWHEEL HOUSING - REPLACE

EXC.4JJ1 J1430 11.9
ADD:
A - EXC. 4HK1 Engine Fitted '05/'08 Cab Models............................................................... .6
B - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .6
C - With A/C (EXC.4HK1 Engine Fitted '05/'08 Cab Models).............................................. .6
D - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2
E - Automatic Transmission (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)...................... .8
F - Automatic Transmission (4HK1 Engine Fitted '05/'08 Cab Models)............................... 1.8
G - With Smoother (EXC.4HK1 Engine Fitted '05/'08 Cab Models)..................................... .6
H - With Smoother (4HK1 Engine Fitted '05/'08 Cab Models)............................................. 1.8
J - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models).................................... 2.4
K - With Crew Cab............................................................................................................... 2.2
L - With Noise Cover........................................................................................................... .6
M - 4x4 Models.................................................................................................................... 1.0
4JJ1 J1431 2.5
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.2
B - Automatic Transmission................................................................................................. .8
C - Manual Transmission..................................................................................................... .7
D - With A/C......................................................................................................................... .2
E - With Crew Cab............................................................................................................... 2.2
F - With Noise Cover........................................................................................................... .6
G - 4x4 Models..................................................................................................................... 1.0

MOUNT, ENGINE - REPLACE

POLICY: P
FRONT RIGHT J1500 .5
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.3
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 1.0
(CONTINUED)
J - 42 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - 4JJ1 Engine 4x4 Model.................................................................................................. .3
FRONT LEFT J1501 .5
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.1
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. .8
C - 4JJ1 Engine 4x4 Model.................................................................................................. .1
FRONT BOTH J1507 .6
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 2.6
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 2.0
C - 4JJ1 Engine 4x4 Model.................................................................................................. .5
REAR J1510 .5
ADD:
A - With Noise Cover........................................................................................................... .6

PLUG, EXPANSION - REPLACE J1600 .5

POLICY: P
NOTE: Add appropriate labor operation time's for removal of necessary
components to gain access to plug to regular labor hours column.

PLUG, OIL GALLERY - REPLACE

POLICY: P
INC: R&R flywheel.
4J J1643 2.4
ADD:
A - With Noise Cover........................................................................................................... .6
4B J1644 4.1
ADD:
A - With Noise Cover........................................................................................................... .6
4H J1645 5.5
ADD:
A - With Noise Cover........................................................................................................... .6
 ENGINE J - 43

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BLOCK, ENGINE FITTED - R&R OR REPLACE

POLICY: P, T
INC: R&R engine assy.
4JJ1 J1802 17.0
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.9
B - To Replace Cylinder Head............................................................................................. 3.7
C - To Recondition or Replace All Valves............................................................................ 3.9
D - To Boring....................................................................................................................... ST
E - Automatic Transmission................................................................................................. .8
F - Manual Transmission..................................................................................................... .6
G - With A/C........................................................................................................................ .5
H - With Crew Cab............................................................................................................... 3.7
J - With Noise Cover............................................................................................................ .6
K - 4x4 Models..................................................................................................................... 1.0
4J J1803 17.2
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - To Boring....................................................................................................................... ST
D - With Turbocharger (4J** Engines)................................................................................. 1.0
E - With EGR Cooler (4J** Engines).................................................................................... .5
F - Automatic Transmission................................................................................................. .8
G - With A/C........................................................................................................................ .8
H - With Crew Cab............................................................................................................... 3.7
J - With Noise Cover............................................................................................................ .6
K - 4x4 Models..................................................................................................................... 1.0
4B J1804 12.8
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - To Boring....................................................................................................................... ST
D - Automatic Transmission................................................................................................. .8
E - With A/C......................................................................................................................... .8
F - With Crew Cab............................................................................................................... 3.7
G - With Noise Cover........................................................................................................... .6
(CONTINUED)
J - 44 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
H - 4x4 Models..................................................................................................................... 1.0
4H J1805 14.4
ADD:
A - 4HE1-TC Engine............................................................................................................ 3.2
B - 4H** Engines (EXC.4HE1-TC and 4HK1 Engines Fitted '05/'08 Cab Models)............... 2.5
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 2.5
D - To Replace Cylinder Head (INC. Add. E)....................................................................... 2.5
E - To Recondition or Replace All Valves............................................................................ 1.7
F - To Boring........................................................................................................................ ST
G - Automatic Transmission （EXC. 4HK1 Engine Fitted '05/'08 Cab Models)................... .8
H - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models)................................... .6
J - With A/C (EXC.4HK1 Engine Fitted '05/'08 Cab Models)............................................... .8
K - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2
L - With Crew Cab............................................................................................................... 3.7
M - With Noise Cover........................................................................................................... .6
N - 4x4 Models..................................................................................................................... 1.0

ENGINE PARTIAL/BASIC - REPLACE

POLICY: A, P, T
INC: R&R engine assy.
4JJ1 J1822 14.6
ADD:
A - 4JJ1 Engine Fitted '08 Cab Model................................................................................. .7
B - To Replace Cylinder Head (INC Add. C)........................................................................ 3.7
C - To Recondition or Replace All Valves............................................................................ 3.9
D - Automatic Transmission................................................................................................. .8
E - Manual Transmission..................................................................................................... .6
F - With A/C......................................................................................................................... .5
G - With Crew Cab............................................................................................................... 3.7
H - With Noise Cover........................................................................................................... .6
J - 4x4 Models..................................................................................................................... 1.0
4J J1823 11.6
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
(CONTINUED)
 ENGINE J - 45

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - With Turbocharger (4J** Engines)................................................................................. 1.0
D - With EGR Cooler (4J** Engines)................................................................................... .5
E - Automatic Transmission................................................................................................. .8
F - With A/C......................................................................................................................... .8
G - With Crew Cab............................................................................................................... 3.7
H - With Noise Cover........................................................................................................... .6
J - 4x4 Models..................................................................................................................... 1.0
4B J1824 11.6
ADD:
A - To Replace Cylinder Head (INC. Add. B)....................................................................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - Automatic Transmission................................................................................................. .8
D - With A/C......................................................................................................................... .8
E - With Crew Cab............................................................................................................... 3.7
F - With Noise Cover........................................................................................................... .6
G - 4x4 Models..................................................................................................................... 1.0
4H J1825 12.9
ADD:
A - 4HE1-TC Engine............................................................................................................ 3.2
B - 4H** Engines (EXC.4HE1-TC Engine and 4HK1 Engine Fitted '05/'08 Cab Models)..... 2.5
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 2.5
D - To Recondition or Replace All Valves............................................................................ 1.7
E - To Replace Cylinder Head (INC. Add. D)....................................................................... 2.5
F - Automatic Transmission (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)...................... .8
G - With Smoother (4HK1 Engine, EXC. 4HK1 Engine Fitted '05/'08 Cab Models)............ 1.7
H - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models)................................... .6
J - With A/C (EXC.4HK1 Engine Fitted '05/'08 Cab Models)............................................... .8
K - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2
L - With Crew Cab............................................................................................................... 3.7
M - With Noise Cover........................................................................................................... .6
N - 4x4 Models..................................................................................................................... 1.0
O - To Recondition or Replace All Valves (4HK1 Engine)................................................... 3.4
P - To Replace Cylinder Head (INC. Add. O) (4HK1 Engine).............................................. 4.2
J - 46 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

ENGINE ASSEMBLY - REPLACE

POLICY: A, P, T
4JJ1 J1882 5.7
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.7
B - Automatic Transmission................................................................................................. .8
C - Manual Transmission..................................................................................................... .6
D - With A/C......................................................................................................................... .5
E - With Crew Cab............................................................................................................... 3.7
F - 4x4 Models..................................................................................................................... 1.0
4J J1883 5.0
ADD:
A - Automatic Transmission................................................................................................. .8
B - With Smoother............................................................................................................... 1.7
C - With A/C......................................................................................................................... .6
D - With Crew Cab............................................................................................................... 3.7
E - With Noise Cover........................................................................................................... .6
F - 4x4 Models..................................................................................................................... 1.0
4B J1884 4.3
ADD:
A - Automatic Transmission................................................................................................. .8
B - With Smoother............................................................................................................... 1.7
C - With A/C......................................................................................................................... .6
D - With Crew Cab............................................................................................................... 3.7
E - With Noise Cover........................................................................................................... .6
F - 4x4 Models..................................................................................................................... 1.0
4H J1885 3.6
ADD:
A - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)....................................... 2.2
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ 1.8
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. 1.5
D - Automatic Transmission (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)..................... .8
E - With Smoother (EXC.4HK1 Engine Fitted '05/'08 Cab Models)..................................... 1.7
F - Manual Transmission (4HK1 Engine Fitted '05/'08 Cab Models)................................... .6
G - With A/C (4HK1 Engine Fitted '95 Cab Model).............................................................. .4
H - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2
(CONTINUED)
 ENGINE J - 47

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
J - With Crew Cab............................................................................................................... 3.7
K - With Noise Cover (EXC.4HK1 Engine Fitted '05/'08 Cab Models)................................. .6
L - 4x4 Models..................................................................................................................... 1.0

CAP, RADIATOR FILLER - REPLACE J3020 .3

INC: Diagnosis to pressure test cap.

COCK OF PLUG, RADIATOR DRAIN - REPLACE J3040 .4

INC: Drain and refill.

RADIATOR ASSEMBLY - R&R J3080 1.2

ADD:
A - 4JH1 Engine (EXC. 4JH1-TC Engine)........................................................................... .3
B - With Crew Cab............................................................................................................... 1.1
C - 4JJ1 Engine................................................................................................................... .6

RADIATOR ASSEMBLY - REPLACE J3100 1.2

POLICY: T
INC: Drain and refill.
ADD:
A - 4JH1 Engine (EXC. 4JH1-TC Engine)........................................................................... .3
B - With Crew Cab............................................................................................................... 1.1
C - 4JJ1 Engine................................................................................................................... .6

COOLER, ENGINE OIL - REPLACE

POLICY: P, T
INC: Drain and refill.
4J J3123 1.4
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 2.8
B - 4JJ1 Engine Fitted '08 Cab Model................................................................................. 2.1
C - To Repair Core.............................................................................................................. 1.2
D - To Replace Core............................................................................................................ 1.2
E - With Crew Cab............................................................................................................... 1.9

(CONTINUED)
J - 48 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
4B J3124 4.6
ADD:
A - To Repair Core............................................................................................................... 1.2
B - To Replace Core............................................................................................................ 1.2
C - With Crew Cab............................................................................................................... 1.9
4H J3125 2.9
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model.............................................. .4
B - To Repair Core............................................................................................................... 1.2
C - To Replace Core............................................................................................................ 1.2
D - With Crew Cab............................................................................................................... 1.9

TUBE, OVERFLOW - REPLACE J3180 .3

SHROUD, RADIATOR FAN - REPLACE

ONE PIECE J3247 .6
ADD:
A - 4JJ1 Engine................................................................................................................... .4

RESERVOIR, RADIATOR COOLANT - REPLACE J3260 .2

CLAMP, RADIATOR HOSE - REPLACE

ONE J3340 .3
ADD:
A - To Replace Clamp (One Additional).............................................................................. .2
B - To Replace Clamp (Two Additional)............................................................................... .3
C - To Replace Clamp (Three Additional)............................................................................ .4
D - To Replace Clamp (Four Additional).............................................................................. .5

HOSE, ENGINE COOLANT - REPLACE

POLICY: T
INC: Drain and refill radiator as nec.
UPPER J3362 .4
LOWER J3363 .5
BOTH J3367 .6
(CONTINUED)
 ENGINE J - 49

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ADD:
A - With Crew Cab (EXC. J3363)........................................................................................ .7

BELLMOUTH, FAN GUIDE - R&R J3370 .5

ADD:
A - With Crew Cab............................................................................................................... 1.7
B - 4JJ1 Engine................................................................................................................... .3

COOLING FAN - REPLACE J3380 .6

POLICY: T
INC: R&R fan clutch assy if any.
ADD:
A - With Crew Cab............................................................................................................... 1.1
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .5

CLUTCH ASSEMBLY, COOLING FAN - REPLACE J3390 .6

ADD:
A - With Crew Cab............................................................................................................... 1.1
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .5

PULLEY, COOLANT PUMP - REPLACE J3420 .6

POLICY: P, T
INC: Adjust belt tension.
ADD:
A - With Crew Cab............................................................................................................... .7
B - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... .2
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .6

PUMP AND/OR GASKET, COOLANT - REPLACE

POLICY: P, T
INC: Drain and refill radiator as nec.
4J J3483 .6
ADD:
A - 4J** Engines (EXC. 4JJ1 Engine).................................................................................. 1.2
B - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .5
(CONTINUED)
J - 50 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
C - With A/C......................................................................................................................... .3
D - With Crew Cab............................................................................................................... 1.0
4B J3484 1.2
ADD:
A - With A/C......................................................................................................................... .3
B - With Crew Cab............................................................................................................... 1.0
4H J3485 .6
ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .7
B - 4H** Engines (EXC. 4HK1 Engine Fitted '05/'08 Cab Models)....................................... .5
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. .5
D - With A/C......................................................................................................................... .3
E - With Crew Cab............................................................................................................... 1.0

THERMOSTAT, OUTLET AND/OR GASKET - REPLACE J3500 .4

POLICY: P
INC: Drain and refill radiator as necessary and test thermostat.
ADD:
A - 4JJ1 Engine................................................................................................................... .2
B - With Crew Cab............................................................................................................... .9

HOUSING AND/OR GASKET, THERMOSTAT - REPLACE J3520 .7

POLICY: P

COOLING SYSTEM - FLUSH J3540 1.0

INC: Drain cooling system, R&R thermostat, flush with clear water
and test coolant.

PULLEY AND/OR FAN, GENERATOR - REPLACE J4020 .5

POLICY: T
ADD:
A - With Crew Cab............................................................................................................... .1
 ENGINE J - 51

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BEARING, GENERATOR - REPLACE

INC: R&R generator, separate end frame, and R&R rotor.
FRONT J4042 .9
REAR J4043 .8
BOTH J4047 1.0
ADD:
A - With Crew Cab............................................................................................................... .4
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .2

DIODE, CHARGING SYSTEM (JUMPER) - REPLACE J4050 1.5

INC: R&R and disassemble generator as nec.
ADD:
A - With A/C (4HE1-TC Engine).......................................................................................... .6
B - With Crew Cab............................................................................................................... .4
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .2

REGULATOR, VOLTAGE - TEST AND REPLACE J4060 1.7

POLICY: T
INC: R&R and disassemble generator as nec.
ADD:
A - With A/C (4HE1-TC Engine).......................................................................................... .6
B - With Crew Cab............................................................................................................... .4

GENERATOR ASSEMBLY - DISASSEMBLE, INSPECT, TEST AND

REASSEMBLE
POLICY: T
INC: R&R generator assy.
DIESEL J4080 .5
ADD:
A - To Replace Rotor, Drive End Frame, Pulley, Fan and/or Front Bearing........................ .5
B - To Replace Stator.......................................................................................................... .1
C - To Replace Diode Trio................................................................................................... .8
D - To Recondition Complete.............................................................................................. .8
INC: All of the above additions.
NOTE: All of the above additions include time to inspect and test the
components on the bench upon installation of a new part.
(CONTINUED)
J - 52 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
E - With A/C (4HE1-TC Engine).......................................................................................... .6
F - With Crew Cab............................................................................................................... .4
G - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models.................................................... .2

GENERATOR ASSEMBLY - REPLACE

POLICY: T
INC: Transfer pulley and adjust belt tension.
DIESEL J4100 .5
ADD:
A - With A/C (4HE1-TC Engine).......................................................................................... .6
B - With A/C (4JH1-T/4JA1 Engines)................................................................................... .5
C - With A/C (4HK1 Engine Fitted '95 Cab Model).............................................................. .3
D - With Crew Cab............................................................................................................... .4
E - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .2
F - With A/C (4HK1 Engine Fitted '05/'08 Cab Models)....................................................... .2

BRACE, GENERATOR ADJUSTING - REPLACE J4120 .4

POLICY: T

BRACKET, GENERATOR MOUNTING - REPLACE

POLICY: T
DIESEL J4160 1.1
ADD:
A - With A/C......................................................................................................................... .3
B - With A/C (4HE1-TC Engine).......................................................................................... .6
C - With Crew Cab............................................................................................................... .4
D - 4JJ1 Engine Fitted '05 Cab Model................................................................................. .7
E - 4JJ1 Engine Fitted '08 Cab Model................................................................................. .4

SENSOR, CAMSHAFT ANGLE - REPLACE J4350 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .3
C - With Crew Cab............................................................................................................... .2
 ENGINE J - 53

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SOLENOID, STARTER MOTOR - REPLACE J4580 1.1

POLICY: T

DRIVE ASSEMBLY, STARTER MOTOR - REPLACE J4600 .8

POLICY: T
INC: R&R starter motor.

MOTOR ASSEMBLY, STARTER - R&R J4620 .7

POLICY: T
ADD:
A - To Replace Starter Drive Assy....................................................................................... .4
B - To Recondition Starter Motor (INC. Adds A and D)....................................................... 1.4
C - To Replace Field Coils................................................................................................... .5
D - To Recondition Armature............................................................................................... .5

MOTOR ASSEMBLY, STARTER - REPLACE J4640 .7

POLICY: T

SOLENOID, OR ACTUATOR FAST IDLE (DIESEL) - REPLACE J4750 .4

INC: Adjustment of fast idle speed.

GLOW PLUG - REPLACE

ONE J4790 .3
ADD:
A - To Replace Glow Plug (One or Two).............................................................................. .2
B - To Replace Glow Plugs (All).......................................................................................... .2
C - 4HK1 Engine.................................................................................................................. .4
D - With Crew Cab............................................................................................................... .4
E - R&R EGR Cooler and/or EGR Valve............................................................................. 1.1

CONTROLLER, QOS - REPLACE J4791 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3

DROPPING RESISTOR - REPLACE J4793 .3

J - 54 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

AFTER GLOW TIMER - REPLACE J4794 .3

SWITCH, QOS THERMO - REPLACE J4796 .4

AIR CLEANER ASSEMBLY - REPLACE

POLICY: A, E
4J J5003 .5
ADD:
A - 4J** Engines (EXC. 4JJ1 Engine).................................................................................. .2
B - With Crew Cab............................................................................................................... .2
4B J5004 .4
ADD:
A - With Crew Cab............................................................................................................... .2
4H J5005 .5
ADD:
A - With Crew Cab............................................................................................................... .2

ELEMENT, AIR CLEANER - REPLACE J5010 .3

DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE J5020 .3

POLICY: E
ADD:
A - 4JJ1 Engine................................................................................................................... .3

DUCT AND/OR HOSE, TURBO. TO INLET MANIFOLD - REPLACE J5023 .4

ADD:
A - With Crew Cab............................................................................................................... .1

VALVE ASSEMBLY, INTAKE THROTTLE - R&R OR REPLACE J5275 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... .2
C - With Crew Cab............................................................................................................... 1.2
 ENGINE J - 55

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CABLE, ACCELERATOR CONTROL - REPLACE

POLICY: T
4J J5333 .6
ADD:
A - With Crew Cab............................................................................................................... .6
4B J5334 .7
ADD:
A - With Crew Cab............................................................................................................... .6
4H J5335 .7
ADD:
A - With Crew Cab............................................................................................................... .6

MOTOR AND/OR CABLE, ENGINE STOP - REPLACE

DIESEL J5340 1.0
ADD:
A - With Crew Cab............................................................................................................... .6

SOLENOID, ENGINE STOP - REPLACE

POLICY: E
DIESEL J5345 .3
ADD:
A - With Crew Cab............................................................................................................... .6

PEDAL, ACCELERATOR - REPLACE J5350 .4

ENGINE EXHAUST BRAKE SYSTEM COMPONENTS - REPLACE

POWER CHAMBER J5391 .5
VALVE ASSEMBLY J5393 .8
MAGNETIC VALVE J5394 .2
ADD:
A - Diagnosis Time (Only J5394)......................................................................................... .3
SWITCH ASSEMBLY, COMBINATION J5395 .3
SWITCH, ACCELERATOR EXHAUST BRAKE J5396 .3
SWITCH, CLUTCH EXHAUST BRAKE J5397 .3
J - 56 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

FILTER, FUEL ELEMENT - REPLACE J5420 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .2
B - With Crew Cab (4HK1 Engine)...................................................................................... .2

VALVE, OVERFLOW, INJECTION PUMP - REPLACE J5424 .3

PUMP AND/OR GASKET, FUEL - REPLACE

POLICY: T
MECHANICAL J5430 .3
ADD:
A - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .4

LIMITER, FUEL PRESSURE(DIESEL) - REPLACE J5565 .7

ADD:
A - 4JJ1 Engine................................................................................................................... .2

RAIL ASSEMBLY, COMMON, FUEL INJECTION (DIESEL) - R&R OR REPLACE J5665 .9

ADD:
A - With Crew Cab............................................................................................................... 1.7
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... .9
C - 4JJ1 Engine................................................................................................................... .3

INTERCOOLER COMPONENTS - REPLACE

INTERCOOLER ASSEMBLY J5685 .6
ADD:
A - With Crew Cab............................................................................................................... 1.0
B - 4JJ1 Engine................................................................................................................... .3
TURBO TO INTERCOOLER INLET PIPE J5690 .3
ADD:
A - With Crew Cab............................................................................................................... .8
INTER COOLER TO INTAKE MANIFOLD PIPE J5691 .3
ADD:
A - With Crew Cab............................................................................................................... .8

(CONTINUED)
 ENGINE J - 57

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ONE RUBBER HOSE J5692 .3
ADD:
A - With Crew Cab............................................................................................................... .5
TWO RUBBER HOSE J5693 .5
ADD:
A - With Crew Cab............................................................................................................... .5

TURBOCHARGER ASSEMBLY - REPLACE

POLICY: A, P
4JJ1 J5862 2.2
ADD:
A - With Crew Cab............................................................................................................... .8
4J J5863 1.7
ADD:
A - 4J**-T Engines (EXC. 4JH1-T/4JA1-TC Engines).......................................................... 1.2
B - With Crew Cab............................................................................................................... .8
4B J5864 1.9
ADD:
A - With Crew Cab............................................................................................................... .8
4H J5865 1.9
ADD:
A - 4HK1 Engines Fitted '05/'08 Cab Models....................................................................... .5
B - With Crew Cab............................................................................................................... .8

PIPE, OIL PRESSURE (TURBO) - REPLACE J5866 .6

ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ 1.1
B - With Crew Cab............................................................................................................... .8
C - 4HK1 Engine Fitted '05/'08 Cab Models........................................................................ .3

PIPE, OIL RETURN (TURBO) - REPLACE J5867 .6

ADD:
A - 4JJ1 Engine................................................................................................................... 1.1
J - 58 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HOSE, WATER RETURN (TURBO) - REPLACE J5885 .5

ADD:
A - 4JJ1 Engine................................................................................................................... .3
B - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... .6

HOSE, WATER FEED (TURBO) - REPLACE J5886 .4

ADD:
A - 4JJ1 Engine................................................................................................................... 1.3

VALVE,MAGNETIC,VGS - REPLACE J5890 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... .2

SENSOR,VACUUM,VGS - REPLACE J5895 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3

INJECTOR, FUEL (DIESEL) - R&R OR REPLACE

POLICY: T
ONE J5926 .7
ADD:
A - To Replace Additional Injector (One or Two, EXC. 4HK1 Engine)................................. .2
B - To Replace Additional Injector (One or Two, 4HK1 Engine).......................................... .4
C - To Replace All Injectors (EXC. 4HK1 Engine)............................................................... .3
D - To Replace All Injectors (4HK1 Engine)........................................................................ .8
E - To Adjust Injection Pressure (1 - 2)................................................................................ .3
F - To Adjust Injection Pressure (3 - 4)................................................................................ .5
G - To Lap Nozzle................................................................................................................ ST
H - 4BD2-TC Engine............................................................................................................ .4
I - 4JH1-T Engine................................................................................................................. .4
J - 4HK1 Engine Fitted '95 Cab Model................................................................................. .8
K - Program ECU................................................................................................................. .3
L - Diagnosis Time............................................................................................................... .3
M - With Crew Cab.............................................................................................................. 1.8
N - 4JJ1 Engine................................................................................................................... .2
(CONTINUED)
 ENGINE J - 59

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
O - 4HK1 Engine Fitted '05/'08 Cab Models........................................................................ 1.4

SLEEVE AND/OR GASKET, NOZZLE HOLDER - REPLACE

NOTE: Only '95 Cab Model.
ONE CYL J5930 6.2
ADD:
A - To Replace Sleeve and/or Gasket Nozzle Holder (Each Additional CYL)...................... .2
B - To Replace All Sleeve and/or Gasket Nozzle Holder..................................................... .3
C - With A/C......................................................................................................................... .4
D - With Crew Cab............................................................................................................... 1.8

LINE, FUEL INJECTION HIGH PRESSURE DIESEL - R&R OR REPLACE

POLICY: T
ONE J5935 .6
ADD:
A - To Replace Additional Line (One, EXC. 4HK1 Engine).................................................. .2
B - To Replace Additional Line (One, 4HK1 Engine)........................................................... .3
C - To Replace Additional Line (Two).................................................................................. .3
D - To Replace All Lines...................................................................................................... .4
E - 4JH1-T Engine............................................................................................................... .6
F - 4HK1 Engine.................................................................................................................. .3
G - With Crew Cab............................................................................................................... 1.7
H - 4JJ1 Engine................................................................................................................... .2

LINE, FUEL RETURN - REPLACE J5937 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .4
B - 4HK1 Engine.................................................................................................................. .9
C - With Crew Cab............................................................................................................... 1.1

PUMP, FUEL INJECTION DIESEL - R&R OR REPLACE

POLICY: A, P, T
4JJ1 J5952 4.4
ADD:
A - 4JJ1 Engine Fitted '05 Cab Model................................................................................. 1.4
(CONTINUED)
J - 60 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
B - Diagnosis Time.............................................................................................................. .3
C - With Crew Cab............................................................................................................... 1.7
D - To Replace Gasket........................................................................................................ .1
GEAR TYPE; 4J J5953 2.4
ADD:
A - 4JH1-T Engine............................................................................................................... .6
B - 4JG2 Engine (Belt Drive Type)....................................................................................... 2.4
C - With Crew Cab............................................................................................................... 1.7
D - To Replace Gasket........................................................................................................ .1
GEAR TYPE; 4B J5954 3.8
ADD:
A - With Crew Cab............................................................................................................... 1.7
B - To Replace Gasket........................................................................................................ .1
GEAR TYPE; 4H J5955 1.2
ADD:
A - 4H*1 Engines (EXC. 4HK1 Engine)............................................................................... .9
B - 4HK1 Engine Fitted '95 Cab Model................................................................................ .5
C - 4HK1 Engine (Euro4 Specification) Fitted '05 Cab Model............................................. .3
D - Diagnosis Time.............................................................................................................. .3
E - With Crew Cab............................................................................................................... 1.7
F - To Replace Gasket......................................................................................................... .1

GEAR AND/OR ADVANCE TIMING MECHANISM, FUEL INJECTION J5962 2.0

PUMP - REPLACE
POLICY: P, T
ADD:
A - 4H*1 Engines................................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.7

TIMING, FUEL INJECTION PUMP DIESEL - ADJUST J5965 .6

POLICY: E
 ENGINE J - 61

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

FRP(FUEL RAIL PRESSURE) / SCV(SUCTION CONTROL VALVE) J5995 .2

- REPLACE (ON VEHICLE)
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.2
C - 4JJ1 Engine................................................................................................................... .4

VALVE, PCV - REPLACE J6000 .3

POLICY: E
ADD:
A - With Crew Cab............................................................................................................... .1

PIPE, EGR - R&R OR REPLACE J6269 .5

ADD:
A - With Crew Cab............................................................................................................... .6

VALVE AND/OR GASKET, EGR - REPLACE J6270 .4

POLICY: E, P
ADD:
A - 4HK1 Engine.................................................................................................................. .2
B - With Crew Cab............................................................................................................... 1.2
C - Diagnosis Time.............................................................................................................. .3

MOTOR, EGR VALVE - REPLACE J6271 .2

POLICY: E, P
ADD:
A - Diagnosis Time.............................................................................................................. .3

COOLER, EGR VALVE - REPLACE J6275 .5

ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .4
B - With Crew Cab............................................................................................................... .6
C - To Replace Additional (One).......................................................................................... .1
D - 4JJ1 Engine................................................................................................................... 1.0
E - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... .6
J - 62 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

HOSES, EGR/EFE VACUUM - REPLACE J6320 .4

SWITCH, EGR/EFE THERMAL VACUUM - REPLACE J6340 .4

POLICY: E

CHAMBER ASSEMBLY, DIAPHRAGM - REPLACE J6353 .4

SENSOR, CRANKSHAFT ANGLE - REPLACE J6355 .4

ADD:
A - 4HK1 Engine Fitted '95 Cab Model................................................................................ .3
B - Diagnosis Time.............................................................................................................. .3

SERVICE PROGRAMMING SYSTEM - REPROGRAM J6358 .5

CONTROLLER, EDU (ENGINE DRIVE UNIT) - REPLACE J6359 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROLLER, ECM (ENGINE CONTROL MODULE) - R&R OR REPLACE J6360 .4

POLICY: E
ADD:
A - To Program.................................................................................................................... .4
B - Diagnosis Time.............................................................................................................. .3

CONTROL MODULE,VGS,TURBOCHARGER - REPLACE J6365 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, FUEL TEMPERATURE - REPLACE J6368 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.2
 ENGINE J - 63

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SENSOR, COOLANT TEMPERATURE - REPLACE J6369 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.2

SENSOR, IAT/MAT (INTAKE AIR TEMPERATURE / MANIFOLD AIR TEMPERATURE) J6371 .4

- REPLACE
ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, O-2 (EXHAUST OXYGEN) - REPLACE J6372 .2

POLICY: E
ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, THROTTLE POSITION - REPLACE J6374 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... .2
C - EXC. 4JJ1/4HK1 Engines (Euro4 Specification)............................................................ .1

SENSOR, EGR VACUUM - REPLACE J6377 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, AIR FLOW - REPLACE J6378 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

SWITCH - REPLACE
ACCELERATOR J6381 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
J - 64 ENGINE

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SENOR, BOOST PRESSURE - REPLACE J6383 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... .1

SENSOR, BARO - REPLACE J6384 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROLLER, EGR - REPLACE J6396 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, ENGINE SPEED - REPLACE J6540 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, FUEL PRESSURE, COMMON RAIL (DIESEL) - REPLACE J6547 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONVERTER, DC - DC, CNG (MULTIPOINT INJECTION) - REPLACE J7005 .6

COIL, IGNITION, CNG (MULTIPOINT INJECTION) - REPLACE J7010 .2

NOTE: To replace (one or all).
ADD:
A - Diagnosis Time.............................................................................................................. .3

PLUGS, SPARK, CNG (MULTIPOINT INJECTION) - REPLACE

ALL J7020 .4

SENSOR, GAS PRESSURE / TEMPERATURE, CNG (MULTIPOINT INJECTION) - REPLACE J7211 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
 ENGINE J - 65

ENGINE
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SENSOR, MANIFOLD AIR PRESSURE, CNG (MULTIPOINT INJECTION) - REPLACE J7212 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, INTAKE AIR TEMPERATURE, CNG (MULTIPOINT INJECTION) - REPLACE J7213 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, KNOCK, CNG (MULTIPOINT INJECTION) - REPLACE J7214 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

INJECTOR, GAS, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE

ONE J7500 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Additional Injector (One)........................................................................................... .2
C - To Additional Injectors (Two)......................................................................................... .3
D - To Additional Injectors (All)............................................................................................ .4
E - To Clean Filters (All)...................................................................................................... .4
F - To Replace Filters (All)................................................................................................... .4
K TRANSAXLE AND TRANSMISSION

K
 TRANSAXLE AND TRANSMISSION K - 5

CLUTCH & CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CLUTCH SYSTEM, HYDRAULIC - BLEED K0040 .3

PEDAL, SHAFT AND/OR BUSHING, CLUTCH - REPLACE K0060 .7

INC: Adjust linkage.

PUSH ROD AND/OR SEAL, CLUTCH PEDAL - REPLACE K0080 .7

POLICY: T
INC: Adjust linkage.

SPRING, CLUTCH PEDAL RETURN - REPLACE K0100 .3

CYLINDER, CLUTCH MASTER - R&R OR REPLACE K0600 .5

POLICY: T
INC: Bleed system.
ADD:
A - To Recondition Clutch Master Cyl.................................................................................. .3
B - '95 Cab Model................................................................................................................ .3

CYLINDER, SLAVE - R&R OR REPLACE K0620 .5

POLICY: T
INC: Bleed system.
ADD:
A - To Recondition Slave Cyl............................................................................................... .3
B - With Noise Cover........................................................................................................... .6

BOOSTER ASSEMBLY CLUTCH - R&R OR REPLACE K0630 1.2

ADD:
A - To Recondition Booster.................................................................................................. ST

LINE, CLUTCH HYDRAULIC (MASTER CYLINDER TO SLAVE CYLINDER) - REPLACE

POLICY: T
PIPE K0646 .7
ADD:
A - With Noise Cover........................................................................................................... .6
K - 6 TRANSAXLE AND TRANSMISSION

CLUTCH & CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SENSOR, CLUTCH STROKE (HSA) - REPLACE K0650 .7

ADD:
A - Diagnosis Time.............................................................................................................. .3

BEARING, CLUTCH RELEASE - REPLACE

INC: R&R trans., adjust clutch free travel and/or linkage for all series.
(4 x 2) K0700 2.1
ADD:
A - To Replace Clutch Disc and/or Pressure Plate.............................................................. .4
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ 1.6
(4 x 4) K0701 3.0
ADD:
A - To Replace Clutch Disc and/or Pressure Plate.............................................................. .4
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ 1.6

DISC AND/OR PRESSURE PLATE, CLUTCH - REPLACE

POLICY: A, T
INC: R&R trans., adjust clutch free travel and/or linkage for all series.
(4 x 2) K0800 2.2
ADD:
A - To Replace Clutch Fork Shaft and/or Bushings............................................................. .3
B - To Replace Clutch Pilot Bearing.................................................................................... .3
C - To Replace Flywheel...................................................................................................... .4
D - To Replace Clutch Release Bearing.............................................................................. .3
E - With Noise Cover........................................................................................................... .6
F - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................. 1.6
(4 x 4) K0801 3.2
ADD:
A - To Replace Clutch Fork Shaft and/or Bushings............................................................. .3
B - To Replace Clutch Pilot Bearing.................................................................................... .3
C - To Replace Flywheel...................................................................................................... .4
D - To Replace Clutch Release Bearing.............................................................................. .3
E - With Noise Cover........................................................................................................... .6
F - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................. 1.6
 TRANSAXLE AND TRANSMISSION K - 7

CLUTCH & CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

COUPLING, FLUID - REPLACE K0900 2.5

ADD:
A - With Noise Cover........................................................................................................... .6
B - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 1.7
C - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... .5

LINKAGE OR CABLE, SHIFT - ADJUST K1020 .3

K - 8 TRANSAXLE AND TRANSMISSION

MANUAL TRANSMISSION CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LEVER, GEARSHIFT CONTROL - REPLACE K1060 .4

POLICY: T

LEVER, GEARSHIFT CONTROL (SMOOTHER) - REPLACE K1065 .4

SEAL AND/OR BOOT, FLOOR MOUNTED GEARSHIFT - REPLACE

TRANSMISSION GEARSHIFT K1080 .5

SHIFT CABLE, GEARSHIFT CONTROL - REPLACE K1190 .6

ADD:
A - With Noise Cover........................................................................................................... .6

LEVER, PTO CONTROL - REPLACE K2020 .3

POWER TAKE OFF (PTO) - REPLACE K2030 .8

ADD:
A - To Recondition PTO....................................................................................................... 1.2
B - With Noise Cover........................................................................................................... .6

CABLE, PTO CONTROL - REPLACE K2035 .6

ADD:
A - '08 Cab Model................................................................................................................ .2

SENSOR, VEHICLE SPEED - REPLACE K2050 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, INPUT SHAFT SPEED - REPLACE K2051 .3

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3
 TRANSAXLE AND TRANSMISSION K - 9

MANUAL TRANSMISSION CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SENSOR, ATF TEMPERATURE - REPLACE K2054 3.5

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 1.7
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... .5

SENSOR, TURBINE SPEED - REPLACE K2056 .3

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3

SENSOR, SHIFT STROKE - REPLACE K2057 2.5

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 2.1
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... 1.0

SENSOR, SELECT STROKE - REPLACE K2058 2.5

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 2.1
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... 1.0

GEAR AND/OR SEAL SPEEDOMETER DRIVEN - REPLACE K2060 .4

K - 10 TRANSAXLE AND TRANSMISSION

MANUAL TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

6 SPEED TRANSMISSION OF 6TH GEAR SET - REPLACE K2145 4.8

NOTE: Only MZZ transmission.
INC: R&R Transmission case. To replace 6th gear, clutch hub, shift rod and shift arm.

GEAR AND/OR SHIFT ROD,6TH,TRANSMISSION - REPLACE K2150 1.3

SEAL, TRANSMISSION EXTENSION REAR OIL - REPLACE K2160 2.2

POLICY: P
INC: D&C front universal joint and hanger bearing support to frame.
Drain and refill trans. R&R hand brake and yoke flange.
DOES NOT INC R&R trans assy or recondition universal joint.

COVER AND/OR GASKET, TRANSMISSION SHIFT - R&R OR REPLACE K2240 .6

POLICY: P
INC: R&R shift linkage and shift cover
and gasket. Clean, inspect and retorque.
DOES NOT INC: Recondition remote control assy.
ADD:
A - With Noise Cover........................................................................................................... .6

SHIFT CONTROL BOX ASSEMBLY, SMOOTHER - R&R OR REPLACE K2246 3.3

ADD:
A - To Recondition Shift Control Box................................................................................... 1.4
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 2.2
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... 1.2

SOLENOID, SELECT (SMOOTHER) - REPLACE K2490 2.2

ADD:
A - With Noise Cover........................................................................................................... .6
B - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ .7
 TRANSAXLE AND TRANSMISSION K - 11

MANUAL TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SOLENOID, SHIFT (SMOOTHER) - REPLACE K2491 2.2

ADD:
A - To Replace Both............................................................................................................ .3
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ .7

TRANSMISSION ASSEMBLY - RECONDITION

POLICY: P, T
INC: R&R trans., adjust clutch free travel and/or linkage for all series.
INC: R&R transfer assy. for 4x4 models.
DOES NOT INC: Recondition trans.
NOTE: EXC. smoother.
(4 x 2) K2700 2.1
ADD:
A - To Recondition Shifter Cover......................................................................................... .4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal.......................... .4
C - To Replace Main Drive Gear Bearing............................................................................ 2.0
INC: The above add condition.
D - To Recondition Main Shaft............................................................................................. 2.6
E - To Replace Case Extension And Seal........................................................................... .5
F - To Replace Speedometer Drive Gear............................................................................ .6
G - To Replace Case........................................................................................................... 1.2
H - To Recondition Counter Shaft........................................................................................ 1.0
I - With Noise Cover............................................................................................................ .6
J - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................. 1.6
(4 x 4) K2701 3.0
ADD:
A - To Recondition Shifter Cover......................................................................................... .4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal.......................... .4
C - To Replace Main Drive Gear Bearing............................................................................ 2.0
INC: The above add condition.
D - To Recondition Main Shaft............................................................................................. 2.6
E - To Replace Case Extension And Seal........................................................................... .5
F - To Replace Speedometer Drive Gear............................................................................ .6
G - To Replace Case........................................................................................................... 1.2
H - To Recondition Counter Shaft........................................................................................ 1.0
(CONTINUED)
K - 12 TRANSAXLE AND TRANSMISSION

MANUAL TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
I - With Noise Cover............................................................................................................ .6
J - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................. 1.6

TRANSMISSION ASSEMBLY (SMOOTHER) - RECONDITION K2705 7.7

POLICY: P, T
INC: R&R trans., adjust clutch free travel and/or linkage, recondition trans.
INC: R&R transfer assy. for 4x4 models.
NOTE: MYY trans. with smoother.
ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3
C - EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models..................................................... 5.4
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05 Cab Model................................... 4.2

TRANSMISSION ASSEMBLY - REPLACE

POLICY: A, P, T
(4 x 2) K2720 2.6
ADD:
A - With Smoother (EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models).......................... 1.7
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ 1.4
D - With Smoother (4JJ1/4HK1 Engines Fitted '05/'08 Cab Models)................................... .4
(4 x 4) K2721 3.5
ADD:
A - With Smoother (EXC. 4JJ1/4HK1 Engines Fitted '05/'08 Cab Models).......................... 1.7
B - With Noise Cover........................................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted '08 Cab Model............................................................ 1.4
D - With Smoother (4JJ1/4HK1 Engines Fitted '05/'08 Cab Models)................................... .4

OIL PAN AND/OR GASKET, SMOOTHER - R&R OR REPLACE K2805 .8

ADD:
A - With Noise Cover........................................................................................................... .6
 TRANSAXLE AND TRANSMISSION K - 13

MANUAL TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CONTROL UNIT, SMOOTHER - REPLACE K2960 .7

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - '08 Cab Model................................................................................................................ .2
K - 14 TRANSAXLE AND TRANSMISSION

AUXILIARY TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LEVER, TRANSFER CASE GEARSHIFT - REPLACE K4133 1.0

VALVE, SWITCH, VACUUM - REPLACE K4135 .3

ADD:
A - To Replace One Additional............................................................................................ .1

ACTUATOR, TRANSFER 2W/4W SHIFT - REPLACE K4140 .4

SEAL, TRANSFER CASE OIL - REPLACE

POLICY: P
FRONT K4162 .7
REAR K4163 .8
FRONT INPUT K4164 2.4

TRANSFER CASE ASSEMBLY - RECONDITION

POLICY; P, T
MAN TRANS K4400 2.9
 TRANSAXLE AND TRANSMISSION K - 15

AUTOMATIC TRANSMISSION CONTROLS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

INDICATOR PLATE AND/OR ASSEMBLY SHIFT RANGE INDICATOR - REPLACE K5100 .3

SHIFT KNOB - R&R OR REPLACE K5110 .3

POLICY: T

SHIFT LEVER, CONTROL LINKAGE - REPLACE K5170 .8

POLICY: T
ADD:
A - EXC. 4HK1 Engine Fitted '05/'08 Cab Models............................................................... .2
K - 16 TRANSAXLE AND TRANSMISSION

AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

OIL COOLER PIPES, TRANSMISSION - REPAIR OR REPLACE

POLICY: T
INLET K5262 1.0
OUTLET K5263 .6
BOTH K5267 1.3
CURVED LOOP PIPE - A/T K5268 1.9
ADD:
A - With Noise Cover........................................................................................................... .6

OIL COOLER HOSES, TRANSMISSION - REPAIR OR REPLACE

POLICY: T
RADIATOR SIDE : BOTH K5287 .8
A/T SIDE : BOTH K5288 .7
ADD:
A - With Noise Cover........................................................................................................... .6

LEVEL GAUGE (DIPSTICK), TRANSMISSION ATF - REPLACE K6130 .3

ADD:
A - With Crew Cab............................................................................................................... .2

FILLER TUBE AND/OR GASKET, TRANSMISSION - REPLACE K6140 .4

POLICY: P
ADD:
A - With Noise Cover........................................................................................................... .6

INHIBITOR SWITCH, TRANSMISSION - REPLACE K6275 .5

POLICY: P, T
INC: D&C shift arm, cable-transmission side
ADD:
A - With Noise Cover........................................................................................................... .6

COVER AND/OR GASKET, POWER TAKE OFF (PTO) - REPLACE K6280 .6

ADD:
A - With Noise Cover........................................................................................................... .6
 TRANSAXLE AND TRANSMISSION K - 17

AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BOLTS, CONVERTER TO FLYWHEEL - REPLACE K6300 1.0

POLICY: P
ADD:
A - With Noise Cover........................................................................................................... .6

DRIVEN GEAR AND/OR GASKET, SPEEDOMETER - REPLACE K6320 .3

POLICY: P

SENSOR, VEHICLE SPEED - REPLACE K6330 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, SPEED, A/T REVOLUTION - REPLACE K6331 .6

ADD:
A - With Noise Cover........................................................................................................... .6
B - Diagnosis Time.............................................................................................................. .3

OIL SEAL, EXTENSION HOUSING FLANGE YOKE - REPLACE K6360 .8

POLICY: P
INC: Drain and refill ATF.
ADD:
A - '95 Cab Model................................................................................................................ .6

COMPANION FLANGE - REPLACE K6365 .6

POLICY: P
ADD:
A - '95 Cab Model................................................................................................................ .7

SEALED PLUG - REPLACE K6367 .3

ADD:
A - With Noise Cover........................................................................................................... .6

SEALED BOLT - INSTALL K6368 .3

ADD:
A - With Noise Cover........................................................................................................... .6
K - 18 TRANSAXLE AND TRANSMISSION

AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

OIL PRESSURE TEST K6400 .6

ADD:
A - With Noise Cover........................................................................................................... .6

OIL PAN AND/OR GASKET, TRANSMISSION - R&R OR REPLACE

POLICY: P
TRANSMISSION K6500 1.3
ADD:
A - To Replace Oil filter........................................................................................................ .2
B - To Replace Solenoids (One or All, EXC. Pressure Control Solenoid)........................... .3
C - With Noise Cover........................................................................................................... .6

SWITCHES AND/OR SENSORS - REPLACE K6515 1.2

NEUTRAL, THERMO, OVER-DRIVE, TRANSFER-POSITION SWITCHES
THERMO A/T SENSOR, THERMO T/F SENSOR
POLICY: P
ADD:
A - With Noise Cover........................................................................................................... .6

TRANSMISSION CONTROL MODULE - R&R OR REPLACE K6517 .3

POLICY: P
ADD:
A - '95 Cab Model................................................................................................................ .2
B - Diagnosis Time.............................................................................................................. .3
C - To Reprogram................................................................................................................ .3

DROPPING RESISTOR - REPLACE K6518 .3

POLICY: P

VALVE BODY, TRANSMISSION - R&R OR REPLACE

POLICY: P
INC: K6500 R&R transmission oil pan.
MAIN CASE K6560 1.8

(CONTINUED)
 TRANSAXLE AND TRANSMISSION K - 19

AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
ADD:
A - To Replace Spool Valves or Springs (One or All).......................................................... .6
B - To Replace Accumulator Pistons (One or All)................................................................ .5
C - To Replace Separator Plate or Gaskets........................................................................ .3
D - To Clean and Recondition Valve Body (Main Case)...................................................... .7
E - To Replace Oil Filter...................................................................................................... .2
F - With Noise Cover........................................................................................................... .6

PARKING PAWL SHAFT, ROD OR SPRING - REPLACE K6640 1.7

POLICY: P
INC: Drain and refill, R&R propeller shaft, center bearing,
speedometer drive gear and cable.
ADD:
A - With Noise Cover........................................................................................................... .6

ATF THERMO SENSOR - REPLACE K6645 .3

ADD:
A - With Noise Cover........................................................................................................... .6

AUTOMATIC TRANSMISSION ASSEMBLY - REPLACE K7000 3.4

POLICY: A, P, T
ADD:
A - To Replace Torque Converter........................................................................................ .2
B - To Replace Front Oil Seal.............................................................................................. .3
C - To Flush Cooling Line.................................................................................................... .7
D - With Noise Cover........................................................................................................... .6
E - '92 To '97 Models........................................................................................................... 1.3
F - '98 To '06 Models........................................................................................................... .7

TORQUE CONVERTER ASSEMBLY - REPLACE K7020 3.4

POLICY: A, P, T
INC: K7000 R&R automatic transmission assembly.
ADD:
A - '92 To '97 Models........................................................................................................... 1.4
B - With Noise Cover........................................................................................................... .6
K - 20 TRANSAXLE AND TRANSMISSION

AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CONVERTER HOUSING, TRANSMISSION - REPLACE K7040 3.6

POLICY: P, T
INC: R&R torque converter.
ADD:
A - '92 To '97 Models........................................................................................................... 1.4
B - With Noise Cover........................................................................................................... .6

SEAL, TRANSMISSION OIL PUMP - REPLACE K7100 3.5

POLICY: P
ADD:
A - '92 To '97 Models........................................................................................................... 1.4
B - With Noise Cover........................................................................................................... .6

OIL PUMP AND/OR GASKET, TRANSMISSION - REPLACE K7120 3.8

POLICY: P, T
INC: K7000 R&R automatic transmission assembly.
K7020 R&R torque converter.
ADD:
A - To Replace Front Oil Pump Seal................................................................................... .3
B - To Recondition Oil Pump............................................................................................... .4
C - '92 To '97 Models........................................................................................................... 1.4
D - With Noise Cover........................................................................................................... .6

AUTOMATIC TRANSMISSION ASSEMBLY - RECODITION K7900 14.9

POLICY: A, P, T
INC: K7000 R&R automatic transmission assembly.
K7020 R&R torque converter.
ADD:
A - With Noise Cover........................................................................................................... .6
B - 4HK1 Engine Fitted '05/'08 Cab Models......................................................................... 1.5
L FUEL AND EXHAUST

L
 FUEL AND EXHAUST L - 3

FUEL AND EXHAUST

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

PIPES, FUEL - REPLACE

POLICY: T
NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
RETURN OR FEED LINES, TANK TO ENGINE COMPARTMENT L0120 .5

HOSES, FUEL TANK AREA - REPLACE L0240 .3

POLICY: T

BRACKET, FUEL SEDIMENTER - REPLACE L0700 .4

ADD:
A - With Crew Cab............................................................................................................... .5

SEDIMENTER ASSEMBLY, FUEL - REPLACE L0740 .4

SENSOR ASSEMBLY, SEDIMENTOR - REPLACE L0748 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .2
B - EXC.4HK1 Engine (Euro4 Specification) Fitted '05/'08 Cab Models.............................. .2

CAP, FUEL TANK - REPLACE L1020 .3

GAUGE UNIT ASSEMBLY, FUEL TANK - REPLACE L1228 .4

TANK, FUEL - REPLACE L1280 .7

INC: Drain and refill tank.

CORE, FUEL COOLER - REPLACE L1290 .3

HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE L2020 .3

ADD:
A - To Replace Additional Hanger and/or Clamp................................................................. .2
B - To Replace Two Additional Hanger and/or Clamp......................................................... .3
L - 4 FUEL AND EXHAUST

FUEL AND EXHAUST

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

SEAL, EXHAUST PIPE - REPLACE L2040 .6

POLICY: E
ADD:
A - With Skid Plate............................................................................................................... .3

PIPE, FRONT EXHAUST - REPLACE L2160 .6

POLICY: E
ADD:
A - EXC. 4JJ1/4HK1 Engines (Euro4 Specification) Fitted '05/'08 Cab Models.................. .4

CONVERTER, EXHAUST CATALYTIC - REPLACE L2300 .4

POLICY: E, T
INC: Check system for leaks.
ADD:
A - Diagnosis Time.............................................................................................................. .3

PIPE, INTERMEDIATE EXHAUST - REPLACE L2420 .6

MUFFLER - REPLACE L2584 .4

INC: Check system for leaks.

DIESEL PARTICULATE DEFUSER ASSY - R&R OR REPLACE L2600 1.1

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3

DIESEL PARTICULATE DEFUSER - RECONDITION AND/OR CLEAN L2610 2.0

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3

DIESEL PARTICULATE DEFUSER - SLOW REGENERATION L2611 .5

POLICY: A
INC: Replace engine oil.
NOTE: This operation code is to be used with other operation code. Do not use by itself.
 FUEL AND EXHAUST L - 5

FUEL AND EXHAUST

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

DIESEL PARTICULATE DEFUSER FILTER - R&R L2612 1.6

POLICY: A

DIESEL PARTICULATE DEFUSER REAR COVER - REPLACE L2615 1.6

DIESEL PARTICULATE DEFUSER CATALYTIC CONVERTER - REPLACE L2620 1.7

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3

MAGNETIC VALVE, EXHAUST THROTTLE, L2625 .4

DIESEL PARTICULATE DEFUSER - REPLACE
INC: Check system

VALVE, EXHAUST THROTTLE, DIESEL PARTICULATE DEFUSER - REPLACE L2626 .6

POWER CHAMBER, EXHAUST THROTTLE VALVE, L2627 .2

DIESEL PARTICULATE DEFUSER - REPLACE

PIPE, DIFFERENTIAL PRESSURE,DIESEL PARTICULATE DEFUSER L2630 .4

- REPLACE (ONE OR ALL)

SENSOR, TEMPERATURE,DIESEL PARTICULATE DEFUSER L2680 .4

- REPLACE (ONE OR ALL)
ADD:
A - Diagnosis Time.............................................................................................................. .3

SENSOR, DIFFERENTIAL PRESSURE,DIESEL PARTICULATE DEFUSER L2685 .4

- REPLACE
ADD:
A - Diagnosis Time.............................................................................................................. .3

PIPE, TAIL - REPLACE L2800 .3

INC: Align and check system.
L - 6 FUEL AND EXHAUST

FUEL AND EXHAUST

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

EXHAUST SYSTEM (COMPLETE) - REPLACE L2904 1.1

POLICY: A
INC: Replace hangers, brackets or clamps as nec.

CONTAINER, GAS, CNG (MULTIPOINT INJECTION) - REPLACE

POLICY: A
RIGHT L3110 2.3
LEFT L3120 2.3

FILLING UNIT, CNG (MULTIPOINT INJECTION) - REPLACE L3205 .5

COUPLER, GAS CHARGE, CNG (MULTIPOINT INJECTION) - REPLACE L3206 .5

VALVE, CHECK, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE L3210 .4

VALVE, SERVICE, CNG (MULTIPOINT INJECTION) - REPLACE L3215 .4

REGULATOR, GAS PRESSURE, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE L3505 .8

VALVE, AUTOMATIC, CNG (MULTIPOINT INJECTION) - REPLACE L3705 .8

ADD:
A - Diagnosis Time.............................................................................................................. .3

CARTRIDGE FILTER, GAS, CNG (MULTIPOINT INJECTION) - REPLACE L3980 .3

N ELECTRICAL

N
N - 12 ELECTRICAL

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BATTERY - REPLACE
POLICY: A, T
ONE N0110 .3
BOTH N0117 .3
ADD:
A - Diagnosis Time.............................................................................................................. .2

CABLES, BATTERY - REPLACE

POLICY: T
POSITIVE N0120 .4
NEGATIVE N0126 .4

RETAINER AND/OR BOLTS, BATTERY - REPLACE N0150 .3

TRAY OR SUPPORT, BATTERY - REPLACE N0160 .4

HORN ASSEMBLY - REPLACE

HIGH NOTE N0200 .3
LOW NOTE N0201 .3

HEADLAMP ASSEMBLY - REPLACE

INC: Aim headlamps.
ONE N0250 .4
BOTH N0252 .5

HEADLAMP HOUSING - REPLACE

INC: Aim headlamps.
ONE N0260 .5
BOTH N0261 .8

HEADLAMP - AIM
ONE N0265 .4
BOTH N0266 .4
 ELECTRICAL N - 13

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

ACTUATOR, HEADLIGHT LEVELING - REPLACE

RIGHT N0281 .5
LEFT N0282 .5

SEALED BEAM AND/OR RETAINING RING, HEADLAMP - REPLACE

INC: Aim headlamps.
RIGHT N0300 .4
LEFT N0301 .4
ADD:
A - To Replace Headlamp Bulb (One Side)......................................................................... .2

BULBS, LAMP - REPLACE

NOTE: Per one lamp housing.
: Names of lamp; housings; bulbs.
BACK UP; RH; ONE N0415 .3
BACK UP; LH; ONE N0416 .3
BACK UP; BOTH; TWO N0417 .4
HEAD; RH; ONE OR ALL N0442 .3
HEAD; LH; ONE OR ALL N0443 .3
HEAD; BOTH; TWO OR ALL N0444 .4
COURTECY; ONE; ONE N0480 .3
COURTECY; TWO; TWO N0481 .4
DOME; ONE; ONE N0507 .3
DOME; TWO; TWO N0508 .3
FLUORESCENT; ONE: ONE N0509 .2
INSTRUMENT PANEL CLUSTER; ONE; ONE OR ALL N0627 .4
ADD:
A - '95 Cab Model; (Only N0627)......................................................................................... .2
INSTRUMENT PANEL WARNING; ONE; ONE OR ALL N0647 .4
ADD:
A - '95 Cab Model; (Only N0647)......................................................................................... .2
LICENSE; ONE; ONE N0657 .3
LICENSE; TWO; TWO N0658 .3
PARK AND TURN SIGNAL; RH; ONE OR ALL N0685 .4
PARK AND TURN SIGNAL; LH; ONE OR ALL N0686 .4
PARK AND TURN SIGNAL; BOTH; TWO OR ALL N0687 .5
(CONTINUED)
N - 14 ELECTRICAL

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
SIDE TURN SIGNAL; RH; ONE N0692 .2
SIDE TURN SIGNAL; LH; ONE N0693 .2
SIDE TURN SIGNAL; BOTH; TWO N0694 .3
POSITION INDICATOR; ONE; ONE N0725 .3
SIDE MARKER, FRONT; RH; ONE N0736 .3
SIDE MARKER, FRONT; LH; ONE N0737 .3
SIDE MARKER, REAR; RH; ONE N0746 .4
SIDE MARKER, REAR; LH; ONE N0747 .4
STOP, TAIL AND TURN SIGNAL; RH; ONE OR ALL N0765 .3
STOP, TAIL AND TURN SIGNAL; LH; ONE OR ALL N0766 .3
STOP, TAIL AND TURN SIGNAL; BOTH; TWO OR ALL N0767 .4
FOG: RH; ONE N0852 .2
FOG; LH; ONE N0853 .2
FOG; BOTH; TWO N0854 .3

LENS AND/OR GASKET, LAMP - REPLACE

NOTE: Per one lamp housing.
: Names of lamp; housings; lenses.
COURTECY; ONE; ONE N1139 .3
COURTECY; TWO; TWO N1140 .3
LUGGAGE COMPARTMENT; ONE; ONE N1145 .3
DOME; ONE; ONE N1156 .3
DOME; TWO; TWO N1157 .3
FLUORESCENT; ONE: ONE N1158 .1
LICENSE; ONE; ONE N1176 .3
LICENSE; TWO; TWO N1177 .3
PARK AND TURN SIGNAL; RH; ONE N1215 .4
PARK AND TURN SIGNAL; LH; ONE N1216 .4
PARK AND TURN SIGNAL; BOTH; TWO N1217 .5
STOP, TAIL AND TURN SIGNAL; RH; ONE N1224 .4
STOP, TAIL AND TURN SIGNAL; LH; ONE N1225 .4
STOP, TAIL AND TURN SIGNAL; BOTH; TWO N1226 .5
MAP; RH; ONE N1314 .3
MAP; LH; ONE N1315 .3
MAP; BOTH; TWO N1316 .3
 ELECTRICAL N - 15

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LAMP ASSEMBLY - REPLACE

DOME; ONE OR ALL N1456 .3
DOME (FLUORESCENT LAMP) N1457 .2
FOG; RIGHT N1466 .3
FOG; LEFT N1467 .3
LICENSE; ONE OR BOTH N1477 .3
PARK AND TURN SIGNAL; RIGHT N1520 .5
PARK AND TURN SIGNAL; LEFT N1521 .5
REAR COMBINATION; RIGHT N1524 .5
REAR COMBINATION; LEFT N1525 .5
SIDE TURN SIGNAL; RIGHT N1564 .2
SIDE TURN SIGNAL; LEFT N1565 .2

FUSE, FUSIBLE LINK - REPLACE N1720 .3

INC: One or more.

FLASHER UNIT - REPLACE N1750 .3

SWITCH - REPLACE
INC: Replace fuse where nec.
NOTE: Switch or sending unit.
BACK-UP LIGHT N2030 .4
ADD:
A - With Noise Cover (N2030 Only)..................................................................................... .5
POWER WINDOW; FRONT RIGHT N2144 .3
POWER WINDOW; FRONT LEFT N2145 .3
POWER WINDOW; FRONT CENTER N2146 .3
ENGINE OIL PRESSURE N2220 .4
ENGINE COOLANT TEMPERATURE N2230 .4
DPD (DIESEL PARTICULATE DEFUSER) N2237 .3
4WD(FOUR WHEEL DRIVE) N2240 .3
FOG LAMP N2244 .4
HAZARD WARNING N2247 .3
LIGHTING N2290 .4

(CONTINUED)
N - 16 ELECTRICAL

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
HEADLIGHT DIMMER (COMBINATION) N2310 .5
ADD:
A - With Air Bag (N2310 Only)............................................................................................. 1.2
HEADLIGHT LEVELING N2315 .3
IGNITION N2320 .4
LOW AIR PRESSURE N2340 .3
ADD:
A - To Replace Each Additional (N2340 Only)..................................................................... .1
NEUTRAL; M/T N2360 .4
ADD:
A - With Noise Cover (N2360 Only)..................................................................................... .5
PARKING BRAKE LIGHT N2380 .4
STOP LIGHT N2440 .4
EMERGENCY MAIN (SMOOTHER) N2451 .6
ADD:
A - Diagnosis Time (N2451 Only)........................................................................................ .3
EMERGENCY SHIFT (SMOOTHER) N2454 .6
ADD:
A - Diagnosis Time (N2454 Only)........................................................................................ .3
ECONO MODE CHANGEOVER (SMOOTHER) N2455 .6
ADD:
A - Diagnosis Time (N2455 Only)........................................................................................ .3
TURN SIGNAL (COMBINATION) N2530 .6
ADD:
A - With Air Bag (N2530 Only)............................................................................................. 1.2
WINDSHIELD WIPER/WASHER (COMBINATION) N2610 .6
ADD:
A - With Air Bag (N2610 Only)............................................................................................. 1.2
SWITCH, OFF (HSA) - REPLACE N2710 .3
ADD:
A - Diagnosis Time (N2710 Only)........................................................................................ .3
B - EXC. '08 Cab Model....................................................................................................... .2
SWITCH, ADJUST (HSA) - REPLACE N2711 .4
ADD:
A - Diagnosis Time (N2711 Only)........................................................................................ .3
(CONTINUED)
 ELECTRICAL N - 17

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

(CONT'D)
SWITCH, CLUTCH FLUID PRESSURE (HSA) - REPLACE N2712 .6
ADD:
A - Diagnosis Time (N2712 Only)........................................................................................ .3
SWITCH, RESET (HSA) - REPLACE N2713 .4
ADD:
A - Diagnosis Time (N2713 Only)........................................................................................ .3
POWER TAKE OFF (PTO) N2730 .3
4x4 INDICATOR LIGHT N2778 .2

RELAY - REPLACE
INC: Replace fuse where nec.
STARTER N2810 .3
HEAD LIGHT N2820 .3
TAIL LIGHT N2830 .3
DIMMER N2850 .3
CHARGE N2870 .3
HORN N2880 .3
WIPER N2900 .3
A/C COMPRESSOR N2910 .3
A/C CONDENSOR N2912 .3
GLOW PLUG N2922 .3
POWER WINDOW N2980 .3
CNG GAS CUT N2998 .3

MOTOR - REPLACE
POWER WINDOW; FRONT RIGHT N3310 .7
POWER WINDOW; FRONT LEFT N3311 .7
ADD:
A - '95/'05 Cab Models......................................................................................................... .4

MOTOR, WIPER - R&R

INC: Replace fuse where necessary.
WINDSHIELD N3510 .4
ADD:
A - '05 Cab Model................................................................................................................ .2
N - 18 ELECTRICAL

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

MOTOR, WIPER - REPLACE

WINDSHIELD N3520 .3
ADD:
A - '05 Cab Model................................................................................................................ .3
B - '95 Cab Model................................................................................................................ .1

BLADE, WIPER - REPLACE

WINDSHIELD N3615 .3

ARM, WIPER - REPLACE

INC: One or both.
WINDSHIELD N3620 .3

LINK, WINDSHIELD WIPER OPERATING - REPLACE

BOTH N3637 .2
ADD:
A - '05 Cab Model................................................................................................................ 5.1
B - '95 Cab Model................................................................................................................ 1.1

HOSES, NOZZLES, WASHER AND/OR WIPER STOPS - REPLACE

INC: One or all.
WINDSHIELD N3700 .3

CONTAINER AND COVER, WASHER - REPLACE

WINDSHIELD N3750 .3
ADD:
A - '95/'05 Cab Models......................................................................................................... .3

PUMP ASSEMBLY, WASHER - R&R OR REPLACE

INC: One or both.
WINDSHIELD N3860 .3
ADD:
A - '95 Cab Model................................................................................................................ .5

LIGHTER ASSEMBLY, CIGARETTE - REPLACE N4010 .3

 ELECTRICAL N - 19

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

LENS AND/OR BEZEL, INSTRUMENT CLUSTER - REPLACE N4120 .3

ADD:
A - '95/'05 Cab Models......................................................................................................... .2

CLOCK ASSEMBLY - R&R N4200 .3

CLOCK ASSEMBLY - REPLACE N4210 .3

SPEEDOMETER - REPLACE N4310 .5

ADD:
A - '95 Cab Model................................................................................................................ .3

CABLE, SPEEDOMETER - R&R OR REPLACE

ALL SERIES N4399 1.0

METER BOARD ASSEMBLY - REPLACE N4410 .3

NOTE; '08 Cab model only.
ADD:
A - Diagnosis Time.............................................................................................................. .3

TACHOMETER - R&R N4500 .5

ADD:
A - '95 Cab Model................................................................................................................ .3

TACHOMETER - REPLACE N4510 .5

ADD:
A - '95 Cab Model................................................................................................................ .3

GAUGE - REPLACE
INC: R&R instrument cluster nec.
ENGINE COOLANT TEMPERATURE N4640 .5
ADD:
A - '95 Cab Model................................................................................................................ .3
FUEL N4680 .5
ADD:
A - '95 Cab Model................................................................................................................ .3
N - 20 ELECTRICAL

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BUZZER, BACK - REPLACE N5110 .3

CIRCUIT, PRINTED - R&R OR REPLACE

INSTRUMENT CLUSTER N5140 .5

COIL ASSEMBLY, SRS (AIR BAG) - REPLACE N5810 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3

G-SENSOR, SRS (AIR BAG) - REPLACE N5811 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

SRS - AIR BAG - REPLACE

POLICY: A
DRIVER N5820 .3
PASSENGER N5821 .1
ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROL UNIT, VEHICLE SPEED SENSOR - REPLACE N5845 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3

CONTROL UNIT, SRS (AIR BAG) - REPLACE N5860 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3

DATA RECORDING MODULE (DRM) - DOWNLOAD N5950 .4

POLICY: A

BODY CONTROL MODULE (BCM) - DOWNLOAD N5951 .2

POLICY: A

DATA RECORDING MODULE (DRM) - REPLACE N5953 .6

POLICY: A
 ELECTRICAL N - 21

ELECTRICAL
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

BODY CONTROL MODULE (BCM) - REPLACE N5954 .7

POLICY: A

WIRING AND/OR CONNECTOR - REPAIR

NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
INC: Connect and use diagnostic equipment to locate problem,
R&R any necessary components and replace fuse if necessary.
AIR CONDITIONING N6030 .5
CAB MAIN N6070 .5
CHASSIS; FRONT N6112 .5
CHASSIS; REAR N6113 .5
DOME; LIGHT N6180 .5
DOOR WINDOW; RIGHT FRONT N6254 .5
DOOR WINDOW; LEFT FRONT N6255 .5
ENGINE N6270 .5
HEADLIGHT N6290 .5
HEATER N6310 .5
INSTRUMENT PANEL N6360 .5

HARNESS, WIRING - REPLACE

INSTRUMENT PANEL N7060 3.9
ADD:
A - '95/'05 Cab Models......................................................................................................... 2.2
ENGINE N7063 2.3
DOOR; RIGHT FRONT N7066 .8
DOOR; LEFT FRONT N7067 .8
CHASSIS; FRONT N7112 1.5
NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond 1.5 hours.
CHASSIS; REAR N7113 .5
NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
R ACCESSORIES

R
R - 2 ACCESSORIES

ACCESSORIES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

STANDING WAVE RATIO SWR - ADJUST R0120 .5

ANTENNA COMPONENTS - REPLACE R0220 .2

ADD:
A - '95 Cab Model................................................................................................................ .2

RADIO RECEIVER - R&R R0750 .4

POLICY: A

CASSETTE DECK - R&R R0751 .4

POLICY: A

RADIO RECEIVER - REPLACE R0760 .4

POLICY: A

CASSETTE DECK - REPLACE R0761 .4

POLICY: A

GRILLE, RADIO SPEAKER - R&R OR REPLACE

FRONT RIGHT R0910 .4
FRONT LEFT R0911 .4

SPEAKER, RADIO - REPLACE

FRONT RIGHT R0940 .4
FRONT LEFT R0941 .4
ADD:
A - '95 Cab Model................................................................................................................ .2

GLASS; MIRROR, OUTSIDE REAR VIEW - REPLACE

MANUAL; RIGHT R3260 .4
MANUAL; LEFT R3261 .4

MIRROR COMPONENTS, OUTSIDE REAR VIEW - REPLACE

MANUAL; RIGHT R3390 .4
MANUAL; LEFT R3391 .4
 ACCESSORIES R - 3

ACCESSORIES
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

CONTROLLER, IMMOBILIZER - REPLACE R9047 .6

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3

KEYLESS ENTRY SYSTEM - REPLACE

POLICY: A
CONTROL UNIT R9050 .5
KEY; REMOTE CONTROLLER R9054 .1
BATTERY; KEY, REMOTE CONTROLLER R9056 .2

DIGITAL OR ANALOG TACHOGRAPH - R&R OR REPLACE R9200 .3

POLICY: A
S NON WARRANTY (PANEL REPLACEMENT)

S
S - 2 NON WARRANTY (PANEL REPLACEMENTS)

PANEL REPLACEMENTS
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

PANEL ASSEMBLY, FRONT - REPLACE S0500 18.7

INC: R&R bumper, outside mirror, Fr. windshield glass,
instrument panel, steering shaft, evapo. and heater unit.
 NON WARRANTY (PANEL REPLACEMENTS) S - 3

CORROSION PERFORATION REPAIRS

OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**

THE FOLLOWING OPERATIONS SHOULD BE USED TO IDENTIFY

REPAIRS ON RUST THROUGH PERFORATION DAMAGE
THE TIME ALLOWANCES SHOWN INCLUDE ALL METAL
AND PAINT WORK NECESSARY TO COMPLETE THE REPAIR.

PANEL, GRILLE HEADER AND/OR FRONT END - CORROSION S5030 1.5

PERFORATION REPAIR.

RADIATOR SUPPORT AND/OR TIE BAR - CORROSION PERFORATION REPAIR S5050 1.5

PANEL MOTOR COMPARTMENT SIDE AND WHEELHOUSE INCLUDING S5110 1.5

STRUT TOWER - CORROSION PERFORATION REPAIR
POLICY: A

PILLAR, WINDSHIELD - CORROSION PERFORATION REPAIR S5150 1.5

POLICY: A

PANEL ROOF - CORROSION PERFORATION REPAIR S5170 1.5

POLICY: A

PANEL FLOOR - CORROSION PERFORATION REPAIR S5230 1.5

POLICY: A

DOOR - CORROSION PERFORATION REPAIR S5250 1.5

POLICY: A

PANEL CAB REAR - CORROSION PERFORATION REPAIR S5310 1.5

POLICY: A