Mitsubishi Fuso FE Service Manual

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Summary of Contents for Mitsubishi Fuso FE

Page 2 STRUCTURE AND OPERATION Electronic Governor P31532 5 Linear DC motor 1 Housing 6 Link 2 Control rack position sensor 7 Emergency engine stop lever 3 Cover 8 Sensing gear 4 Coil assembly Linear DC motor The linear DC motor 5 moves the coil assembly 4 vertically in accordance with signals from the electronic governor con- trol unit.
Page 3 13EB Emergency engine stop lever The emergency engine stop lever 7 is connected to the link 6. Via a cable, it enables the link to be moved from the driver’s seat. In the event of a system fault that prevents the engine from being stopped normally, operation of the emergency engine stop lever forces the control rack A to move to the position at which fuel injection is terminated.
Page 4 TROUBLESHOOTING 1. INSPECTION PROCEDURES Diagnostic Function • Whenever the starter switch is placed at ON, the diagnostic function is activated to check all the sensors, etc. If any of them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same time, the fault location is stored in memory, and the system enters the backup mode.
Page 5 13EB Inspection Flowchart The system inspection can be performed effectively by use of the Multi-Use Tester II. The types of system inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic trouble code outputs. •...
Page 6 TROUBLESHOOTING 2. CONNECTION OF MULTI-USE TESTER II 0 Special Tools l a i c i l – - i t 19492 - i t - i t – 19141 – MH063580 19493 – - i t 20538 - i t - i t –...
Page 7 13EB 3. READING AND ERASING DIAGNOSTIC TROUBLE CODES Two types of methods are available for reading or erasing a diagnostic trouble code; one using the Multi-Use Tester II and one using the vehicle side diagnostic functions. (1) Method using Multi-Use Tester II Current Diagnostic Trouble Code •...
Page 8 TROUBLESHOOTING Reading Diagnostic Trouble Code • Diagnostic trouble codes are indicated by the number of times the red 10s digit Units digit warning lamp 3 flashes and their duration. • The flashing intervals also differ between the 10s digit and the units digit.
Page 9 13EB 4. DIAGNOSTIC TROUBLE AND CHECK ITEMS Diagnosis Warning Electronic control unit countermeasure(s) in the case of Fault location Drive ability code lamp failure (back-up mode) Normal — — Pre-stroke actuator Amber Provides control with “0” as correction value. learning function Sub-control rack position Amber Normal control using the main control rack position sensor...
Page 10 TROUBLESHOOTING Diagnosis code Diagnosis display Cause Remedy code condition (s) Faulty timing rod, timing sleeve or other Repair or replace the injection pump Indicates that pre-stroke learning function has not parts in the injection pump assembly. assembly. been executed. Faulty adjusment or pre-stroke position Repair or replace the injection pump sensor assembly.
Page 11 13EB Diagnosis code Diagnosis display Cause Remedy code condition (s) Open or short in harness wire or poor Inspect the harness and the connector Displayed if the output connector contact between the pre-stroke Õ P13EB-41 voltage of the pre-stroke position sensor and the engine control position sensor is less than 0.9 V or more than unit...
Page 12 TROUBLESHOOTING Diagnosis code Diagnosis display Cause Remedy code condition (s) Displayed if the output Open or short in harness wire or poor Inspect the harness and the connector Õ P13EB-41 voltage of the control rack connector contact between the control position sensor I is less rack position sensor and the engine than 0.5 V or more than...
Page 13 13EB Diagnosis code Diagnosis display Cause Remedy code condition (s) Faulty engine control main unit In order to reset the engine control unit, Displayed if the engine temporarily turn the starter switch OFF and control unit is faulty. erase the diagnostic codes by opening the memory clear switch Õ...
Page 14 TROUBLESHOOTING 5. Service of Multi-Use Tester II Multi-Use Tester-II display Inspection procedure Data signal Type of data Inspection condition Evaluation criterion ENGINE SPEED . rpm Gradual acceleration (during engine Synchronization with tachometer operation) TARGET RACK . mm Starter switch ON 3 mm REAL RACK .
Page 15 INSPECTION OF ELECTRICAL EQUIPMENT 13EB < Left side of engine > 31550 1 Idling speed adjustment potentiometer 13 Engine speed sensor 2 Relay box 14 Exhaust brake 3-way magnetic valve 3 Exhaust brake cut relay < A/T > 15 Transmission neutral switch < M/T > Transmission neutral relay <...
Page 16 INSPECTION OF ELECTRICAL EQUIPMENT Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Output voltage of idling speed adjustment Knob pulled 1 to 3 V — potentiometer – Replace Knob 3.6 to 4.3 V — pushed 16184 92.5 to 101.5 Ω...
Page 17 13EB Unit : mm {in.} Location Maintenance item Standard value Limit Remedy < Connector: 3 pin > (3 pin) – (3 pin) 16165 (3 pin) – < Connector: 10 pin > (10 pin) Repair or Resistances (10 pin) – 16160 replace the in- 9.0 to 9.8 Ω...
Page 18 INSPECTION OF ELECTRICAL EQUIPMENT Service procedure Inspection of idling speed adjustment potentiometer • Disconnect the harness A of the idling speed adjustment potentiometer 1 from the cab-side harness B. Then, connect an inspection harness C between harnesses A and B. (The inspection harness must be made specially for this procedure.) •...
Page 19 13EB Inspection of exhaust brake relay (Open type 4 pin) • Follow the table below to inspect continuity : 1 2 3 4 No current Current – – : There is continuity between terminal 07142 – : Indicates that 12 volts DC is applied to the line between the terminals.
Page 20 INSPECTION OF ELECTRICAL EQUIPMENT Inspection of pre-stroke actuator Perform the following inspections. If any abnormality is evident, have inspection and repair performed by the nearest MFTA Dealer. CAUTION – The pre-stroke actuator 8 must be inspected when the engine is cold.
Page 21 13EB Engine speed sensor [Inspection] Main unit • Measure the resistance between terminals • If the measured value deviates from the standard value, replace engine speed sensor 13. 3 2 1 CAUTION – Be sure to check the tightening torque of engine speed 13785 sensor 13.
Page 22 INSPECTION OF ELECTRICAL EQUIPMENT Inspection of emergency engine stop button • Push emergency engine stop button 17 in all the way. • In this step, make sure that stop lever A of the governor is in contact with stopper bolt B. •...
Page 23 LOCATIONS OF PARTS 13EB < View C > < View A > < Automatic transmission > < Manual transmission > 1 Combination switch Left side view Upper view 2 Starter switch 3 Engine control unit < FG > 4 Exhaust brake cut relay (ABS) Exhaust brake cut relay (A/T) 5 Transmission neutral relay (M/T) 6 Relay box...
Page 24 ELECTRICAL WIRING DIAGRAM 13EB 44413 13EB-41...
Page 25 Group 14A Cooling < 4M5 > ' 98 Minor Change Pub No. TWSE0101-14A...
Page 26 INDEX SPECIFICATIONS ................14A- 2 STRUCTURE AND OPERATION ............14A- 2 TROUBLESHOOTING ................14A- 4 ON-VEHICLE INSPECTION AND ADJUSTMENT • Replacing Coolant and Cleaning Cooling System ....14A- 6 • Air Bleeding of Cooling System ..........14A- 8 • Gas Leak Testing ................14A- 8 RADIATOR ....................
Page 27 SPECIFICATIONS SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Kind of cooling system Forced water circulation system Water pump type Belt-driven involute type Thermostat type Wax-pellet, bottom bypass type (with jiggling valve) Automatic cooling fan coupling type Continuous control type Radiator type Tube and corrugated fin type Coolant capacity L {qts}...
Page 28 Water Pump 1 Case 2 Unit seal 3 Impeller 4 Unit bearing 5 Pulley A: Drain hole P29545 Thermostat 1 Oil cooler 2 Thermostat 3 Thermostat cover A : From radiator B : From cylinder head C : To water pump D : With high coolant temperature E : With low coolant temperature Thermostat 2 is a bottom bypass type that uses wax-...
Page 29 TROUBLESHOOTING Symptoms Remarks Possible causes × × Loose or damaged × Excessive tension V-ribbed belt or V-belt × Oil on belt × × × Water pump fitted poorly × × Unit bearing defective × × Water pump Impeller defective × ×...
Page 30 M E M O 14A-5...
Page 31 ON-VEHICLE INSPECTION AND ADJUSTMENT Replacing Coolant and Cleaning Cooling System 1 Pressure cap 2 Drain cock 3 Water drain plug Ê 2Ê P29573 Ê Tightening torque Unit: N⋅m {ft.lbs, kgf⋅m} Location Parts to be tightened Tightening torque Remarks Drain cock 2 {14.5, 0.2} —...
Page 32 Method of cleaning the cooling system depends on its condition. Ordinary condition Extremely dirty coolant Clogged radiator Cleaning using water Cleaning using Radipet 7 or equivalent Drain the coolant Make a solution of FUSO Radiator Cleaner (Radipet 7 or equivalent) in a 5 to 10% ratio to the total volume of coolant (Work procedure) Fill the radiator with the solution...
Page 33 ON-VEHICLE INSPECTION AND ADJUSTMENT Air Bleeding of Cooling System • Remove the pressure cap. Then, introduce cooling water little by little up to the water outlet pipe neck. Do not pour water up to the outlet port brim, otherwise water would overflow out of the outlet port after the engine is started as water will expand due to temperature rise.
Page 34 M E M O 14A-9...
Page 35 RADIATOR Disassembly sequence 1 Clamp 2 Upper hose Ê 3 Clamp 4 Clamp Ê 5 Lower hose 6 Radiator support 7 Baffle plate 8 Support cushion 9 Radiator assembly P14A-12 Assembly sequence Ê Follow the disassembly sequence in re- verse. P29301 Ê...
Page 36 M E M O 14A-11...
Page 37 RADIATOR Radiator Assembly Ê Ù Ê Ê 2Ê Ù 9 Ê P41248 Disassembly sequence 1 Radiator shroud 5 Side member 9 O-ring 2 Drain cock 6 Upper tank 10 Core 3 Radiator assembly 7 O-ring Ù : Non-reusable part 4 Bolt 8 Lower tank CAUTION –...
Page 38 Ê Tightening torque Unit: N m {ft.lbs, kg fm} Location Parts to be tightened Tightening torque Remarks Drain cock 2 {1.4, 0.2} — Bolt (side member mounting) 13 {9.4, 1.3} — 0 Special tool Location Tool name and shape Part No. Application Lock &...
Page 39 RADIATOR Upper tank and lower tank Remove and reinstall the tanks using the 0 Lock and Break Tool. A : Attachment (for tank removal) B : Attachment locking bolt C : Slide handle D : Stopper/adjuster bolt E : Attachment (for tank installation) 24680 [Removal] •...
Page 40 [Inspection] • Check the tank mounting channels H of the core 10 for foreign mat- ters. • If foreign matter is stuck inside the mounting channels, rub them away with sandpaper (approximately #1000) or blow them out with com- pressed air. CAUTION –...
Page 41 RADIATOR • Clinch the tabs F of the core 10 to hold the tank 6, 8 in the illustrated order. : Two center tabs on each side : Remaining tabs in illustrated sequence 0 : Lock and Break Tool (with attachment E) NOTE do not allow the 0 Lock and Break Tool to be The sides...
Page 42 [Repair] NOTE Repair is carried out by tungsten inert gas arc (TIG) welding, which requires the skill of a trained welder. WARNING – To avoid danger, dry the core 10 completely before welding. • Clean both edges B of the leaky tube and their surroundings C using a stainless steel wire brush.
Page 43 COOLING FAN, V-RIBBED BELT, V-BELT AND WATER PUMP < Without refrigeration compressor > Ù Ê Ê 10 Ê 3Ê P29768 Ù < With refrigeration compressor > Ê Ê 10 Ê 3 Ê P29769 Disassembly sequence *a : Altenator ^ Gr 54 1 Nut 6 V-ribbed belt (for water pump) *b : Compressor <...
Page 44 Service standard Unit: mm {in.} Maintenance item Standard Value Limit Remedy Location — V-ribbed belt tension (for refrigerator) 6 to 8 {0.24 to 0.31} Adjust V-ribbed belt tension When belt is new 9 to 11 {0.35 to 0.43} — Adjust (for water pump) When belt in use is re-tensioned 11 to 13 {0.43 to 0.51}...
Page 45 COOLING FAN, V-RIBBED BELT, V-BELT AND WATER PUMP V-belt and V-ribbed belt tension < Without refrigerator > [Inspection] NOTE Before checking for tension, crank the engine one turn or more clockwise. Apply force of approximately 98 N {22 lbf, 10 kgf} to the span center of the V-belt 5 and V-ribbed belt 6, and measure the extent of belt deflection A.
Page 46 [Adjustment] CAUTION – • Excessive tension in the V-belt 5 or V-ribbed belt 6 may damage the belt and related bearings. • Keep the V-belt 5 or V-ribbed belt 6 free of oil. If the belt becomes oily, it may slip, resulting in overheating of the engine and insuffi- cient charging of the battery.
Page 47 WATER HOSE & PIPE Disassembly sequence 1 Pressure cap 2 Bolt 3 Water outlet pipe 4 Gasket Ê 5 O-ring 6 Bolt 7 Water outlet case 8 Gasket 9 Bolt 10 Heater hose elbow 11 Gasket Ù Ù *a : Cylinder head ^ Gr 11A *b : Breather cover ^ Gr 11A Ù...
Page 48 Service procedure Pressure cap inspection (1) Pressure valve opening pressure If the gauge reading deviates from the standard value, replace the pressure cap 1. 00194 (2) Vent valve inspection • Observe the water level B in the reservoir tank A. •...
Page 49 THERMOSTAT Disassembly sequence Ê 1 Clamp 2 Water pipe 3 Rubber hose 4 Bolt 5 Thermostat cover 6 Thermostat 7 Water temperature sensor Ê ^ Gr 54 * : Oil cooler ^ Gr 12A Assembly sequence Ê Follow the disassembly sequence in re- verse.
Page 50 M E M O 14A-25...
Page 51 Group 14B Cooling < 4D3 > ' 98 Minor Change Pub No. TWSE0101-14B...
Page 52 INDEX SPECIFICATIONS ................. 14B- 2 STRUCTURE AND OPERATION ..........14B- 2 TROUBLESHOOTING ..............14B- 4 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 14B- 6 • Replacing Coolant and Cleaning Cooling System ......14B- 8 • Air Bleeding of Cooling System ............14B- 8 •...
Page 53 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Kind of cooling system Forced water circulation system Water pump type Belt-driven involute type Thermostat type Wax-pellet, bottom bypass type (with jiggling valve) Automatic cooling fan coupling type Continuous control type Radiator type Tube and corrugated fin type Coolant capacity L {qts} 13 {14}...
Page 54 Water Pump 1 Case 2 Unit seal 3 Impeller 4 Ball bearing 5 Flange A : Drain hole The water pump is provided with a drain hole A to prevent the ingress of coolant to the ball bearing 4 when the unit seal 2 is damaged.
Page 55 TROUBLESHOOTING Symptoms Remarks Possible causes Loose or damaged V-belt Tension excessive Oily Water pump installation faulty Unit bearing faulty Water pump Impeller faulty Unit seal faulty Unit bearing-to-flange and to-impeller fitting loose Case installation faulty Gasket faulty Thermostat Valve opening temperature too high, valve remains closed Valve opening temperature too low, valve remains open Water leaking from water temperture sensor Space between core and fins clogged...
Page 56 M E M O...
Page 57 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Replacing Coolant and Cleaning Cooling System 1 Pressure cap 2 Radiator drain plug 3 Crankcase drain plug 06362 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Crankcase drain plug 34 to 39 {25 to 29, 3.5 to 4.0} —...
Page 58 Method of cleaning the cooling system depends on its condition. Ordinary condition Extremely dirty coolant Clogged radiator Cleaning using water Cleaning using Radipet 7 or equivalent Drain the coolant Make a solution of FUSO Radiator Cleaner (Radipet 7 or equivalent) in a 5 to 10% ratio to the total volume of coolant (Work procedure) Fill the radiator with the solution...
Page 59 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Air Bleeding of Cooling System • Remove the pressure cap and keep the coolant temperature at 90°C {194°F} while letting the engine idle and bleed the air out completely. Keep the temperature adjusting lever of the heater controller at maxi- mum so that the coolant can circulate freely in the heater piping area.
Page 60 M E M O...
Page 61 RADIATOR - Ê 3 Ê 1 3 Ê- 5 Ê 12Ù Ê 8 13 Ê 42268 Disassembly sequence 10 Baffle plate 1 Hose clamp 11 Radiator drain plug 2 Inlet hose 12 O-ring 3 Hose clamp 13 Nut 4 Outlet hose 14 Support cushion 5 Bolt 15 Radiator...
Page 62 - Lubricant Location Points of application Kinds Quantity Thread area of bolt Engine oil As required Service procedure Support cushion Place support cushion 14 so that thread part A (shorter than the other 14 mm {0.55 in.} side) comes to the radiator side for mounting. 22 mm {0.87 in.} 05802...
Page 63 COOLING FAN AND V-BELT 12209 Disassembly sequence 1 V-belt (Compressor) 7 Bolt 2 V-belt (Fan) 8 Coupling plate 3 Nut 9 Water pump pulley 4 Cooling fan 5 Nut *a : Tension pulley ^ Gr 54 6 Automatic cooling fan coupling *b : Cooler compressor ^ Gr 54 Assembly sequence Follow the disassembly sequence in reverse.
Page 64 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy V-belt tension (Air-conditioner) 16 to 20 {0.63 to 0.79} — Adjust V-belt tension (Fan) 12 to 16 {0.47 to 0.63} — Adjust 0 Special tools Unit : mm {in.} Location Tool name and shape Part No.
Page 65 COOLING FAN AND V-BELT • Measure the extent of flex A of V-belts 1, 2 at this point, and if the measured value deviates from the standard value, adjust as fol- lows. 1, 2 03615 [Adjustment] (1) Adjustment of V-belt tension for fan •...
Page 66 Automatic cooling fan coupling [Inspection] Carry out the following inspection of automatic cooling fan coupling 6 and if any fault is found, replace the unit. • Check for any leakage of lubricating oil sealed in the coupling body. • Rotate automatic cooling fan coupling 6 by hand, and check for any irregularity in rotation related to the coupling bearing or any abnormal noise.
Page 67 WATER PUMP Removal sequence 1 Water pump assembly 2 O-ring Ù : Non-reusable parts Installation sequence Follow the removal sequence in reverse. 2 - Ù 12210 CAUTION– • Be sure to replace water pump assembly 1 as an assembly if it is faulty because it is a unit construction. •...
Page 68 M E M O...
Page 69 THERMOSTAT Disassembly sequence 1 Pressure cap 2 Thermostat cover 3 Thermostat cover gasket 4 Thermostat 5 Thermostat case 6 Thermostat case gasket 7 Bypass pipe 8 O-ring 9 Water temperature sensor Ù (Water temperature gauge and multi- purpose timing control unit) ^ Gr 54 10 Overheating switch ^ Gr 54 11 Water temperature sensor...
Page 70 Service procedure Inspection of pressure cap (1) Pressure valve opening pressure If the measured value deviates from the standard value, replace pressure cap 1. 00194 (2) Inspection of vent valve • Take note of the liquid level B of reservoir tank A beforehand. •...
Page 71 THERMOSTAT Thermostat [Inspection] Stir the water using stick A to maintain an even water temperature in the container, then carry out the following tests. If the measured value deviates from the standard value, replace thermostat 4. (1) Valve opening temperature •...
Page 72 Group 15A Intake and Exhaust < 4M5 > ' 98 Minor Change Pub No. TWSE0101-15A...
Page 73 INDEX SPECIFICATIONS / STRUCTURE AND OPERATION ......15A- 2 15A- 2 1. Air Cleaner ..................... 15A- 3 2. Turbocharger Assembly ............... TROUBLESHOOTING ................15A- 4 ON-VEHICLE INSPECTION AND ADJUSTMENT 15A- 5 Measurement of Turbocharger Boost Pressure ........AIR DUCT AND AIR CLEANER 15A- 8 <...
Page 74 SPECIFICATIONS / STRUCTURE AND OPERATION SPECIFICATIONS c i f t l i f s t i STRUCTURE AND OPERATION 1. Air Cleaner 1 Air box 2 Air cleaner assembly 3 Unloader valve • The air cleaner assembly 2 utilizes a single element.
Page 75 2. Turbocharger Assembly 1 Actuator 2 Compressor cover 3 Compressor wheel 4 Thrust sleeve 5 Thrust bearing 6 Bearing 7 Bearing housing 8 Turbine back plate 9 Turbine housing 10 Shaft and turbine wheel 11 Piston ring 12 Thrust ring 13 Oil deflector 14 Insert 13 12 11 10...
Page 76 TROUBLESHOOTING × × × × l f f l i a × l f f l i a × × v i t × × × × × × × × n i l × l i o × × ×...
Page 77 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measurement of Turbocharger Boost Pressure Service standards °C 6 { ° – – 0 Special tool c i l 0 4 0 0 — MH061366 P01524 • Before measuring the boost pressure, clean or replace the air cleaner element.
Page 78 ON-VEHICLE INSPECTION AND ADJUSTMENT [Correction for engine speed] From the engine speed during boost pressure measurement, subtract the median of the maximum idling speed. From the result, determine the boost pressure correction value (Pa) in accordance with the graph. {1.57, 40} Median: 3,750 rpm {0.79, 20} [Calculation of corrected boost pressure]...
Page 79 M E M O 15A-7...
Page 80 AIR DUCT AND AIR CLEANER < EXCEPT CREW CAB > Ê6 11Ê 4Ê 10Ê 7Ê 9Ê Ù 3Ê Ê14 Ê15 15Ê 1Ê 21Ê P41249 Disassembly sequence 1 Clamp 9 Clamp 17 Rubber seal 2 Connector 10 Bolt 18 Air cleaner cap 3 Bolt 11 Bolt 19 Air cleaner element...
Page 81 Service procedure Installation of air duct • Fit clamp 7 over protrusions A of air duct 8. • Push air duct 8 in until it hits air cleaner case 14. P41250 Installation of air box Align slit A of air box 16 with key B of air cleaner case 14. 09959 Installation of rubber seal Align slit A of rubber seal 17 with key B of air cleaner case 20.
Page 82 AIR DUCT AND AIR CLEANER < EXCEPT CREW CAB > Air cleaner element [Cleaning] • Blow compressed air of 685 kPa {100 psi, 7 kgf/cm } or less through air cleaner element 19 from the inside. • When using compressed air, move the blower’s nozzle up and down along the pleats of air cleaner element 19 evenly.
Page 83 M E M O 15A-11...
Page 84 AIR DUCT AND AIR CLEANER < CREW CAB > 5 Ê Ê 20 Ê Ê Ê Ê 22 Ê Ê Ù 4 Ê 1 Ê 10 Ê Ê 7 Ê 2 Ê Ê 8 Ê P45750 Disassembly sequence 1 Clamp 12 Bolt 23 Air duct 2 Clamp...
Page 85 Service procedure Installation of connector Align painted mark A on connector 16 with protrusion B on air inlet pipe 19, and push in the connector. A : White paint mark P42273 Installation of connector Align painted mark A on connector 21 with protrusion B on air inlet pipe 19, and push in the connector.
Page 86 AIR DUCT AND AIR CLEANER < CREW CAB > Installation of air cleaner cap : Alignment mark “ ” P13152 Air cleaner element [Cleaning] • Blow compressed air of 685 kPa {100 psi, 7 kgf/cm } or less through air cleaner element 29 from the inside. •...
Page 87 TURBOCHARGER Disassembly sequence 1 Bolt 2 Insulator 3 Eyebolt Ê 4 Oil pipe 5 Bolt Ê 6 Oil return pipe 7 Gasket 8 Nut 9 Front pipe Ù 10 Nut 11 Exhaust pipe stay Ê 12 Nut Ê 13 Exhaust pipe 14 Coupler gasket Ê...
Page 88 TURBOCHARGER Service procedure Installation of turbocharger assembly Before installing the turbocharger assembly 18, pour engine oil into the oil hole A to ensure smooth operation of the internal parts. P29475 15A-16...
Page 89 Turbocharger assembly Operation before disassembly P15A-18 Disassembly sequence 1 Hose Ù 2 Actuator 3 Bolt 4 Coupling 5 Turbine housing 6 Snap ring 7 Compressor cover 8 O-ring 9 Cartridge assembly Ê Ù : Non-reusable part Assembly sequence Follow the disassembly sequence in reverse. Inspection after assembly P15A-18 P29476...
Page 90 TURBOCHARGER Service procedure Operations before disassembly Make alignment marks A on the coupling 4, turbine housing 5, com- pressor cover 7, and cartridge assembly 9. P29477 Cleaning after disassembly • Visually check the disassembled parts for scorches, abrasion, and other marks that may be difficult to see after cleaning. Replace any part that appears defective.
Page 91 Installing snap ring • Fit snap ring 6 onto compressor cover 7 with its tapered surface A facing upward. WARNING – When fitting snap ring 6, hold it down to prevent it from flying off. P01532 Removal of compressor cover CAUTION –...
Page 92 INTERCOOLER Disassembly sequence Ê 1 Clamp 2 Air inlet hose Ê 3 Clamp 4 Air inlet pipe 5 Clamp Ê 6 Air inlet hose Ê 7 Clamp Ê 8 Rubber hose 9 Clamp 10 Air inlet pipe 11 Clamp 12 Air inlet hose 13 Intercooler *a : Radiator ^ Gr 14A *b : Intake manifold...
Page 93 M E M O 15A-21...
Page 94 INTAKE MANIFOLD Ù Ù Ê Ê Ê Ê Ê P37459 Disassembly sequence 1 Nut 7 Nut 13 Gasket A 2 Actuator assembly 8 Spring *a: Cylinder head ^ Gr 11A 3 Pressure hose 9 Intake manifold B *b: Vacuum hose 4 Bolt 10 Gasket B 5 Boost pressure sensor...
Page 95 Ê Tightening torques Unit: N⋅m {ft.lbs, kgf⋅m} – – Pressure hose fitting – – – Service procedure Clearance between butterfly valve and intake manifold B Apply a vacuum of more than 67 kPa {19.7 in.Hg, 500 mmHg} to the actuator assembly 2 to bring the double nut into contact with its bracket. While keeping this condition, adjust the clearance B between the butterfly valve A and the intake manifold B 9 for the specified standard value using the oblong holes C in the actuator assembly bracket.
Page 96 EXHAUST MANIFOLD Disassembly sequence 1 Bolt 2 Insulator 3 Lower insulator 4 Nut Ê 5 Spacer 6 Exhaust manifold 7 Gasket Ù * : Cylinder head ^ Gr 11A Ù : Non-reusable part Reassembly sequence Follow the disassembly sequence in reverse. Ê...
Page 97 M E M O 15A-25...
Page 98 EXHAUST PIPE AND MUFFLER < Except crew cab > < Crew cab > Ê 1 Ê 1Ê Ê Ê 8Ê Ê 8 Ê Ê 10Ê 10 Ê 13254 P45752 Disassembly sequence 1 Nut 11 Front pipe 2 Tail pipe 12 Exhaust brake unit ^ Gr 35A 3 Nut 13 Front pipe 4 Bolt...
Page 99 Ê Tightening torque Unit: N⋅m {ft.lbs, kgf⋅m} 1, 8, 15 (Tail pipe, center pipe and muffler mounting) – – – Service procedure Installation of front pipe assembly Install front pipe assembly 9 so that the offset tolerance in the vertical and horizontal sections between the front and back of bellows A con- forms to the specified value.
Page 100 Group 15B Intake and Exhaust < 4D3 > ' 98 Minor Change Pub No. TWSE0101-15B...
Page 101 INDEX SPECIFICATIONS ................. 15B- 2 STRUCTURE AND OPERATION ..........15B- 2 TROUBLESHOOTING ..............15B- 5 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 15B- 6 • Measurement of Turbo Boost Pressure ..........AIR DUCT AND AIR CLEANER ............ 15B- 8 TURBOCHARGER ................ 15B-12 INTERCOOLER ................
Page 102 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Items Specifications Air cleaner element Cyclone paper filter type Turbocharger Model TD05 Manufacturer MITSUBISHI HEAVY INDUSTRIES Intercooler type Air-cooled, tube and corrugated fin type STRUCTURE AND OPERATION Air Cleaner 1 Air box 2 Air cleaner assembly 3 Unloader valve •...
Page 103 Waste gate mechanism • The waste gate mechanism relieves the boost pressure of excess exhaust gas using actuator 1. This controls the boost pressure appro- priately and prevents the turbocharger from overrunning, and prevents excessive pressure in the intake manifold. •...
Page 104 STRUCTURE AND OPERATION Muffler 1 Muffler 2 Catalytic converter A : Exhaust gas intake Converter 2 is built into muffler 1 to decrease the amount of particulate matter (PM) in the exhaust gas. 13243 15B-4...
Page 105 TROUBLESHOOTING Symptoms Remarks Possible causes Air cleaner Air cleaner element clogged Bearing faulty Carbon deposits on shaft and turbine wheel Shaft and turbine wheel interfering with turbine backplate Shaft and turbine wheel interfering with turbine housing Shaft and turbine wheel bent Shaft and turbine wheel broken Compressor wheel interfering with compressor housing Turbocharger...
Page 106 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Measurement of Turbo Boost Pressure Service standards Location Maintenance item Standard value Limit Remedy — Boost pressure (Air temperature 20°C {68°F}, — 36 kPa Inspect Atmospheric pressure 100 kPa {29.9 in. Hg, {10.6 in. Hg, and adjust 760 mmHg}) 270 mmHg}/...
Page 107 [Correction for engine speed] {1.57, 40} Subtract the engine speed actually used for measuring the boost pres- sure from the median of the no-load maximum engine speed. Identify the 0.79, 20} boost pressure correction value (Pa) according to the graph. {0, 0} Median value : 3700 rpm –2.7...
Page 108 AIR DUCT AND AIR CLEANER 4 Ê 5 Ê Ù Ê Ê 9 1 Ê 42271 Disassembly sequence 10 Air box 11 Rubber seal 1 Clamp 12 Air cleaner cap 2 Connector 13 Air cleaner element 3 Air inlet duct 14 Air cleaner case 4 Clamp 5 Clamp...
Page 109 Service procedure Installation of air duct • Fit clamp 7 over protrusions A of air duct 8. • Push air duct 8 in until it hits air cleaner case 14. 08786 Installation of air box Align slit A of air box 10 with key B of air cleaner case 14. 09959 Installation of rubber seal Align slit A of rubber seal 11 with key B of air cleaner case 14.
Page 110 AIR DUCT AND AIR CLEANER Air cleaner element [Cleaning] • Blow compressed air of 685 kPa {100 psi, 7 kgf/cm } or less through air cleaner element 13 from the inside. • When using compressed air, move the blower’s nozzle up and down along the pleats of air cleaner element 13 evenly.
Page 111 M E M O 15B-11...
Page 112 TURBOCHARGER Removal sequence 1 Bolt 2 Insulator 3 Eye bolt 4 Oil pipe 5 Oil return pipe Ê 6 O-ring 3 Ê 7 Bolt 8 Seal ring 9 Exhaust pipe connector 10 Nut 11 Turbocharger assembly Õ P15B-14 Ù 12 Gasket *a : Air hose Õ...
Page 113 Service procedure Installation of seal ring Offset splits A of seal rings 8 at 180°. 07573 Installation of turbocharger assembly When installing turbocharger assembly 11, supply engine oil via oil port A as required to ensure that parts move smoothly. 13244 Installation of gasket Install gasket 12 to exhaust manifold *d in the direction as illustrated.
Page 114 TURBOCHARGER Turbocharger Assembly Work before disassembly Õ P15B-15 - Ê 3 Ù Disassembly sequence 1 Hose 2 Actuator 3 Bolt 4 Coupling 5 Turbine housing 6 Snap ring 7 Compressor cover 8 O-ring 9 Cartridge assembly Ù : Non-reusable parts 13246 Assembly sequence Follow the disassembly sequence in reverse.
Page 115 Service procedure Work before disassembly Put alignment marks A on coupling 4, turbine housing 5, compressor cover 7 and cartridge assembly 9. 13247 Inspection after assembly Turn the turbine wheel and the compressor wheel of cartridge assembly 9 to make sure that they turn smoothly. 13248 Installation of coupling Install coupling 4 onto turbine housing 5 in the direction as illustrated.
Page 116 TURBOCHARGER Installation of snap ring Install snap ring 6 into compressor cover 7 with taper surface A upward. WARNING– Use your hand to hold snap ring 6 in place to prevent it from springing out. 01532 Removal of compressor cover CAUTION–...
Page 117 M E M O 15B-17...
Page 118 INTERCOOLER Disassembly sequence Ê 3 1 Clamp 2 Air inlet hose 3 Clamp Ê 3 4 Air inlet hose 5 Clamp 6 Bolt 7 Air inlet pipe 1 Ê 8 Clamp 9 Air inlet hose 10 Bolt Ê 5 11 Boost air temperature sensor Ê...
Page 119 Service procedure Installation of air inlet hose “ ” Align alignment mark “ ” of air inlet hose 4 with padded part A of air inlet pipe 7. 06179 Inspection of intercooler • Fit plug A on one of the air inlets of intercooler 12 and close the hole on the boost air temperature sensor, while connecting the hose to the other.
Page 120 INTAKE MANIFOLD Disassembly sequence 1 Vacuum hose 2 Bolt Ê 3 Boost pressure sensor ^ Gr 13EB 4 Bolt 5 Joint pipe Ê 6 Over-boost valve 7 Bolt 8 Intake manifold assembly 9 Gasket *1 : Cylinder head ^ Gr 11B Ê...
Page 121 M E M O 15B-21...
Page 122 EXHAUST MANIFOLD Ê2 Ù 36726 Disassembly sequence 1 Insulator 7 Gasket 2 Nut *1 : Cylinder head ^ Gr 11B 3 Distance spacer *2 : Insulator Õ P15B-12 4 Front exhaust manifold 5 Joint Ù : Non-reusable parts 6 Rear exhaust manifold Assembly sequence Follow the disassembly sequence in reverse.
Page 123 Service procedure Installation of joint A : Plastic hammer 4, 6 P42277 Installation of gasket Install gasket 7 on cylinder head *1 in the direction as illustrated. A : Grommet lip 13253 15B-23...
Page 124 EXHAUST PIPE AND MUFFLER Disassembly sequence < FE > 1 Nut 2 Tail pipe 3 Nut 4 Bolt Ê 5 Exhaust pipe bracket 1 Ê 6 Nut 7 Bolt 8 Nut 9 Front pipe assembly 10 Nut 11 Front pipe 8 Ê...
Page 125 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks 1, 8, 14 Nut (Tail pipe, center pipe and muffler mounting) 26 to 33 {20 to 25, 2.7 to 3.4} — Nut (Front pipe assembly mounting) 20 to 25 {14 to 18, 2.0 to 2.5} —...
Page 126 Group 21 Clutch ' 98 Minor Change Pub No. TWSE0101-21...
Page 127 INDEX SPECIFICATIONS ................21- 2 STRUCTURE AND OPERATION ............ 21- 2 TROUBLESHOOTING ..............21- 5 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 21- 6 • Clutch Fluid (Brake Fluid) Replacement and Air Bleeding ..... 21- 8 • Clutch Pedal Free Play ................CLUTCH PEDAL ................
Page 128 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Clutch Model C4W30 Drive type Strap drive Clutch disc Type Dry, single plate type Pressure plate Type Diaphragm spring type Control type Hydraulic pressure type Clutch master cylinder Manufacturer NISSIN KOGYO Clutch power cylinder Manufacturer NISSIN KOGYO STRUCTURE AND OPERATION...
Page 129 Clutch Master Cylinder 08189 1 Valve stem 5 Spring seat A : From fluid tank 2 Return spring 6 Valve spring B : To clutch power cylinder (hydraulic 3 Pressure cup 7 Valve case pressure) 4 Piston 8 Valve seal When clutch pedal is depressed •...
Page 130 STRUCTURE AND OPERATION Clutch Body 1 Clutch housing 2 Strap plate 3 Clutch cover 4 Pivot ring 5 Diaphragm spring 6 Clutch release bearing 7 Clutch release rocker arm 8 Rocker arm pivot 9 Pressure plate 10 Clutch disc 11 Flywheel 12 Drive pinion 12386 When clutch pedal is released...
Page 131 TROUBLESHOOTING Symptoms Remarks Possible causes Diaphragm spring heights uneven Pressure plate warped or faulty Clutch cover Diaphragm spring fatigued assembly Rivets loose Strap plate bent Disc deformed Disc rivets loose Disc torsion spring fatigued or fractured Spline worn Clutch disc Spline rusted Facing worn Facing surface hardened...
Page 132 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Clutch Fluid (Brake Fluid) Replacement and Air Bleeding Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Bleeder screw 10.8 to 14.7 {8 to 11, 1.1 to 1.5} —...
Page 133 • Supply new brake fluid to the “MAX” level of fluid tank 4. Depress clutch pedal 3 repeatedly until the old brake fluid discharged from vinyl pipe 2 is replaced by the new brake fluid. “MAX” “MIN” 11773 (2) Air bleeding of clutch system NOTE Carry out this operation maintaining the brake fluid level in fluid tank 4 between “MAX”...
Page 134 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Clutch Pedal Free Play Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Push rod stroke 4 {0.16} — Adjust or replace Clutch pedal free play 36 to 53 {1.42 to 2.09} —...
Page 135 [Confirmation] Push clutch pedal 6 with your hand until you feel a resistance and measure free play B. If the measured value deviates from the standard value, readjust or replace the clutch disc. : 36 to 53 mm {1.42 to 2.09 in.} 03480 21-9...
Page 136 CLUTCH PEDAL Disassembly sequence 1 Fluid hose 8 Ê 2 Fluid hose 3 Clevis pin 4 Nut 5 Clutch master cylinder Õ P21-12 6 Clutch switch ^ Gr 54 7 Lock nut 8 Nut 9 Clevis pin 10 Spring holder 11 Return spring 12 Plate 13 Nut...
Page 137 Service procedure Adjustment after assembly Adjustment of clutch pedal Adjust clevis * of clutch master cylinder 5 so that clutch pedal 20 is installed as illustrated. Õ P21-13 180±3 mm {7.09±0.12 in.} 165 mm {6.50 in.} 03696 Removal and installation of fluid hose •...
Page 138 CLUTCH MASTER CYLINDER Disassembly sequence 1 Clevis Ê 2 Lock nut 3 Retaining ring 4 Stop plate 5 Push rod 6 Clip 7 Packing 8 Union collar 9 Piston assembly Ù 7 10 Cylinder body Ù : Non-reusable parts Assembly sequence 8 →...
Page 139 Service procedure Adjustment of push rod length • If the length, as illustrated, deviates from the specified value, loosen nut 2, and adjust the length of push rod 5 by turning clevis 1. • Measure the length while push rod 5 is touching stop plate 4. •...
Page 140 CLUTCH POWER CYLINDER Removal sequence 1 Fluid hose 2 Return spring 3 Bolt 3 Ê 4 Clutch power cylinder assembly Õ P21-15 *a : Push rod cap *b - *b : Clutch release rocker arm Installation sequence Follow the removal sequence in reverse. 12392 Ê...
Page 141 Clutch Power Cylinder Assembly Disassembly sequence 1 Push rod cap 2 Lock nut 3 Push rod 4 Dust cover 5 Piston cup 6 Piston 7 Bleeder cap Ê 8 8 Bleeder screw 9 Cylinder body Ù : Non-reusable parts Assembly sequence 5 - Ù...
Page 142 WORK BEFORE REMOVAL AND INSTALLATION OF CLUTCH BODY 14121 Work sequence before removal 1 Place wheel chocks. 2 Disconnect the negative battery cable. ^ Gr 54 3 Jack up the front axle using a garage jack. 4 Support the front frame on rigid jack stands. 5 Remove the transmission.
Page 143 M E M O 21-17...
Page 144 CLUTCH BODY Removal sequence 1 Bolt 2 Clutch cover assembly 3 Clutch disc * : Flywheel ^ Gr 11B : Positioning pins (two points) WARNING– Be careful when you handle pressure Ê plate and lever assembly 2 because it is rather heavy.
Page 145 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Clutch alignment arbor MH061387 Holding of clutch disc ø120 {4.72} ø20 {0.79} ø28.94 {1.14} 01270 ø28.94 {1.14} Sleeve MH061425 Inspection of installed height of diaphragm spring ø45 {1.77} 03509...
Page 146 CLUTCH BODY [Flatness of pressure plate] If the measured value is higher than the limit, replace clutch cover assembly 2. 05973 [Friction surface of pressure plate] Measure pressure plate friction surface C at specified position D (meas- uring position of friction surface must be within the maximum and mini- mum diameters), and if the measured value is lower than the limit, replace clutch cover assembly 2.
Page 147 Clutch disc (1) Height of facing Measure dimension A of clutch disc 3. If the measured value is lower than the limit, replace the clutch disc. 12401 (2) Play in direction of revolution • Reshape feeler gauge B for insertion into drive pinion spline C, and measure play.
Page 148 CLUTCH CONTROL Ê 12403 Disassembly sequence 1 Retaining spring 4 Rocker arm pivot 2 Clutch release bearing 5 Clutch rocker arm cover 3 Clutch release rocker arm 6 Clutch housing NOTE Do not remove rocker arm pivot 4 unless it is faulty. Assembly sequence Follow the disassembly sequence in reverse.
Page 149 Group 22 Manual Transmission ' 98 Minor Change Pub No. TWSE0101-22...
Page 150 INDEX SPECIFICATIONS ................22- 2 STRUCTURE AND OPERATION ............ 22- 2 TROUBLESHOOTING ..............22- 5 WORK BEFORE REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY ............22- 7 REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY..................22- 8 GEAR SHIFTER UPPER ..............22-10 REAR COVER AND REVERSE IDLER GEAR ....... 22-16 TRANSMISSION BODY ..............
Page 151 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Mode of control Floor shift remote control Transmission model M035S5 5.380 3.028 Gear ratio 1.700 1.000 0.722 Reverse 5.380 Oil capacity L {qts} Approximately 3.7 {3.9} Mass kg {lb} Approximately 83 {183} STRUCTURE AND OPERATION Transmission Assembly P45171 6 1st and reverse constant-mesh assembly...
Page 152 Synchromesh Mechanism Double cone type Single cone type < 2nd and 3rd > 05751 05752 1 Synchronizer ring (Single cone type) 7 Mainshaft Inner synchronizer ring (Double cone type) 8 Synchronizer hub 2 Shifting key 9 Synchronizer sleeve 3 Outer synchronizer ring (Double cone type) 10 Drive pinion (Single cone type) 4 Center cone (Double cone type) 2nd gear (Double cone type)
Page 153 STRUCTURE AND OPERATION Interlock Mechanism 1 4th and 5th shift rail < In neutral > 2 2nd and 3rd shift rail 3 1st and reverse shift rail 4 Interlock pin The interlock mechanism is designed to avoid double en- gagement of gears. When 2nd and 3rd shift rail 2 is shifted, interlock pins other than interlock pin 4 in the 2nd and 3rd shift rail are pushed by the 2nd and 3rd shift rail to lock other P45704...
Page 154 TROUBLESHOOTING Symptoms Remarks Possible causes Mainshaft rear lock nut loose Mainshaft thrust washer worn Mainshaft bearing worn or damaged Synchronizer ring and synchronizer sleeve spline worn Synchronizer ring and gears taper cone area worn Mainshaft pilot bearing worn or damaged Transmission Drive pinion bearing worn or damaged body faulty...
Page 155 TROUBLESHOOTING Symptoms Remarks Possible causes Clutch faulty Clutch engagement poor ^ Gr 21 Clutch pedal play adjusted incorrectly Single cone Contacting surfaces of synchro- type nizer ring and gear assembly taper cone worn Double Contacting surfaces of synchro- Synchronizer faulty cone type nizer inner and outer rings and center cone worn...
Page 156 WORK BEFORE REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY 14096 Work sequence before removal 1 Place wheel chocks. 2 Disconnect negative battery cable. ^ Gr 54 3 Jack up the front axle on a garage jack. 4 Support the front frame on rigid stands. WARNING–...
Page 157 REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY Removal sequence Ê 1 Selector rod Õ P22-40 2 Shift rod Õ P22-40 3 Cross shaft Õ P22-52 4 Harness (Ground) 5 Speedometer cable 6 Chassis harness 7 Parking brake ^ Gr 36 8 Propeller shaft ^ Gr 25 9 Inspection plug 10 Drain plug 11 Transfer ^ Gr 24...
Page 158 Transmission assembly [Supporting transmission] Support transmission assembly 15 on transmission jack A. 07611 [Removal] • Insert a screwdriver into the three removal grooves to remove trans- mission assembly 15 from the engine. CAUTION– Make sure that you remove hoses and cables correctly during service operations.
Page 159 GEAR SHIFTER UPPER Disassembly sequence 1 Bolt Ù Ê 1 6 Ê 2 Gear shifter upper assembly 3 Backup lamp switch 4 Screw plug 5 Interlock pins - Ê 3 6 Bolt 7 Poppet spring plate 8 Poppet springs < without 4th and 5th > 9 Poppet springs <...
Page 160 Service procedure Removal of interlock pin • 1st and reverse shift rail A is provided with hole B (ø3 mm {0.12 in.}) for the removal of interlock pin 5. P45707 • When 1st and reverse shift rail A is shifted into reverse, hole B for removal of the interlock pin aligns with the interlock pin holes of the other shift rails, backup lamp switch 3 installation hole and screw plug 4 hole.
Page 161 GEAR SHIFTER UPPER Gear Shifter Upper Assembly Disassembly sequence 1 Air breather 2 Neutral switch ^ Gr 54 3 Nut 3 Ê 4 Lock pin 5 Bushing 6 Gear selector lever 7 Washer 8 Gear selector lever 9 Spring pin 10 Torsion shaft 11 4th and 5th return spring - Ù...
Page 162 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 4th and 5th return spring free length 40.05 {1.58} 38.05 {1.50} Replace 1st and reverse return spring free length 39.9 {1.57} 37.9 {1.49} Replace Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened...
Page 163 GEAR SHIFTER UPPER Service procedure Removal of spring pin • Tap spring pin 9 using an M4 tap. • Attach 1 spring pin puller with an M4 screw A of appropriate length, and pull out spring pin 9 using 2 reverse shaft puller. 02400 Installation of torsion shaft and gear shift slide lever 45°...
Page 164 Installation of oil seal Apply grease to lip area A of oil seal 17 with bushing 18 press-fitted onto selector lever case 19, and press-fit evenly in the direction as illustrated. 06254 Bushing [Removal] Bushing 18 is press-fitted onto selector lever case 19. For replacement, remove using a screwdriver.
Page 165 5 Oil seal < FE > 12 Bolt (Upper: 2) * : Transmission body 13 Bolt (Lower: 4) 6 Speedometer gear bushing < FE > Ù : Non-reusable parts 7 Bolt < FE > 14 Reverse idler gear cover As for FG refer to ^ Gr 24 Assembly sequence Follow the disassembly sequence in reverse.
Page 166 - Lubricant and sealant Location Points of application Kinds Quantity Friction surfaces of speedometer gear and speedometer Molybdenum disulfide base grease As required gear bushing Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required Contact surfaces between rear cover and transmission case THREEBOND 1215...
Page 167 REAR COVER AND REVERSE IDLER GEAR Installation of oil seal Apply grease to lip area A of oil seal 5, and drive oil seal evenly into speedometer gear bushing 6 in the direction as illustrated using bar B (approximately ø14 mm {0.55 in.}). 03578 Installation of speedometer gear bushing Due to its eccentric center arrangement, speedometer gear bushing 6...
Page 168 Reverse idler gear cover [Removal] • After removing bolt 12, 13 insert scraper A between transmission 12, 13 body * from the lower right or left of reverse idler gear cover 14. Use a plastic hammer B, if necessary. • With the scraper A inserted, push forward the scraper clockwise and counterclockwise to the upper part of reverse idler gear cover 14 along the flange of the cover, then removing the cover.
Page 169 TRANSMISSION BODY Disassembly sequence 1 Bolt 2 Oil seal 3 Front bearing retainer 4 Snap ring Ê 5 5 Bolt 6 Transmission case 7 Bolt 8 Bearing retainer 9 Shift rail and shift fork Õ P22-26 10 Countershaft assembly Õ P22-36 11 Drive pinion assembly Õ...
Page 170 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Bolt (Front bearing retainer mounting) 44 {33, 4.5} — Bolt (Transmission case mounting) 54 {40, 5.5} — Bolt (Bearing retainer mounting) 44 {33, 4.5} —...
Page 171 TRANSMISSION BODY Unit : mm {in.} Location Tool name and shape Part No. Application Set pin MH063385 Removal of countershaft assembly (Not Required (for holding sub-gear) for USA) 39.5 {1.56} 14916 Steel lifting band MH063410 251{9.88} Removal and installation of countershaft 22884 10, 11, 12 assembly, drive pinion assembly and...
Page 172 Removal and installation of snap ring 08382 Removal of transmission case • Remove the main shaft and countershaft rear bearings. Õ P22-36 • Install 0 eye bolts to transmission case 6, and attach wires to prepare for lifting by a crane. •...
Page 173 TRANSMISSION BODY Removal and installation of shift rail and shift fork, countershaft assembly, drive pinion assembly and mainshaft assembly [Removal] • When removing or installing shift rail and shift fork 9, countershaft assembly 10, drive pinion assembly 11 and mainshaft assembly 12, handle them as a group.
Page 174 M E M O 22-25...
Page 175 TRANSMISSION BODY Shift Rail and Shift Fork Disassembly sequence (For disassembling shift rail and shift fork only) 1 Spring pin 2 4th and 5th shift fork 3 Spring pin 4 4th and 5th shift rail jaw 5 4th and 5th shift rail 6 Spring pin 7 2nd and 3rd shift fork 8 Spring pin...
Page 176 1368GI Service procedure Driving-in spring pin For installation of spring pins 1, 3, 6, 8, 11, 13, position the openings in the direction of the shift rail axes. CAUTION– • Be careful when driving in spring pins 1, 3, 6, 8, 11, 13, that you do not subject shift rails 5, 10, 15 to excessive strain, because this would cause faults such as bent shift rails.
Page 177 DRIVE PINION ASSEMBLY Disassembly sequence 1 Snap ring 2 Drive pinion bearing 3 Pilot bearing 4 Drive pinion Assembly sequence Follow the disassembly sequence in reverse. 07641 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Snap ring expander MH061268...
Page 178 Service procedure Removal and installation of snap ring 09968 Drive pinion bearing [Removal] 09920 [Installation] Press-fit drive pinion bearing 2 with its snap ring groove facing the gear side. 06283 22-29...
Page 179 MAINSHAFT ASSEMBLY Work before disassembly Õ P22-32 Disassembly sequence 1 Bearing 2 1st gear thrust washer 3 1st gear assembly 4 Needle bearing 5 Snap ring 6 Synchronizer sleeve 7 Synchronizer hub 8 Reverse gear assembly 9 Needle bearing 10 Snap ring 11 Synchronizer ring 12 Synchronizer sleeve 13 Shifting key...
Page 180 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy End play of 1st gear assembly 0.15 to 0.46 {0.0059 to 0.018} 0.70 {0.028} Replace 3, 4, 31 Play in the diameter direction after assembling 0.02 to 0.06 {0.00079 to 0.0024} 0.12 {0.0047} Replace 1st gear assembly...
Page 181 MAINSHAFT ASSEMBLY 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Bearing puller and installer MH062697 Removal and installation of mainshaft rear bearing ø96.8 {3.81} 08978 5, 10, Snap ring expander MH061268 Removal and installation of snap ring 17, 21 (Obtain Locally) 01137...
Page 182 (2) Double cone synchromesh • Before disassembling synchronizer center cone 23, 2nd gear assem- bly 19, and 3rd gear assembly 29, put alignment marks B on them. Similarly, put alignment marks C on synchronizer inner ring 22, and synchronizer outer ring 24. When reusing parts, align the alignment marks to reassemble.
Page 183 MAINSHAFT ASSEMBLY 5FMQ Removal and installation of snap ring GITV 09969 Clearance between synchronizer ring or 13, 26 11, 24 synchronizer outer ring and shifting key If the measured value for clearance A is higher than the limit, replace faulty parts. 06290 Clearance between synchronizer ring and gear assemblies...
Page 184 Installation of shifting key spring 13, 26 • Place shifting keys 13, 26 into keyways of synchronizer hubs 15, 28, 14, 27 and install shifting key springs 14, 27 taking care to locate the open- ings away from the shifting key positions. •...
Page 185 COUNTERSHAFT ASSEMBLY Disassembly sequence 1 Countershaft front bearing 2 Countershaft assembly 3 Countershaft rear bearing Assembly sequence Follow the disassembly sequence in re- verse. 14918 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Bearing puller and installer MH062697 Removal and installation of countershaft...
Page 186 Service procedure Countershaft front bearing [Removal] 09924 [Installation] Press-fit countershaft front bearing 1 with its snap ring groove facing the gear side. 09925 Positioning of sub-gear Turn sub-gear 4 to the right using 1 jig assembly, and insert 2 set pin into alignment hole A, in the direction as illustrated to secure the sub-gear, with all parts assembled except for snap ring 2 and countershaft front bearing 1.
Page 187 COUNTERSHAFT ASSEMBLY Countershaft rear bearing [Removal] 09926 [Installation] Press-fit countershaft rear bearing 7 with its snap ring groove facing the gear. 09927 22-38...
Page 188 M E M O 22-39...
Page 189 TRANSMISSION CONTROL - Ê Ê To shift rod No.3 To selector rod No.2 To shift rod No.2 To selector rod No.3 P45898 Removal sequence 9 Change lever assembly Õ P22-44 1 Shift rod No.1 10 Lever assembly Õ P22-46 2 Selector rod No.1 11 No.1 cross lever assembly Õ...
Page 190 Service procedure Installation of rod < Ball joint type > • Tighten nuts A, B at specified torque. A : Ê 16 to 24 N·m {12 to 17 ft.lbs, 1.6 to 2.4 kgf·m} B : Ê 19 to 24 N·m {14 to 17 ft.lbs, 1.9 to 2.4 kgf·m} P45896 •...
Page 191 TRANSMISSION CONTROL • Turn the turn buckles of shift rod No.4 7 and selector rod No.4 8 to adjust change lever assembly 9 position. Left and right Fore-and-aft direction H (mm {in.}) direction J (mm {in.}) (Distance from steering (Distance from instrument panel) wheel center) 362 to 372 {14.3 to 14.6} 301 to 311 {11.9 to 12.2}...
Page 192 M E M O 22-43...
Page 193 TRANSMISSION CONTROL Change Lever Assembly Disassembly sequence 1 Bolt 2 Bolt Ê 2 3 Lever assembly 4 Wave washers 5 Spacer 6 Collar 7 Bolt 8 Spacer 9 Collar 10 Return spring 11 Bushing 12 Cross sleeve 13 Change lever bracket Assembly sequence 1 Ê...
Page 194 Service procedure Selection of spacer and installation of wave washer • Select spacer 5 to give specified clearance A when bolt 2 is tightened : 0.8 to 1.3 mm {0.031 to 0.051 in.} at specified torque. Two thicknesses are available for the spacers: 0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
Page 195 TRANSMISSION CONTROL Lever Assembly Disassembly sequence 1 Bolt Ê 1 2 Bolt 3 Cover 4 Dust boot 5 Bushing 6 Lever bracket A 7 Nut Ê 8 Lock pin 9 Lever 13 - 10 Spacer 11 Bushing 12 Shift lever 13 Selector lever 14 Cover 15 Dust boot...
Page 196 34JK Service procedure Installation of cover and dust boot 5, 16 3, 14 • Press in covers 3, 14 fully. 4, 15 • Pack grease into interior space A of dust boots 4, 15. 06315 Tightening nuts Tighten nut 7 at specified torque, pressing it to direction A at approxi- mately 98 N {22 lbf, 10 kgf}.
Page 197 TRANSMISSION CONTROL No.1 Cross Lever Assembly Disassembly sequence 1 Bolt 1 Ê Ù 2 Bolt 3 Cover 4 Dust boot 5 Bushing 13 - 6 Lever bracket 7 Nut 8 Lock pin 9 Lever 10 Spacer 11 Bushing 12 Selector lever 13 Shift lever 14 Cover 15 Dust boot...
Page 198 34JK Service procedure Installation of cover and dust boot 3, 14 5, 16 4, 15 • Press in covers 3, 14 fully. • Pack grease into interior space A of dust boot 4, 15. 06315 Tightening nut Tighten nut 7 at specified torque pressing it to direction A at approxi- mately 98 N {22 lbf, 10 kgf}.
Page 199 TRANSMISSION CONTROL Shift Lever Assembly Disassembly sequence 1 Bolt 1 Ù 2 Nut 3 Bushing 4 Shift lever 5 Spacer 6 Shift lever bracket Ê Ù : Non-reusable parts Assembly sequence 6→5 →2→1 08417 4→3 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque...
Page 200 Selector Lever Assembly Disassembly sequence 1 Ê Ù 1 Bolt 2 Nut 3 Bushing 4 Selector lever 5 Spacer 6 Selector lever bracket Ê Ù : Non-reusable parts Assembly sequence 6→5 →2→1 4→3 06319 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque...
Page 201 TRANSMISSION CONTROL Cross Shaft Assembly Disassembly sequence 1 Nut Ê 1 2 Bolt 2 Ù 3 Cross shaft bracket 4 Bolt 5 Cross shaft bushing 4 Ê 6 Cross shaft boot 7 Cross shaft Ù :Non-reusable parts Assembly sequence 7→6→5→3→2→1→4 06322 Ê...
Page 202 Group 23 Automatic Transmission ' 98 Minor Change Pub No. TWSE0101-23...
Page 203 INDEX SPECIFICATIONS ................23- 2 STRUCTURE AND OPERATION ............23- 3 TROUBLESHOOTING PROCEDURES ..........23-40 TROUBLESHOOTING ................ 23-42 ON-VEHICLE INSPECTION AND ADJUSTMENT 23-52 • Stall Test ......................23-53 • Time Lag Test ....................23-54 • Line Pressure Test ..................23-56 •...
Page 204 SPECIFICATIONS Specifications Vehicle model Item Manufacturer Aisin Seiki Co., Ltd. Transmission type M035A4 Torque converter Type 3-element, 1-stage, 2-phase (with lock-up clutch) Stall torque ratio 1.82 Type Planetary gear type, 4 forward speeds, 1 reverse speed 3.018 1.548 Automatic transmission Gear ratio 1.000 0.703...
Page 205 4 Overdrive direct clutch 13 1st and reverse brake 22 Intermediate shaft 5 Overdrive brake 14 Rear planetary gear 23 Extension housing < FE > 6 Overdrive one-way clutch 15 Parking lock gear 24 Speedometer drive gear 7 Overdrive planetary gear 16 Output shaft 25 Transfer case adapter <...
Page 206 STRUCTURE AND OPERATION Control Mechanisms Control system Multi-plate clutches Torque converter Overdrive input Multi-plate brakes Output shaft (lock-up piston) One-way clutches shaft Planetary gears Oil pump Vehicle speed sensor Control valves Valve body Shift solenoid Throttle pressure Lock-up Timing Shift solenoid solenoid solenoid solenoid...
Page 207 Control block diagram Shift control (incl. O/D shift control) Accelerator position Shift signal*1 solenoid 1 Throttle Accelerator pressure sensor*3 control Shift solenoid 2 Inhibitor switch Shift pattern selector control Engine Throttle speed pressure sensor solenoid Overdrive Lock-up OFF switch Lock-up control solenoid temperature...
Page 208 STRUCTURE AND OPERATION The control functions can be roughly divided into shift control, lock-up control and 2-3 shift control. The electronic control unit electronically controls these functions precisely in accordance with driving conditions. Chart of control items, inputs and outputs Shift Control item Shift...
Page 209 Lock-up control The lock-up mechanism eliminates slippage of the torque converter for improved power transmitting efficiency. Based on the accelerator operation signal transmitted from the accelerator sensor and the signal from the vehicle speed sensor, the automatic transmission electronic control unit outputs a signal according to the predetermined shift curve. This signal is sent to the lock-up solenoid mounted on the valve body, and engages or disengages the lock-up mechanism.
Page 210 STRUCTURE AND OPERATION • Engine speed sensor The 2-3 shift timing control becomes inactive to ensure proper vehicle operation. • Shift solenoid 1 and shift solenoid 2 If a solenoid malfunction occurs when the transmission is in the D, 2 or L range, the operating conditions of the solenoids change as shown in the following table.
Page 211 Electronic Control Devices 1 Automatic transmission electronic control unit 2 Accelerator sensor 3 Vehicle speed sensor 31508 31509 Automatic transmission electronic control unit The automatic transmission electronic control unit is mounted near the brake booster on the driver’s seat side. It determines the vehicle operating conditions based on signals sent from sensors, and outputs signals to solenoids to regulate shift control, lock-up control and other automatic transmission functions.
Page 212 STRUCTURE AND OPERATION Vehicle speed sensor < Except FE640 > This sensor is mounted on the extension housing of the transmission, and converts the vehicle speed to a pulse signal by means of the parking lock gear and sends it to the automatic transmission electronic control unit. <...
Page 213 Engine speed sensor The sensor converts the engine revolution speed to a pulse signal, and outputs to the electronic governor control unit. This signal is then transmitted from the electronic governor control unit to the automatic transmission control unit. Overdrive OFF switch Overdrive OFF switch This switch is mounted on the range selector lever.
Page 214 STRUCTURE AND OPERATION Hydraulic Control Devices Valve Layout Diagram Upper valve body P31513 Lower valve body P31514 23-12...
Page 215 Valve Functions Upper valve body Valve name Description of function 2-3 Shift valve Switches between 2nd and 3rd gears When range selector is shifted to R range while vehicle is moving Reverse inhibitor valve forward at moderate or high speed, this valve, operated by solenoid output, prevents shifting to reverse.
Page 216 STRUCTURE AND OPERATION Shift Function 21 22 13 14 P29810 1 Overdrive direct clutch (C0) 13 Overdrive input shaft 2 Overdrive brake (B0) 14 Overdrive one-way clutch (F0) 3 Overdrive planetary carrier 15 Overdrive planetary sun gear 4 Overdrive planetary ring gear 16 Input shaft 5 Overdrive planetary pinion gears 17 Rear clutch (C2)
Page 217 Clutch, Brake and Solenoid Operations Shift position Remarks Parking Parking Reverse Reverse Neutral Neutral Automatic shifting 1↔ 2↔ 3 ↔ 4 Overdrive OFF mode ↔ Overdrive 1↔ 2↔ 3 Automatic shifting ↔ 1↔ 2 Locked in 1st gear 1← 2 ← 3 (3rd gear shifting occurs only when timing solenoid activates.) S1 and S2 refer to shift solenoid 1 and shift solenoid 2, respectively...
Page 218 STRUCTURE AND OPERATION Overdrive Direct Clutch P29811 1 Overdrive direct clutch drum 7 Clutch plates 13 Overdrive input shaft 2 O-ring 8 Clutch discs 14 Input shaft 3 Overdrive direct clutch piston 9 Clutch flange 4 O-ring 10 Snap ring A : Operating pressure 5 Overdrive clutch return springs 11 Overdrive planetary sun gear...
Page 219 Front Clutch (C1) P29812 1 Front clutch drum 13 Rear clutch hub 7 Clutch cushion plate 14 Snap ring 2 O-ring 8 Clutch plates 3 O-ring 15 Input shaft 9 Clutch discs 4 Front clutch piston 16 Intermediate shaft 10 Thrust bearing race 5 Front clutch return springs 11 Thrust bearing 6 Snap ring...
Page 220 STRUCTURE AND OPERATION Rear Clutch (C2) P29813 1 Snap ring 13 Rear clutch hub 7 Rear clutch piston 2 Clutch flange 8 O-ring A : Operating pressure 3 Clutch discs 9 O-ring 4 Clutch plates 10 Rear clutch drum 5 Snap ring 11 Input shaft 6 Rear clutch piston return 12 Front and rear planetary...
Page 221 Overdrive Brake (B0) P29814 1 Snap ring 6 Snap ring 11 Overdrive case 2 Brake flange 7 Overdrive brake return springs 12 Overdrive direct clutch 3 Clutch discs 8 Overdrive brake piston 13 Overdrive planetary sun gear 4 Brake plates 9 O-ring 5 Brake plates 10 O-ring...
Page 222 STRUCTURE AND OPERATION 2nd Brake (B1) P29815 1 Snap ring 6 2nd brake return springs 11 Rear clutch 2 Brake flange 7 Brake piston No. 1 12 Front and rear planetary sun 3 Clutch discs 8 O-ring gears 4 Brake plates 9 O-ring 5 Snap ring 10 Center support...
Page 223 1st and Reverse Brake (B2) 11 12 P29816 1 Snap ring 7 1st and reverse brake return 12 Transmission case 2 Brake flange springs 13 Front planetary carrier 3 Clutch discs 8 1st and reverse brake piston 4 Brake cushion plate 9 O-ring A : Operating pressure 5 Brake plates...
Page 224 STRUCTURE AND OPERATION Planetary Gears Overdrive planetary gear P29866 Front and rear planetary gears 07468 P29817 1 Pinion gear 7 Overdrive pinion gears 13 Rear sun gear 2 Ring gear 8 Overdrive ring gear 14 Rear planetary carrier 3 Sun gear 9 Front sun gear 15 Rear pinion gears 4 Planetary carrier...
Page 225 No. 2 One-Way Clutch 1 Front planetary carrier and No. 2 one-way clutch inner race 2 No. 2 one-way clutch 3 No. 2 one-way clutch outer race P29819 • During acceleration in the 1st gear, the No. 2 one-way clutch 2 engages and becomes interlocked with the front planetary carrier.
Page 226 STRUCTURE AND OPERATION Torque Transmission Process 13 14 P29810 1 Overdrive direct clutch 13 Overdrive input shaft 2 Overdrive brake 14 Overdrive one-way clutch 3 Overdrive planetary carrier 15 Overdrive planetary sun gear 4 Overdrive planetary ring gear 16 Input shaft 5 Overdrive planetary pinion gears 17 Rear clutch 6 Front clutch...
Page 227 D, and 2 Ranges (1st Gear) Planetary gear rotates as assembly Fixed in position by one-way clutch Output Input Output Input P29820 Overdrive direct clutch 1, front clutch 6, overdrive one-way clutch 14 and No. 2 one-way clutch 9 activate to provide the 1st gear.
Page 228 STRUCTURE AND OPERATION Power transmitting process Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18 → Rear planetary ring gear 11 → Rear planetary pinion gears 12 →...
Page 229 D Range (2nd Gear) Front planetary sun gear Rear planetary sun gear Planetary gear rotates as assembly locked in position locked in position Input Output P29821 Front clutch 6, 2nd brake 7 and overdrive one-way clutch 14 activate to provide the 2nd gear. In this gear, overdrive one- way clutch 14 transmits the rotating force of input shaft 16 to rear planetary pinion gears 12 by means of intermediate shaft 18 and rear planetary ring gear 11.
Page 230 STRUCTURE AND OPERATION D, 2 and L Ranges (3rd Gear) 20 23 Planetary gear Planetary gear Planetary gear rotates as assembly rotates as assembly rotates as assembly P29822 Overdrive direct clutch 1, front clutch 6, rear clutch 17 and Overdrive one-way clutch 14 activate to provide the 3rd gear. In this gear, front clutch 6 and rear clutch 17 cause intermediate shaft 18 and front and rear sun gears 20, 23 to rotate in the same direction.
Page 231 D Range (4th Gear) 23 12 Overdrive planetary sun gear 15 Planetary gear rotates as assembly Planetary gear rotates as assembly Output Input P29823 If the overdrive conditions (see the table below) are fulfilled when the transmission is in 3rd gear, overdrive direct clutch 1 disengages, and overdrive brake 2 activates at the same time to provide the overdrive gear ratio.
Page 232 STRUCTURE AND OPERATION 2 Range (2nd Gear) 22 11 Rear planetary sun gear Planetary gear Front planetary sun locked in position rotates as assembly gear locked in position Input Output P29824 The rotating power is transmitted in the same way as in the previously described 2nd gear in the D range. However, when engine brake is applied, overdrive direct clutch 1 activates and prevents overdrive planetary sun gear 15 from rotating clockwise.
Page 233 L Range (1st Gear) 9 19 Planetary gear Front planetary carrier rotates as assembly fixed in position Input Output Output Input P29825 The rotating power is transmitted in the same way as in the previously described 1st gear in the D and L ranges. However, when the engine brake is applied, 1st and reverse brake 8 activates and prevents front planetary carrier 19 from rotating clockwise.
Page 234 STRUCTURE AND OPERATION R Range Front planetary carrier Planetary gear in fixed position rotates as assembly Output Input P29826 In the R range, overdrive direct clutch 1, overdrive one-way clutch 14, rear clutch 17 and 1st and reverse brake 8 activate to provide reverse gear.
Page 235 N Range P29827 • N range Since front clutch 6 and rear clutch 17 are disengaged, the driving force of input shaft 16 is not transmitted to output shaft 24. P Range 1 Parking lock gear 2 Output shaft 3 Transmission case 4 Parking lock pawl P29828 •...
Page 236 STRUCTURE AND OPERATION Torque Converter 1 Pump impeller 2 Turbine liner 3 Stator 4 Lock-up damper 5 One-way clutch 6 Front converter cover 7 Lock-up piston • The torque converter transfers engine torque to the transmission. It transmits engine torque by means of oil when it is not in a lock-up condition, and it transfers power via the lock-up piston when it is in a lock-up condition.
Page 237 Oil Pump 1 Driven gear 2 Crescent 3 Drive gear 4 Oil pump body 5 Outlet port 6 Inlet ports P29830 • Feature ..The oil pump gears have a small number of gear teeth and features a special high-performance tooth profile.
Page 238 STRUCTURE AND OPERATION Operation Error Protection Device 13990 31559 23-36...
Page 239 1 Key interlock solenoid 10 Automatic transmission reverse 18 Key interlock electronic control 2 Starter switch buzzer unit 3 Automatic transmission knob 11 Shift lock link 19 Automatic transmission elec- 4 Shift button 12 Shift lock release knob tronic control unit 5 Overdrive OFF switch 13 P range switch 20 Backup lamp relay...
Page 240 STRUCTURE AND OPERATION P shift lock device • With selector lever 6 in the P range, when the elec- tric current (see the table below) supplied to shift lock actuator 9 sets the shift lock actuator in lock position A, pin 7 is restrained by shift lock link 11 and disallows pressing of shift button 4.
Page 241 Selector lever reverse position warning device When starter switch 2 is ON, moving selector lever 6 to the R (reverse) range activates the reverse position detecting switch (inhibitor switch: built into automatic transmission) and turns on automatic transmission re- verse buzzer 10 to warn the driver that the selector lever is in the reverse position.
Page 242 TROUBLESHOOTING PROCEDURES Automatic transmission problems can be caused by the following malfunctions. • Engine malfunction • Improperly adjusted parts • Faulty hydraulic system • Faulty mechanical functions • Faulty electrical system When diagnosing the above abnormalities, be sure to inspect the following basic items. •...
Page 243 Types of Self-Diagnosis The following two types of self-diagnosis function can be selected. Self-diagnosis Using diagnosis switch Using MUT-II Disconnect the diagnosis switch Data list function (plug connector) to indicate mal- Flight recorder function function codes. Data of malfunctions stored in Connect the MUT-II to the automatic the memory can be deleted with transmission electronic control unit via...
Page 244 TROUBLESHOOTING Using diagnosis switch to recall diagnosis codes and using memory clear switch to delete diagnosis codes The diagnosis switch is used for the analysis of malfunction, and the memory clear switch allows deletion of stored diagnosis codes. Recalling diagnosis code Õ P23-42 •...
Page 245 Procedure for reading diagnosis codes Code “1-2” is indicated as follows • The automatic transmission electronic control unit’s memory is 2nd-time indication stored with the data of all malfunctions that occurred after the previous self-diagnosis operation. • The warning lamp turns off for 2.4 seconds after the self-diagnosis operation starts, then indicates a code.
Page 246 TROUBLESHOOTING Diagnosis Code Chart Diagnosis Problem location Judgement criterion Fail-safe measure code Normal Power supply voltage Power supply voltage remains below 7.5 V for 1 second or longer with range selector in a position other than P or N range. Vehicle speed sensor 1 •...
Page 247 Diagnosis Code Chart Diagnosis Problem location Judgement criterion Fail-safe measure code Inhibitor switch • No signal Operates as D range and prohibits shifting to 4th gear. • Two or more signals • Control function activates based on priority order of L > R > 2 > D > N (P). •...
Page 248 TROUBLESHOOTING Procedure for servicing with MUT-II 0 Special tools Location Tool name and shape Part No. Application — MUT-II MB991496 19492 — MUT-II harness MK327601 System inspection 19141 — ROM pack (MRT-E8.1) MH063580 19493 Connecting the MUT-II • Turn the starter switch to the LOCK position. •...
Page 249 Inspection using MUT-II The MUT-II indicates diagnosis codes that provide information of malfunctioning items (devices that require inspection). The MUT-II indicates sensor signal conditions with numerical values (service data). Comparison of the service data with judgement criteria allows evaluation of the transmission operation. Diagnosis codes and service data codes can be effectively used for troubleshooting.
Page 250 TROUBLESHOOTING Indicated by MUT-II Indicated by MUT-II Inspection procedure Malfunctioning item Service Diagno Service Judgement (devices that require data Signal name Inspection condition data criterion -sis code inspection) code Driving in 1st and 2nd gears SHIFT VALVE 1 SHIFT VALVE 1 Driving in 3rd and 4th gears Driving in 2nd and 3rd gears SHIFT VALVE 2...
Page 251 Indicated by MUT-II Indicated by MUT-II Inspection procedure Malfunctioning item Service Diagno Service Judgement (devices that require data Signal name Inspection condition -sis code data criterion inspection) code Closed throttle PWM SIG. < Except PWM PERCENT Accelerator pedal pressed gradually Continuous increase FE640 >...
Page 252 TROUBLESHOOTING Symptoms and problems Malfunction Abnormal Abnormal shift operation movement Suspected problem factor Automatic transmission fluid level and condition Control linkage Inhibitor switch Accelerator sensor Vehicle speed sensor Engine speed sensor Engine idle speed Line pressure Shift solenoid 1 Shift solenoid 2 Timing solenoid Lock-up solenoid Starter circuit...
Page 253 Malfunction Slippage Others Excess shock during shifting Suspected problem factor Automatic transmission fluid level and condition Control linkage Inhibitor switch Accelerator sensor Vehicle speed sensor Engine speed sensor Engine idle speed Line pressure Shift solenoid 1 Shift solenoid 2 Timing solenoid Lock-up solenoid Starter circuit Overdrive OFF switch...
Page 254 • Conduct tests in the same way with the range selector lever in each of the 2, L and R ranges. • Stall speed FE 639 1810±150 rpm FE 649, FG 639 1890±150 rpm FE 640 2070±150 rpm Diagnosis of test result...
Page 255 Time Lag Test Purpose To check the conditions of overdrive direct clutch, front clutch, rear clutch and 1st and reverse brake. Measuring procedure • Bring the oil temperature to normal operating level of between 50 and 80°C {122 and 176°F}. •...
Page 256 ON-VEHICLE INSPECTION AND ADJUSTMENT Line Pressure Test Purpose To check the oil pump capacity, control valve functions and leaks in hydraulic circuit. Measuring procedure CAUTION – The line pressure test requires two persons. One person must observe tire movement and wheel chocks from outside the vehicle, while the other person conducts the test.
Page 257 Diagnosis of test result Measuring result Suspected abnormality Faulty adjustment of throttle cable Higher than standard Sticking of regulator valve value in all ranges Sticking of throttle valve Faulty adjustment of throttle cable Sticking of regulator valve Lower than standard Sticking of throttle valve value in all ranges Excessive wear of oil pump...
Page 258 ON-VEHICLE INSPECTION AND ADJUSTMENT Road Test Measuring procedure Before the road test, check the level and condition of the auto- matic transmission fluid. Also make sure that the range selector cable and the accelerator control cable are properly adjusted. Operate the automatic transmission in every range position dur- ing the road test and check slippage and other operating condi- tions during shifting of gears.
Page 259 Lock-up vehicle speeds < FE6 9 > Unit : km/h {mph} Throttle opening Shifting Vehicle speed 3rd gear ON (Overdrive ON) 48.09 to 50.56 {29.9 to 31.4} Half throttle 3rd gear ON (Overdrive OFF) 53.03 to 55.49 {33.0 to 34.5} 4th gear ON 56.38 to 58.85 {35.0 to 36.6} 3rd gear ON...
Page 260 ON-VEHICLE INSPECTION AND ADJUSTMENT Inspection of Automatic Transmission Fluid (ATF) If the automatic transmission has insufficient ATF, the pump draws air together with ATF. Air bubbles mixed in the ATF cause a “sponge” effect and lower the pressure. This can cause slipping of internal clutches. On the other hand, if the ATF level is too high, excess air bubbles also result when rotating parts agitate the ATF, thus causing the same effect as when the ATF level is low.
Page 261 Changing Automatic Transmission Fluid (ATF) (1) Drain • Place an ATF receiving tray under the automatic transmission oil pan. Remove the drain plug located at the back side of the pan to drain ATF. Tightening torque: 27 N m {20 ft.lbs, 2.8 kgf •...
Page 262 REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY Preparation Removal sequence 1 Exhaust pipe ^ Gr 15 2 Selector cable Õ P23-76 3 Electrical harness 4 Propeller shaft ^ Gr 25 5 Parking brake ^ Gr 36 6 Oil cooler hose Õ P23-66 7 Speedometer cable CAUTION –...
Page 263 Removal Removal sequence 1 Bolt 2 Bolt 3 Dust cover 4 Bolt (8) 5 Bolt 6 Bolt Ê Ê 7 Bolt (4) 8 Drive plate 9 Automatic transmission as- sembly 1 Ê A : Torque converter 4 Ê B : Flywheel C : Pilot section Ê...
Page 264 REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY Service procedure Automatic transmission assembly [Removal] • Remove dust cover 3. 07934 • Turn the engine so that bolt 4 is positioned at service window D. • Remove eight bolts 4. Remove two bolts at each of the four loca- tions by turning the engine and stopping at the proper position.
Page 265 • Check to make sure that torque converter A is properly mounted in 40 mm {1.57 in.} or more automatic transmission assembly 9. When the torque converter is properly installed, the distance between the surface of drive plate 8 and the case mounting surface is as indicated in the diagram.
Page 266 REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY • Align the bolt holes of drive plate 8 and flywheel B by looking through service hole D, and mount bolts 4. • Temporarily tighten all eight bolts, two bolts at each of the four loca- tions, by turning the engine and stopping at the proper position.
Page 267 M E M O 23-65...
Page 268 OIL COOLER Ê20 23Ê Ê22 Ê 3 6 Ê 3 4 1 3 Ê Ê 3 Ê Ê- Ê11 P31017 Removal sequence 10 Automatic transmission fluid 18 Oil cooler front support 1 Hose clamps thermostat switch 19 Oil cooler rear support 2 Rubber hoses 11 Plug 20 Bolt...
Page 269 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Operating temper- When rising (OFF→ON) 97±3°C {207±5.4°F} — Replace ature of automatic transmission fluid When falling (ON→OFF) 90°C {194°F} MIN thermostat switch Thermostat valve Starting operation 76.5±3°C {170±5.4°F} —...
Page 270 OIL COOLER Service procedure Inspection of automatic transmission fluid thermostat 97±3°C {207±5.4°F} switch Carry out the following inspection and replace automatic transmission 90°C {194°F} MIN fluid thermostat switch 10 if there are any faults. • Check that there is no continuity between terminals ambient temperature of 20±5°C {68±9°F}.
Page 271 M E M O 23-69...
Page 272 AUTOMATIC TRANSMISSION CONTROL Range Selector Lever 4 Ê Ê 15 - Ê 14 - Ê 10 Ê Ê 19 Ê Ê Ê Ê Ê P31504 23-70...
Page 273 Disassembly sequence 18 Indicator panel 34 Pin 1 Nut 19 Bolt 2 Shift lock release knob 35 Ball spring 3 Adapter 20 Shift lock actuator 36 Ball support 21 Automatic transmission 37 Steel ball 4 Screw reverse buzzer 5 Screw 38 Selector lever 22 Ball joint 6 Range selector lever cover...
Page 274 AUTOMATIC TRANSMISSION CONTROL Service procedure Removal of connector Using screwdriver A, pull out terminal B of overdrive OFF switch 12 from the inside of connector 7 and remove the connector. 07625 Switch button, overdrive OFF switch [Removal] • Using screwdriver A, remove switch button 11 from overdrive OFF switch 12.
Page 275 Other loads Inspection of shift lock actuator Brake switch Power supply Switch Operating mode P-range switch Brake P range Unlock Lock ←      Lock Unlock 07489 Check to make sure that shift lock actuator 20 is in operating mode under the above power supply and switch position.
Page 276 AUTOMATIC TRANSMISSION CONTROL P-range switch [Inspection]  : There is continuity between terminals Replace P-range switch 40 if it is faulty. 07630 [Installation] Install P-range switch 40 so that it is OFF when the range selector lever is in the P range. 23-74...
Page 277 Lever Assembly Disassembly sequence 1 Nut Ê 2 Clip 3 Nut 4 Nut 5 Spacer (for adjustment) 6 Bushings 7 Lever 8 Collar 9 Lever bracket Ê 1 Ê *a : Range selector lever Õ P23-70 *b : Selector cable Õ P23-76 Assembly sequence →5 →*b→2...
Page 278 AUTOMATIC TRANSMISSION CONTROL Ê 8 Ê Ê 6 11 Ê P31143 23-76...
Page 279 Removal sequence A : To range selector lever 1 Clip 8 Nut 2 Nut 9 Bushing *a : Automatic transmission unit 3 Selector cable 10 Lever *b : Transmission control shift lever 4 Insulator 11 Nut Õ P23-80 5 Bracket 12 Bracket 6 Nut 13 Bracket...
Page 280 AUTOMATIC TRANSMISSION CONTROL • Shake automatic transmission lever knob B back and forth. P29852 • Check to make sure that automatic transmission lever knob B is in the D range, and tighten nuts A on selector cable 3 to the specified torque. P29853 •...
Page 281 M E M O 23-79...
Page 282 REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS Ù Ê Ê Ê - Ù Ê Ù Ù Ê 15 Ê 7 Ê Ù Ù Ù 5 Ê Ê Ê Ê Ê P45140 Removal sequence 1 Drain plug 14 Inhibitor switch 27 Bolt 2 Bolt 15 Nut 28 Speedometer sleeve lock plate 3 Oil pan...
Page 283 Service standards Location Maintenance item Standard value Limit Remedy 560 to 680 Ω Speed sensor resistance (at normal temperature) — Replace OFF→ON 143 to 151°C {289 to 304°F} Oil temperature switch — Replace activating temperature ON→OFF Approximately 125°C {257°F} Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened...
Page 284 REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS 0 Special tools Location Tool name and shape Part No. Application Oil seal installer MH063608 Installation of oil seal P29857 Service procedure Oil pan [Removal] • Remove bolts 2. CAUTION – To prevent oil pan 3 from dropping when separating the sealant from the oil pan, keep several bolts (not tightened) mounted at intervals of three bolt holes.
Page 285 Inspection of speed sensor • Measure the resistance between the connector terminals shown in the diagram. If the measured value deviates from the standard value, the connector is defective. • Standard resistance between terminals: 560 to 680 Ω (at normal temperature) P29859 Inhibitor switch...
Page 286 REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS Oil temperature switch 143 to 151°C {289 to 304°F} Place oil temperature switch assembly 19 in a container filled with water. Vary the temperature of the water, and check to make sure that Approximately 125°C {257°F} the switch operates (ON and OFF) at the specified temperatures.
Page 287 Installation of oil seal < FE > CAUTION – After the oil seal 25 is removed, clean the surface of the extension housing of automatic transmission unit *a to which oil seal is mounted. • Apply grease on the lip section of oil seal 25.
Page 288 INSPECTION AND ADJUSTMENT OF OTHER DEVICES P45143 1 Automatic transmission fluid cooler fan relay 2 Accelerator sensor Service standards Location Maintenance item Standard value Limit Remedy Minimum relay operating voltage 11 V or higher — Replace Service procedure Inspection of relay (constant-open type, 4-pin) 1 2 3 4 Remarks Electric current not supplied...
Page 289 Accelerator sensor < Except FE640 > Initial voltage data storage When accelerator sensor 2 is dismounted or replaced, it is neces- sary to save the initial voltage value (full throttle) in the automatic transmission electronic control unit memory. Check items •...
Page 290 LOCATIONS OF PARTS 1 Starter switch (key interlock solenoid installed) < Transfer > 2 Meter cluster < Automatic transmission > < View A > < View C > 3 Fuse box < 4M5 > < 4D3 > 4 Engine electronic control unit 5 Pulse divider 6 Diode 7 Multi-use tester II connector...
Page 291 ELECTRICAL WIRING DIAGRAM < 4D3 > 44415 23-91...
Page 292 ELECTRICAL WIRING DIAGRAM < 4M5 > 44415 23-93...
Page 293 Group 24 Transfer ' 98 Minor Change Pub No. TWSE0101-24...
Page 294 INDEX SPECIFICATIONS ................24- 2 STRUCTURE AND OPERATION ............ 24- 2 TROUBLESHOOTING ..............24- 4 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY ..24- 6 FRONT DRIVE ................. 24- 10 IDLER GEAR AND REAR DRIVE ........... 24- 16 TRANSFER CONTROL ..............24- 22...
Page 295 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Model Gear ratio HIGH 1.090 1.987 Gear oil Oil quantity L {qts.} 3.0 {3.2} Dry mass (including transmission body) kg {lb} Approximately 190 {420} Control Front drive and HIGH-LOW switching floor change remote control STRUCTURE AND OPERATION Transfer Body 1 Transmission main shaft...
Page 296 The transfer functions as both the distributer for four-wheel < Manual transmission > drive and as the sub-transmission with a reduction device. This transfer is a three-shaft constant-mesh type. HIGH/LOW changeover and front drive ON/OFF are control- led by a transfer control lever in the cab. To front axle To rear axle HIGH...
Page 297 TROUBLESHOOTING Symptoms Possible causes Front drive shaft and constant sleeve splines worn Hub and HIGH/LOW constant sleeve splines worn Idler shaft bearing worn or damaged Output shaft bearing worn or damaged Drive shaft needle bearing worn or damaged Transfer Gears damaged body faulty Output shaft LOW gear and HIGH gear backlash excessive...
Page 298 M E M O 24-5...
Page 299 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY < Manual transmission > Ê Ù Ù Ê Ê Ù Ù Ê Ù 27275 Ê Ê Ù < Automatic transmission > Ê Ê 18 - Ù Ê Ù 19 - Ù P41139 Disassembly sequence 10 Oil seal <...
Page 300 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 7, 14 Drive shaft gear and transfer idler gear backlash 0.08 to 0.22 {0.0031 to 0.0087} 0.50 {0.020} — Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque...
Page 301 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY Service procedure Installation of needle bearing 0 : Needle roller bearing installer 06399 Removal and installation of lock nut 0 : Socket wrench 06400 Installation of oil seal Apply grease to lip area A of oil seal 10, and press-fit it. 0 : Oil seal installer 06401 24-8...
Page 302 M E M O 24-9...
Page 303 FRONT DRIVE Ê 3 Ù Ê ÙÊ Ê Ê8 Ê 9 1Ê Ê Ù - Ê 5 Ù 16 Ê15 Ê Ù 41442 Disassembly sequence 1 Bolt 14 Interlock ball 29 Synchronizer sleeve 2 Shift rail cover 15 Lock nut 30 Front drive shift fork 3 Bolt 16 O-ring...
Page 304 NOTE HIGH and LOW shift rail 12 cannot be disassembled unless front drive shift rail 32 is set to front drive ON. Assembly sequence 40→39→38→37→36→35→34→33 → 25 32→31→30→28→27→26 ↑ →18→17→16→15→14→10 13→12→11 →9→8→7→6→5→4→3→2→1 24→23→22→21→20→19 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit...
Page 305 FRONT DRIVE - Lubricant and/or sealant Location Points of application Specified lubricant and/or sealant Quantity Mounting surface of transfer assembly transfer case side cover THREEBOND 1215 As required Thread area of screw plug THREEBOND 1215 As required Thread area of screw plug THREEBOND 1215 As required Thread area of pierce bolt...
Page 306 Service procedure Removal and installation of set bolt Tighten shift fork mounting set bolt 11, 25 at specified torque, and stake the thread area at three points using a punch. 06405 Inspection of shift rail If the measured value is higher than the limit, correct or replace shift rails 12, 32.
Page 307 FRONT DRIVE Installation of oil seal Apply grease to lip area A of oil seal 23, and press-fit it. 1 : Bearing installer 2 : Differential bearing inner race installer adapter 06409 Installation of oil seal Apply grease to lip area A of oil seal 39 and press-fit it into transfer assembly 40.
Page 308 M E M O 24-15...
Page 309 IDLER GEAR AND REAR DRIVE 1Ê Ù 27Ê-Ù Ù 9 Ê - Ù Ê Ù Ù Ù Ê Ê Ù - 45212 Disassembly sequence 1 1st/reverse check switch < Manual transmission > 20 Thrust washer 2 Dust plug < Manual transmission > 21 Rear drive shaft HIGH gear 3 Bolt 22 Needle bearing...
Page 310 NOTE • Check backlash and end play of gears before disassembly. • Do not remove needle bearing 24 from rear drive shaft 17 unless it is faulty. Assembly sequence 33→34 →30→29→28→27 36→35 →19→18→13→12→24 32→31 →9→2→1 17→23→26→25→16→15→14→22→21→20 8→7→6→5→4 →3 11→10 NOTE •...
Page 311 IDLER GEAR AND REAR DRIVE - Lublicant and/or sealant Location Points of application Specified lublicant and/or sealant Quantity Friction surfaces between speedometer gear and speedometer Molybdenum disulfide grease As required gear bushing Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required Thread area of bolt THREEBOND 1104J As required...
Page 312 Service procedure Inspection before service Starting torque of transfer idler gear • Disassemble parts, and measure the torque with push gauge A leaving only transfer idler gear 33 in transfer case. If the value deviates from the standard value, adjust it using shim •...
Page 313 IDLER GEAR AND REAR DRIVE Installation of speedometer gear bushing Due to its eccentric center arrangement, speedometer gear bushing 8 allows replacement of speedometer gear 5 with gears having a different number of teeth by changing only the installation direction, the worm gear does not have to be changed.
Page 314 MPRUV Play of rear drive shaft gear in diameter direction after assembly If the measured value is higher than the limit, replace faulty parts. NOTE When replacing needle bearing 22, 26, use bearings from the same color package. 01149 Installation of needle bearing 0 : Needle roller bearing installer 06420 24-21...
Page 315 TRANSFER CONTROL Control Cable < Removal from the transfer side > Work before removal Õ P24-22 Ê Ê Removal sequence 2 Ê 1 Bolt 2 Nut 3 Nut 4 HIGH/LOW control cable 5 2H/4H control cable 6 Shift rail cover *a : Transfer body *b : HIGH/LOW shift rail *c : Front drive shift rail...
Page 316 HIGH/LOW, 2H/4H Control Cable [Removal] • Remove bolt 1 securing shift rail cover 6. 27281 • Remove shift rail cover 6, and then remove inner cable A of HIGH/ *b, *c LOW and 2H/4H control cables 4 and 5, from HIGH/LOW shift rail *b, *b, *c and front drive shift rail *c.
Page 317 TRANSFER CONTROL • Screw nut 3 into shift rail cover 6 and tighten it to the specified torque. 2 mm CAUTION– {0.079 in.} • Ensure that the HIGH/LOW and four-wheel / two-wheel drive control cables are not positioned incorrectly. The cable with the white line C is for HIGH/LOW. •...
Page 318 M E M O 24-25...
Page 319 TRANSFER CONTROL Control cable < Removal from the transfer control cable side > Removal Sequence 1 Nuts 2 Bolt 3 Lock pin 4 Nuts 5 HIGH/LOW control cable 6 Nut 7 2H/4H control cable Ê Installation sequence Follow the removal sequence in reverse. Ê2 6Ê...
Page 320 Service procedure Adjustment after installation • Position shift lever A on position 4H. 27280 • Adjust the distance between the center of the steering wheel and 245 mm {9.65 in.} center of the shift lever knob A using the nuts 6. 27290 •...
Page 321 TRANSFER CONTROL Transfer Control Level Ê 17 Ê 2 Ê - 14 12 Ê 10 Ê 27292 Disassembly sequence 1 Pin 9 Spring 17 Shift lever knob 2 Nut 10 Bolt 18 Change lever assembly 3 Support holder 11 Conical spring 19 Bracket 4 Spring 12 Nut...
Page 322 Assembly sequence 15→14→13→11 22→21→20→19→10→12→8→7→6→5→4→3→2→1 ↑ 18→17→16→9  Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Spring load (installation 133 {5.24}) 46 N {10 lbf, 4.7 kgf} 41 N Replace {9 lbf,4.2 kgf} Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened...
Page 323 Group 25 Propeller Shaft ' 98 Minor Change Pub No. TWSE0101-25...
Page 324 INDEX SPECIFICATIONS ................25- 2 STRUCTURE AND OPERATION ............ 25- 3 TROUBLESHOOTING ..............25- 4 REMOVAL AND INSTALLATION OF PROPELLER SHAFT 25- 6 < Transmission, transfer to rear axle > ............25- 7 < Front axle to transfer > ................REAR PROPELLER SHAFT 25- 8 <...
Page 325 SPECIFICATIONS Model Item Pipe Outer diameter×Wall thickness mm {in.} 6.35×2.6 {2.50×0.10} 63.5×3.5{2.50×0.14} 82.6×2.3 {3.25×0.091} Universal joint Spider outer diameter mm {in.} 19 {0.75} 21 {0.83} Needle bearing Outer diameter mm {in.} 2.5 {0.098} 3 {0.12} Length mm {in.} 13 {0.51} 15.3 {0.60} Slip yoke joint Spline diameter...
Page 326  Parking brake drum  Center bearing   Front axle  Rear axle  < FE >  Rear propeller shaft   Front propeller shaft    A : Single-shaft connection at rear B : Twin-shaft connection at rear ...
Page 327 TROUBLESHOOTING Propeller shaft Symptoms Noise from propeller vibrating shaft Possible causes Flange yoke assembly direction incorrect Companion flange tightening torque excessive Greasing insufficient Slip yoke joint Spline play excessive Clearance in spider axial direction excessive Universal joint Needle bearing greasing insufficiently Needle bearing worn Greasing insufficient Center bearing...
Page 328 M E M O 25-5...
Page 329 REMOVAL AND INSTALLATION OF PROPELLER SHAFT < TRANSMISSION, TRANSFER TO REAR AXLE> 4 Ê Ù 5 Ê Ù Ê Ù Ù Ê 1 05199 Service procedure Work before removal WARNING– • Since the propeller shaft will be removed, the parking brake cannot be used.
Page 330 REMOVAL AND INSTALLATION OF PROPELLER SHAFT < FRONT AXLE TO TRANSFER > 2 Ê Ù Ù Ê 1 05399 Service procedure Work before removal WARNING– • Since the propeller shaft will be removed, you must chock the wheels securely so the vehicle does not move. •...
Page 331 REAR PROPELLER SHAFT < P2 : FG639 > Ù Ù 03155 Disassembly sequence 1 Snap ring 5 Spider 9 Slip yoke joint 2 Needle bearing 6 Retainer packing 10 Rear propeller shaft 3 Flange yoke 7 Sealed packing 4 Grease nipple 8 Grease nipple Ù...
Page 332 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Universal joint tool set MB999024 A : Yoke assembly A : MB999025 Removal and installation of needle bearing B : Push rod B : MB999026 C : Guide C : MB999010 (Obtain Locally)
Page 333 REAR PROPELLER SHAFT < P2 : FG639 > Needle bearing [Removal] • Put alignment marks on needle bearing 2 and spider 5. • Put alignment marks on flange yoke 3 and slip yoke joint 9 and propeller shaft 10. 0 : Universal joint tool set 9, 10 03207 [Press-fitting]...
Page 334 Supply of grease via grease nipple Pack grease via grease nipple 8 until grease starts overflowing from dust plug A of slip yoke joint 9. 03213 Play between slip yoke joint and rear propeller shaft spline • Measure play A in the rotation direction between slip yoke joint 9 and rear propeller shaft 10 at the spline area.
Page 335 REAR PROPELLER SHAFT < P2 : FG649 > Ù Ù 05185 Inspection before disassembly Õ P25-13 Disassembly sequence 1 Snap ring 5 Spider 9 Rear propeller shaft 2 Needle bearing 6 Slip yoke joint 3 Flange yoke 7 Sealed packing Ù...
Page 336 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Universal joint tool set MB999024 A : Yoke assembly A : MB999025 Removal and installation of needle bearing B : Push rod B : MB999026 C : Guide C : MB999010 (Obtain Locally)
Page 337 REAR PROPELLER SHAFT < P2 : FG649 > [Installation] B : Drift 03217 Needle bearing [Removal] • Put alignment marks on needle bearing 2 and spider 5. • Put alignment marks on flange yoke 3 and slip yoke joint 6. 0 : Universal joint tool set 03207 [Press-fitting]...
Page 338 Installation of sealed packing Install sealed packing 7 onto propeller shaft 9 in the direction illustrated until it is flush with the propeller shaft. 02691 Supply of grease via grease nipple Pack grease via grease nipple 8 until grease starts overflowing from dust plug A of slip yoke joint 6.
Page 339 REAR PROPELLER SHAFT < P3 > Ù 1 Ù Ù 05321 Inspection before disassembly Õ P25-17 Disassembly sequence 1 Snap ring 5 Grease nipple 9 Grease nipple 2 Shim 6 Spider 10 Slip yoke joint 3 Needle bearing 7 Retainer packing 11 Rear propeller shaft 4 Flange yoke 8 Sealed packing...
Page 340 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Universal joint tool set MB999024 A : Yoke assembly A : MB999025 Removal and installation of needle bearing B : Push rod B : MB999026 C : Guide C : MB999010 (Obtain Locally)
Page 341 REAR PROPELLER SHAFT < P3 > Clearance between needle bearing and spider Measure the play towards the diameter direction between needle bear- ing 3 and spider 6. If the measured value is higher than the limit, replace with universal joint spider kit. 00231 Installation of retainer packing and sealed packing •...
Page 342 Play between slip yoke joint and rear propeller shaft spline • Measure play A in the rotation direction between slip yoke joint 10 and rear propeller shaft 11 at the spline area. If the measured value is higher than the limit, replace the faulty parts. •...
Page 343 FRONT PROPELLER SHAFT 7 Ê Ù 03039 Inspection before disassembly Õ P25-21 Disassembly sequence 1 Snap ring 7 Nut 13 Center bearing assembly 2 Shim 8 Disc spring 14 Front propeller shaft 3 Needle bearing 9 Companion flange 4 Flange yoke 10 Holder Ù...
Page 344 - Lubricant Location Points of application Kinds Quantity Supply via grease nipple Wheel bearing grease [NLGI No.2 (Li soap)] Pack until grease overflows from needle bearing oil seal Pack interior of center bearing assembly Bearing grease [NLGI No.3 (Li soap)] 70 to 100% of capacity (20 to 29 g)
Page 345 FRONT PROPELLER SHAFT [Press-fitting] 03208 Clearance between needle bearing and spider Measure the play towards the diameter direction between needle bear- ing 3 and spider 6. If the measured value is higher than the limit, replace with universal joint spider kit. 00231 Installation of disc spring Install disc spring 8 with its convex side A facing nut 7.
Page 346 Greasing center bearing assembly • Inspect the center bearing assembly for leaking grease every 50000 km {31000 miles} or at regular safety inspection. If a substantial grease leak is found, pack grease into housing A. • Apply grease to seal lip area B. NOTE Bearing does not require greasing because it is sealed.
Page 347 BALANCING PROPELLER SHAFT (1) After correcting propeller shaft deflection or replacing the flange yoke, universal joint, or related parts, measure the balance of the completed propeller shaft assembly on a balancing machine and attach balance weights as required to correct amount of imbalance to within the permissible range. (2) Use the polar coordination method to correct dynamic balance.
Page 348 • Available balance weights Mass (g {oz}) Radius (mm {in.}) Appropriate propeller shaft 2 {0.071} 31 {1.22} A, B 4 {0.14} 31 {1.22} 33 mm {1.3 in.} 31 mm {1.22 in.} in radius 6 {0.21} 31 {1.22} in radius 8 {0.28} 31 {1.22} P2 <...
Page 349 Group 26A Front Axle ' 98 Minor Change Pub No. TWSE0101-26A...
Page 350 INDEX SPECIFICATIONS ................ 26A- 2 STRUCTURE AND OPERATION ..........26A- 2 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 26A- 4 • Adjustment of Wheel Alignment ............26A- 7 • Adjustment of Steering Angle ............... 26A- 7 • Measurement of Side Slip ..............WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE..
Page 351 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Vehicle model FE639 FE649, FE640 Item Front axle Model F020T F035T Type I section, reverse Elliot type Outer diameter × Length mm {in.} Kingpin 28×180 {1.10×7.09} Tread mm {in.} 1665 {65.6} Mass kg {lb} Approximately 125 {275} Approximately 155 {340} STRUCTURE AND OPERATION Front Axle, Knuckle and Kingpin...
Page 352 Wheel Hub and Rotor 45194 1 Hub bolt 6 Wheel speed sensor 11 Lock nut 2 Wf~’l hub 7 Spacer 12 Hub cap 3 Disc brake assembly 8 Inner bearing 13 Outer bearing 4 Rotor 9 Disc Rotor * : Brake pad wear indicator 5 Oil seal 10 Washer 26A-3...
Page 353 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Adjustment of Wheel Alignment Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Wheel Toe-in (with tires on the ground) 0 to 6 {0 to 0.24} — — alignment Camber 1°00'±30' —...
Page 354 • Align the two points of toe-in gauge B to the respective marks A on the front tires. Measure the distance C between the marks at the front of the vehicle. 00888 • Rotate the tires 180° and measure the distance D between the ↑...
Page 355 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE • While keeping the bubble in level J centered, measure the camber angle by reading the scale mark at the center of the bubble on camber scale K. Follow this procedure to measure the camber angles on the left and right sides.
Page 356 Adjustment of Steering Angle Service standards Location Maintenance item Standard value Limit Remedy — Steering angle Inside (Outside : reference) 42° (33°) — Adjust Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Lock nut (Knuckle stopper bolt fastening) 46.5±7 {34±5.4, 4.75±0.75} —...
Page 357 WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE 14096 Work sequence before removal 1 Place wheel chocks. 2 Disconnect the negative battery cable. ^ Gr 54 3 Jack up the front axle with a garage jack. 4 Support the front frame on jack stands. WARNING–...
Page 358 M E M O 26A-9...
Page 359 WHEEL HUB AND ROTOR 30 Ê < FE639 > 23 Ê Ê 4 Ê 7 Ê 27 - 11 Ê Ù Ê Ê 9 Ê Ê 4 Ê < FE639 > < FE649, FE640 > Ê < FE649, FE640 > 24 Ê...
Page 360 Assembly sequence Follow the disassembly sequence inreverse. WARNING– • Do not allow oil or grease to adhere on the pad surface of disc brake assembly 12 or the rotor surface of wheel hub and rotor assembly 17 or rotors 25. •...
Page 361 WHEEL HUB AND ROTOR - Lubricant Location Points of application Kinds Quantity Pack wheel hub cap FE639 Wheel bearing grease [NLGI No.2 (Li soap)] 65±10 g {2.29±0.35 oz} FE649, FE640 Wheel bearing grease [NLGI No.2 (Li soap)] 90±10 g {3.17±0.35 oz} 16, 20 Pack the space between rollers of outer bearing inner race Wheel bearing grease [NLGI No.2 (Li soap)] As required...
Page 362 Service procedure Starting torque of wheel hub bearing 14 16 [Adjustment] • Tighten lock nut 14 at specified torque (primary tightening) while turning wheel hub and rotor assembly 17. Then, slacken off. • Turn wheel hub and rotor assembly 17 several times to smooth operation of outer bearings 16 and 22, and inner bearings 20 and 21, and retighten lock nut 14 at specified torque (secondary tighten- ing).
Page 363 WHEEL HUB AND ROTOR Wheel speed sensor [Removal] To prevent damaging pole piece A in wheel speed sensor 6, remove the wheel speed sensor before removing wheel hub and rotor assembly 17. 07677 [Installation] The connector of wheel speed sensor 6 is color-coded. Install the wheel speed sensors to the proper wheels according to the following table.
Page 364 Inspection of open circuit in harness To check the harness for an open circuit, disconnect the harness clamp from the vehicle side, then bend and pull harness at the clamp to checkk if a momentary open circuit results. Also inspect the termi- nal contact conditions in the connector.
Page 365 WHEEL HUB AND ROTOR Removal and installation of lock nut Refer to adjustment of the starting torque of the wheel hub bearing. Õ P26A-13 12117 Packing grease in outer bearing inner race and inner bearing inner race 16, 20 A : Grease pump nozzle B : Between rollers 01000 Rotor...
Page 366 Installation of oil seal Apply grease to lip area A of oil seal 19 and press-fit it. 12118 Inner bearing outer race [Removal] Drive out inner bearing outer race 21 from the two indented parts A in wheel hub 27. B : Pin-punch 12119 [Installation]...
Page 367 WHEEL HUB AND ROTOR Installation of hub bolt Hub bolt 26 is marked with “L” (left) or “R” (right) to indicate the side it is to be installed on. Check this symbol before installing the bolt. “L”, “R” 05490 26A-18...
Page 368 FRONT AXLE, KNUCKLE AND KINGPIN Ù Ê11 Ê Ê11 Ê Ê Ù Ê Ù Ê Ê 12123 Disassembly sequence 1 Split pin 14 Key 27 Grease nipple 2 End plug 15 Knuckle arm 28 Dust seal 3 Ball seat 16 Nut 29 Kingpin bushing 4 Drag link ^ Gr 37 17 Key...
Page 369 FRONT AXLE, KNUCKLE AND KINGPIN Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Kingpin outer diameter –0.020 27.9 {1.098} Replace [28] –0.053  –0.00079  [1.102]  –0.0021 Inner diameter of kingpin bushing +0.033 — Replace [28] (After press-fitting into knuckle)
Page 370 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Kingpin puller MB999013 A : Pipe A: MB999014 Removal of kingpin B : Bolt B: MB999015 C : Cap C: MB999016 ø47 {1.85} D : Nut D: MB999017 06102 ø30...
Page 371 FRONT AXLE, KNUCKLE AND KINGPIN • Install knuckle arm 15 after applying grease to thread area B. (Do not grease the taper surface of knuckle arm and knuckle 32.) • Tighten new nut 13 at specified torque. Without loosening the nut, insert split pin C into the pin hole to lock the nut.
Page 372 Kingpin shim, knuckle, and front axle [Inspection] • Assemble kingpin 23 and thrust bearing 25 temporarily, and turn knuckle 32 a couple of times to smooth its operation. • Measure the clearance between the upper surface of front axle 34 and the lower part of knuckle 32.
Page 373 FRONT AXLE, KNUCKLE AND KINGPIN Dust seal and kingpin bushing [Removal] When removing the upper part of kingpin bushing 29, remove dust seal 28 at the same time. 12124 [Installation] • Press-fit kingpin bushing 29 so that gap A between kingpin bushing 29 and knuckle 32 is within 0 to 1 mm {0 to 0.039 in.}.
Page 374 Inspection of front axle < Longitudinal > (1) Measurement of bend in front axle in longitudinal and vertical directions • Pass a piece of thread A through the kingpin hole of front axle 34 and hang weights B on both ends. •...
Page 375 Group 26B Front Axle ' 98 Minor Change Pub No. TWSE0101-26B...
Page 376 INDEX SPECIFICATIONS .................26B- 2 STRUCTURE AND OPERATION ..........26B- 2 TROUBLESHOOTING ..............26B- 6 ON-VEHICLE INSPECTION AND ADJUSTMENT 26B- 8 • Adjustment of Wheel Alignment ............26B- 12 • Adjustment of Steering Angle ..............26B- 13 • Measurement of Side Slip ............... WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE ................26B- 14 WHEEL HUB AND BRAKE DRUM ..........26B- 16...
Page 377 SPECIFICATIONS / STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Front axle Model F020TW Type Full floating type with birfield joint Tread Torque mm {in.} 1665 {65.6} Model D1H modified Type Single-reduction gear Reduction Tooth shape Hypoid gear Speed reduction ratio 5.714 Differential Tooth shape Straight bevel gear...
Page 378 Free-wheel Hub A — A 05602 • In the case of a four-wheel drive vehicle, even when it is running in rear-wheel drive only, the drive shaft *, differential, propeller shaft, and driving parts of the transfer front drive shaft continue to run due to transmission of rotation from the wheels.
Page 379 STRUCTURE AND OPERATION Axle, Knuckle, and Drive Shaft 12 11 26614 1 Tie rod arm 7 Oil seal 13 Trunnion bearing 2 Tie rod assembly 8 Boot band 14 Spacer 3 Knuckle arm 9 Dust boot 15 Needle bearing 4 Kingpin, upper 16 Axle shaft assembly 10 Retainer 5 Conical spring...
Page 380 Reduction and Differential 05607 1 Companion flange assembly 12 Differential pinion gear 2 Lock nut 13 Pinion shaft 3 Oil seal 14 Final drive gear 4 Front bearing 15 Bearing cap 5 Front bearing shim 16 Lock plate 6 Pinion spacer 17 Side bearing nut 7 Oil stopper 18 Side bearing...
Page 381 TROUBLESHOOTING Power transmission Symptoms incorrect Possible causes Front axle housing bent Drive shaft assembly bent Drive shaft assembly damaged Drive shaft assembly disengaged from differential gear spline Wheel hub, knuckle Birfield joint in drive shaft assembly faulty and drive shaft, and Kingpin bearing loose axle housing Knuckle bearing worn Oil seal faulty...
Page 382 TROUBLESHOOTING Power transmission Symptoms incorrect Possible causes Final drive gear backlash excessive Final drive gear backlash or tooth contact adjusted incorrectly Final drive pinion starting torque adjusted incorrectly Lock nut loose Differential gear backlash excessive Reduction and Front or rear bearing seized differential Front or rear bearing worn Front or rear bearing broken...
Page 383 ON-VEHICLE INSPECTION AND ADJUSTMENT Adjustment of Wheel Alignment Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Wheel Toe-in (with tires on the ground) 0 to 6 {0 to 0.24} — — alignment Camber 1°00'±30' —...
Page 384 • Align the two points of toe-in gauge B to the respective marks A on the front tires. Measure the distance C between the marks at the front of the vehicle. 00888 • Rotate the tires 180° and measure the distance D between the marks at the rear of the vehicle with the tires on the ground.
Page 385 ON-VEHICLE INSPECTION AND ADJUSTMENT (2) Measurement of camber • Point the front wheels exactly forward. • Remove cover assembly 5 and attach 0 alignment gauge adapter. Then, attach camber/caster kingpin gauge J. 05610 • While keeping the bubble in level K centered, measure the camber angle by reading the scale mark at the center of the bubble on camber scale L.
Page 386 • Unlock turning radius gauges M, and set the scale at 0°. • As in measuring camber explained previously, attach camber/caster kingpin gauge J tightly to the front wheel hub and keep the bubble centered. • Apply the brake to the front wheels and turn the steering wheel slowly from the 0°...
Page 387 ON-VEHICLE INSPECTION AND ADJUSTMENT Adjustment of Steering Angle Service standards Location Maintenance item Standard value Limit Remedy — Steering angle Inside (Outside : reference) 30° (29°) — Adjust Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Lock nut (Knuckle stopper bolt tightening)
Page 388 Measurement of Side Slip NOTE Be sure that wheel alignment is adjusted correctly before meas- uring side slip. • Point the front wheels exactly forward. • Maintain this position and slowly move vehicle forward, over side slip tester A, as slowly as possible. NOTE Make sure, when measuring side slip, that the wheels point exactly forward when the vehicle passes over side slip tester A.
Page 389 WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE 14096 Work sequence before removal 1 Place wheel chocks. 2 Disconnect the negative battery cable. ^ Gr 54 3 Jack up the front axle with a garage jack. 4 Support the front frame on jack stands. WARNING–...
Page 390 M E M O 26B-15...
Page 391 WHEEL HUB AND BRAKE DRUM Ê Ù Ê Ê Ê Ù Ù- Ê Ê Ê Ê -Ê - 18 3 Ê - 22 Ù5 Ù P45191 Disassembly sequence 1 Clip 19 Snap ring 36 Outer bearing race 2 Brake hose 20 Retainer 37 Nut 3 Screw...
Page 392 Assembly sequence *→49→48→47→46 →41→43→30→29→28→27→26→12→11→10→4→3→2→1 45→44→42 4 : 9→8→7→6→5 12 : 24→23→22→21→20→19→18→17→16→15→14→13 25 : Free-wheel hub assembly 30 : 38→39→29→37→36→35→34→33→32→31 WARNING– • You must bleed air from the brake system after installing the brake hose, failure to do so would cause the brake to malfunction.
Page 393 WHEEL HUB AND BRAKE DRUM - Lubricant and/or sealant Location Points of application Specified lubricant and/or sealant Quantity Contact surfaces of snap ring and knob Wheel bearing grease [NLGI No.2 (Li soap)] As required O-ring Wheel bearing grease [NLGI No.2 (Li soap)] As required Contact surfaces of knob and retainer Wheel bearing grease [NLGI No.2 (Li soap)] As required Contact surfaces of knob and cover...
Page 394 Unit : mm {in.} Location Tool name and shape Part No. Application ø92.5 ø60 {2.36} {3.64} *2 Bearing installer MB999069 (Obtain Locally) ø94.5 {3.72} 05621 ø71 ø51 {2.01} {2.80} *3 Bearing installer MB999099 (Obtain Locally) (T90ST26) ø88.5 {3.48} 05621 Service procedure Starting torque of wheel hub bearing [Adjustment] •...
Page 395 WHEEL HUB AND BRAKE DRUM Removal and installation of brake hose First remove brake hose 2 from bracket A (on the frame), then remove the brake hose from wheel brake B. For installation, follow this procedure in reverse. CAUTION– Make sure that brake hose 2 is not twisted when you install it. 05625 Removal of housing assembly Remove snap ring 10, and insert bolts 11 (to the same depth) into two...
Page 396 • If wheel hub and brake drum assembly 30 cannot be removed be- cause of stepped wear A in brake drum 40, remove the backing plate cover. Turn adjuster B in the opposite direction to the arrow on the backing plate to increase the clearance between the brake drum and brake shoe assembly C.
Page 397 WHEEL HUB AND BRAKE DRUM Outer bearing outer race [Removal] Drive out outer bearing outer race 36 evenly from three indented parts B in wheel hub 39. A : Pin-punch 05632 [Press-fitting] 1 : Bearing installer 2 : Bearing installer 05633 Installation of nut and hub bolt •...
Page 398 Measurement of resistance between terminals Measure resistance between the terminals of wheel speed sensor 42. If the measured value deviates from the standard value, replace the wheel speed sensor. 36326 Measurement of insulation resistance Measure resistance between body B and each terminal of wheel speed sensor 42.
Page 399 WHEEL HUB AND BRAKE DRUM • Using pliers, hold wheel speed sensor 42 at shaded section A in the diagram, and remove it by turning it slightly. CAUTION – • Do not hold wheel speed sensor 42 with pliers at positions other than shaded section A shown in the diagram.
Page 400 Installation of wheel speed sensor harness and clips Starting from the wheel brake side, secure the harness of wheel speed sensor 42 in place at white tape sections A using clips 43, while making sure that there is no interference, twisting or excessive sagging of the harness.
Page 401 KNUCKLE AND DRIVE SHAFT 7 Ê - Ê 1 12 - Ù Ê Ù Ê 10 - Ê 7 Ê 1 - 13 Ê - Ù Ù Ê 16 26619 Disassembly sequence 1 Nut 11 Kingpin, upper 21 Steering knuckle 2 Tie rod assembly ^ Gr 37 12 Knuckle arm 22 Boot band...
Page 402 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Deflection in drive shaft assembly (Inner shaft) 0.75 {0.030} or less 1.5 {0.059} Replace Play in axial direction of drive shaft assembly 0.4 {0.016} or less — Replace Birfield joint Starting torque of steering knuckle...
Page 403 KNUCKLE AND DRIVE SHAFT 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application ø70 {2.76} Bearing installer MB999097 (Obtain Locally) (T90ST30) ø84 {3.31} 05619 ø41 ø61 {1.61} {2.40} Bearing installer MB999101 (Obtain Locally) (T90ST25) ø78.5 {3.09} 05621...
Page 404 [Installation] Insert drive shaft assembly 6 into steering knuckle 21 with flat part C of the Birfield joint facing upwards. CAUTION– Be careful not to damage oil seal 26, when installing drive shaft assembly 6. 26620 Spacer and conical spring [Adjustment of pre-pressure in trunnion bearing] Assemble conical spring 9 and spacer 8 (thickness=3.2 mm {0.13 in.}) and temporarily tighten kingpin, upper 11 with assembly bolt 7 as illus-...
Page 405 KNUCKLE AND DRIVE SHAFT Installation of dust seal and dust boot Install dust boot 23 on kingpin ball yoke area A in axle housing 27. Then, mount dust seal 18 while widening its end part. CAUTION– Do not widen dust seal 18 too much. 05643 Assembly of steering knuckle Install kingpin, lower 15 into steering knuckle 21.
Page 406 Trunnion bearing outer race [Removal] A : Pin-punch 05647 [Press-fitting] 1 : Bearing installer 2 : Bearing installer 05648 Press-fitting of oil seal • Apply grease to lip area B of oil seal 26. • Press-fit oil seal 26 in the direction as illustrated so that the oil seal is level with the end of kingpin ball yoke A of axle housing 27.
Page 407 AXLE HOUSING Disassembly sequence 1 Inspection plug 2 Drain plug 3 Nut 4 Nut 5 Reduction and differential assembly Õ P26B-34 6 Nut 7 U-bolt nut 8 U-bolt 9 Front spring pad 10 Vent plug 11 Axle housing * : Propeller shaft ^ Gr 25 Ù...
Page 408 - Sealant Location Points of application Specified sealant Quantity Axle housing contact surface of vent plug THREEBOND 1104J or 1215 As required Reduction and differential assembly mounting surface of THREEBOND 1215 As required axle housing Service procedure Service operations before removal and after installation (1) Before removing any part, remove inspection plug 1 and drain plug 2 and drain the gear oil from axle housing 11.
Page 409 REDUCTION AND DIFFERENTIAL Ù -Ê 9 Ê Ù Ù Ù 1 Ê 4 Ê 05655 Work before disassembly Õ P26B-37 Inspection before disassembly Õ P26B-37 Disassembly sequence 1 Bolt 12 Pinion shaft 22 Rear bearing shim 2 Lock plate 13 Differential pinion 23 Final drive pinion 3 Side bearing nut 14 Differential gear...
Page 410 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Deflection of rear of final drive gear within 0.05 {0.0020} — — 10, 23 Backlash between final drive gear and final 0.15 to 0.20 — Adjust or drive pinion {0.0059 to 0.0078} replace...
Page 411 REDUCTION AND DIFFERENTIAL Unit : mm {in.} Location Tool name and shape Part No. Application ø56 {2.20} Bearing installer MB999079 Press-fitting of side bearing inner race ø46 {1.81} 05659 25.5 Pinion rear bearing MB999045 Removal of rear bearing inner race {1.00} remover {0.02}...
Page 412 Unit : mm {in.} Location Tool name and shape Part No. Application *2 Bearing installer adapter MB999105 Press-fitting of oil seal (Use in combination) (T90ST07) ø88 {3.46} ø50 05667 {1.97} ø57 {2.24} Bearing installer MB999100 (T90ST31) ø70 {2.76} 05668 26, 27 Press-fitting of front and rear bearing outer ø79 race (Press-fit in combination)
Page 413 REDUCTION AND DIFFERENTIAL (3) Backlash between differential pinion and differential gear Measure backlash between differential pinion 13 and differential gear 05673 (4) Tooth contact of final drive gear Apply red lead primer to the surfaces of three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times.
Page 414 [Measurement] • Measure final drive gear 10 backlash at three points on the circumfer- ence of the final drive gear. 06710 • If backlash deviates from the standard value, rotate left and right side < When backlash is too small > bearing nuts 3 and move final drive gear 10 as illustrated using 0 side bearing adjusting tool to adjust backlash.
Page 415 REDUCTION AND DIFFERENTIAL (4) Tooth contact of final drive gear [Inspection] Apply red lead primer to the surfaces of three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times. E : Examine tooth contact using paper. [Adjustment] If tooth contact deviates excessively from the standard value, adjust by increasing or decreasing backlash and rear bearing shim 22.
Page 416 Maintenance item Assembly standards Tooth contact position Lengthwise di- From center towards edge rection of tooth Vertical direction From center towards top of tooth for final drive gear and center for final drive pinion Tooth contact shape Length Approximately 50 to 70% of tooth width Width Approximately 50 to 70% of tooth depth Degree of tooth contact...
Page 417 REDUCTION AND DIFFERENTIAL Service procedure Removal of bearing cap Put alignment marks A on bearing cap 5 to distinguish left and right. 05678 Side bearing inner race [Removal] 0 : Adapter 05679 [Press-fitting] 0 : Bearing installer 05680 Final drive gear [Removal] Put alignment marks A on final drive gear 10 and differential case 16.
Page 418 Lock pin [Removal] A : Punch 05683 [Press-fitting] After press-fitting lock pin 11, stake part B at two points. 05684 Play between differential gear and drive shaft spline in the rotating direction If the measured value is higher than the limit, replace faulty parts. A : Rear axle shaft B : Play 01065...
Page 419 REDUCTION AND DIFFERENTIAL Final drive pinion assembly [Selection of rear bearing shim] • Install 1 pinion gauge temporarily in differential carrier 29 together with the parts illustrated. • Tighten lock nut 17 using 2 socket to adjust starting torque A of the pinion gauge to the standard value.
Page 420 [Measurement of starting torque] • After installing companion flange assembly 18, tighten lock nut 17 at specified torque. Measure starting torque A of final drive pinion 23 using 0 socket. • If the measured value deviates from the standard value, select pinion spacer 20 and front bearing shim 19 to adjust the starting torque to the standard value.
Page 421 REDUCTION AND DIFFERENTIAL Front bearing outer race [Removal] Drive out front bearing outer race 26 evenly from three indented parts A of differential carrier 29. B : Pin-punch 05695 [Press-fitting] 1 : Bearing installer 2 : Bearing installer 05696 Rear bearing outer race and oil stopper [Removal] Drive out rear bearing outer race 27 and oil stopper 28 evenly from three indented parts A of differential carrier 29.
Page 422 Group 27 Rear Axle ' 98 Minor Change Pub No. TWSE0101-27...
Page 423 INDEX SPECIFICATIONS ................27- 2 STRUCTURE AND OPERATION ............27- 3 TROUBLESHOOTING ................. 27- 7 WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE..................27- 9 WHEEL HUB AND BRAKE DRUM < FE639, FG > ......27- 10 WHEEL HUB AND ROTOR < FE640, FE649 > ........27- 20 AXLE HOUSING ..................
Page 424 SPECIFICATIONS Vehicle model FE639, FG FE640 FE649 Item Rear axle Model R033T Type Full floating shaft tube system Model D033H Type Single-reduction gear Reduction Tooth shape Hypoid gear Speed reduction ratio 5.714 5.285 5.714 Differential Tooth shape Straight bevel gear Grade * Normal : Maximum air temperature during operation below 40°C {104°F} Gear oil...
Page 425 STRUCTURE AND OPERATION Wheel Hub and Brake Drum < FE639, FG > 1 Hub bolt 2 Wheel hub 3 Inner bearing 4 Inner oil seal 5 Wheel speed sensor 6 Rotor 7 Brake assembly 8 Brake drum 9 Axle housing 10 Outer bearing 11 Lock nut 12 Lock washer...
Page 426 STRUCTURE AND OPERATION Reduction and Differential 08326 1 Companion flange 14 Final drive gear 2 Lock nut 15 Differential case, LH 3 Dust cover 16 Bearing cap 4 Oil seal 17 Lock plate 5 Front bearing 18 Adjusting screw 6 Collar 19 Side bearing 7 Rear bearing 20 Differential pinion...
Page 427 MULTIPLE LIMITED SLIP DIFFERENTIAL ASSEMBLY 27600 7 Spring plate 1 Limited slip differential assembly 8 Thrust washer 2 Differential case, LH 9 Pressure ring 3 Side gear 10 Pinion shaft 4 Differential case, RH 11 Differential pinion 5 Friction disc 6 Friction plate Friction disc 5 and friction plate 6 engage side gear 3 and differential case RH 4, respectively.
Page 428 STRUCTURE AND OPERATION Operation mechanism When the wheel of one side starts spinning, a rotational difference between side gear 3 and differential cases, LH 2 and RH 4 occurs. Then, friction disc 5 and friction plate 6 start rotating with a relative difference in revolution speed.
Page 429 TROUBLESHOOTING Power transmission Symptoms insufficient Possible causes Axle shaft mounting bolt loose Axle shaft fractured Axle shaft slips out of engagement Oil seal faulty Air breather clogged Wheel hub, Wheel hub bearing seized brake drum, Wheel hub bearing worn disc rotor, Wheel hub bearing rotation faulty or axle housing Wheel hub bearing broken...
Page 430 TROUBLESHOOTING Power transmission Symptoms insufficient Possible causes Front and rear bearings seized Front and rear bearings worn Front and rear bearings broken Pinion pilot bearing worn Pinion pilot bearing seized or broken Reduction Pinion spider broken and differential Differential gear or differential pinion broken Differential gear or differential pinion seized Differential gear or differential pinion worn Differential gear washer worn or damaged...
Page 431 WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE 14177 Work sequence before removal 1 Place wheel chocks. 2 Disconnect the negative terminal of the battery cable. ^ Gr 54 3 Jack up the rear axle using a garage jack. 4 Support the rear frame on jack stands. WARNING–...
Page 432 WHEEL HUB AND BRAKE DRUM < FE639, FG > Ù Ê 3 Ê Ù Ù Ê 8 Ê Ê Ù 5 Ê P45196 Disassembly sequence 19 Brake drum 1 Brake pipe 10 Lock nut 20 Hub bolt 2 Wheel speed sensor 11 Outer bearing inner race 21 Wheel hub 3 Bolt...
Page 433 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 1600 ± 10% Ω Resistance between terminals — — Wheel speed sensor Insulation resistance 100 kΩ minimum — — Axle shaft Bend of shaft center 1 {0.039} or less 2 {0.079} Replace Wobble of flange face...
Page 434 WHEEL HUB AND BRAKE DRUM < FE639, FG > 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Lock nut adjustment tool MB999150 Removal and installation of lock nut 12.7 {0.50} 70 {2.76} 05617 Hub puller components MB999070 A : Hub puller body...
Page 435 Service procedure Starting torque of wheel hub bearing [Adjustment] • Tighten lock nut 10 at specified torque for primary tightening, while turning wheel hub and brake drum assembly 12. • Slacken off lock nut 10 completely. • Turn wheel hub and brake drum assembly 12 several times to smooth operation of outer bearings 11, 17 and inner bearings 15, 16.
Page 436 WHEEL HUB AND BRAKE DRUM < FE639, FG > [Inspection] Pole piece A in wheel speed sensor 2 is magnetized by a built-in magnet and attracts metals. Do not allow metal particles to stick to the pole piece. 07666 Measurement of resistance between terminals Measure resistance between the terminals of wheel speed sensor 2.
Page 437 • As shown in the diagram, position the harness of wheel speed sensor 2, starting from rear axle housing section A and moving toward the frame, making sure that there is no twisting or unnecessary slack in the harness. Use clips 4 and cable ties B to secure the harness in place, then connect connectors C.
Page 438 WHEEL HUB AND BRAKE DRUM < FE639, FG> [Installation] Apply grease to lip area B of outer oil seal 7 and press-fit the outer oil seal in the direction as illustrated. 06616 Removal and installation of lock nut Adjust and measure the starting torque of wheel hub bearing during installation.
Page 439 • If wheel hub and brake drum assembly 12 cannot be removed be- cause of stepped wear A in brake drum 19, do the following: • Remove the backing plate cover. • Lift lever B. C : Wire approximately ø2 mm {0.079 in.} •...
Page 440 WHEEL HUB AND BRAKE DRUM < FE639, FG > Inner bearing outer race [Removal] Drive out inner bearing outer race 16 evenly from three indented parts A in wheel hub 21. B : Pin-punch 06622 [Installation] 06623 Outer bearing outer race [Removal] Drive out outer bearing outer race 17 evenly from three indented parts A in wheel hub 21.
Page 441 Installation of hub bolt Hub bolt 20 is marked with L (left) or R (right) to indicate the side it is to be mounted on. Check this symbol before press-fitting the bolt. “L”, “R” 06653 27-19...
Page 442 WHEEL HUB AND ROTOR < FE640, FE649 > Ù 7 Ê Ù Ê Ù 32 Ê - 33 Ê Ê Ê 4 10 Ê 19 Ê - Ê Ù Ê12 16 Ê Ê Ê Ê P45197 Disassembly sequence 31 Hub bolt 1 Brake pipe 13 Dust shield 23 Wheel hub and rotor...
Page 443 Assembly sequence Follow the disassembly sequence in reverse. WARNING– • Do not allow oil or grease to adhere on the pad surface of disc brake assembly 15 or the surface rotor 24. • You must bleed air from the brake system after assembly, failure to do so would cause the brake to malfunction.
Page 444 WHEEL HUB AND ROTOR < FE640, FE649 > 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Lock nut adjustment tool M B999150 Removal and installation of lock nut 12.7 {0.50} 70 {2.76} 05617 Hub puller components M B999070 A : Hub puller body...
Page 445 Service procedure Starting torque of wheel hub bearing [Adjustment] • Tighten lock nut 21 at specified torque for primary tightening, while turning wheel hub and rotor assembly 23. • Slacken off lock nut 21completely. • Turn wheel hub and rotor assembly 23 several times to smooth operation of outer bearings 22, 29 and inner bearings 27, 28.
Page 446 WHEEL HUB AND ROTOR < FE640, FE649 > [Installation] The connector of wheel speed sensor 5 is color-coded. Install the wheel speed sensors to the proper wheels according to the following table. Right/left Installation location Connector color Connector shape identification tape Left wheel Gray Female...
Page 447 Inspection of open circuit in harness To check the harness for an open circuit, disconnect the harness clamp from the vehicle side, then bend and pull harness at the clamp to check if a momentary open circuit results. Also inspect the terminal contact conditions in the connector.
Page 448 WHEEL HUB AND ROTOR < FE640, FE649 > [Installation] • Knock pin hole E of axle shaft 17 is the second hole clockwise from disassembly screw hole A. • To mount axle shaft 17, align knock pin D with knock pin hole E. 12154 Outer oil seal [Removal]...
Page 449 Removal of wheel hub and rotor assembly Remove wheel hub and rotor assembly 23 using mounting bolt 16 of axle shaft 17. CAUTION– Make sure you remove wheel hub and rotor assembly 23 in a straight line to prevent damage to inner oil seal 26. 06643 Rotor [Inspection]...
Page 450 WHEEL HUB AND ROTOR < FE640, FE649 > Installation of inner oil seal Press-fit inner oil seal 26 so that it is flush with the end of wheel hub 33. 06647 Inner bearing outer race [Removal] Drive out inner bearing outer race 28 evenly from three indented parts A in wheel hub 33.
Page 451 Installation of nut, hub bolt • Hub bolt 31 is marked with L (left) or R (right) to indicate the side it is to be mounted on. Check this symbol before press-fitting the bolt. “ L ”, “ R ” 06677 •...
Page 452 AXLE HOUSING 6 Ê 1 Ê Ê 2 Ê 8 Ù Ê 9 Ê Ê 7 Ê 12155 Work before disassembly Õ P27-32 Disassembly sequence 1 Inspection plug 8 Nut 14 Axle housing 2 Drain plug 9 Bolt 3 Clip *a : Shock absorber ^ Gr 34 10 Reduction and differential assembly Õ...
Page 453 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Axle housing Runout of outer bearing mating area 0.5 {0.020} or less 1 {0.039} Replace Difference of center area before and 1 {0.039} or less 5 {0.20} Replace after turning Ê...
Page 454 AXLE HOUSING Service procedure Work before disassembly Remove inspection plug 1 and drain plug 2, then drain the gear oil from axle housing 14. WARNING– The oil temperature is high immediately after the vehicle has stopped, so take care not to scald yourself. Work after assembly 06680 Fill axle housing 14 with the specified amount of gear oil via inspection...
Page 455 [Application of sealant] • Apply sealant to reduction and differential assembly 10 mounting surface of axle housing 14. • Apply sealant around the periphery of indented area E for part D. • Apply sealant linearly to part F. NOTE Make sure that sealant does not ooze from the mounting surface after installing reduction and differential assembly 10.
Page 456 REDUCTION AND DIFFERENTIAL Ù Ê Ê Ê 19 Ù Ê 35 - Ê 9 Ê - 06749 Work before disassembly Õ P27-38 Inspection before disassembly Õ P27-38 Disassembly sequence 1 Bolt 12 Differential case, LH 25 Lock ring 2 Lock plate 13 Differential case, RH 26 Pinion pilot bearing 3 Adjusting screw...
Page 457 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) • Adjust using 6, 7 Starting torque of side bearing 1.96 to 2.94 N·m — adjusting {1.4 to 2.2 ft.lbs, 0.20 to 0.30 kgf·m} screw •...
Page 458 REDUCTION AND DIFFERENTIAL - Lubricant and sealant Location Points of application Kinds Quantity 9, 11 Entire surface of bolt Rust preventive As required Thread area of final drive gear LOCTITE 271 As required Thread area of bolt LOCTITE 271 As required Lip area of oil seal Wheel bearing grease [NLG1 No.2 (Li soap)] As required Pinion pilot bearing mounting surface of differential carrier...
Page 459 Unit : mm {in.} Location Tool name and shape Part No. Application Pinion rear bearing MB999045 Removal of rear bearing inner race 25.5 {1.00} remover {0.020} 02956 ø52 {2.05} Pinion bearing installer MH061005 Press-fitting of rear bearing inner race {4.92} ø62 {2.44} 01077 ø88 {3.46}...
Page 460 REDUCTION AND DIFFERENTIAL Service procedure Work before disassembly Mount differential carrier 35 on 0 differential working base assembly. 06750 Inspection before disassembly Inspect for faulty parts before disassembly. (1) Wobble of rear face of final drive gear Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the center of final drive gear 10.
Page 461 (4) Tooth contact of final drive gear Apply red lead to three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times. B : Examine tooth contact using paper. 01045 Inspection and adjustment after assembly (1) Inspection of wobble of back face of final drive gear Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the center of final drive gear 10.
Page 462 REDUCTION AND DIFFERENTIAL (4) Tooth contact of final drive gear [Inspection] Apply red lead to three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times. B : Examine tooth contact using paper. [Adjustment] If tooth contact has deteriorated, adjust by increasing or decreasing backlash and shim 34.
Page 463 Adjustment of tooth contact Method of adjustment Moving direction Advance final drive pinion to final drive gear Tooth contact moves towards (Shims are reduced) tooth root < Leading edge > < Trailing edge > Retard final drive pinion from final drive gear Tooth contact moves towards (Shims are added) tooth tip...
Page 464 REDUCTION AND DIFFERENTIAL Side bearing inner race [Removal] A : Gear puller (General tool) NOTE Make sure you keep left and right side bearings 6, 7 separate after removal, and be careful not to mix them up when installing them. 06752 [Installation] 06753...
Page 465 Installation of differential case RH and differential case • Apply rust preventive to the entire surface of bolts 11. • Apply lock paint to thread area A of bolts 11. • Tighten bolts 11 at specified torque. CAUTION– • Be sure to apply rust preventive because of the need to tighten bolts 11 at specified torque.
Page 466 REDUCTION AND DIFFERENTIAL [Inspection of starting torque after installation] • Apply load of approximately 39.2 kN {8.8 klbf, 4000 kgf} to companion 39.2 KN flange 23 or tighten lock nut 21 at specified torque. {8.8 klbf, 4000 kgf} • Install spring balance B at 114 mm {4.49 in.} outer periphery point of bearing retainer 33.
Page 467 [Installation] • Apply lock paint to entire mounting surface G of pinion pilot bearing 26 of differential carrier 35. CAUTION– • Be sure to let the lock paint harden undisturbed for 30 minutes to two hours after installation. • Be sure to wait at least three hours before running the vehicle, and if possible wait 24 hours to let the lock paint harden.
Page 468 REDUCTION AND DIFFERENTIAL Rear bearing inner race [Removal] 02959 [Installation] 06762 Installation of oil seal 06763 Installation of front bearing inner race 06764 27-46...
Page 469 Front bearing outer race [Removal] Drive out front bearing outer race 31 evenly from three indented parts A in bearing retainer 33. B : Pin-punch 06765 [Installation] 06766 Rear bearing outer race [Removal] Drive out rear bearing outer race 32 evenly from three indented parts A in bearing retainer 33.
Page 470 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY DISASSEMBLY AND ASSEMBLY 17 18 1 Ê 06769 Disassembly sequence 1 Bolt 7 Spring plate 14 Friction plate 2 Final drive gear 8 Friction plate 15 Pressure ring 3 Multiplate limited slip differential 9 Friction disc 16 Side gear assembly 10 Friction plate...
Page 471 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Rotation torque of multiplate When putting in a 200 to 295 N·m — Inspect limited slip differential new clutch plate {150 to 215 ft.lbs, 20.5 to 30 kgf·m} internal parts assembly and replace...
Page 472 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY Service procedure Final drive gear Apply LOCKTITE to thread area A of all the bolt holes of final drive gear CAUTION– • Be sure to let bolts 1 harden for at least an hour, after installation, before driving.
Page 473 [Inspection for deformation] Check friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 for deformation by mounting dial gauge A on a base and rotating the plate or disc and measuring its flatness. 8 to 14 06736 [Measurement of thickness] Measure the thickness of the friction surfaces and the protruding parts 9, 11, 13...
Page 474 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY • Calculate dimension D between the surfaces of differential cases LH 5 and RH 19 which come in contact with spring plate 7 when the two cases are assembled. D = E + F – G •...
Page 475 [Assembly] Assemble the different parts in differential case RH 19 in the direction 17 18 as illustrated. CAUTION– • Make sure that friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 are installed in the correct order and that spring plate 7 is assembled in the correct direction.
Page 476 Group 27 Rear Axle ' 98 Minor Change Pub No. TWSE0304-27...
Page 477 INDEX SPECIFICATIONS ................27- 2 STRUCTURE AND OPERATION ............27- 3 TROUBLESHOOTING ................. 27- 7 WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE..................27- 9 WHEEL HUB AND BRAKE DRUM < FE639, FG > ......27- 10 WHEEL HUB AND ROTOR < FE640, FE649 > ........27- 20 AXLE HOUSING ..................
Page 478 SPECIFICATIONS Vehicle model FE639, FG FE640 FE649 Item Rear axle Model R033T Type Full floating shaft tube system Model D033H Type Single-reduction gear Reduction Tooth shape Hypoid gear Speed reduction ratio 5.714 5.285 5.714 Differential Tooth shape Straight bevel gear Grade * Normal : Maximum air temperature during operation below 40°C {104°F} Gear oil...
Page 479 STRUCTURE AND OPERATION Wheel Hub and Brake Drum < FE639, FG > 1 Hub bolt 2 Wheel hub 3 Inner bearing 4 Inner oil seal 5 Wheel speed sensor 6 Rotor 7 Brake assembly 8 Brake drum 9 Axle housing 10 Outer bearing 11 Lock nut 12 Lock washer...
Page 480 STRUCTURE AND OPERATION Reduction and Differential 08326 1 Companion flange 14 Final drive gear 2 Lock nut 15 Differential case, LH 3 Dust cover 16 Bearing cap 4 Oil seal 17 Lock plate 5 Front bearing 18 Adjusting screw 6 Collar 19 Side bearing 7 Rear bearing 20 Differential pinion...
Page 481 MULTIPLE LIMITED SLIP DIFFERENTIAL ASSEMBLY 27600 7 Spring plate 1 Limited slip differential assembly 8 Thrust washer 2 Differential case, LH 9 Pressure ring 3 Side gear 10 Pinion shaft 4 Differential case, RH 11 Differential pinion 5 Friction disc 6 Friction plate Friction disc 5 and friction plate 6 engage side gear 3 and differential case RH 4, respectively.
Page 482 STRUCTURE AND OPERATION Operation mechanism When the wheel of one side starts spinning, a rotational difference between side gear 3 and differential cases, LH 2 and RH 4 occurs. Then, friction disc 5 and friction plate 6 start rotating with a relative difference in revolution speed.
Page 483 TROUBLESHOOTING Power transmission Symptoms insufficient Possible causes Axle shaft mounting bolt loose Axle shaft fractured Axle shaft slips out of engagement Oil seal faulty Air breather clogged Wheel hub, Wheel hub bearing seized brake drum, Wheel hub bearing worn disc rotor, Wheel hub bearing rotation faulty or axle housing Wheel hub bearing broken...
Page 484 TROUBLESHOOTING Power transmission Symptoms insufficient Possible causes Front and rear bearings seized Front and rear bearings worn Front and rear bearings broken Pinion pilot bearing worn Pinion pilot bearing seized or broken Reduction Pinion spider broken and differential Differential gear or differential pinion broken Differential gear or differential pinion seized Differential gear or differential pinion worn Differential gear washer worn or damaged...
Page 485 WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE 14177 Work sequence before removal 1 Place wheel chocks. 2 Disconnect the negative terminal of the battery cable. ^ Gr 54 3 Jack up the rear axle using a garage jack. 4 Support the rear frame on rigid racks. WARNING–...
Page 486 WHEEL HUB AND BRAKE DRUM < FE639, FG > Ù Ê 3 Ê Ù Ù Ê 8 Ê 5 Ê Ù P54265 Disassembly sequence 19 Brake drum 1 Brake pipe 10 Lock nut 20 Hub bolt 2 Wheel speed sensor 11 Outer bearing inner race 21 Wheel hub 3 Bolt...
Page 487 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 1600 ± 10% Ω Resistance between terminals — — Wheel speed sensor Insulation resistance 100 kΩ minimum — — Axle shaft Bend of shaft center 1 {0.039} or less 2 {0.079} Replace Wobble of flange face...
Page 488 WHEEL HUB AND BRAKE DRUM < FE639, FG > 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Lock nut adjustment tool MB999150 Removal and installation of lock nut 12.7 {0.50} 70 {2.76} 05617 Hub puller components MB999070 A : Hub puller body...
Page 489 Service procedure Starting torque of wheel hub bearing [Adjustment] • Tighten lock nut 10 at specified torque for primary tightening, while turning wheel hub and brake drum assembly 12. • Slacken off lock nut 10 completely. • Turn wheel hub and brake drum assembly 12 several times to smooth operation of outer bearings 11, 17 and inner bearings 15, 16.
Page 490 WHEEL HUB AND BRAKE DRUM < FE639, FG > [Inspection] Pole piece A in wheel speed sensor 2 is magnetized by a built-in magnet and attracts metals. Do not allow metal particles to stick to the pole piece. 07666 Measurement of resistance between terminals Measure resistance between the terminals of wheel speed sensor 2.
Page 491 • As shown in the diagram, position the harness of wheel speed sensor 2, starting from rear axle housing section A and moving toward the frame, making sure that there is no twisting or unnecessary slack in the harness. Use clips 4 and cable ties B to secure the harness in place, then connect connectors C.
Page 492 WHEEL HUB AND BRAKE DRUM < FE639, FG> [Installation] Apply grease to lip area B of outer oil seal 7 and press-fit the outer oil seal in the direction as illustrated. 06616 Removal and installation of lock nut Adjust and measure the starting torque of wheel hub bearing during installation.
Page 493 • If wheel hub and brake drum assembly 12 cannot be removed be- cause of stepped wear A in brake drum 19, do the following: • Remove the backing plate cover. • Lift lever B. C : Wire approximately ø2 mm {0.079 in.} •...
Page 494 WHEEL HUB AND BRAKE DRUM < FE639, FG > Inner bearing outer race [Removal] Drive out inner bearing outer race 16 evenly from three indented parts A in wheel hub 21. B : Pin-punch 06622 [Installation] 06623 Outer bearing outer race [Removal] Drive out outer bearing outer race 17 evenly from three indented parts A in wheel hub 21.
Page 495 Installation of hub bolt Hub bolt 20 is marked with L (left) or R (right) to indicate the side it is to be mounted on. Check this symbol before press-fitting the bolt. “L”, “R” 06653 27-19...
Page 496 WHEEL HUB AND ROTOR < FE640, FE649 > Ù 7 Ê Ù Ê Ù 32 Ê - 33 Ê Ê Ê 4 10 Ê 19 Ê Ê Ù Ê12 16 Ê Ê Ê Ê P45197 Disassembly sequence 31 Hub bolt 1 Brake pipe 13 Dust shield 23 Wheel hub and rotor...
Page 497 Assembly sequence Follow the disassembly sequence in reverse. WARNING– • Do not allow oil or grease to adhere on the pad surface of disc brake assembly 15 or the surface rotor 24. • You must bleed air from the brake system after assembly, failure to do so would cause the brake to malfunction.
Page 498 WHEEL HUB AND ROTOR < FE640, FE649 > 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Lock nut adjustment tool M B999150 Removal and installation of lock nut 12.7 {0.50} 70 {2.76} 05617 Hub puller components M B999070 A : Hub puller body...
Page 499 Service procedure Starting torque of wheel hub bearing [Adjustment] • Tighten lock nut 21 at specified torque for primary tightening, while turning wheel hub and rotor assembly 23. • Slacken off lock nut 21completely. • Turn wheel hub and rotor assembly 23 several times to smooth operation of outer bearings 22, 29 and inner bearings 27, 28.
Page 500 WHEEL HUB AND ROTOR < FE640, FE649 > [Installation] The connector of wheel speed sensor 5 is color-coded. Install the wheel speed sensors to the proper wheels according to the following table. Right/left Installation location Connector color Connector shape identification tape Left wheel Gray Female...
Page 501 Inspection of open circuit in harness To check the harness for an open circuit, disconnect the harness clamp from the vehicle side, then bend and pull harness at the clamp to check if a momentary open circuit results. Also inspect the terminal contact conditions in the connector.
Page 502 WHEEL HUB AND ROTOR < FE640, FE649 > [Installation] • Knock pin hole E of axle shaft 17 is the second hole clockwise from disassembly screw hole A. • To mount axle shaft 17, align knock pin D with knock pin hole E. 12154 Outer oil seal [Removal]...
Page 503 Removal of wheel hub and rotor assembly Remove wheel hub and rotor assembly 23 using mounting bolt 16 of axle shaft 17. CAUTION– Make sure you remove wheel hub and rotor assembly 23 in a straight line to prevent damage to inner oil seal 26. 06643 Rotor [Inspection]...
Page 504 WHEEL HUB AND ROTOR < FE640, FE649 > Installation of inner oil seal Press-fit inner oil seal 26 so that it is flush with the end of wheel hub 33. 06647 Inner bearing outer race [Removal] Drive out inner bearing outer race 28 evenly from three indented parts A in wheel hub 33.
Page 505 Installation of nut, hub bolt • Hub bolt 31 is marked with L (left) or R (right) to indicate the side it is to be mounted on. Check this symbol before press-fitting the bolt. “ L ”, “ R ” 06677 •...
Page 506 AXLE HOUSING 6 Ê 1 Ê Ê 2 Ê 8 Ù 9 Ê Ê 7 Ê 11 Ê 54271 Work before disassembly Õ P27-32 Disassembly sequence 1 Inspection plug 8 Nut 14 Axle housing 2 Drain plug 9 Bolt 3 Clip *a : Shock absorber ^ Gr 34 10 Reduction and differential assembly Õ...
Page 507 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Axle housing Runout of outer bearing mating area 0.5 {0.020} or less 1 {0.039} Replace Difference of center area before and 1 {0.039} or less 5 {0.20} Replace after turning Ê...
Page 508 AXLE HOUSING Service procedure Work before disassembly Remove inspection plug 1 and drain plug 2, then drain the gear oil from axle housing 14. WARNING– The oil temperature is high immediately after the vehicle has stopped, so take care not to scald yourself. Work after assembly 06680 Fill axle housing 14 with the specified amount of gear oil via inspection...
Page 509 [Application of sealant] • Apply sealant to reduction and differential assembly 10 mounting surface of axle housing 14. • Apply sealant around the periphery of indented area E for part D. • Apply sealant linearly to part F. NOTE Make sure that sealant does not ooze from the mounting surface after installing reduction and differential assembly 10.
Page 510 REDUCTION AND DIFFERENTIAL Ù Ê Ê Ê 19 Ù Ê 35 - Ê 9 Ê - 06749 Work before disassembly Õ P27-38 Inspection before disassembly Õ P27-38 Disassembly sequence 1 Bolt 12 Differential case, LH 25 Lock ring 2 Lock plate 13 Differential case, RH 26 Pinion pilot bearing 3 Adjusting screw...
Page 511 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) • Adjust using 6, 7 Starting torque of side bearing 1.96 to 2.94 N·m — adjusting {1.4 to 2.2 ft.lbs, 0.20 to 0.30 kgf·m} screw •...
Page 512 REDUCTION AND DIFFERENTIAL - Lubricant and sealant Location Points of application Kinds Quantity 9, 11 Entire surface of bolt Rust preventive As required Thread area of final drive gear LOCTITE 271 As required Thread area of bolt LOCTITE 271 As required Lip area of oil seal Wheel bearing grease [NLG1 No.2 (Li soap)] As required Pinion pilot bearing mounting surface of differential carrier...
Page 513 Unit : mm {in.} Location Tool name and shape Part No. Application Pinion rear bearing MB999045 Removal of rear bearing inner race 25.5 {1.00} remover {0.020} 02956 ø52 {2.05} Pinion bearing installer MH061005 Press-fitting of rear bearing inner race {4.92} ø62 {2.44} 01077 ø88 {3.46}...
Page 514 REDUCTION AND DIFFERENTIAL Service procedure Work before disassembly Mount differential carrier 35 on 0 differential working base assembly. 06750 Inspection before disassembly Inspect for faulty parts before disassembly. (1) Wobble of rear face of final drive gear Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the center of final drive gear 10.
Page 515 (4) Tooth contact of final drive gear Apply red lead to three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times. B : Examine tooth contact using paper. 01045 Inspection and adjustment after assembly (1) Inspection of wobble of back face of final drive gear Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the center of final drive gear 10.
Page 516 REDUCTION AND DIFFERENTIAL (4) Tooth contact of final drive gear [Inspection] Apply red lead to three or four teeth of final drive gear 10, examine tooth contact by turning the gears a few times. B : Examine tooth contact using paper. [Adjustment] If tooth contact has deteriorated, adjust by increasing or decreasing backlash and shim 34.
Page 517 Adjustment of tooth contact Method of adjustment Moving direction Advance final drive pinion to final drive gear Tooth contact moves towards (Shims are reduced) tooth root < Leading edge > < Trailing edge > Retard final drive pinion from final drive gear Tooth contact moves towards (Shims are added) tooth tip...
Page 518 REDUCTION AND DIFFERENTIAL Side bearing inner race [Removal] A : Gear puller (General tool) NOTE Make sure you keep left and right side bearings 6, 7 separate after removal, and be careful not to mix them up when installing them. 06752 [Installation] 06753...
Page 519 Installation of differential case RH and differential case • Apply rust preventive to the entire surface of bolts 11. • Apply lock paint to thread area A of bolts 11. • Tighten bolts 11 at specified torque. CAUTION– • Be sure to apply rust preventive because of the need to tighten bolts 11 at specified torque.
Page 520 REDUCTION AND DIFFERENTIAL [Inspection of starting torque after installation] • Apply load of approximately 39.2 kN {8.8 klbf, 4000 kgf} to companion 39.2 KN flange 23 or tighten lock nut 21 at specified torque. {8.8 klbf, 4000 kgf} • Install spring balance B at 114 mm {4.49 in.} outer periphery point of bearing retainer 33.
Page 521 [Installation] • Apply lock paint to entire mounting surface G of pinion pilot bearing 26 of differential carrier 35. CAUTION– • Be sure to let the lock paint harden undisturbed for 30 minutes to two hours after installation. • Be sure to wait at least three hours before running the vehicle, and if possible wait 24 hours to let the lock paint harden.
Page 522 REDUCTION AND DIFFERENTIAL Rear bearing inner race [Removal] 02959 [Installation] 06762 Installation of oil seal 06763 Installation of front bearing inner race 06764 27-46...
Page 523 Front bearing outer race [Removal] Drive out front bearing outer race 31 evenly from three indented parts A in bearing retainer 33. B : Pin-punch 06765 [Installation] 06766 Rear bearing outer race [Removal] Drive out rear bearing outer race 32 evenly from three indented parts A in bearing retainer 33.
Page 524 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY DISASSEMBLY AND ASSEMBLY 17 18 1 Ê - 06769 Disassembly sequence 1 Bolt 7 Spring plate 14 Friction plate 2 Final drive gear 8 Friction plate 15 Pressure ring 3 Multiplate limited slip differential 9 Friction disc 16 Side gear assembly 10 Friction plate...
Page 525 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Rotation torque of multiplate When putting in a 201 to 295 N·m — Inspect limited slip differential new clutch plate {150 to 215 ft.lbs, 20.5 to 30 kgf·m} internal parts assembly and replace...
Page 526 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY Service procedure Installation of final drive gear • Apply rust preventive to the entire surface of bolts 1. • Apply lock paint to the threads area A of all the bolt holes of final drive gear 2.
Page 527 [Inspection for deformation] Check friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 for deformation by mounting dial gauge A on a base and rotating the plate or disc and measuring its flatness. 8 to 14 06736 [Measurement of thickness] Measure the thickness of the friction surfaces and the protruding parts 9, 11, 13...
Page 528 MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY • Calculate dimension D between the surfaces of differential cases LH 5 and RH 19 which come in contact with spring plate 7 when the two cases are assembled. D = E + F – G •...
Page 529 [Assembly] Assemble the different parts in differential case RH 19 in the direction 17 18 as illustrated. CAUTION– • Make sure that friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 are installed in the correct order and that spring plate 7 is assembled in the correct direction.
Page 530 Group 31 Wheel and Tire ' 98 Minor Change Pub No. TWSE0101-31...
Page 531 INDEX SPECIFICATIONS ................31-2 TROUBLESHOOTING ................ 31-2 WHEEL AND TIRE ................31-3...
Page 532 SPECIFICATIONS/TROUBLESHOOTING SPECIFICATIONS Item Air pressure kPa {psi, kgf/cm Tire size Application wheel Vehicle model Front Rear FE639 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50} 16×6K-127-9 (GVWR : 11600 lb, 5260 kg) (wheel with 5 studs) FE639 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50} 16×6K-127-9 (GVWR : 13500 lb, 6120 kg)
Page 533 WHEEL AND TIRE Work for Removal and Installation of Wheel and Tire 14233 Work sequence 1 Place wheel chocks. 2 Jack up the front or rear axle using a garage jack placed under the center of the axle. 3 Support the frame on jack stands. WARNING–...
Page 534 WHEEL AND TIRE NOTE Use right-hand threaded wheel nuts marked “R” for right side wheel and left-hand threaded wheel nuts marked “L” for left side wheel. < Single tire > Removal sequence 1 Wheel nut 2 Tire assembly Õ P31-5 5 Hub bolt 6 Hub Cleaning before installation...
Page 535 Tire Assembly Disassembly sequence 1 Tire 2 Disc wheel Assembly sequence Follow the disassembly sequence in re- verse. 11389 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Horizontal deflection of tire (When assembled) 3.5 {0.14} or less —...
Page 536 WHEEL AND TIRE [Correction] • Put chalk marks on tire 1, disc wheel 2, and hub bolt * (positions A as illustrated). • Remove tire 1 from disc wheel 2. 11391 • Measure deflection of disc wheel 2. If the most deflective position is near the chalk mark, reinstall tire 1 rotating it half a turn from the chalk mark and tighten nuts.
Page 537 Group 33 Front Suspension ' 98 Minor Change Pub No. TWSE0101-33...
Page 538 < FG > ......................LEAF SPRING ASSEMBLY 33- 12 < FE > ......................33- 14 < FG > ......................SHOCK ABSORBER 33- 16 < FE > ......................33- 17 < FG > ......................STABILIZER < FE > ................ 33- 18...
Page 539 27079 Leaf spring assembly 2, shock absorber 1, and stabilizer 3 < FE > are installed between frame *b and front axle *a to support the vehicle body mass and absorb vibration and shock from the road surface to prevent them from being directly transmitted to the vehicle body thereby protecting the crew, the vehicle body, and the cargo.
Page 540 Damaged or broken < FG > Shock absorber Noticeable oil leaking or damping force decreased Rubber bushing worn Installation loose Stabilizer < FE > Stabilizer deformed or bushing worn Tire Tires worn unevenly ^ Gr 31 Tires and wheels unbalanced...
Page 541 (on the joint between the front axle and the propeller shaft). < FG > 6 Remove the brake hose joint (on the frame). 7 Remove the clamp of the brake pad wear indicator harness and disconnect the connector on the frame side. < FE > 8 Remove the drag link. ^ Gr 37 Ù...
Page 542 WARNING– You must bleed air from the brake system after installing the brake hose, failure to do so would cause the brake to malfunction. ^ Gr 35A CAUTION– Be sure that the brake hose is not twisted when you install it. Ê...
Page 543 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FE > Removal sequence 1 U-bolt nut 2 U-bolt 3 Front axle bumper 4 Nut 5 Spring pin 6 Rubber bushing 7 Ê 7 Nut 8 Shackle plate 9 Spring shackle 10 Rubber bushing 11 Leaf spring assembly Õ...
Page 544 Service procedure Installation of spring pin Install spring pin 5 to front spring hanger 12 with indent A of the spring pin fitted to protrusion B of the front spring hanger. 27082 Installation of shackle plate Install shackle plate 8 with stamped mark “ ” facing the leaf spring. “...
Page 545 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FG > Removal sequence 1 U-bolt nut 2 U-bolt Ê12 3 Front spring pad 4 Nut 5 Spring pin 6 Rubber bushing 7 Nut 8 Shackle plate 9 Spring shackle 10 Rubber bushing 11 Leaf spring assembly Õ...
Page 546 Service procedure Front spring pad Mount front spring pad 3 with protrusion A facing the outside of the vehicle. 06722 Installation of spring pin Install spring pin 5 to front spring hanger 14 with indent A of the spring pin fitted to protrusion B of the front spring hanger. 06982 Installation of shackle plate Install shackle plate 8 with stamped mark “...
Page 547 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FG > Front axle bumper Mount front axle bumper 13 with arrow mark “ ” facing the outside of the vehicle. ” “ 05839 33-10...
Page 548 M E M O 33-11...
Page 549 LEAF SPRING ASSEMBLY < FE > Disassembly sequence 1 Collar 2 Center nut Ê 3 Caster shim 4 Rivet 5 Clip 6 Leaf spring 5 Ù Ù : Non-reusable parts Assembly sequence Ù Follow the disassembly sequence in reverse. 27086 Ê...
Page 550 [Installation] • Align alignment marks A on the side of leaf springs 6, assemble the component leaf springs, then tighten center nut 2 temporarily. 27089 • Compress leaf springs 6 using a press, tighten center nut 2 at speci- fied torque, then bend over clips 5. 27090 Rivet [Removal]...
Page 551 LEAF SPRING ASSEMBLY < FG > Disassembly sequence 1 Collar Ê 2 Center nut 3 Rivet 4 Clip 4 Ù 5 Rivet 6 Clip Ù 7 Leaf spring Ù : Non-reusable parts Assembly sequence Follow the disassembly sequence in 6 Ù reverse.
Page 552 [Installation] • Align alignment marks A on the side of leaf springs 7, assemble the component leaf springs, then tighten center nut 2 temporarily. 27094 • Compress leaf springs 7 using a press, tighten center nut 2 at speci- fied torque, then bend over clips 4, 6 using a hammer. 4, 6 27095 Rivet...
Page 553 SHOCK ABSORBER < FE > Removal sequence Ê 1 1 Lock nut 2 Upper side washer 3 Rubber bushing 4 Rubber bushing 5 Upper side washer 6 Nut 7 Eye washer 8 Washer 9 Rubber bushing 10 Shock absorber Installation sequence Follow the removal sequence in reverse.
Page 554 SHOCK ABSORBER < FG > Removal sequence Ê 1 1 Lock nut 2 Upper side washer 3 Rubber bushing 4 Rubber bushing 5 Upper side washer 6 Nut 7 Rubber bushing 8 Shock absorber Installation sequence Follow the removal sequence in reverse. Ê...
Page 555 STABILIZER < FE > Removal sequence 1 Lock nut 2 Upper side washer Ê 1 3 Rubber bushing 4 Centering washer 5 Centering washer 6 Rubber bushing 7 Upper side washer 8 Nut 9 Stabilizer hanger 10 U-bolt nut 11 Nut 12 Stabilizer upper bracket Ê...
Page 556 Service procedure Stabilizer hanger mounting 5.0 to 5.5 mm • Mount stabilizer hanger 9 to radiator support *e perpendicularly. {0.20 to 0.22 in.} • Tighten lock nut 1 so that the top of stabilizer hanger 9 protrudes from the lock nut by the amount as illustrated. 05911 Stabilizer upper bracket mounting 667±1 mm {26.3±0.039 in.}...
Page 557 Group 34 Rear Suspension ' 98 Minor Change Pub No. TWSE0101-34...
Page 558 OF REAR SUSPENSION ..............34- 4 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY 34- 6 < FE > ......................34- 10 < FG > ......................LEAF SPRING ASSEMBLY............. 34- 14 SHOCK ABSORBER ............... 34- 17 STABILIZER < FE > ............... 34- 18...
Page 559 In addition, irregular vibration from the wheels is restrained, ensuring driving stability. Stabilizer 3 < FE > is installed to prevent sway. 34-2...
Page 560 Helper rubber or helper spring stopper damaged or broken Noticeable oil leaking or damping force decreased Shock absorber Rubber bushing worn Bolt loose Stabilizer < FE > Stabilizer deformed, bushing worn Tires worn unevenly ^ Gr 31 Tire Tires and wheels unbalanced...
Page 561 WORK BEFORE REMOVAL AND INSTALLATION OF REAR SUSPENSION 5 Ê Ù 45744 Removal sequence 1 Place wheel chocks. 2 Disconnect the negative battery cable. ^ Gr 54 3 Jack up the rear axle with a garage jack. 4 Support the rear frame on jack stands. 5 Put alignment marks A on the rear axle companion flange and the propeller shaft flange yoke, then remove the nuts (on the joint between the rear axle and the propeller shaft).
Page 562 Installation sequence Follow the removal sequence in reverse. WARNING– You must bleed air from the brake system and install the load sensing valve (with load sensing valve) after installing the brake hose, failure to do so would cause the brake to malfunction. ^ Gr 35A CAUTION–...
Page 563 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FE > 21 Ê 24 Ê 19 Ê 21 13 Ê Ê 14 - Ê Ê1 06349 Removal sequence 1 U-bolt nut 10 Spring pin 19 Nut 11 Side washer 20 Helper rubber 2 U-bolt 12 Leaf spring assembly Õ...
Page 564 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) 6, 10, 12 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5 {0.020} — leaf spring assembly {[1.10] 0.0016 to 0.0055} 6, 23 Clearance between spring pin and rear [28] 0.02 to 0.08...
Page 565 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FE > Service procedure Removal of spring pin Remove spring pins 6, 10, 15 using 0 spring pin remover. 6, 10, 15 06351 Adjustment of side washer (for adjustment) • Using side washer 11, adjust the clearance between leaf spring as- sembly 12 and spring shackle 18 to the standard value.
Page 566 M E M O 34-9...
Page 567 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FG > 21 Ê Ê 19 Ê 21 13 Ê Ê 8 Ê 4 14 - Ê 08109 Removal sequence 19 Nut 10 Shackle pin 1 U-bolt nut 20 Helper rubber 11 Side washer (for adjustment) 2 U-bolt 12 Leaf spring assembly Õ...
Page 568 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) 6, 12 Clearance between spring pin and bushing of [28] 0.04 to 0.14 — leaf spring assembly {[1.10] 0.0016 to 0.0055} {0.020} 6, 23 Clearance between spring pin and rear [28] 0.04 to 0.14...
Page 569 REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FG > Service procedure Removal of spring pin and shackle pin • Remove spring pins 6, 15 using 0 spring pin remover. • Knock shackle pin 10 out from the inside of the vehicle using a hammer.
Page 570 M E M O 34-13...
Page 571 LEAF SPRING ASSEMBLY Disassembly sequence Ê 1 Bushing 2 Bolt 3 Pipe 4 Center nut 5 Rivet 6 Clip 7 Helper spring 8 Spacer 9 Rivet 10 Clip 11 Main spring Ù Ù : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
Page 572 Service procedure Removal and installation of bushing 0 : Bushing installer 06791 Center nut [Removal] • Put alignment marks A on the sides of helper springs 7, spacer 8, and main springs 11. 06792 • Compress helper springs 7, spacer 8, and main springs 11, then remove center nut 4.
Page 573 LEAF SPRING ASSEMBLY Rivet [Removal] Drill out staked ends A of rivets 5, 9 on a drill press, then remove clips 6, 6, 10 5, 9 07605 [Installation] Using riveting machine B, mount clips 10, 6 by staking rivets 9, 5. 10, 6 9, 5 06796...
Page 574 SHOCK ABSORBER Removal sequence 1 Nut 2 Washer 3 Washer Ê 1 4 Rubber bushing 1 Ê 5 Shock absorber Installation sequence Follow the removal sequence in reverse. 08168 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Nut (Shock absorber mounting)
Page 575 STABILIZER < FE > Removal sequence 1 Nut 2 Bolt 3 Stabilizer bracket 4 Stabilizer reinforcement 5 Bolt 6 Plate Ê 1 2 Ê 7 Clamp 8 Bushing 9 Stabilizer hanger 10 Stabilizer bushing 11 Nut Ê 12 Bushing 13 Stabilizer bar...
Page 576 Service procedure Stabilizer bushing 685±1 mm {27.0±0.039 in.} Mount stabilizer bushings 10 with their end surfaces aligned with marks A on stabilizer bar 13. 05597 34-19...
Page 577 Group 35A Brake ' 98 Minor Change Pub No. TWSE0101-35A...
Page 578 INDEX SPECIFICATIONS ................35A- 2 STRUCTURE AND OPERATION ............ 35A- 3 TROUBLESHOOTING ..............35A-24 ON-VEHICLE INSPECTION AND ADJUSTMENT 35A-30 • Replacement of Brake Fluid ................. 35A-32 • Air Bleeding of Brake System ..............35A-36 • Inspection and Adjustment of Brake Pedal Free Play ....... •...
Page 579 SPECIFICATIONS < Service Brake Equipment > Vehicle model FE639, FG FE64 Item Brake booster Type Tandem type (Master vac) Diaphragm diameter ø8+ø9 ø9+ø10 Manufacturer BOSCH BRAKING SYSTEMS CO., LTD. Brake master Inner diameter mm {in.} ø30.16 {1.19} ø31.75 {1.25} cylinder Stroke Front mm {in.}...
Page 580 STRUCTURE AND OPERATION Brake System P45167 1 Brake booster (master vac) 2 Fluid tank 9 Rear wheel brake 3 Brake master cylinder 10 Front wheel brake 4 Vacuum tank 5 Vacuum switch A : Fluid line 6 Check valve B : Vacuum line 7 Vacuum pump C : Hose 8 Hydraulic unit...
Page 581 STRUCTURE AND OPERATION Brake Booster (Master Vac) and Brake Master Cylinder < Brake master cylinder > < Brake booster (master vac) > 05248 < Brake booster (master vac) > < Brake master cylinder > 1 Front diaphragm 16 Primary piston 2 Front diaphragm plate 17 Primary piston return spring 3 Rear diaphragm...
Page 582 When depressing brake pedal 12929 Action of brake booster (master vac) • When the brake pedal is released, chambers C and D are subjected to the vacuum created by the vacuum pump. • Depressing the brake pedal activates operating rod 10, placing poppet 7 in tight contact with the seat of valve body 11. This action closes vacuum valve A, cutting off the vacuum to chamber D.
Page 583 STRUCTURE AND OPERATION Fluid leakage in the front brake system • Depressing the brake pedal makes push rod 13 push in primary piston 16. However, if the brake fluid in the front brake system leaks, hydraulic pressure is not generated in the front brake system. •...
Page 584 When releasing brake pedal 12931 Action of brake booster (master vac) • When the brake pedal is depressed, atmospheric air flows into chamber D as chamber C is subjected to negative pressure generated by the vacuum pump. • When the brake pedal is released, since the pressing force acting on the operating rod 10 also is released, valve plunger 6 contacts poppet 7 tightly, closing breather valve B to cut off the flow of atmospheric air into chamber D.
Page 585 STRUCTURE AND OPERATION • When secondary piston 19 returns to its original position, the pressure difference between chambers G and H is diminished, and packing cup 22 closes the small passage J. The hydraulic oil in the brake pipe flows from chamber H to the fluid tank via return port E.
Page 586 Front Drum Brake Assembly 1 Back plate 2 Brake shoe assembly 3 Return spring 4 Wheel cylinder assembly The front drum brake assembly has two-leading brakes installed, and with single action wheel cylinder assembly 4, the action coming from leading shoes when brake shoe assembly 2 is forward provides increased braking force through its independent double action.
Page 587 STRUCTURE AND OPERATION Automatic adjustment mechanism Operation • When the brake pedal is pushed, hydraulic pressure from the brake master cylinder enters chamber B, driving out piston assembly 4 and pulling spring and fitting 1. Lever 3 interlocks with spring and fitting 1, rotating on pin 2.
Page 588 • When the clearance between the brake drum and brake lining increases, movement of piston assem- bly 4 and lever 3 increase. C : Lever travel E : portrusion of adjustor screw • The force of lever 3 increases the rotation of ad- juster assembly 6 and the force of screw of adjuster assembly ejects adjusting screw 7, and brake shoe assembly A expands.
Page 589 STRUCTURE AND OPERATION Front Disc Brake 1 Brake pad wear indicator 2 Disc rotor 3 Torque member 4 Outer pad 5 Inner pad 6 Caliper 7 Piston Inner pad 5 is fitted with brake pad wear indicator 1 that gives warning when it is time to replace outer pad 4 and the inner pads.
Page 590 Automatic adjustment mechanism Operation • When the brake pedal is pushed, hydraulic pressure from the brake master cylinder enters chamber B, driving out piston assembly 4 and pulling spring and fitting 1. Lever 3 interlocks with spring and fitting 1, rotating on pin 2. C : Level travel D : Protrusion of piston assembly 12836...
Page 591 STRUCTURE AND OPERATION • As the clearance between the brake drum and the brake lining increases, the amount of protrusion of piston assem- bly 4 also increases, as does the amount of travel of lever 3. C : Lever travel E : Protrusion of adjuster screw •...
Page 592 Rear Disc Brake 1 Brake pad wear indicator 2 Disc rotor 3 Torque member 4 Outer pad 5 Inner pad 6 Caliper 7 Piston Inner pad 5 is fitted with brake pad wear indicator 1 that gives warning when it is time to replace outer pad 4 and the inner pads.
Page 593 STRUCTURE AND OPERATION Vacuum Pump 1 Check valve assembly 2 Vane 3 Rotor 4 Housing A : Inlet B : Outlet 05224 • The vacuum pump is installed on the timing gear case and is rotated by the injection pump gear or camshaft gear. •...
Page 594 M E M O 35A-17...
Page 595 STRUCTURE AND OPERATION Exhaust Brake System < Manual transmission > 12841 < Automatic transmission > 12842 35A-18...
Page 596 1 Fuse box 12 Clutch switch < Manual transmission > 2 Meter cluster 13 Inhibiter switch < Automatic transmission > 3 Exhaust brake indicator lamp 14 Automatic transmission electric control unit 4 Air cleaner < Automatic transmission > 5 Vacuum tank 15 Exhaust brake cut relay 6 Exhaust brake 3-way magnetic valve 16 Exhaust brake switch <...
Page 597 STRUCTURE AND OPERATION Operation Electrical System < Manual transmission > 12843 < Automatic transmission > 12844 When exhaust brake switch 16 is turned ON, exhaust brake indicator lamp 3 within meter cluster 2 lights up and the exhaust brake 3-way magnetic valve 6 operates. At this time, depressing the clutch pedal (clutch switch 12 OFF) or the accelerator pedal (accelerator switch 17 OFF) temporarily releases the exhaust brake.
Page 598 Exhaust Brake Unit 1 Spring 2 Diaphragm 3 Push rod 4 Butterfly valve 12835 Intake Silencer 1 Push rod 2 Actuator assembly 3 Butterfly valve 4 Intake pipe 13569 35A-21...
Page 599 STRUCTURE AND OPERATION Brake fluid level switch 1 Fluid tank 2 Float 3 Brake fluid level switch *a : For brakes *b : For clutch • Brake fluid level switch 3, installed on fluid tank 1, monitors the brake fluid level in the fluid tank. If the brake fluid level drops below the specified level, float 2 moves and lights up the warning lamp within the meter cluster to alert the driver.
Page 600 M E M O 35A-23...
Page 601 TROUBLESHOOTING Wheel Brake One-sided braking Noise and shock Symptoms when brakes are applied Possible causes ^ Gr 31 Tires Air pressures uneven, etc. ^ Gr 31 Left and right tire sizes different Axle Wheel hub bearing adjusted incorrectly ^ Gr 26A, 26B, 27 Left and right wheelbase difference excessive ^ Gr 26A, 26B, 27 ^ Gr 26A, 26B...
Page 602 One-sided braking Noise and shock Symptoms when brakes are applied Possible causes Wheel Brake drum or disc rotor glazed brakes Brake drum cracked Brake drum clogged by foreign particles Brake drum deformed or eccentric Disc rotor thickness uneven Brake shoe deformed or damaged Brake shoe twisted or tilted Shoe hold down cup broken Moving parts greased insufficiently...
Page 603 TROUBLESHOOTING Brake drums Brakes Symptoms overheating squeaking Remarks Possible causes ^ Gr 31 Tires Air pressures uneven, etc. ^ Gr 31 Left and right tire sizes different ^ Gr 26A, Axle Wheel hub bearing adjusted incorrectly 26B, 27 ^ Gr 26A, Left and right wheelbase difference excessive 26B, 27 ^ Gr 26A, 26B...
Page 604 Brakes Brake drums Symptoms squeaking overheating Remarks Possible causes Wheel Brake drum cracked brakes Brake drum clogged by foreign particle Brake drum deformed or eccentric Disc rotor thickness uneven Brake shoe deformed or damaged Brake shoe twisted or tilted Shoe hold down cup broken Moving parts greased insufficiently Brake pedal Brake pedal stroke faulty (45 mm {1.77 in.} or more at 490 N {110 lbf, 50 kgf} foot pressure)
Page 605 TROUBLESHOOTING Exhaust Brake Symptoms Remarks Possible causes Vacuum Degree of vacuum insufficient system Pipe crushed 3-way Does not work ^ Gr 54 magnetic valve Exhaust Valve assembly does not work brake Valve assembly shaft stuck unit Vacuum chamber does not work Electric Electric system faulty ^ Gr 54...
Page 606 M E M O 35A-29...
Page 607 Parts to be tightened Tightening torque Remarks Air bleeder Front disc brake < FE > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9} — Front wheel cylinder < FG > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9} —...
Page 608 > brake > • Connect vinyl pipes A : one to the front disc brake < FE >, the front drum brake < FG > one to the rear drum brake < FE639 (except FE639 6, FG > or the rear disc brake < FE639 6, FE64 >.
Page 609 Parts to be tightened Tightening torque Remarks Air bleeder Front disc brake < FE > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9} — Front wheel cylinder < FG > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9} —...
Page 610 > brake system. • Connect vinyl pipes A : one to the front disc brake < FE >, the front drum brake < FG >, one to the rear drum brake < FE639, FG639 > or the rear disc brake < FE649 >.
Page 611 ON-VEHICLE INSPECTION AND ADJUSTMENT (1) Air bleeding during regular maintenance, and hydraulic unit replacement When air bleeding is conducted during regular maintenance or when the hydraulic unit is replaced, brake fluid flows into the secondary side (operating circuit) of the hydraulic unit. Therefore, bleed the primary side (normal circuit) by following the procedures below.
Page 612 (2) Air bleeding of secondary side If the system starts operating before air bleeding of the primary side is complete, air can enter the secondary side. In the event the system accidentally starts before the completion of primary side air bleeding, follow the procedures below to bleed air.
Page 613 ON-VEHICLE INSPECTION AND ADJUSTMENT Inspection and Adjustment of Brake Pedal Free Play Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Free play of brake pedal 10 to 15 {0.39 to 0.59} — Adjust [Inspection] Check if brake pedal free play A confirms to the standard valve with the engine stopped.
Page 614 Inspection and Replacement of Disc Brake Pad Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 5, 6 Thickness of FE639 Front disc brake 12 {0.47} 4 {0.16} Replace (except FE639 6) outer and inner pads FE639 6 Front disc brake 14 {0.55}...
Page 615 ON-VEHICLE INSPECTION AND ADJUSTMENT • Remove lower slide pin bolt 3. • Turn caliper 4 upward and secure it using wire. CAUTION– • Make sure that you do not smear, or get dust on, the grease applied to slide pin bolt 3. •...
Page 616 • Push piston 7 until it makes contact with the bottom of caliper 4. 0 : Piston expander 06824 • Slacken off caliper 4, taking care not to damage piston boot 8. • Bleed the bushing. • Apply rubber grease thinly to the outer periphery of slide pin 3. Apply brake fluid thinly to the thread area of slide pin bolt.
Page 617 ON-VEHICLE INSPECTION AND ADJUSTMENT Drum Brake Lining Thickness Inspection and Replacement Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Thickness of brake lining — 4 {0.16} Replace (Side shoulder means wear limit) [Inspection] NOTE Be sure to inspect at two points for each wheel per side.
Page 618 Inspection of Brake Booster (Master Vac) Service standards Location Maintenance item Standard value Limit Remedy — Air tightness with no load (with vacuum meter at Vacuum drop after 15 seconds 67 kPa {19.7 in. Hg, 500 mmHg} and engine stopped) should be 3.3 kPa {0.98 in.
Page 619 ON-VEHICLE INSPECTION AND ADJUSTMENT (2) Inspection of brake booster (master vac) operation NOTE If the brake booster (master vac) is faulty, determine the qual- ity of the brake booster (master vac) as an independent device by means of a bench test specified by the maker’s service station.
Page 620 Inspection with a simplified tester Airtightness inspection • Before inspection, observe the operation of check valve 2 fitted to vacuum hose 1. Õ P35A-41 • Remove vacuum hose 1 from brake booster (master vac) 3, place the end without the white mark on the brake booster (master vac) and connect it to vacuum meter A.
Page 621 ON-VEHICLE INSPECTION AND ADJUSTMENT Inspection of characteristics • Inspect characteristics after the airtightness inspection is finished. • If the results of the following two inspections are good, the opera- tion is normal. If any fault is found in any of the two inspections, the following parts are likely to be faulty.
Page 622 Brake booster (master vac) performance diagram < 8 inch+9 inch > 93 {27.6, 700} 80 {23.6, 600} 7850 {1760, 800} 67 {19.7, 500} 5880 {1320, 600} 3920 {880, 400} 0 {0, 0} 1960 {440, 200} 0 {0, 0} 1960 {440, 200} {220, 100} Force pushing the operating rod (N {lbf, kgf}) 06548...
Page 623 BRAKE MASTER CYLINDER Ê 3 11381 Disassembly sequence 1 Retaining ring 5 Clamp A : Master vac support * : Brake pedal and brake booster 2 Primary piston assembly 6 Connector assembly Õ P35A-48 3 Set bolt 7 Cylinder body 4 Secondary piston assembly WARNING–...
Page 624 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Set bolt 6.86 to 8.82 {5.1 to 6.5, 0.7 to 0.9} — - Lubricant Location Points of application Specified lubricant Quantity Periphery of retaining ring Rubber grease As required Service procedure...
Page 625 BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC) 4 Ê Ê 12942 Disassembly sequence 1 Nut 10 Brake pedal 6 Spring 2 Clevis pin 11 Stop lamp switch 7 Collar 3 Brake booster (master vac) ^ Gr 54 8 Bushing 4 Nut 12 Support assembly 9 Pedal pad 5 Bolt...
Page 626 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Nut (Brake booster mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4} — Nut (Brake pedal mounting) 34.3 to 53.9 {25 to 40, 3.5 to 5.5} —...
Page 627 FRONT WHEEL BRAKE < FE639 (EXCEPT FE639 6 : DISC BRAKE > This illustration shows the left side wheel disc brake viewed from the left front. Ù Ê Ù Ù Ê Ù Ù 06971 Disassembly sequence 1 Slide pin bolt 9 Inner shim A 16 Bushing 2 Piston boot...
Page 628 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 8, 13 Thickness of outer and inner pads 12 {0.47} 4 {0.16} Replace Disc rotor Wobble (When installed on front axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace Thickness 20 {0.79}...
Page 629 FRONT WHEEL BRAKE < FE639 (EXCEPT FE639 6 : DISC BRAKE > Service procedure Measurement of dragging torque • Fasten spring balance A to hub bolt B and measure the tangential force. • If the measured value is the specified value, the torque conforms to the standard value.
Page 630 Installation of bushing A : Push bar approximately ø8 mm {0.31 in.} long After installation, apply grease to the whole inner periphery of bushing 16 and its contact surface with slide pin bolt 1. 06962 Installation of pin boot • Apply grease to pin boot groove A of torque member 19, the whole surface of guide hole B, and contact surface C between slide pin bolt 1 and pin boot 17.
Page 631 FRONT WHEEL BRAKE < FE639 6, FE64 : DISC BRAKE > This illustration shows the left side wheel disc brake viewed from the left front. Ù Ê Ù Ù Ê Ù 12648 Disassembly sequence 9 Inner shim A 16 Bushing 1 Slide pin bolt 10 Inner shim B 17 Pin boot...
Page 632 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 8, 13 Thickness of outer and inner pads 14 {0.55} 4 {0.16} Replace Disc rotor Wobble (When installed on front axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace Thickness 40 {1.57}...
Page 633 FRONT WHEEL BRAKE < FE639 6, FE64 : DISC BRAKE > Service procedure Measurement of dragging torque • Fasten spring balance A to hub bolt B and measure the tangential force. • If the measured value is the specified value, the torque conforms to the standard value.
Page 634 Installation of bushing A : Push bar approximately ø8 mm {0.31 in.} long After installation, apply grease to the whole inner periphery of bushing 16 and its contact surface with slide pin bolt 1. 06962 Installation of pin boot • Apply grease to pin boot groove A of torque member 18, the whole surface of guide hole B, and contact surface C between slide pin bolt 1 and pin boot 17.
Page 635 FRONT WHEEL BRAKE < DRUM BRAKE > Front Wheel Brake Assembly 9 Ê Ê Ê 12 Ê 9 Ê 14 Ù 05878 Disassembly sequence 1 Return spring 12 Bolt 2 Shoe hold down cup 13 Connector 3 Shoe hold down spring 14 Bolt 4 Shoe hold down pin 15 Wheel cylinder assembly Õ...
Page 636 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Return spring load (Installed length 190 {7.48}) 195 to 235 N 175 N Replace {44 to 53 lbf, 19.8 to 24.2 kgf} {40 lbf, 18 kgf} Brake shoe assembly (Thickness of brake lining) 10.0 {0.39} 4.0 {0.16} Replace...
Page 637 FRONT WHEEL BRAKE < DRUM BRAKE > • Adjust the brake shoe clearance as follows, so that 0.3 mm {0.012 in.} feeler gauge B can be inserted or extracted through check hole A, between brake drum * and brake lining 7 with a little resistance. 00320 •...
Page 638 [Installation] Insert a small Phillips screwdriver C into the hook of return spring 1, insert the tip of the screwdriver into return spring installation hole D of brake shoe assembly 5 to pry on the return spring. 05880 Inspection of brake shoe assembly If thickness A of brake lining 7 is lower than the limit, replace the brake lining on the same axle as a unit.
Page 639 FRONT WHEEL BRAKE < DRUM BRAKE > [Installation] • Clean the mounting surfaces of brake lining 7 and brake shoe 8 with cleaning fluid and dry them. • Insert rivets 6 from brake lining 7 side, and caulk the rivets at the specified load so that there is no clearance between brake shoe 8 and the brake lining.
Page 640 Wheel Cylinder Assembly Disassembly sequence 1 Spring 2 Spring and fitting 3 Lever 4 Adjusting screw 5 Adjuster 6 Washer Ù 7 Piston cup 8 Piston 9 Boot 10 Bleeder screw 11 Body Ê Ù Ù : Non-reusable parts Assembly sequence 05376 11→10→9 →6→5→4→3→2→1...
Page 641 REAR WHEEL BRAKE < DRUM BRAKE > Rear Wheel Brake Assembly Ê 9 Ê 11 Ù6 05972 Disassembly sequence 1 Return spring 10 Spacer 2 Shoe hold down cup 11 Bolt 3 Shoe hold down spring 12 Wheel cylinder assembly Õ P35A-70 4 Shoe hold down pin 13 Cover 5 Brake shoe assembly...
Page 642 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Return spring load (Installed length 190 {7.48}) 195 to 235 N 175 N Replace {44 to 53 lbf, 19.8 to 24.2 kgf} {40 lbf, 18 kgf} Brake shoe assembly (Thickness of brake lining) 10.0 {0.39} 4.0 {0.16} Replace...
Page 643 REAR WHEEL BRAKE < DRUM BRAKE > • Adjust the brake shoe clearance as follows, so that 0.3 mm {0.012 in.} feeler gauge B can be inserted or extracted through check hole A, between brake drum * and brake lining 7 with a little resistance. 00320 •...
Page 644 [Installation] Insert a small Phillips screwdriver C into the hook of return spring 1, insert the tip of the screwdriver into return spring installation hole D of brake shoe assembly 5 to pry on the return spring. 05880 Inspection of brake shoe assembly If thickness A of brake lining 7 is lower than the limit, replace the brake lining on the same axle as a unit.
Page 645 REAR WHEEL BRAKE < DRUM BRAKE > [Installation] • Clean the mounting surfaces of brake lining 7 and brake shoe 8 with cleaning fluid and dry them. • Insert rivets 6 from brake lining 7 side, and stake the rivets at the specified load so that there is no clearance between brake shoe 8 and the brake lining.
Page 646 M E M O 35A-69...
Page 647 REAR WHEEL BRAKE < DRUM BRAKE > Wheel Cylinder Assembly Disassembly sequence 1 Spring 2 Spring and fitting Ù 3 Lever 4 Piston cup 5 Piston 6 Boot 7 Adjusting screw 8 Adjuster Ù 9 Washer Ù 10 Piston cup 11 Piston 12 Boot 13 Bleeder screw...
Page 648 Service procedure Installation of spring Install the closed hook of spring 1 on body 14 side. 05587 Installation of washer Install the washer with its black side facing adjuster 8. 06149 35A-71...
Page 649 REAR WHEEL BRAKE < DISC BRAKE > This illustration shows the left side wheel disc brake viewed from the left front. - Ê Ù - Ù 18 - Ù Ù - 5 Ê 06979 Disassembly sequence 1 Slide pin bolt 8 Outer pad 15 Pad liner B 2 Piston boot...
Page 650 Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy 8, 13 Thickness of outer and inner pads 14 {0.55} 4 {0.16} Replace Disc rotor Wobble (When installed on rear axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace Thickness 40 {1.57}...
Page 651 REAR WHEEL BRAKE < DISC BRAKE > Service procedure Measurement of dragging torque • Fasten spring balance A to hub bolt B and measure the tangential force. • If the measured value is the specified value, the torque conforms to the standard value.
Page 652 Installation of bushing A : Push bar approximately ø8 mm {0.31 in.} long After installation, apply grease to the whole inner periphery of bushing 16 and its contact surface with slide pin bolt 1. 06962 Installation of pin boot • Apply grease to pin boot groove A of torque member 18, the whole surface of guide hole B, and contact surface C between slide pin bolt 1 and pin boot 17.
Page 653 VACUUM PUMP Ù 3 - Ù 05412 Disassembly sequence 1 Check valve assembly 5 Vane : Positioning pin 2 Bolt 6 Rotor Ù : Non-reusable parts 3 O-ring 7 O-ring 4 Cylinder 8 Flange Assembly sequence Follow the disassembly sequence in reverse. Service standards Location Maintenance item...
Page 654 M E M O 35A-77...
Page 655 EXHAUST BRAKE SYSTEM Exhaust Brake Unit Disassembly sequence 1 Bolt 2 Cover 3 Clevis pin 4 Nut 5 Clevis 6 Lock nut Ê 6 7 Bearing 8 Vacuum chamber 9 Nut 10 Lever 11 Bolt 12 Nut 12 Ê 13 Adjusting bolt 14 Bracket 9 Ê...
Page 656 Service procedure Adjustment of clevis Install vacuum chamber 8 on bracket 14, and adjust the position of clevis 5 so that the hole of the clevis is half the pitch of the hole of lever 10. 05257 Test of vacuum chamber airtightness Arrange piping as illustrated, and apply vacuum of 67 kPa {19.7 in.
Page 657 EXHAUST BRAKE SYSTEM Intake Silencer Disassembly sequence 1 Bolt 2 Nut 3 Actuator 4 Spacer 5 Thrust plate 6 O-ring 7 Intake manifold Ù : Non-reusable parts Assembly sequence Follow the disassembly sequence in reverse. Adjustment after assembly Õ P35A-81 6-Ù...
Page 658 Service procedure Adjustment after assembly • Loosen bolts 1. • While applying negative pressure of 67 kPa {19.7 in. Hg, 500 mmHg} to actuator 3, adjust the position of the actuator so that clearance B between intake manifold 7 and butterfly valve A con- forms to the standard value.
Page 659 Group 35E Anti-Lock Brake System (ABS) ' 98 Minor Change Pub No. TWSE0101-35E...
Page 660 INDEX SPECIFICATIONS ................35E- 2 STRUCTURE AND OPERATION ........... 35E- 2 ON-VEHICLE INSPECTION AND ADJUSTMENT 35E-15 • Periodic Inspection Procedures .............. • Inspection of Wheel Speed Sensor Signal Waveform 35E-16 Using Oscilloscope .................. 35E-17 • Hydraulic Unit Operation Check .............. TROUBLESHOOTING 35E-19 •...
Page 661 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Brake system Vacuum servo Number of sensors/number of channels 4S/4K Manufacturer NIPPON ABS STRUCTURE AND OPERATION Anti-lock Brake System (ABS) The anti-lock brake system (ABS) prevents tire slippage due to wheel lockup caused by sudden braking and braking on slippery road surfaces.
Page 662 Rear wheel lockup (both rear tires) Steering direction Braking point 07730 When the steering wheel is operated with the rear wheels in a lockup condition, the front tires try to change the vehicle’s traveling direction, but the rear tires slide sideways, causing the vehicle to spin. If wheel lockup occurs in a vehicle traveling in a straight direction, the force of inertia continues to push the vehicle straight ahead from the back of the vehicle due to the lack of stopping force in the rear tires, and the vehicle can spin.
Page 663 STRUCTURE AND OPERATION Structure of anti-lock brake system Brake fluid line Electric line P 35951 1 Brake booster (Mastervac) 7 Hydraulic unit 2 Brake master cylinder 8 Relay box 3 Anti-lock brake system warning lamp 9 Wheel speed sensor 4 Exhaust brake cut relay 10 Rotor 5 G sensor <...
Page 664 Anti-lock brake system function Input signals Electronic control unit Output signals Hydraulic unit Solenoid valve (for front-axle left wheel) Wheel speed sensor →   → • Pressure holding valve (for front-axle left wheel) • Pressure reducing valve Wheel speed sensor →...
Page 665 STRUCTURE AND OPERATION Anti-lock brake system control function To provide optimum stopping power, the ABS controls the braking force based on the slip rate determined by the relationship between the wheel speed and the vehicle speed. When the brake is applied, the resulting force slows down the wheel rotation, thus reducing the vehicle speed.
Page 666 Anti-lock brake system operation Anti-lock brake system control characteristic curve Actual vehicle speed Vehicle speed and wheel speed Estimated vehicle speed Wheel Slip rate setting speed Wheel acceleration/ deceleration speed – b Pressure decrease Pressure Signal (from hold electronic control unit) Pressure increase...
Page 667 STRUCTURE AND OPERATION Hydraulic Unit (1) Internal circuit P36687 35E-8...
Page 668 1 Check valve (front right wheel) 13 Reservoir (rear system) A: From master cylinder 2 Solenoid valve (holding 14 Plunger pump (rear system) (front system) pressure for front right wheel) 15 Inlet valve (rear system) B: From master cylinder 3 Check valve (front left wheel) 16 Outlet valve (rear system) (rear system) 4 Solenoid valve (holding...
Page 669 STRUCTURE AND OPERATION (2) Braking in normal conditions (anti-lock brake system not activated) : when brake pedal is depressed : when brake pedal is released The Figure shows the hydraulic control for the front left wheel. P36688 • In the conditions where the brake pedal is depressed but ABS is not activated, no control signals are sent to the solenoid valve 6 (reducing pressure for front left wheel) and the solenoid valve 4 (holding pressure for front left wheel) in the hydraulic unit.
Page 670 (3) When anti-lock brake system is activated (for reducing pressure) The Figure shows the hydraulic control for the front left wheel. P36689 • If the front left wheel shows signs of locking when the brake pedal is depressed, the electronic control unit sends the control signals to the solenoid valve 6 (reducing pressure for front left wheel) and the solenoid valve 4 (holding pressure for front left wheel).
Page 671 STRUCTURE AND OPERATION (4) When anti-lock brake system is activated (for holding pressure) The Figure shows the hydraulic control for the front left wheel. P36690 If the brake fluid pressure D in the wheel brake should be maintained for sustained anti-lock brake system control, the electronic control unit sends the pressure holding signal to the solenoid valve 4 (holding pressure for front left wheel) and stops control signal to the solenoid valve 6 (reducing pressure for front left wheel).
Page 672 (5) When anti-lock brake system is activated (for increasing pressure) The Figure shows the hydraulic control for the front left wheel. P36691 • If the brake fluid pressure D in the wheel brake should be increased, the electronic control unit stops sending control signals to the solenoid valve 4 (holding pressure for front left wheel) and solenoid valve 6 (reducing pressure for front left wheel) in the hydraulic unit.
Page 673 (front-axle right-wheel input) Hydraulic unit (front-axle right-wheel Wheel speed sensor brake fluid pressure decrease) (front-axle left-wheel input) < FE > Hydraulic unit (front-axle left-wheel G sensor (power supply) < FG > brake fluid pressure decrease) Ground –...
Page 674 ON-VEHICLE INSPECTION AND ADJUSTMENT Periodic Inspection Procedures (1) Periodic inspection of Anti-lock brake system • Inspect the vehicle’s Anti-lock brake system following the procedure below. • If an abnormality is found in this inspection, further inspect the Anti- lock brake system using 0 MUT-II (multi-use tester-II) by referring to TROUBLESHOOTING section.
Page 675 ON-VEHICLE INSPECTION AND ADJUSTMENT Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope Inspect the rotor for dents using an oscilloscope, since the tester cannot be used for dent detection. NOTE Use an oscilloscope with a waveform recording function. • Lift the wheel to be tested off the ground, and disconnect the connec- tor at the wheel speed sensor.
Page 676 Hydraulic Unit Operation Check Operation check using MUT-II • Lift the vehicle using a jack and support it with jack stands, or position the tires on brake tester rollers. WARNING– • The brake tester rollers and tires must be dry during inspection. •...
Page 677 ON-VEHICLE INSPECTION AND ADJUSTMENT   Press  Pedal  operation   MUT-II actuator test Release  (one of items Nos. 11 through 14) Operation starting   Pressure  increase     Solenoid valve  position 3 sec Pressure ...
Page 678 TROUBLESHOOTING Troubleshooting Procedures Inspection flow chart The MUT-II allows efficient inspection of the anti-lock brake system. The types of system inspections can be roughly divided according to the malfunction condition and diagnosis code, as shown below. • Inspection based on individual malfunction diagnosis codes stored in the electronic control unit •...
Page 679 TROUBLESHOOTING Inspection of anti-lock brake system warning lamp Check the anti-lock brake system warning lamp to make sure that the following operation turns on the lamp. • Set the starter switch to the ON position, and check that the anti-lock brake system warning lamp lights for about 1 second and turns off.
Page 680 Deletion of diagnosis codes MUT-II Ground Connect terminal No. 16 of the MUT-II connector to the chassis for connector terminal grounding. While depressing the brake pedal, turn the starter switch on No. 16 Open and off ten times in intervals of 1 second or less. Turn the key off, Starter 1 sec Data...
Page 681 TROUBLESHOOTING Tool name and shape Part No. Application Inspection of Anti-lock brake system MUT-II harness MB991499 (for circuit tester) 20536 Memory card MB991500 (for MUT-II) 20538 Connecting the MUT-II • Turn the starter switch to the LOCK position. • Connect the 2 MUT Communication Harness to the 1 MUT-II, and insert the 3 ROM Pack.
Page 682 Diagnosis Code Chart Diagnosis codes can be read by using the MUT-II or anti-lock brake system warning lamp. Malfunction location Diagnosis code MUT-II display Description of malfunction FR-SNSR OPEN Broken wire to front-axle right-wheel speed sensor FL-SNSR OPEN Broken wire to front-axle left-wheel speed sensor RR-SNSR OPEN Broken wire to rear-axle right-wheel speed sensor RL-SNSR OPEN...
Page 683 TROUBLESHOOTING Service Data MUT-II display Inspection condition Criterion FR SPEED FL SPEED Constant-speed driving Same as speedometer indication RR SPEED RL SPEED ECU VOLTAGE Starter switch ON Same as battery voltage G-SNS VOLTAGE Vehicle parked on level surface 2.3 ± 1.0 V Brake pedal depressed STOP LAMP SW ON/OFF...
Page 684 ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS 45327 35E-26...
Page 685 1 Starter switch 6 Fuse box 12 Rear wheel speed sensor, RH 2 Exhaust brake cut relay 7 Stop lamp switch 13 Rear wheel speed sensor, LH 3 Relay box 8 G sensor 14 Hydraulic unit 4 Multi-use tester-II connector 9 Meter cluster 15 High current fuse box 5 Anti-lock brake system...
Page 686 Group 36 Parking Brake ' 98 Minor Change Pub No. TWSE0101-36...
Page 687 INDEX SPECIFICATIONS ................36- 2 STRUCTURE AND OPERATION ............ 36- 2 TROUBLESHOOTING ..............36- 3 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE • Adjustment of Parking Brake Shoe Clearance 36- 4 and Ratchet Bar Pulling Stroke ..............PARKING BRAKE CONTROL ............36- 6 PARKING BRAKE ASSEMBLY ............
Page 688 SPECIFICATIONS/STRUCTURE AND OPERATION SPECIFICATIONS Item Specifications Brake Type Propeller shaft internal expanding type brake Operation type Mechanical cable type Parking brake Type Dual-servo type assembly Inner diameter of drum mm {in.} ø190 {7.48} Lining width × Thickness mm {in.} 45×4.0 {1.77×0.16} STRUCTURE AND OPERATION Parking Brake Control 1 Parking brake ratchet bar...
Page 689 TROUBLESHOOTING Symptoms Remarks Possible causes Inner cable stretched or damaged Parking brake cable Inner cable rusted Inner spring of cable deteriorated, fractured Ratchet bar and ratchet pawl engaging incorrectly Parking brake Pulling stroke insufficient ratchet bar Pulling stroke excessive Shoe clearance insufficient Shoe clearance excessive Parking brake drum inner surface deformed or distorted Parking brake...
Page 690 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Adjustment of Parking Brake Shoe Clearance and Ratchet Bar Pulling Stroke Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Brake shoe clearance 0.2 to 0.25 {0.0079 to 0.0098} —...
Page 691 M E M O 36-5...
Page 692 PARKING BRAKE CONTROL 14107 Removal sequence 1 Parking brake ratchet bar assembly Õ P36-7 2 Parking brake cable * : Parking brake assembly Õ P36-8 WARNING– • You must place wheel chocks securely in place to prevent the vehicle from moving. •...
Page 693 Parking Brake Ratchet Bar Assembly Disassembly sequence 1 Push nut 2 Pin 3 Ratchet pawl 4 Ratchet spring 5 Push nut 6 Pin 7 Return spring 8 Ratchet bar 9 Parking brake switch ^ Gr 54 10 Grommet 11 Clip 12 Support Assembly sequence Follow the disassembly sequence in re-...
Page 694 Remarks Nut (Propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12} — Lock nut (Companion FE (Manual transmission), FG 245 to 345 {180 to 255, 25 to 35} — flange mounting) FE (Automatic transmission) 125 {94, 13} —...
Page 695 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application ø90 {3.54} ø100 {3.94} Flange puller MH061848 Removal of companion flange ø95 {3.74} 03618 Service procedure Removal of companion flange 03609 36-9...
Page 696 BACKING PLATE AND SHOE ASSEMBLY Disassembly sequence 1 Shoe return spring 2 Washer 3 Strut spring 4 Shoe hold down cup 5 Shoe hold down spring 6 Shoe hold down pin 7 Adjuster 8 Adjuster spring 9 Strut 10 Retainer 11 Parking lever 12 Shoe and lining assembly 13 Backing plate...
Page 697 Service procedure Applying grease to adjuster and backing plate • Apply grease to contact surface C between both ends of adjuster 7 and shoe and lining assembly 12. • Apply grease to area D of the anchor pin and sliding face E (6 points) of backing plate 13.
Page 698 Group 37 Steering ' 98 Minor Change Pub No. TWSE0101-37...
Page 699 • Performance Verification Test of Power Steering System ..... STEERING SYSTEM ............... 37- 14 STEERING COLUMN SUBASSEMBLY .......... 37- 20 POWER STEERING BOOSTER 37- 24 < FE > ......................37- 30 < FG > ......................POWER STEERING OIL PUMP ............37- 36 POWER STEERING OIL TANK............37- 40 POWER STEERING FLUID LINE ...........
Page 700 SPECIFICATIONS Model Item Steering wheel Type 2-spoke type Outer diameter mm {in.} 400 {15.7} Steering shaft Type Universal joint type (High tilt and telescopic type) Power steering Manufacturer KOYO SEIKO booster Type Ball nut type Form Integral type Gear ratio 22.6 Cylinder diameter mm {in.}...
Page 701 STRUCTURE AND OPERATION Steering System 1 Steering wheel 2 Steering column subassembly 3 Power steering booster 4 Pitman arm 5 Drag link 6 Knuckle arm 7 Tie rod 8 Tie rod arm 08220 Shifting lock lever A from lock position B to release position C produces high tilt D, and turning telescopic lever E (counterclockwise) from lock position F to re- lease position G allows telescopic movement H.
Page 702 STRUCTURE AND OPERATION Power Steering System 1 Power steering oil tank 2 Power steering oil pump 3 Power steering booster : Fluid flow 08371 Power Steering Booster 23 22 27494 37-4...
Page 703 1 Lock nut 11 Valve housing 21 Backup ring 2 Sector shaft 12 Dust cover 22 U-packing 3 Gear box 13 Input shaft 23 Needle bearing 4 Steel ball 14 Oil seal 24 Needle bearing 5 Circulator 15 Bearing 25 U-packing 6 Adjusting plate 16 Rotary valve 26 Backup ring...
Page 704 STRUCTURE AND OPERATION Power Steering Oil Pump 06801 1 Cam ring 9 Oil seal 17 Relief valve assembly 2 Vane 10 Side plate 18 Flow control spring 3 Rotor 11 Bolt 19 Bolt 4 Pin 12 Cover 20 Body 5 Lock nut 13 Suction connector 6 Gear 14 Shaft...
Page 705 Relief Valve Assembly Operation of flow control valve (1) When not operating (Oil pump rotating at low speed) Since pressure generated from pressure chamber A is low when the oil pump is rotating at low speed, fluid pressure in chamber B is also low.
Page 706 TROUBLESHOOTING Symptoms Remarks Possible causes Bearing damaged or worn Ball or groove of ball screw set shaft worn Air bled insufficiently Fluid viscosity unsuitable Power steering booster system faulty Flow control valve malfunctioning Rack or ball screw set shaft gear worn Sector shaft bearing worn Power steering booster mounting bolt loose Ball screw set shaft and sector shaft play incorrect...
Page 707 Symptoms Remarks Possible causes Kingpin lubricated incorrectly Front wheel alignment (toe-in, camber, caster) incorrect Thrust bearing damaged ^ Gr 26A, B Wheel hub bearing worn or damaged Kingpin or bushing worn or damaged Front axle deformed Knuckle arm, tie rod arm, knuckle, etc. tightened incorrectly ^ Gr 33 U-bolt of front spring, nut loose...
Page 708 Wheelbase gap between left and right excessive ^ Gr 25 Propeller shaft run out excessive ^ Gr 26A Front axle bent < FE > ^ Gr 26B Front axle housing bent < FG > ^ Gr 27 Rear axle housing bent...
Page 709 ON-VEHICLE INSPECTION AND ADJUSTMENT Change of Power Steering Fluid Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Pressure tube 29 to 39 {22 to 29, 3 to 4} — Return tube 39 to 49 {29 to 36, 4 to 5} —...
Page 710 ON-VEHICLE INSPECTION AND ADJUSTMENT Bleeding of Power Steering System - Fluid Location Points of application Kinds Quantity Power steering oil tank Automatic transmission fluid (DEXRON Filler cap or DEXRON II type) dipstick between MIN and CAUTION– Do not keep the steering wheel turned fully to the left or right for more than fifteen seconds when the engine is running, as this can cause the power steering oil pump to seize up.
Page 711 Relief set pressure 9.3 MPa to 1500 rpm, and close stop valve B to measure maximum relief pressure {1350 lbf/in , 95 kgf/cm } < FE >, fluid pressure 10.3 MPa {1490 lbf/in , 105 kgf/ } < FG >...
Page 712 STEERING SYSTEM Ê 8 Ê - 12 Ê 14 Ê < FE > Ù Ê Ê Ê 33 Ê 21 Ê Ù Ê Ê 28 < FG > Ê Ê 31 33 Ê 30369 37-14...
Page 713 10 Horn spring 24 Dust cover * : Front axle assembly 11 Contact plate 25 Bolt < FE > ^ Gr 26 12 Cover assembly 26 Bolt < FG > ^ Gr 26B 13 Steering wheel 27 Steering column subassembly Õ...
Page 714 STEERING SYSTEM Service procedure Removal of horn pad • Insert a flat-tip screwdriver into the space between steering wheel assembly 9 and shoulder sections A, B of horn pad 5, and disengage the latch by prying open the horn pad with the screwdriver until a clicking sound is produced.
Page 715 Install steering wheel assembly 9. Using a long socket wrench, tighten Start procedure > nut 8 at specified torque 39 to 49 N·m {29 to 36 ft.lbs, 4 to 5 kgf·m} Looseness found No looseness Rotate telescopic shaft B counterclockwise with your fingers and check for looseness Set telescopic lever 7 to specified lock po- >...
Page 716 STEERING SYSTEM Head cutting bolt, starter switch [Removal] • After removing bracket 16, drill a ø5.5 to 6.0 mm {0.22 to 0.24 in.} hole 10 to 15 mm {0.39 to 0.59 in.} deep on cutting face A of head cutting bolt 17 for mounting starter switch 18.
Page 717 M E M O 37-19...
Page 718 STEERING COLUMN SUBASSEMBLY Ê 2 Ê 23 Ê - - Ê 23 Ê 11 6 Ê Ù 20 Ê Ê Ù 18 - Ù 07019 37-20...
Page 719 Disassembly sequence 11 Nut 21 Lever support 1 Return spring 12 Lock lever 22 Clevis pin 2 Nut 13 Split pin 23 Bolt 3 Support bracket 14 Return spring 24 Column support upper 4 Spring seat 15 Return spring 25 Telescopic shaft assembly 5 Steering column assembly 16 Snap ring 26 Column support lower...
Page 720 STEERING COLUMN SUBASSEMBLY Service procedure Installation of stopper Install stoppers 7 on steering shaft assembly 10 in the direction as illustrated so that they straddle bearing spacer 8. 11310 Steering shaft assembly • Before removing steering shaft assembly 10, be sure to make align- ment mark A.
Page 721 Installation of clevis pin Drive clevis pin 22 into column support upper 24 so that the drive dimension is obtained. 13 mm {0.51 in.} 07000 37-23...
Page 722 POWER STEERING BOOSTER < FE > Ù 15 Ê Ù 20 Ê Ù Ù Ù 17 Ù 19 Ù Ù Ù 18 Ù Ù 16 Ê Ê Ù Ù 27495 Inspection before disassembly Õ P37-26 Disassembly sequence 1 Lock nut...
Page 723 Assembly sequence 25 → 24 → 23 → 22 → 21 → 16 → 15 → 14 → 5 → 4 → 3 → 2 → 1 ↑ 20 → 19 → 18 → 17     13 → 12 → 11 → 10 → 9 ...
Page 724 POWER STEERING BOOSTER < FE > 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application 49 {1.93} 76 {2.99} Pitman arm puller MH062472 Removal of pitman arm 01355 Service procedure Inspection before disassembly [Measurement of total starting torque] Before disassembly, measure the total starting torque for a reference during assembly.
Page 725 [Installation] Align slit B of the V-groove of sector shaft 8 on the same line as slit A of the V-groove of pitman arm 2 when installing it. 06691 Sector shaft and side cover [Removal] • Turn ball screw set shaft 20 counterclockwise to the lock position, then turn it clockwise approximately 2.6 turns, so that slit A of the V-groove at the end of sector shaft 8 is in the neutral position as illustrated.
Page 726 POWER STEERING BOOSTER < FE > Installation of U-packing Apply grease to lip area A of U-packing 11, 23 and install into gear box 12, 24 11, 23 25 as illustrated. 27502 Installation of oil seal Apply grease to lip area A of oil seal 21 and install into gear box 25 as illustrated.
Page 727 M E M O 37-29...
Page 728 POWER STEERING BOOSTER < FG > Ù 25 Ù 18 Ê Ù 19 Ù Ê Ù Ù Ù 20 Ù 27 Ù 26 9 Ù Ù Ê 4 14 Ù Ê Ù Ê 08221 Inspection before disassembly Õ P37-32 Disassembly sequence 1 Lock nut 13 Special nut 25 Seal ring...
Page 729 NOTE Do not disassemble needle bearing 10, 30 and ball screw set shaft 28 unless they are faulty. Inspection after assembly Õ P37-33 Assembly sequence 16 → 15 → 14 32 → 31 → 30 → 29 → 18 → 17 → 13 → 4 → 3 → 2 → 1 28 →...
Page 730 POWER STEERING BOOSTER < FG > - Lubricant and/or sealant Location Points of application Specified lubricant and/or sealant Quantity 3, 17 Pack interior of dust cover Wheel bearing grease [NLGI No.2 (Li soap)] As required Nut fixing point THREEBOND 1104 As required 23, 29 Lip area of oil seal...
Page 731 Inspection after assembly [Measurement of total starting torque] • While turning ball screw set shaft 28, one quarter of a turn left and right from the neutral position using a torque meter, drive adjusting bolt 7 in, then adjust so that the total starting torque or the engage- ment torque is within the standard value.
Page 732 POWER STEERING BOOSTER < FG > • Loosen nut 5 and remove bolt 4. After making sure that sector shaft 8 is in the neutral position, tap the end of the sector shaft, and pull out side cover 12 together with the sector shaft. B : Plastic-headed mallet 06693 [Installation]...
Page 733 [Installation] • Install inner race of bearing 15 onto the end of ball screw set shaft 28, then install the outer race of the bearing onto end cover 16 and screw into gear box 32. 08224 • Making sure that the rotation torque of ball screw set shaft 28 is not uneven, thread end cover 16, using 0 end cover wrench, until the rotation torque is within the standard value.
Page 734 POWER STEERING OIL PUMP 11 Ê Ù 18 Ù 6 Ê 8 Ù 7 20 Ù 21 Ù Ù 5 Ê 1 3 Ê 06805 Disassembly sequence 1 Lock nut 10 Flow control spring 19 Side plate 2 Gear 11 Bolt 20 O-ring 3 Bolt 12 Pin...
Page 735 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) 9, 22 Clearance between relief valve assembly and body [14] 0.01 to 0.02 0.03 {0.0012} — and shaft assembly {[0.55] 0.00039 to 0.00079} Flow control spring free length 36.5 {1.44} 33.5 {1.32}...
Page 736 POWER STEERING OIL PUMP Installation of vane With R point of vane 15 facing outside A, install it on rotor 16 and make sure that the vane moves smoothly. If it is faulty, replace cartridge 14. R point 06809 Installation of cam ring and side plate •...
Page 737 M E M O 37-39...
Page 738 POWER STEERING OIL TANK Disassembly sequence 3 Ê 1 Filler cap 2 Strainer 3 Screw 4 Filter 5 Packing 6 Tank Ù : Non-reusable parts 5 Ù Assembly sequence Follow the disassembly sequence in re- verse. 27004 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened...
Page 739 POWER STEERING FLUID LINE Removal sequence 1 Nut 2 Pressure hose 3 Clamp 4 Rubber hose Ê 1 5 Clamp 6 Rubber hose 7 Pressure tube Ê 8 8 Return tube *a : Power steering oil tank *b : Power steering oil pump *c : Power steering booster 7 Ê...
Page 740 10 Ball stud seat 3 Spring *b : Knuckle arm 11 Ball stud seat 4 Ball stud seat < FE > ^ Gr 26A 12 Spring 5 Ball stud seat < FG > ^ Gr 26B 13 Grease nipple 6 Grease nipple Ù...
Page 741 1289 Service procedure Installation of split pin and end plug Approximately 4 mm {0.16 in.} • Tighten end plug 2, 9 fully, then slacken it off by one half of a turn. • Place split pins 1, 8 so that the heads face the outside of the vehicle. •...
Page 742 TIE ROD ASSEMBLY Disassembly sequence 1 Clip 2 Dust cover 3 Clamp bolt 4 Tie rod end 5 Tie rod NOTE Do not remove clip 1 or dust cover 2 unless they Ê 3 are faulty. Assembly sequence Follow the disassembly sequence in reverse. 07260 Service standards Unit : mm {in.}...
Page 743 Ensure that ball B rotates evenly. 07262 [Installation] : 74 mm {2.91 in.} < FE > • Screw in tie rod end 4 so that dimension D of the tie rod end and clamp 68 mm {2.68 in.} < FG >...
Page 744 Group 37 Steering ' 98 Minor Change Pub No. TWSE0304-37...
Page 745 INDEX SPECIFICATIONS ................37- 2 STRUCTURE AND OPERATION ............ 37- 3 TROUBLESHOOTING ..............37- 8 ON-VEHICLE INSPECTION AND ADJUSTMENT 37- 11 • Change of Power Steering Fluid ............... 37- 12 • Bleeding of Power Steering System ............37- 12 • Steering Wheel Play ................... 37- 13 •...
Page 746 SPECIFICATIONS Model Item Steering wheel Type 2-spoke type Outer diameter mm {in.} 400 {15.7} Steering shaft Type Universal joint type (High tilt and telescopic type) Power steering Manufacturer KOYO SEIKO booster Type Ball nut type Form Integral type Gear ratio 22.6 +3°...
Page 747 STRUCTURE AND OPERATION Steering System 1 Steering wheel 2 Steering column subassembly 3 Power steering booster 4 Pitman arm 5 Drag link 6 Knuckle arm 7 Tie rod 8 Tie rod arm 08220 Shifting lock lever A from lock position B to release position C produces high tilt D, and turning telescopic lever E (counterclockwise) from lock position F to re- lease position G allows telescopic movement H.
Page 748 STRUCTURE AND OPERATION Power Steering System 1 Power steering oil tank 2 Power steering oil pump 3 Power steering booster : Fluid flow 08371 Power Steering Booster 23 22 27494 37-4...
Page 749 1 Lock nut 11 Valve housing 21 Backup ring 2 Sector shaft 12 Dust cover 22 Y-packing assembly 3 Gear box 13 Input shaft 23 Needle bearing 4 Steel ball 14 Oil seal 24 Needle bearing 5 Circulator 15 Bearing 25 Y-packing assembly 6 Adjusting plate 16 Rotary valve...
Page 750 STRUCTURE AND OPERATION Power Steering Oil Pump 42680 1 Cam ring 8 Oil seal 15 Relief valve assembly 2 Vane 9 Side plate 16 Flow control spring 3 Rotor 10 Bolt 17 Bolt 4 Pin 11 Cover 18 Body 5 Gear 12 Suction connector 6 Snap ring 13 Shaft...
Page 751 Relief Valve Assembly Operation of flow control valve (1) When not operating (Oil pump rotating at low speed) Since pressure generated from pressure chamber A is low when the oil pump is rotating at low speed, fluid pressure in chamber B is also low.
Page 752 TROUBLESHOOTING Symptoms Remarks Possible causes Bearing damaged or worn Ball or groove of ball screw set shaft worn Air bled insufficiently Fluid viscosity unsuitable Power steering booster system faulty Flow control valve malfunctioning Rack or ball screw set shaft gear worn Sector shaft bearing worn Power steering booster mounting bolt loose Ball screw set shaft and sector shaft play incorrect...
Page 753 Symptoms Remarks Possible causes Kingpin lubricated incorrectly Front wheel alignment (toe-in, camber, caster) incorrect Thrust bearing damaged ^ Gr 26A, B Wheel hub bearing worn or damaged Kingpin or bushing worn or damaged Front axle deformed Knuckle arm, tie rod arm, knuckle, etc. tightened incorrectly ^ Gr 33 U-bolt of front spring, nut loose...
Page 754 Wheelbase gap between left and right excessive ^ Gr 25 Propeller shaft run out excessive ^ Gr 26A Front axle bent < FE > ^ Gr 26B Front axle housing bent < FG > ^ Gr 27 Rear axle housing bent...
Page 755 ON-VEHICLE INSPECTION AND ADJUSTMENT Change of Power Steering Fluid Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Pressure tube 29 to 39 {21 to 29, 3 to 4} — Return tube 39 to 49 {29 to 36, 4 to 5} —...
Page 756 ON-VEHICLE INSPECTION AND ADJUSTMENT Bleeding of Power Steering System - Fluid Location Points of application Specified fluid Quantity — Power steering oil tank Automatic transmission fluid (DEXRON Filler cap or DEXRON II type) dipstick between MIN and CAUTION– Do not keep the steering wheel turned fully to the left or right for more than fifteen seconds when the engine is running, as this can cause the power steering oil pump to seize up.
Page 757 Performance Verification Test of Power Steering System Service standards Location Maintenance item Standard value Limit Remedy — Steering system fluid pressure (With hands off 490 kPa {71 psi, 5 kgf/cm — Repair steering wheel) — Relief set pressure (Measure with engine speed at 9.3 MPa {1350 psi, 95 kgf/cm Maximum Replace...
Page 758 STEERING SYSTEM Ê 8 Ê - 12 Ê 14 Ê < FE > Ù Ê Ê Ê 33 Ê 21 Ê Ù Ê Ê 28 < FG > Ê Ê 31 33 Ê 30369 37-14...
Page 759 10 Horn spring 24 Dust cover * : Front axle assembly 11 Contact plate 25 Bolt < FE > ^ Gr 26A 12 Cover assembly 26 Bolt < FG > ^ Gr 26B 13 Steering wheel 27 Steering column subassembly 14 Screw Õ...
Page 760 STEERING SYSTEM Service procedure Removal of horn pad • Insert a flat-tip screwdriver into the space between steering wheel assembly 9 and shoulder sections A, B of horn pad 5, and disengage the latch by prying open the horn pad with the screwdriver until a clicking sound is produced.
Page 761 Install steering wheel assembly 9. Using a long socket wrench, tighten Start procedure > nut 8 at specified torque 39 to 49 N·m {29 to 36 ft.lbs, 4 to 5 kgf·m} Looseness found No looseness Rotate telescopic shaft B counterclockwise with your fingers and check for looseness Set telescopic lever 7 to specified lock po- >...
Page 762 STEERING SYSTEM Head cutting bolt, starter switch [Removal] • After removing bracket 16, drill a ø5.5 to 6.0 mm {0.22 to 0.24 in.} hole 10 to 15 mm {0.39 to 0.59 in.} deep on cutting face A of head cutting bolt 17 for mounting starter switch 18.
Page 763 M E M O 37-19...
Page 764 STEERING COLUMN SUBASSEMBLY Ê 1 Ê 22 Ê - - Ê 22 5 Ê Ù Ê 10 19 Ê Ê Ù 17 - Ù 52502 37-20...
Page 765 Disassembly sequence 10 Nut 20 Lever support 1 Nut 11 Lock lever 21 Clevis pin 2 Support bracket 12 Split pin 22 Bolt 3 Spring seat 13 Return spring 23 Column support upper 4 Steering column assembly 14 Return spring 24 Telescopic shaft assembly 5 Nut 15 Snap ring...
Page 766 STEERING COLUMN SUBASSEMBLY Service procedure Installation of stopper Install stoppers 7 on steering shaft assembly 6 in the direction as illustrated so that they straddle bearing spacer 8. 11310 Steering shaft assembly • Before removing steering shaft assembly 6, be sure to make align- ment mark A.
Page 767 Installation of clevis pin Drive clevis pin 21 into column support upper 23 so that the drive dimension is obtained. 13 mm {0.51 in.} 07000 37-23...
Page 768 POWER STEERING BOOSTER Ù 15 Ê Ê Ù Ù Ù 17 Ù 19 Ù Ù Ù 18 Ù Ù 20 Ê Ê Ù Ù 53327 Inspection before disassembly Õ P37-26 Disassembly sequence 1 Lock nut 11 Backup ring 21 Oil seal 2 Pitman arm 12 Adjusting bolt 22 Needle bearing...
Page 769 Assembly sequence 25 → 24 → 23 → 22 → 21 → 20 → 15 → 14 → 5 → 4 → 3 → 2 → 1 ↑ 16 → 19 → 18 → 17     7 → 11 → 10 → 9 → 8 ...
Page 770 POWER STEERING BOOSTER 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application 49 {1.93} 76 {2.99} Pitman arm puller MH062472 Removal of pitman arm 01355 Service procedure Inspection before disassembly [Measurement of total starting torque] Before disassembly, measure the total starting torque for a reference during assembly.
Page 771 [Installation] Align slit B of the V-groove of sector shaft 6 on the same line as slit A of the V-groove of pitman arm 2 when installing it. 06691 Sector shaft and side cover [Removal] • Turn ball screw set shaft 16 counterclockwise to the lock position, then turn it clockwise approximately 2.6 turns, so that slit A of the V-groove at the end of sector shaft 6 is in the neutral position as illustrated.
Page 772 POWER STEERING BOOSTER Installation of Y-packing Apply grease to lip area A of Y-packing 10, 23 and install into gear box 10, 23 11, 24 25 as illustrated. 27502 Installation of oil seal Apply grease to lip area A of oil seal 21 and install into gear box 25 as illustrated.
Page 773 M E M O 37-29...
Page 774 POWER STEERING OIL PUMP <FE640> Ù 4 Ê 5 Ù 6 1 Ê 16 Ù Ù 9 Ê 3 Ù Ù 19 P54259 <Except FE640> 9 Ê 16 Ù Ù 4 Ê 5 Ù 6 18 Ù 19 Ù Ù 3 Ê...
Page 775 Disassembly sequence 1 Bolt 8 Flow control spring 17 Side plate 2 Suction connector 9 Bolt 18 O-ring 3 O-ring 10 Cover 19 O-ring 4 O-ring 11 Pin 20 Body and shaft assembly 5 Connector 12 Cartridge assembly 6 O-ring Ù...
Page 776 POWER STEERING OIL PUMP Service procedure Inspection of relief valve assembly Block one side of the hole of relief valve assembly 7, with your finger C, then when air pressure A of 390 to 490 kPa {57 to 71 psi, 4 to 5 kgf/cm is applied from the other side, check whether air is released from small hole B at the rear.
Page 777 • Align cam ring 15 with pin 11 of cover 10, then install the cam ring. 07426 37-33...
Page 778 POWER STEERING OIL TANK Disassembly sequence 3 Ê 1 Filler cap 2 Strainer 3 Screw 4 Filter 5 Packing 6 Tank Ù : Non-reusable parts 5 Ù Assembly sequence Follow the disassembly sequence in re- verse. 27004 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened...
Page 779 POWER STEERING FLUID LINE Removal sequence 1 Nut 2 Pressure hose 4 Ê 3 Rubber hose 4 Ê 4 Clamp Ê 1 5 Rubber hose 6 Pressure tube 7 Return tube Ê 7 *a : Power steering oil tank *b : Power steering oil pump *c : Power steering booster 6 Ê...
Page 780 10 Ball stud seat 3 Spring *b : Knuckle arm 11 Ball stud seat 4 Ball stud seat < FE > ^ Gr 26A 12 Spring 5 Ball stud seat < FG > ^ Gr 26B 13 Grease nipple 6 Grease nipple Ù...
Page 781 1289 Service procedure Installation of split pin and end plug Approximately 4 mm {0.16 in.} • Tighten end plug 2, 9 fully, then slacken it off by one half of a turn. • Place split pins 1, 8 so that the heads face the outside of the vehicle. •...
Page 782 TIE ROD ASSEMBLY Disassembly sequence 1 Dust cover 2 Clamp bolt 3 Tie rod end 4 Tie rod Ù - 1 NOTE Do not remove dust cover 2 unless it is faulty. Ê 2 Assembly sequence Follow the disassembly sequence in reverse. 54272 Service standards Unit : mm {in.}...
Page 783 Service procedure Tie rod end [Inspection] Move ball stud area A vertically and horizontally to inspect for looseness. Ensure that ball B rotates evenly. 52510 [Installation] : 74 mm {2.91 in.} • Screw in tie rod end 3 so that dimension D of the tie rod end and clamp C differs by 1.5 mm {0.059 in.} or less between left and right.
Page 784 Group 41 Frame ' 98 Minor Change Pub No.TWSE0101-41...
Page 785 INDEX SPECIFICATIONS ................41-2 STRUCTURE AND OPERATION ............41-2 INSPECTION AND REPAIR OF FRAMES ........41-2...
Page 786 SPECIFICATIONS/STRUCTURE AND OPERATION/INSPECTION AND REPAIR OF FRAMES SPECIFICATIONS Item Specifications Frame type Ladder type Cross section configuration of side rail shape channel section STRUCTURE AND OPERATION 1 Side rail 2 Transmission mounting cross member < Automatic transmission > 3 Cross member 4 Front engine mounting support 5 Front engine mounting support bracket...
Page 787 Ê Tightening torque Unit : N·m {ft.lbs, kg·m} Location Parts to be tightened Tightening torque Remarks — Bolt ( area bolt : M10×1.25) 60 to 80 {43 to 58, 6 to 8} — — Bolt ( area bolt : M12×1.25) 98 to 120 {72 to 87, 10 to 12} —...
Page 788 INSPECTION AND REPAIR OF FRAMES • Using a grinder, etc., grind a 90° V-section channel, two-thirds of the frame thickness, then weld. WARNING– You must cover any flammable materials, such as pipelines, wiring harnesses, rubber parts, and the fuel tank, that are near the welding site.
Page 789 • After welding, grind bead A at right angles B to remove shaded area C as illustrated and grind the area flat. • Finish the surface so that the frame thickness is identical to the original thickness. 00243 [Repairing cracks caused by rivets or bolt holes] •...
Page 790 INSPECTION AND REPAIR OF FRAMES Inspection for loose rivets • Gently tap the rivet head using an inspection hammer and judge the condition by checking the vibration using the tip of your finger, or by listening to the sound. • Rust between rivet and frame indicates that the rivet is loose. CAUTION–...
Page 791 Group 42 ' 98 Minor Change Pub No.TWSE0101-42...
Page 792 INDEX SPECIFICATIONS ................42- 2 STRUCTURE AND OPERATION ............ 42- 3 TROUBLESHOOTING ..............42-12 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 42-17 • Adjustment of Cab Tilt ................42-18 • Adjustment of Door Fitting ............... REMOVAL AND INSTALLATION OF CAB < TILT CAB > ................... 42-21 <...
Page 793 SPECIFICATIONS Item Specifications * Fixed cab Tilt cab ← Cab assembly Type Cab over type (Forward control type) Mass kg {lb} Approximately 390 {860} Approximately 580 {1280} Cab tilt Type Torsion bar type — Tilt angle 45° — Cab mounting Type Semi-floating type Fixed type...
Page 794 STRUCTURE AND OPERATION Front Cab Mounting < Tilt Cab > “R” 08036 1 Anchor lever 6 Front rubber assembly 2 Bushing 7 Front cab mounting bracket, RH 3 Torsion bar 8 Adjusting bolt 4 Front floor cross member assembly 5 Front cab mounting bracket, LH Since torsion bar 3 has torsional direction, it is marked “R”...
Page 795 STRUCTURE AND OPERATION Rear Cab Mounting < Tilt Cab > 1 Side rubber 2 Anchor hook 3 Spacer “L” “R” 4 Rear mounting post 5 Plate 6 Rear rubber assembly 7 Cab hold bracket A : Liquid 05776 • Anchor hooks 2 are marked “L” and “R” to identify left and right. •...
Page 796 Cab Tilt Link < Tilt cab > 05794 1 Lock handle rod 5 L-lever 9 Cab tilt lock switch 2 Link assembly, LH 6 L-lever rod 3 Center rod 7 Lock handle A : Center rod adjusting point 4 Link assembly, RH 8 Lock latch •...
Page 797 STRUCTURE AND OPERATION Front Door Locking System 1 Door lock knob 2 Door lock rod 3 Door opening rod 4 Inside handle 5 Door lock actuator < Centralized control door lock > 6 Door lock cylinder 7 Door lock cylinder rod 8 Outside handle 9 Door opening rod 10 Door lock latch...
Page 798 Front Door Glass Opening System 1 Door glass < With power windows > 2 Carrier plate 3 Glass holder 4 Cable 5 Rail 6 Regulator 7 Power window motor < With power windows > Regulator handle < Manual regulator > A : Carrier plate moving range •...
Page 799 STRUCTURE AND OPERATION Rear Door Glass Opening System < Crew Cab > 1 Glass holder 2 Arm 3 Arm 4 Rail 5 Door glass 6 Rail 7 Regulator 8 Regulator handle A : Arm rotating range • Glass holder 1 holds rail 4 on door glass 5.
Page 800 Wiper and Washer F — F H — H 11295 1 Wiper arm and blade assembly 12 Washer hose 2 Nut 13 Hose joint 3 Pivot cap 14 Nut 4 Nut 5 Wiper link assembly A : Weatherstrip ends 6 Packing washer B : Front garnish 7 Nut C : Front panel...
Page 801 STRUCTURE AND OPERATION Emergency Locking Retractor (ELR) Type Seat Belt 14187 1 Sash guide 7 Emergency locking retractor 12 Pawl 2 Cover assembly 13 Ratchet gear 3 Webbing 8 Spindle 14 Sensor spring 4 Buckle assembly 9 Locking gear 15 Lock arm 5 Tongue plate 10 Mechanism lever 16 Clutch...
Page 802 Webbing detecting lock • When the vehicle is subjected to a sudden impact, such as a crash, webbing 3 retracts according to the movement of passengers, and spindle 8 rotates. • As the rotation of spindle 8 is higher than the specified value, the repercussive force of sensor spring 14 can no longer retain lock arm 15.
Page 803 TROUBLESHOOTING Cab as a Whole Symptoms Remarks Possible causes Cab mounting loose or play Front rubber, rear rubber deteriorated Cab mounted incorrectly Link assembly from anchor hook does not release L-lever release faulty Torsion bar damaged or fatigued Cab-related Torsion bar arm installation position incorrect Link assembly not hooked to anchor hook Link assembly contact with side cushion incorrect Cab tilt lock switch adjusted incorrectly...
Page 804 Symptoms Remarks Possible causes ^ Gr 26 Front axle-related Axle seat resonance Reduction gear engaged incorrectly ^ Gr 27 Rear axle-related Differential gear engaged incorrectly Wheel and tire run-out excessive Wheel and Wheel and tire unbalanced ^ Gr 31 tire-related Size and kinds of tire unequal Wheel mounting surface warped Front...
Page 805 TROUBLESHOOTING Door Lock Symptoms Remarks Possible causes Door installation faulty Striker installation faulty Faulty door locking mechanism of door latch Door latch rod deformed Door latch rod disconnected Door latch rod interference Door lock cylinder deformed Faulty auto door lock switch in power window & door lock switch Door lock actuator faulty ^ Gr 54 Fuse or high-current fuse blown...
Page 806 Power Window Symptoms Remarks Possible causes Power window switch faulty Power window regulator faulty ^ Gr 54 Power window regulator mounting faulty Fuse and high-current fuse burnt-out Wiring broken or connection faulty Power window glass and door belt line molding rattling 42-15...
Page 807 TROUBLESHOOTING Wiper and Washer Symptoms Remarks Possible causes Wiper motor faulty Washer motor faulty Wiper and washer switch faulty ^ Gr 54 Multipurpose timing control unit faulty Wiper relay faulty Fuse, high-current fuse blown Wiring broken or connection faulty Wiper motor crank arm set position faulty Wiper link and wiper arm connection faulty Wiper blade faulty Wiper arm faulty...
Page 808 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Adjustment of Cab Tilt Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Lock nut (Anchor hook mounting) 83 to 98 {61 to 72, 8.5 to 10.0} —...
Page 809 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Adjustment of Door Fitting Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Bolt (Upper and lower hinge mounting) 17 to 25 {12 to 19, 1.7 to 2.6} —...
Page 810 Door Fitting Dimensions < Front door > 12.4±2.0 mm 6.9±1.0 mm {0.49±0.079 in.} {0.27±0.039 in.} 6.4±1.0 mm 6.2±1.0 mm 11.9±1.0 mm {0.25±0.039 in.} 12.4±2.0 mm {0.49±0.079 in.} {0.24±0.039 in.} {0.47±0.039 in.} C — C A — A B — B 12.3±2.5 mm {0.48±0.098 in.} 10±2.0 mm...
Page 811 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE < Rear door (Fixed cab) > +0.12 {0.26 in.} –1 –0.039 +0.039 {0.51 in.} –3 –0.12 A — A 13±2 mm {0.51±0.079 in.} 6.4±2 mm {0.25±0.079 in.} B — B 13±2 mm {0.51±0.079 in.} 12.5±2.5 mm {0.49±0.098 in.} 13±2 mm {0.51±0.079 in.} 6.4±2 mm {0.25±0.079 in.}...
Page 812 REMOVAL AND INSTALLATION OF CAB < TILT CAB > Preliminary Work < 4D3 > < 4M5 > 45179 Disassembly sequence 1 Battery (negative terminal) ^ Gr 54 Work items 2 Front grille • Draining, filling, and air bleeding of clutch fluid and 3 Pressure cap ^ Gr 14A, B brake fluid ^ Gr 21, Gr 35A 4 Radiator drain plug ^ Gr 14A, B...
Page 813 REMOVAL AND INSTALLATION OF CAB < TILT CAB > Work Inside Cab Disassembly sequence 1 Parking brake cable ^ Gr 36 Assembly sequence Follow the disassembly sequence in reverse. 11380 Work from Front of Cab Disassembly sequence 1 Speedometer cable 2 Connection between cab harness and chassis harness...
Page 814 Work with Cab Tilted Up < 4D3 > < 4M5 > 45180 Disassembly sequence 1 Vacuum hose 4 Range selector cable < Automatic transmission > 2 Heater hose (Engine in) ^ Gr 55B ^ Gr 23 3 Heater hose (Engine out) ^ Gr 55B 5 No.2 shift rod <...
Page 815 REMOVAL AND INSTALLATION OF CAB < TILT CAB > Removal and Installation of Tilt Cab Body Disassembly sequence 1 Nut 2 Bolt 3 Bolt 4 Anchor lever 5 Bolt 6 Bolt 7 Bolt 8 Bolt 9 Cab assembly *1 : Cab stay *2 : Front floor cross member *3 : Steering yoke 7 Ê...
Page 816 Service procedure Cab assembly [Removal] • Tilt cab assembly 9 and lock cab stay *1 securely. • Remove bolt 3, and remove anchor lever 4. • Of the three bolts that retain front floor cross member *2, remove bolts 5, 6 at rear side, leaving bolt 8 at front side. 08045 •...
Page 817 REMOVAL AND INSTALLATION OF CAB < TILT CAB > • Set up hoist attachment C for the cab as illustrated. CAUTION– • Make sure when you set up hoist attachment C that it is capable of lifting cab assembly 9 which weighs approximately 390 kg {860 lb}.
Page 818 • Slowly lower cab assembly 9 further, and remove hoist attachment C after it comes down fully. • Tighten front bolt 8, one of the three bolts used for installing front floor cross member *2. 08055 • Securely support cab on crane A to tilt cab assembly 9. B : Use a wood block for protecting the rear of the cab •...
Page 819 REMOVAL AND INSTALLATION OF CAB < FIXED CAB > Preliminary Work 45181 Disassembly sequence 1 Battery (negative terminal) ^ Gr 54 Work items 2 Front grill • Draining, filling, and air bleeding of clutch fluid and 3 Pressure cap < Heater > 4D3, 4M4 ^ Gr 14A, B brake fluid 4 Radiator drain plug <...
Page 820 Work Inside Cab 11380 45182 Disassembly sequence 1 Parking brake cable ^ Gr 36 2 Front heater hose (outlet) ^ Gr 55 3 Front heater hose (return) ^ Gr 55 Assembly sequence Follow the disassembly sequence in reverse. 42-29...
Page 821 REMOVAL AND INSTALLATION OF CAB < FIXED CAB > Work on Cab Front and Under Cab Disassembly sequence 1 Speedometer cable 2 No.2 shift rod 3 No.2 selector rod 4 Connection between cab harness and chassis harness 5 Horn 6 Vacuum hose Assembly sequence Follow the disassembly se- quence in reverse.
Page 822 M E M O 42-31...
Page 823 REMOVAL AND INSTALLATION OF CAB < FIXED CAB > Removal and Installation of Fixed Cab Body Ê 4 Ê 7 Ê Ê 08061 Disassembly sequence *a : Front floor cross member 1 Bolt 7 Nut *b : Rubber assembly 2 Bolt 8 Plate *c : Rear rubber assembly 3 Garnish...
Page 824 Service procedure Cab assembly [Removal] • Remove bolt 1 from the inside of cab assembly 11, and bolt 2 from the outside. • Remove nut 4 that fixes rubber assembly *b, then remove cone point bolt 9 and nut 7 that fix rear rubber assembly *c. 08062 08063 •...
Page 825 REMOVAL AND INSTALLATION OF CAB < FIXED CAB > [Installation] • Mount hoist attachment A at center-of-gravity point D of cab assembly 11. Õ P42-33 08065 • Slowly lower cab assembly 11 horizontally to insert steering yoke *d into steering shaft *e, aligning alignment mark E. 08066 •...
Page 826 M E M O 42-35...
Page 827 FRONT CAB MOUNTING < Tilt Cab > Disassembly sequence Ù 1 Bolt 2 Bolt 3 Nut 4 Bolt 5 Anchor lever 6 Bolt 7 Front cab mounting bracket, RH 8 Front rubber assembly, RH 9 Bushing, RH 10 Torsion bar 11 Front floor cross member assembly 12 Bushing, LH Ê...
Page 828 - Lubricant Location Points of application Kinds Quantity 8, 13 Contact area between front rubber assemblies and front floor Rubber grease As required cross member assembly Service procedure Installation of front rubber assembly Install front rubber assembly RH 8 and LH 13 fitting protrusions A to the indents B of mounting bracket RH 7 and LH 14 respectively.
Page 829 FRONT CAB MOUNTING < Fixed Cab > Disassembly sequence Ê Ù 1 Bolt 2 Bolt 3 Bolt 4 Front cab mounting bracket, RH 5 Front rubber assembly, RH 6 Bushing, RH 7 Front floor cross member assembly 8 Bushing, LH 9 Front rubber assembly, LH 10 Front cab mounting bracket, LH 2 Ê...
Page 830 Service procedure Installation of front rubber assembly • Install front rubber assembly, LH 9 and, RH 5 fitting protrusions A to the indents B of mounting bracket, LH 10 and, RH 4 respectively. • After installation, apply grease to the entire periphery of contact area C with front floor cross member assembly 7.
Page 831 REAR CAB MOUNTING < Tilt Cab > Disassembly sequence 1 Bolt 2 Nut 3 Plate 4 Anchor hook 5 Spacer 6 Nut 7 Side rubber 8 Cab hold bracket Ê 9 9 Bolt Ê 6 10 Rear rubber assembly 11 Rear mounting post Ù...
Page 832 < Fixed Cab > Disassembly sequence 1 Lock nut 2 Plate 3 Cone point bolt Ê 5 4 Plate 5 Nut 6 Plate 7 Plate 8 Bolt 9 Bolt Ê 9 10 Rubber 11 Rear mounting post 12 Nut 13 Cab bracket assembly Ù...
Page 833 CAB TILT LINK 9 Ê Ê 7 Ê 1 Ê 11293 Disassembly sequence 7 Bolt 1 Bolt 2 Cab tilt lock switch ^ Gr 54 8 L-lever assembly 3 Lock handle assembly 9 Bolt 4 Center rod 10 Link assembly, RH 5 Bolt * : Rear mounting post 6 Link assembly, LH...
Page 834 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Bolt (Lock handle assembly mounting) 29 to 39 {22 to 29, 3 to 4} — Bolt (Link assembly, LH mounting) 29 to 39 {22 to 29, 3 to 4} —...
Page 835 CAB TILT LINK Cab Stay Removal sequence 1 Bolt 2 Cab stay assembly 3 Bolt WARNING– You must use a hoist to support the cab when you remove the cab stay assembly. Installation sequence Follow the removal sequence in reverse. Ê...
Page 836 DOOR Door Hinge and Striker Disassembly sequence 1 Door harness 2 Bolt 3 Bolt 4 Door assembly Õ P42-46 5 Bolt 6 Upper hinge 7 Bolt Ê 5 8 Lower hinge 9 Screw 10 Striker 10 11 Ê 2 11 Shim Ê...
Page 837 FRONT DOOR Door Assembly < Except crew cab > - 22 20 Ê 29 - Ê 36555 42-46...
Page 838 < Crew cab > Ê Ê P45743 42-47...
Page 839 FRONT DOOR Disassembly sequence 12 Side combination lamp ^ Gr 54 1 Cover 23 Lower sash 2 Door lock knob 13 Outer weather strip 24 Nut 3 Guard bar 14 Inner weather strip 25 Glass holder 4 Pull handle cover 15 Waterproof cover 26 Door glass 5 Ashtray <...
Page 840 Service procedure Installation of door lock knob • Install door lock knob 2 to door lock rod A of door lock actuator 21, and turn the knob fully in clockwise direction. • Back off door lock knob 2 by turning it 1 or 2 turns in counterclockwise direction.
Page 841 FRONT DOOR Removal and installation of door glass Remove all parts supporting door glass 26, then remove the door glass through the open space in the door. • Pull door glass 26 all the way to the top. • Remove bolt B through hole A in door panel 31, and remove lower sash 23.
Page 842 REAR DOOR < CREW CAB > Door Hinge and Striker Disassembly sequence 1 Lower panel 2 Bolt 3 Bolt 4 Door assembly Õ P42-52 5 Bolt 6 Upper hinge 7 Bolt 8 Lower hinge 9 Screw 9 Ê 10 Striker 11 Shim 12 Grommet Ê...
Page 843 REAR DOOR < CREW CAB > Door Assembly 16 - 23 - 21 Ê - 22 14 Ê 15 - - 13 Ù Ù 24 08029 Disassembly sequence 1 Pull handle cover 10 Outer weatherstrip 19 Door glass 2 Inside handle cover 11 Inner weatherstrip 20 Run channel 3 Regulator handle...
Page 844 - Lubricant Location Points of application Specified lubricant Quantity Turning part of inside handle SHOWA SHELL SEKIYU SUNLITE LA2 As required Friction part of door lock assembly KYODO YUSHI MULTEMP TAS As required Friction part of outside handle SHOWA SHELL SEKIYU SUNLITE LA2 As required Friction part of regulator assembly DYNAMIC GB...
Page 845 CAB EXTERIOR FITTING Front Panel 14 Ê Ê Ê 11362 Disassembly sequence 1 Screw 8 Wiper arm and blade assembly 14 Nut 2 Front grille Õ P42-60 15 Hose joint 3 Front side panel, RH 9 Pivot cap 16 Front garnish 4 Front side panel, LH 10 Nut 5 Side garnish, RH...
Page 846 Service procedure Removal and installation of front grille • Remove screws 1 (two points) from front grilles 2. 200 mm {7.87 in.} • Lift up the ends of clips C (two points), located in the center of front grilles 2, using a screwdriver, and unlock them from the clips. •...
Page 847 CAB EXTERIOR FITTING Step and Fender 11240 Removal sequence 1 Step 2 Step garnish 3 Fender garnish 4 Set bolt * : Cab assembly Installation sequence Follow the removal sequence in reverse. NOTE This illustration only shows the step and fender for the left side; the same service procedure described above is used for the right side.
Page 848 M E M O 42-57...
Page 849 MIRROR Removal sequence 1 Outside mirror stay assembly, LH Ê 2 Nut 3 Washer (Stainless) 4 Washers Ù 5 Sub mirror stay 6 Sub mirror stay 7 Mirror holder B 8 Mirror holder 9 Packing 10 Outside mirror 11 Lower bracket 12 Main mirror stay 13 Outside mirror stay assembly, RH Ù...
Page 850 Service procedure Installation of mirror holder Install mirror holder 8 onto main mirror stay 12 in the direction as illustrated. A : Indent of main mirror stay 12. 11368 Installation of main mirror stay Install main mirror stay 12 and lower bracket 11 so that alignment marks “...
Page 851 WIPER AND WASHER Ê Ê Ê Ê Ê Ê Ê Ê P45912 Disassembly sequence 1 Nut 17 Washer tank 2 Wiper arm and blade assembly 18 Washer motor ^ Gr 54 3 Wiper blade 19 Nut 4 Blade rubber 20 Wiper link assembly 5 Screw 21 Packing washer 6 Washer nozzle assembly...
Page 852 Ê Tightening torque Unit : N·m {ft.lbs, kgf·m} Location Parts to be tightened Tightening torque Remarks Nut (Wiper arm and blade assembly mounting) 9.8 to 15 {7.2 to 11, 1 to 1.5} — Nut (Packing washer mounting) 14 to 20 {10 to 14, 1.4 to 2} —...
Page 853 WIPER AND WASHER Inspection of wiper arm If the measured value deviates from the standard value, replace wiper arm 8. 45915 Packing washer Because the shape of packing washer 21 for the passenger’s side and packing washer 22 for the driver’s side are different, be careful not to mix them up during assembly.
Page 854 M E M O 42-63...
Page 855 CAB INTERIOR FITTING Trim 12242 Removal sequence 1 Front pillar grip, LH 7 Scuff plate, LH 13 Lower rear pillar trim, RH 2 Front pillar trim, LH 8 Scuff plate, RH 14 Upper rear pillar trim, RH 3 Roof side trim, LH 9 Seat belt assembly, LH 15 Rear trim clip 4 Front pillar grip, RH...
Page 856 CAB INTERIOR FITTING Headlining 12373 Removal sequence 6 Sun visor, LH 1 Grip 7 Hook 2 Lens 8 Headlining clip 3 Cab lamp assembly ^ Gr 54 9 Headlining 4 Sun visor, RH 5 Hook Installation sequence Follow the removal sequence in reverse. 42-65...
Page 857 INSTRUMENT PANEL Lower Panel 11296 Disassembly sequence *3 : Water hose 1 Bolt 8 Side panel bracket *4 : Cooling unit 2 Bolt 9 Fuse box lid *5 : Blower unit 10 Center lower panel 3 Assistant driver's side lower panel 4 Window washer tank *1 : Front floor 5 Center lower panel...
Page 858 Meter Bezel 11297 Disassembly sequence 1 Ashtray 10 Bracket, LH 2 Cup holder 11 Bracket, RH 3 Meter bezel 12 Radio < Option > 4 Cigarette lighter ^ Gr 54 13 Box 5 Protector 14 Bracket, LH 6 Meter cluster ^ Gr 54 15 Bracket, RH 7 Card holder 16 Glove compartment...
Page 859 INSTRUMENT PANEL Instrument Panel 11298 Disassembly sequence 1 Fluid tank lid 8 Side demister grille 15 Instrument panel bracket 2 Glove compartment 9 Air outlet grille 3 Glove compartment lid *1 : Front inner pillar 10 Instrument panel frame 4 Glove compartment *2 : Fluid tank ^ Gr 35A 11 Relay bracket 5 Glove compartment lid...
Page 860 M E M O 42-69...
Page 861 WINDOW GLASS Disassembly sequence 1 Weatherstrip 2 Windshield Ù 3 Weatherstrip 4 Rear window glass Ù : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Ù 10440 - Lubricant Location Points of application Kinds Quantity 1, 3 Lip area of weatherstrip Soapy water As required...
Page 862 • Push windshield 2 inward from the outside of the cab firmly. • Inside the cab, pull one end of cord H to install lip A of weatherstrip 1 into flange lip B of the cab. 00032 • Pull cord H in the numbered order as illustrated and at the same time have someone push windshield 2 into weatherstrip 1, tapping the windshield with a rubber-headed mallet.
Page 863 Group 54 Electrical Pub No. TWSE0101-54...
Page 864 INDEX HOW TO READ THIS GROUP HOW THIS GROUP IS STRUCTURED ......2 GENERAL LIGHTING CIRCUIT SPECIFICATIONS ............54-0-2 HEADLAMP CIRCUIT ........... 54-3-2 STRUCTURE AND OPERATION DAYTIME RUNNING LIGHT CIRCUIT ....54-3-4 1. Starter ..............54-0-6 TAIL , CLEARANCE AND 2.
Page 865 C FUSE, METER, SENSOR AND MOTOR ....54-10-6 BRAKE PAD WARNING CIRCUIT ....... 54-5-6 D HEATER AND AIR-CONDITIONER ......54-10-8 ATF TEMPERATURE WARNING CIRCUIT ..^ Gr 23 E DOOR ..............54-10-10 CAB TILT WARNING CIRCUIT ......54-5-7 F ROOF ..............54-10-11 FUEL FILTER WARNING CIRCUIT ......
Page 866 ON-VEHICLE INSPECTION AND ADJUSTMENT INSPECTION OF PREHEATING SYSTEM ..54-13-2 HEADLAMP AIMING ..........54-13-4 INSPECTION OF BRAKE FLUID LEVEL SWITCH ......54-13-6...
Page 867 HOW TO READ THIS GROUP HOW THIS GROUP IS STRUCTURED ........... 2...
Page 868 Installation area of harness on the vehicle Circuit number BT20A Color of wire Chassis Cross section of conductor WT01 0.85-LY <FE> MU04 0.85-LgR <FE> Circuits for other specification for other Water temperature model or type sensor <FE> Chassis AA6A Engine <FG>...
Page 869 1 Index number: Each circuit has its own Index number respectively and has three digits ( How to read index number • By proper using of the index number, it is possible to locate the correct place immediately since the circuit drawing of this manual book are classified as function by function.
Page 870 Wire Colors Example: WB means a wire whose ground color is white and whose stripe is black. W (Wire ground color) B (Stripe) 07384 Wire ground color Wire ground color + Stripe White White red White black White blue White green Black Black white Black yellow...
Page 871 GENERAL...
Page 872 SPECIFICATIONS Battery Item Specifications Model 115E41R Voltage × Quantity 12 × 2 (Parallel connection) Capacity (5-hour rating) Alternator Specifications Item Manufacturer MITSUBISHI ELECTRIC Type Alternator with built-in regulator (without brush external fan) Model A4TU0488 A4TU0781 Output 12-100 54-0-2...
Page 873 Engine starter, Glow Specifications Item Manufacturer MITSUBISHI ELECTRIC Reduction gear mechanism Planetary gears Model M8T55073 M8T55371 Starter Out put V-kW 12-3 Magnetic switch 8 or less operating voltage Model U1X11272 U1T11672 Excitation current 12-4 Starter relay Closing voltage 8 or less Operating voltage 3.5 or more Allowable cutoff current...
Page 874 SPECIFICATIONS Lighting Item Specifications Model Seald beam Type Reflex type Headlamp Main beam Dipped beam 60/40 (Main/Dipped) 21 × 2 Front turn signal lamp (serving also as hazard warning lamp) Clearance lamp Side turn signal lamp (serving also as hazard warning lamp) Clearance and side marker lamp Stop / Tail lamp 27/8...
Page 875 Meter Item Specifications Manufacturer DENSO Rated voltage Lighting bulb 3, 3.4 Indicator lamp bulb Meter cluster Warning lamp bulb Bulb for automatic transmission 1.12 shift indicator Rated current 50 or less (Mean value) Meter warning buzzer Sound pressure dB (at 1 m {3.3 ft.}) Relay, Motor, Horn, Buzzer Item Specifications...
Page 876 STRUCTURE AND OPERATION 1. Starter < 4D3 > View A 16 17 10297 1 Pinion stopper 11 Rear bearing 21 Front bearing 2 Spring 12 Rubber packing 22 Pinion 3 Front bracket 13 Armature 23 Starter relay 4 Lever 14 Yoke assembly 5 Ball 15 Rubber packing B : Terminal B...
Page 877 < 4M5 > 41153 1 Rear bracket 10 Spring 19 Rubber packing 2 Brush holder 11 Pinion stopper 20 York assembly 3 Brush 12 Pinion 21 Armature assembly 4 Brush spring 13 Front brearing 22 Rear bearing 5 Magnetic switch 14 Overrunning clutch 6 Ball 15 E-ring...
Page 878 STRUCTURE AND OPERATION 2. Alternator < 4M5 > View A P44587 1 Rectifier 7 Front bracket B : Terminal B 2 Rotor assembly 8 Field coil E : Terminal E 3 Stator assembly 9 Rear bracket L : Terminal L 4 Fan 10 Regulator R : Terminal R...
Page 879 < 4D3 > View A P36348 1 Rectifier 7 Front bracket B : Terminal B 2 Rotor assembly 8 Field coil E : Terminal E 3 Stator assembly 9 Rear bracket L : Terminal L 4 Fan 10 Regulator R : Terminal R 5 Pulley 11 Rear bearing 6 Front bearing...
Page 880 STRUCTURE AND OPERATION Features of alternator with neutral diodes • The alternator is the same as the current alternator except neutral diodes C and D added. • These neutral diodes C and D enable this alternator to provide higher DC output during operation at high speeds than the alternator without neutral diodes.
Page 881 When the voltage at neutral point exceeds 16 volts The positive diode C adds extra output to the DC output for supply to each electric equipment. 07034 When the voltage at neutral point drops below 0 volt The negative diode D supplies the output from neutral point through the other 3 diodes.
Page 882 STRUCTURE AND OPERATION 3. Lamp Headlamp 1 Sealed beam unit (Main beam) 2 Sealed beam unit (Dipped beam) 3 Screw (Dipped beam, vertical adjustment) 4 Screw (Dipped beam, horizontal adjustment) 5 Screw (Main beam, vertical adjustment) 6 Screw (Main beam, horizontal adjustment) 7 Housing 8 Extension spring 9 Extension spring...
Page 883 Daytime running light system Input signal (IN) Daytime running light electronic Output signal (OUT) control unit → → Lighting switch (OFF) Rear combination lamp (Tail lamp) → Alternator charge (L) signal → Headlamp → Parking brake switch (Dipped beam) → Starter switch (M) signal →...
Page 884 STRUCTURE AND OPERATION • Daytime running light electronic control unit circuit diagram Meter cluster Lighting switch Dimmer switch Starter TAIL Main switch(M) TAIL&HEAD Dimmer Passing Brake fluid level switch DRL electronic control unit Parking brake switch Headlamp relay (LOW) Headlamp relay (HIGH) Rear combination...
Page 885 M E M O 54-0-15...
Page 886 STRUCTURE AND OPERATION 4. MUTIC (Multipurpose Timing Control Unit) • This control unit is an integrated control unit for controlling the following functions. Õ P54-0-20 Preheating function Õ P54-0-19 Intermittent wiper activation function Õ P54-0-22 Starter continuous-ON prevention function • For controlling each function, sensors and switches are needed as sources of information, and they are provided for respective systems.
Page 887 • The MUTIC is internally made up roughly of the input interface circuit, CPU*a, ROM*b, and output interface circuit. *a: An abbreviation for Central Processing Unit. It compares the input information and the information stored in the ROM and makes a decision and sends commands to the outputs. *b: An abbreviation for Read-Only Memory.
Page 888 STRUCTURE AND OPERATION MUTIC (Multipurpose Timing Control Unit) Functional Circuit Diagram A M F S LOCK (OFF) DC 12 START volts DC 12 volts A : To starter relay B : To inhibitor switch < A/T > or diode unit < M/T > A/T : Automatic transmission M/T: Manual transmission WASH...
Page 889 Part name Principal function sensors Information signal Starter switch Start position detection A : Start signal Fuse box — — J : Starter continuous-ON cancellation Safety relay — signal Neutral start relay — — Meter cluster — — Battery charge indicator lamp —...
Page 890 STRUCTURE AND OPERATION Preheating Function This preheating function aims to enhance the engine start up when the engine coolant is low in cold weather or temperature. MUTIC (Multipurpose Timing Control Unit) controls the entire function as follows: Pre-glow and After-glow START A The preheating is operated with a pre-glow before the engine starting...
Page 891 Operation mode • Where the engine coolant temper- ature is 60°C {140 °F} or more. START Starter switch Alternator charge signal B Glow relay 08656 • Where the engine coolant temper- ature is 0 to 60°C {32 to 140°F}. START Starter switch Alternator charge signal B...
Page 892 STRUCTURE AND OPERATION Starter Continuous-ON Prevention Function • This function prevents a starter overrun. • If the starter continues to operate for more than a preset time after the engine starts, the MUTIC detects a starter continuous-ON condition, and stops the current to the starter and starter relay to prevent the starter from seizing. When a preset time elapses after the engine starts, the safey relay is activated (opening of contact) by signal B from the alternator (terminal L).
Page 893 5. LAC (Lighting and Alarm Control Unit) • This control unit is an integrated control unit for controlling the following functions. Õ P54-0-25 Brake pad wear alarm function • For controlling each function, sensors and switches are needed as sources of information, and they are provided for respective systems.
Page 894 STRUCTURE AND OPERATION System function schematic Input signal (IN) Output signal (OUT) Brake pad wear alarm func- Disc brake warning lamp Brake pad wear indicator tion Terminal Connecting Terminal Connecting destinations destinations Starter switch (M terminal) — — — — Ground Disc brake warning lamp —...
Page 895 LAC (Lighting and Alarm Control Unit) Functional Circuit Diagram Brake Pad Wear Alarm Function DC12 volts B A M F S LOCK (OFF) START DISC BRAKE P44592 Part name Principal function sensors Information signal High-current fuse box — — Fuse box —...
Page 896 TROUBLESHOOTING Power and charging Symptoms Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown ^ Gr 14 V-belts loose ^ Gr 14 V-belts damaged Battery faulty Stator coil broken Stator coil short-circuited with core Field coil faulty Alternator Rectifier faulty Regulator faulty...
Page 897 Engine starting, preheating and stopping Starter operates Symptoms but engine does not start Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding High-current fuse blown Fuse blown Battery insufficiently charged Magnetic switch contacts stuck or fused together Starter Open circuit in magnetic switch coil Overrunning clutch malfunctioning Pinion worn or damaged...
Page 898 TROUBLESHOOTING Lighting Headlamp Symptoms Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Battery capacity insufficient Alternator output insufficient Bulb burnt-out Power (wattage) of bulb is lower than specified value Power (wattage) of bulb is higher than specified value Lighting switch faulty Combination switch Turn signal lamp switch faulty...
Page 899 Turn signal lamp Symptoms (also used as hazard) Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Battery capacity insufficient Alternator output insufficient Bulb burnt-out Power (wattage) of bulb is lower than specified value Power (wattage) of bulb is higher than specified value Lighting switch faulty Turn signal lamp switch faulty Combination switch...
Page 900 TROUBLESHOOTING Lighting Symptoms Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Battery capacity insufficient Alternator output insufficient Bulb burnt-out Power (wattage) of bulb is lower than specified value Power (wattage) of bulb is higher than specified value Lighting switch faulty Turn signal lamp switch faulty Combination switch...
Page 901 Meter Symptoms Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Internal circuits of meter cluster faulty Printed wiring board of meter cluster faulty Engine speed sensor coil open-circuited ^ Gr 11, 13 Engine speed sensor improperly mounted Tachometer Tachometer faulty ^ Gr 13E...
Page 902 TROUBLESHOOTING Cigarette lighter and Audio Cigarette Symptoms Audio lighter Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Cigarette lighter faulty Tail lamp relay faulty Antenna and antenna cable connection faulty Speaker faulty Left and right speaker impedance different Accessory noise generation source Accessory Noise...
Page 903 Horn Symptoms Horn Remarks Possible causes Defective connector connection, harness open/short circuit, defective grounding Fuse blown Horn switch faulty Horn faulty Horn stay warped Battery voltage insufficient 54-0-33...
Page 904 POWER, CHARGE AND GROUND CIRCUIT...
Page 905 110 POWER CIRCUIT 44356 54-1-2...
Page 906 44357 54-1-3...
Page 907 110 POWER CIRCUIT 44358 54-1-4...
Page 908 44359 54-1-5...
Page 909 110 POWER CIRCUIT 44360 54-1-6...
Page 910 44361 54-1-7...
Page 911 110 POWER CIRCUIT 44362 54-1-8...
Page 912 44363 54-1-9...
Page 913 110 POWER CIRCUIT 44364 54-1-10...
Page 914 115 RESERVE POWER CIRCUIT 44365 54-1-11...
Page 915 125 BATTERY CHARGING CIRCUIT 44366 54-1-12...
Page 916 M E M O 54-1-13...
Page 917 130 GROUND 1 1 1 1 1 Wiper motor 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 6 6 6 6 6 5 5 5 5 5 P44742 54-1-14...
Page 918 Location Circuit No. Wire diameter-wire color Remarks 1 1 1 1 1 EA01 2 2 2 2 2 EA02 3 3 3 3 3 GCE1 1.25-B GCE2 1.25-B GCE3 1.25-B GCE4 1.25-B GCE7 1.25-B 4 4 4 4 4 EA01 EA02 EA10 FEE1...
Page 919 130 GROUND 44367 54-1-16...
Page 920 44368 54-1-17...
Page 921 130 GROUND 44369-1 54-1-18...
Page 922 44369-2 54-1-19...
Page 923 STARTING AND PREHEATING CIRCUIT...
Page 924 210 ENGINE STARTING CIRCUIT 44370 54-2-2...
Page 925 44371 54-2-3...
Page 926 220 ENGINE PREHEATING CIRCUIT 44373 54-2-4...
Page 927 225 ENGINE WARM-UP CIRCUIT 44374 54-2-5...
Page 928 225 ENGINE WARM-UP CIRCUIT 44375 54-2-6...
Page 929 LIGHTING CIRCUIT...
Page 930 310 HEADLAMP CIRCUIT 44376 54-3-2...
Page 931 M E M O 54-3-3...
Page 932 313 DAYTIME RUNNING LIGHT CIRCUIT 44377-1 54-3-4...
Page 933 44377-2 54-3-5...
Page 934 TAIL, CLEARANCE AND LICENSE PLATE LAMP CIRCUIT 44378 54-3-6...
Page 935 325 STOP LAMP CIRCUIT 44379 54-3-7...
Page 936 330 TURN SIGNAL AND HAZARD LAMP CIRCUIT 44380 54-3-8...
Page 937 340 BACKUP LAMP CIRCUIT 44381 54-3-9...
Page 938 340 BACKUP LAMP CIRCUIT 44382 54-3-10...
Page 939 345 CAB LAMP CIRCUIT 44383 54-3-11...
Page 940 348 ILLUMINATION LAMP CIRCUIT 44384 54-3-12...
Page 941 349 MARKER AND IDENTIFICATION LAMP CIRCUIT 44385 54-3-13...
Page 942 352 VAN BODY DOME LIGHT CIRCUIT 44386 54-3-14...
Page 943 METER CIRCUIT...
Page 944 401 METER CLUSTER INTERNAL CIRCUIT 44387 54-4-2...
Page 945 B : AU10A A : AU13A C : AU10A E : AL2A Backward view of meter cluster D : AU16C P45110 54-4-3...
Page 946 410 TACHOMETER CIRCUIT 44388 54-4-4...
Page 947 44389 54-4-5...
Page 948 412 SPEED SENSOR CIRCUIT 44390 54-4-6...
Page 949 420 FUEL GAUGE CIRCUIT 44391 54-4-7...
Page 950 425 WATER TEMPERATURE GAUGE CIRCUIT 44392 54-4-8...
Page 951 INDICATOR AND WARNING LAMP CIRCUIT...
Page 952 510 PARKING BRAKE INDICATOR CIRCUIT 44393 54-5-2...
Page 953 515 BRAKE WARNING CIRCUIT 44394 54-5-3...
Page 954 535 ENGINE OIL LEVEL AND OIL PRESSURE WARNING CIRCUIT 44395 54-5-4...
Page 955 537 OVERHEATING WARNING CIRCUIT coolant 44396 54-5-5...
Page 956 540 BRAKE PAD WARNING CIRCUIT 44397 54-5-6...
Page 957 550 CAB TILT WARNING CIRCUIT 44399 54-5-7...
Page 958 566 FUEL FILTER WARNING CIRCUIT 44400 54-5-8...
Page 959 CAB SIDE ELECTRICAL CIRCUIT...
Page 960 610 CIGARETTE LIGHTER CIRCUIT 44401 54-6-2...
Page 961 612 AUDIO CIRCUIT 44402 54-6-3...
Page 962 614 WIPER AND WASHER CIRCUIT 44403 54-6-4...
Page 963 616 HORN CIRCUIT 44404 54-6-5...
Page 964 618 HEATER CIRCUIT 44405 54-6-6...
Page 965 622 POWER WINDOW AND AUTO DOOR LOCK CIRCUIT 44406 54-6-7...
Page 966 629 MIRROR HEATER CIRCUIT 44407 54-6-8...
Page 967 CHASSIS SIDE ELECTRICAL CIRCUIT...
Page 968 710 EXHAUST BRAKE CIRCUIT 44408 54-7-2...
Page 969 44409 54-7-3...
Page 970 710 EXHAUST BRAKE CIRCUIT 44410 54-7-4...
Page 971 ENGINE AND TRANSMISSION SIDE ELECTRICAL CIRCUIT...
Page 972 810 FOUR-WHEEL DRIVE CIRCUIT 44411 54-8-2...
Page 973 850 TRANSMISSION POWER TAKE-OFF CIRCUIT 45947 54-8-3...
Page 974 OTHERS CIRCUIT...
Page 975 910 MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT 44412-1 54-9-2...
Page 976 44412-2 54-9-3...
Page 977 PARTS INSTALLATION POSITION...
Page 978 A SWITCH 01 to 14 A02a A10, 11 A01 Mirror heater switch A02 Warm-up switch A02a Transmission power take-off switch connector A03 Idling speed adjustment potentiometer A04 Van body dome light switch A05 Parking brake switch A06 Emergency engine stop switch < 4M5 > A07 Stop lamp switch A08 Clutch switch A09 Engine oil level check switch...
Page 979 20 to 25 < Except crew cab > A20, 21 < Crew cab > (Front) (Front) (Rear) (Rear) A20 Memory clear switch < Engine control > A21 Diagnosis switch < Engine control > A22 Door switch, LH A23 Cab tilt lock switch A24 Door switch, RH A25 Vacuum switch P44480...
Page 980 B RELAY AND ELECTRONIC CONTROL UNIT 01 to 38 B10, B11 B05, B06 B06, B07 < 4M5 > < 4D3 > < 4D3 > < 4M5 > < View a > B21 B22 B23 B24 B25 B26 P44536 54-10-4...
Page 981 < Engine electronic control unit > < 4D3 > < 4M5 > [CM28A] [CM30A] [AH12A] [AH16A] [CM35A] [AH22A] [AH26A] [BZ26A] [BZ16A] [BZ12A] [BZ22A] < Automatic transmission < Anti-lock brake system electronic control unit > electronic control unit > [AH16A] [AH12A] [AH26A] [AK22A] [AK20A]...
Page 982 C FUSE, METER, SENSOR AND MOTOR 01 to 07 [AU10A] [AU10A] [AU13A] [AU16C] C01 Overheating warning buzzer C02 Meter cluster C03 Accelerator pedal position sensor C04 G sensor < FG > [ ]: Meter connector P44538 54-10-6...
Page 983 C05 Wiper motor C06 Fuse box C07 Windshield washer motor P42963 54-10-7...
Page 984 D HEATER AND AIR-CONDITIONER 01 to 04 (Õ B16 Condenser fan relay B17 Air- conditioner relay) D01 Heater control assembly D02 Blower motor D03 Blower resistor D04 Thermostat P42878 54-10-8...
Page 985 M E M O 54-10-9...
Page 986 E DOOR 01 to 05 * This illustration show the left side door, the right side door is symmetrical. E01 Power window switch E02 Side turn signal lamp E03 Door speaker E04 Power window motor E05 Door lock actuator P42800 54-10-10...
Page 987 F ROOF 01 to 06 < Except crew cab > F01 Cab lamp F02 Clearance and side marker lamp, RH [Connection of roof harness and cab harness] F03 Identification lamp (Õ J01) F04 Clearance and side marker lamp, LH F05 Rear cab lamp, RH F06 Rear cab lamp, LH <...
Page 988 JOINT OF MAIN HARNESS CONNECTORS 01 to 06 [Meter harness] [Roof harness] [Door harness, LH] [Door switch harness, LH] [Cab harness] J01 Connection of cab harness and roof harness J02 Optional connector (6pin) J03 Connection of cab harness and door switch harness, LH J04 Connection of cab harness and door harness, LH J05 Connection of cab harness and meter harness J06 Connection of cab harness and column harness...
Page 989 07 to 13 [Center panel harness] [Cab harness] J10a [Cab harness] [Door switch harness, RH] [Door harness, RH] [Door switch [Door switch harness, LH] harness, RH] [Rear door switch harness] J07 Connection of cab harness and automatic transmission harness J08 Connection of cab harness and door harness, RH J09 Connection of cab harness and door switch harness, RH J10 Multi use tester-II connector J10a Connection of heater harness and center panel harness...
Page 990 R ENGINE 01 to 21 < 4D3 > R01 Engine oil pressure switch R02 Alternator R03 Thermostat switch R04 Glow plug R05 Engine oil level sensor R06 Overheating switch R07 Water temperature sensor (Connects to water temperature gauge and multipur- pose timing control unit) R08 Water temperature sensor (Connects to engine electronic control unit)
Page 991 < 4M5 > No relevant parts in a missing number R17 Top dead center speed sensor R18 Fuel temperature sensor R19 Spil valve R20 Fuel injection rate adjustment read only memory R21 Timer control valve P41180 54-10-15...
Page 992 S TRANSMISSION 01 to 10 < Manual trasmission > Upper view < FG > < Automatic transmission > Right side view Left side view < Transfer > S01 Transmission neutral switch S02 Backup lamp switch S03 First/reverse check switch S04 Inhibitor switch S05 Automatic transmission terminal to solenoid and temperature sensor S06 Vehicle speed sensor <...
Page 993 T SWITCH AND SENSOR 01 to 12 T01 Dual pressure switch connector T02 Front brake pad wear indicator, RH T03 Front wheel speed sensor, RH T04 Water separator sensor T05 Rear brake pad wear indicator, RH T06 Rear wheel speed sensor, RH T07 Rear wheel speed sensor, LH T08 Rear brake pad wear indicator, LH T09 Automatic transmission fluid cooler...
Page 994 BATTERY, FUSE AND CONNECTOR V MAGNETIC VALVE, MOTOR AND ACTUATOR W BUZZER AND LAMP 01 to 11 01 to 05 01 to 06 U01 Connection of chassis harness W03 to W05 and rear chassis harness U02 Relay box < Anti-lock brake system > U03 Rear clearance lamp connector, RH U04 Rear side marker lamp connector, RH U05 Rear identification lamp connector...
Page 995 INSPECTION OF PARTS...
Page 996 SWITCH Inspection of combination switch • Follow the table below to check for continuity. : There is continuity between terminals. • If any fault is found, replace the switch. AQ15A AQ13A 07133 AQ13A Connector connection table 1 2 3 7 8 9 F G Body Internal ground...
Page 997 Inspection of starter switch • Follow the table below to check for continuity. • If any fault is found, replace the switch. ^ Gr 37 (1) Inspection of continuity AP2A AN6A 2 1 3 4 2 — LOCK ± • (OFF) AN2A AP2A AN6A 07057 START...
Page 998 SWITCH Inspection of engine oil level check switch • Follow the table below to check for continuity. ON (CHECK) : There is continuity between terminals. • If any fault is found, replace the switch. P14307 1 1 1 1 1 2 2 2 2 2 Inspection of vacuum switch Perform the following checks, and if any fault is found, replace the...
Page 999 Inspection of door switch • Follow the table below to check for continuity. 1 1 1 1 1 : There is continuity between terminals. • If any fault is found, replace the switch. ^ Gr 42 2 2 2 2 2 07080 1 1 1 1 1 Inspection of parking brake switch...
Page 1000 SWITCH Inspection of engine oil pressure switch 2 2 2 2 2 Perform the following checks, and if any fault is found, replace the switch. (1) Inspection by without applying air pressure Make sure that there is continuity between terminals (body).
Page 1001 Inspection of van body dome light switch 5 6 7 • Follow the table below to check for continuity. LED (Operation indication light : There is continuity between terminals. • If any fault is found, replace the switch. P14220 Inspection of thermostat switch •...

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