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TOMCAR Utility Vehicle Service Manual

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TOMCAR
Service Manual
06222010-v2.0

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Summary of Contents for TOMCAR Utility Vehicle

  • Page 1 TOMCAR Service Manual 06222010-v2.0...
  • Page 2 Transmission CVT Reconditioning  Engine CVT Reconditioning  Shock System Removal and Installation  Shock Disassembly and Assembly  Accumulator Disassembly and Assembly  TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 3 Transmission Removal  Transmission Disassembly and Assembly  Transmission Installation  Engine Engine Removal  Engine Installation  Water Pump Replacement (Diesel)  TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...

  • Page 4: Pre Ride Inspection

    10 Rear Engine Air Filter 11 Coolant Level 12 Headlights / Taillights 13 Hand Brake Operation 14 CVT Belt I = Inspect C = Clean TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 5 18 Install wheels 19 Adjust parking brake 20 Check for leaks 21 Check electrical system Lights Horn Warning lights Windshield wipers 22 Check wiper blades TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 6 27 Grease steering box and check steering system for free play 28 Check windshield washer fluid 29 Inspect throttle cable and linkage 30 Test CVT for proper operation 31 Test drive vehicle TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 7 DOT 4 0.5L Lines Coolant Front Ball Joints Steering Box Multipurpose Grease As Needed Locate Fittings and Grease Rear Drive Shafts CVT (Transmission Side) TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 8 Fuel Injector Pressure Check/Adjust Preliminary Fuel Filter Replace Replace Replace Replace Repeat Every Repeat Every Repeat Every 1500M 3000M 18000M *Engine Oil: SEA 15W40 TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 9 Remove the front wheels. Aggressively shake the a-arms while observing the a-arm hinge points. There should be no free play. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 10 If more than 2 to 3 mm of free play is present replace the shock ball joints. Inspect the shock for leaks. Shock Ball Joint TJ15 TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 11 If more than 2 to 3 mm of free play is present replace shock ball joints. Inspect the shocks for leaks. Shock Ball Joint TJ15 TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 12 Check the gap using a feeler gauge. Adjust the gap to 1.0 – 1.1mm (0.039 – 0.043 in) carefully bending the ground electrode. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 13 If a new filter was installed, it may take some time for fuel to fill the filter before dripping from the Banjo Bolt. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 14 Fill transmission with 2.5 qrt of 80w90 gear oil. Make sure the transmission breather is clean. Reinstall fill plug. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 15 CVTs. If an adjustment is necessary see Belt Tension Adjustment Belt should not be dry, cracked, or otherwise damaged. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 16 Inspect harness to make sure the harness is clear of all moving parts and all hot surfaces. Add zip ties if original ties have come loose. Inspect and clean battery terminals. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 17 Test drive Test drive vehicle and check: Steering operation Brake operation Acceleration Noises Gauge operation Seat belt operation Transmission operation High/Low/ Reverse/Diff lock TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 18 2-7mm movement at the pedal end. 1. Break loose the ball joint jam nut (1). Remove the bolt (2) and nut (3) that hold the push rod to the pedal. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 19 Tech Tip: It is very important that the push rod is adjusted properly. If the push rod is not adjusted correctly the brakes can drag and or lock TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg.
  • Page 20 Using a brake caliper wrench reset the piston by rotating the wrench clockwise until the piston completely retracted back into the piston housing. WARNING: TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 21 Remove the 2 caliper mount bolts. 2. Remove the brake caliper and mount bracket from the final drive. 1. Disconnect the parking brake cable and the brake line. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 22 IMPORTANT: After removing any brake hose and/or fitting from the brake system the brake system will have to be bled for proper operation. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 23 Secure the caliper out of the way. 3. Remove the cotter pin and remove the hub nut. 4. Remove the rotor assembly from the spindle. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 24 5. Hub puller TM50171 may be required if the rotor assembly will not come off easily. 6. Remove and inspect the 3 axle keys from both the left and right rear rotor assemblies. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 25 2. Tighten the nut until the nut stop. Locate the hole in the shaft and tighten 1 additional notch and install the cotter pin. 3. Install the brake caliper assembly. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 26 4. Tighten the mount bolt and torque to 105nm. IMPORTANT: After removing any brake hose and/or fitting from the brake system the brake system will have to be bled for proper operation. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 27 4. Remove the two upper nuts and washers. Nut – 13mm 5. Remove the two lower nuts and washers through the access holes below the booster to pedal rod. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 28 6. Install the new booster, washers and tighten the 4 nuts. 7. Install the push rod. 8. Connect the push rod ball joint. (See: Brake Pedal Adjustment) Connect the master cylinder. (See: Master Cylinder Replacement) TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 29 3. Replace the master cylinder, tighten the nuts and reinstall the hoses and lines. 4. If connections are damaged replace them. 5. Bleed brakes. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 30 Try fitting the master cylinder again. Lock nut – 8mm Push rod – 6mm TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 31 Measure the distance exposed. c. Adjust the steering shaft equally on both sides to half the distance measured in step b. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 32 6. Set the hub with TM50410 - hub level bar parallel to the vehicle frame using a level. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 33 2mm closer to the frame then the rear side of the bar. 9. Reattach the steering dust boot with cable ties. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 34 The red line marks the needed inclination for the wheel. ۫ (Top View) Forward TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 35 4. Remove vice grips installed on step 6. Check steering for smooth, proper operation with vehicle on the ground. TOMCAR USA, I c. 1727 E. D eer Valle Ro Bldg. 2, Ste. 1...
  • Page 36 Tech Tip If ball joint spins and nut will not tighten, apply pressure from bottom side of the ball joint lock ball joint in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 37 24mm 3. Install a new steering rod. 4. Install a new steering tie rod end and reconnect to spindle. Refer to “Steering alignment section”. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 38 4. Inspect the ball joint, housing and cap for damage and or wear. 5. Remove the 2 Allen set screws and remove the 2 copper washers. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 39 The rubber boot is important for keeping the grease in the ball joint and keeping the dirt out, replace it when it is cracked and or torn. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 40 A-arm. If there is any damage to the housing then replace the whole A-arm. See: A-arm replacement section. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg.
  • Page 41 2. Disconnect the lower shock mount. 3. Remove the a-arm bolts (1) and (2) and pull out the lower a-arm. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 42 This will help protect the exposed threads from the bolt from getting damaged by rocks, and will be easier to remove next time. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 43 1. Place the transmission in neutral. 2. Pull C.V.T. belt (1) up with right hand while sliding it over the rim of the Transmission CVT plate (2) with left hand. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 44 5. Width of belt: Standard (new) - 35mm (1.36 in.) Service limits - 33.5mm (1.30 in.) 6. Belt should not be dry, cracked, or otherwise damaged. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 45 2. Mount the belt completely on the Engine CVT first. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 46 5. The gap should be 5-7 cm (2.0-2.9in) measured at midpoint between the two CVTs. If an adjustment is necessary see Belt Tension Adjustment TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 47 17mm 8. Loosen the four exhaust nuts. 13mm 9. Move engine forward or backwards until correct belt tension is reached. 10.Tighten all nuts and bolts TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 48 4. Place the CVT on a firm surface and push down on the moving plate. It should move smoothly all the way up and down. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 49 2. Attach the CVT puller (TM50170). 13mm wrench 24mm socket 3. Remove the CVT Note: Be aware not to lose the spacer or the gear-shaft key. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 50 If CVT fits without the keyway check that the keyway is straight and the groove is clean and smooth. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 51 8. Secure the engine CVT firmly in place with crankshaft washer, bolt and torque to 67.7N*m (50Ft*lb). Socket – 16mm TOMCAR USA, I c. 1727 E. D eer Valle Ro Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 52 CVT on the holder. Disassembly 1. Remove the CVT o-ring housing TM6880. Inspect for cracks, wear and condition of the o-ring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 53 Replace with new if damaged. 5. Remove the move plate and inspect. It should be smooth without deformation, abrasion or grooves. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 54 Replace the plate and the spring if there is any damage. any damage. 8. Inspect the Fix-plate and main shaft. They should be smooth without grooves or deformations. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...

  • Page 55: Exploded View

    Reassembly Reassembly Exploded View 1. Place the Transmission CVT shaft on the holder and apply anti-seize to the threads. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 56 5. Insert the wear strips (TM6930 two strips) into the groove. Note: Make sure the ends for the top strip is 180 degrees opposite the end of the lower strip. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 57 6. Slide the move plate into place. 7. Insert the (TM6892) spring leg into the hole in the bottom of the inner spin guide (TM6852). TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 58 9. Screw on and tighten the inner guide using TM50185. 10.Grease generously (±25gr.). 11.Slide the outer spin guide (TM6832) into place, make sure that the grease nipple (TM7990) is in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 59 2. Using TM50130 rotate the move plate counter clockwise two more holes than the one marked, this will preload the spring inside. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 60 If the belt slips during steep climbs (loud squealing, ratcheting noises from belt) the CVT spring will have to be tightened by rotating the plate one more hole. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 61 1. Engine CVT Wrench TM50185 2. TM50080 scale 3. Wrench 10mm 4. 5mm Allen bit 5. Sockets: 10mm, 13mm 6. Vice Exploded View TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 62 4. Secure the CVT holder in a vice and place CVT on the holder. 5. Use CVT wrench TM50185 to unscrew roller plate (counter clockwise). TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 63 Reassembly 1. Apply anti-seize to the threads. Apply anti-seize to the main shaft. 3. Close the roller plate tightly with tool TM50185. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024...
  • Page 64 (TM6725) guide hole. Grease lightly. Grease the guide shaft thread Place the spring housing into position and tighten the 4 nuts. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 65 Test for proper function by pushing the Variator up and down, check for smoothness. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 66 When removing a shock remove the o-rings and bushings before removing the shock. When installing the shock, install the bushings and o-rings just before you set the shock into the mounts. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 67 Secure the shock absorber in a vice (Do not to lock the vice jaw on the ball joint). Depress the air piston to remove the pressurized air. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 68 With a hammer lightly tap on the shock cap to release it. Use the Tomcar special shock holding tool TM50500 Place the shock with the holder in the vice. Using a wrench loosen the shock cap, (Do not unscrew completely off).
  • Page 69 CAUTION Make sure that the shock absorber is not pointed at anybody. 11. Unscrew the shock cap. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 70 13. Take off the springs and plastic spacer. 14. With a hammer lightly tap on the cylinder in the area around the shock seal housing. This will help loosen the housing. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 71 Do not unscrew it completely all the oil will spill out. 17. Place the shock in an upright position and unscrew the seal housing. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 72 19. Drain the oil from the shock cylinder. 20. Insert a long screw driver to remove the shock piston. 21. Examine the inside of the cylinder for abrasion damage. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 73 O-ring underneath. 25. Remove the inner seal and the wiper. Reasembly Install the new O-ring on the shock seal housing. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 74 To insert the oil retainer in to the seal housing, squeeze it in and press it into place. Install the wiper with the rims towards the outside. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 75 Inspect the shock rod for any scratches, dents and/or pits. Any damage to the rod will result in the shock leaking. Place the shock spring support on the rod. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 76 Place the rubber support on the rod. Apply a thin coat of oil to the shock seal housing and place on the rod with the thread towards the top. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 77 Install the shock rebound washer onto the shock rod. Install the O-ring from PR038 onto the shock oil piston. 10. Install the nylon bushing from PR038, stretch it slightly. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 78 11. Install the oil piston on the rod and tighten the nut. 12. Make sure that the shock rebound washer still has free play. 13. Install the O-ring onto the shock gas piston. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 79 IMPORTANT: Make sure the cylinder stays lock in place over the air piston spacer through to step 26 to ensure the air chamber will be correct size. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 80 22. Insert the piston into the cylinder until the oil just starts to come over the top of the piston. This pushes out the excess air. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 81 26. Slowly tighten the housing. The remaining trapped air and a slight amount of oil will be forced out around the threads. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 82 IMPORTANT: Do not let the rod retract into the cylinder. If this happens the air piston be forced up and the air chamber size will change. 28. Install the shock spacer. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 83 29. Apply anti-seize approximately 1/3 of the way down the threads of the cylinder. 30. Install the second shock spring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 84 31. Install the shock spring nut until it touches the spring. 32. Prepare the shock cap. 33. Insert the O-ring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 85 34. Apply anti-seize to the O-ring and threads. 35. Apply anti-seize to the air valve. 36. Screw in the valve and tighten (not to tight). 37. Screw on the shock cap. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 86 39. Tighten the shock cap. 40. Turn the spring nut and set the spring preload. 41. There should be about 1.5cm of thread. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 87 42. Inflate the shock with pressurized air 100psi. 43. Check that there are no air leaks from the valve or shock cap. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 88 Remove the hose from the shock. Loosen and remove the accumulator cylinder Remove the piston from the cylinder and replace the o-ring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 89 Install new cylinder cap o-ring. Apply anti-seize on the threads and install the cap. The piston will need to set at the depth of 61mm. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 90 12. Install a copper washer on both sides of the banjo hose fitting. 13. Tighten the fitting onto the accumulator while holding the hose in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 91 17. The accumulator must be positioned based on which side of the vehicle the shock will be installed on. (Right side of vehicle). (Left side of vehicle) TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 92 22. Loosen the hose banjo fitting slowly till a small amount of oil bleeds out. This procedure will bleed the air from within the shock. 23. Retighten the hose bolt. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 93 24. Pressurize the accumulator to 100psi. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 94 6. Remove the cam wheel by loosening the 2 Allen set screws (1). 7. Remove grease nipple (2). 8. Remove final drive nut (3) using the special Tomcar wrench TM50190. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 95 10. Carefully pull out the final drive. Axle Removal 1. Remove the final drive spanner nut and speedometer speed ring. 2. Remove the axle from the transmission assembly. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 96 2. After draining the oil turn over and remove all the bolts that hold the final drive cover. 3. Remove the cover and gasket. 4. Remove the three retainer plates. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 97 7. Turn over the final drive and remove the brake rotor. 8. Remove the lower drive axle. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 98 11. Remove the sprocket and examine for any damage, broken teeth or deformations. 12. Remove the two inner axle bearings from the final drive housing. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 99 14. Turn over the housing and remove the two outer bearings. 15. Examine the bearings they should roll smooth and should not have any free play. 16. Inspect housing for damage. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 100 3. Place the bearing housing on the holder and remove the nut. 4. Remove the final drive bracket and spacer. 5. Remove the snap ring retainer. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 101 8. Remove the final drive spacer examine for damage. 9. Remove the upper axle shaft nut. Note: Securing the axle from below will prevent it from spinning. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 102 11. Remove the spacer. 12. Remove the upper sprocket and chain. 13. Examine the sprocket for any broken teeth deformation or any other damage. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 103 15. Remove the inner housing O-ring. 16. Use a hammer and long bar to push out the center bearing plate. 17. Remove the O-ring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 104 18. Remove the bearing. 19. Remove the inner bearings inside the housing. 20. Remove the inner seal. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 105 21. Remove the chain tensioner. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 106 Final Drive – Assembly. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 107 4. Install the second bearing. When both bearings are installed the second bearing should be flush with the casing. 5. Use a chisel to stake the bearing in 3 locations. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 108 See exploded view at beginning of this section. 3. Result. Install lower outer axle bearings 1. Install new O-ring (OR030) in the spacer (TM25400). TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024...
  • Page 109 4. Use chisel to stake the bearing in three locations. Install upper outer axle bearing 1. Reposition the case with the outer side facing 2. Coat the bearing housing with oil. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 110 4. Use a seal installer and install the seal. 5. Result. 6. Use a bearing installer TM50316 to install small bearing Tmx7 TM88302 TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024...
  • Page 111 3. Install an O-ring into the groove on the final drive shaft. O-ring Tmx7 OR019 Shaft Tmx7 TM25353 4. Brush oil on Shaft. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 112 TM25633 8. Result. 9. Install the chain onto the sprocket and make sure that each link of the chain is seated onto the sprocket teeth. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 113 2. Push the tension block in and align the holes in the block with the holes in the case. 3. Position case on its side. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 114 1. Spread the chain to make room to install the lower sprocket. 2. Install the lower sprocket with the shoulder facing down. 3. Tmx7 4. TM25654 TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024...
  • Page 115 8. Carefully install the axel all the way in until the bottom edge of the threaded portion of the axle is flush with the sprocket. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 116 12. Align the cotter pin hole in the shaft with the groove in the axle nut. 13. Install the cotter pin and bend the ends so it can not fall out. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 117 2. Install 2 6mmx12mm guide studs in each of the retainer plates. 3. Install the gasket into place. 4. Install the cover plate. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024...
  • Page 118 5. Apply lock tight to the bolts. 6. Pull up on the guide studs and install bolts. 7. Replace the guide studs with bolts. 8. Tighten all 24 cover bolts. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 119 Oil seal Tmx7 TM87040 11. Turn over the bearing housing and apply oil inside the bearing housing. 12. Install the bearing. Tmx7 TM88302 TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 120 Assemble outer bearing housing and bracket 1. Apply oil to the inside of the outer bearing housing (TM25383) and install the bearing. 2. Install the snap ring (TM89180). TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 121 4. Install the bearing shaft (TM25380) with the nut end towards the inside (the side with the snap ring). 5. Use press to install the shaft. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 122 9. Make sure that the 3 holes on bracket are located at the top. This will determine if the bearing housing will fit right or left side 10. Install the lock nut (TM7099). TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 123 Install center bearing housing 1. Install 3 keys (TM86626) all the way until they are flush with the sprocket. 2. Apply oil to the inside of the case.. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 124 5. Install spacer all the way into the housing seal.. Tmx7 TM25424 6 . Install and tighten the self-locking nut. Tmx7 TM7099 TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 125 11. Use a marker and mark the bearing housing and the final drive housing 12. Use hammer to tighten the bearing housing one complete revolution. Use tool TM50192 TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 126 Rotate the axle by turning the brake rotor as you work the o- ring in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 127 Torque bolts to 70NM 6. Install and tighten the final drive nut (3) using the special Tomcar wrench TM50190. 7. Install and tighten the cam wheel and tighten the Allen bolt (1). 8. Install and tighten the grease nipple (2).
  • Page 128 (1). 3. Remove grease nipple (2). 4. Remove final drive nut (3) using the special Tomcar wrench TM50190. 5. Disconnect the final drive from the vehicle by removing the 6 bolts and nuts that hold the final drive bracket (1).
  • Page 129 Note: it might be necessary to remove the exhaust pipe for extra clearing. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 130 (Tomcar Part: TM50175) remove the pie shaped (Tomcar Part: TM50175) remove the pie shaped gear. Remove the selector sprocket and the key.
  • Page 131 Install an M8x30mm bolt into the hole where the plug was removed and used to separate the left and right case halves. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 132 If the reverse gears are not damaged, this will not need to come apart. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 133 The output shaft bearing is kept in place with an external snap ring. Remove and replace the bearing and reinstall the snap ring. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 134 The large steel spacer ( ) can be set on the case’s top bearing next. Set the small cog with the ridge facing upward on top of the spacer. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 135 Mount the large high gear cog onto the secondary shaft. Next place the heavy steel washer on top of the high gear cog. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 136 Fit the gear selector sprocket onto the shift drum shaft and bolt it in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 137 Tech Tip: Apply a small amount of grease to the roller bearing (1) to keep the bearing from falling off the diff. lock assembly during installation. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...
  • Page 138 Rotate the axle by turning the brake rotor as you work the o- ring in place. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 139 Allen bolt (1). 6. Refit the grease nipple (2). 7. Refit the final drive nut (3) using the special Tomcar wrench TM50190. 8. Hook up the transmission shift linkage. Note : Follow the following procedure to verify shift linkage adjustment is correct.
  • Page 140 TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 141 10. Using two 13mm wrenches, remove the bolts attaching the air filter assembly to the mounting bracket. It is not necessary to remove the mounting bracket. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 142 After removing the bolts for the “P” clamps, move the wires and vacuum line out of the way for engine removal. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 143 17mm bolts that secure the engine to the engine tray. After verifying that all lines, wires, and hoses are clear you may now carefully remove the engine. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 144 After adjustments, loop the excess cable and zip tie the loop to the throttle arm as shown. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 145 (19mm wrench) on the fuel block and depressing the fuel pump prime lever until fuel drips from the fitting. Tighten the fitting enough to seat the crush washers. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 146 Ensure exhaust gasket is in place before tightening the 2-10mm nuts onto the exhaust manifold studs. Tighten the 4-13mm muffler nuts. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 147 Use Teflon sealant on this plug. Replace radiator cap. Start engine and check for leaks, loose connections, and verify fluid levels before returning to service. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1...
  • Page 148 Inspect the pulley for any damage or wear. Remove the timing belt. Use caution to ensure the crankshaft and camshaft pulleys are not rotated. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024...
  • Page 149 3 full turns, and repeat tensioning procedure again. 12.Install the timing cover to the engine and install the 5 hex head screws. Torque these 10Nm. TOMCAR USA, Inc. 1727 E. Deer Valley Road Bldg. 2, Ste. 1 Phoenix, AZ 85024 06222010-v2.0...
  • Page 150 Torque to 360Nm. 14.Replace the cooling system hoses and the alternator belt. Tension the alternator belt and fill the cooling system before returning to service. TOMCAR USA, Inc. 1727 E. D eer Valley Road Bldg. 2, Ste. 1 Phoenix, A Z 85024 06222010-v2.0...

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