New Canter 2017

For Egypt

For Egypt Pub.No.00ELT0061, APRIL 2014 Pub.No.00ELT0061, APRIL 2014

014

Shop Manual

Shop Manual chassis

GROUP INDEX GENERAL ........................................ CLUTCH ........................................... MANUAL TRANSMISSION..............

For Egypt

PROPELLER SHAFT.......................

Shop Manual

FRONT AXLE................................... REAR AXLE .....................................

chassis

WHEEL, TIRE................................... FRONT SUSPENSION..................... REAR SUSPENSION .......................

FOREWORD

BRAKE .............................................

This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso CANTER series truck, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributors. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future.

PARKING BRAKE............................ STEERING ....................................... BUMPER, FRAME ........................... CAB MOUNTING, TILT .................... DOOR ............................................... EXTERIOR ....................................... INTERIOR.........................................

APRIL 2014

HEATER, VENTILATION .................

Applicable models FE

©2014 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

00 21 22 25 26 27 31 33 34 35 36 37 41 42 43 51 52 55

This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1. ENGINE volume (Pub.No.00ELT0060) Group No.

Group subject

00

GENERAL

11

ENGINE

12

LUBRICATION

13

FUEL AND ENGINE CONTROL

14

COOLING

15

INTAKE AND EXHAUST

2. CHASSIS volume (Pub.No.00ELT0061) Group No.

Group subject

00

GENERAL

21

CLUTCH

22

MANUAL TRANSMISSION

25

PROPELLER SHAFT

26

FRONT AXLE

27

REAR AXLE

31

WHEEL, TIRE

33

FRONT SUSPENSION

34

REAR SUSPENSION

35

BRAKE

36

PARKING BRAKE

37

STEERING

41

BUMPER, FRAME

42

CAB MOUNTING, TILT

43

DOOR

51

EXTERIOR

52

INTERIOR

55

HEATER, VENTILATION

3. ELECTRICAL volume (Pub.No.00ELT0062) Group No. 54

Group subject ELECTRICAL

GROUP 00 GENERAL VEHICLE MODEL CODING SYSTEM ................................................ 00-2 EQUIPMENT MODEL CODING SYSTEM .......................................... 00-3 POWER TRAIN TABLE ...................................................................... 00-4 HOW TO READ THIS MANUAL ......................................................... 00-6 1. Illustrated Parts Breakdown and Service Procedures ................... 00-8 2. How to Read Circuits .................................................................. 00-10 CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE ........ 00-14 PRECAUTIONS FOR MAINTENANCE OPERATION ...................... 00-16 JACKING UP..................................................................................... 00-26 TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-28

00-1

VEHICLE MODEL CODING SYSTEM 1 2 3 4 5 6 7 8 9 10

F E 8 4 C E 1

Basic vehicle type

F

Cab-over engine truck

2

Load capacity, drive system

E

2 ton class and over, 4 × 2

3

Cab type

8

Wide cab

4

Rigid axle Light duty vehicle (G.V.W. 6000 to 6900 kg)

5

Rigid axle Light duty vehicle (G.V.W. 7000 kg or more)

C

4D33

E

3350 mm

G

3850 mm

4

Vehicle variations, Suspension

5

Engine

6

Wheelbase

7

Chassis arrangement for use

8

Rear tire arrangement, Payload

9

Vehicle specification

10

Steering position

00-2

None 6 None L

Standard use Rear double Payload 3000 kg to 4000 kg Standard use Left-hand drive vehicle

00

EQUIPMENT MODEL CODING SYSTEM Model code indication in this manual

Model code indication on name plate

Code explanation

Engine 4D33

4

D

3

3 Intra-series sequence of development Sequence of development by series Diesel engine Number of cylinders (4 cylinders)

Clutch C3W28

C

3

W

28 Disc outside diameter Facing material (W: Woven) Typical load capacity (tonnage class) of vehicle Initial letter of “clutch”

Transmission M025S5

M

025

S

5 Number of forward speeds Meshing (S: Synchromesh) Typical load capacity (tonnage class) of vehicle Initial letter of “transmission”

Propeller shaft P2

P

2 Typical load capacity (tonnage class) of vehicle Initial letter of “propeller shaft”

Front axle F300T

F

300

T Type of vehicle (T: Truck) Typical load capacity (tonnage class) of vehicle Initial letter of “front axle”

Rear axle R020T

R

02

0

T Type of vehicle (T: Truck) Intra-series sequence of development Typical load capacity (tonnage class) of vehicle Initial letter of “rear axle”

Reduction and differential D035H

D

03

5

H Tooth form (H: Hypoid gear) Intra-series sequence of development Typical load capacity (tonnage class) of vehicle Initial letter of “differential” in reduction and differential

00-3

POWER TRAIN TABLE Engine

Clutch

Transmission

Propeller shaft

Rear axle

Reduction & Differential

FE84CE6LBH2

4D33

C4W30

M035S5

P3

R035T

D035H

FE85CG6LBH2

4D33

C4W30

M035S5

P3

R035T

D035H

Vehicle model

00-4

00 M E M O

00-5

HOW TO READ THIS MANUAL This manual consists of the following parts: • Specifications • Structure and Operation • Troubleshooting • Circuits • Electrical Equipment Installation Positions • Inspection of Electrical Equipment • On-vehicle Inspection and Adjustment • Service procedures • Connector configuration chart On-vehicle Inspection and Adjustment • Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are described including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedures • Procedures for servicing components and parts off the vehicle are described centering on key points in their removal, installation, disassembly, reassembly, inspection, etc. Inspection • Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given. • Some routine visual checks and cleaning of some reused parts are not described but must always be included in actual service work. Caution • This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING

Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION

Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or better understandings.

Terms and Units • Front and rear The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to as the rear. • Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value • Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit • When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired.

00-6

00 Tightening torque • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) • When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry. Units • Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Système International d’Unités Example: 390 N·m {40 kgf·m} Metric unit SI unit Unit Force Moment of force Positive pressure Pressure

Vacuum pressure

SI unit {metric unit}

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N·m {kgf·m}

9.80665 N·m {1 kgf·m}

kPa {kgf/cm2}

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH2O}

9.80665 Pa {1 mmH2O}

Volume

dm3 {L}

1 dm3 {1 L}

Heat quantity

J {kcal}

4186.05 J {1 kcal}

W {kcal/h}

1.16279 W {1 kcal/h}

kW {PS}

0.7355 kW {1 PS}

Heat flow Power

00-7

HOW TO READ THIS MANUAL 1. Illustrated Parts Breakdown and Service Procedures Symbol

*a

00-8

Denotation

Application

Remarks Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are specified.

Tightening torque

Parts not tightened to standard torques (standard torques specified where necessary for servicing)

Locating pin

Parts to be positioned for installation

Non-reusable parts

Parts not to be reused

Lubricant and/or sealant

Parts to be coated with lubricant or sealant for assembly or installation

Special tool

Parts for which special tools are required for Tool name/shape and part number are shown in service operation table.

Associated part

Parts associated with those removed/disassembled for servicing

Necessary lubricant and/or sealant, quantity required, etc. are specified in table.

00

00-9

HOW TO READ THIS MANUAL 2. How to Read Circuits

00-10

00 2.1 Index number: 100 to 999 • Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its own index number.

2.2 Key number: A01 to Z99 • Key numbers indicate electrical equipment installation locations. The installation location of a part can be easily found using its key number shown in a circuit diagram. All of the electrical equipment installation locations are listed in Gr54-10.

2.3 Part name 2.4 Connector type (type indication) • A list of the connectors used is included in Gr54-14.

2.5 Connector terminal number

2.6 Major harness division • Major harness divisions are shown.

2.7 Wiring variations between different specifications • Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.

2.8 Code number: #001 to #999 • Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspection procedure for a electrical equipment can be found using its code number shown in a circuit diagram.

2.9 Grounding point: [1] to [99] • Locations where wires are grounded to the vehicle. All of the grounding points are listed in 130 .

2.10 Harness connection • The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.

2.11 Circuit number, wire diameter, wire color

00-11

HOW TO READ THIS MANUAL Wire color Wire color B

Br

G

Gr, Gy

L

Lg

Base color + tracer BW

Black/ BY white

Black/ BR yellow

BP

Black/ BV pink

Black/ B Br violet

Black

Black/ BO blue

Black/ orange

Brown/ BrR yellow

Brown/ BrG red

Brown/ BrL green

Brown/ blue

Green/ GL black

Green/ GO blue

Green/ orange

Gray/ GrY white

Gray/ yellow

Black/ brown

BrW

Brown/ BrB white

Brown/ BrY black

BrGr

Brown/ BrV gray

Brown/ Violet

GW

Green/ GR white

Green/ GY red

Green/ GB yellow

GGr

Green/ GBr gray

Green/ GV brown

Green/ violet

Brown

Green GrL, GyL

Gray/ GrR, blue GyR

Gray/ GrB, red GyB

GrG

Gray/ GrBr green

Gray/ brown

LW

Blue/ LR white

LGr

Blue/gray LBr

Light LgR green

Light green/ LgY red

Gray

Black/ BL green

Black/red BG

Blue

Blue/red LY

Gray/ GrG, black GyG

Blue/ LB yellow

Light green/ LgB yellow

Orange/ OB blue

P

Pink PB

Pink/ PG black

Pink/ PL green

Pink/ PW blue

RW

Red/ RB white

Red/ RY black

Red/ RG yellow

RBr

Red/ Rgr brown

Sb V

W

Y

00-12

Orange/ OG black

Light green/ LgW black

Orange OL

R

Blue/ LO black

Blue/ LG orange

Blue/ green

Pink/ PGr white

Pink/gray PV

Pink/ violet

Red/ RL green

Red/blue RO

Red/ orange

Blue/ brown

O

Pu

Gray/ GrW, green GyW

Light green/ white

Orange/ green

Purple Red

Red/ Gray

Sky blue Violet/yelVW low

Violet/ VR white

Violet/red VG

Violet/ VGr green

Violet/ VB gray

Violet/ black

WR

White/ WB red

White/ WL black

White/ WG blue

White/ WO green

White/ WV orange

White/ violet

WBr

White/ WY brown

White/ yellow

YR

Yellow/ YB red

Yellow/ YG black

Yellow/ YL green

Yellow/ YW blue

Yellow/ YO white

Yellow/ orange

YP

Yellow/ YV pink

Yellow/ YGr violet

Yellow/ YBr gray

Yellow/ brown

Violet VY

White

Yellow

00 M E M O

00-13

CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE • Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every vehicle and engine has its own number. These numbers are required for registration and related inspection of the vehicle.

• Name plate contains the following information. • MODEL • CHASSIS No. • MAX. G.V.W. • MAX AXLE LOADS

00-14

00 M E M O

00-15

PRECAUTIONS FOR MAINTENANCE OPERATION • Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors about the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently. • Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this manual. • Perform service operations on a level surface. Before starting, take the following preparatory steps: • To prevent soiling and damage, place covers over the seats, trim and floor in the cab and over the paintwork of the body.

• Prepare all the general and special tools necessary for the job.

WARNING • Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage.

• After tilting the manual type cab, always fit the stopper firmly onto the lock lever to lock the cab stay.

• Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions. • Identify the mass of the item being lifted. Use a cable that is strong enough to support the mass. • When lifting the engine, always use the engine hanger.

00-16

00 • Put the sling round the load at a point of balance if there are no proper hoisting hangers.

• Work within an area of safety just in case the load should slip off the sling.

• Never work in shoes that have oily soles. When working with a partner or in a group, use pre-arranged signals and pay constant attention to safety. Be careful not to touch switches and levers unintentionally.

• Check for oil leakage before washing the vehicle. You might miss the defect if the vehicle is washed first.

00-17

PRECAUTIONS FOR MAINTENANCE OPERATION • Prepare replacement parts ready for installation.

• Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts.

• When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective rotation, fatigue, clogging and any other possible defect.

• To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts’ functionality and appearance. • After removing parts from the vehicle, cover the area to keep it free of dust. • Be careful not to mix up identical parts, similar parts and parts that have left/right alignments. • Keep new replacement parts and original (removed) parts separately. • Apply the specified oil or grease to U-seals, oil seals, dust seals and bearings before reassembly. • Always use the specified oils and greases when performing inspection or replacement. Immediately wipe away any excess oil or grease with a rag.

00-18

00 • Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and other items that might wound your hands.

• Before working on the electrical system, disconnect the battery (–) terminal to prevent short circuits.

CAUTION • Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. (Semiconductor components may otherwise be damaged.) • Disconnect the (–) battery cable, then insulate the (–) terminal of the battery and (–) battery cable with insulating tape or the like. • If the (–) battery cable is not disconnected, battery voltage will remain constantly applied to the B terminal, inviting danger of electric shock. • Carefully handle sensors relays, and other items that are sensitive to shock and heat. Do not remove or paint the cover of any control unit.

• When separating connectors, grasp the connectors themselves rather than the harnesses. • To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them together until they click.

• Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.

00-19

PRECAUTIONS FOR MAINTENANCE OPERATION • When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily operate on the battery voltage.

1. Handling Precautions for Electric Circuits CAUTION • Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can hasten corrosion, particularly with the chassis harness.

1.1 Inspection of Harnesses (1) Inspections with connectors fitted together (1.1) Waterproof connectors • Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust.

(1.2) Non-waterproof connectors • Perform the inspection by inserting a test probe C into the wireentry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage.

(2) Inspections with connectors separated (2.1) Inspections on female terminals • Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections.

00-20

00 (2.2) Inspections on male terminals • Perform the inspection by applying test probes directly to the pins. .

CAUTION • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuitry.

• When using a multimeter to check continuity, do not allow the test probes to touch the wrong terminals.

1.2 Inspection of Connectors (1) Visual inspection • Check that the connectors are fitted together securely.

• Check whether wires have been separated from their terminals due to pulling of the harness.

• Check that male and female terminals fit together tightly.

• Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances.

00-21

PRECAUTIONS FOR MAINTENANCE OPERATION (2) Checking for loose terminals • If connector terminal retainers become damaged, male and female terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings.

1.3 Inspections when a fuse blows • Remove the fuse, then measure the resistance between ground and the fuse’s load side. Next, close the switch of each circuit connected to the fuse. If the resistance measurement between any switch and ground is zero, there is a short circuit between the switch and the load. If the resistance measurement is not zero, the circuit is not currently shorted; the fuse likely blew due to a momentary short circuit. • The main causes of short circuits are as follows: • Harnesses trapped between chassis parts • Harness insulation damage due to friction or heat • Moisture in connectors or circuitry • Human error (accidental short-circuiting of components)

1.4 Inspection of Chassis Ground • A special ground bolt is used to tighten a ground terminal. When servicing the ground point, be sure to follow the procedures described below: • When reinstalling the ground bolt Tighten the ground bolt to the specified torque. • When relocating the ground point A special ground bolt must be used. Spot-weld a nut to a frame and tighten the ground bolt to the specified torque. Be sure to apply touch-up paint to the welded point.

2. Service Precautions for Alternators • When servicing alternators, observe the following precautions: • Never reverse the polarity of battery connections. If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator.

00-22

00 • Never disconnect the battery terminals with the engine running. Disconnection of the battery terminals during engine operation would cause a surge voltage, leading to deterioration of the diodes and regulator.

• Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could damage the diodes and regulator.

• Keep alternators dry. Water on alternators can cause internal short circuits and damage.

• Never operate an alternator with the B and L terminals short-circuited. Operation with the B and L terminals connected together would damage the diode trio.

• Disconnect the battery terminals before quick-charging the battery with a quick charger. Unless the battery terminals are disconnected, quick-charging can damage the diodes and regulator.

00-23

PRECAUTIONS FOR MAINTENANCE OPERATION 3. Intermittent Faults • An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be reproduced by performing the following checks on individual connectors and other parts: • Gently move connectors up and down and to left and right. • Gently move wiring harnesses up and down and to left and right. • Gently wiggle sensors and other devices by hand. • Gently wiggle wiring harnesses on suspension systems and other moving parts. • Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corresponding to diagnosis codes and/or fault symptoms.

00-24

00 4. Precautions for Arc Welding • When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless appropriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the negative cable of the welder is connected, might be largely damaged.

• Current flows backward as shown below.

4.1 From battery (–) terminal To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery’s (–) terminal.

4.2 Procedure • Turn the starter switch to the LOCK position. ↓ • Disconnect the battery’s (–) terminal. ↓ • Cover all parts of the vehicle that may be damaged by welding sparks. ↓ • Connect the welder’s (–) cable to the vehicle as close as possible to the area being welded. Do not connect the welder’s (–) cable to the cab if the frame is being welded, and vice versa. ↓ • Set the welding current in accordance with the part being welded.

00-25

JACKING UP

Jacking up procedure 1 Apply chocks to the rear wheels. 2 Raise the front of the vehicle using a bottle jack or garage jack. 3 Place jack stands to support the frame on the front side of the vehicle.

WARNING • Apply chocks to the rear wheels to hold the vehicle in place. • Do not remove the chocks until service operations are finished. • It is extremely dangerous to support the vehicle with a bottle jack or garage jack alone. Use jack stands additionally to support the frame on the front side of the vehicle. • Leave the bottle jack or garage jack and jack stands in place until all service operations are completed. Be sure not to remove them during work.

00-26

00

Jacking up procedure 1 Apply chocks to the front wheels. 2 Raise the rear of the vehicle using a bottle jack or garage jack. 3 Place jack stands to support the frame on both sides of the vehicle.

WARNING • Apply chocks to the front wheels to hold the vehicle in place. • Do not remove the chocks until service operations are finished. • It is extremely dangerous to support the vehicle with a bottle jack or garage jack alone. Use jack stands additionally to support the frame on both sides of the vehicle. • Leave the bottle jack or garage jack and jack stands in place until all service operations are completed. Be sure not to remove them during work.

00-27

TABLE OF STANDARD TIGHTENING TORQUES 1. Tightening Torques • Tightening torques are roughly classified into the following two categories: Tightening torque

Definition

Availability of torque specifications in text

How to determine tightening torque Locate a bolt or nut corresponding to actual part in the following standard tightening torque table.

Standard tightening torque

Tightening torque determined according to thread size and material of bolts and nuts

None

Specified tightening torque

Tightening torque of bolts and nuts except those defined in “Standard tightening torque”, or that of bolts and nuts not identified in the following tables

Provided

Tightening torque is shown in the text.

• Fasteners used in a location denoted by “wet” should always be tightened in a wet condition (lubricated with engine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition.

2. Table of Standard Tightening Torque • Threads and bearing surfaces shall be dry (tightened in a dry condition). • If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt. • Automotive screws see coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with nominal diameter of 10 mm or larger. (1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m}) Strength 4T

7T

(stud)

Nominal diameter mm

00-28

8T

(stud)

(stud)

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

M5

2 to 3 {0.2 to 0.3}

–

4 to 6 {0.4 to 0.6}

–

5 to 7 {0.5 to 0.7}

–

M6

4 to 6 {0.4 to 0.6}

–

7 to 10 {0.7 to 1.0}

–

8 to 12 {0.8 to 1.2}

–

M8

9 to 13 {0.9 to 1.3}

–

16 to 24 {1.6 to 2.4}

–

19 to 28 {1.9 to 2.9}

–

M10

18 to 27 {1.8 to 2.8}

17 to 25 {1.7 to 2.5}

34 to 50 {3.5 to 5.1}

32 to 48 {3.3 to 4.9}

45 to 60 {4.6 to 6.1}

37 to 55 {3.8 to 5.6}

M12

34 to 50 {3.5 to 5.1}

31 to 45 {3.2 to 4.6}

70 to 90 {7.1 to 9.2}

65 to 85 {6.6 to 8.7}

80 to 105 {8.2 to 11}

75 to 95 {7.6 to 9.7}

M14

60 to 80 {6.1 to 8.2}

55 to 75 {5.6 to 7.6}

110 to 150 {11 to 15}

100 to 140 {10 to 14}

130 to 170 {13 to 17}

120 to 160 {12 to 16}

M16

90 to 120 {9.2 to 12}

90 to 110 {9 to 11}

170 to 220 {17 to 22}

160 to 210 {16 to 21}

200 to 260 {20 to 27}

190 to 240 {19 to 24}

M18

130 to 170 {13 to 17}

120 to 150 {12 to 15}

250 to 330 {25 to 34}

220 to 290 {22 to 30}

290 to 380 {30 to 39}

250 to 340 {25 to 35}

M20

180 to 240 {18 to 24}

170 to 220 {17 to 22}

340 to 460 {35 to 47}

310 to 410 {32 to 42}

400 to 530 {41 to 54}

360 to 480 {37 to 49}

M22

250 to 330 {25 to 34}

230 to 300 {23 to 31}

460 to 620 {47 to 63}

420 to 560 {43 to 57}

540 to 720 {55 to 73}

490 to 650 {50 to 66}

M24

320 to 430 {33 to 44}

290 to 380 {30 to 39}

600 to 810 {61 to 83}

540 to 720 {55 to 73}

700 to 940 {71 to 96}

620 to 830 {63 to 85}

00 Strength 8.8 (Nut 4T)

8.8 (Nut 6T)

Automotive screw thread

Nominal diameter mm

M10

18 to 27 {1.8 to 2.8}

45 to 60 {4.6 to 6.1}

M12

34 to 50 {3.5. to 5.1}

80 to 105 {8.2 to 11}

M14

60 to 80 {6.1 to 8.2}

130 to 170 {13 to 17}

(2) Hexagon flange bolts (Unit: N·m {kgf·m}) Strength 4T

Nominal diameter mm

7T

8T

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

M6

4 to 6 {0.4 to 0.6}

–

8 to 12 {0.8 to 1.2}

–

10 to 14 {1.0 to 1.4}

–

M8

10 to 15 {1.0 to 1.5}

–

19 to 28 {1.9 to 2.9}

–

22 to 33 {2.2 to 3.4}

–

M10

21 to 31 {2.1 to 3.2}

20 to 29 {2.0 to 3.0}

45 to 55 {4.6 to 5.6}

37 to 54 {3.8 to 5.5}

50 to 65 {5.1 to 6.6}

50 to 60 {5.1 to 6.1}

M12

38 to 56 {3.9 to 5.7}

35 to 51 {3.6 to 5.2}

80 to 105 {8.2 to 11}

70 to 95 {7.1 to 9.7}

90 to 120 {9.2 to 12}

85 to 110 {8.7 to 11}

Strength 8.8 (Nut 4T)

8.8

Automotive screw thread Nominal diameter mm

M10

21 to 31 {2.1 to 3.2}

50 to 65 {5.1 to 6.6}

M12

38 to 56 {3.9 to 5.7}

90 to 120 {9.2 to 12}

00-29

TABLE OF STANDARD TIGHTENING TORQUES (3) Hexagon nuts (Unit: N·m {kgf·m}) Strength 4T

Nominal diameter mm

6T (Bolt 7T)

6T (Bolt 8T)

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

Automotive screw thread

Coarse screw thread

M5

2 to 3 {0.2 to 0.3}

–

4 to 6 {0.4 to 0.6}

–

5 to 7 {0.5 to 0.7}

–

M6

4 to 6 {0.4 to 0.6}

–

7 to 10 {0.7 to 1.0}

–

8 to 12 {0.8 to 1.2}

–

M8

9 to 13 {0.9 to 1.3}

–

16 to 24 {1.6 to 2.4}

–

19 to 28 {1.9 to 2.9}

–

M10

18 to 27 {1.8 to 2.8}

17 to 25 {1.7 to 2.5}

34 to 50 {3.5 to 5.1}

32 to 48 {3.3 to 4.9}

45 to 60 {4.6 to 6.1}

37 to 55 {3.8 to 5.6}

M12

34 to 50 {3.5 to 5.1}

31 to 45 {3.2 to 4.6}

70 to 90 {7.1 to 9.2}

65 to 85 {6.6 to 8.7}

80 to 105 {8.2 to 11}

75 to 95 {7.6 to 9.7}

M14

60 to 80 {6.1 to 8.2}

55 to 75 {5.6 to 7.6}

110 to 150 {11 to 15}

100 to 140 {10 to 14}

130 to 170 {13 to 17}

120 to 160 {12 to 16}

M16

90 to 120 {9.2 to 12}

90 to 110 {9 to 11}

170 to 220 {17 to 22}

160 to 210 {16 to 21}

200 to 260 {20 to 27}

190 to 240 {19 to 24}

M18

130 to 170 {13 to 17}

120 to 150 {12 to 15}

250 to 330 {25 to 34}

220 to 290 {22 to 30}

290 to 380 {30 to 39}

250 to 340 {25 to 35}

M20

180 to 240 {18 to 24}

170 to 220 {17 to 22}

340 to 460 {35 to 47}

310 to 410 {32 to 42}

400 to 530 {41 to 54}

360 to 480 {37 to 49}

M22

250 to 330 {25 to 34}

230 to 300 {23 to 31}

460 to 620 {47 to 63}

420 to 560 {43 to 57}

540 to 720 {55 to 73}

490 to 650 {50 to 66}

M24

320 to 430 {33 to 44}

290 to 380 {30 to 39}

600 to 810 {61 to 83}

540 to 720 {55 to 73}

700 to 940 {71 to 96}

620 to 830 {63 to 85}

(4) Hexagon flange nuts (Unit: N·m {kgf·m}) Strength 4T

Nominal diameter mm

Automotive screw thread

Coarse screw thread

M6

4 to 6 {0.4 to 0.6}

–

M8

10 to 15 {1.0 to 1.5}

–

M10

21 to 31 {2.1 to 3.2}

20 to 29 {2.0 to 3.0}

M12

38 to 56 {3.9 to 5.7}

35 to 51 {3.6 to 5.2}

(5) Tightening torques of general flare nuts (Unit: N·m {kgf·m}) Pipe diameter Tightening torque

00-30

mm

φ4.76

φ6.35

φ8

φ10

φ12

φ15

17 {1.7}

25 {2.6}

39 {4.0}

59 {6.0}

88 {9.0}

98 {10}

00 (6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m}) Nominal diameter × wall thickness

6×1

mm

Tightening torque

20

+6 0

{2.0

10 × 1.25 +0.6 0

}

34

+10 0

{3.5

+1.0 0

12 × 1.5 }

49

+10 0

{5.0

+1.0 0

15 × 1.5 }

54

+5 0

64

+5 0

{5.5

+0.5 0 }

(7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m}) Nominal diameter Tightening torque

in.

1/4 13

+4 0

{1.3

3/8 +0.4 0

}

29

+5 0

{3.0

1/2 +0.5 0 }

49

+5 0

{5.0

5/8 +0.5 0 }

{6.5

+0.5 0 }

00-31

GROUP 21 CLUTCH SPECIFICATIONS............................................................................... 21-2 STRUCTURE AND OPERATION 1. Clutch Control .............................................................................. 21-3 2. Clutch Master Cylinder ................................................................. 21-4 3. Clutch Proper and Direct Power Cylinder ..................................... 21-5 TROUBLESHOOTING ........................................................................ 21-7 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacement of Brake Fluid (Clutch System) ................................ 21-8 2. Air Bleeding of Brake Fluid (Clutch System) ............................... 21-10 3. Inspection of Clutch Disc Wear Limit ...........................................21-11 4. Inspection and Adjustment of Clutch Pedal ................................ 21-12 5. Clutch Action .............................................................................. 21-13 CLUTCH PEDAL............................................................................... 21-14 CLUTCH MASTER CYLINDER ........................................................ 21-16 CLUTCH HOSE................................................................................. 21-18 CLUTCH PROPER............................................................................ 21-20 CLUTCH CONTROL ......................................................................... 21-24

21-1

SPECIFICATIONS Item Clutch model Drive type Clutch disc type Pressure plate type Control system

Specifications C4W30 Strap drive Dry, single plate type Diaphragm spring type Fluid pressure type

Clutch master cylinder manufacturer

NISSIN KOGYO

Direct power cylinder manufacturer

NISSIN KOGYO

21-2

STRUCTURE AND OPERATION

21

1. Clutch Control

• Fluid pressure is used to control the clutch operation. • When the clutch pedal is pressed, the boosted force is then applied to the clutch master cylinder. This pressurizes the brake fluid inside the clutch master cylinder, pushing the direct power cylinder and disengaging the clutch.

21-3

STRUCTURE AND OPERATION 2. Clutch Master Cylinder

2.1 When clutch pedal is depressed • The piston is pushed to the right by the push rod, pressurizing the brake fluid in the cylinder. • This brake fluid pressure is transmitted to the direct power cylinder.

2.2 When clutch pedal is released • The piston is pushed back to the left by the combined force of oil pressure from the direct power cylinder and the return spring. • This opens up the port that has been blocked by the pressure cup, connecting the cylinder to the brake fluid tank. This allows the oil pressure to completely drain to the tank.

21-4

21 3. Clutch Proper and Direct Power Cylinder

• Clutch engagement and disengagement are controlled by the brake fluid pressure from the clutch master cylinder acting on the piston of the direct power cylinder, and are achieved by the operation of the piston and the release bearing.

21-5

STRUCTURE AND OPERATION 3.1 When clutch pedal is released • There is no brake fluid pressure acting on the direct power cylinder. The piston and release bearing remain in their home positions. • The force of the diaphragm spring acts on the pressure plate, which in turn keeps the clutch disc pressed against the flywheel. • Pressed against the flywheel, the clutch disc rotates together with the flywheel and transmits the engine power to the transmission drive pinion.

3.2 When clutch pedal is depressed • Brake fluid pressure from the clutch master cylinder moves the piston in the direct power cylinder. • As it moves, the piston pushes the release bearing, which in turn pushes the diaphragm spring. • The diaphragm spring pivots around the pivot ring. This movement, via the strap plate, causes the pressure plate to retract from the flywheel. As a result, the clutch disc separates from the flywheel, cutting off the transmission of engine power to the transmission.

21-6

21

TROUBLESHOOTING

O

O

O

O

Diaphragm spring fatigued Clutch cover

O

O

Loose rivets

O

O

Strap plate bent

O

O

Disc deformed

O

O

O

O

O

O O

Disc torsion spring fatigued or damaged Clutch disc

Clutch pedal

O O

O

O

Spline rusted

O

O

O O

Facing worn

O

Facing surface hardened

O

O

Facing oily or greasy

O

O

Pedal free play insufficient

O

O

Pedal free play excessive

O

Pedal stroke insufficient

O

O

Pedal sliding part faulty

Clutch master cylinder

Direct power cylinder

O

Spline worn

Piston and pressure cup sliding movement faulty

Reference Gr

O

Pressure plate warped or faulty

Disc rivets loose

Clutch pedal requires too much effort

O

Judder when vehicle starting

O

Clutch makes noise on engagement

O

Clutch makes noise on disengagement

Clutch does not engage smoothly

Diaphragm spring heights uneven

Clutch slips

Possible causes

Clutch disengaged but drags

Symptoms

O O

Spring fatigued

O

O

O

O

O

O

Brake fluid passage port clogged

O

O

O

O

Piston and piston cup sliding movement faulty

O

O

O

O

Brake fluid passage port clogged

O

O

O

O

Release bearing faulty

O

Transmission drive pinion spline worn

O

Engine idling speed too low

O

O

O

O

Gr22 O

Engine mounting fatigued

Gr13 O

Flywheel warped, deformed or worn forming steps

O

Flywheel pilot bearing faulty

O

Air mixed in clutch fluid (brake fluid) system

O

Clutch fluid (brake fluid) system leaking

O

O

O

O

Gr11

21-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacement of Brake Fluid (Clutch System) • Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the two systems. This section describes the replacement of the clutch fluid (brake fluid) for the clutch system. In order to completely replace the clutch fluid (brake fluid), the brake fluid in the brake system should also be replaced. (See Gr35.)

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Bleeder screw

Tightening torque

Remarks

6.9 to 8.8 {0.7 to 0.9}

–

Lubricant and/or sealant Mark –

Points of application Brake fluid tank

Specified lubricant and/or sealant

Quantity

Brake Fluid (SAE J1703 or FMVSS No. 116 DOT3)

As required

CAUTION • Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. • If brake fluid is spilled onto the paintwork, immediately wipe it off. • Be sure to use new Brake Fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of different properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of brake fluid, causing the boiling point to drop as well as the clutch rubber parts to swell. Faulty operation of the clutch will result. • Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty clutch operation. • Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.

1.1 Work before replacement • Install one end of a vinyl pipe onto the bleeder screw. Place the loose end into a container.

21-8

21 1.2 Replacement of brake fluid • Replace the brake fluid in the following sequence.

CAUTION • Replacement of old brake fluid with new brake fluid in the clutch fluid line can be recognized by a change in color of the brake fluid being discharged through the vinyl pipe. Loosen the bleeder screw. Press and release the clutch pedal repetitively until brake fluid is no longer discharged. Fill brake fluid up to the “MAX” level on the brake fluid tank. Tighten the bleeder screw. Cycle the clutch pedal several times, then depress and hold the pedal. Loosen the bleeder screw to discharge the brake fluid.

No air in brake fluid

Air in brake fluid Tighten the bleeder screw.

Release the clutch pedal and wait for at least one second. Add brake fluid up to the “MAX” level on the tank.

Tighten the bleeder screw to the specified torque. Release the clutch pedal. Add brake fluid up to the “MAX” level on the tank. Finish

21-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Air Bleeding of Brake Fluid (Clutch System) • Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the two systems. This section describes the air bleeding procedures for the clutch system. For air bleeding procedures for the brake system. (See Gr35.)

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Bleeder screw

Tightening torque

Remarks

6.9 to 8.8 {0.7 to 0.9}

–

Lubricant and/or sealant Mark –

Points of application Brake fluid tank

Specified lubricant and/or sealant

Quantity

Brake Fluid (SAE J1703 or FMVSS No. 116 DOT3)

As required

CAUTION • Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. • If brake fluid is spilled onto the paintwork, immediately wipe it off. • Be sure to use new Brake Fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of different properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of brake fluid, causing the boiling point to drop as well as the clutch rubber parts to swell. Faulty operation of the clutch will result. • Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty clutch operation. • Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.

2.1 Work before air bleeding • Install one end of a vinyl pipe onto the bleeder screw. Place the loose end into a container.

21-10

21 2.2 Air bleeding of brake fluid • Bleed the air in the following sequence. Fill brake fluid up to the “MAX” level on the brake fluid tank. Cycle the clutch pedal several times, then depress and hold the pedal. Loosen the bleeder screw to discharge the brake fluid.

No air in brake fluid

Air in brake fluid Tighten the bleeder screw. Release the clutch pedal and wait for at least one second.

Tighten the bleeder screw to the specified torque. Release the clutch pedal. Add brake fluid up to the “MAX” level on the tank. Finish

3. Inspection of Clutch Disc Wear Limit • Remove grommet from the clutch housing, and check to see if the rod of clutch direct power cylinder has reached the flange of release bearing. • If the rod has reached the flange, replace the clutch disc.

21-11

ON-VEHICLE INSPECTION AND ADJUSTMENT 4. Inspection and Adjustment of Clutch Pedal • Perform inspection and adjustment of clutch pedal after finishing air bleeding in clutch system.

Service standards (Unit: mm) Location

Standard value

Limit

Remedy

–

Clutch pedal installed height

Maintenance item

196 to 202

–

Adjust

–

Clutch pedal play

0.2 to 4.0

9.0

Replace

–

Clearance between clutch pedal and floor

40 or more

–

Adjust or replace

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Nut (push rod securing)

Tightening torque

Remarks

15 to 20 {1.5 to 2.0}

–

4.1 Clutch pedal installed height [Inspection] • Measure the height of the center of the clutch master cylinder from that of the clutch pedal pad with the engine stopped and the clutch pedal released. • If the measurement deviates from the standard value, adjust the height by turning the push rod of the clutch master cylinder. [Adjustment] • Loosen the nut and turn the push rod of the clutch master cylinder to bring the installed height of the clutch pedal into the standard value range. • Tighten the nut to the specified torque. • After tightening the nut, check the clutch pedal play and clearance between the clutch switch and clutch pedal.

4.2 Clutch pedal play • With the engine stopped, measure the clutch pedal play. • If the measurement exceeds the limit, replace the clutch pedal.

4.3 Clearance between clutch pedal and floor • Perform the following inspection with two persons to establish the position at which the clutch is about to reengage. • Apply the chocks to the wheels and the parking brake. Run the engine at idle. • Depressing the clutch pedal, shift the gear shift lever to the forward highest gear position. • Gradually release the clutch pedal, and measure the clearance between the pedal and floor just before the clutch is engaged.

WARNING • Be careful not to allow the vehicle from starting suddenly. Pay full attention to the surrounding condition. • If the measured value is less than the standard value, repeat the adjustment of the play of clutch pedal or replace faulty parts.

21-12

21 5. Clutch Action • Check that pressing the clutch pedal does not create any abnormal noise or require excessive effort. • Check that gear shifting can be performed easily with the clutch pedal pressed. Check also that the clutch engagement is smooth and without any drag as the pedal is gradually released. • If any abnormality is encountered, repair or replace faulty parts.

21-13

CLUTCH PEDAL

Removal sequence 1 2 3 4 5 6

Clevis pin Clutch master cylinder (See later section.) Cylinder bracket Booster bracket Clutch switch Stopper

7 Pedal pad 8 Bushing 9 Clutch pedal : Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

2

Clearance between push rod and piston of clutch master cylinder

0.2 to 1.2

–

Adjust

Clearance between thread area point of clutch switch and stopper

0.1 to 1.5

–

Replace

5, 6

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (push rod of clutch master cylinder mounting)

Tightening torque

Remarks

15 to 20 {1.5 to 2.0}

–

Lubricant and/or sealant Mark

Points of application Inside surface of bushing Sliding area of clutch pedal in return spring Sliding area of clevis pin

21-14

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Chassis grease [NLGI No. 1 (Li soap)]

As required

21 Inspection procedure Inspection: Clearance between clutch switch and stopper • Measure the clearance between the threaded end of the clutch switch and the stopper. If the measurement deviates from the standard value, adjust the clearance. • After adjustment, tighten the lock nut of the clutch switch.

CAUTION • To prevent a clutch slip, make sure that the threaded end of the clutch switch does not contact with the stopper.

Work after installation Adjustment: Clearance between push rod and piston of clutch master cylinder • Adjust the clearance between the clutch master cylinder’s push rod and piston by using the clutch pedal as follows. • Using a finger, depress the clutch pedal in the center. • Set the pedal travel, from the point at which the first resistance is felt to the point at which the second resistance is felt, to the illustrated value. (This distance corresponds to the clearance between the push rod and the piston.) This is done by turning the push rod in or out. • With the pedal travel set to the illustrated value, the push rod-topiston clearance should conform to the standard value. • After the adjustment, tighten the lock nut to the specified torque.

21-15

CLUTCH MASTER CYLINDER Disassembly sequence 1 2 3 4 5 6 7 8

Clevis Circlip Stop plate Push rod Piston Union collar O-ring Cylinder body

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Clutch master cylinder kit

Service standards (Unit: mm) Location 5, 8

Maintenance item Clearance between piston and cylinder body

Standard value

Limit

Remedy

0.02 to 0.1

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Lock nut

Tightening torque

Remarks

15 to 20 {1.5 to 2.0}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Rubber Grease

0.1 to 0.3 g

Metal rubber #20 (rust preventive oil)

As required

Push rod end contact face with piston Piston cup sliding face against cylinder body Cylinder body inner face

Removal procedure Removal: Piston • Close the end of the nipple in the cylinder and use shop towel or the like to cover the cylinder opening for removing the piston. • Feed compressed air gradually starting from 0 kPa {0 kgf/cm2} to remove the piston.

WARNING • Do not apply compressed air suddenly at high pressure. Otherwise, the piston will fly out with full force.

21-16

21 M E M O

21-17

CLUTCH HOSE Removal sequence 1 Eyebolt 2 Clutch hose

*a: *b::

Connector Clutch housing Non-reusable parts

Installation sequence Follow the removal sequence in reverse. • After installation, bleed air from the clutch system. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Eyebolt

20 to 25 {2.0 to 2.5}

–

Nut (installation of clutch hose)

45 to 55 {4.6 to 5.6}

–

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Cap nut A

B

16

M12 × 1.25

ME538216

Prevention of brake fluid leakage when disconnecting brake hose

Removal procedure Removal: Clutch hose • Place a container under the connected part of the clutch hose and loosen the eyebolt while holding the connector.

CAUTION • Be sure to hold the connector while loosening the eyebolt. Otherwise, the connection between the connector and the direct power cylinder may loosen.

21-18

21 • Release the clutch hose together with the eyebolt and the gaskets from the connector, quickly fit to the eyebolt, and tighten it so that the brake fluid would not leak from this end. The fluid leak from the connector is ignorable and just receive it by the container.

CAUTION • Loosening the eyebolt causes the brake fluid to leak. Work quickly.

• After disconnecting the clutch hose, temporarily install an M12 x 1.25 mm bolt to prevent foreign matter and grease from entering the connector.

CAUTION • Installing the clutch hose with the connected part stained with foreign matter or grease may cause a brake fluid leak or incomplete clutch disengagement.

Installation procedure Installation: Clutch hose • Install the clutch hose by following the removal procedure in reverse. (See “ Removal: Clutch hose”.) • After installation, check that the clutch hose does not contact with other parts around it.

CAUTION • When installing the clutch hose, be sure not to apply tension to or twist it.

21-19

CLUTCH PROPER

Removal sequence

*a::

1 Clutch cover 2 Clutch disc

Flywheel Locating pin

Installation sequence Follow the removal sequence in reverse.

CAUTION • To prevent clutch slippage, keep the surfaces of the clutch cover, clutch disc and flywheel free from oil and grease.

Service standards (Unit: mm) Location 1

Standard value

Limit

Pressure plate flatness

Maintenance item

0 to 0.05

–

Diaphragm spring finger height unevenness

0 to 1.0

–

1.9 to 2.5

0.2

Depth from facing surface to rivet 2

Clutch disc

Play in revolving direction in splines

0.05 to 0.23

0.5

Vertical runout

0 to 1.0

1.5

Lateral runout

0 to 0.8

1.5

Remedy Replace

Replace

Lubricant and/or sealant Mark

Points of application Entire surface of splines Fill in the grease grooves of splines

21-20

Specified lubricant and/or sealant

Quantity

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

0.8 to 1.1 g 3.2 to 4.2 g

21 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Clutch alignment arbor A

B

C

MH061387

Holding clutch disc

MH061425

Checking diaphragm spring for installed height

MH061424

Adjusting diaphragm spring

φ28.94 φ20 120

Sleeve A

B

φ45

φ28.94

Plate A

φ400

Removal procedure Removal: Clutch cover • Insert into the flywheel pilot bearing. While supporting the clutch disc with , remove the clutch cover.

Inspection procedure Inspection: Clutch cover (1) Pressure plate flatness • Place a straightedge across the friction surface of the pressure plate. Using a feeler gauge, measure the clearance between the gauge and the surface in several locations selected randomly. • Obtain the flatness of the pressure plate by subtracting the smallest clearance measured from the greatest clearance measured. • If the flatness is equal to or exceeds the specified limit, replace the clutch cover.

21-21

CLUTCH PROPER (2) Play of diaphragm spring • Inspect the diaphragm spring for play. • If the spring has play, the clutch cover needs to be replaced.

(3) Diaphragm spring finger height unevenness • Place on a surface plate. Then, install the clutch cover onto . • Install and onto the assembly. Using a feeler gauge, measure the diaphragm spring finger for uneven height. • If the unevenness is equal to or exceeds the limit, replace the clutch cover.

Inspection: Clutch disc (1) Depth from facing surface to rivet • Measure depth from the clutch disc facing surface to the rivet. • If the measured value is equal to or less than the limit, replace the clutch disc.

(2) Play in revolving direction in splines • Reshape a feeler gauge such that it can be inserted into the drive pinion splines. Then, using the gauge, measure the splines for play in revolving direction. • If the measured value is equal to or exceeds the limit, replace the clutch disc.

Installation procedure Installation: Clutch disc • Insert into the flywheel pilot bearing to support the clutch disc. • Install the clutch cover by tightening the bolts diagonally and gradually.

21-22

21 M E M O

21-23

CLUTCH CONTROL

Removal sequence 1 2 3 4 5

6 Direct power cylinder (See later section.) 7 Oil seal 8 Clutch housing

Connector Bleeder cap Bleeder screw O-ring Grommet

: Non-reusable parts

CAUTION • When handling the direct power cylinder, be careful not to smear it with mineral oil such as engine oil and transmission oil. The smeared cylinder can cause brake fluid leakage.

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Connector

33 to 49 {3.4 to 5.0}

–

Bleeder screw

6.9 to 8.8 {0.7 to 0.9}

–

44.5 {4.5}

–

Bolt (direct power cylinder mounting)

Lubricant and/or sealant Mark

Points of application Direct power cylinder mating face with clutch housing Oil seal lips

21-24

Specified lubricant and/or sealant

Quantity

ThreeBond 1215

As required

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

21 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

MH063322

Protecting oil seal during direct power cylinder installation

MH062714

Oil seal installation

Oil seal installer A φ36.5

Oil seal installer A φ89

Installation procedure Installation: Oil seal • Apply grease onto the oil seal lips. Then, install the oil seal onto the direct power cylinder making sure that the seal faces as shown in the drawing.

Installation: Direct power cylinder • After cleaning the sealant application surfaces, apply sealant as required. • Install onto the drive pinion to protect the oil seal previously installed onto the direct power cylinder.

21-25

CLUTCH CONTROL Direct Power Cylinder

Disassembly sequence 1 2 3 4 5 6 7 8 9

Snap ring Release bearing Oil seal Rear spring stopper Front spring stopper Boots Spring Front inner cup Rear inner cup

10 11 12 13 14 15

Outer cup Piston Pipe Cylinder body A O-ring Cylinder body B

: Non-reusable parts

CAUTION • If the pipe is removed from the cylinder body A, the pipe mounting threads on the cylinder body A may distort or deform, resulting in the leak of brake fluid. If the pipe is removed from the cylinder body A, the cylinder body A must be replaced.

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • Install the piston correctly: It needs to be faced as shown in the drawing, and the cups should not be dislodged. An incorrectly installed piston causes brake fluid leakage and clutch drag.

21-26

21 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Pipe Bolt (mounting of cylinder bodies A and B)

Tightening torque

Remarks

13.7 to 16.7 {1.4 to 1.7}

–

6.9 to 8.8 {0.7 to 0.9}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Rubber Grease

0.1 to 0.2 g

Metal rubber #20 (rust preventive oil)

As required

Front inner cup sliding face with cylinder body B Cylinder body A sliding face Cylinder body B sliding face

Removal procedure Removal: Piston • With the bleeder screw fitting hole or opening of cylinder body A blocked, feed compressed air gradually starting from 0 kPa {0 kgf/cm2} to remove the piston.

WARNING • Do not apply compressed air suddenly at high pressure, or the piston will fly out with full force.

Removal: Cylinder body A • Install bolts (M8 × 1.25 mm) evenly into the jacking holes on cylinder body A and remove the body.

21-27

CLUTCH CONTROL Installation procedure Installation: Front inner cup, rear inner cup and outer cup • Install the front inner cup, rear inner cup, and outer cup onto the piston, facing them in the illustrated directions.

CAUTION • Install the front inner cup, rear inner cup, and outer cup correctly, facing them in the illustrated directions. Incorrectly installed cups cause brake fluid leakage and clutch drag. • Do not apply grease onto the rear inner cup or the outer cup. Otherwise, brake fluid will leak. • Apply only a thin coat of grease to the front inner cup. Greasing it too much can cause brake fluid leakage. Installation: Front spring stopper • Install the front spring stopper onto cylinder body A such that its cutout aligns with the rod on the body and that it faces in the illustrated direction.

Installation: Release bearing • Install the release bearing onto cylinder body B such that its flange aligns with the rod on cylinder body A and that it faces in the illustrated direction.

21-28

GROUP 22 MANUAL TRANSMISSION SPECIFICATIONS............................................................................... 22-2 STRUCTURE AND OPERATION 1. Transmission ................................................................................ 22-3 2. Synchromesh Mechanism ............................................................ 22-4 3. Interlock Mechanism .................................................................... 22-6 4. Speedometer Gear Bushing .......................................................... 22-6 TROUBLESHOOTING ........................................................................ 22-7 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Transmission Oil Leakage ....................................... 22-8 2. Inspection of Looseness in Transmission Mounting Bolts ............ 22-8 3. Inspection of Play and Looseness in Companion Flange .............. 22-8 4. Inspection and Replacement of Transmission Oil ......................... 22-9 REMOVAL AND INSTALLATION OF TRANSMISSION................... 22-10 GEAR SHIFTER UPPER................................................................... 22-14 REAR COVER AND PARKING BRAKE........................................... 22-20 REVERSE IDLER GEAR .................................................................. 22-26 TRANSMISSION BODY.................................................................... 22-30 DRIVE PINION .................................................................................. 22-40 MAINSHAFT...................................................................................... 22-42 COUNTERSHAFT ............................................................................. 22-50 TRANSMISSION CONTROL ............................................................ 22-52 BEARING PULLER AND INSTALLER ............................................. 22-57

22-1

SPECIFICATIONS Item

Specifications

Transmission model

Gear ratio

Classification

M035S5 (5.380/0.722) 1st

5.380

2nd

3.028

3rd

1.700

4th

1.000

5th

0.722

Reverse

5.380

Gear oil

API GL-3, GL-4

Engine oil General

Transmission oil

Viscosity (application /SAE viscosity number)

Quantity

API CC GL-3

80

GL-4

Warm

GL-3

90

Tropical

GL-4

90

Long period CC of high-speed

30 or 40 dm3 {L}

Mass Mode of control

• Transmission oil depends on the driving conditions.

22-2

kg

Approx. 3.6 {3.6} Approx. 80 Instrument panel shift remote control

STRUCTURE AND OPERATION

22

1. Transmission

• The transmission uses an interlock mechanism to avoid double engagement.

22-3

STRUCTURE AND OPERATION 2. Synchromesh Mechanism • The synchromesh mechanism, when a shift change is made, synchronizes the rotation speed of the mainshaft, drive pinion and synchronizer hub that rotates integrally with the mainshaft with that of the gear to be shifted. Synchromesh type

Gears of application

Single cone type

4th, 5th

Triple cone type

2nd, 3rd

2.1 Single cone type The following descriptions are for 4th and 5th synchronizer.

• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the synchronizer hub has a spline that engages the synchronizer sleeve and three grooves. • Shifting plungers are inserted into these grooves. When the gear shift is in neutral, the shifting plunger engage grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting plunger springs. • Synchronizer rings are inserted into the respective taper cone of each gear. • The outer splines of the synchronizer rings engage the synchronizer sleeve. On the synchronizer hub are three grooves in which protrusions of the synchronizer rings are inserted. These grooves are wider than the width of protrusions of the synchronizer rings. • Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play. • When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which engages the synchronizer sleeve, moves to the gear and presses the synchronizer ring against the taper cone of the gear (Figure B). • The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchronous operation. • The rotation speed of the synchronizer hub becomes gradually closer to that of the gear gear due to the synchronous operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to move smoothly to engage the synchronizer hub and gear, completing the shift change (Figure C).

22-4

22 2.2 Triple cone type The following descriptions are for 2nd gear of 2nd and 3rd synchronizer.

• The synchromesh structure and operation of the triple cone type are basically the same as for the single cone type. The synchronizer ring is divided into three parts (synchronizer inner ring, synchronizer center cone and synchronizer outer ring) and the center cone (both the inside and outside surfaces are tapered) and the inner ring (both the inside and outside surfaces are tapered) are sandwiched between the outer ring and the taper cone of each gear to shorten the time required for synchronization with cone clutches at three locations. • Six protrusions on the outside of the synchronizer center cone fit into corresponding gear holes. As in the taper cone of the single cone type, the center cone and the gear are installed as if integrated. • The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the synchronizer hub has a spline that engages the synchronizer sleeve and three grooves. • Shifting plungers are inserted into these keyways. When the gear shift is in neutral, the shifting plungers engage grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting plunger springs. • The synchronizer outer ring and synchronizer inner ring are inserted into synchronizer center cones, respectively. • The outer spline of the synchronizer outer ring engages the synchronizer sleeve. On the synchronizer hub are three grooves in which protrusions of the synchronizer outer ring are inserted. These grooves are wider than the width of protrusions of the synchronizer outer ring. • The synchronizer outer ring rotates relative to the synchronizer sleeve by the amount of play. • When the gear shift is in neutral (figure A), moving the shift fork in the direction of the arrow as illustrated, moves the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which engages the synchronizer sleeve, moves to the gear and presses the synchronizer outer ring and the center cone against the taper cone of the synchronizer center cone and the synchronizer inner ring, respectively and in addition, presses the inner ring against the gear (figure B). • The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchronous operation. • The rotation speed of the synchronizer hub becomes gradually closer to that of the gear due to the synchronous operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to move smoothly to engage the synchronizer hub and gear, completing the shift change (figure C).

22-5

STRUCTURE AND OPERATION 3. Interlock Mechanism • The interlock mechanism prevents double engagement of gears. • When the 2nd and 3rd shift rail is shifted, interlock pins except the interlock pin in the 2nd and 3rd shift rail are pushed by the 2nd and 3rd shift rail, which locks other shift rails.

4. Speedometer Gear Bushing • The speedometer gear bushing is eccentric, and displacing the installed position allows it to correspond to the different number of teeth of the speedometer gear. • The numbers marked on the front at four locations show the range of the number of teeth of the corresponding speedometer gear. “15-17”: Number of tooth 15 to 17 • An identification mark showing the number of teeth is marked on the speedometer gear.

22-6

Identification mark

A

B

C

D

L

E

F

Number of teeth

15

16

17

18

19

20

21

Gear ratio

3.0

3.2

3.4

3.6

3.8

4.0

4.2

22

TROUBLESHOOTING

O

Mainshaft thrust washer worn

O

O

Mainshaft bearing worn or damaged

O

O

Synchronizer ring and synchronizer sleeve spline worn

O

Mainshaft pilot bearing worn or damaged

O

O

Drive pinion bearing worn or damaged

O

Countershaft bearing worn or damaged

O

Needle bearings of gears worn or damaged

O

Possible causes

Synchronizer ring and gears taper cone area worn Transmission body faulty

O O

Mainshaft and countershaft gears backlash excessive

O

Spline of gears worn

Synchronizer faulty

O

Gears damaged

O

Transmission oil insufficient

O

Triple cone type

Contacting surface of synchronizer ring and gear taper cone worn

O

O

Contacting surface of synchronizer inner and outer rings and center cone worn

O

O

Contacting surface of synchronizer inner ring and gear taper cone worn

O

O

Synchronizer ring spline chamfer worn

O

Shifting plunger worn

O

Shifting plunger spring deteriorated or damaged

O

Synchronizer sleeve worn or damaged

Control mechanisms faulty

Clutch faulty

Reference Gr

O

Mainshaft and countershaft gears worn or damaged

Single cone type

Noise when changing gear

O

Noise when cruising

Gears hard to engage

Mainshaft rear lock nut loose

Noise when engine is idling

Gears slip out of engagement

Symptoms

O

Control cable adjustment faulty

O

Control cable routing inadequate

O

Control cable length inadequate

O

Bushings worn

O

Steel ball and groove of shift rail worn

O

Poppet spring of shift rail fatigued or damaged

O

O

O

Shift rail sliding movement faulty

O

Shift fork jaws worn

O

Shift fork bent

O

Clutch disengagement faulty

O

O Gr21

Clutch pedal play faulty

O

O

22-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Transmission Oil Leakage 1.1 Inspection of oil leakage at each part of transmission body • Check the oil leakage at each part of transmission body in visual. If the oil leakage is found, replace the defective part.

1.2 Inspection of oil leakage around transmission mounting part • Check there is not oil stain on transmission mounting part caused by oil leakage from engine. • If there is the oil stain, remove the transmission and clean the mounting surface of clutch housing using brake cleaner etc. after repairing oil leakage part. Because the oil stain may loosen the transmission mounting bolts. (See “REMOVAL AND INSTALLATION OF TRANSMISSION”.)

2. Inspection of Looseness in Transmission Mounting Bolts Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Bolt (transmission mounting)

Tightening torque M10

47.1 {4.8}

M12

82.4 {8.4}

Remarks –

• Check the transmission mounting bolts for looseness. • Retighten any loose bolt to the specified torque.

3. Inspection of Play and Looseness in Companion Flange • Check the propeller shaft mounting bolts for looseness. (See Gr25.) • Move the parking brake drum in axial and vertical directions to check for excessive play between the companion flange and main shaft. • If excessive play is detected, remove the propeller shaft, then check the lock nut for looseness and the splines on companion flange and main shaft for abnormalities. If any part is found defective, replace the part. (See “REAR COVER” section.)

22-8

22 4. Inspection and Replacement of Transmission Oil WARNING • Temperature of transmission oil is high immediately after driving. Perform work when oil is cold.

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Inspection plug Drain plug

Tightening torque

Remarks

68.6 ± 14.7 {7.0 ± 1.5}

–

Lubricant and/or sealant Mark –

–

Points of application Thread area of inspection plug Thread area of drain plug

Transmission case

Specified lubricant and/or sealant

Quantity

ThreeBond 1105

As required

Gear oil General: API GL-3 or GL-4 SAE80 Warm region: API GL-3 SAE90 Tropical region: API GL-4 SAE90 Engine oil Long period of high-speed driving: API CC SAE30 or SAE40

Approx. 3.6 dm3 {3.6 L}

• Oil depends on the driving conditions. [Inspection] (1) Inspection of oil quantity • Remove the inspection plug, and check that oil is filled up to the neck. • If oil is not sufficient, fill oil from the inspection plug hole up to the neck. • After filling, apply sealant to the inspection plug and tighten it to the specified torque. (2) Inspection of oil quality and inclusions • When draining transmission oil, check for oil quality, metal chips and metal powder. • If an abnormally large amount of metal chips and metal powder is found, disassemble the transmission assembly for service, as abnormalities may be caused inside. [Replacement] • Remove the drain plug to drain transmission oil. Drainage can be made quickly with the inspection plug removed. • After draining transmission oil, apply sealant to the drain plug and tighten it to the specified torque. Magnet type drain plugs should be cleaned before installation. • Fill transmission oil in the specified quantity from the inspection plug hole. • After filling, wait for 1 minute or more to check that oil is filled up to the neck of the inspection plug hole by inserting a finger to the inspection plug hole. If oil is not sufficient, replenish it. • After completing work, apply sealant to the inspection plug and tighten it to the specified torque.

22-9

REMOVAL AND INSTALLATION OF TRANSMISSION Removal sequence 1 2 3 4

Propeller shaft (See Gr25.) Cluch hose Parking brake cable (See Gr36.) Transmission

• When the oil stain is found inside of clutch housing after removing the transmission, check the oil leakage portion of transmission or engine and replace the defective part.

Installation sequence Follow the removal sequence in reverse. • Check and adjust the parking brake lever after the installation. (See Gr36.)

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (transmission mounting) Bolt (transmission mounting)

Tightening torque

Remarks

130 to 170 {13 to 17}

–

M10

47.1 {4.8}

M12

82.4 {8.4}

–

Lubricant and/or sealant Mark

Points of application Drive pinion spline Engine mounting surface of clutch housing

22-10

Specified lubricant and/or sealant

Quantity

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

As required

ThreeBond 1215

As required

22 Removal procedure Removal: Transmission • Support the transmission on the transmission jack and remove transmission mounting bolts.

• Insert a screwdriver into the three removal grooves and remove the transmission from the engine. • Move the transmission backward until the spline of the drive pinion is detached from the clutch.

CAUTION • Make sure that you pull the transmission out in a straight line. If you seesaw the transmission violently, you will damage the spline that connects the drive pinion and the clutch.

Installation procedure Installation: Transmission • Check the spline of the drive pinion for rust. • If rust is found, remove it using a wire brush. • Rub grease evenly onto the clutch disc sliding surface of the drive pinion using your hand.

CAUTION • Make sure that you apply only the necessary amount of grease because too much grease would drip and cause clutch slip.

22-11

REMOVAL AND INSTALLATION OF TRANSMISSION [Applying sealant] • Apply sealant following manners shown below.

CAUTION • Take care not to apply sealant under any of the following conditions. Otherwise it causes water infiltration. • There is dust, oil, grease, etc. on the mating surface. • The diameter or thickness of the applied sealant is extremely different at each part. • The applied sealant has some breaks. • The applied sealant covers the bleeding hole of the clutch housing and engine parts. • Clean the mating surfaces of each part. • Apply sealant on the width center of the mating surfaces so that the diameter of the applied sealant is the same as the diameter of the nozzle. The line of applying sealant is illustrated. • Clean the mating surfaces of each part. • Apply sealant evenly on the entire mating surfaces. [Installation] • After applying the sealant, install the transmission before the sealant dries. Be sure not to allow the sealant to be displaced. • Do not start the engine within one hour after installing the transmission. • When loosening or removing transmission mounting bolts, be sure to reapply the sealant. • Support the transmission on the transmission jack, and insert the transmission into the pilot bearing of the flywheel paying attention to the drive pinion spline. • Tighten transmission mounting bolts to the specified torque.

22-12

22 M E M O

22-13

GEAR SHIFTER UPPER Removal sequence 1 Gear shifter upper (See later section.) 2 Poppet spring plate 3 Poppet spring 4 Steel ball 5 Backup lamp switch 6 Screw plug 7 Interlock pin

*a:

Transmission case : Locating pin : Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Service standards Location 3

Maintenance item Poppet spring installed load (installed length 21.7)

Standard value

Limit

Remedy

61.2 ± 5.9 N {6.24 ± 0.6 kgf}

43 N {4.4 kgf}

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (gear shifter upper mounting) Bolt (poppet spring plate mounting) Backup lamp switch Screw plug

Tightening torque

Remarks

23.5 {2.4}

–

29.4 to 39.2 {3 to 4}

–

37.3 {3.8}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Gear shifter upper mounting surface of transmission case

ThreeBond 1194

As required

ThreeBond 1215

As required

Mating surface of poppet spring plate and transmission case Thread area of backup lamp switch Thread area of screw plug

22-14

22 Removal procedure Removal: Interlock pin • Shift the 1st and reverse shift rail to the reverse position in such a way that the interlock pin removal hole is in alignment with the interlock pin itself.

• Remove the interlock pins by pushing them out with a wire.

Installation procedure Installation: Gear shifter upper [Applying sealant] • Apply sealant onto the transmission case, following manners shown below.

CAUTION • Take care not to apply sealant under any of the following conditions. Otherwise it causes oil leak. • There is dust, oil, grease, etc. on the mating surface. • The diameter or thickness of the applied sealant is extremely different at each part. • The applied sealant has some breaks. • Clean the mating surfaces of each part. • Apply sealant on the width center of the mating surfaces so that the diameter of the applied sealant is the same as the diameter of the nozzle. The line of applying sealant is illustrated. • Clean the mating surfaces of each part. • Apply sealant evenly on the entire mating surfaces. [Installation] • After applying the sealant, install the gear shifter upper before the sealant dries. Be sure not to allow the sealant to be displaced. • Do not start the engine within one hour after installing the gear shifter upper. • When loosening or removing gear shifter upper mounting bolts, be sure to reapply the sealant.

22-15

GEAR SHIFTER UPPER Gear Shifter Upper

Disassembly sequence 1 2 3 4 5 6

Air breather Transmission neutral switch Spring pin Torsion shaft Gear shift sliding lever Spring retainer

7 8 9 10 11 12

Assembly sequence Follow the disassembly sequence in reverse.

22-16

Return spring Lock pin Gear select lever Washer Gear select lever Oil seal

13 Oil seal 14 Select lever case : Non-reusable parts

22 Service standards (Unit: mm) Location 7

Maintenance item Return spring installed load (installed length 26.8)

Standard value

Limit

Remedy

71.3 ± 6.9 N {7.28 ± 0.7 kgf}

50 N {5.1 kgf}

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Transmission neutral switch

Tightening torque

Remarks

49 ± 2.9 {5.0 ± 0.3}

–

6.9 {0.7}

–

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Nut (lock pin mounting)

Lubricant and/or sealant Mark

Points of application Transmission neutral switch mounting groove of torsion shaft Sliding area of washer Lip area of oil seal Thread area of transmission neutral switch

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Spring pin puller A

MH062445

M12 × 1.25 Removal of spring pin Reverse shaft puller A

03726-82000

M12 × 1.25

22-17

GEAR SHIFTER UPPER Removal procedure Removal: Spring pin • Tap the spring pin using an M4 tap. • Insert spring pin puller with an M4 screw of appropriate length into the spring pin, and remove the spring pin using reverse shaft puller.

Installation procedure Installation: Gear select lever • Apply grease and sealant to portions shown of the gear shift case. • Install the gear select lever while turning so that the oil seal is not damaged in the lip.

Installation: Torsion shaft • Install the torsion shaft so that the angle the punch mark “ ” at the tip of the torsion shaft forms with the gear shift slide lever is as illustrated.

22-18

22 M E M O

22-19

REAR COVER AND PARKING BRAKE

Disassembly sequence 1 O-ring 2 Dust plug 3 Parking brake drum (See Gr36.) 4 Companion flange 5 Reamer bolt 6 Parking brake (See Gr36.)

7 8 9 10 11 12 13

Vehicle speed sensor Spring pin Speedometer gear O-ring Oil seal Speedometer gear bushing Oil seal

14 Rear cover 15 Speedometer worm 16 Pin : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 4 9, 12

22-20

Maintenance item Runout at socket portion of companion flange Clearance between speedometer gear and speedometer gear bushing

Standard value

Limit

Remedy

0 to 0.15

0.15

Replace

0.04 to 0.09

0.15

Replace

22 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

245 to 343 {25 to 35}

–

52.0 to 66.7 {5.3 to 6.8}

–

14.7 to 29.4 {1.5 to 3}

–

Bolt (speedometer gear bushing mounting)

23.5 {2.4}

–

Bolt (rear cover mounting)

44.5 {4.5}

–

Lock nut Reamer bolt Vehicle speed sensor

Lubricant and/or sealant Mark

Points of application O-ring Lip area of oil seal Sliding area of speedometer gear and speedometer gear bushing Transmission case mounting surface of rear cover

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

As required

ThreeBond 1215

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Flange puller A

B

C

φ95

φ100

φ90

MH061848

Removal of companion flange

MH062691

Installation of oil seal

Oil seal installer A

B

C

φ64

φ50

17

Work before removal Alignment marks: Speedometer gear bushing • The installed direction of the speedometer gear bushing is determined by the number of the speedometer gear teeth. • Make alignment marks to prevent misassembly.

22-21

REAR COVER AND PARKING BRAKE Removal procedure Inspection: Runout at socket portion of companion flange • After removing the parking brake drum, measure the runout at the socket portion of the companion flange. • If the measurement exceeds the limit, replace the companion flange.

Removal: Companion flange

Inspection procedure Inspection: Clearance between speedometer gear and speedometer gear bushing • If the clearance exceeds the limit, replace the speedometer gear bushing.

Installation procedure Installation: Oil seal • Install the oil seal in the rear cover in the illustrated direction. • After installation, apply grease to the lip area of the oil seal.

22-22

22 Installation: Rear cover [Applying sealant] • Apply sealant following manners shown below.

CAUTION • Take care not to apply sealant under any of the following conditions. Otherwise it causes oil leak. • There is dust, oil, grease, etc. on the mating surface. • The diameter or thickness of the applied sealant is extremely different at each part. • The applied sealant has some breaks. • Clean the mating surfaces of each part. • Apply sealant on the width center of the mating surfaces so that the diameter of the applied sealant is the same as the diameter of the nozzle. The line of applying sealant is illustrated. • Clean the mating surfaces of each part. • Apply sealant evenly on the entire mating surfaces. [Installation] • After applying the sealant, install the rear cover before the sealant dries. Be sure not to allow the sealant to be displaced. • Do not start the engine within one hour after installing the rear cover. • When loosening or removing rear cover mounting bolts, be sure to reapply the sealant. Installation: Oil seal • Apply grease to the lip area of the oil seal. • Install the oil seal evenly in the illustrated direction using a round bar with an outer diameter of approx. 14 mm.

Installation: Spring pin • Install the spring pin in the illustrated direction to prevent the speedometer gear from slipping off.

22-23

REAR COVER AND PARKING BRAKE Installation: Speedometer gear bushing • When replacing the speedometer gear bushing, align the alignment mark of the old part with that of the rear cover to install.

22-24

22 M E M O

22-25

REVERSE IDLER GEAR

Disassembly sequence 1 2 3 4

Power take-off cover Reverse idler gear shaft Side washer Reverse idler gear

5 Side washer

*a:

Transmission case : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location –

Maintenance item Play in the diameter direction of reverse idler gear End play of reverse idler gear

Standard value

Limit

0.045 to 0.086

0.2

0.26 to 0.64

0.9

Remedy Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (power take-off cover mounting)

Tightening torque

Remarks

44.5 {4.54}

–

Lubricant and/or sealant Mark

Points of application Power take-off cover mounting surface of transmission case

22-26

Specified lubricant and/or sealant

Quantity

Loctite 5999

As required

22 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Reverse shaft puller 03726-82000

A

Removal of reverse idler gear shaft

M12 × 1.25

Removal procedure Removal: Power take-off cover • Insert a scraper from the lower right or lower left of the power take-off cover to remove the power take-off cover.

CAUTION • Beware that prying the scraper halfway could deform the power take-off cover or damage the transmission case.

Inspection: Reverse idler gear • After the power take-off cover is removed, perform the following check. If the measurement exceeds the limit, replace defective parts. • Check the play again after assembly and make sure it does not exceed the limit.

(1) Play in the diameter direction

(2) End play • Measure the end play using feeler gauge.

Removal: Reverse idler gear shaft

22-27

REVERSE IDLER GEAR Installation procedure Installation: Power take-off cover [Applying sealant] • Apply sealant onto the transmission case, following manners shown below.

CAUTION • Take care not to apply sealant under any of the following conditions. Otherwise it causes oil leak. • There is dust, oil, grease, etc. on the mating surface. • The diameter or thickness of the applied sealant is extremely different at each part. • The applied sealant has some breaks. • Clean the mating surfaces of each part. • Apply sealant on the width center of the mating surfaces so that the diameter of the applied sealant is the same as the diameter of the nozzle. The line of applying sealant is illustrated. • Clean the mating surfaces of each part. • Apply sealant evenly on the entire mating surfaces. [Installation] • After applying the sealant, install the power take-off cover before the sealant dries. Be sure not to allow the sealant to be displaced. • Do not start the engine within one hour after installing the power take-off cover. • When loosening or removing power take-off cover mounting bolts, be sure to reapply the sealant.

22-28

22 M E M O

22-29

TRANSMISSION BODY

Disassembly sequence 1 2 3 4 5 6 7 8

Inspection plug Drain plug Direct power cylinder Snap ring Mainshaft rear bearing Countershaft rear bearing Transmission case Bearing retainer

9 10 11 12 13

Shift rail and shift fork (See later section.) Countershaft (See later section.) Drive pinion (See later section.) Mainshaft (See later section.) Clutch housing

: Locating pin : Non-reusable parts

NOTE • After removing clutch direct power cylinder, perform work with the transmission body laid vertically on its clutch housing side. • If the countershaft, drive pinion and mainshaft assembly is not to be disassembled, only the shift rail and shift fork can be removed with the assembly still fitted in the clutch housing.

22-30

22 Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (bearing retainer mounting) Bolt (direct power cylinder mounting) Bolt (transmission case mounting) Inspection plug Drain plug

Tightening torque

Remarks

44.5 {4.5}

–

54 {5.5}

–

68.6 ± 14.7 {7.0 ± 1.5}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

ThreeBond 1215

As required

ThreeBond 1105

As required

Clutch housing mounting surface of front bearing retainer Clutch housing mounting surface of clutch direct power cylinder Transmission case mounting surface of clutch housing Thread area of inspection plug Thread area of drain plug

22-31

TRANSMISSION BODY Special tools (Unit: mm) Mark

Tool name and shape

Snap ring expander

Part No.

Application

MH061268

Removal and installation of snap ring

Bearing puller and installer A B φ96.8

Removal of mainshaft rear bearing

40

MH062697 Bearing puller and installer A B φ94

Installation of mainshaft rear bearing

φ48

Bearing puller and installer A B φ76.8

Removal of countershaft rear bearing

30

MH062696 Bearing puller and installer A B φ80

Installation of countershaft rear bearing

φ42

Eyebolt A

MH062340

Lifting of transmission case

MH063410

Removal and installation of countershaft, mainshaft and drive pinion

M10 × 1.5

Steel lifting band A 251

22-32

22 Mark

Tool name and shape

Part No.

Application

Eye nut A

MH063308

Removal and installation of countershaft, mainshaft and drive pinion

MH062888

For preventing synchromesh from sticking when mainshaft is driven

M24 × 1.5

Synchromesh guard A B 98

29.9

Removal procedure Removal: Mainshaft rear bearing

Removal: Countershaft rear bearing

22-33

TRANSMISSION BODY Removal: Transmission case • Install on the transmission case and make preparations for lifting it up with a crane. • After removing the bolts, lift up the transmission case while hitting the rear end portions (arrow indicating) of the countershaft and mainshaft and the rear rib portions (arrow indicating) of the clutch housing with a plastic hammer to remove the transmission case.

CAUTION • Be sure to hit the ribs as illustrated because hitting other areas may break the clutch housing.

• Secure the countershaft and the 2nd gear area of the mainshaft with for safety. Be sure to tighten the steel lifting band enough to prevent it from coming undone, but not excessively.

22-34

22 Removal: Shift rail and shift fork, countershaft, drive pinion and mainshaft • Leave the countershaft and mainshaft secured with . • Install on the mainshaft and make preparations for lifting it up with a crane. • Secure the shift rail and shift fork with a rubber band to prevent it from coming undone from the mainshaft. • Put a piece of wood on the clutch housing and lift it up while hitting it with a plastic hammer to remove. • When lifting up, be sure to support the drive pinion with your hand to prevent it from falling.

Installation procedure Installation: Shift rail and shift fork, countershaft, drive pinion and mainshaft • When driving in the drive pinion, mainshaft and countershaft, install to prevent the drive pinion and synchronizer of the mainshaft from sticking. • Place the synchronizer sleeve of mainshaft in neutral position before installing the shift rail and shift fork on the mainshaft. • Be sure to remove all the special tools used.

Installation: Transmission case [Applying sealant] • Apply sealant onto the clutch housing, following manners shown below.

CAUTION • Take care not to apply sealant under any of the following conditions. Otherwise it causes oil leak. • There is dust, oil, grease, etc. on the mating surface. • The diameter or thickness of the applied sealant is extremely different at each part. • The applied sealant has some breaks. • Clean the mating surfaces of each part. • Apply sealant on the width center of the mating surfaces so that the diameter of the applied sealant is the same as the diameter of the nozzle. The line of applying sealant is illustrated. • Clean the mating surfaces of each part. • Apply sealant evenly on the entire mating surfaces.

22-35

TRANSMISSION BODY [Installation] • After applying the sealant, install the transmission case before the sealant dries. Be sure not to allow the sealant to be displaced. • Do not start the engine within one hour after installing the transmission case. • When loosening or removing transmission case mounting bolts, be sure to reapply the sealant. Installation: Countershaft rear bearing • Install the countershaft rear bearing on the transmission case in the illustrated direction.

Installation: Mainshaft rear bearing • Install the mainshaft rear bearing on the transmission case in the illustrated direction.

22-36

22 M E M O

22-37

TRANSMISSION BODY Shift Rail and Shift Fork

Disassembly sequence 1 2 3 4 5 6 7 8 9

Spring pin Spring pin 4th and 5th shift rail 4th and 5th shift fork 4th and 5th shift rail jaw Spring pin Spring pin 2nd and 3rd shift rail 2nd and 3rd shift rail jaw

10 11 12 13 14 15

*a::

2nd and 3rd shift fork Spring pin Spring pin 1st and reverse shift rail 1st and reverse shift rail jaw 1st and reverse shift fork Mainshaft Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 3, 8, 13

Maintenance item Bend of shift rail

4, 10, 15 Tilt of shift fork claw 4, 10, 15, a

*

22-38

Clearance between shift fork and synchronizer sleeve of mainshaft

Standard value

Limit

Remedy

0 to 0.04

0.05

Correct or replace

0 to 0.1

0.2

Replace

0.3 to 0.6

1.0

Replace

22 Inspection procedure Inspection: Tilt of shift fork claws • Measure the tilt (difference between A and A’) of claw A-A’ against the shift rail hole of shift forks with pressing the rail to Vblock and standing it vertically. • If the measurement exceeds the limit, replace the shift forks.

Inspection: Clearance between shift fork and synchronizer sleeve of mainshaft • If the measurement exceeds the limit, replace defective parts.

Inspection: Bend of shift rail • Measure the extent of bending at the middle of each of shift rail. • While rotating the shift rail by one revolution, read how much the dial gauge needle will move. A half of the reading observed represents the bend, if any, of the rail. • If the measurement exceeds the limit, replace the shift rail.

Installation procedure Installation: Spring pin • Install the spring pin in the illustrated direction (the spring pin notch to be positioned forward or rearward of the vehicle). When installing the spring pin, leave 0 to 0.5 mm outside from each shift rail or each shift rail jaw. • Drive the spring pin carefully so as not to impose too much load on each shift rail and each shift rail jaw.

22-39

DRIVE PINION Disassembly sequence 1 Snap ring 2 Drive pinion bearing 3 Drive pinion

Assembly sequence Follow the disassembly sequence in reverse.

Special tools (Unit: mm) Mark

Tool name and shape

Snap ring expander

Part No.

Application

MH061268

Removal and installation of snap ring

Bearing puller and installer A B φ92.5

Removal of drive pinion bearing

62.5 MH062697

Bearing puller and installer A B φ94

22-40

φ48

Installation of drive pinion bearing

22 Removal procedure Removal: Drive pinion bearing

Installation procedure Installation: Drive pinion bearing • Install the drive pinion bearing, facing the grooved side in the illustrated direction.

22-41

MAINSHAFT

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

1st gear thrust washer 1st gear Needle bearing Snap ring Synchronizer sleeve Synchronizer hub Reverse gear Needle bearing Snap ring Pilot bearing Snap ring 4th and 5th synchronizer (See later section.) 5th gear

Assembly sequence Follow the disassembly sequence in reverse.

22-42

14 15 16 17 18 19 20 21 22 23 24

*a:

Needle bearing Snap ring 2nd gear thrust washer 2nd gear Needle bearing Bearing spacer Snap ring 2nd and 3rd synchronizer (See later section.) 3rd gear Needle bearing Mainshaft Drive pinion

22 Service standards (Unit: mm) Location

–

–

–

Maintenance item

End play

Play in the diameter direction

Standard value

Limit

1st gear

0.15 to 0.46

0.7

2nd gear

0.15 to 0.61

0.8

3rd gear

0.15 to 0.46

0.7

5th gear

0.2 to 0.56

0.8

Reverse gear

0.15 to 0.46

0.7

1st gear

0.02 to 0.05

0.12

2nd gear

0.02 to 0.05

0.12

3rd gear

0.02 to 0.06

0.12

5th gear

0.05 to 0.09

0.2

Reverse gear

0.04 to 0.07

0.12

5th gear and 4th and 5th synchronizer

1.23 to 1.47

0.5

1.23 to 1.47

0.5

Drive pinion and 4th and 5th synClearance between gear and syn- chronizer chronizer ring 2nd gear and 2nd and 3rd synchronizer 3rd gear and 2nd and 3rd synchronizer

10

Play in the diameter direction of pilot bearing

Remedy

Replace

Replace

Replace 1.16 to 1.74

0.7

1.16 to 1.74

0.7

0.04 to 0.08

0.12

Replace

Special tools Mark

Tool name and shape

Snap ring expander

Part No.

Application

MH061268

Removal and installation of snap ring

Work before removal Inspection: End play of gears • Measure the end play using the feeler gauge. • If the measurement exceeds the limit, replace defective parts.

22-43

MAINSHAFT Inspection: Play in the diameter direction of gears • If the measurement exceeds the limit, replace defective parts.

Alignment marks: Each synchronizer and each gear • Put alignment marks on the each gear and the synchronizer sleeve of the each synchronizer so that the combination of their mating surfaces can be maintained when reassembled.

Inspection procedure Inspection: Clearance between gear and synchronizer ring of synchronizer • When measuring the clearance, press the ring and the center cone evenly against the gear and measure all around the circumference. • If the measurement is less than the limit, replace the ring and the gear.

<Single cone type> • When measuring the clearance, press the ring evenly against the gear and measure all around the circumference. • If the measurement is less than the limit, replace the ring and the gear or the drive pinion.

Inspection: Play in the diameter direction of pilot bearing • Carry out the measurement with installing the drive pinion, pilot bearing and mainshaft and holding the mainshaft as illustrated. • Measure the play with moving the gear of drive pinion in diameter direction. • If the measurement exceeds the limit, replace the pilot bearing.

22-44

22 M E M O

22-45

MAINSHAFT 4th and 5th Synchronizer

Disassembly sequence 1 2 3 4 5

Synchronizer ring Synchronizer sleeve Shifting plunger Shifting plunger spring Synchronizer hub

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 1, 5

Maintenance item Clearance between synchronizer ring protrusion and synchronizer hub groove

Standard value

Limit

Remedy

3.0 to 3.3

4.0

Replace

Work before removal Alignment marks: Synchronizer sleeve and synchronizer hub • Put alignment marks on the synchronizer ring and hub, each at one location, aligning with the alignment mark put on the synchronizer sleeve before disassembly.

Inspection procedure Inspection: Clearance between synchronizer ring protrusion and synchronizer hub groove • If the clearance exceeds the limit, replace defective parts.

22-46

22 Installation procedure Installation: Synchronizer sleeve and synchronizer hub • When replacing the synchronizer sleeve or synchronizer hub with a new one, align the three keyways of the synchronizer hub with three locations of the stub gear tooth of the synchronizer sleeve to install.

22-47

MAINSHAFT 2nd and 3rd Synchronizer

Disassembly sequence 1 2 3 4 5 6 7

Synchronizer inner ring Synchronizer center cone Synchronizer outer ring Synchronizer sleeve Shifting plunger Shifting plunger spring Synchronizer hub

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 3, 7

Maintenance item Clearance between synchronizer outer ring protrusion and synchronizer hub groove

Standard value

Limit

Remedy

3.0 to 3.3

4.0

Replace

Work before removal Alignment marks: Synchronizer inner ring, center cone, outer ring and hub • Put alignment marks on the synchronizer inner ring, center cone, outer ring and hub, each at one location, aligning with the alignment mark put on the synchronizer sleeve before disassembly.

Inspection procedure Inspection: Clearance between synchronizer outer ring protrusion and synchronizer hub groove • If the clearance exceeds the limit, replace defective parts.

22-48

22 Installation procedure Installation: Synchronizer sleeve and synchronizer hub • When replacing the synchronizer sleeve or synchronizer hub with a new one, align the three keyways of the synchronizer hub with three locations of the stub gear tooth of the synchronizer sleeve to install.

22-49

COUNTERSHAFT Disassembly sequence 1 Countershaft front bearing 2 Countershaft gear

Assembly sequence Follow the disassembly sequence in reverse.

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Bearing puller and installer A B φ72

Application

Removal of countershaft front bearing

49.5

MH062696 Bearing puller and installer A B φ80

φ42

Installation of countershaft front bearing

Removal procedure Removal: Countershaft front bearing

Installation procedure Installation: Countershaft front bearing • Install the countershaft front bearing in the illustrated direction.

22-50

22 M E M O

22-51

TRANSMISSION CONTROL

Removal sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

Gear shift lever knob Lock nut (staking type) Shift cable Lock nut (staking type) Select cable Collar Instrument panel bracket Gear shift lever (See later section.) Gear shift lever cover Gear shift lever bracket Lock nut (staking type) Lock nut (staking type) Rod

Installation sequence Follow the removal sequence in reverse.

22-52

14 15 16 17 18 19 20 21 a: *b: *

Bushing Counter lever Counter bracket Cross shaft bracket Cross shaft bushing Cross shaft boot Counter weight Cross shaft

Torsion shaft Gear select lever : Non-reusable parts

22 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

19 to 24 {1.9 to 2.4}

–

59 to 83 {6.0 to 8.5}

–

15 to 20 {1.5 to 2.0}

–

19 to 28 {1.9 to 2.9}

–

59 to 78 {6 to 8}

–

Nut (rod mounting)

9 to 14 {0.9 to 1.4}

–

Nut (counter lever mounting)

27 to 34 {2.8 to 3.5}

–

9.8 to 14.7 {1.0 to 1.5}

–

Lock nut (shift cable mounting) Lock nut (select cable mounting) Lock nut (rod mounting) Shift cable

Lock nut on transmission side

Select cable

Lock nut on transmission side

Bolt (cross shaft mounting) Nut (counter bracket mounting) Nut (counter weight mounting) Nut (cross shaft mounting)

Shift cable (lock nut at ball joint) Select cable (lock nut at ball joint)

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Internal circumference and circumference of bushing Internal circumference and circumference of cross shaft bushing Filling in cross shaft boot

Inspection procedure Inspection: Shift cable, select cable • Check the damage and deformation to the attached parts of clamp and bracket. If any fault is found, replace the fault parts. • Check the motion of cable, bend of limited parts and damage of the cable. If any fault is found, replace the cable. • Check the damage to the cable boot and ball joint. If any fault is found, replace the cable.

Installation procedure Installation: Cross shaft • Insert the cross shaft so that the punch mark “ ” of the torsion shaft on the transmission is positioned at the center of the slit of the cross shaft.

22-53

TRANSMISSION CONTROL Installation: Lock nut <Staking type> • Install the lock nut so that 2 or more threads of the rod or bolt are protruded from the nut. Then tighten the nut to the specified torque. • After installing the lock nut, stake it at three points as shown in the illustration. • Thread-lock cement is precoated on the threads of the lock nut. • Be sure to replace the nuts each time they are loosened or removed.

Installation: Shift cable, select cable • Allow a bending radius of 260 mm or more during storage and handling of the cables. Keep a bending radius as much as possible even after the cables are installed. • Install the cable such that only a minimal bending force is applied to the under head portion of the casing cap. • Avoid subjecting the guide pipe movable portion at the cable end to movement exceeding a permissible angle of 5 degrees. • Make sure that each clamp is installed with the same orientation as that before removal. • Where cable clamping positions are identified with a mark, install the clamp in such a way that it covers the marking completely. • Install each clamp such that it is perpendicular to the cable. • Make sure that the joint at the cable end is installed with the same orientation as that before removal. • If there is an uneven contact between the holder portion boot and stud portion of the ball joint at the cable end, or if the cable boot kinks, remove the cable from the levers on both ends of the cable and perform the following adjustment procedure: • Rotate the cable rod to remove the kink from the cable boot. • Loosen the cable nut and adjust orientation of the ball joint within a half turn.

CAUTION • To prevent damage, check that the engagement margin in threads between the ball joint and cable rod is 8 mm or more.

22-54

22 • Connect the shift cable and select cable with each clamp temporarily tightened. • Permanently tighten the lock nuts and each clamp of the cables in this order with no excessive force applied to the shift cable and select cable.

CAUTION • When tightening lock nuts, tighten B without moving A on the transmission.

• Make sure when operating the gear shift lever that it shifts and selects each position smoothly. • Adjust the gear shift lever with the lock nut on the transmission and lock nut on the gear shift lever. Fore-and-aft direction C (adjusted with the shift cable) Distance from the upper center panel

274 mm

Tilt the gear shift lever forward

E

Move the cable lock nut to the transmission direction.

Tilt the gear shift lever backward

F

Move the cable lock nut to the gear shift lever direction.

Right-and-left direction D (adjusted with the select cable) Distance from the center of the steering wheel in the neutral position of the gear shift lever knob in line of the 2nd to 3rd gear

303 mm

Tilt the gear shift lever rightward.

F

Move the cable lock nut to the gear shift lever direction.

Tilt the gear shift lever leftward.

E

Move the cable lock nut to the transmission direction.

CAUTION • When adjusting cable length, do not move the torsion shaft and gear selector lever from the neutral position. • When adjusting the select position, align neutral position of the transmission with neutral position of the gear shift lever.

22-55

TRANSMISSION CONTROL Gear Shift Lever

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12

Shift lever Lever support Insulator Case Bushing Shift rod Case Insulator Return spring Shift bushing Selector lever Plate

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

19 to 28 {1.9 to 2.8}

–

Bolt (lever support mounting)

4 to 6 {0.4 to 0.6}

–

Nut (selector lever mounting)

10 to 15 {1 to 1.5}

–

Bolt (shift lever mounting)

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Multipurpose grease [NLGI No. 2 (Li soap)]

As required

Sliding area of case and shift rod Internal circumference and circumference of bushing Entire return spring Internal circumference and circumference of shift bushing

22-56

22

BEARING PULLER AND INSTALLER

• Bearing pullers and installers are special tools used for removing and installing the bearings listed in the table below and used in this group. • For each puller (for removing) and each installer (for installing), use the components of the bearing pullers and installers in combination.

Component Adapter

MH062696

Puller

Installer

Puller

Installer

Puller

Installer

Puller

Installer

MH062590

Plug

03726-81017

Bolt

MH062700

O O

Body

MH062701

O

Protector

MH061306

O

Countershaft bearing claw

03726-81012

Bearing claw

MH062707

Mainshaft bearing claw

MH061305

Bearing claw

MH062706

Bearing claw

MH062589

Plug

MH062697

Part No.

Countershaft rear bearing

Mainshaft rear bearing

Drive pinion bearing Bearing puller and installer

Countershaft front bearing

Application

O O

O

O

O

O O

O

03726-81017

O

Bolt

MH062700

O

Body

MH062702

O

Protector

ME624229

O

Mainshaft bearing claw

ME624226

Bearing claw

MH062636

O O

O

O

O

O O

O

22-57

GROUP 25 PROPELLER SHAFT SPECIFICATIONS............................................................................... 25-2 STRUCTURE AND OPERATION 1. Configuration of Propeller Shaft Connection ................................ 25-2 2. Propeller Shaft .............................................................................. 25-3

TROUBLESHOOTING ........................................................................ 25-4 REMOVAL AND INSTALLATION OF PROPELLER SHAFT ............. 25-6 PROPELLER SHAFT.......................................................................... 25-8

25-1

SPECIFICATIONS / STRUCTURE AND OPERATION SPECIFICATIONS Item Propeller shaft

Model

STRUCTURE AND OPERATION 1. Configuration of Propeller Shaft Connection

25-2

Specifications P3

25 2. Propeller Shaft

• Relative positions of the transmission and rear axle vary depending upon the unevenness of the road surface and the vibration and load fluctuations that occur during vehicle operation. The universal joint and the slip yoke joint are provided to absorb these influences.

25-3

TROUBLESHOOTING

Slip yoke joint

Universal joint

Insufficient grease

O

Excessive play at spline

O

Excessive clearance in axial direction of spider shaft

O

O O

Insufficient needle bearing greasing Worn out needle bearing

O O

O

Insufficient grease Center bearing

Propeller shaft

Seizure, wear or improper rotation

25-4

O O

O

O

Deteriorated or deformed cushion rubber

O

Loose hanger mounting bolt

O

Loose mounting bolts

O

Bent

O

Dynamic balance improper

O

Transmission in high speed gear

Abnormal noise at normal running

O

Abnormal noise from propeller shaft Abnormal noise at acceleration from zero or at coasting

Wrong combination of flange yoke directions

Vibration at low speed

Possible causes

Vibration at high speed

Symptoms Propeller shaft vibrates

O

O

25 M E M O

25-5

REMOVAL AND INSTALLATION OF PROPELLER SHAFT

Removal sequence 1 Propeller shaft <Without center bearing> (See later section.) 2 Propeller shaft <With center bearing> (See later section.) : Non-reusable parts

CAUTION • Securely chock the wheels so that the vehicle does not move. • Do not remove the chocks until the entire operation is completed.

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

Nut (propeller shaft mounting)

Parts to be tightened

100 to 120 {10 to 12}

–

Nut (front propeller shaft hanger mounting)

47 to 65 {4.8 to 6.6}

–

Lubricant and/or sealant Mark

Points of application Supply through grease nipple of propeller shaft

25-6

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

25 Work before removal Alignment mark: Propeller shaft • Be sure to make alignment marks before removal.

Work after installation Lubrication: Propeller shaft <Without center bearing> • Fill grease through grease nipple until clean grease overflows from the hole in dust plug of slip yoke joint.

25-7

PROPELLER SHAFT <Without Center Bearing>

• Balance piece installing position (at propeller shaft) depends on the unbalance of the propeller shaft.

Disassembly sequence 1 2 3 4 5

Snap ring Needle bearing Flange yoke Snap ring Needle bearing

6 7 8 9 10

Grease nipple Spider Grease nipple Slip yoke joint Retainer packing

11 Shield packing 12 Propeller shaft : Non-reusable parts

CAUTION • Be careful not to damage the needle bearing because it is fitted with a seal.

Assembly sequence Follow the disassembly sequence in reverse, excepting: 12→10→11→9 Repair kit: Universal joint spider kit • Be sure to reinstall removed parts at their original positions. • Correct dynamic balance after replacement of parts. • Fill grease through the grease nipple of the slip yoke joint after mounting the propeller shaft to the vehicle. (See “REMOVAL AND INSTALLATION OF PROPELLER SHAFT”.)

25-8

25 Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

0 to 0.06

–

Adjust

Permissible amount of unbalance of propeller shaft (periphery of pipe)

10 g max./3000 rpm

–

Adjust

Clearance between needle bearing and flange yoke (“–” indicates interference.)

–0.033 to 0.008

0.1

Replace

0.01 to 0.06

0.1

Replace

–0.033 to 0.008

0.1

Replace

Play in rotating direction between slip yoke joint and propeller shaft spline

0.01 to 0.09

0.3

Replace

Play in diametric direction between slip yoke joint and propeller shaft spline

0.02 to 0.16

0.3

Replace

0 to 0.3

0.4

Correct or replace

–

Axial clearance of spider

– 2, 3 2, 5, 7

Play between needle bearing and spider

5, 9, 12

Clearance between needle bearing and slip yoke joint or propeller shaft (“–” indicates interference.)

9, 12

12

Bend of propeller shaft

Lubricant and/or sealant Mark

Points of application Supply through grease nipple Shield packing lips Propeller shaft spline

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Universal joint tool set A: Yoke assembly B: Push rod C: Guide D

E

F

φ29

φ29

φ27.7

Application

MB999024 A: MH064128 B: MB999026 C: MB999010

Removal and installation of needle bearing

Work before removal Inspection: Axial clearance of spider • Press down on the needle bearing, and measure clearance between snap ring and needle bearing. • If the measurement exceeds the standard value, change snap ring thickness for adjustment. To adjust, use snap rings for both ends with the same thickness. Select optimal combination of snap rings from the table below if necessary. Variety and combination of snap rings (solid line indicates best combination) Thickness

Identification color

Combination

Thickness

Identification color

1.49 mm

None

1.49 mm

None

1.52 mm

Black

1.52 mm

Black

1.55 mm

Blue

1.55 mm

Blue

1.58 mm

Yellow

1.58 mm

Yellow

1.61 mm

Purple

1.61 mm

Purple

1.64 mm

None

1.64 mm

None

1.67 mm

Black

1.67 mm

Black

1.70 mm

Blue

1.70 mm

Blue

25-9

PROPELLER SHAFT Alignment mark: Propeller shaft • To prevent assembly of wrong parts, make alignment marks on flange yoke, slip yoke joint and propeller shaft.

Removal procedure Removal: Needle bearing • Fit -C into -A from outside. • Applying -B to needle bearing, operate spider and remove needle bearing.

-A to force out

Inspection procedure Inspection: Play between needle bearing and spider • If the measurement exceeds the limit, replace with the universal joint spider kit.

Inspection: Play between slip yoke joint and propeller shaft spline • Check the following, and replace the slip yoke joint and the propeller shaft as a set if the measurement exceeds the limit. (1) Play of spline in rotating direction (2) Play of spline in diametric direction

25-10

25 Inspection: Bend of propeller shaft • Before measuring the bend of pipe, remove paint from the propeller shaft where the dial gauge is set and the pipe is supported with V blocks using a paint remover. • Measure bend of propeller shaft at the center of its pipe portion. • To measure the bend of propeller shaft, turn it fully once and read the dial gauge indicator. The bend is one half of the indicated value. • If the measurement deviates from the standard value, correct the bend with a press or replace the propeller shaft.

CAUTION • Remove paint taking care not to damage the pipe portion of the shaft. • Check the propeller shaft for cracks in the welded area after correcting the bend using a press. If a crack is caused, replace the propeller shaft instead of correcting it by welding.

Installation procedure Installation: Retainer packing • Hold retainer packing against slip yoke joint and caulk tabs (at eight places).

Installation: Grease nipple • Fit grease nipple to the spider facing it in the illustrated direction.

• Install spiders on both ends of the propeller shaft so that their respective grease nipple faces in the same direction.

25-11

PROPELLER SHAFT Installation: Needle bearing • Fit -C into -A from inside. • Applying -B to needle bearing, operate needle bearing into place.

-A to install

Work after installation Lubrication: Grease nipple • Fill grease through grease nipple until supplied grease overflows from four oil seals of the spider. • If grease does not overflow from all of the four oil seals or rust, water and dirt come out with grease, replace the spider with the spider kit.

Inspection: Permissible unbalance amount of propeller shaft [Inspection] • Measure the balance amount (dynamic balance) of the propeller shaft on a balancing machine. • If the measurement deviates from the standard value, adjust the balance amount in the following procedure. [Adjustment] • Attach appropriate balance pieces at the illustrated points so that the unbalance amount comes within the standard value. • Maximum balance piece allowance for one point is 100 g. • Use a combination that keeps the number of balance pieces to a minimum. Available balance pieces Mass 2g 4g 6g 8g 10 g 12 g 16 g 24 g

25-12

25 M E M O

25-13

PROPELLER SHAFT <With Center Bearing>

• Balance piece installing position (at propeller shaft) depends on the unbalance of the propeller shaft.

Disassembly sequence 1 2 3 4 5 6

7 8 9 10 11 12

Snap ring Needle bearing Flange yoke Snap ring Needle bearing Grease nipple

13 Center bearing 14 Propeller shaft

Spider Washer Companion flange Hanger Holder Cushion rubber

: Non-reusable parts

CAUTION • Be careful not to damage the needle bearing because it is fitted with a seal.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Universal joint spider kit • Be sure to reinstall removed parts at their original positions. • Correct dynamic balance after replacement of parts.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

–

Axial clearance of spider

0 to 0.06

–

Adjust

–

Permissible amount of unbalance of propeller shaft (periphery of pipe)

5 g max./3000 rpm

–

Adjust

2, 3

Clearance between needle bearing and flange yoke (“–” indicates interference.)

–0.033 to 0.008

0.1

Replace

0.01 to 0.06

0.1

Replace

–0.033 to 0.008

0.1

Replace

0 to 0.3

0.4

Correct or replace

2, 5, 7

Play between needle bearing and spider

5, 14

Clearance between needle bearing and propeller shaft (“–” indicates interference.)

14

25-14

Bend of propeller shaft

25 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (companion flange mounting)

Tightening torque

Remarks

290 to 390 {30 to 40}

–

Lubricant and/or sealant Mark

Points of application Supply through grease nipple Fill space in center bearing housing

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Heat-resisting grease [NLGI No. 3]

70 to 100% of space capacity (20 to 29 g)

Center bearing seal lips

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Universal joint tool set A: Yoke assembly B: Push rod C: Guide D

E

F

φ29

φ29

φ27.7

Application

MB999024 A: MH064128 B: MB999026 C: MB999010

Removal and installation of needle bearing

Work before removal Inspection: Axial clearance of spider • Press down on the needle bearing, and measure clearance between snap ring and needle bearing. • If the measurement exceeds the standard value, change snap ring thickness for adjustment. To adjust, use snap rings for both ends with the same thickness. Select optimal combination of snap rings from the table below if necessary. Variety and combination of snap rings (solid line indicates best combination). Thickness

Identification color

Thickness

Identification color

1.49 mm

None

1.49 mm

None

1.52 mm

Black

1.52 mm

Black

1.55 mm

Blue

1.55 mm

Blue

1.58 mm

Yellow

1.58 mm

Yellow

1.61 mm

Purple

1.61 mm

Purple

1.64 mm

None

1.64 mm

None

1.67 mm

Black

1.67 mm

Black

1.70 mm

Blue

1.70 mm

Blue

Combination

25-15

PROPELLER SHAFT Alignment mark: Propeller shaft • To prevent assembly of wrong parts, make alignment marks on flange yoke, companion flange and propeller shaft.

Removal procedure Removal: Needle bearing • Fit -C into -A from outside. • Applying -B to needle bearing, operate spider and remove needle bearing.

-A to force out

Inspection procedure Inspection: Play between needle bearing and spider • If the measurement exceeds the limit, replace with the universal joint spider kit.

Inspection: Center bearing • Check at every 50,000 km or each official vehicle inspection. If excessive grease outflow is evident, pack grease in center bearing housing up to 70 to 100% (20 to 29 g) of space capacity. • Apply grease to seal lips. • The ball bearing portion of center bearing is provided with oil seal and requires no supply of grease.

25-16

25 Inspection: Bend of propeller shaft • Before measuring the bend of pipe, remove paint from the propeller shaft where the dial gauge is set and the pipe is supported with V blocks using a paint remover. • Measure bend of propeller shaft at the center of its pipe portion. • To measure the bend of propeller shaft, turn it fully once and read the dial gauge indicator. The bend is one half of the indicated value. • If the measurement deviates from the standard value, correct the bend with a press or replace the propeller shaft.

CAUTION • Remove paint taking care not to damage the pipe portion of the shaft. • Check the propeller shaft for cracks in the welded area after correcting the bend using a press. If a crack is caused, replace the propeller shaft instead of correcting it by welding.

Installation procedure Installation: Grease nipple • Fit grease nipple to the spider facing it in the illustrated direction.

Installation: Needle bearing • Fit -C into -A from inside. • Applying -B to needle bearing, operate needle bearing into place.

-A to install

Work after installation Lubrication: Grease nipple • Fill grease through grease nipple until supplied grease overflows from four oil seals of the spider. • If grease does not overflow from all of the four oil seals or rust, water and dirt come out with grease, replace the spider with the spider kit.

25-17

PROPELLER SHAFT Inspection: Permissible unbalance amount of propeller shaft [Inspection] • Measure the balance amount (dynamic balance) of the propeller shaft on a balancing machine. • If the measurement deviates from the standard value, adjust the balance amount in the following procedure. [Adjustment] • Attach appropriate balance pieces at the illustrated points so that the unbalance amount comes within the standard value. • Maximum balance piece allowance for one point is 100 g. • Use a combination that keeps the number of balance pieces to a minimum. Available balance pieces Mass 2g 4g 6g 8g 10 g 12 g 16 g 24 g

25-18

GROUP 26 FRONT AXLE SPECIFICATIONS............................................................................... 26-2 STRUCTURE AND OPERATION 1. Wheel Hub and Brake Drum .......................................................... 26-3 2. Knuckle and Kingpin, Front Axle .................................................. 26-4 TROUBLESHOOTING ........................................................................ 26-5 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. 2. 3. 4. 5. 6.

Inspection and Adjustment of Wheel Alignment ........................... 26-6 Inspection and Adjustment of Steering Angle ............................. 26-10 Inspection of Side Slip ................................................................ 26-10 Inspection of Tie Rod End Ball Joint ............................................26-11 Inspection of Wheel Bearing for Play ...........................................26-11 Inspection of Knuckle Joint for Play ............................................26-11

WHEEL HUB AND BRAKE DRUM................................................... 26-12 KNUCKLE AND KINGPIN, FRONT AXLE ....................................... 26-20 TIE ROD ............................................................................................ 26-28

26-1

SPECIFICATIONS Specifications

Item Front axle

Model Type

FE84

FE85

F300T

F350T Reverse Elliot, “I” beam

Kingpin outer diameter × length

mm

28 × 180

Tread (dimension notified to the authorities)

mm

1665

Mass

26-2

kg

Approx. 160

Approx. 170

STRUCTURE AND OPERATION

26

1. Wheel Hub and Brake Drum

26-3

STRUCTURE AND OPERATION 2. Knuckle and Kingpin, Front Axle

26-4

26

TROUBLESHOOTING

O

Wheel hub bearing seized, worn or rotation faulty Wheel hub bearing broken

Wheel hub, knuckle and kingpin, front axle

O O

O

Clearance between kingpin and kingpin bushing excessive

O

O

Greasing to kingpin insufficient

O

Kingpin thrust bearing seized, worn or rotation faulty

O

Vertical clearance between knuckle and front axle excessive

O

Knuckle arm and tie rod arm tightening nuts loose

O

Ball stud tightening nut of tie rod end loose

O

Tie rod end ball stud worn

O O

Knuckle bent

O

Front axle bent

O

Various parts of front axle tightened excessively

O O

One of front springs worn-out or broken Tire inflation pressure uneven Tire inflation pressure too little

Tire

O

O

Kingpin worn

U-bolt nut of front suspension loose

Gr33

O O

O O

Inflation pressure uneven for right and left tires

O

Size and type of right and left tires different

O

Outer diameters of right and left tires remarkably different

O

Handling of tires inadequate

Reference Gr

O

Tie rod bent

Front suspension

Uneven wear or early wear of front tires

O

Steering pulls to one side

Steering wheel return poor

O

Steering angle adjustment faulty

Unable to steer the steering wheel

Steering feels stiff

Wheel alignment misaligned

Steering wheel shakes

Possible causes

Intermittent noise while cruising

Continuous noise while cruising

Symptoms

O

Gr31

O

26-5

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Adjustment of Wheel Alignment Before carrying out inspection and adjustment of wheel alignment, set the vehicle to the following condition. • Park the vehicle unloaded on a level place. • The vehicle needs to be equipped with proper size tires. • If the wear condition of tires on the right is remarkably different from that of tires on the left, replace tires. • Tires need inflation to specified pressure. • Correct if the vehicle tilts due to faulty suspension. • Service all parts of the front axle and ensure that there is no fault such as the following. • Play at or loose kingpin • Loose front wheel hub • Loose bolts used for tightening various parts of tie rod arm, knuckle arm and tie rod • Bend of knuckle and front axle • Adjust play at steering wheel properly. • For wheel alignment, which is related to the side slip amount, both wheel alignment and the side slip amount must conform to the standard values.

Service standards (Unit: mm) Location

Maintenance item Toe-in

–

Camber Caster Kingpin inclination angle

Standard value

Limit

Remedy

0 to 6

–

Adjust

1°00’ ± 1°00’

–

Replace

1°15’ ± 45’

–

Replace

8° ± 30’

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

–

Clamp nut (tie rod end clamp fastening)

–

Alignment gauge adapter

Tightening torque

Remarks

20 to 29 {2 to 3}

–

113 ± 15 {11.5 ± 1.5}

–

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Hub cap wrench A

B

0.5

78°

MB999108

Removal of hubcap

MH063428

Measurement of camber, caster and kingpin inclination angle

Alignment gauge adapter

26-6

A

B

C

D

φ80

69

φ45

M24 × 1.5

26 1.1 Inspection and adjustment of toe-in [Inspection] • Direct the front wheels exactly to forward running position. • Put a mark on both the right and left tires at the height of the front wheel axis in the center of the tire width.

• Align the two points of the toe-in gauge with respective marks and measure distance A between the marks.

• Push the vehicle to roll the tires 180 degrees. • Measure distance B between the marks that have moved to the rear of the vehicle. • If toe-in (difference between A and B) deviates from the standard value, adjust.

[Adjustment] • Loosen the right and left clamp nuts. • Turn the tie rod with a pipe wrench to adjust the toe-in. C: When adjusting to the toe-in direction D: When adjusting to the toe-out direction • After adjustment, tighten the clamp nut to the specified torque.

• Hold down the tie rod end toward the front of the vehicle with the front wheels directed to forward running position so that the right and left tie rod ends are in contact with the ball studs at the same time. In this state adjust so that the specified toe-in is achieved and tighten the clamp nut to secure the tie rod.

26-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1.2 Inspection of camber • Direct the front wheels exactly to forward running position. • Remove the hub cap using .

• Remove the lock nut.

CAUTION • Do not apply a vehicle weight to the hub bearing with the lock nut loosened. • Wipe off grease from the knuckle end, attach to the specified torque. • Attach the camber/caster/kingpin gauge.

and tighten it

• Place the level so that the bubble remains in the middle. • Read center of bubble on camber scale to find the camber. Do the same for the right and left front tires. • If the measured value deviates from the standard value, abnormalities such as wear of kingpin and kingpin bushing, loose hub bearing, and bend of knuckle and front axle are suspected. Inspect each part and replace defective parts.

1.3 Inspection of caster and kingpin inclination angle • Prepare a platform with the same height as the turning radius gauge and place it under the rear wheels so that the vehicle may be placed level. • Apply chocks to the rear wheels. • Keep the turning radius gauge locked. • Jack up the vehicle and set the right and left front wheels so that respective ground contact area centers of the two wheels and turn table centers may meet.

• Unfasten locking of the turning radius gauge and set the scale to 0 degrees. • As with the camber measurement in Section 1.2, attach the camber/caster/kingpin gauge and set the level so that the bubble remains in the middle.

26-8

26 • Apply brake, and with brake applied to the front wheels, turn steering wheel slowly from the point of 0 degrees on the turning radius gauge until the direction is changed by 20 degrees to the right side in the case of the right front wheel and to 20 degrees to the left in the case of the left front wheel.

NOTE • It is not possible to make exact measurements unless the brake remains applied, otherwise the wheels will turn slightly. • After setting the steering at 20 degrees, set the caster scale and the center of the bubble of the kingpin scale to 0 degrees by turning the adjuster.

NOTE • Pay attention to the kingpin scale because it has scales for right and left: align the right kingpin scale in the case of the right front wheel, and left kingpin scale in the case of the left front wheel. • Reverse this position, turn the steering wheel slowly until the direction of the front wheels changes by 20 degrees in the opposite direction. • Read the center of the bubbles at this position of the caster scale and kingpin scale to find caster and kingpin inclination angles. • If the measured value deviates from the standard value, abnormalities such as wear of kingpin and kingpin bushing, loose hub bearing, and bend of knuckle and front axle are suspected. Inspect each part and replace defective parts. • After inspection, install the lock nut and measure the starting torque of the wheel hub bearing. (See “WHEEL HUB AND BRAKE DRAM”.) • If the starting torque deviates from the standard value, check the wheel bearings and perform expedient adjustment. (See “WHEEL HUB AND BRAKE DRAM”.) • Fill the specified amount of grease into wheel hub by using the nozzle so that the outer bearing is covered with grease and then install a new hub cap. (See “WHEEL HUB AND BRAKE DRAM”.)

26-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspection and Adjustment of Steering Angle • Perform steering angle inspection and adjustment only after wheel alignment inspection and adjustment has been completed.

Service standards Location –

Maintenance item Steering angle

Standard value

Inside (outside steering angle is for reference only)

45°

+0° –2°

Limit

Remedy

–

Adjust

(34°)

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Lock nut (knuckle stopper bolt mounting)

Tightening torque

Remarks

46.5 ± 7 {4.75 ± 0.75}

–

• Set the turning radius gauge and a platform on the vehicle in the same manner as in the case of the caster and kingpin inclination angle measurement performed in Section 1.3. • Turn the steering wheel right or left completely from the position where the turning radius gauge is set to 0 degrees, and read the scale of the turning radius gauge to measure the steering angle. • If the measurement value deviates from the standard value, adjust with the knuckle stopper bolt and tighten the lock nut to the specified torque.

3. Inspection of Side Slip • Perform side slip inspection only after wheel alignment inspection and adjustment has been completed. • For the side slip amount, which is related to wheel alignment, both the side slip amount and wheel alignment must conform to the standard values.

Service standards (Unit: mm) Location –

Maintenance item Side slip amount (per 1 m)

Standard value

Limit

Remedy

3 or less

–

Adjust

• Set the front wheels exactly to forward running position. • Move the vehicle forward past the side slip tester as slowly as possible to inspect side slip.

NOTE • Pay attention to the following when moving over the side slip tester. • Be sure to hold steering exactly at the forward running position, and make no turn. • Do not apply brake. • Keep the speed constant. • If the measurement value deviates from the standard value, inspect and adjust wheel alignment.

26-10

26 4. Inspection of Tie Rod End Ball Joint 4.1 Play • Hold the tie rod section of the tie rod with the vehicle kept stationary, and move it in the back-and-forth, up-and-down and right-and-left directions to check for play at ball joints of the tie rod end.

NOTE • Be sure to check for play at ball joints of both right and left sides of the tie rod. • If feeling play with your hand, replace the tie rod end of the tie rod.

4.2 Dust cover • Check that there are no wear, cracks or damage. Their abnormalities can cause water to enter the ball joint, resulting in premature wear. • If wear, crack, or damage is present, inspect traces of water entry and occurrence of rust in the ball joint. If any abnormality is found, replace the tie rod end. If no abnormality is found, replace the dust cover and reapply grease.

5. Inspection of Wheel Bearing for Play • Jack up the vehicle. • Try to move the top and bottom of the front tire by hands in the illustrated directions to inspect the wheel bearing for play. • If play is found with the feel of hands, repeat the inspection procedure while having the brake pedal depressed by another personnel. When the play is removed by operating the brake pedal, the symptom indicates that there is play in the wheel bearing, not in the suspension or other related parts. Then inspect the turning torque of the wheel bearing and adjust it as required. (See “WHEEL HUB AND BRAKE DRUM“.) • If the turning torque of the wheel bearing cannot be adjusted correctly or the play still remains after the adjustment, replace the wheel bearing with a new one. (See “WHEEL HUB AND BRAKE DRUM”.)

6. Inspection of Knuckle Joint for Play • Jack up the vehicle. • Try to move the top and bottom of the front tire by hands in the illustrated directions to inspect the knuckle joint for play. • If play is found with the feel of hands, repeat the inspection procedure while having the brake pedal depressed by another personnel. If there is any play, it may be caused by the play in the knuckle joint. Check each part and replace a defective part. (See “KNUCKLE AND KING PIN, FRONT AXLE”.)

26-11

WHEEL HUB AND BRAKE DRUM

Disassembly sequence 1 2 3 4 5 6 7 8 9

Brake pipe Brake hose Hub cap Lock nut Lock washer Outer bearing inner race Oil seal Inner bearing inner race Inner bearing outer race

10 11 12 13 14 15

Outer bearing outer race Brake drum (See Gr35.) Hub bolt Wheel hub Front drum brake (See Gr35.) Spacer

: Non-reusable parts

• Plug the brake hose to prevent entry of dust and dirt after it has been removed.

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • Make sure that the brake lining surface of the front drum brake and inner surface of the brake drum are free from grease to avoid malfunction of brakes. • Make sure that the brake hose is not twisted when you install it. • Adjust the brake shoe clearance after assembly. (See Gr35.) • Bleed air from the brake system after assembly. (See Gr35.)

Service standards (Unit: mm) Location –

26-12

Maintenance item

Standard value

Limit

Remedy

Starting torque of wheel hub bearing (tangential force at hub bolt position with oil seal assembled)

1 to 3.5 N·m {0.10 to 0.35 kgf·m} (tangential force: 8.8 to 28.4 N {0.9 to 2.9 kgf})

–

Adjust or replace

26 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

13 to 17 {1.3 to 1.7}

–

113 ± 15 {11.5 ± 1.5}

–

59 {6}

Back-off angle 45° (1/8 of a turn)

Nut (brake drum and wheel hub mounting)

343 ± 39 {35 ± 4}

–

Nut (front drum brake mounting)

118 ± 20 {12 ± 2}

–

Brake hose Primary tightening Lock nut

Secondary tightening after complete tightening

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity 90 ± 10 g

Pack outside of wheel hub Pack inside of wheel hub

FE84

215 ± 10 g

FE85

Pack space between rollers of outer bearing inner race and inner bearing inner race

Wheel bearing grease [NLGI No. 2 (Li soap)]

275 ± 30 g As required

Lip area of oil seal

: For a wheel hub

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Hub cap wrench A

B

0.5

78°

MB999108

Removal of hub cap

MB999097

Installation of oil seal (to be used in combination with )

MB999099 or MB999069

Installation of oil seal (to be used in combination with ) Installation of inner bearing outer race and outer bearing outer race (to be used in combination with )

MB999100

Installation of inner bearing outer race and outer bearing outer race (to be used in combination with )

Oil seal installer A

B

φ84

φ70

Bearing installer

Part No.

A

B

MB999099

φ88.5

φ51

MB999069

φ94.5

φ60

C φ71

Location Outer bearing outer race

φ92.5 Oil seal and inner bearing outer race

Bearing installer A

B

φ70

φ57

26-13

WHEEL HUB AND BRAKE DRUM Removal procedure Removal: Brake hose • When removing the brake hose, remove it from the frame side first, and then from the wheel brake side.

Removal: Hub cap

Removal: Wheel hub and brake drum • If the brake drum has stepped wear and the wear prevents the wheel hub and brake drum from being removed, the removal can still be effected by taking the following procedure. • Turn the adjuster from the adjusting hole in the opposite direction to the arrow on the backing plate to increase the clearance between the brake drum and the brake shoe. Then, remove the wheel hub and brake drum.

CAUTION • Correct or replace the brake drum if any fault is found. Removal: Inner bearing outer race • Drive out the inner bearing outer race by tapping evenly at three notches in the wheel hub.

Removal: Outer bearing outer race • Drive out the outer bearing outer race by tapping evenly at three notches in the wheel hub.

26-14

26 Inspection procedure Inspection: Outer bearing inner race • Inspect the outer bearing inner race after cleaning the bearing to remove grease completely. • If any damage, wear, or poor rotating condition is evident in the inner race, replace it with a new one. • The inner race and outer race should be replaced as a set.

Inspection: Inner bearing inner race • Inspect the inner bearing inner race in the same manner as for the outer bearing inner race. (See “ Inspection: Outer bearing inner race”.) Inspection: Wheel hub (1) Visual inspection • Check the disc wheel mounting surface of the wheel hub by watching and touching. If there is damage or crack on it, replace the wheel hub. • Make sure that there is not rust, dust, paint or foreign body on the disc wheel mounting surface of the wheel hub to prevent the wheel nut to loosen. • If any abnormality is found, remove it with sandpaper. (2) Wear in disc wheel mounting part of wheel hub • Clean the wheel mounting surface of the wheel hub before inspection. • Place a straightedge on the hub so as to contact to the two hub bolts on the disc wheel mounting surface.

CAUTION • Make sure that the straightedge does not run onto the hub bolt. • Using feeler gauges to measure the amount of wear at the outer periphery of the wheel hub. Measure the amount of wear in the area of every hub bolt. • If the amount of wear at any point exceeds the following standard value, inspect the crack check of wheel hub. Wear standard value: 0.8 mm (3) Crack check • Check if there is not crack on the entire rounded corner on the root of flange of the wheel hub by magnetic particle or liquid penetrant testing. If crack is found, replace the wheel hub. • If crack is found on the wheel hub bolt, replace it. • If there is crack or stepped wear on the wheel hub mounting surface of wheel disc, replace it. (See Gr31.)

26-15

WHEEL HUB AND BRAKE DRUM Installation procedure Installation: Hub bolt • Screw the nut into the hub bolt until just before they become flush. • Drive the hub bolt into the wheel hub vertically by hitting the end face of the nut.

• Assemble the brake drum and wheel hub with the hub bolt. After tightening the nut to the specified torque, crimp it with a punch.

Installation: Outer bearing outer race

Installation: Inner bearing outer race

Installation: Packing grease in inner bearing inner race • Insert the grease pump nozzle into the space between rollers of the inner bearing inner race to pack grease sufficiently.

26-16

26 Installation: Oil seal • Apply grease to the lip area of oil seal and install the oil seal in the wheel hub so that the oil seal faces in the illustrated direction and the end surface of oil seal is flush with the end surface of wheel hub.

Installation: Packing grease in outer bearing inner race • Follow the same procedure as for packing the inner bearing inner race with grease. (See “ Installation: Packing grease in inner bearing inner race”.) Installation: Packing grease inside of wheel hub

CAUTION • Wheel bearing seized may be caused unless following these manners. • Apply the specific amount of grease measured by measurement cup or etc. • As shown in the illustrations at the left, fill grease inside of the hub body in such a manner that grease covers the outer bearing and inner bearing outer races. Make sure that grease reaches the outer bearing and inner bearing.

Installation: Wheel hub and brake drum • Slowly install the wheel hub and brake drum so as not to cause damage to the oil seal. • Position the wheel hub and brake drum only 20 mm before the backing plate, and hereafter slowly tighten the lock nut to install the wheel hub and brake drum.

26-17

WHEEL HUB AND BRAKE DRUM Adjustment: Starting torque of wheel hub bearing

CAUTION • Unless this adjustment procedure is performed, seizure of the wheel hub bearing can be caused. [Adjustment] • Tighten the lock nut to the specified torque (primary tightening) while turning the wheel hub and brake drum, and then loosen it completely. • Smooth operation of the outer bearing and inner bearing by turning the wheel hub and brake drum several times, and then tighten the lock nut to the specified torque (secondary tightening). • Return the lock nut by approximately 45 degrees (1/8 of a turn) and secure it with a split pin. If pin holes do not align, align them in the course of loosening. Make sure that there is no play in the axial direction. [Inspection] • After installing the lock nut, perform the following inspection. • Measure the tangential force at the hub bolt position using a spring balance. • If the tangential force is within the specified value, the starting torque conforms to the standard value. When the measured value is the specified value, install the split pin following either of method in the illustration. • If the measurement value deviates from the specified value, repeat adjustment because the adjustment of the lock nut may be insufficient. • If the result is found to be abnormal, replace the outer and inner bearings.

Installation: Packing grease outside of wheel hub

CAUTION • Unless this packing procedure is performed, seizure of the wheel hub bearing can be caused. • For a grease amount, pack the specified amount using a measuring cup. • Pack grease up to the lock plate using a grease pump nozzle so that a wall is formed outside the outer bearing as shown in the illustration.

CAUTION • Do not pile grease in the wheel hub cap. Otherwise, grease does not reach the outer bearing, causing poor lubrication of the bearing.

26-18

26 Installation: Brake hose • To install the brake hose, follow the removal procedure in reverse. (See “ Removal: Brake hose”.) • After installing, make sure that the brake hose does not interfere in the perpheral parts.

CAUTION • Make sure that the brake hose is not twisted when you install it.

26-19

KNUCKLE AND KINGPIN, FRONT AXLE

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12

Tie rod (See later section.) Knuckle arm Tie rod arm Dust plug Dust cap Lock pin Kingpin Grease nipple Plug Dust seal Bushing Knuckle stopper bolt

13 14 15 16 17 18 19

*a: *b: *c::

Lock nut Knuckle Thrust bearing Kingpin shim U-bolt Stud bolt Front axle Drag link Shock absorber Stabilizer Non-reusable parts

CAUTION • When removing the tie rod, take care not to damage the dust cover. Damaging the dust cover may cause water infiltration and wear-out the early stage.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Kingpin kit • After assembly, check and adjust toe-in. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

26-20

26 Service standards (Unit: mm) Location 7

Maintenance item Outer diameter of kingpin

Standard value

Limit

Remedy

27.947 to 27.980

27.9

Replace

7, 11

Clearance between kingpin and bushing

0.020 to 0.086

0.15

Replace

7, 19

Clearance between kingpin and front axle

0.020 to 0.074

0.1

Replace

28.000 to 28.033

–

Replace

0.02 to 0.10

0.20

Adjust

11 14, 19 19

Inner diameter of bushing (after having been pressed into knuckle) Vertical clearance between knuckle and front axle Front axle

Horizontal bend

–

2

Vertical bend

–

2

8° ± 30’

–

Kingpin inclination angle

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

93 ± 25 {9.5 ± 2.5}

–

345 ± 49 {35 ± 5}

–

33 ± 5 {3.4 ± 0.5}

–

46.5 ± 7 {4.75 ± 0.75}

–

FE84

162 ± 15 {16.5 ± 1.5}

Nut color: Yellow

FE85

175 ± 5 {17.8 ± 0.5}

Nut color: Green

Stud

88 {9} or more

–

137 {14} or more

–

Nut (tie rod mounting) Nut (knuckle arm mounting) Nut (tie rod arm mounting) Nut (lock pin mounting) Lock nut (knuckle stopper bolt tightening) Nut (U-bolt mounting) Stud bolt

Nut (return)

Lubricant and/or sealant Mark

Points of application Knuckle arm and tie rod arm threads

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required when parts are reused

Lip area of dust seal Inside surface of bushing Top face of thrust bearing Both sides of kingpin shim

As required Chassis Grease [NLGI No. 1 (Li soap)]

Fill from grease nipple Stud threads of stud bolt

Loctite 271

Until grease starts overflowing from dust plug As required

26-21

KNUCKLE AND KINGPIN, FRONT AXLE Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Kingpin puller A: Pipe B: Bolt C: Cap D: Nut E

MB999013 A: MB999014 B: MB999015 C: MB999016 D: MB999017

Removal of kingpin

MB999066 A: MB999067 B: MB999068

Removal and installation of kingpin bushing

φ47

Bushing installer A: Bushing installer A B: Bushing installer B

C

D

E

F

G

φ25

φ30

φ28

φ25

φ32.8

Removal procedure Removal: Lock pin • Remove the nut, spring washer and washer. • Screw in the nut again until just before it is flush with the lock pin, and lightly tap the nut to loosen the lock pin.

• Remove the nut, apply a pin punch of wood to the lock pin and lightly tap it to remove.

Removal: Kingpin • Screw

26-22

-B into the kingpin threads to remove the kingpin.

26 Inspection procedure Inspection: Outer diameter of kingpin • Take measurement at a total of four levels on the kingpin: two levels for the axle fitting portion and one level each for the upper and lower knuckle fitting portions. • If the measurement value is under the limit, replace the kingpin with a new one.

Inspection: Clearance between kingpin and bushing • Measure the inner diameter of the upper and lower bushings using a cylinder gauge and calculate the clearance deducting the outer diameter of the kingpin from the inner diameter of the bushing. If the clearance exceeds the limit, replace the bushings with new ones.

Replacement of bushing [Removal] • Remove the upper bushing and dust seal at the same time using .

[Installation] • Install the bushing using so that a step height between the bushing and knuckle is within 1 mm. • The oil hole of the bushing must not deviate from the screw hole of the knuckle more than 5 mm.

26-23

KNUCKLE AND KINGPIN, FRONT AXLE • Apply grease to the lip area of the dust seal and install it on the knuckle in the illustrated direction.

Inspection: Thrust bearing • Inspect the aspect and smooth turning of the thrust bearing. If any crack, damage, or un-smooth turning is found, replace the thrust bearing with a new one.

Inspection: Front axle (1) Bend of front axle in the back-and-forth direction and vertical direction • Put a piece of thread through kingpin holes of the front axle and hang weights at both ends. • Use a square to find bend to each of back-and-forth and vertical directions. • If the measurement value exceeds the limit, replace the front axle.

(2) Kingpin inclination angle • Set the kingpin on the front axle as illustrated to measure the angle. • If the measurement value deviates from the standard value, replace the front axle.

26-24

26 (3) Clearance between kingpin and front axle • Measure the inner diameter of the axle’s hole where the kingpin is inserted using a cylinder gauge and calculate the clearance deducting the outer diameter of the kingpin from the inner diameter. If the clearance exceeds the limit, replace the axle or the kingpin with a new one.

Installation procedure Installation: Stud bolt • Apply Loctite to front axle mounting threads of the stud bolt. • Install the stud bolt to the dimension as illustrated.

Installation: Plug • After installing the plug, crimp the knuckle at three evenly spaced points of the plug circumference avoiding previously crimped points.

Installation: Knuckle • After temporarily assembling the thrust bearing, knuckle and kingpin into the front axle, move the knuckle several times to smooth its operation. • Measure clearance between the front axle top face and the knuckle bottom.

• If the measurement value exceeds the limit, adjust with a kingpin shim. Thickness of kingpin shims available 0.15, 0.40, 0.50, 0.60, 0.70 mm (five thicknesses)

CAUTION • Select a kingpin shim so that the clearance is as small as possible within the range of the standard value. • After assembly, make sure that the knuckle moves smoothly.

26-25

KNUCKLE AND KINGPIN, FRONT AXLE Installation: Lock pin • Install the lock pin so that the taper part of the lock pin is aligned with the notch of the kingpin.

Installation: Tie rod arm and knuckle (1) When one or both the tie rod arm and knuckle need reassembly, making use of existing parts • Polish the entire tapered surfaces of the tie rod arm and knuckle evenly by means of sand paper #120 or higher until sand paper score is visible on polished surfaces. (This does not apply to new replacement parts.) • Clean the tapered surfaces and thread areas of the tie rod arm and knuckle.

NOTE • Use acetone, cleaning fluid for color check, or equivalent as solvent. • Apply grease to the thread area of the tie rod arm and install it.

CAUTION • When installing the tie rod arm, make sure that tapered surfaces of the tie rod arm and knuckle are free from grease. • Tighten the nut to the specified torque. Be sure to align pin holes in the course of tightening and insert the split pin as illustrated. (2) When both the tie rod arm and knuckle for assembling are new parts • Clean tapered surfaces and thread areas of the tie rod arm and knuckle. • Apply grease to the thread area of the tie rod arm and install it.

CAUTION • When installing the tie rod arm, make sure that tapered surfaces of the tie rod arm and knuckle are free from grease. • Tighten the nut to the specified torque. Be sure to align pin holes in the course of tightening and insert the split pin as illustrated.

26-26

26 Installation: Knuckle arm and knuckle (1) When one or both the knuckle arm and knuckle need reassembly, making use of existing parts • Polish the entire tapered surfaces of the knuckle arm and knuckle evenly by means of sand paper #120 or higher until sand paper score is visible on polished surfaces. (This does not apply to new replacement parts.) • Clean the tapered surfaces and thread areas of the knuckle arm and knuckle.

NOTE • Use acetone, cleaning fluid for color check, or equivalent as solvent. • Apply grease to the thread area of the knuckle arm and install it.

CAUTION • When installing the knuckle arm, make sure that tapered surfaces of the knuckle arm and knuckle are free from grease. • Tighten the nut to the specified torque. Be sure to align pin holes in the course of tightening and insert the split pin as illustrated. (2) When both the knuckle arm and knuckle for assembling are new parts • Clean tapered surfaces and thread areas of the knuckle arm and knuckle. • Apply grease to the thread area of the knuckle arm and install it.

CAUTION • When installing the knuckle arm, make sure that tapered surfaces of the knuckle arm and knuckle are free from grease. • Tighten the nut to the specified torque. Be sure to align pin holes in the course of tightening and insert the split pin as illustrated. Installation: Tie rod • Install the tie rod with its identification marking, which is applied to the left thread tie rod end side of the rod, coming to the left side of the vehicle. Identification marking: Blue

26-27

TIE ROD Disassembly sequence 1 Tie rod end 2 Tie rod

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

1

Ball joint of tie rod end

2

Bend of tie rod

Play (± 980 N {± 100 kgf} loaded) Rotation torque

Standard value

Limit

0 to 0.15

–

1.0 to 5.9 N·m {0.1 to 0.6 kgf·m}

–

–

1

Remedy Replace Correct or replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (tie rod end tightening)

Tightening torque

Remarks

20 to 29 {2 to 3}

–

Lubricant and/or sealant Mark

Points of application Lip area of dust cover of tie rod end

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Inspection procedure Inspection: Tie rod end (1) Play • Fix the tie rod end with a vise.

CAUTION • Take care not to deform or damage the dust cover when fixing it with a vise. • The position of the ball joint with applying no load is adjusted to standard position. • Measure each play of the ball joint with applying the specified push and pull load from the standard position. • Total each play and if the total deviates from standard value, replace the tie rod end.

26-28

26 (2) Rotation torque • Install the tie rod mounting nut on the tie rod end. • Install the socket, adapter and torque wrench to measure the rotation torque. • If the measurement value deviates from the standard value, replace the tie rod end.

(3) Dust cover • Check that there are no wear, cracks or damage. These abnormalities can cause water to enter the ball joint, resulting in premature wear. • If wear, crack, or damage is present, inspect traces of water entry and occurrence of rust in the ball joint. If any abnormality is found, replace the tie rod end. If no abnormality is found, replace the dust cover and reapply grease. Inspection: Bend of tie rod • Measure the bend of the tie rod at its center.

NOTE • Give the tie rod one complete turn and read the dial gauge at this time. The bend is one half of the reading. • If the measurement value exceeds the limit, correct or replace the tie rod.

Installation procedure Installation: Tie rod end • Screw in the tie rod end so that difference of dimension A between the tie rod end and the clamp is within 1.5 mm when comparing to right side with the left. A: Approximately 74 mm

CAUTION • Ensure that there is no more than a one turn difference between the right and left side in terms of the amount of turns used to screw in the tie rod end. • Secure the tie rod ends so that illustrated axis B-B on the right is parallel to that on the left.

26-29

GROUP 27 REAR AXLE SPECIFICATIONS............................................................................... 27-2 STRUCTURE AND OPERATION 1. Wheel Hub and Brake Drum .......................................................... 27-3 2. Reduction and Differential ............................................................ 27-4 TROUBLESHOOTING ........................................................................ 27-6 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Replacement of Axle Oil ....................................... 27-8 2. Inspection of Wheel Bearing for Play ............................................ 27-9 WHEEL HUB AND BRAKE DRUM................................................... 27-10 AXLE HOUSING ............................................................................... 27-20 REDUCTION AND DIFFERENTIAL.................................................. 27-24

27-1

SPECIFICATIONS Item Rear axle

Reduction

Specifications

Model

R035T

Type

Banjo type, full floating

Model

D035H

Type

Single-reduction hypoid gear

Gear ratio Differential

Gear oil

Tooth shape

Straight bevel gear

Classification

API GL-5

Viscosity (application/SAE viscosity) Quantity

Mass

6.166

Below 40°C

90

Above 40°C

*140

dm3 {L}

4.5 {4.5}

kg

250 (approx.)

*: Use the gear oil with a SAE viscosity of 140 when a vehicle is used under heavily-loaded, severe conditions such as continuous driving on uphill grades. However, the air temperature must be above 10°C. • The mass differs between vehicle models.

27-2

STRUCTURE AND OPERATION

27

1. Wheel Hub and Brake Drum

27-3

STRUCTURE AND OPERATION 2. Reduction and Differential

27-4

27 M E M O

27-5

TROUBLESHOOTING

Wheel hub bearing seized, worn or rotation faulty

Wheel hub, axle shaft, axle housing

O

Axle shaft mounting bolts loose

O

O

Axle shaft broken

O

Axle shaft slips out of spline of side gear

O O

Oil seal faulty

O

Axle housing bent

O

Inspection plug and drain plug loose

O

Vent plug clogged

O

Gear oil excessive Gear oil insufficient

O O

Sealant faulty

O

Reduction and differential assembly mounting nuts and bolts loose

O

O

Differential carrier cracked or damaged

O

Bearing cap mounting bolts loose

O

Side bearing seized, worn or rotation faulty

O

Side bearing broken O

O O

Reduction pinion or reduction gear damaged

O

Reduction gear backlash or tooth contact adjusted incorrectly

27-6

O

Reduction pinion or reduction gear worn

Reduction gear backlash excessive

O O

Side bearing preload adjusted incorrectly Reduction pinion or reduction gear broken

O

O O

Oil seal faulty

Reduction and differential

Oil leakage from the neighbourhood of axle shaft mounting part

Oil leakage from differential carrier and axle housing

O

Wheel hub bearing broken

Axle shaft to spline of side gear backlash excessive

Oil leakage from companion flange assembly

Propeller shaft turns but vehicle does not move

Tires drag while cornering

Noise while cornering

Intermittent noise while cruising

Possible causes

Continuous noise while cruising

Noise when starting and changing gears

Symptoms Power transmission insufficient

O O

O O

O

Reference Gr

27

Front and rear bearings seized

O

Front and rear bearings worn

O

Front and rear bearings broken O

Pinion pilot bearing seized or broken Reduction and differential Pinion shaft and pinion spider broken

O O

Reduction gear and differential case mounting bolt and nut loose

O

Side gear backlash excessive

O

O

O

O

Side gear or differential pinion seized Side gear or differential pinion worn Side gear washer worn or damaged

Reference Gr

O

Pinion pilot bearing worn

Side gear or differential pinion broken

Oil leakage from the neighbourhood of axle shaft mounting part

O

Oil leakage from differential carrier and axle housing

O

Oil leakage from companion flange assembly

Lock nut loose

Propeller shaft turns but vehicle does not move

O

Tires drag while cornering

O

Noise while cornering

Continuous noise while cruising

Starting torque of pinion bearing faulty

Possible causes

Intermittent noise while cruising

Noise when starting and changing gears

Symptoms Power transmission insufficient

O

O

O

O

O

O

O

O

O

27-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Replacement of Axle Oil WARNING • The oil temperature is high immediately after the vehicle has stopped, so take care not to scald yourself.

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Inspection plug Drain plug

Tightening torque

Remarks

98 to 120 {10 to 12}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant Gear oil Normal:

–

Axle housing

*Hot areas:

Maximum air temperature during operation below 40°C API GL-5 SAE90 Maximum air temperature during operation above 40°C API GL-5 SAE140

Quantity

4.5 dm3 {4.5 L}

* Use the gear oil with a SAE viscosity of 140 under heavily-loaded, severe conditions such as continuous driving on uphill grades. However, the air temperature must be above 10°C. [Inspection] (1) Checking for oil leaks • Check the differential casing for oil leaks by visually observing or by hand. • If any oil leak is found, replace defective parts.

(2) Inspection of oil quantity • Remove the inspection plug, and check that oil is filled up to the neck. • If oil is not sufficient, fill oil from the inspection plug hole up to the neck. (3) Inspection of oil quality and inclusions • When draining gear oil, check for oil quality, metal chips and metal powder. • If an abnormally large amount of metal chips and metal powder is found, disassemble the assembly for service, as abnormalities may be caused inside.

27-8

27 [Replacement] • Remove the drain plug to drain gear oil. Drainage can be made quickly with the inspection plug removed. • As the drain plug (magnet type) is a magnet, clean it before installation. • Fill the specified quantity of gear oil from the inspection plug hole. • After filling, check that oil is filled up to the neck. If oil is not sufficient, replenish it.

2. Inspection of Wheel Bearing for Play • Jack up the vehicle. • Try to move the top and bottom of the rear tire by hands in the illustrated directions to inspect the wheel bearing for play. • If play is found with the feel of hands, repeat the inspection procedure while having the brake pedal depressed by another personnel. When the play is removed by operating the brake pedal, the symptom indicates that there is play in the wheel bearing, not in the suspension or other related parts. Then inspect the turning torque of the wheel bearing and adjust it as required. (See “WHEEL HUB AND BRAKE DRUM”.) • If the turning torque of the wheel bearing cannot be adjusted correctly or the play still remains after the adjustment, replace the wheel bearing with a new one. (See “WHEEL HUB AND BRAKE DRUM”.)

27-9

WHEEL HUB AND BRAKE DRUM

Disassembly sequence 1 2 3 4 5 6 7 8 9

Brake pipe Axle shaft Outer oil seal Lock plate Lock nut Lock washer Outer bearing inner race Oil seal Inner bearing inner race

10 11 12 13 14 15

Inner bearing outer race Outer bearing outer race Brake drum Hub bolt Wheel hub (See Gr35.) Rear drum brake (See Gr35.)

: Locating pin : Non-reusable parts

• Plug the brake pipe to prevent entry of dust and dirt after it has been removed.

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • Make sure that the brake lining surface of the rear drum brake and the inner surface of the brake drum are free from grease to avoid malfunction of brakes. • Bleed air from the brake system after assembly. (See Gr35.) • Adjust brake shoe clearance after assembly. (See Gr35.)

27-10

27 Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

–

Starting torque of wheel hub bearing (tangential force at hub bolt position with oil seal assembled)

2.0 to 3.9 N·m {0.2 to 0.4 kgf·m} (tangential force: 17 to 32 N {1.7 to 3.3 kgf})

–

Adjust or replace

2

Axle shaft

Bend at center Bend at flange face

0 to 1

2

Replace

0 to 0.03

0.05

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (axle shaft mounting) Lock nut

Primary tightening Secondary tightening after complete tightening

Nut (brake drum and wheel hub mounting) Nut (rear drum brake mounting)

Tightening torque

Remarks

98 to 120 {10 to 12}

–

150 to 180 {15 to 18}

–

50 to 60 {5 to 6}

–

340 ± 40 {35 ± 4}

–

64 to 83 {6.5 to 8.5}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Lip area of outer oil seal Thread area of lock nut Pack space between rollers of outer bearing inner race and inner bearing inner race Lip area of oil seal Pack interior of wheel hub

370 ± 37 g

27-11

WHEEL HUB AND BRAKE DRUM Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Lock nut adjust tool A

B

80

12.7

MC888793

Hub puller

MB999070

A: Hub puller body B: Attachment C: Bolt D

E

φ50

165

A: MH064134 (MB999071) B: MH064136 (MB999073) C: MH064135 (MB999072

Oil seal installer A

B

φ84

φ70

Removal and installation of lock nut

MB999097

Removal of wheel hub and brake drum

Installation of inner and outer bearing outer races (to be used in combination)

Bearing installer A

B

φ124 φ109

C

MH063629

φ77

Oil seal installer A

B

MH061752

Installation of oil seal

φ130 φ100

Removal procedure Removal: Outer oil seal • To remove the outer oil seal, pull protrusions on the outer periphery of the outer oil seal evenly around the whole circumference with pliers.

27-12

27 Removal: Lock nut

Removal: Wheel hub and brake drum • If the brake drum has stepped wear and the wear prevents the wheel hub and brake drum from being removed, the removal can still be effected by taking the following procedure. • Turn the adjuster from the adjust hole in the opposite direction to the arrow on the backing plate to increase the clearance between the brake drum and the brake shoe. Then, remove the wheel hub and brake drum.

CAUTION • Correct or replace the brake drum if any fault is found. • Install using axle shaft mounting bolts to remove the wheel hub and brake drum.

Removal: Inner bearing outer race • Drive out the inner bearing outer race by tapping evenly at three or four notches in the wheel hub.

Removal: Outer bearing outer race • Drive out the outer bearing outer race by tapping it evenly at three or four notches in the wheel hub.

27-13

WHEEL HUB AND BRAKE DRUM Inspection procedure Inspection: Axle shaft • Perform the following inspection. If the measurement is out of the standard value, replace the axle shaft. (1) Bend at shaft center • Give the axle shaft one complete turn and read the dial gauge at this time. The bend is one half of the reading. (2) Lateral runout at flange face

Inspection: Outer bearing inner race • Inspect the outer bearing inner race after cleaning the bearing to remove grease completely. • If any damage, wear, or poor rotating condition is evident in the inner race, replace it with a new one. • The inner race and outer race should be replaced as a set.

Inspection: Wheel hub (1) Visual inspection • Check the disc wheel mounting surface of the wheel hub by watching and touching. If there is damage or crack on it, replace the wheel hub. • Make sure that there is not rust, dust, paint or foreign body on the disc wheel mounting surface of the wheel hub to prevent the wheel nut to loosen. • If any abnormality is found, remove it with sandpaper. (2) Wear in disc wheel mounting part of wheel hub • Clean the wheel mounting surface of the wheel hub before inspection. • Place a straightedge on the hub so as to contact to the two hub bolts on the disc wheel mounting surface.

CAUTION • Make sure that the straightedge does not run onto the hub bolt. • Using feeler gauges to measure the amount of wear at the outer periphery of the wheel hub. Measure the amount of wear in the area of every hub bolt. • If the amount of wear at any point exceeds the following standard value, inspect the crack check of wheel hub. Wear standard value: 0.8 mm

27-14

27 (3) Crack check • Check if there is not crack on the entire rounded corner on the root of flange of the wheel hub by magnetic particle or liquid penetrant testing. If crack is found, replace the wheel hub. • If crack is found on the wheel hub bolt, replace it. • If there is crack or stepped wear on the wheel hub mounting surface of wheel disc, replace it. (See Gr31.)

Inspection: Inner bearing inner race • Inspect the inner bearing inner race in the same manner as for the outer bearing inner race. (See “ Inspection: Outer bearing inner race”.)

Installation procedure Installation: Hub bolt • Screw the nut into the hub bolt and stop just before it becomes flush. • Drive the hub bolt into the wheel hub vertically by hitting the end face of the nut.

• Assemble the brake drum and wheel hub with the hub bolt. After tightening the nut to the specified torque, crimp it with a punch.

Installation: Outer bearing outer race

27-15

WHEEL HUB AND BRAKE DRUM Installation: Inner bearing outer race

Installation: Packing grease in inner bearing inner race • Insert the grease pump nozzle into the space between rollers of the inner bearing inner race to pack grease sufficiently.

Installation: Oil seal • Apply grease to the lip area of oil seal and install the oil seal in the wheel hub so that the oil seal faces in the illustrated direction and the end surface of oil seal is flush with the end surface of wheel hub.

Installation: Packing grease in outer bearing inner race • Follow the same procedure as for packing the inner bearing inner race with grease. (See “ Installation: Packing grease in inner bearing inner race”.)

27-16

27 Installation: Packing grease in wheel hub

CAUTION • Wheel bearing seized may be caused unless following these manners. • Apply the specific amount of grease measured by measurement cup or etc. • As shown in the illustrations at the left, fill grease inside of the hub body in such a manner that grease covers the outer bearing and inner bearing outer races. Make sure that grease reaches the outer bearing and inner bearing.

Installation: Wheel hub and brake drum • Slowly install the wheel hub and brake drum so as not to cause damage to the oil seal. • Mount the wheel hub and brake drum without jiggling until backing plate extends 20 mm from the edge of the brake drum. Then, tighten the lock nut slowly.

Adjustment: Starting torque of wheel hub bearing

CAUTION • Unless this adjustment procedure is performed, seizure of the wheel bearing can be caused. [Adjustment] • Mount the lock washer. • Tighten the lock nut to the specified torque (primary tightening) while turning the wheel hub and rotor, and then loosen it completely. • Smooth operation of the outer bearing and inner bearing by turning the wheel hub and rotor several times, and then tighten the lock nut to the specified torque (secondary tightening).

27-17

WHEEL HUB AND BRAKE DRUM • Insert the flat area of the lock plate, aligning it with the notch of the axle housing, and mount two bolts diagonally to the lock nut. • If the lock nut does not align with a screw hole of the lock plate, align by loosening the lock nut. Make sure that there is no play in the axial direction.

[Inspection] • After installing the lock plate, carry out the following inspections. • Make sure that there is no drag in the brake lining and brake drum. • If any abnormality is found, adjust the brake shoe clearance. • Measure the tangential force at the hub bolt position using a spring balancer. • If the tangential force is within the specified value, the starting torque conforms to the standard value. If the measured value deviates from the specified value, repeat adjustment because the adjustment of the lock nut may be insufficient. • If the result is found to be abnormal, replace the outer and inner bearings.

27-18

27 M E M O

27-19

AXLE HOUSING

Removal sequence 1 2 3 4 5 6 7 8

Inspection plug Drain plug Reduction and differential (See later sections.) Brake pipe Brake hose Vent plug U-bolt Brake pipe

9 Connector 10 Axle housing a: *b: * *c:

Propeller shaft Shock absorber Leaf spring

: Non-reusable parts

CAUTION • Plug the brake hose and the brake pipe to prevent entry of dust and dirt after they have been removed. • When installing and removing the axle housing, take care not to damage the brake hose and brake pipe.

Installation sequence Follow the removal sequence in reverse.

27-20

27 Service standards (Unit: mm) Location

Maintenance item

6

Injection-valve opening pressure of vent plug

10

Axle housing

Runout at outer bearing portion Difference between before and after rotation at center

Standard value

Limit

Remedy

4.9 kPa {0.05 kfg/cm2} or less

–

Replace

0 to 0.5

1

0 to 1

5

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

98 to 120 {10 to 12}

–

100 to 120 {10 to 12}

M12

Nut (reduction and differential mounting)

69 to 93 {7 to 9.5}

–

Bolt (reduction and differential mounting)

83 to 108 {8.5 to 11}

–

Inspection plug Drain plug Nut (propeller shaft mounting)

Brake hose

25.5 to 34.3 {2.6 to 3.5}

–

Nut (U-bolt mounting)

339.1 ± 51 {34.6 ± 5.2}

M18

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

ThreeBond 1215

As required

Thread area of bolt Reduction and differential mounting surface of axle housing Axle housing mounting surface of vent plug

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

MB999102

Removal and installation of reduction and differential

Differential carrier base A φ28

Work before removal Inspection: Play of companion flange • If there is play in the forward, backward, vertical, lateral or rotating direction, replace all of the following parts. • Front bearing and rear bearing • Pinion pilot bearing • Pinion bearing collar • Reduction gear set • Companion flange

27-21

AXLE HOUSING Removal procedure Removal: Reduction and differential • Remove the saucer of the garage jack and place on it. Fabricate the pin as illustrated, insert and fix it with the bolts that were used to fix the saucer. • Screw two bolts evenly into the reduction and differential removal screw holes (as shown in illustration) to remove the reduction and differential. Bolt size: M12 × 1.25 mm

Inspection procedure Inspection: Axle housing • Horizontally support the inner bearing fittings at both ends of the housing spindle of the axle housing. • Perform the following inspection. If the measurement is out of limit, replace the axle housing. (1) Runout at outer bearing portion • Apply a dial gauge to the outer bearing fitting and turn it 360 degrees to measure runout. (2) Difference between before and after rotation at center • For measurement of A1 and A2, place the axle housing at right angles using a square and measure A1. Then, turn it 180 degrees and measure A2.

Installation procedure Installation: Reduction and differential • Clean the seal surface of each part. • Apply sealant to the reduction and differential mounting surface of the axle housing evenly and without breaks. Apply sealant in a straight line direction for illustrated position A and along the outer periphery for notches of illustrated position B.

27-22

27 M E M O

27-23

REDUCTION AND DIFFERENTIAL

Disassembly sequence 1 2 3 4 5

Lock plate Side bearing nut Bearing cap Side bearing outer race Side bearing inner race

6 7 8 9

Differential (See later sections.) Pinion (See later sections.) Shim Differential carrier

CAUTION • Be sure to replace the bearing cap, differential carrier and bolts as a differential carrier set. • Be sure to replace the differential reduction gear and reduction pinion as a reduction gear set. • Keep side bearings that have been removed separated from each other and ensure that during installation each one is correctly placed. • Record the number and thickness of shims to use them as reference at assembly.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 4, 5 6 6, 7

27-24

Maintenance item Starting torque of side bearing Wobble at back face of reduction gear Backlash between reduction gear and reduction pinion

Standard value

Limit

Remedy

2.0 to 2.9 N·m {0.2 to 0.3 kgf·m}

–

Adjust

0 to 0.1

–

Replace

0.20 to 0.28

0.5

Adjust or replace

27 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

19.6 to 26.5 {2.0 to 2.7}

–

200.9 {20.5}

–

66.6 to 90.2 {6.8 to 9.2}

–

Points of application

Specified lubricant and/or sealant

Quantity

Pinion pilot bearing mounting surface of differential carrier

Loctite 601

As required

Bolt (lock plate mounting) Bolt (bearing cap mounting) Bolt (pinion mounting)

Lubricant and/or sealant Mark

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Differential working base assembly H

J

K

L

40

20

11

φ11

Component

Part No.

Attachment A

MB999034

–

RA

F

G

R158

30°

φ13

(Flange stopper is unused)

– MB999040

B

Holder

MB999036

C

Holder

MB999037

D

Working base

MB999035

E

Flange stopper

MB999096

Adapter A

B

φ45

φ59

Workbench for reduction and differential

MB999076

Removal of side bearing inner race (to be used in combination with commercial bearing puller)

MH061748

Installation of side bearing inner race

MH061745

Installation of pinion (two pieces are used)

Bearing installer A

B

φ80

φ70

Bearing retainer guide pin

A

B

C

D

18

85

12

M12 × 1.25

27-25

REDUCTION AND DIFFERENTIAL Work before removal Preparatory work: Installation of differential working base assembly • Install the reduction and differential on

.

Alignment marks: Bearing cap and differential carrier • Put alignment marks on the bearing cap and differential carrier for correct identification of right and left parts.

Removal procedure Removal: Side bearing inner race

Removal: Pinion • Screw two bolts evenly into the pinion removal screw holes to remove the pinion.

27-26

27 Installation procedure Selection: Shim • Calculate shim thickness by using the following formula based on the machining error data stamped on pinion and differential carrier. • Formula: Shim thickness = 0.5 − a + b + 0.2 a: 1/100 of numeral stamped on outer periphery of flange of differential carrier flange b: Numeral stamped on top of pinion • Select the shim(s) based on the calculated shim thickness. Thickness of shims available: 0.1 and 0.2 mm (2 types)

Installation: Pinion • Apply sealant to the pilot bearing mounting surface of the differential carrier.

• Aligning the embossed alignment mark on the bearing retainer of the pinion assembly with that on the differential carrier, mount the pinion assembly.

CAUTION • Leave for 30 minutes to 2 hours after installation to let the sealant harden. • Wait at least three hours or, if feasible, 24 hours before running the vehicle to let the sealant harden.

Inspection: Starting torque of pinion bearing • The starting torque of the pinion in single unit should be the standard value. • With the pinion installed, measure the starting torque of the pinion bearing using a torque wrench installed at the pinion. • Record the measured starting torque for reference when the starting torque of the side bearing is calculated.

27-27

REDUCTION AND DIFFERENTIAL Installation: Side bearing inner race

Work after installation Adjustment: Backlash between reduction gear and reduction pinion • Adjust backlash with the side bearing nut, taking care not to allow the side bearing starting torque to change. • When one side bearing nut is loosened, be sure to tighten the other one by the same amount to prevent the side bearing starting torque from changing.

Inspection: Wobble at back face of reduction gear • Measure wobble at the illustrated position of the reduction gear. • If the measurement value deviates from the standard value, replace the reduction gear and reduction pinion of the differential as a set.

Inspection: Tooth contact of reduction gear [Inspection] • Apply red lead to three to four teeth at three equally spaced points of the reduction gear. • Give the reduction gear several turns to check for tooth contact. Tooth contact off-center to the small end side under no load comes to the center under load. • Adjust tooth contact if it is remarkably offset.

27-28

27 [Adjustment] • Optimize tooth contact by increasing or decreasing shim thickness or adjusting backlash between reduction gear and reduction pinion (using side bearing nut).

CAUTION • If teeth are abnormally worn or tooth contact is excessively concentrated at the large end or small end side, always replace both the reduction gear and reduction pinion as a reduction gear set.

Tooth contact on reduction gear

Adjustment procedure

Concentrated at addendum

Advance reduction pinion to reduction gear (shims are reduced)

Concentrated at dedendum

Retard reduction pinion from reduction gear (shims are added)

Concentrated at large end side

Advance reduction gear to reduction pinion center (less backlash)

Concentrated at small end side

Retard reduction gear from reduction pinion center (more backlash)

27-29

REDUCTION AND DIFFERENTIAL Inspection: Starting torque of side bearing [Inspection] • Measure total starting torque of the pinion assembly using a torque wrench and calculate the starting torque of the side bearing using the following formula. Pinion bearing starting torque is the value obtained at earlier measurement of pinion bearing starting torque. (Total starting torque – Starting torque of the pinion bearing) × Final ratio = Starting torque of side bearing • If the calculated value of side bearing starting torque deviates from the standard value, adjust. [Adjustment] Adjustment by means of the right- and left-hand adjusting screws. • Always adjust both adjusting screws by the same amount. • The starting torque must be adjusted without causing the backlash between the reduction gear and reduction pinion out of the standard value.

27-30

27 Differential

Disassembly sequence 1 2 3 4 5 6 7 8

Reduction gear Differential case RH Side gear washer Side gear Pinion washer Differential pinion Pinion spider Differential case LH

CAUTION • Be sure to replace the differential case RH and the differential case LH as a differential case set. • Be sure to replace the side gear and the differential pinion as a side gear set.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Standard value

Limit

Remedy

Backlash between side gear and spline of axle shaft

0.05 to 0.15

0.5

Replace

4, 6

Backlash between side gear and differential pinion

0.15 to 0.20

0.5

Replace

6, 7

Clearance between differential pinion and pinion spider

0.17 to 0.27

0.5

Replace

4

Maintenance item

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Bolt (reduction gear mounting)

166.6 to 225.4 {17 to 23}

–

Bolt (differential case RH and differential case LH mounting)

83.3 to 112.7 {8.5 to 11.5}

–

Specified lubricant and/or sealant

Quantity

Rust preventive

As required

Loctite 271

As required

Lubricant and/or sealant Mark

Points of application Entire bolt Thread area of bolt Bolt tip of differential case LH

27-31

REDUCTION AND DIFFERENTIAL Work before removal Alignment marks: Reduction gear and differential case LH • Put alignment marks on the reduction gear and differential case LH.

Inspection procedure Inspection: Backlash between side gear and differential pinion • If backlash is found faulty, the thickness of the side gear washer and pinion washer is probably inappropriate.

Inspection: Backlash between side gear and axle shaft • If the measurement value exceeds the limit, replace defective parts.

Installation procedure Installation: Differential case RH and differential case LH • Apply rust preventive to the entire surface of the bolt. After applying it, blow off the excess rust preventive on the bolt using compressed air. • Apply thread lock cement to the bolt threads. • Tighten the bolt to the specified torque.

CAUTION • Make sure to apply rust preventive when tightening the bolt to the specified torque. • Wait at least one hour after installation before actually running the vehicle to let the thread lock cement harden. • Wait at least four hours after installation before operating the vehicle at full torque to let the thread lock cement harden.

27-32

27 Installation: Reduction gear and differential case LH • Apply rust preventive to the entire surface of the bolt. After applying it, blow off the excess rust preventive on the bolt using compressed air. • Apply thread lock cement at the entry of bolt holes on differential case LH. • Tighten the bolt to the specified torque.

CAUTION • Make sure to apply rust preventive when tightening the bolt to the specified torque. • Wait at least one hour after installation before actually running the vehicle to let the thread lock cement harden. • Wait at least four hours after installation before operating the vehicle at full torque to let the thread lock cement harden.

Work after installation Inspection: Backlash between side gear and differential pinion • If the measurement value deviates from the standard value, replace the side gear washer and pinion washer. Thickness of side gear washers available 3.0 mm (one thickness) Thickness of pinion washers available 1.6 mm (one thickness)

CAUTION • Use side gear washers of the same thickness for the right and left sides. • Use pinion washers of the same thickness at four locations.

27-33

REDUCTION AND DIFFERENTIAL Pinion

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

Lock nut Companion flange Dust cover Collar Rear bearing inner race Lock ring Pinion pilot bearing Reduction pinion Oil seal Front bearing inner race Front bearing outer race Rear bearing outer race Bearing retainer

: Non-reusable parts

NOTE • Record the height of the collar to use it as reference at assembly.

Assembly sequence Follow the disassembly sequence in reverse except for the following sequence. 11→8→7→6→5→4→10→9→3

Service standards Location

–

7

Maintenance item When new bearing is used Starting torque of pinion bearing (tangential force at outer periphery point of bearing retainer) When old bearing is reused Play in radial direction of pinion pilot bearing

Standard value

Limit

Remedy

2.0 to 2.9 N·m {0.20 to 0.30 kgf·m} (tangential force: 34 to 52 N {3.5 to 5.3 kgf})

–

Adjust or replace

1.6 to 2.4 N·m {0.16 to 0.24 kgf·m} (tangential force: 27 to 41 N {2.8 to 4.2 kgf})

–

Adjust or replace

–

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Lock nut (companion flange mounting)

Tightening torque

Remarks

372.4 to 470.4 {38 to 48}

–

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

Lubricant and/or sealant Mark

Points of application Lip area of oil seal

27-34

27 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Pinion bearing remover A

B

25.6

0.5

MB999045

Removal of rear bearing inner race

MH061005

Installation of rear bearing inner race and front bearing inner race

MH061976

Installation of pinion pilot bearing

MH061750

Installation of oil seal

MH061977

Installation of front bearing outer race

MH061264

Installation of rear bearing outer race

Pinion bearing installer A

B

C

φ62

φ52

125

Pinion pilot bearing installer A

B

φ45.2 φ39.2

Oil seal installer A

B

φ112

φ88

Pinion bearing installer A

B

φ89

φ78

Pinion bearing installer A

B

φ99

φ88

27-35

REDUCTION AND DIFFERENTIAL Work before removal Inspection: Play in radial direction of pinion pilot bearing • Hold the pinion and measure the play with moving the pinion pilot bearing in radial direction. • If the measurement value exceeds the limit, replace the pinion pilot bearing.

Removal procedure Removal: Reduction pinion

Removal: Rear bearing inner race

Removal: Front bearing outer race • Drive out the front bearing outer race by tapping evenly at three notches in the bearing retainer.

27-36

27 Removal: Rear bearing outer race • Drive out the rear bearing outer race by tapping evenly at three notches in the bearing retainer.

Installation procedure Installation: Rear bearing outer race

Installation: Front bearing outer race

Installation: Pinion pilot bearing • Install the pinion pilot bearing with its retaining ring placed on the gear.

Installation: Rear bearing inner race

27-37

REDUCTION AND DIFFERENTIAL Installation: Front bearing inner race • Install the front bearing inner race with the pinion assembled into the bearing retainer.

Inspection: Starting torque of pinion bearing • Apply the specified load to the companion flange or tighten the lock nut to the specified torque. • Measure the tangential force at outer periphery point of the bearing retainer using a spring balancer.

CAUTION • Securely fix the companion flange to measure. • Do not assemble the oil seal when measuring the tangential force. • If the measured tangential force is within the specified value, the starting torque conforms to the standard value. • If the measurement value deviates from the standard value, adjust by changing a collar. Thickness of collars available: 15.600 to 16.200 mm (25 thickness in 0.025 mm increments)

Installation: Oil seal • Apply grease to the lip area of the oil seal and install it on the bearing retainer in the illustrated direction.

27-38

GROUP 31 WHEEL, TIRE SPECIFICATIONS............................................................................... 31-2 TROUBLESHOOTING ........................................................................ 31-3 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Looseness in Wheel Nuts ........................................ 31-4 WHEEL, TIRE...................................................................................... 31-6

31-1

SPECIFICATIONS

31-2

Tire size

Wheel type

Standard tire inflation pressure

7.50-16-10

16 × 6.00GS-127

525 kPa {5.25 kgf/cm2}

31

TROUBLESHOOTING

Too high Toe-in

Wheel alignment

Camber

Worn in concave (one spot or more)

Worn in pit over the entire periphery

Worn in serration

O

O

O

O

Reference Gr

O

Excessive

O

Insufficient

O O

Excessive

O

Insufficient

O

Excessive toe-out Multiple misalignment

Worn in feather pattern from inside out

O

Worn in wave pattern

Too low

Tire pressure

Worn in feather pattern from outside in

O

Inside worn

Overload

Outside worn

Possible causes

Center worn

Tire tread wear

Both shoulders worn

Symptoms

O

O

O

O

Wheels out of balance

O

O

O

O

Wheel bearing loose

O

O

O

O Gr26, 27

Knuckle arm bent

O

Gr26

O

O

O

O

O

O

O

O

O

Left and right tie-rods different in length

O

Tie-rod end loose

O

Brake drum eccentrically mounted

O

Axle bent

O

Gr26 O

Gr26, 27

O

Gr26, 27

Left and right wheels steered at improper angles

O Gr26

Hard acceleration, braking, or steering

O

Specific road surface conditions

O

O

31-3

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Looseness in Wheel Nuts Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Wheel nut

Tightening torque

Remarks

490 ± 49 {50 ± 5}

–

(1) Single tire • Tighten the wheel nuts to the specified torque using a torque wrench. • If frequent loosening of tightened wheel nut or other similar abnormality is found, check the wheel nuts, hub bolts, and disc wheel for crack or other damage which may cause the abnormal condition. (See “WHEEL, TIRE”.) (2) Double tire • Loosen outer wheel nuts of half of the wheel bolts (alternately) and then tighten the inner wheel nuts to the specified torque using a torque wrench. Only the 5-stud type wheel is shown in the drawing. • Retighten the loosened outer wheel nut to the specified torque using a torque wrench. • Follow the same procedure for the remaining outer wheel nuts and inner wheel nuts of half of the wheel bolts. • If frequent loosening of tightened wheel nut or other similar abnormality is found, check the wheel nuts, hub bolts, and disc wheel for cracks or other damage which may cause the abnormal condition. (See “WHEEL, TIRE”.)

31-4

31 M E M O

31-5

WHEEL, TIRE

CAUTION • Use right-hand threaded wheel nuts marked “R” for right side wheels and left-hand threaded wheel nuts marked “L” for left side wheels.

Removal sequence 1 Wheel nut <Single tire> Wheel nut (outer) 2 Tire (See later section.) 3 Wheel nut (inner)

4 Tire (See later section.)

*a:

Hub bolt

Installation sequence Follow the removal sequence in reverse.

CAUTION • The wheel nuts are designed to be tightened without any coating of grease. Never grease the wheel nuts. Even if tightened to the specified torques, greased wheel nuts can become loose. • Be sure to use the genuine wheel nuts and tighten them to the specified torque to avoid damage to the hub bolts and looseness of the wheel nuts.

Service standards (Unit: mm) Location 2, 4

31-6

Maintenance item Tire lateral runout (sideway deflection)

Standard value

Limit

Remedy

3.5 or less

–

Correct or replace

31 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Wheel nut

Tightening torque

Remarks

490 ± 49 {50 ± 5}

–

Inspection procedure Inspection: Tire • Measure the tire for lateral runout (sideway deflection). • If the measured value is equal to or exceeds the standard value, correct as follows.

Correction: Tire • Mark the tire, disc wheel, and one of the hub bolts in the illustrated locations. • Remove the tire from the disc wheel.

• Measure the disc wheel for lateral runout. • If the disc wheel’s maximum runout is located near the mark on the wheel, install the tire such that the mark on the tire is 180° away from the mark on the disc wheel. • Measure the tire again for lateral runout. • If the measured value still does not conform to the standard value, replace the tire.

31-7

WHEEL, TIRE Installation procedure Installation: Tire • To prevent hardware and parts from becoming loose and/or damaged, thoroughly clean the following areas, removing rust, dirt, paint and foreign matter, before installing the tire. A: Threaded portion of hub bolt B: Wheel mounting surface of hub C: Wheel alignment area of hub D: Mating surfaces of disc wheel E: Wheel nut mounting surface of disc wheel F: Threaded portion of wheel nut G: Spherical portion of wheel nut

• Install the wheel nuts by tightening them with fingers as far as they go to ensure that they smoothly turn. If there is any abnormality such as a sticking point, replace the hub bolt. (See Gr26 and 27.) • The wheel nuts should be tightened in the diagonal sequence in a few steps. Lastly, use a torque wrench to retighten them to the specified torque. • When tightening the nuts with an impact wrench, use care of the time of tightening, compressed air pressure intensity or the like to prevent overtightening and use a torque wrench to retighten them in the final step.

31-8

31 M E M O

31-9

WHEEL, TIRE Tire

Disassembly sequence 1 2 3 4 5

Side ring Washer Tube Tire Disc wheel

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

–

Tire assembly static unbalance tolerance

1

Side ring gap (after inflating air)

5

Disc wheel

Standard value

Limit

Remedy

70 g or less

–

Correct

2 to 6

–

Flatness (at hub surface)

0.4 or less

–

Lateral runout (sideway deflection)

2.0 or less

–

Radial runout (vertical deflection)

1.8 or less

–

Replace

Work before removal Inspection: Side ring end gap • After inflating the tire to the specified pressure, measure the end gap of the side ring. • If the measurement deviates from the standard value, replace the side ring.

31-10

31 Inspection procedure Inspection: Disc wheel (1) Visual inspection • Visually inspect the disc wheel for deformation, crack, deterioration, stepped wear on the wheel hub mounting surface. If any abnormality is found, replace the disc wheel with a new one. • If any abnormality is found on the disc wheel, inspect the wheel hub. (See Gr26 and 27.)

(2) Flatness • Measure flatness around the inner and outer peripheries of hub bolt holes in the disc wheel. • If the measurement deviates from the standard value, replace the disc wheel.

(3) Runout • If the measured value is equal to or exceeds the standard value, replace the disc wheel.

Installation procedure Installation: Tire • Install the tire such that the yellow mark (light point mark) on the tire is aligned with the air valve on the disc wheel.

Installation: Balance weight • Install the balance weights on only front wheels to adjust the wheel balance. • To reduce allowable static unbalance value to standard value or less, install the balance weight on the side ring.

31-11

WHEEL, TIRE • Use a 1-pound resin hammer to drive balance weights into position. • To install a balance weight, tap the clip of the weight in the center at 1, 2 and 3 in that order.

• Leave a clearance of approx. 0 to 1 mm between the clip and the side ring. Ensure that the balance weight is not loose after installation. • Do not use a balance weight that has been improperly tapped or dropped to the floor during installation attempt. • When 2 weights are being installed, these weights should be as much equal to each other as possible in weight. Also remember that the center point between the weights will become the support point for a balancer.

31-12

GROUP 33 FRONT SUSPENSION STRUCTURE AND OPERATION 1. Front Suspension Elements .......................................................... 33-2 TROUBLESHOOTING ........................................................................ 33-3 STABILIZER .......................................................................... 33-4 SHOCK ABSORBER .......................................................................... 33-6 LEAF SPRING..................................................................................... 33-8

33-1

STRUCTURE AND OPERATION 1. Front Suspension Elements

• The front suspensions shown above both use a spring shackle connected to the rear end of the leaf spring (shackle-link type suspension). • The stabilizer prevents the vehicle from pitching, keeping it parallel with the ground.

33-2

33

TROUBLESHOOTING

Deformed stabilizer bar or link

Shock absorber

Substantial loss of oil and damping capacity Rubber bushing worn

O

Loose fitting

O O

O

Broken

O

O

Loose U-bolt

O

O

Spring bushing worn

O

O O

Tire and wheel needs balancing Excessive tire pressure

Wheels out of alignment

Poor linearity

Vehicle tilted

Cyclical shocks from underneath

O

Uneven wear Tire

Reference Gr

O

Cracks or other damage Leaf spring

Heavy rolling

Road bumps/pits received as shocks

Possible causes

Tends to be noisy

Feels as if floating

Symptoms

O O

O Gr31

O O Gr26

33-3

STABILIZER

Removal sequence 1 2 3 4

5 Stabilizer bar bracket

Stabilizer link Stabilizer clamp Stabilizer bushing Stabilizer bar

: Non-reusable parts

CAUTION • When removing the stabilizer link, take care not to damage the dust cover. Damaging the dust cover may cause water infiltration and wear-out the early stage.

Installation sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location 1

Maintenance item Starting torque

Stabilizer link

Play

Standard value

Limit

Remedy

0.68 to 1.96 N·m (0.7 to 2.0 kgf·m}

0.5 N·m {0.05 kgf·m}

Replace

0 to 0.1

0.2

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (U-bolt mounting)

Tightening torque

Remarks

175 ± 5 {17.8 ± 0.5}

Nut color: Green

90 to 120 {9.0 to 12}

–

Nut (stabilizer mounting) Nut (stabilizer link mounting) Nut (stabilizer bar bracket mounting)

Lubricant and/or sealant Mark

Points of application Dust cover lips on stabilizer link

33-4

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

33 Inspection procedure Inspection: Stabilizer link (1) Starting torque • Install a nut onto the stabilizer link. • Install a socket and a torque wrench onto the nut. Measure the starting torque of the stabilizer link. • If the measurement value does not conform to the standard value, replace the stabilizer link.

(2) Play • If the measurement value does not conform to the standard value, replace the stabilizer link.

(3) Dust cover • Check that there are no wear, cracks or damage. These abnormalities can cause water to enter the ball joint, resulting in premature wear. • If any abnormality is found, replace the stabilizer link.

Installation procedure Installation: Stabilizer clamp and bushing • Position the stabilizer bushing onto the stabilizer bar such that the end of the bushing aligns with the mark on the bar. Clamp them in place with the stabilizer clamp.

33-5

SHOCK ABSORBER

Removal sequence 1 2 3 4 5

6 Rubber bushing 7 Shock absorber 8 Washer

Washer Rubber bushing Rubber bushing Washer Washer

: Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (rubber bushing mounting)

33-6

Tightening torque

Remarks

13 to 17 {1.3 to 1.7}

–

33 Installation procedure Installation: Rubber bushing • Tighten the nut until the rubber bushing is squeezed to the illustrated dimension. • Install the split pin as shown in the illustration.

Installation: Rubber bushing • Make sure that dimension A in the illustration becomes equal to the following dimension after tightening the nuts. A: 4.7 mm

33-7

LEAF SPRING Removal sequence 1 2 3 4 5 6 7 8 9 10 11 12 13

U-bolt Front axle bumper Spring pin Rubber bushing Rubber bushing Shackle plate Spring shackle Rubber bushing Rubber bushing Rubber bushing Rubber bushing Leaf spring (See later section.) Spacer

*a:

Front spring hanger : Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

CAUTION • The cambers of the right-hand and left-hand leaf spring assemblies are different from each other. Ensure that both assemblies are installed correctly. Reversed installation results in a slanted vehicle. • U-bolt and mounting nut are non-reusable. • Make sure to jack the vehicle up when tightening the U-bolt mounting nut to specified torque. • Make sure to tighten the U-bolt mounting nut in dry tightening. If putting any oil or solvent on the nut, never use it.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

3 to 5

Radial clearance between spring pin and rubber bushings

0 to 0.04

0.5

Replace

4, 5, a

Axial clearance between rubber bushings and front spring hanger

0

0.5

Replace

6 to 11

Axial clearance between shackle plate, spring shackle and rubber bushings

0

0.5

Replace

7 to 11

Radial clearance between spring shackle and rubber bushings

0 to 0.04

0.5

Replace

*

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (U-bolt mounting) Nut (leaf spring mounting)

33-8

Tightening torque

Remarks

FE84

162 ± 15 {16.5 ± 1.5}

Nut color: Yellow

FE85

175 ± 5 {17.8 ± 0.5}

Nut color: Green

93 to 127 {9.5 to 13}

–

33 Work before removal Inspection: Axial clearance between rubber bushings and front spring hanger • Measure the indicated clearances using a feeler gauge. • If the measurement exceeds the limit, replace the rubber busing.

Inspection: Axial clearance between shackle plate, spring shackle and rubber bushings • Measure the indicated clearances using a feeler gauge. • If the measurement exceeds the limit, replace the rubber busing.

Installation procedure Installation: Spring pin • Install the spring pin such that the concave on the pin engages with the convex on the frame.

Installation: Front axle bumper • With the unloaded vehicle, slide the front axle bumper on the leaf spring to the rear of the vehicle until it is against the center nut of the leaf spring. Then, install the bumper using U-bolts.

33-9

LEAF SPRING Leaf Spring

Disassembly sequence 1 2 3 4 5 6

7 Leaf spring (No. 4) 8 Leaf spring (No. 5) 9 Caster shim

Collar Leaf spring (No. 1) Leaf spring (No. 2) Rivet Clip Leaf spring (No. 3)

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (assembly of leaf spring)

33-10

Tightening torque

Remarks

35 to 52 {3.5 to 5.5}

–

33 Removal procedure Compression: Leaf spring • Using a press, compress the leaf spring as illustrated for subsequent operations. • Using a chisel or the like, open the bent ends of the clip.

Removal: Clip • Using a drill press, break the flattened head of the rivet and remove the clip from the leaf spring (No. 2).

Installation procedure Installation: Caster shim • Install the caster shim with the chamfered (or rounded) portion facing upward in order not to damage the seat and spring.

Installation: Clip • Using a riveting machine, rivet a clip onto the leaf spring.

Installation: Leaf spring • Temporarily tighten the leaf spring with the bolt. • Compress the leaf spring using a press and tighten the nut to the specified torque. • After installing the nut, bend the clip with a hammer.

33-11

GROUP 34 REAR SUSPENSION STRUCTURE AND OPERATION 1. Rear Suspension Elements ........................................................... 34-2 TROUBLESHOOTING ........................................................................ 34-3 STABILIZER .......................................................................... 34-4 SHOCK ABSORBER .......................................................................... 34-5 LEAF SPRING..................................................................................... 34-6

34-1

STRUCTURE AND OPERATION 1. Rear Suspension Elements

• The rear suspensions shown above both use a spring shackle connected to the rear end of the leaf spring (shackle-link type suspension). • The stabilizer prevents the vehicle from pitching, keeping it parallel with the ground.

34-2

34

TROUBLESHOOTING

Cracks or other damage Leaf spring

O

Loose U-bolt

O

Spring bushing worn

O

Thrust clearance of metal bushing-type spring pin or shackle pin

O

Helper rubber or helper spring stopper damaged or broken

O

Spring pin over-tightened

O

Stabilizer deformed, bushing worn Shock absorber

Tire

O O

Rubber bushing worn

O

Loose fitting

O

Tire and wheel needs balancing Excessive tire pressure

Reference Gr

O

Broken

Substantial loss of oil and damping capacity

Excessive rolling while cruising

Cyclical shocks from underneath

Road bumps/pits received as shocks

Possible causes

Tends to be noisy

Feels as if floating

Symptoms

O O

Gr31

34-3

STABILIZER Removal sequence 1 2 3 4 5 6 7 8 9

*a: *b: *c:

Stabilizer upper bracket Plate Clamp Bushing Stabilizer hanger Stabilizer bushing Bushing Stabilizer bar Stabilizer lower bracket U-bolt Spring pad Leaf spring

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

70 to 95 {7.0 to 9.5}

–

Nut (stabilizer upper bracket mounting)

39 to 60 {3.9 to 6.0}

–

Nut (plate, clamp and stabilizer hanger mounting)

12 to 15 {1.2 to 1.5}

–

Nut (stabilizer hanger mounting) Nut (stabilizer lower bracket mounting)

Installation procedure Installation: Stabilizer bushing • Mount stabilizer bushings with their end surfaces aligned with marks on stabilizer bar.

34-4

34

SHOCK ABSORBER Removal sequence 1 2 3 4 5 6 7

Washer Washer Rubber bushing Rubber bushing Shock absorber Washer Washer

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (shock absorber mounting)

Tightening torque

Remarks

26.4 to 33.3 {2.7 to 3.4}

–

34-5

LEAF SPRING Leaf Spring Assembly Layout

• This section divides the leaf spring in 5 areas and describes removal and installation procedures for each area. For information on specific components, refer to the corresponding area descriptions. U-bolt U-bolt nut Spring pin Bushing Spring shackle Bushing Helper rubber Helper spring stopper Leaf spring

34-6

Area 1 (center section of leaf spring) Area 2 (front section of leaf spring) Area 3 (rear section of leaf spring) Area 4 (stoppers) Area 5 (leaf springs)

34 Removal sequence 1 Stabilizer lower bracket 2 U-bolt 3 Spring pad

*a:

Rear axle

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (U-bolt mounting)

Tightening torque

Remarks

339.1 ± 51.0 {34.6 ± 5.2}

–

34-7

LEAF SPRING Area 2 (front section of leaf spring)

Removal sequence 1 2 3 4 5

*a:

Grease nipple Spring pin Side washer (for adjustment) Side washer (for adjustment) Rear spring hanger Leaf spring

Installation sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

2, 5

Radial clearance between spring pin and rear spring hanger

0 to 0.04

0.3

Replace

2, a

*

Radial clearance between spring pin and leaf spring bushing

0.04 to 0.14

0.5

Replace

*

Axial clearance between rear spring hanger and leaf spring

0.1 to 1.0

1.0

Adjust or replace

5, a

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (spring pin mounting)

Tightening torque

Remarks

29.4 to 37.2 {3.0 to 3.8}

–

Lubricant and/or sealant Mark

Points of application Supply from grease nipple

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Spring pin remover A M22 × 1.5

34-8

MB999112

Removal of spring pin

34 Work before removal Inspection: Axial clearance between rear spring hanger and leaf spring • Measure the spring-to-hanger clearance using feeler gauge. If the measurement value is equal to or exceeds the limit, adjust by means of side washers. Side washer sizes available: 0.5 mm, 1.0 mm

Removal procedure Removal: Spring pin • Attach to the grease nipple fitting hole in the spring pin, and remove the spring pin while hitting it with the slide hammer part of .

Installation procedure Installation: Spring pin • Using a proper bolt, align the bolt hole in the rear spring hanger with the bolt groove in the spring pin.

CAUTION • Do not use the spring pin mounting bolt for alignment.

34-9

LEAF SPRING Area 3 (rear section of leaf spring)

Removal sequence 1 2 3 4 5 6 7 8 9 10 11

*a:

Grease nipple Spring pin Side washer (for adjustment) Side washer (for adjustment) Grease nipple Spring pin Side washer (for adjustment) Side washer (for adjustment) Bushing Spring shackle Rear shackle hanger Leaf spring

Installation sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 2, 10

Maintenance item

Limit

Remedy

0 to 0.04

0.3

Replace

Radial clearance between spring pin and leaf spring

0.04 to 0.14

0.5

Replace

6, 9

Radial clearance between spring pin and bushing

0.04 to 0.14

0.5

Replace

6, 11

Radial clearance between spring pin and rear shackle hanger

0 to 0.04

0.3

Replace

10, 11

Axial clearance between spring shackle and rear shackle hanger

0.1 to 0.9

1.0

Adjust or replace

*a

Axial clearance between spring shackle and leaf spring

0.5 to 1.2

1.5

Adjust or replace

*

2, a

10,

Radial clearance between spring pin and spring shackle

Standard value

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (spring pin mounting)

Tightening torque

Remarks

29.4 to 37.2 {3.0 to 3.8}

–

Lubricant and/or sealant Mark

Points of application Supply from grease nipple

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Spring pin remover A M22 × 1.5

34-10

MB999112

Removal of spring pin

34 Work before removal Inspection: Axial clearance between spring shackle and rear shackle hanger • Measure the spring-to-hanger clearance using feeler gauge. If the measurement value is equal to or exceeds the limit, adjust by means of side washers. Side washer sizes available: 0.5 mm, 1.0 mm

Inspection: Axial clearance between spring shackle and leaf spring • Measure the spring-to-hanger clearance using feeler gauge. If the measurement value is equal to or exceeds the limit, adjust by means of side washers. Side washer sizes available: 0.5 mm, 1.0 mm

Removal procedure Removal: Spring pin (lower) • Attach to the grease nipple fitting hole in the spring pin, and remove the spring pin while hitting it with the slide hammer part of .

Removal: Spring pin (upper) • Attach to the grease nipple fitting hole in the spring pin, and remove the spring pin while hitting it with the slide hammer part of .

34-11

LEAF SPRING Installation procedure Installation: Spring pin (upper) • Using a proper bolt, align the bolt hole in the shackle hanger with the bolt groove in the spring pin.

CAUTION • Do not use the spring pin mounting bolt for alignment.

Installation: Spring pin (lower) • Using a proper bolt, align the bolt hole in the spring shackle with the bolt groove in the spring pin.

CAUTION • Do not use the spring pin mounting bolt for alignment.

34-12

34 Area 4 (stoppers)

Removal sequence 1 Helper rubber 2 Helper spring stopper

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (helper rubber mounting)

Tightening torque

Remarks

11.8 to 14.7 {1.2 to 1.5}

–

Installation procedure Installation: Helper rubber • The arrow on the back of the helper rubber should be turned to the illustrated direction.

34-13

LEAF SPRING Area 5 (leaf spring)

• The above schematic is only an example. Details may differ depending on vehicle models, such as the number of spring leaves, spacers, and the parts used.

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11

Leaf spring (helper No. 1) Leaf spring (helper No. 2) Leaf spring (helper No. 3) Rivet Clip Leaf spring (helper No. 4) Leaf spring (helper No. 5) Leaf spring (helper No. 6) Leaf spring (helper No. 7) Spacer Pipe

Assembly sequence Follow the disassembly sequence in reverse.

34-14

12 13 14 15 16 17 18 19 20

Metal bushing Leaf spring (main No. 1) Leaf spring (main No. 2) Leaf spring (main No. 3) Rivet Clip Leaf spring (main No. 4) Leaf spring (main No. 5) Leaf spring (main No. 6)

: Non-reusable parts

34 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (assembly of leaf spring)

Tightening torque

Remarks

69 to 93 {7.0 to 9.5}

–

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Bushing installer A: Bushing installer A

MB999066 A: MB999067 B: MB999068

B: Bushing installer B

C

D

E

F

G

φ28

φ25

φ32.8

φ25

φ30

Removal and installation of metal bushing

Removal procedure Compression: Leaf spring • Using a press, compress the leaf spring as illustrated for subsequent operations. • Using a chisel or the like, open the bent ends of the clip.

Removal: Clip • Using a drill press, break the flattened head of the rivet and remove the clip from the leaf spring.

Removal: Metal bushing

34-15

LEAF SPRING Installation procedure Installation: Clip • Using a riveting machine, rivet a clip onto the leaf spring.

Installation: Metal bushing • Install the metal bushing in a manner similar to that for removal. (See “ Removal: Metal bushing”.) Installation: Leaf spring • Temporarily tighten the leaf spring with the bolt. • Compress the leaf spring using press and tighten the nut to the specified torque. • Bend the clip with a hammer.

34-16

GROUP 35 BRAKE SPECIFICATIONS............................................................................... 35-2 STRUCTURE AND OPERATION 1. Brake System ............................................................................... 35-3 2. Vacuum Pump .............................................................................. 35-5 3. Vacuum Booster and Brake Master Cylinder ................................. 35-6 4. Front Drum Brake ........................................................................35-11 5. Rear Drum Brake ........................................................................ 35-12 TROUBLESHOOTING ...................................................................... 35-13 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacement of Brake Fluid ........................................................ 35-16 2. Air Bleeding of Brake System ..................................................... 35-17 3. Inspection and Adjustment of Brake Pedal ................................. 35-19 4. Inspection of Drum Brake Lining Thickness ............................... 35-21 5. Inspection and Adjustment of Brake Shoe Clearance ................. 35-22 6. Inspection and Adjustment of Vacuum Line Hose....................... 35-23 7. Inspection of Vacuum Pump ....................................................... 35-23 8. Inspection of Vacuum Booster .................................................... 35-24 VACUUM PUMP................................................................................ 35-28 BRAKE MASTER CYLINDER .......................................................... 35-30 BRAKE PEDAL AND VACUUM BOOSTER..................................... 35-34 FRONT DRUM BRAKE..................................................................... 35-36 REAR DRUM BRAKE ....................................................................... 35-42

35-1

SPECIFICATIONS Vacuum Booster and Brake Master Cylinder Item

Specifications

Boosting type Vacuum booster

Vacuum tandem type

Diaphragm diameter

inch

Manufacturer

Bosch mm

φ31.75

Front

mm

16.0

Rear

mm

16.0

Inner diameter Brake master cylinder

Stroke

φ9 + φ10

Manufacturer

NISSIN KOGYO

Front Drum Brake Item

Specifications

Brake type

2-leading type

Brake drum inner diameter

mm

φ320

Brake lining width × thickness

mm

110 × 9.7

Adjusting type

mm

Manual

Wheel cylinder inner diameter

mm

φ31.75

Rear Drum Brake Item

Specifications

Brake type

Dual 2-leading type

Brake drum inner diameter

mm

φ320

Brake lining width × thickness

mm

110 × 10.4

Adjusting type

mm

Manual

Wheel cylinder inner diameter

mm

φ31.75

Vacuum Pump Item

Specifications

Type Output Manufacturer

35-2

Vane type 3

cm {mL}

90 {90} MITSUBISHI ELECTRIC

35

STRUCTURE AND OPERATION 1. Brake System 1.1 Brake fluid line

1 2 3 4

Vacuum booster Brake fluid level switch Brake fluid tank Brake master cylinder

5 Front wheel brake 6 Rear wheel brake 7 Stop lamp switch

• The brake system incorporating the vacuum booster uses vacuum to provide servo-assisted braking to all wheels of the vehicle onto which it is mounted.

35-3

STRUCTURE AND OPERATION 1.2 Vacuum booster line

35-4

35 2. Vacuum Pump

• The vacuum pump is mounted onto the timing gear case, and is driven by the timing gear. • The check valve is provided to ensure that no air or engine oil flow from the vacuum pump back to the vacuum tank when the engine is stationary.

2.1 Operation • A rotor with 3 movable vanes is housed in a cylindrical housing. As the rotor rotates, the vanes are pressed against the inner face of the housing by centrifugal force. • The rotor is eccentrically mounted relative to the housing. As the rotor rotates, air in the vacuum tank is sucked through the pump inlet and then compressed before being discharged through the outlet. The suction-compression-discharge cycle is repeated to generate vacuum in the vacuum tank. • The inside of the housing is lubricated and cooled by engine oil. After lubrication/cooling, the engine oil together with the compressed air is returned through the pump outlet and into the oil pan.

35-5

STRUCTURE AND OPERATION 3. Vacuum Booster and Brake Master Cylinder

• The vacuum booster magnifies the stepping force applied onto the brake pedal (therefore reduces the operator’s pedal effort) through the utilization of pressure difference between the vacuum it generates and the atmospheric pressure. The system is of a tandem type and has 2 vacuum chambers, achieving size reduction while offering a great capacity for highly efficient boosting performance. • The brake master cylinder serves both the front and rear brake systems that are independent of each other. Should fluid leakage occur in either the front or rear brake system, stopping power can still be provided by whichever system is intact.

35-6

35 3.1 When brake pressed

pedal

is

de-

(1) Vacuum booster operation • With the brake pedal released and no stepping force applied to the brake pedal, the operating rod and the valve plunger are held to the right by the force of the valve return spring. The atmospheric pressure valve remains closed while the vacuum valve remains open. • The vacuum pump creates vacuum in chamber A. As the atmospheric pressure valve is closed, no outside air flows into chamber B. Instead, vacuum in chamber A flows through the air passage and into chamber B. Chambers A and B are both filled with vacuum, and there is no pressure difference between the chambers. No boosting occurs. • As the brake pedal is depressed, the stepping force acts on the operating rod. This seats the poppet onto the valve body, closing the vacuum valve and cutting off vacuum supply into chamber B. As the brake pedal is depressed further, the valve plunger separates from the poppet. This opens the atmospheric pressure valve, allowing outside air into chamber B. There is now a pressure difference between chambers A and B. • The stepping force, boosted as a result of the pressure difference between chambers A and B, overcomes the force of the diaphragm plate spring, pushing the front and rear diaphragms and the push rod to operate the brake master cylinder.

35-7

STRUCTURE AND OPERATION (2) Brake master cylinder operation • As the push rod pushes the primary piston, the return port is closed by the piston cup. Fluid pressure now builds up in chamber C. • The pressure buildup is sent to the front brake system and at the same time pushes the secondary piston. • The center valve in front of the secondary piston separates from the stopper pin. The center valve return spring now closes the center valve, seating it onto the secondary piston. • Fluid pressure now builds up in chamber D in front of the secondary piston, and the pressure is sent to the rear brake system.

3.2 Fluid leakage in front brake system • As the brake pedal is depressed, the push rod moves to push the primary piston. As there is fluid leakage in the front brake system, no fluid pressure builds up in that system. • As the brake pedal is depressed further, the primary piston overcomes the force of the primary piston return spring and, via the retainer, pushes the secondary piston. Fluid pressure is now sent to the rear brake system.

3.3 Fluid leakage in rear brake system • As the brake pedal is depressed, the push rod moves to push the primary and secondary pistons. As there is fluid leakage in the rear brake system, no pressure builds up in that system. • As the brake pedal is depressed further, the tip of the secondary piston contacts the cylinder body while the primary piston continues to be pushed. Fluid pressure builds up further in the front brake system.

35-8

35 3.4 When brake pedal is released (1) Vacuum booster operation • With the brake pedal depressed, chamber A is filled with vacuum generated by the vacuum pump while chamber B is open to the atmosphere. When the brake pedal is released, the stepping force no longer acts on the operating rod. This causes the valve plunger to seat on the poppet, closing the atmospheric pressure valve and cutting off air flow into chamber B.

• In further progression, the poppet separates from the valve body. This opens the vacuum valve, allowing vacuum from the vacuum pump to flow into chamber B. As there is now no pressure difference between chambers A and B, the diaphragm plate spring pushes back the front and rear diaphragms along with the push rod to their original positions.

(2) Brake master cylinder operation • As the push rod returns to its original position, the secondary piston immediately starts to be pushed back by the force of the secondary piston return spring. The speed of return is gradual as there is no difference between chambers C and D in fluid pressure supplied by the brake master cylinder. • As the secondary piston starts to return to its original position, the pressure in chamber D becomes lower than the pressure in chamber C. The pressure difference causes the packing cup to buckle, allowing the fluid pressure in chamber C to flow through the orifices and into chamber D.

35-9

STRUCTURE AND OPERATION • With the secondary piston back in its original position, there is no difference in fluid pressure between chambers C and D. The packing cup restores its original shape, blocking the orifices. The liquid pressure in the brake line now flows through the center valve, which has been open since hitting the stopper pin. The liquid pressure then returns through the inlet port to the brake fluid tank.

• The fluid pressure in the primary (front) brake line returns through the return port to the brake fluid tank.

35-10

35 4. Front Drum Brake • The front drum brake is of a 2-leading type. • Single-acting wheel cylinders activate brake shoes, both as a leading shoe, in forward-travel braking. By selfboosting effect, the 2-leading shoe brake generates a great stopping power.

4.1 Wheel cylinder

35-11

STRUCTURE AND OPERATION 5. Rear Drum Brake • The rear drum brake is of a dual 2leading type. • Double-acting wheel cylinders activate brake shoes, both as a leading shoe, in forward- and rearward-travel braking. By self-boosting effect, the dual 2leading shoe brake generates a great stopping power.

5.1 Wheel cylinder

35-12

35

TROUBLESHOOTING

Backing plate surface rough

O O

Deterioration or incorrect material used for brake lining

O

Brake lining unevenly worn or with rough surface

O

O

Fade (lining surface deterioration)

O

Brake lining worn to limit

O

Incorrect contact of brake lining

O

O

Brake lining worn radius uneven O

Shoe return spring fatigued or broken

O

Brake drum worn Brake drum surface rough

O

O

Wheel cylinder malfunction

Brake drum deformed

O

O

O O

O O O

Gr26, 27

O

Brake drum inaccurately machined

O

Brake drum cracked

O

Foreign matter in brake drum

O

Brake shoe deformed or damaged

O

Shoe hold cup broken Movable parts insufficiently lubricated

Other

O

Lubricant or moisture on brake lining surface

Brake drum worn unevenly

Reference Gr

O

Backing plate deformed or incorrectly installed

Wheel brake

Continuous noise during brake application (at low vehicle speed)

Noise generated when wheels are turned with jacked-up vehicle

Reduced pedal travel

Insufficient stopping power

Other

Locking point varies

Unstable stopping power

Stopping power different from right to left

Possible causes

Noise and shock when brake pedal depressed

Brake application one sided

Brake drag (slow disengagement after pedal release)

Symptoms

O O

35-13

TROUBLESHOOTING

Brake pedal

Brake fluid

Incorrect pedal travel

O

Fluid level low

O

Fluid leakage

O

Air ingress

O

Vapor lock

O

Vacuum drop vacuum booster

O

Vacuum booster

Faulty vacuum booster

O

Axle

35-14

Other

Continuous noise during brake application (at low vehicle speed)

Noise generated when wheels are turned with jacked-up vehicle

Reference Gr

O

Incorrectly adjusted, too much play

Vacuum system

Tire

Reduced pedal travel

Insufficient stopping power

Other

Locking point varies

Unstable stopping power

Stopping power different from right to left

Possible causes

Noise and shock when brake pedal depressed

Brake application one sided

Brake drag (slow disengagement after pedal release)

Symptoms

Tire pressure uneven between wheels

O

Different tire sizes from left to right

O

Wheel hub bearing incorrectly adjusted

O

Wheelbase different from left to right

O

Incorrect wheel alignment

O

O Gr31 O

Gr26, 27 Gr26

35

Backing plate surface rough

O

Shoe trapped on backing plate surface

O

Backing plate deformed or incorrectly installed

O

Lubricant or moisture on brake lining surface

O

Wear powder attached on brake lining

O

Brake lining worn Wheel brake

O

Incorrect contact of brake lining

O

Wheel cylinder malfunction

O

O

Faulty wheel cylinder piston cup

O

O

Shoe return spring fatigued or broken

O

Brake drum glazed

O O

Gr26, 27

Brake drum deformed or center deviation

O

Brake shoe deformed or damaged Abnormal pedal return

Gr26, 27

O

Brake shoe twisted or sagged

O O

Pedal play insufficient Brake pedal

O

Linkage rusted or deformed

O

Return spring fatigued or broken

O

Vacuum booster operating rod thrust

O

Brake fluid

Brake pipe over-tightened, resulting in poor fluid return

Vacuum booster

Faulty vacuum booster

Brake master cylinder

Faulty piston cup

Axle

Reference Gr

Brake drag

Abnormal brake pedal return

Judder

Other

Brakes used under severe conditions

Brake noise Noisy when vehicle is new, or after brake lining replacement

Possible causes

Overheating on specific wheel(s)

Brake drum overheating

Overheating on all wheels

Symptoms

Clogged return port Wheel hub bearing incorrectly adjusted King pin bushing worn

O O O O O

O

O

Gr26, 27

O

Gr26

35-15

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacement of Brake Fluid • Brake fluid is shared by the brake and clutch systems, and is divided in the brake fluid tank into the two systems. This section describes the replacement of the brake fluid for the brake system. In order to completely replace the brake fluid, the brake fluid in the clutch system should also be replaced. (See Gr21.)

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Air bleeder

Tightening torque

Remarks

6.86 to 8.83 {0.7 to 0.9}

–

Specified lubricant and/or sealant

Quantity

Brake fluid (SAEJ1703 or FMVSS No. 116 DOT3)

As required

Lubricant and/or sealant Mark –

Points of application Brake fluid tank

WARNING • Be sure to use new brake fluid. Do not mix it with brake fluid of different properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of brake fluid, causing the boiling point to drop as well as the brake rubber parts to swell. Faulty operation of the brake will result. • Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty brake operation. • Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.

CAUTION • Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. If brake fluid is spilled onto the paintwork, immediately wipe it off. • During brake fluid replacement operation, a change in color of the brake fluid being discharged indicates that the old brake fluid in the system has been replaced with new brake fluid. • During the replacement, be sure to keep the brake fluid level at the “MAX” mark on the tank.

1.1 Work before replacement • In order to ensure that the vacuum booster functions properly, start the engine and keep it running at idle until the replacement is completed. • Install one end of a vinyl pipe onto each air bleeder. Place the loose end into a container.

1.2 Replacement of brake fluid • Loosen each bleeder screw, and depress and release the brake pedal repetitively until brake fluid is no longer discharged from the pipes. • While filling the brake fluid tank with new brake fluid up to the “MAX” mark, cycle the brake pedal repetitively until the old brake fluid being discharged is replaced with new brake fluid. Tighten each air bleeder to the specified torque. • Proceed to Air Bleeding of Brake System.

35-16

35 2. Air Bleeding of Brake System • Brake fluid is shared by the brake and clutch systems, and is divided in the brake fluid tank into the two systems. This section describes the air bleeding of the brake system. (See Gr21.)

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Air bleeder

Tightening torque

Remarks

6.86 to 8.83 {0.7 to 0.9}

–

Specified lubricant and/or sealant

Quantity

Brake fluid (SAEJ1703 or FMVSS No. 116 DOT3)

As required

Lubricant and/or sealant Mark –

Points of application Brake fluid tank

WARNING • Be sure to use new brake fluid. Do not mix it with brake fluid of different properties or with mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of brake fluid, causing the boiling point to drop as well as the brake rubber parts to swell. Faulty operation of the brake will result. • Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty brake operation. • Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.

CAUTION • Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. If brake fluid is spilled onto the paintwork, immediately wipe it off. • Brake fluid level drops during the air bleeding operation. Be sure to keep the brake fluid level at the “MAX” mark on the tank.

2.1 Work before air bleeding • In order to ensure that the vacuum booster functions properly, start the engine and keep it running at idle until the replacement is completed. • Install one end of a vinyl pipe onto each air bleeder. Place the loose end into a container.

35-17

ON-VEHICLE INSPECTION AND ADJUSTMENT 2.2 Air bleeding of brake system • Perform the air bleeding sequence described below on each of the 4 wheels in the order of the following table. Order of air bleeding

Brake system

1

Wheel Front right

Front

2 3

Front left Rear right

Rear

4

Rear left

Loosen the air bleeder. Slowly depress and release the brake pedal. Repeat this several times until a sufficient amount of brake fluid is discharged from the pipe.

Tighten the air bleeder. Cycle the brake pedal several times, and finally depress and hold it. Loosen the air bleeder. With the brake pedal still depressed, allow the brake fluid to drain.

Air in brake fluid

No air in brake fluid

Tighten the air bleeder to the specified torque. Repeat the above procedures on all of the remaining wheels.

Air bleeding is completed.

35-18

35 3. Inspection and Adjustment of Brake Pedal CAUTION • Securely chock the wheels so that the vehicle does not move. Do not remove the chocks until the entire operation is completed. • Inspection and adjustment of the brake pedal must be carried out after those of the following are completed. • Bleeding of brake system • Initial adjustment of clearance between brake drum and shoes

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

233 ± 3

–

Adjust

40 or more

–

Adjust

–

Installed height of brake pedal

–

Clearance between floor and brake pedal (when pressed with a force of 490 N {50 kgf})

–

Brake pedal free play

0.1 to 3.0

–

Adjust

–

Clearance between threaded end of stop lamp switch and brake pedal

0.5 to 1.5

–

Adjust

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Lock nut (operating rod securing)

Tightening torque

Remarks

21.6 ± 2.94 {2.2 ± 0.3}

–

3.1 Brake pedal installed height [Inspection] • Remove the center lower cover of the instrument panel so that measurement can be performed. • With the engine stopped and the brake pedal released, measure the height (H) from the center of the brake master cylinder to the center of the brake pedal. • If the measurement deviates from the standard value, adjust the height by turning the operating rod of the vacuum booster. [Adjustment] • Loosen the lock nut and turn the operating rod to bring the installed height of the brake pedal into the standard value range. • Tighten the lock nut to the specified torque. • After tightening the lock nut, press the brake pedal and check the brake pedal play and clearance between the brake pedal and floor.

3.2 Clearance between depressed brake pedal and floor [Inspection] • Pull off the floor mat to prepare for the measurement. • With the engine idling, depress the brake pedal with a force of 490 N {50 kgf} and measure the clearance between the brake pedal and floor. • If the measurement deviates from the standard value, adjust the brake pedal height by turning the operating rod of the vacuum booster or hydraulic booster. [Adjustment] • See “3.1 Brake pedal installed height”.

35-19

ON-VEHICLE INSPECTION AND ADJUSTMENT 3.3 Brake pedal play • Check the brake pedal play with the vehicle in the following state. • Stop the engine and set the starter switch to ON. • Without the parking brake applied, depress the brake pedal several times until the buzzer sounds. Then, apply the parking brake to stop the buzzer. • Depress the brake pedal several more times.

[Inspection] • Depress the center of the brake pedal pad with a finger until you feel resistance to measure the brake pedal play. • If the measurement deviates from the standard value, adjust the installed height of the brake pedal. [Adjustment] • See “3.1 Brake pedal installed height”.

3.4 Clearance between threaded end of stop lamp switch and brake pedal • Measure the clearance between the threaded end of the stop lamp switch and the stop for the brake pedal. If the measurement deviates from the standard value, adjust the clearance. • After adjustment, secure the part with the lock nut.

CAUTION • To prevent brake drag, ensure that the threaded end of the stop lamp switch does not interfere with the stop for the brake pedal.

35-20

35 4. Inspection of Drum Brake Lining Thickness CAUTION • To ensure correct operation of the brakes, be sure to inspect both linings on each wheel.

Service standards (Unit: mm) Location –

Maintenance item Brake lining thickness

Standard value

Limit

Remedy

Front drum brake

9.7

Rear drum brake

10.4

4.0 (Side shoulder means wear limit)

Replace

• Remove the inspection hole plug from the inspection hole in the backing plate. Through the inspection hole, measure the thickness of the brake lining. • If any lining is worn down to the step on the side face, replace all linings on that axle. • After the inspection, be sure to install the plug onto the inspection hole.

35-21

ON-VEHICLE INSPECTION AND ADJUSTMENT 5. Inspection and Adjustment of Brake Shoe Clearance CAUTION • To ensure correct operation of the brakes, be sure to inspect both shoes on each wheel.

Service standards (Unit: mm) Location –

Maintenance item Brake shoe clearance

Standard value

Limit

Remedy

0.2

–

Inspect, and adjust as required

[Inspection] • Cycle the brake pedal a couple of times to bring the brake shoes to conditions appropriate for the inspection. • Through the inspection hole, insert a feeler gauge between the brake drum and lining. The gauge should be able to be inserted and out with slight resistance. • If the clearance does not conform to the standard value, perform the following adjustment.

[Adjustment] • Turn adjuster of wheel cylinder through adjusting hole of the back plate in the direction of the arrow to attain light braking, and return four or five notches to obtain the clearance of the standard value.

35-22

35 6. Inspection and Adjustment of Vacuum Line Hose CAUTION • Be careful not to allow moisture into the check valve. • During the inspection, ensure that the check valve opens as well as closes correctly. • Do not attempt to remove the check valve from the vacuum hose. • Inspect the vacuum hose (with check valve inside) as follows, and replace if defective. • Check the hose for crack or other damage. Before replacing the hose, connect its marked end to the engine side. • Blow into the hose from its engine connecting end. The check valve should close to prevent air passage. • Inhale from the engine connecting end of the hose. The check valve should open to allow air passage.

7. Inspection of Vacuum Pump Service standards Location –

Maintenance item

Standard value

Time to reach vacuum of 69.3 kPa {520 mmHg}

Vacuum pump at 1500 rpm (engine at 725 rpm)

Time to reach vacuum of 78.6 kPa {590 mmHg}

Vacuum pump at 3000 rpm (engine at 1450 rpm)

Within 20 sec.

Limit

Remedy

–

Replace

• Install a vacuum gauge between the vacuum tank and the vacuum pump. • Start the engine and measure the time taken to reach the specified degree of vacuum. • If the measured time does not conform to the standard value, replace the vacuum pump. (See Gr11.)

35-23

ON-VEHICLE INSPECTION AND ADJUSTMENT 8. Inspection of Vacuum Booster • The vacuum booster can be inspected in 2 ways: one without using any tester and the other using a simplified tester. In either way, ensure that the brake piping and hosing and their connections are free of leakage, damage, or other faults.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

–

Precision inspection (vacuum loss) (vacuum of 67 kPa {500 mmHg}, 15 sec. after engine stop)

3.3 kPa {25 mmHg} or less

–

Replace

4360 kPa {44.5 kgf/cm2} (pedal pressed with a force of 98 N {10 kgf})

–

8800 kPa {89.7 kgf/cm2} (pedal pressed with a force of 295 N {30 kgf})

–

315 kPa {3.2 kgf/cm2} (pedal pressed with a force of 98 N {10 kgf})

–

1550 kPa {15.8 kgf/cm2} (pedal pressed with a force of 295 N {30 kgf})

–

–

–

Fluid pressure at vacuum of 67 kPa {500 mmHg}

Fluid pressure at vacuum of 0 kPa {0 mmHg}

Replace

Replace

8.1 Inspection of check valve in vacuum hose

CAUTION • Be careful not to allow moisture into the check valve. • During the inspection, ensure that the check valve opens as well as closes correctly. • Do not attempt to remove the check valve from the vacuum hose. • Start the engine and charge the vacuum tank with vacuum. • Stop the engine, and immediately remove the clamp fixing the vacuum hose onto the vacuum pipe, and hold the hose in your mouth. • Blow into the hose. The check valve should close, preventing the breath from passing it. • Suck on the hose while depressing the brake pedal. The check valve should immediately open, allowing air to pass. • If any fault is encountered during the above inspections, replace the check valve complete with the vacuum hose.

8.2 Operational check of vacuum booster

CAUTION • The vacuum booster operational checks described below are only of summary nature. If the vacuum booster continues to malfunction, perform a bench test specified by a service station of the manufacturer on the vacuum booster after removing it from the vehicle. • If the vacuum booster is found to be faulty during the specified testing, ask the service station of the manufacturer for repair.

35-24

35 (1) Operational check without any tester • Inspect the check valve in the vacuum hose for normal operation. • Perform the checks described below. If any fault is found during these checks, inspect the following parts. • Vacuum booster • Vacuum pump [Check 1] • Start the engine and run it for 1 to 2 minutes. Stop the engine. • Depress the brake pedal repetitively with the normal stepping force. • The pedal stroke should become smaller each time the pedal is depressed.

[Check 2] • With the engine stationary, depress the brake pedal several times. • With the brake pedal depressed, start the engine. The pedal should sink slightly.

[Check 3] • With the engine running and the brake pedal depressed, stop the engine. • The brake pedal should maintain the same height for approximately 30 seconds.

35-25

ON-VEHICLE INSPECTION AND ADJUSTMENT (2) Operational check with a simplified tester (2.1) Airtightness check • Inspect the check valve in the vacuum hose for normal operation. • Remove the vacuum hose from the vacuum booster and connect it to the vacuum gauge. • Connect another hose (not equipped with a check valve) onto the vacuum booster and the vacuum gauge. • Install 2 pressure gauges and 1 stepping-force gauge as illustrated. Bleed the pressure gauges of air. • Perform the following checks. If any fault is encountered during these checks, inspect the vacuum booster. [Check 1] • Start the engine. When the reading on the vacuum gauge has reached 67 kPa {500 mmHg}, stop the engine. • The vacuum lost in approximately 15 seconds of the engine stop should conform to the standard value. [Check 2] • Start the engine, and depress the brake pedal. When the reading on the vacuum gauge has reached 67 kPa {500 mmHg}, stop the engine. • The vacuum lost in approximately 15 seconds of the engine stop should conform to the standard value. (2.2) System characteristics check • Perform the following system characteristics checks after the airtightness check described above is completed. • Perform the following checks. If any fault is encountered during these checks, inspect the vacuum booster. [Check 1] • Start the engine. When the reading on the vacuum gauge has reached 67 kPa {500 mmHg}, depress the brake pedal with the specified stepping forces. • The fluid pressures indicated on the pressure gauges should conform to the specified values. [Check 2] • Start the engine. When the reading on the vacuum gauge has reached 0 kPa {0 mmHg}, depress the brake pedal with the specified stepping forces. • The fluid pressures indicated on the pressure gauges should conform to the specified values.

35-26

35 (2.3) Vacuum booster performance graph

35-27

VACUUM PUMP Disassembly sequence 1 2 3 4 5 6

Check valve Cylinder O-ring Vane Rotor Housing

: Locating pin : Non-reusable parts • For removal and installation procedures, see Gr11.

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (cylinder and housing assembling) Check valve

Tightening torque

Remarks

8.8 ± 2 {0.9 ± 0.2}

–

30 to 35 {3.1 to 3.6}

–

Lubricant and/or sealant Mark

Points of application O-ring

35-28

Specified lubricant and/or sealant

Quantity

Engine oil

As required

35 M E M O

35-29

BRAKE MASTER CYLINDER

Disassembly sequence 1 2 3 4 5 6

7 8 9 10

Bracket Retaining ring Piston guide Primary piston Set pin Secondary piston

Connector O-ring Cylinder body Seal

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse, except the following sequence. 2 → 10 → 1 Repair kit: Master cylinder repair kit • After assembly, make the inspection and adjustment of brake pedal. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Service standards (Unit: mm) Location 4 4, 6, 9 6

35-30

Maintenance item Primary piston spring load Clearance between primary and secondary pistons and cylinder body Secondary piston spring load

Standard value

Limit

Remedy

113.7 to 125.4 N {11.6 to 12.8 kgf}

110.7 N {11.3 kgf}

Replace

0.02 to 0.10

0.2

Replace

81.3 to 91.1 N {8.3 to 9.3 kgf}

79.4 N {8.1 kgf}

Replace

35 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (bracket mounting) Nut (brake master cylinder mounting) Screw (set pin mounting)

Tightening torque

Remarks

9 to 14 {0.9 to 1.4}

–

9.8 to 15.7 {1 to 1.6}

–

8.8 to 11.8 {0.9 to 1.2}

–

Lubricant and/or sealant Mark

Points of application Sliding face of primary piston Sliding face of secondary piston Seal lips and outer periphery Seal ring groove

Specified lubricant and/or sealant

Quantity

Rust preventive

As required

Rubber grease

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Support tool MK528895

A

B

No. of splines: 23

30

A

B

36

φ11.5

Adjustment of vacuum booster push rod

MK528896

Box spanner MB999062

A

B

C

Width across flats: 8

120

120

Adjustment of vacuum booster push rod

35-31

BRAKE MASTER CYLINDER Removal procedure Removal: Secondary piston • Position the cylinder body such that the set pin faces down. Using a rod or the like, compress the secondary piston to ease out the set pin.

CAUTION • As the secondary piston is compressed, the set pin will fall out. Be sure to catch it with your hand. Do not drop it on the floor.

• With ports A blocked, feed compressed air in the direction of the arrow, gradually increasing pressure from 0 kPa {0 kgf/cm2}, to remove the secondary piston.

WARNING • Do not apply compressed air suddenly and at high pressure. Otherwise, the secondary piston may fly out with full force.

Installation procedure Installation: Secondary piston • Position the cylinder body such that the set pin hole faces up. Using a rod or the like, insert the secondary piston into the cylinder body while at the same time trying to insert the set pin. • If necessary, rotate the secondary piston to align the groove on the piston with the set pin hole.

Installation: Seal • Apply grease onto the lips and outer periphery of the seal. Also, pack grease into the seal’s ring groove. Then, face the seal in the illustrated direction before installing it onto the cylinder body.

CAUTION • Ensure that the seal has been assembled correctly onto the cylinder body, i.e. facing the illustrated direction and without roll-up or damage. Otherwise, vacuum may be lost through the seal.

35-32

35 Inspection: Brake pedal and vacuum booster • If the brake master cylinder or the primary piston is replaced, be sure to inspect and, if required, adjust the illustrated distance between the push rod and the end of the brake pedal and vacuum booster. [Inspection] • Remove the vacuum hose from the brake pedal and vacuum booster to fill the vacuum booster with the atmospheric pressure.

CAUTION • The vacuum booster needs to be filled with the atmospheric pressure to obtain accurate results from the inspection. • Measure the distance (illustrated) between the push rod and the end of the brake pedal and vacuum booster. • If the measurement value does not conform to the specified value, adjust the distance as follows. [Adjustment] • Set the distance to the specified value by turning the push rod in or out.

35-33

BRAKE PEDAL AND VACUUM BOOSTER

Disassembly sequence 1 2 3 4

5 Pedal pad 6 Brake pedal and pedal support

Clevis pin Vacuum booster Bracket Stop lamp switch

: Non-reusable parts

• Do not attempt to disassemble the vacuum booster.

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

9 to 14 {0.9 to 1.4}

–

Nut (bracket mounting) Nut (brake pedal and pedal support mounting) Nut (vacuum booster mounting)

Lubricant and/or sealant Mark

Points of application Return spring of brake pedal and pedal support; Inner periphery of clevis pin hole

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

Installation procedure Installation: Stop lamp switch • Set the distance between the threaded end of the stop lamp switch and the stop for the brake pedal and pedal support to the illustrated value. Then, fix the assembly with the lock nut.

CAUTION • To prevent brake drag, ensure that the threaded end of the stop lamp switch does not interfere with the stop for the brake pedal.

35-34

35 M E M O

35-35

FRONT DRUM BRAKE

Disassembly sequence 1 2 3 4 5 6 7 8 9

Return spring Shoe hold-down cup Shoe hold-down spring Shoe hold-down cup Shoe hold-down pin Rivet Brake lining Brake shoe Brake pipe

10 11 12 13 14 15

*a::

Spacer Connector Wheel cylinder (See later section.) Cover Cover Backing plate Brake drum Non-reusable parts

• For removal and installation of the front drum brake and brake drum, see Gr26.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Brake lining kit

CAUTION • Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will be reduced. • When replacing the brake lining, clean the threaded portions of the wheel cylinder adjuster and adjust screw and coat them with rubber grease. • After assembly, make the adjustment of brake shoe clearance. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

35-36

35 Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

195 to 235 N {19.8 to 24.2 kgf}

175 N {18.0 kgf}

Replace

10.4

4.0 (side shoulder means wear limit)

Replace

Inside diameter

320

322 (

Cylindricity

0.05

1

Return spring load (installed length 190)

7

Brake lining thickness

*a

Brake drum

321)

0.2

Repair or replace

: Shows the correction limit value.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

12.75 to 14.71 {1.3 to 1.5}

–

Bolt (connector mounting)

7.85 to 11.77 {0.8 to 1.2}

–

Bolt (wheel cylinder mounting on adjust screw side)

22.6 to 32.4 {2.3 to 3.3}

–

79.43 to 107.9 {8.1 to 11.0}

–

Brake pipe

Bolt (wheel cylinder mounting on body side)

Lubricant and/or sealant Mark

Points of application Contact areas between brake shoe and wheel cylinder Contact areas between backing plate and brake shoe

Specified lubricant and/or sealant

Quantity

Brake grease

As required

Removal procedure Removal: Return spring • Using a flat-head screwdriver, remove the return spring. To do this, rest the screwdriver on the wheel cylinder adjust screw. Then, with the adjust screw as a fulcrum, engage the screwdriver with the spring hook and pry away the spring.

Removal: Brake lining • Using a drilling machine, break the flattened rivet heads on the brake shoe side to release the brake lining.

35-37

FRONT DRUM BRAKE Inspection procedure Inspection: Brake lining thickness • If any brake lining has worn to the side shoulder, replace the brake linings of both brakes on the same axle.

Inspection: Brake drum (1) Visual inspection • If an abnormal wear or damage is found on the inside of the brake drum, regrind the brake drum inner surface with the wheel hub as a set within the correction limit or replace the drum. (2) Inner diameter • If the measurement value exceeds the limit, replace the brake drum. (3) Cylindricity • If the measurement value exceeds the limit, regrind the brake drum inner surface within the correction limit or replace the drum.

Installation procedure Installation: Backing plate • Grease the backing plate at the illustrated locations.

Installation: Brake pipe • Position the spacer correctly on the bracket so that the brake pipe and spacer assembly will not get clear of the backing plate surface. • After making sure that the brake pipe and spacer assembly is centered on the bracket, close the bracket to secure the brake pipe in such a way that the brake pipe is held pressed evenly by the spacer.

35-38

35 Installation: Brake lining • Using cleaning fluid, clean the surface of the brake shoe to which the brake lining is to be mounted. Dry the brake shoe. • Insert rivets from the lining to the shoe. Stake them, starting from the center of the shoe and moving towards the ends. Ensure that the shoe-to-lining clearances conform to the following specifications. • Around the rivets: 0.05 mm or less • Along the shoe/lining sides: 0.4 mm or less • Along the shoe/lining ends: 0.5 mm or less • Stake the rivets with a force of 21 ± 1.0 kN {2100 ± 100 kgf}.

CAUTION • Replace all of the brake linings on the same axle and the brake linings should be in the same size and have the same identification mark. Otherwise, braking performance can be different from left to right. • After assembly, check the drum-to-lining contact. Correct as required. Installation: Brake shoe • Grease the brake shoe at the illustrated locations.

Installation: Return spring • Engage a small Phillips screwdriver into the return spring hook. Then, using the screwdriver insert the spring hook into the hook hole in the brake shoe and attach the hook onto the shoe.

35-39

FRONT DRUM BRAKE Wheel Cylinder

Disassembly sequence 1 2 3 4 5 6 7 8

Stopper Adjust screw Adjuster Boots Piston Piston cup Air bleeder Body

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Wheel cylinder kit

Service standards (Unit: mm) Location 5, 8

Maintenance item Piston-to-body clearance

Standard value

Limit

Remedy

0.03 to 0.10

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Air bleeder Screw (stopper mounting)

Tightening torque

Remarks

6.86 to 8.83 {0.7 to 0.9}

–

2.35 to 3.53 {0.24 to 0.36}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Rubber grease

As required

Threaded portion of adjust screw Sliding face of adjuster Sliding face of piston

35-40

35 M E M O

35-41

REAR DRUM BRAKE

Disassembly sequence 1 2 3 4 5 6 7 8

Return spring Shoe hold-down cup Shoe hold-down spring Shoe hold-down cup Shoe hold-down pin Rivet Brake lining Brake shoe

9 10 11 12 13 14

Brake pipe Spacer Wheel cylinder (See later section.) Cover Cover Backing plate

*a:

Brake drum : Non-reusable parts

• For removal and installation procedures of the rear drum brake and brake drum, see Gr27.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Brake lining kit

CAUTION • Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will be reduced. • When replacing the brake lining, clean the threaded portions of the wheel cylinder adjuster and adjust screw and coat them with rubber grease. • After assembly, make the adjustment of brake shoe clearance. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

35-42

35 Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

195 to 235 N {19.8 to 24.2 kgf}

175 N {18.0 kgf}

Replace

10.4

4.0 (side shoulder means wear limit)

Replace

Inside diameter

320

322 (

Cylindricity

0.05

1

Return spring load (installed length 190)

7

Brake lining thickness

*a

Brake drum

321)

0.2

Repair or replace

: Shows the correction limit value.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Brake pipe

12.75 to 14.71 {1.3 to 1.5}

–

Bolt (wheel cylinder mounting)

79.43 to 107.9 {8.1 to 11.0}

–

Lubricant and/or sealant Mark

Points of application Contact areas between brake shoe and wheel cylinder Contact areas between backing plate and brake shoe

Specified lubricant and/or sealant

Quantity

Brake grease

As required

Removal procedure Removal: Return spring • Using a flat-head screwdriver, remove the return spring. To do this, rest the screwdriver on the wheel cylinder adjust screw. Then, with the adjust screw as a fulcrum, engage the screwdriver with the spring hook and pry away the spring.

Removal: Brake lining • Using a drilling machine, break the flattened rivet heads on the brake shoe side to release the brake lining.

35-43

REAR DRUM BRAKE Inspection procedure Inspection: Brake lining thickness • If any brake lining has worn to the side shoulder, replace the brake linings of both brakes on the same axle.

Inspection: Brake drum (1) Visual inspection • If an abnormal wear or damage is found on the inside of the brake drum, regrind the brake drum inner surface with the wheel hub as a set within the correction limit or replace the drum. (2) Inner diameter • If the measurement value exceeds the limit, replace the brake drum. (3) Cylindricity • If the measurement value exceeds the limit, regrind the brake drum inner surface within the correction limit or replace the drum.

Installation procedure Installation: Backing plate • Grease the backing plate at the illustrated locations.

Installation: Brake pipe • Position the spacer correctly on the bracket so that the brake pipe and spacer assembly will not get clear of the backing plate surface. • After making sure that the brake pipe and spacer assembly is centered on the bracket, close the bracket to secure the brake pipe in such a way that the brake pipe is held pressed evenly by the spacer.

35-44

35 Installation: Brake lining • Using cleaning fluid, clean the surface of the brake shoe to which the brake lining is to be mounted. Dry the brake shoe. • Insert rivets from the lining to the shoe. Stake them, starting from the center of the shoe and moving towards the ends. Ensure that the shoe-to-lining clearances conform to the following specifications. • Around the rivets: 0.05 mm or less • Along the shoe/lining sides: 0.4 mm or less • Along the shoe/lining ends: 0.5 mm or less • Stake the rivets with a force of 21 ± 1.0 kN {2100 ± 100 kgf}.

CAUTION • Replace all of the brake linings on the same axle and the brake linings should be in the same size and have the same identification mark. Otherwise, braking performance can be different from left to right. • After assembly, check the drum-to-lining contact. Correct as required. Installation: Brake shoe • Grease the brake shoe at the illustrated locations.

Installation: Return spring • Engage a small Phillips screwdriver into the return spring hook. Then, using the screwdriver insert the spring hook into the hook hole in the brake shoe and attach the hook onto the shoe.

35-45

REAR DRUM BRAKE Wheel Cylinder

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11

Stopper Boot Piston Piston cup Adjusting screw Adjuster Boot Piston Piston cup Bleeder screw Body

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Brake lining kit

Service standards (Unit: mm) Location 3, 8, 11

Maintenance item Piston-to-body clearance

Standard value

Limit

Remedy

0.03 to 0.10

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Air bleeder Bolt

Tightening torque

Remarks

6.86 to 8.83 {0.7 to 0.9}

–

2.35 to 3.53 {0.24 to 0.36}

–

Specified lubricant and/or sealant

Quantity

Rubber grease

As required

Lubricant and/or sealant Mark

Points of application Threaded portion of adjust screw Sliding face of adjuster Sliding face of piston

35-46

GROUP 36 PARKING BRAKE SPECIFICATIONS............................................................................... 36-2 STRUCTURE AND OPERATION 1. Parking Brake System .................................................................. 36-3 2. Parking Brake Lever ..................................................................... 36-3 3. Parking Brake ............................................................................... 36-4 TROUBLESHOOTING ........................................................................ 36-5 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Adjustment of Parking Brake Shoe Clearance .............................. 36-6 2. Inspection and Adjustment of Parking Brake Lever ...................... 36-7 PARKING BRAKE CONTROL............................................................ 36-8 PARKING BRAKE............................................................................. 36-12

36-1

SPECIFICATIONS Item Brake

Specifications

Type

Internal expanding type acting on propeller shaft

Operation type

Mechanical cable type

Type Parking brake

Brake drum I.D.

Duo servo type mm

Lining width × thickness mm

36-2

φ190 45 × 4.0

STRUCTURE AND OPERATION

36

1. Parking Brake System

2. Parking Brake Lever • Pulling up the parking brake lever causes the parking brake to be applied. The ratchet pawl of the lever engages with one of the notches on the ratchet plate as the lever is moved up, which holds the lever in a pulled-up position. • Raising slightly the lever from the brake-applied position while pressing the pushbutton disengages the ratchet pawl from the ratchet plate; the lever then can be returned to the original position.

36-3

STRUCTURE AND OPERATION 3. Parking Brake

• The parking lever that actuates the shoe and lining is a built-in component of the parking brake body. Pulling the parking brake lever pulls the parking brake cable, which in turn pulls the parking lever. • When the parking lever is pulled, one shoe and lining is forced to expand with the medium of strut. At the same time, the parking lever directly expands the other shoe and lining. Thus, each shoe and lining works as a leading shoe. • When the parking brake lever (parking lever) is returned to the released position, the repercussive force of the shoe return spring releases the brake.

36-4

36

TROUBLESHOOTING

Parking brake does not work

Parking brake release not smooth (dragging)

Parking brake lever operating physical force insufficient

Parking brake lever operating physical force excessive

Symptoms

Inner cable stretched or damaged

O

O

O

O

Inner cable improperly adjusted

O

O

O

O

Front parking cable and rear parking cable improperly connected

O

O

O

O

Front parking cable and rear parking cable joints in poor contact

O

O

O

O

Ratchet pole and ratchet plate pawl engaged improperly

O

Possible causes

Parking brake cable

Parking brake lever

Pulling stroke insufficient Pulling stroke excessive

O O

Shoe clearance insufficient

Parking brake

O O

O

O

Shoe clearance excessive

O

O

Parking brake drum inner surface deformed or warped

O

O

Lining worn unevenly

O

O

Brake drum inner surface greasy or oily

O

Lining surface greasy or oily

O

Shoe return spring fatigued or fractured

Reference Gr

O

36-5

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Adjustment of Parking Brake Shoe Clearance Service standards (Unit: mm) Location –

Maintenance item Brake shoe clearance

Standard value

Limit

Remedy

0.1 to 0.25

–

Adjust or inspect

• Chock the front wheels and raise the rear wheels with a jack before adjusting the shoe clearance. • Operate the parking brake lever to release the parking brake. (The parking lever is released from locking.) • Using a standard screwdriver inserted through the shoe adjusting hole in the parking brake drum, turn the adjusting screw in the expansion direction shown to bring the shoe into close contact with the brake drum. • Turn the adjusting screw 8 to 10 notches in the contraction direction shown from the position where the shoe is in close contact with the drum. The shoe clearance should be adjusted to the standard value.

36-6

36 2. Inspection and Adjustment of Parking Brake Lever Service standards Location

Maintenance item

Standard value

Limit

Remedy

–

Parking brake lever pulling stroke (with operating physical force of 300 N {30 kgf})

7 to 9 notches

–

Adjust or inspect

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Lock nut

Tightening torque

Remarks

19 to 28 {1.9 to 2.9}

–

[Inspection] • Count the number of notches over which the parking brake lever moves when pulled with a specified force from the brake released position. • If the notch count does not conform to the standard value, adjust the length of the parking brake cable as necessary. • If the standard value cannot be reached by adjusting the parking brake cable length, check the parking brake shoe-to-drum clearance.

[Adjustment] • Pull the outer cable of the parking brake cable with a force of 60 to 100 N {6 to 10 kgf} to zero the parking brake shoe clearance.

CAUTION • If the heat insulator for the parking brake cable slips out of place, the outer cable may be damaged due to heat from the exhaust pipe. When pulling the outer cable, take care not to move the heat insulator. • While pulling the parking brake cable, tighten the adjust nut until it seats the cable support end. • Lock the adjust nut with the lock nut. • Operate the parking brake lever several times with the force of 500 N {50 kgf}. • Pull the outer cable of the rear parking brake cable again with the force of 60 to 100 N {6 to 10 kgf}.

CAUTION • If the heat insulator for the parking brake cable slips out of place, the outer cable may be damaged due to heat from the exhaust pipe. When pulling the outer cable, take care not to move the heat insulator. • Holding the parking brake cable in the pulled state, turn the adjusting nut until its distance from the casing cap reaches 3 to 5 mm as shown in the illustration. • Return the parking brake cable to the original position. • Tighten the lock nut to the specified torque.

36-7

PARKING BRAKE CONTROL

Removal sequence 1 2 3 4

5 6 7 8

Push nut Push turn rivet Cover Parking brake switch

Parking brake lever Cap Front parking brake cable Rear parking brake cable

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (front parking brake cable attaching) Bolt (parking brake lever mounting) Bolt (front parking brake cable attaching) Rear parking brake cable to front parking brake cable connection

Tightening torque

Remarks

4 to 6 {0.4 to 0.6}

–

12 to 15 {1.2 to 1.5}

–

55 to 70 {5.6 to 7.1}

–

Lubricant and/or sealant Mark

Point of application Contact surfaces of parking brake lever

36-8

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

36 Removal procedure Removal: Front parking brake cable • Loosen the nut connecting the front and rear parking brake cables, then separate the front parking brake cable case from the rear parking brake cable. • Remove the cap and pull out the clevis from the front parking brake cable case and remove it following steps 1, 2 and 3 in that order as shown.

Installation procedure Installation: Cap • Attach the cap to the clevis of the rear parking brake cable from the direction shown in the illustration. • Fit the cap into the clevis all the way so that the flange of the cap comes out at the other side of the clevis.

36-9

PARKING BRAKE CONTROL Installation: Parking brake cable • Connect the front parking brake cable to the rear parking brake cable by following the removal procedure in reverse. • Attach the front parking brake cable to the parking brake lever by fully tightening nut A, then tightening nut B to the specified torque.

CAUTION • The cable must not be bent at clamped portions. • There must not be torsion in the boot. • Avoid any interference with other components when routing the cable.

36-10

36 M E M O

36-11

PARKING BRAKE Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14

*a: *b::

Shoe return spring Washer Strut spring Shoe holddown cup Shoe holddown spring Shoe holddown cup Shoe holddown pin Adjuster Adjuster spring Strut Retainer Shoe and lining Parking lever Backing plate Parking brake drum Retainer Non-reusable parts

• For removal and installation of the parking brake and parking brake drum, see Gr22. Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • To prevent poor working of the brake, do not smear the surface of shoe and lining with grease or oil. • After reassembly, make the inspection and adjustment of brake shoe clearance. (See “ON-VEHICLE INSPECTION AND ADJSTMENT”.)

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

1

Installed load of shoe return spring (installed length: 67.1)

58.8 ± 5.9 N {6 ± 0.6 kgf}

49 N {5 kgf}

Replace

3

Installed load of strut spring (installed length: 49)

29.4 ± 2.9 N {3 ± 0.3 kgf}

26 N {2.7 kgf}

Replace

5

Installed load of shoe holddown spring (installed length: 15.5)

78.5 ± 7.9 N {8 ± 0.8 kgf}

71 N {7.2 kgf}

Replace

9

Installed load of adjuster spring (installed length: 78.2)

58.8 ± 5.9 N {6 ± 0.6 kgf}

49 N {5 kgf}

Replace

12

Brake lining thickness of shoe and lining

1.4

Replace

*a

Parking brake drum

+0.2 0

φ190

Squareness

0 to 0.05

–

Concentricity

0 to 0.1

–

Cylindricity

0 to 0.05

–

0.0049 N·m {0.5 gf·m} or less

–

Static rotation imbalance

36-12

4.0

Inner diameter

φ191

Replace

36 Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Brake grease (AKB100)

As required

Adjuster ends in contact with shoe and lining Backing plate anchor pin and surface in contact with shoe and lining

Inspection procedure Inspection: Brake lining thickness of shoe and lining • If the measurement value is lower than the limit, replace the shoe and lining.

Inspection: Parking brake drum (1) Visual inspection • If an abnormal wear or damage is found on the parking brake drum, replace the parking brake drum. (2) Inner diameter, squareness, concentricity, cylindricity and static rotation imbalance • If the measurement value exceeds the limit or deviates from the standard value, replace the parking brake drum.

36-13

GROUP 37 STEERING SPECIFICATIONS............................................................................... 37-2 STRUCTURE AND OPERATION 1. Steering System ........................................................................... 37-3 2. Oil Flow ........................................................................................ 37-3 3. Power Steering Gear Assembly .................................................... 37-4 4. Power Steering Oil Pump .............................................................. 37-6 TROUBLESHOOTING ........................................................................ 37-8 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Steering Wheel Play .................................................................... 37-10 2. Steering Column Looseness ....................................................... 37-10 3. Inspection of Rods and Arms for Looseness .............................. 37-10 4. Inspection of Power Steering System Mounts for Looseness ......37-11 5. Inspection and Replacement of Power Steering Oil .....................37-11 6. Performance Verification Test of Power Steering System ........... 37-13 7. Inspection of Drag Link Ball Joint ............................................... 37-13 STEERING COLUMN........................................................................ 37-14 POWER STEERING GEAR ASSEMBLY AND DRAG LINK ............ 37-22 POWER STEERING OIL PUMP ....................................................... 37-34 POWER STEERING OIL TANK ........................................................ 37-37

37-1

SPECIFICATIONS Steering Wheel, Steering Shaft and Power Steering Gear Assembly Item Steering wheel Steering shaft

Specifications

Type

2-spoke type

Outer diameter

mm

Type

400 Universal joint type (tilt and telescopic type)

Power Steering Gear Assembly Item

Specifications

Manufacturer

Hitachi Automotive systems steering

Type

Ball nut type

Form

Integral form

Item number

454-00005

Gear ratio

22.2

Cylinder diameter

mm

80

Power Steering Oil Pump Item

Specifications

Manufacturer

KYB

Type

Vane type

Manufacturer’s item number Delivery rate Adjusted flow volume Adjusted pressure (relief valve) Permissible revolutions

37-2

B4230-09037 3

cm {mL}/rev. 3

dm {L}/min. MPa

{kgf/cm2} rpm

9.6 {9.6} 6 to 8 {6 to 8} 10.8 +0.2 {110 +2 } –0.3 –3 600 to 6500

STRUCTURE AND OPERATION

37

1. Steering System

2. Oil Flow

37-3

STRUCTURE AND OPERATION 3. Power Steering Gear Assembly

• A rotary valve is adopted for the valve, the center of the power steering. For steering reaction force and return of the valve, the valve operates lightly and smoothly at low speed by means of the torsion bar, and provides stable steering feel up to high speed.

37-4

37 3.1 When moving straight forward • As equal pressure is applied to cylinder chambers A and B on both sides of the piston, the piston is placed in neutral position.

3.2 When turning the steering wheel • When the steering wheel is turned, the stub shaft is twisted, which causes the rotor to shut off oil supply passages to cylinder chamber B. As a result, pressure difference is caused between cylinder chamber A and cylinder chamber B, and the piston moves, facilitating rotation of the worm shaft. The illustration shows a condition when the steering wheel is turned to the left.

3.3 When hydraulic circuit fails • The turning force of the stub shaft alone turns the worm shaft.

37-5

STRUCTURE AND OPERATION 4. Power Steering Oil Pump

• The power steering oil pump is a hydraulic source pump with the vane in the rotor groove and is geared to the engine. • The power steering oil pump consists of a cartridge that discharges oil, a flow control valve that controls the oil flow rate and a relief valve that prevents free oil pressure rise. • The flow control valve maintains constant the quantity of oil to the power steering gear assembly during steering wheel manipulation. The relief valve assembly is provided in the flow control valve to prevent oil pump pressure from rising beyond necessary level during stationary swing operation.

37-6

37 4.1 Flow control valve (1) Operation of flow control valve assembly (1.1) When not functioning (oil pump in operation at low speed) • Oil pressure in the chamber A is weaker than the combined force of oil pressure in the chamber B and tension of the flow control spring, and the flow control valve remains stationary.

(1.2) When functioning (oil pump in operation at middle to high speeds) • Oil pressure in the chamber A overcomes the combined force of oil pressure in the chamber B and tension of the flow control spring, and the flow control valve is shifted. • Port is made open to release oil pressure, and the flow rate from the chamber C is maintained constant.

(2) Operation of relief valve • When the combined force of oil pressure in the chamber B and tension of the flow control spring overcomes oil pressure in the chamber A, the flow control valve is shifted. Further increased oil pressure in the chamber B pushes the relief valve to open port, thus preventing excessive oil pressure from going to the chamber C.

37-7

TROUBLESHOOTING

Faulty steering column and link mechanism

Oil quantity insufficient

Faulty front axle, etc.

Noise from oil pump (low whirring)

Noise from oil pump (squeaking)

Noise from oil pump (grinding)

Oil pump oil pressure abnormal

Oil leakage

Steering angle insufficient or different between right and left

Oil quantity excessive

Reference Gr

O

Air bleeding insufficient

O

O

Oil viscosity unsuitable

O

Hydraulic circuit clogged

O

Power steering gear assembly faulty

O

O

Power steering gear assembly improperly installed

O

O

Gear engagement rotating torque incorrectly adjusted

O

O

O

O

O

O

O O

Pitman mounting position incorrect

O

Steering shaft universal joint abnormally worn, or damaged

O

Link deformed

O

Drag link ball joint abnormally worn, or damaged

O

O

Tie rod ball joint abnormally worn, or damO aged

O

O O

Steering angle off center between left and right

O

Tie rod bent

O

King pin poorly greased

O

Front wheel alignment (toe-in, camber and caster) incorrect

O

Thrust bearing damaged

O

O O

O

Wheel hub bearing worn out or damaged

O

O

O

King pin or bushing worn out or damaged

O

O

O

O

O

Front axle deformed

O Gr26

Knuckle arm, tie rod arm, knuckle, etc. improperly tightened

O

Front spring U-bolt, nut, etc. loose

O

Gr33

Front tire radial and lateral runout; static and dynamic balance incorrect

O

Gr31

Front axle parts overtightened

O

Steering angle incorrectly adjusted Mounted parts, connections loose Knuckle stopper bolt improperly adjusted

37-8

Steering wheel does not turn

Steering wheel return not smooth

O

Steering wheel vibration

O

Steering wheel pulled to one side

Steering wheel play excessive and unstable

Faulty power steering mechanism

Possible causes

Steering wheel heavy to operate

Symptoms

O

O

O O

Gr26

37

Faulty oil pump

Oil pump housing faulty

O

O-ring, oil seal faulty

O

Bolt improperly tightened

O

Maximum generated oil pressure insufficient

O

Oil line crushed or clogged

O

Air caught in oil pump O

Mounting bolt and nut loose

Other abnormalities

Noise from oil pump (low whirring)

Noise from oil pump (squeaking)

O O

Load excessive rearward of load-carrying platform

O

Load excessive on one side of loading bed

O

Difference excessive in wheelbase between left and right

O

Propeller shaft runout excessive

O

Rear axle housing bent

Gr25

O

Final drive gear and final drive pinion damaged or improperly engaged

O

Gr27

O O

Difference excessive in degree of wear between left and right tires

O

Left and right tires different in outer diameter

O

Front tire radial and lateral runout, static and dynamic balance incorrect Braking force unbalanced

O O

Valve malfunctioning

Tire pressure excessive

O

O

Pump body faulty

Tire pressure insufficient

Reference Gr

O

Oil pump interior seized

Load excessive forward of load-carrying platform

Noise from oil pump (grinding)

Oil pump oil pressure abnormal

Oil leakage

Steering angle insufficient or different between right and left

Steering wheel does not turn

Steering wheel return not smooth

Steering wheel vibration

Steering wheel pulled to one side

Steering wheel play excessive and unstable

Possible causes

Steering wheel heavy to operate

Symptoms

Gr31

O O

Gr35

37-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Steering Wheel Play Service standards (Unit: mm) Location –

Maintenance item Steering wheel play (measured at outer periphery of wheel)

Standard value

Limit

Remedy

At engine start

5 to 50

–

Replace

Engine stopped

10 to 20

–

Adjust

• With the vehicle placed straight forward, perform the following checks.

1.1 At engine start • Start the engine and gently turn the steering wheel left and right to measure its peripheral play. • If the play deviates from the standard value check tightening points of steering shaft and steering linkage parts as pitman arm to knuckle, and replace those parts if they have any looseness.

1.2 When engine is stopped • Stop the engine and turn the steering wheel left and right within the range where the drag link does not move (tangential force on the periphery: 5 N {0.5 kgf}) to measure its peripheral play. • If the play deviates from the standard value, adjust the play with the adjusting screw of the power steering booster.

2. Steering Column Looseness • Push and pull the steering wheel by hand to check the steering column for looseness. • With the steering column tilted all the way forward, pull the steering wheel backward and check the steering column for looseness. • If the steering column is loose, adjust the tilting and telescoping lever.

3. Inspection of Rods and Arms for Looseness • Check the rods and arms of drag link, pitman arm for damage and looseness. • If any abnormality is found, replace the faulty parts or tighten the parts to the specified torque.

37-10

37 4. Inspection of Power Steering System Mounts for Looseness • Check the mounting sections of power steering oil tank, power steering oil pump and power steering gear assembly for looseness. • Check the connections of hose and pipe for looseness. • If any looseness is found, tighten the loose parts to the specified torque.

5. Inspection and Replacement of Power Steering Oil Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Feed pipe and return pipe

Tightening torque

Remarks

11.8 to 17.6 {1.2 to 1.8}

–

Lubricant and/or sealant Mark –

Points of application Power steering oil tank

Specified lubricant and/or sealant

Quantity

Between MIN Automatic transmission fluid and MAX of (DEXRON, DEXRON II, DEXRON III power steering oil type) tank

5.1 Oil leakage • Check the power steering oil tank, power steering oil pump, power steering gear assembly and hose and pipe connections for oil leak. Check also the hoses for blister due to deterioration, damage and crack. • If any oil leak is found, tighten the connection or replace the faulty parts.

5.2 Oil level check • Check that the hydraulic fluid is within the specified oil level range. • Pour additional fluid if necessary.

5.3 Replacement [Draining] • Jack up the front wheels. • Clean the port areas of feed and return pipes to prevent ingress of dirt, dust, and other foreign matters inside the power steering gear assembly. • Loosen feed and return pipes connected to the power steering gear assembly. • Repeatedly turn the steering wheel fully left and right to drain the fluid from the power steering gear assembly. • After draining the fluid, tighten the feed and return pipes to specified torque.

37-11

ON-VEHICLE INSPECTION AND ADJUSTMENT [Filling] • Pour fluid into the power steering oil tank up to the bottom of the strainer. • Bleed the power steering system of air.

5.4 Air bleeding • Pour fluid into the power steering oil tank up to the bottom of the strainer. • With the engine stopped, jack up the front wheels. • Repeatedly turn the steering wheel fully left and right. When the fluid level has dropped, add enough fluid to maintain the fluid level within the specified range. • Start the engine to idle. • When the fluid level has dropped, stop the engine and add enough fluid to maintain the fluid level within the specified range. • Restart the engine. While checking for a drop in fluid level, turn the steering wheel fully left and right and add fluid as much as necessary. Repeat this practice until the fluid level is stabilized within the specified range. • Turn the steering wheel fully left and right repeatedly.

CAUTION • To avoid seizure of the power steering oil pump, do not keep the steering wheel turned fully to left or right for more than 10 seconds when the engine is running. • Do not rev the engine during air bleeding; otherwise, the power steering pipe may be broken. Run the engine at idle. • If there is any abnormal noise or a fluid level fluctuation, there is likely still some air trapped in the power steering system. Turn the steering wheel several times to raise the fluid temperature to approximately 60 to 80°C. • Stop the engine and wait for approximately five minutes. • Lower the front wheels and turn the steering wheel several times. If there is no noise or fluid level fluctuation, the bleeding of the power steering system is completed. • Repeat starting and stopping the engine several times to remove small air bubbles left in the power steering oil tank. • If air bubbles are not removed completely, drive the vehicle for a while, then check for abnormal noise and oil level fluctuation. • When bleeding is finished, check that fluid in the power steering oil tank is within the specified level range. Also check pipe and hose connections for fluid leaks.

37-12

37 6. Performance Verification Test of Power Steering System Service standards Location

Maintenance item

Standard value

–

Power steering system fluid pressure (with hands off steering wheel)

–

Relief set pressure

Limit

Remedy

490 kPa {5 kgf/cm } or less

–

Repair or replace

10.8 +0.2 –0.3 MPa 2 {110 +2 –3 kgf/cm }

–

Replace

2

• Perform the inspection with the following measuring conditions to verify normal operation of the power steering gear assembly and power steering oil pump. • Install oil pressure gauge capable of measuring upward of 13.2 MPa {135 kgf/cm2} and stop valve between power steering oil pump and power steering gear assembly, then bleed air. • Start engine to idle with stop value fully opened. • Turn steering wheel left and right several times to raise fluid temperature up to 50 to 60°C.

CAUTION • To avoid seizure of the power steering oil pump, never close the stop valve for more than 10 seconds.

6.1 Steering wheel operation check • With the front wheels jacked up, turn the steering wheel all the way in both directions to check that it smoothly moves. • If any abnormality is found, disassemble and repair defective parts.

6.2 Power steering system fluid pressure check • Measure the fluid pressure with hands off the steering wheel. If the measurement deviates from the standard value, check the power steering gear assembly and hydraulic circuit for clogging. If clogging is not found, check the power steering oil pump and replace defective parts.

6.3 Relief set pressure check • With the engine speed gradually increased up to 1000 to 1500 rpm, close the stop valve and measure the maximum fluid pressure. Do not leave the stop valve closed for any longer than 10 seconds. • If the measurement deviates from the standard value, check the power steering oil pump and replace defective parts.

7. Inspection of Drag Link Ball Joint 7.1 Backlash • With the vehicle in the stationary state, move the drag link by the rod in the forward, backward, vertical and lateral directions of the vehicle and check for play at the ball joints with power steering gear assembly and knuckle arm. • If play is excessive, replace the drag link.

7.2 Dust cover • Check the dust cover for excessive wear, cracks and other damage. • Replace the drag link if it is defective.

37-13

STEERING COLUMN

Removal sequence 1 2 3 4 5 6 7

37-14

Horn pad Steering wheel Front column cover Rear column cover Combination switch Twist-off bolt Starter switch

8 9 10 11

*a::

Steering column (See later section.) Dust cover Dust cover Dust cover Power steering gear assembly Non-reusable parts

37 Installation sequence Follow the removal sequence in reverse. • After installation, check the steering column for looseness. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Nut (steering column and power steering gear assembly mounting)

22 to 31 {2.2 to 3.2}

–

Nut (steering wheel mounting)

39 to 49 {4.0 to 5.0}

–

Screw (combination switch mounting)

2.5 ± 0.5 {0.25 ± 0.05}

–

Twist-off bolt (starter switch mounting)

14.2 ± 1.5 {1.4 ± 0.15}

–

17 to 25 {1.7 to 2.6}

–

Bolt (steering column mounting)

Lubricant and/or sealant Mark

Points of application Contact ring under steering wheel Horn contact piece on combination switch side

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Work before removal Alignment mark: Steering column and power steering gear assembly • Provide alignment marks on the steering column and power steering gear assembly.

Removal procedure Removal: Horn pad • Lift up the horn pad by the forward edge to remove from the steering wheel.

Removal: Front column cover

37-15

STEERING COLUMN Removal: Starter switch • Drill a hole of 5.5 to 6 mm in diameter to a depth of 10 to 15 mm in the twist-off bolt. • Using the drilled hole, screw the screw extractor counterclockwise into the twist-off bolt and remove it.

Removal: Steering column • To remove the steering column, remove the nut connecting it to the power steering gear assembly, along with the mounting bolts in the cab.

Installation procedure Installation: Steering column • If the spline is off the steering column, assemble it with the yokes facing in the same direction. • Install the steering column using the illustrated bolts. The threaded portion of these bolts is elliptical for grounding the horn circuit properly.

Installation: Starter switch • Install the starter switch using new twist-off bolts. Tighten the bolts to specified torque to snap off their heads.

37-16

37 M E M O

37-33

37 Installation: Steering wheel • Align the three holes of the steering wheel with three protrusions of the cancel cam on the combination switch to attach the steering wheel.

Inspection after installation Inspection: Noise from steering wheel • Lightly turn the steering wheel left and right and check for noise and other abnormalities. • If any abnormality is found, disassemble the steering wheel, remove the cause and reinstall.

37-17

STEERING COLUMN Steering Column

37-18

37 Disassembly sequence 1 2 3 4 5 6 7 8

9 10 11 12 13

Lever cover Lever protector Pin Lock lever Lever shaft nut Lever shaft bolt Spacer Pin

Collar Tilting and telescoping lever Spring Steering column support Steering column

*a:

Link plate : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Screw (lever cover mounting) Nut (lock lever mounting)

Tightening torque

Remarks

1.0 to 1.5 {0.1 to 0.15}

–

3.9 to 5.9 {0.4 to 0.6}

Nut (tilting and telescoping lever mounting)

– –

Bolt (lock lever mounting)

16 to 20 {1.6 to 2.0}

–

Nut (steering column support mounting)

9 to 14 {0.9 to 1.4}

–

Lever shaft nut

35 ± 2.0 {3.6 ± 0.2}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Friction surface of pin Friction surface of collar Staked area of link plate Friction surface and thread of bolt Friction surface of spacer Friction surfaces of steering column support and steering column Thread area of lever shaft nut Friction surface of lever shaft bolt

Work before removal Alignment mark: Nut and lock lever • Be sure to provide alignment marks on the lock lever and nuts before removal.

37-19

STEERING COLUMN Installation procedure Installation: Lock lever • Install the lock lever flush with the lever shaft nut, with the welded part facing in the illustrated direction.

Inspection after installation Inspection: Tilting and telescoping lever operating force • Tilt the steering column all the way forward and telescope it to the mid-point of the movable range. • Push the tilting and telescoping lever in and lock the steering column. In this state, check that the force required to operate the tilting and telescoping lever is 140 N {14 kgf} or more. • Push the steering column forward by hand to check that it is securely held. • Adjust the installed position of the lock lever if necessary.

Adjustment: Lock lever • Loosen nut A. • Move the lock lever to relocate the nut A in the slot from the alignment mark in the arrow direction, then tighten the nut A in that position.

°

37-20

• If the nut A is already at the end of the slot in the lock lever and cannot be relocated, remove the lock lever and turn the nut B one serration (10°) from the alignment mark in the arrow direction, then reinstall the lock lever. • Adjust the tightening position of the nut A so that the tilting and telescoping lever operating force becomes 140 N {14 kgf} or more.

37 M E M O

37-21

POWER STEERING GEAR ASSEMBLY AND DRAG LINK

Removal sequence 1 Drag link 2 Return pipe <M17 × 1.5> 3 Feed pipe <M16 × 1.5>

4 Power steering gear assembly (See later section.) : Non-reusable parts

CAUTION • When removing the drag link, take care not to deform or damage the dust cover. • Do not attempt to disassemble the drag link because it is of unit construction.

Installation sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location 1

Maintenance item Ball joint of drag link

Play (± 980 N {± 100 kgf} loaded) Rotation torque

Standard value

Limit

0 to 0.15

–

0.1 to 5.9 N·m {0.01 to 0.6 kgf·m}

–

Remedy Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (drag link mounting) Feed pipe and return pipe Nut (power steering gear assembly mounting) Bolt (power steering gear assembly mounting)

37-22

Tightening torque

Remarks

137 to 196 {14 to 20}

–

11.8 to 17.6 {1.2 to 1.8}

–

83.5 to 108 {8.5 to 11}

–

37 Lubricant and/or sealant Mark

Points of application Lip area of drag link ball joint dust cover

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Inspection procedure Inspection: Drag link (1) Play • Fix the drag link with a vise.

CAUTION • Take care not to deform or damage the dust cover when fixing it with a vise. • The position of the ball joint with applying no load is adjusted to standard position. • Measure each play of the ball joint with applying the specified push and pull load from the standard position. • Total each play and if the total deviates from standard value, replace the tie rod end. (2) Rotation torque • Install the drag link mounting nut on the drag link. • Install the socket, adapter and torque wrench to measure the rotation torque. • If the measurement value deviates from the standard value, replace the drag link.

(3) Dust cover • Check the dust cover for wear, cracks and other damage. These abnormalities may cause water infiltration to the ball joint and wear out it at early stage. • If any abnormality is found in the dust cover, replace the drag link.

Installation procedure Installation: Drag link • Align a slot in the lock nut with the split pin hole in the ball joint by turning the lock nut in the tightening direction while checking the torque is within the specified range, then install the split pin as shown in the illustration.

37-23

POWER STEERING GEAR ASSEMBLY AND DRAG LINK Power Steering Gear Assembly

37-24

37 Disassembly sequence 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

Pitman arm Dust cover Needle bearing Y-packing Backup ring O-ring Side cover Retainer Adjusting screw Sector shaft

• Do not remove parts marked

21 22 23 24 25 26 27

Dust cover Ball tube clip Ball tube Steel ball Plug O-ring Seal ring Piston Worm shaft assembly O-ring

Valve housing Oil seal Backup ring Y-packing Needle bearing O-ring Body

: Non-reusable parts

unless absolutely necessary.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Repair kit

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

0.88 N·m {0.09 kgf·m} or less

–

0 to 0.25 N·m {0 to 0.025 kgf·m}

–

0.15 to 0.78 N·m {0.015 to 0.08 kgf·m}

–

0 to 0.1

–

Adjusting screw side

φ34.975

φ34.875

Pitman side

φ44.975

φ44.875

0 to 0.5

–

Replace

0.11

0.16

Replace

Starting torque –

Power steering gear assembly

Engagement torque Normal turning torque

9, 10 10

Axial play between sector shaft and adjusting screw Sector shaft outer diameter

18, 19

Play in diametric direction between piston and worm shaft assembly

18, 27

Clearance between piston and body

Remedy

Adjust

Replace Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

294 to 343 {30 to 35}

–

Bolt (sector shaft mounting)

53.9 to 63.7 {5.5 to 6.5}

–

Nut (adjusting screw tightening)

63.7 to 73.5 {6.5 to 7.5}

–

Lock nut (pitman arm fastening)

Bolt (valve housing attaching) Screw (ball tube clip fitting) Plug

53.9 to 63.7 {5.5 to 6.5}

–

4.41 to 5.39 {0.45 to 0.55}

–

147 to 166 {15 to 17}

–

37-25

POWER STEERING GEAR ASSEMBLY AND DRAG LINK Lubricant and/or sealant Mark

Points of application Nut contact surface of side cover Thread area of adjusting screw

Specified lubricant and/or sealant

Quantity

HERME-SEAL 101Y or ThreeBond 1102

As required

Multi-purpose grease [NLGI No. 2 (Li soap)]

As required

Inner periphery of backup ring Inner periphery of Y-packing Inner periphery of retainer Adjusting screw contact surface of sector shaft Inner surface of ball tube

Special tools (Unit: mm) Mark

Tool name and shape

Preload socket

Part No.

Application

MH064110 (MB991006)

Measurement of power steering gear assembly starting torque

Pitman arm puller A

B

49

76

MH062472

Removal of pitman arm

MH062881 *910-21719

Forming of backup ring

MH063814 *910-11004

Forming of backup ring and installation of oil seal

MC811948 *910-21200

Removal of O-ring and seal ring

Insert tool assembly A

B

C

D

φ35

φ25

53.5

φ33

Insert tool assembly

Needle A

B

120

φ3

*: Hitachi Automotive systems steering part numbers

37-26

37 Mark

Tool name and shape

Part No.

Application

Bar A

B

φ12.5

40

MH063815 *910-22813

Turning of retainer

MH063816 *910-21803

Crimping of retainer

MH063812 *910-21730

Forming of piston seal ring

MH062880 *910-21716

Forming of backup ring

Squeeze tool

A

B

C

D

E

F

5

8

18

φ30

4

160

A

B

C

φ98

52

φ85.05

Insert tool

Insert tool A

B

C

D

φ45

φ20

45

φ33

*: Hitachi Automotive systems steering part numbers

Inspection before removal Inspection: Starting torque • Using , measure the starting torque of the power steering gear assembly for reference at the time of reassembly before removal. A: Starting torque (= engagement torque + normal turning torque) B: Engagement torque C: Normal turning torque

°

37-27

POWER STEERING GEAR ASSEMBLY AND DRAG LINK Removal procedure Removal: Pitman arm

Removal: Sector shaft • Before removing, set the sector shaft in neutral position as follows. • Turn the worm shaft assembly counterclockwise into the lock position, then turn it back roughly 2.6 turns to bring the serration missing part of the serrated portion of the sector shaft parallel with the center of the body as shown.

• Loosen nut and remove the sector shaft by tapping the shaft end with a plastic hammer. • The sector shaft cannot be removed if it is not in the neutral position. In this case, bring the shaft into the neutral position before making another removal attempt. Do not try to force the shaft out by striking it hard with a plastic hammer.

Removal: Side cover • Remove the side cover by screwing in the adjusting screw.

37-28

37 Removal: Retainer • Undo the crimp of the retainer (at 2 points) using a chisel.

Removal: Valve housing • Remove the valve housing from the body.

CAUTION • Take care so that balls in the worm shaft assembly do not pop out. • Take care not to scratch or otherwise damage the inner surface of the body and piston.

Removal: Ball tube and steel ball • First remove steel balls from the piston, then remove ball tube clip. Hold the ball tube between fingers and remove it from the piston moving it lightly.

CAUTION • Be careful not to lose the steel balls (28 pieces in all).

Removal: Piston • Holding the valve housing and worm shaft assembly with the piston downward, turn the worm shaft assembly and remove the piston.

CAUTION • Be careful not to tilt the piston during removal. If it is tilted, the steel balls will fall off the race of the piston and the worm shaft assembly, into the piston.

37-29

POWER STEERING GEAR ASSEMBLY AND DRAG LINK Inspection procedure Inspection: Side play of piston and worm shaft assembly • Apply a force of 49 N {5.0 kgf} to the illustrated point A and measure play B (play in the diametric direction) of the valve housing and worm shaft assembly. • If the measurement exceeds the limit, replace the faulty parts.

Installation procedure Installation: Backup ring and Y-packing • Fill grease in the groove of Y-packing and install Y-packing in the illustrated direction. • Install backup ring, formed as shown, using and .

Installation: Oil seal • Install the oil seal to the body in the illustrated direction.

Installation: Seal ring and O-ring • Install seal ring and O-ring in the outer surface grooves of the piston, and form the seal ring to fit in place using .

37-30

37 Installation: Ball tube • Pack grease in one half of the ball tube, place 10 to 11 steel balls in it and put the other half on it. • Place the piston on a flat workbench, align the positions of the valve housing and piston ball race, then while turning the worm shaft assembly, let steel balls fall from the ball tube hole.

CAUTION • Do not draw out the valve housing, worm shaft assembly until its end passes over the ball tube hole during installation, otherwise the steel balls will come out of the ball race.

Installation: Valve housing • Position the gear toothed portion of the valve housing in the illustrated direction so that it engages with the sector shaft. • Install the valve housing to the body, lightly holding it with your hand so that its gear portion does not turn out of position. When installing, align the oil passage ports of the valve housing and body.

CAUTION • Be careful not to damage the seal ring on the piston and the inner surface of the body. Installation: Retainer • Pack grease in the adjusting screw mounting hole on the sector shaft. • Install the adjusting screw into the sector shaft. • Using , tighten the retainer into place in the sector shaft. • Back up the retainer by 180°, retighten it to a torque of 39 N·m {4 kgf·m}, then back it up again by 20°. • Check that the adjusting screw turns smoothly.

•

Using

, crimp the retainer at two places.

37-31

POWER STEERING GEAR ASSEMBLY AND DRAG LINK Installation: Sector shaft • Set the sector shaft in the neutral position and install it into the body. • When installing the sector shaft, cover up its threaded end and serration portions for protection. • Turn the worm shaft assembly to check that it makes roughly five turns lock to lock. • If the number of turns is less, check engagement of the worm shaft assembly with the sector shaft, and correct if necessary.

Adjustment after installation Inspection: Starting torque [Inspection] • Using , measure the starting torque of the power steering gear assembly in the same manner as the measurement before removal. If the measurement deviates from the standard value, adjust the power steering gear assembly for proper starting torque or replace.

[Adjustment] • Loosen nut. • Rotating the worm and stub shaft approximately 1/4 turns left and right, make adjustment for proper starting torque with the adjusting screw.

37-32

POWER STEERING OIL PUMP

Disassembly sequence 1 2 3 4 5 6 7

8 9 10 11 12 13 14

Feed hose Supply hose Suction connector O-ring Pin Cover Cartridge assembly

15 16 17 18 19

Vane Rotor Cam ring O-ring Side plate O-ring Connector

Flow control valve Flow control spring O-ring O-ring Body

: Non-reusable parts

• Do not attempt to the disassemble the flow control valve and body because they are of unit construction. • See Gr11 for removal and installation of the power steering oil pump.

Assembly sequence Follow the disassembly sequence in reverse. Repair kit: Seal repair kit

Service standards (Unit: mm) Location 6

Maintenance item Stepped wear on rotor and vane contact surfaces of cover

Standard value

Limit

Remedy

–

0.05

Replace*

0.01

0.06

Replace

–

0.05

Replace*

8, 9

Clearance between vane and rotor

12

Stepped wear on rotor and vane contact surfaces of side plate

15

Air leakage of flow control valve (applying air pressure 390 to 490 kPa {4 to 5 kgf/cm2})

0 dm3 {0 L}

–

Replace*

Clearance between flow control valve and body

0.01 to 0.02

0.03

Replace*

36.5

33.5

Replace

15, 19 16

Free length of flow control spring

*: Replace the power steering oil pump.

37-34

37 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (hose mounting) Clamp Bolt (cover mounting) Connector Bolt (suction connector mounting)

Tightening torque

Remarks

29.4 to 39.2 {3 to 4}

–

2.9 to 3.4 {0.3 to 0.35}

–

22 to 26 {2.2 to 2.7}

–

49 to 69 {5.0 to 7.0}

–

7.8 to 11.8 {0.8 to 1.2}

–

Lubricant and/or sealant Mark

Points of application Bushing of cover

Specified lubricant and/or sealant

Quantity

Automatic transmission fluid (DEXRON, DEXRON II, DEXRON III type)

As required

Inspection procedure Inspection: Cover • Check if there is not stepped wear or scratch that causes fingernail to catch on the sliding surface of the rotor and vane. If any abnormality is found, replace the power steering oil pump.

Inspection: Vanes and rotor • Check if there is not scratch or wear on the sliding surface of the cover and the side plate by watching and touching. • Check if there is not scratch on the slit surface of the rotor and the vanes by watching and touching. • Install each vane on the rotor with its rounded end facing out, and check all vanes for smooth movement. • Apply light to the rotor with installing the vanes and check if there is not light leakage from the slit between the vane and rotor. • If any abnormality is found, replace the cartridge assembly.

37-35

POWER STEERING OIL PUMP Inspection: Side plate • Check if there is not stepped wear or scratch that causes fingernail to catch on the sliding surface of the rotor and vane. If any abnormality is found, replace the power steering oil pump.

Inspection: Flow control valve and body (1) Air leakage of flow control valve • • • •

Block the port A of the flow control valve by the finger. Apply the specified air pressure to port B. Check if there is not air leakage from port C. If any abnormality is found, replace the power steering oil pump.

(2) Inspection of aspect of flow control valve and body • Check if there is not scratch, wear or edge on the sliding surface of the body and the flow control valve by watching and touching. • If any abnormality is found, replace the power steering oil pump. (3) Flow control valve-to-body clearance • If the measurement exceeds the limit, replace the power steering oil pump.

Installation procedure Installation: Cam ring • Install the cam ring in the illustrated direction to the body.

Installation: Vane • Fit the vane into the rotor, with its round edge facing toward outside.

37-36

37

POWER STEERING OIL TANK

Removal sequence 1 2 3 4

5 Cap 6 Strainer 7 Body

Supply hose Return hose Hose Hose

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Clamp

Tightening torque

Remarks

2.0 to 2.5 {0.20 to 0.25}

–

Installation procedure Installation: Hose • Fit clamps onto the hose oriented in the illustrated direction.

37-37

GROUP 41 BUMPER, FRAME SPECIFICATIONS............................................................................... 41-2 STRUCTURE AND OPERATION 1. Frame ........................................................................................... 41-3 FRONT BUMPER................................................................................ 41-4 FRAME ................................................................................................ 41-6

41-1

SPECIFICATIONS Item Frame type Cross section configuration of side rail

41-2

Specifications Ladder type shaped (open) channel section

STRUCTURE AND OPERATION

41

1. Frame

• The frame has cross members fastened to the web of the side rails (lateral linkage) so that stress on the joints is minimal. This allows joint rivets to maintain tightness and ensures long-lasting high torsional rigidity. • Unlike vertical linkage where cross members are fastened to the flange of side rails, no rivets appear on top of the frame, greatly facilitating body mounting.

41-3

FRONT BUMPER

Removal sequence 1 Front bumper 2 Fog lamp 3 Bumper stay

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (bumper stay mounting) Bolt (fog lamp mounting) Nut (front bumper mounting)

Tightening torque

Remarks

45 to 54 {4.6 to 5.5} 4 to 6 {0.4 to 0.6}

–

26 to 31 {2.7 to 3.2}

Installation procedure Installation: Bumper stay • Install the bumper stay on the frame by tightening the bolts (four places) to the specified torque in the order of the numbers (1 to 4) indicated in the illustration.

41-4

41 M E M O

41-5

FRAME

: Non-reusable parts

CAUTION • Since the mounting bolts or nuts are tightened by a torque-to-yield method, they must not be reused.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

M10 bolt or nut

60 to 80 {6 to 8}

–

M12 bolt or nut

98 to 120 {10 to 12}

–

Inspection procedure Inspection: Frame • Thoroughly remove mud, grease, rust etc. from the outer and inner surfaces of the frame. (1) Inspection for deformation • If deformation or any other defect is found, repair the frame. (2) Inspection for cracks • Remove paint from suspected areas and carefully inspect exposed surfaces for cracks. • If visual inspection is difficult, perform dye check or any other suitable examination. If a crack is found, repair as follows.

41-6

41 (3) Repair of crack in frame • With the vehicle unloaded, level the frame. • Drill a hole with a diameter roughly twice the thickness of the frame plate, 10 mm from the inside end of the crack. • If the crack is within the frame plate, drill holes at both ends of the crack.

• If the edges of the crack are uneven, even them out.

• Using a grinder, cut a 90° V-channel at the crack to a depth of approximately 2/3 of the frame plate thickness, then fill the channel with filler metal by welding.

CAUTION • Avoid gas welding because heat embrittles the material of welded area. Be sure to use electric welding. • Electric welding could allow the welding current to reverse through ground circuit and burn electrical components. To prevent this, be sure to disconnect negative cable from the battery and ground the welding machine at a point near the weld zone before work. • For electric welding, follow other precautions given elsewhere. • If there are any combustibles, such as pipeline, wiring harness, rubber part and fuel tank, near the weld zone, be sure to cover them for protection. • Use low-hydrogen type coated CO2 and arc welding electrodes for welding and check that there are no harmful defects such as undercut and blow hole after welding. • Preheat the area around weld zone to approximately 50 to 350°C before welding when the workshop temperature is below 0°C. • Be sure to protect mountings that may be affected by heat, such as main sills, using heat insulators or the like.

41-7

FRAME • Next, make a similar V-channel on the opposite side of the weld and fill it with filler metal, also by electric welding as well. At the same time, deposit metal to cover up the hole or holes at both ends of the crack by welding. • In cold climates, heat the weld zone to approximately 200°C after welding. • After welding, run a grinder over the bead at right angles A to remove the hatched portion from the weld on each side of the plate. • Finish the ground surfaces flat to a thickness equal to the original plate thickness.

[Repairing crack from rivet or bolt hole] • To make the edges of the cracked hole even, temporarily tighten the bolt in the hole. • First, weld to close the crack at a point at least 20 mm apart from the center of the bolt. For this welding, refer to the aforementioned welding procedures for crack repair. • Remove the temporary bolt. After making hole edges even, weld to close the rest of the crack B. Simultaneously fill the hole with weld metal. • Drill a hole at the location of original hole, and install a rivet or bolt in it. [Repairing using reinforcement plate] • To prevent the concentration of welding stress at both ends C of the reinforcement plate, cut the ends at a bevel of 30° or less for welding. Do not weld at points D. • The reinforcement plate must have enough to cover the cracked area. • Reinforcement plate thickness: Equal to frame plate thickness • Reinforcement plate material: As specified below or equivalent SAPH440 (Hot rolled steel for automobiles), or SS400 (Rolled steel for general structures) • After welding, heat the hatched area to 600 to 700°C.

CAUTION • Be sure to protect mountings that may be affected by heat, such as main sills, using heat insulators or the like.

41-8

41 (4) Inspection of rivets for looseness • Lightly tap the head of each rivet using an inspection hammer and feel or listen for the echo to determine if the rivet is loose. • Rusting between rivet and frame plate is an indication of loosened rivet.

CAUTION • Be sure to replace loose rivets. They could break off or allow cracks to develop from the rivet holes, leading to an accident. (5) Replacement of rivet • To remove a loosened rivet, eliminate its head using a drill or grinder. When a drill is used, make a dent in the middle of the rivet’s head and align the drill bit with the dent as shown. • The rivet hole must be intact.

• Before riveting, clamp the two plates closely together near the rivet hole using a C vice. • Using a riveting machine, drive the rivet (cold rivet) into the rivet hole. • If riveting is unfeasible, ream the rivet hole, drive a reamer bolt into the hole, fully tighten the nut, then weld it in place. Similarly to the reamer bolt and nut, you can also use a flange bolt and a flange nut.

(6) Inspection of bolts and nuts for looseness • Inspect the bolts attaching cross members to the side rails for looseness. If any loose bolt is found, retighten it to specified torque. (7) Drilling hole in frame • When required to drill holes in the frame, heed the following warning. • When drilling holes in the side rail, avoid the illustrated ranges A to prevent cracking. • Grind the edge of drilled hole smooth. • Avoid drilling a hole in the vicinity of a point where the rigidity of the side rail change sharply, such as an area near the joint to the cross member or an end of the stiffener. • The diameter of drilled holes must be 11 mm or smaller and the hole-to-hole distance must be 20 mm or larger.

41-9

GROUP 42 CAB MOUNTING, TILT SPECIFICATIONS............................................................................... 42-2 STRUCTURE AND OPERATION 1. Front Cab Mounting ...................................................................... 42-3 2. Rear Cab Mounting ....................................................................... 42-4 3. Cab Tilt Link ..................................................................... 42-5 TROUBLESHOOTING ........................................................................ 42-6 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Adjustment of Cab Tilt System ......................................... 42-8 REMOVAL AND INSTALLATION OF CAB ............................................................................................ 42-10 ............................................................................................ 42-14 FRONT CAB MOUNTING ............................................................................................ 42-18 ............................................................................................ 42-20 REAR CAB MOUNTING ............................................................................................ 42-22 ............................................................................................ 42-23 CAB TILT LINK ................................................................... 42-24 CAB STAY ........................................................................... 42-26

42-1

SPECIFICATIONS Cab Specifications

Item Tilt type

FE84

FE85

Tilt type cab

Fixed type cab

Kind

Wide cab

Mass

kg

410

420

Cab Mounting Item

Specifications

Type

Fixed type

Kind

Rubber cushioned mounting

Cab Tilt System Item Type Tilt angle Cab tilt lock

42-2

Specifications Torsion bar type 45° Manually operated hook type

STRUCTURE AND OPERATION

42

1. Front Cab Mounting

• The operating physical force for the cab tilt system can be adjusted using the adjusting bolt of the front mounting bracket. • The front rubber cushion reduces the vibration and noise of the cab.

42-3

STRUCTURE AND OPERATION 2. Rear Cab Mounting

• The operating physical force for the lock handle can be adjusted by increasing and decreasing the number of spacers provided between anchor hook and cab hold bracket. • Rear mounting upper and lower rubber cushions reduce the vibration and noise of the cab.

42-4

42 3. Cab Tilt Link

• The length of center rod is adjustable with the adjusting nut.

42-5

TROUBLESHOOTING

Possible causes CabFront cab mounting related prob- Rear cab mounting lems Cab improperly mounted

Engine-related problems

Transmission-related problem

Front mounting bracket loose, play Sagging of front rubber cushion

O

Sagging of mounting rubber cushion

O O

Propeller shaft inclination angle excessive due to increased tilt angle caused by deteriorated engine mounting

O

Engine improperly mounted

O

Intake and exhaust system components improperly installed

O

Gr15

Transmission improperly mounted

O

Gr22

Propeller shaft runout excessive

O

Universal joint excessively worn

O

Backlash excessive at slip yoke joint

O O

Wheel and tire-related problems

Front suspension-related problem Brake-related problems

42-6

Sympathetic vibrations from axle seat

Gr11

Gr25

O

Angle at propeller shaft joint excessive due to increased tilt of drive axle caused by overloading

Rear axle-related problems

Reference Gr

O

Propeller shaft-related problems Center bearing play excessive Angle at propeller shaft joint excessive due to deteriorated center bearing rubber cushions or other causes

Front axle-related problem

High-frequency vibration (above 20 Hz) and noise in cab and steering wheel

Symptoms

Cab shimmy (vibration with pitching and rolling)

Cabs in General

O O

Gr26

Reduction gears in poor mesh

O

Differential gears in poor mesh

O

Wheel and tire runout excessive

O

Wheels and tires out of balance

O

Use of tires different in size or type

O

Wheel mounting surface deformed

O

Friction excessive between spring leaves

O

Brake drum out of balance

O

Brake drum eccentric

O

Gr27

Gr31

Gr33 Gr26, Gr27

42

Possible causes

Cab fails to tilt up

Symptoms

Main hook not released

O

Safety hook not released

O

Torsion bar damaged or fatigued

O

Main hook does not engage with hook pin bracket

Cab cannot lock on rear mounting post.

Manual Cab Tilt System

Reference Gr

O

42-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Adjustment of Cab Tilt System Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Lock nut (anchor hook fitting)

Tightening torque

Remarks

83 to 98 {8.5 to 10}

–

Lubricant and/or sealant Mark –

Points of application Sliding area of lock handle and link

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

1.1 Adjustment of lock handle operating physical force [Inspection] • If the lock handle is excessively light to operate, make adjustment as follows. • If the lock handle is excessively heavy, apply grease to the sliding contact area of handle and link, then operate the handle again for physical operating force. If the lock handle is still heavy, make adjustment as follows. [Adjustment] • Remove the lock nut, then remove the anchor hook. • Adjust the operating physical force increasing or decreasing the number of spacers between anchor hook and cab hold bracket as follows. Number of spacers If lock handle feels too heavy

Increase

If lock handle feels too light

Decrease

• After adjustment, tighten the lock nut to the specified torque.

CAUTION • If the lock handle feels too light, it is an indication that the handle could be easily unlocked by the vibration of the running vehicle.

1.2 Adjustment of latch • If the latch resists, loosen bolts and adjust the installed position of the lock handle using bolt slot. • After adjustment, retighten the bolts.

42-8

42 M E M O

42-9

REMOVAL AND INSTALLATION OF CAB Removal sequence 1 Anchor lever 2 Cab

WARNING • During removal and installation of the cab, the parking brake is not available for holding the vehicle at a standstill. Therefore, be sure to apply chocks to the tires to ensure that the vehicle does not move. • Never remove the chocks until all the operations are completed. • Disconnect all cables, hoses and wires before removal and installation of the cab.

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

59 to 83 {6 to 8.5}

–

Bolt (anchor lever attaching)

34 to 54 {3.5 to 5.5}

–

Bolt (cab mounting)

100 to 120 {10 to 12}

–

Lock nut (anchor lever adjusting bolt locking)

Removal procedure Removal: Cab • Tilt the cab and then engage the stopper with the lock lever to securely lock the cab stay.

42-10

42 • Remove the bolt A, then detach the anchor lever. • Remove the bolts B holding the cab in place.

• Supporting the tilted cab with the crane, remove the cab stay.

• Lower the cab all the way, then remove bolt.

• Make sure to use a sling that is rigid enough to carry the weight of the cab. • The hook portion of the sling must be lined with a rubber piece as shown to prevent deformation of the roof of the cab.

42-11

REMOVAL AND INSTALLATION OF CAB • Hook the sling on the cab roof as shown, then hoist the cab a little to see if it maintains level (balanced at the center of gravity). • Provide alignment marks on the power steering gear assembly and steering column, then separate the steering column. • To prevent the steering column from falling off, tie it securely to the cab using a rigid cord. • Slowly and slightly hoist the cab straightly up to check that all cables, hoses and electric wiring have been disconnected before removing the cab.

WARNING • While the cab is up in the air, be sure to stay out from under it.

Installation procedure Installation: Cab • Hook the sling at center-of-gravity points on both sides of the cab roof, and lift the cab.

• Slowly lower the cab halfway. • Join the power steering gear assembly and steering column together in accordance with the alignment marks.

• Further lower the cab slowly to mount in position, then unhook the sling. • Tighten bolts in the drawing to specified torque.

42-12

42 • Before tilting, support the cab using the crane. • Tilt the cab with the crane, and install the cab stay.

WARNING • Be careful not to tilt the cab more than necessary. Doing so is extremely dangerous because it causes the cab to fall down forward.

• After installing the cab stay, tilt the cab and engage the stopper with the lock lever to securely lock the cab stay. Then, remove the crane from the cab.

• Tighten the bolts A to specified torque. • Align the graduated line of the anchor lever to the illustrated range of D (long division) of the scale graduated on the mounting bracket, then install the bolt B handtight. • Tighten the bolt C until it comes in contact with the anchor lever. Then, further screw in the bolt C 10 mm (6 and 2/3 turns) and tighten the lock nut to the specified torque. • Tighten the handtight bolt B to specified torque.

42-13

REMOVAL AND INSTALLATION OF CAB Removal sequence 1 Plate 2 Plate 3 Cab

*a:

Rear mounting post

WARNING • During removal and installation of the cab, the parking brake is not available for holding the vehicle at a standstill. Therefore, be sure to apply chocks to the tires to ensure that the vehicle does not move. • Never remove the chocks until all the operations are completed. • Disconnect all cables, hoses and wires before removal and installation of the cab.

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

100 to 120 {10 to 12}

–

Nut (cab mounting)

39 to 59 {4 to 6}

–

Bolt (cab mounting)

70 to 95 {7.1 to 9.7}

–

Bolt (cab mounting)

42-14

42 Removal procedure Removal: Cab • Remove bolts from inside and outside the cab.

• Remove nuts from the rear mounting post.

• Make sure to use a sling that is rigid enough to carry the weight of the cab. • Line the hook portion of each sling with a rubber piece to prevent deformation of the roof of the cab.

• Hook the sling on the cab roof as shown, then hoist the cab a little to see if it maintains level (balanced at the center of gravity). • Provide alignment marks on the power steering gear assembly and steering column, then separate the steering column. • To prevent the steering column from falling off, tie it securely to the cab using a rigid cord. • Slowly and slightly hoist the cab straightly up to check that all cables, hoses and electric wiring have been disconnected before removing the cab.

WARNING • When the cab is up in the air, be sure to stay out from under it.

42-15

REMOVAL AND INSTALLATION OF CAB Installation procedure Installation: Cab • Hook the sling at center-of-gravity points on both sides of the cab roof, and lift the cab.

• Slowly lower the cab halfway. • Join the power steering gear assembly and steering column together in accordance with the alignment marks.

• Further lower the cab slowly into place. Then unhook the slings and tighten bolts and nuts to specified torques.

42-16

42 M E M O

42-17

FRONT CAB MOUNTING

Disassembly sequence 1 2 3 4 5 6 7

Anchor lever Torsion bar Front mounting bracket, right-hand Side cushion Bushing Front rubber cushion Front floor cross member

8 9 10 11

Side cushion Bushing Front rubber cushion Front mounting bracket, left-hand

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

100 to 120 {10 to 12}

–

59 to 83 {6 to 8.5}

–

Bolt (anchor lever attaching)

34 to 54 {3.5 to 5.5}

–

Bolt (front mounting bracket attaching)

200 to 270 {20 to 28}

–

Bolt (cab mounting) Nut (anchor lever adjusting bolt tightening)

Lubricant and/or sealant Mark

Points of application Both serrated end portions of torsion bar Front floor cross member contact surface of side cushion

42-18

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Rubber grease

As required

42 Installation procedure Installation: Side rubber cushion and front rubber cushion • Fit the front rubber cushion to the front mounting bracket at an angle within the illustrated range. • After installing the front rubber cushion, fit the side rubber cushion to it and fill grease in the side rubber cushion as shown.

42-19

FRONT CAB MOUNTING

Disassembly sequence 1 2 3 4 5 6

Front mounting bracket, right-hand Side cushion Bushing Front rubber cushion Front floor cross member Side cushion

7 Bushing 8 Front rubber cushion 9 Front mounting bracket, left-hand : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (cab mounting)

Tightening torque

Remarks

70 to 95 {7.1 to 9.7}

–

Bolt (front mounting bracket attaching)

200 to 270 {20 to 28}

–

Bolt (cab mounting)

100 to 120 {10 to 12}

–

Lubricant and/or sealant Mark

42-20

Points of application

Specified lubricant and/or sealant

Quantity

Front floor cross member contact surface of side cushion

Rubber grease

As required

42 Installation procedure Installation: Side rubber cushion and front rubber cushion • Fit the front rubber cushion to the front mounting bracket at an angle within the illustrated range. • After installing the front rubber cushion, fit the side rubber cushion to it and fill grease in the side rubber cushion as shown.

42-21

REAR CAB MOUNTING Disassembly sequence 1 Rear mounting lower rubber cushion 2 Pipe 3 Anchor hook 4 Spacer 5 Side rubber cushion 6 Cab hold bracket 7 Rear mounting upper rubber cushion 8 Rear mounting post : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Lock nut (anchor hook attaching)

83 to 98 {8.5 to 10}

–

Nut (side rubber cushion attaching)

10 to 15 {1.0 to 1.5}

–

Bolt (rear mounting post attaching)

78 to 108 {8 to 11}

–

Installation procedure Installation: Anchor hook • Fit the anchor hooks to the bracket as shown in the illustrations.

CAUTION • When the cab is tilted down with installing the anchor hooks in wrong direction, the links installed in the cab can not hook to the anchor hooks and it may damage both of the anchor hooks and the links.

42-22

42

REAR CAB MOUNTING Disassembly sequence

1 Plate 2 Rear mounting lower rubber cushion 3 Pipe 4 Cone point bolt 5 Plate 6 Rear mounting upper rubber cushion 7 Rear mounting post : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (rear mounting post attaching) Nut (cone point bolt installing) Lock nut (cab mounting)

Tightening torque

Remarks

78 to 108 {8 to 11}

–

39 to 59 {4 to 6}

–

83 to 98 {8.5 to 10}

–

42-23

CAB TILT LINK

Disassembly sequence 1 2 3 4

5 Link (left-hand)

Lock handle Center rod Link (right-hand) Safety hook

*a:

Anchor hook

Assembly sequence Follow the disassembly sequence in reverse. • After assembly, adjust the lock handle operating physical force. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Lubricant and/or sealant Mark

Points of application Contact of link of anchor hook

42-24

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

42 Installation procedure Installation: Center rod • Operate the lock handle in the illustrated direction to unlock the left-hand and right-hand links. • Adjust the center rod nut to bring the shafts of left-hand and right-hand links into contact with brackets.

42-25

CAB STAY WARNING • Before removing the cab stay, be sure to support the cab with a crane or the like so that it does not fall during work.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (cab stay mounting)

42-26

Tightening torque

Remarks

59 to 78 {6 to 8}

–

GROUP 43 DOOR SPECIFICATIONS............................................................................... 43-2 STRUCTURE AND OPERATION 1. Front Door Lock System ............................................................... 43-3 2. Front Door Glass Opening and Closing Mechanism ..................... 43-3 TROUBLESHOOTING ........................................................................ 43-4 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Adjustment of Front Door Alignment ............................................ 43-5 FRONT DOOR..................................................................................... 43-7

43-1

SPECIFICATIONS Item Door lock system Front door

43-2

Door glass opening and closing mechanism

Specifications Manual Manual control type

STRUCTURE AND OPERATION

43

1. Front Door Lock System

2. Front Door Glass Opening and Closing Mechanism

• The door glass is secured to the carrier plate by the medium of the glass holder. • With the rotation of the regulator handle the carrier plate is moved up and down by means of the wire to open and close the door glass.

43-3

TROUBLESHOOTING

Regulator

Regulator faulty

O

Roller resistive

O

Improperly mounted

Reference Gr

O O O

Runchannel damaged

O

Runchannel improperly mounted

O

Door glass improperly installed

Door glass falls by gravity when vehicle is running

Regulator emits noise when vehicle is running

Possible causes

Door glass unsteady when opening and closing

Regulator handle drags

Symptoms

Regulator emits noise when door glass moves up and down

Door Glass Opening and Closing Mechanism

O

O

Door glass and door belt line molding unsteady

O

Door Lock

O O

Rod interfering

O

O

43-4

O

O O

Door latch deformed or damaged Outer handle improperly adjusted

O

O O

Door lock cylinder deformed or damaged Striker deformed

Operation with door lock knob

Rod dislodged

O

Door lock system does not operate

Operation with key

Rod deformed Each door rod

Opening and closing of door not smooth

O

Operating force of outside handle large

Fitting of door improperly adjusted

Door does not open with outside handle

Possible causes

Operating force of inside handle large

Door does not open with inside handle

Symptoms

O O

O O

O O

O

Reference Gr

ON-VEHICLE INSPECTION AND ADJUSTMENT

43

1. Adjustment of Front Door Alignment Tightening torque (Unit: N·m {kgf·m}) Mark – –

Parts to be tightened Bolt (door mounting;

marked)

Bolt (upper and lower hinge mounting;

marked)

Screw (striker mounting)

Tightening torque

Remarks

17 to 26 {1.7 to 2.6}

–

9 to 14 {0.9 to 1.4}

–

• Door alignment is adjusted by changing the positions of the upper and lower hinges and striker. Door alignment dimensions: See 1.3.

1.1 Adjustment of hinge positions • Use • Use

marked bolts to adjust gap. marked bolts to adjust flushness.

1.2 Adjustment of striker position • Use mounting screw to make the adjustment. • To adjust the engagement of the striker with the door lock, change the number of striker shims as required.

43-5

ON-VEHICLE INSPECTION AND ADJUSTMENT 1.3 Front door alignment dimensions

: Flushness dimension (+ for outside of cab; – for inside of cab)

43-6

43

FRONT DOOR Removal sequence 1 2 3 4 5 6

Door (See later section.) Upper hinge Lower hinge Striker Striker shim Door switch

Installation sequence Follow the removal sequence in reverse. • Adjust front door alignment after installation. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (door mounting) Bolt (door mounting) Bolt (upper and lower hinge mounting) Screw (striker mounting)

Tightening torque

Remarks

4 to 6 {0.4 to 0.6}

–

17 to 26 {1.7 to 2.6}

–

9 to 14 {0.9 to 1.4}

–

Lubricant and/or sealant Mark

Points of application Rotating contact parts of upper and lower hinges

Specified lubricant and/or sealant

Quantity

Chassis grease [NLGI No. 1 (Li soap)]

As required

43-7

FRONT DOOR Door

Disassembly sequence 1 2 3 4 5 6 7

8 9 10 11

Clip Regulator handle Clip Lower door trim Trim bracket Waterproof cover Weatherstrip

Door fender Air outlet garnish Weatherstrip Door panel (See later section.)

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Lubricant and/or sealant Mark

Points of application Waterproof cover fitting surface of door panel

43-8

Specified lubricant and/or sealant

Quantity

Butyl tape

As required

43 Removal procedure Removal: Lower door trim

Removal: Air outlet garnish

Installation procedure Installation: Air outlet garnish • Attach the air outlet garnish to the door panel in the illustrated direction, with its claw fitted in the door panel.

Installation: Waterproof cover • Apply butyl tape to the door panel as shown, then attach the waterproof cover to the door panel.

43-9

FRONT DOOR Door Panel

Disassembly sequence 1 2 3 4 5 6 7

Glass holder Door glass Regulator Sash garnish Beltline molding Delta garnish Door lock

8 9 10 11 12 13 14

Assembly sequence Follow the disassembly sequence in reverse.

43-10

Door lock cylinder Outside handle Ash tray Weatherstrip Inside handle inner cover Inside lock cable Inside open cable

15 16 17 18 19 20 21

Inside handle Spring Upper door trim Runchannel Protector Door check Door panel

43 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (upper door trim attaching)

Tightening torque

Remarks

10 to 15 {1.0 to 1.5}

–

Bolt (door glass attaching)

sealant

Nut (regulator attaching) Bolt (regulator attaching)

4 to 6 {0.4 to 0.6}

Bolt (outside handle attaching)

–

Nut (door check attaching) Screw (door lock attaching)

4.9 to 8.2 {0.51 to 0.84}

–

Lubricant and/or sealant Mark

Points of application Bolt threads

Specified lubricant and/or sealant

Quantity

Loctite Dri-Loc 202

As required

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Chassis grease [NLGI No. 2 (urea)]

1g

Sliding contact surface of regulator Sliding contact surface of door lock Rotating contact surface of outside handle Rotating contact surface of inside handle Sliding contact surface of door check

Removal sequence Removal: Sash garnish • Disengage claw A on upper part of the sash garnish from the runchannel, then remove clips (3 places). • Disengage claw B on the lower part of the sash garnish from the door panel.

Removal: Beltline molding • Disengage claws (4 places) and remove the beltline molding from the door panel bead.

Removal: Delta garnish • Disengage clips first and then claw to remove the delta garnish from the door panel.

43-11

FRONT DOOR Installation procedure Installation: Protector • Fit the protectors to the door panel in the illustrated positions.

Installation: Upper door trim • Tighten bolts to specified torque in numerical order (1 to 3) as shown to secure the upper door trim.

Installation: Delta garnish • To install the delta garnish, follow the removal procedure in reverse. (See “ Removal: Delta garnish”.) Installation: Beltline molding • Position the beltline molding with its front side applied to the delta garnish, then engage claws (4 places) with the door panel bead to secure the beltline molding in place.

Installation: Sash garnish • To install the sash garnish, follow the removal procedure in reverse. (See “ Removal: Sash garnish”.) Installation: Regulator • Tighten bolts (3 places) to specified torque in numerical order (1 to 3) as shown, then tighten the remaining bolts and nuts to specified torque.

43-12

GROUP 51 EXTERIOR STRUCTURE AND OPERATION 1. Wiper and Washer System ............................................................ 51-2 TROUBLESHOOTING ........................................................................ 51-3 MIRROR .............................................................................................. 51-4 WIPER AND WASHER ....................................................................... 51-6 FRONT COVER................................................................................... 51-8 FRONT GRILLE, FRONT CORNER PANEL AND HEADLAMP ...... 51-10 STEP ................................................................................................. 51-14 WHEEL HOUSE ................................................................................ 51-15 WINDOW GLASS.............................................................................. 51-16

51-1

STRUCTURE AND OPERATION 1. Wiper and Washer System

51-2

51

TROUBLESHOOTING

O

Wiper electronic control unit faulty

O

Washer injects insufficient amount of fluid

Washer fails to inject washer fluid

O

O

O

O

O

O

O

O

Fuse/high current fuse blown

O

O

Connector improperly connected, harness open-circuited, grounding improper

O

O

O

O

O

O

Wipe blade defective

O

Wiper arm defective

O

O O

O

Washer hose improperly connected

O

O

Washer nozzle clogged

O

O

Washer fluid insufficient

Gr54

O

Wiper link and wiper arm improperly connected

Washer hose twisted

O

O

Wiper relay faulty

Wiper motor crank arm out of position

Reference Gr

O

Washer motor faulty Wiper and washer switch faulty

Washer motor fails to operate

O

Wiper emits noise during operation

O

Wiper does not wipe well

O

Wiper blade stops at improper position

Wiper fails to stop

Wiper motor faulty

Wiper fails to operate intermittently

Possible causes

Wiper fails to operate

Symptoms

Wiper fails to operate in unison with washer

Wiper and Washer

O

51-3

MIRROR

Disassembly sequence 1 Clamp 2 Mirror

3 Cover 4 Mirror stay

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (mirror mounting) Bolt (mirror stay mounting)

Removal procedure Removal: Cover

51-4

Tightening torque

Remarks

9 to 14 {0.9 to 14}

–

51 Installation procedure Installation: Mirror stay • Install the one screw marked and adjust the position of the mirror stay. • Install all the remaining three screws marked to secure the mirror stay. • Fasten the mirror stay nut to the specified torque.

Installation: Mirror • Adjust the height of the mirror by aligning the punch mark on the mirror stay with the clamp edge as shown in the illustration.

51-5

WIPER AND WASHER

Disassembly sequence 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18

Wiper blade Blade rubber Washer nozzle Elbow joint Joint Hose Wiper arm Pivot cap Wiper link Wiper motor bracket

Wiper motor Joint Washer hose Washer hose Joint Washer tank Washer motor Washer hose

• Before disconnecting the connector to remove the wiper motor, pull out cab side harness sufficiently, otherwise it will fall in the cab side and cannot be taken out without removing the instrument panel.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards Location 7

Maintenance item Wiper arm force to press blade against windshield

Standard value

Limit

Remedy

6.2 ± 0.5 N {630 ± 5 gf}

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (wiper arm and blade attaching) Bolt (washer tank attaching)

51-6

Tightening torque 10.8 to 15.7 {1.1 to 1.6} 7.8 to 11.8 {0.8 to 1.2}

Remarks –

51 Inspection procedure Inspection: Wiper arm • Measure the wiper arm force to press the blade against the windshield. • If the measurement deviates from the standard value, replace the wiper arm.

Installation procedure Installation: Wiper arm and blade assemblies • Install the wiper arm and blade assemblies so that the blades come to the illustrated points as much as A and B apart from the edge of weatherstrip. A: 50 mm B: 59 ± 5 mm

51-7

FRONT COVER

Disassembly sequence 1 Front side cover 2 Front cover 3 Collar

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (front cover attaching)

51-8

Tightening torque

Remarks

9 to 14 {0.9 to 1.4}

–

51 Removal procedure Removal: Front side cover

Removal: Front cover

51-9

FRONT GRILLE, FRONT CORNER PANEL AND HEADLAMP

Disassembly sequence 1 2 3 4

Front grille Bracket Lamp rubber Turn signal lamp

5 Dummy lamp 6 Headlamp 7 Front corner panel

CAUTION • Do not attempt to forcefully remove lamp rubber, turn signal lamp, dummy lamp and headlamp. Their mounting claws could be damaged. • Do not remove door opening seal unless absolutely necessary.

Assembly sequence Follow the disassembly sequence in reverse.

51-10

51 Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (headlamp attaching)

Tightening torque

Remarks

4 to 6 {0.4 to 0.6}

–

Removal procedure Removal: Lamp rubber • Slide the lamp rubber sideways to disengage from the claws of the headlamp.

CAUTION • Do not pull the lamp rubber to forcefully remove. It could be damaged.

Removal: Turn signal lamp • Open the door. Loosen screws securing the turn signal lamp from behind to such an extent that they freely turn. • Draw out the loosened screws.

• Close the door. Move the turn signal lamp sideways to disengage its claws. • Ascertain the disengagement of the claws, then pull out the turn signal lamp.

Removal: Dummy lamp • Open the door. Loosen screw securing the dummy lamp from behind to such an extent that it freely turns. • Pull out the loosened screw.

51-11

FRONT GRILLE, FRONT CORNER PANEL AND HEADLAMP • Close the door, and remove the dummy lamp.

Removal: Headlamp

CAUTION • The headlamp has aiming screws at the illustrated positions. Do not mistake them for mounting bolts.

• Lift the headlamp slightly to disengage its claws from the slits, then pull it out.

Removal: Front corner panel • Open the door. Remove two screws securing the front corner panel from behind. • Close the door. Remove three screws securing the front corner panel from front. • Remove the front corner panel.

Installation procedure Installation: Front corner panel • Perform the removal procedure in reverse. (See “ Removal: Front corner panel”.)

51-12

51 Installation: Headlamp • Install the headlamp with its claws inserted in the slits.

Installation: Dummy lamp • Check to see if the threaded portion of cab-side screw protrudes. If it does, move it out of the way in the illustrated direction. • Insert the clip of the dummy lamp into the grommet.

• Open the door. Tighten the screw securing the dummy lamp from behind.

CAUTION • Do not overtighten the screw. Doing so may damage the dummy lamp.

Installation: Turn signal lamp • Check to see if the threaded portions of screws protrude. If they protrude, move them out of the way in the illustrated direction. • Put the claws of the turn signal lamp in the cab-side slits, then press-fit the lamp sideways into place.

• Open the door, and secure the turn signal lamp by tightening screws from behind.

CAUTION • Do not open the door when the turn signal lamp is not seated completely. Doing so may damage the turn signal lamp. • Do not overtighten the screws. Doing so may damage the turn signal lamp.

Installation: Lamp rubber • Perform the removal procedure in reverse. (See “ Removal: Lamp rubber”.)

51-13

STEP

51-14

51

WHEEL HOUSE

Removal sequence 1 Mud guard apron 2 Mud guard lower stay 3 Mud guard upper stay

4 Mud under guard 5 Lower shield panel

Installation sequence Follow the removal sequence in reverse.

51-15

WINDOW GLASS Removal sequence 1 2 3 4

Windshield weatherstrip Windshield glass Rear window weatherstrip Rear window glass

: Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Removal procedure Removal: Windshield weatherstrip and windshield glass • While prying up the lip of the weatherstrip with the tip of a screwdriver, push the windshield glass out from inside the cab.

CAUTION • Be careful not to damage the painted surface of the cab. Damaged surface may form rust.

Installation procedure Installation: Rear window weatherstrip and rear window glass • Fit the rear window weatherstrip round the rear window glass so that the joint of the weatherstrip comes at the bottom center of the glass. • Except for the point mentioned above, install the rear window glass in the same manner as the windshield glass.

51-16

51 Installation: Windshield weatherstrip and windshield glass • Install the weatherstrip with its center reference point aligned with the center of the cut at each corner of the glass.

• Put a piece of strong cord in the cab flange fitting groove in the weatherstrip with its end portions overlapped.

• With the glass strongly pushed from outside, pull out the cord by its ends from inside the cab to gradually fit the flange of the cab into the inner groove of the weatherstrip.

• Pull the cord in the numerical order of steps as shown. At the same time, while tapping with a rubber-headed mallet from outside the cab, settle the windshield glass in place in the weatherstrip. A: Approx. 100 mm from the beginning of straight portion B: Up to the end of straight portion

51-17

WINDOW GLASS • To ensure watertightness, put the hatched part of the weatherstrip inside between the cab and the front cover, front side cover and front corner panel.

51-18

GROUP 52 INTERIOR SEAT ......................................................................................... 52-2 ................................................................................ 52-4

SEAT BELT ......................................................................................... 52-6 INSTRUMENT PANEL ........................................................................ 52-8 TRIM AND SCUFF PLATE................................................................ 52-22 HEAD LINING ................................................................................... 52-24

52-1

SEAT

52-2

52 Removal sequence 1 Knob 2 Reclining cover 3 Back cushion

4 Inner cover 5 Bushing 6 Seat adjuster (right-hand)

7 Seat adjuster (left-hand) 8 Wire 9 Seat cushion

Installation sequence Follow the removal sequence in reverse. • When installing the seat adjusters, be sure to engage the locking device before fitting them onto the seat cushion.

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

Bolt (back cushion mounting)

Parts to be tightened

10 to 15 {1.0 to 1.5}

–

Nut (seat adjuster mounting)

11 to 17 {1.1 to 1.7}

–

1.4 {0.14}

–

34 to 54 {3.5 to 5.5}

–

Screw (knob mounting) Bolt (back cushion mounting)

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Chassis Grease [NLGI No. 1 (Li soap)]

As required

Sliding surface of seat adjuster

Installation procedure Installation: Wire • Install one end of the wire onto the seat adjuster (left-hand). Then, twist the wire a half turn before fitting the other end onto the seat adjuster (right-hand).

52-3

SEAT

52-4

52 Removal sequence 1 2 3 4 5

Reclining cover (right-hand) Knob Snap ring Side back cushion Reclining cover (left-hand)

6 7 8 9

Knob Snap ring Center back cushion Seat cushion

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (back cushion mounting)

Tightening torque

Remarks

19 to 28 {1.9 to 2.8}

–

Removal procedure Removal: Back cushions • With the back cushion folded forward, disengage the clip end of the rear cover.

52-5

SEAT BELT

Removal sequence 1 Shoulder anchor cover 2 Emergency locking retractor 3 Buckle

Installation sequence Follow the removal sequence in reverse.

CAUTION • Never disassemble the emergency locking retractor or buckle.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

34 to 54 {3.5 to 5.5}

–

Bolt (floor anchor mounting) Bolt (shoulder anchor mounting) Bolt (emergency locking retractor mounting) Bolt (buckle mounting)

Removal procedure Removal: Shoulder anchor cover

52-6

52 <Passengers side>

Removal sequence 1 2 3 4 5

Shoulder anchor cover Emergency locking retractor Tongue Buckle Buckle

Installation sequence Follow the removal sequence in reverse.

CAUTION • Never disassemble the emergency locking retractor or buckle.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

34 to 54 {3.5 to 5.5}

–

Bolt (floor anchor mounting) Bolt (shoulder anchor mounting) Bolt (emergency locking retractor mounting) Bolt (buckle mounting) Bolt (tongue mounting)

Removal procedure Removal: Shoulder anchor cover

52-7

INSTRUMENT PANEL Lower Panel

Removal sequence 1 2 3 4 5 6 7 8 9 10 11 12

Cigarette lighter Panel cover Push-on nut (× 8) Shift lever boots Cigarette lighter ring Cigarette lighter protector Hazard switch Card holder Upper center panel Clip Gear shift lever cover Idling control knob

13 14 15 16 17 18 19 20 21 22 23 24

Idling control cable Plug Plug Lid (for inspection of fuses) Clip Lower center panel Passenger panel B Clip Passenger panel A Plug Clip (× 3) Driver panel

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut

52-8

Tightening torque

Remarks

2 to 2.5 {0.2 to 0.3}

–

52 Removal procedure Removal: Panel cover

Removal: Upper center panel

Removal: Hazard switch

Removal: Gear shift lever cover • Push the clips (× 3) in the center to disengage them from the gear shift lever cover.

Removal: Plug

52-9

INSTRUMENT PANEL Removal: Plug

Removal: Lower center panel • Remove the screws (× 4) from the lower center panel. • Push the clips (× 2) in the center to disengage them from the lower center panel.

Removal: Passenger panel B

52-10

52 Removal: Passenger panel A • Remove the screws (× 4) from the passenger panel. • Push the clip (× 1) in the center to disengage it from the passenger panel.

Removal: Plug

Removal: Driver panel • Push the clips (× 3) in the center to disengage them from the driver panel.

52-11

INSTRUMENT PANEL Installation procedure Installation: Driver panel • Insert the clips (× 3) at the illustrated locations and push them in the center to engage into the driver panel.

Installation: Passenger panel A • Insert the clip (× 1) at the illustrated location and push it in the center to engage into the passenger panel. • Install the screws (× 4) to the passenger panel.

52-12

52 Installation: Lower center panel • Insert the clips (× 2) at the illustrated locations and push them in the center to engage into the lower center panel. • Install the screws (× 4) to the lower center panel.

Installation: Gear shift lever cover • Insert the clips (× 3) at the illustrated locations and push them in the center to engage into the gear shift lever cover.

52-13

INSTRUMENT PANEL Driver Upper Panel

Removal sequence 1 2 3 4 5

Radio bracket Box Heater controls Box Plug

Installation sequence Follow the removal sequence in reverse.

52-14

6 7 8 9

Meter bezel Meter cluster Lid (accessories box) Lid (brake fluid tank)

52 Work before removal Removal: Control cables • Turn the temperature control knob of the heater controls to the MAX-COOL position.

• Before disconnecting the cables from the levers, put pairing marks on each cable and its lever. • Disconnect the control cables from the heater unit.

• In order that the control cables can be pulled back at the time of installation, attach string to the ring parts of the cables as shown in the illustration.

52-15

INSTRUMENT PANEL Removal procedure Removal: Radio bracket • Pull out the radio bracket for heater controls until it completely comes out of the instrument panel as shown in the illustration.

CAUTION • Do not pull the bracket with a strong force. Pulling it strongly could give damage to the heater controls and control cables.

Removal: Plug

Removal: Lid (accessories box)

Removal: Lid (brake fluid tank)

Work after installation Installation: Control cables • Of the heater controls, turn the temperature control knob to the MAX-COOL position and also turn the mode selector knob to the face position.

52-16

52 • Pull out the control cables using the string that was attached to them at the time of removal. • According to the pairing marks, reconnect the cables to the heater unit levers correctly. (See Gr55.)

52-17

INSTRUMENT PANEL Passenger Upper Panel

Removal sequence 1 Glove box 2 Plug 3 Parcel tray •

marked: Fastened together with passenger panel A.

Installation sequence Follow the removal sequence in reverse.

52-18

4 Lid

*a:

Passenger panel A

52 Removal procedure Removal: Plug

Removal: Lid

52-19

INSTRUMENT PANEL Instrument Panel

Removal sequence 1 2 3 4 5 6 7

Center duct Driver face duct Center face duct Passenger face duct Clip (× 7) Front defroster duct Side defroster duct

Installation sequence Follow the removal sequence in reverse.

52-20

8 9 10 11 12 13

Air outlet grille Driver instrument panel frame Brake fluid tank Passenger instrument panel frame Plug Instrument panel

52 Removal procedure Removal: Plug

Installation procedure Installation: Front defroster duct • Insert the front defroster duct flanges into the instrument panel ribs. • Insert the instrument panel studs into the front defroster duct holes and clip them together.

52-21

TRIM AND SCUFF PLATE Removal sequence 1 2 3 4

Scuff plate Weatherstrip Grip Front pillar trim

Installation sequence Follow the removal sequence in reverse.

Removal procedure Removal: Front pillar trim

52-22

52 Installation procedure Installation: Weatherstrip • Install the weatherstrip in such a manner that the lip of the strip holds down the front pillar trim and head lining.

Installation: Scuff plate • Install the scuff plate in such a manner that it holds down the lip of the weatherstrip.

52-23

HEAD LINING

Removal sequence 1 2 3 4 5 6 7

Lens Room lamp Inside mirror Sun visor (right-hand) Sun visor hook Sun visor (left-hand) Sun visor hook

8 9 10 11 12 13

Cap Grip Plug Coat hanger Clip (× 8) Head lining

Installation sequence Follow the removal sequence in reverse.

Removal procedure Removal: Lens

52-24

52 Removal: Coat hanger • Remove the coat hanger from the head lining by pulling it in the direction of “2” while pressing it in the direction of “1”.

Installation procedure Installation: Head lining • Locate the head lining correctly onto the cab by installing clips at the locations (× 2). Install clips at the locations (× 6).

52-25

GROUP 55 HEATER, VENTILATION SPECIFICATIONS............................................................................... 55-2 STRUCTURE AND OPERATION 1. Heater ........................................................................................... 55-3 2. Air Duct ........................................................................................ 55-4 3. Heater Control .............................................................................. 55-5 TROUBLESHOOTING ........................................................................ 55-7 HEATER CONTROL ........................................................................... 55-8 AIR DUCT.......................................................................................... 55-12 HEATER UNIT, BLOWER ................................................................. 55-14

55-1

SPECIFICATIONS Item

System

Damper changeover system

Specifications Mode selection

Manual cable type

Air mixing

Manual cable type

Fresh/recirculation changeover

Servomotor rated voltage

V

Manufacturer Heater unit

Heating capacity

W {kcal/h}

55-2

4580 ± 458 {3940 ± 394} Air mixing type

Manufacturer Blower motor voltage

24 MODINE

Temperature control system Blower

Servomotor

MODINE V

24

STRUCTURE AND OPERATION

55

1. Heater

• The blower sends air to the heater unit, where the air is heated by the heater core (heat exchanger). The warmedup air is then sent through the ducts into the cab. • Water (engine coolant) warmed up by the heat from the engine circulates permanently through the heater core, irrespective of whether the thermostat is open or closed.

55-3

STRUCTURE AND OPERATION 2. Air Duct

• The blower sends outside air A or inside air B through the heater unit to the ducts. The flow of air is dependent on the open/closed positions of the various dampers.

55-4

55 3. Heater Control 3.1 Mode selection

• Mode selection (opening/closing the dampers) is achieved by the operation of the mode selection control cables and the resultant movement of the related parts linked to the cables.

3.2 Air mix selection

• Air mix selection is achieved by controlling the positions of the dampers, thereby proportioning the volumes of warm and cool air that is and is not sent through the heater core.

55-5

STRUCTURE AND OPERATION 3.3 Fresh/recirculation changeover

• The fresh/recirculation changeover damper is operated by means of motor.

55-6

55

TROUBLESHOOTING Heater

O

Air mix damper malfunction, not fully closed

O O

O O

Fresh/recirculation selection motor coil open, shorted

O O

Fresh/recirculation selection damper malfunction, not fully closed

O O

O

Thermostat stays open

O

Coolant level low

O

Connector poor contact, harness open, faulty ground

O

Fuse blown

O

O

O

O O

Gr54 O

O

Gr54 Gr14

O

O

O

O

Gr54

O

Duct incorrectly connected Heater unit clogged

Controls require too much effort

O

Mode damper malfunction, not fully closed

Heater piping clogged, loose, incorrectly connected

Reference Gr

Gr54

Blower resistor malfunction

Heater control malfunction

Air volume from vents unstable

No fresh/recirculation selection

O

No temperature setting

Blower motor relay contacts stuck closed, coil open, shorted

Draft from vents

O

No mode selection

Blower motor coil open, shorted

Poor heating

Possible causes

No air from vents

Symptoms

O O

Control wire jammed, incorrectly installed

O

O

O

O

Lever bent

O

O

O

O

Lever sliding section worn, out of grease

O

O

O

O

55-7

HEATER CONTROL

Removal sequence 1 Air mix control cable (YELLOW) 2 Mode selection control cable (NATURAL) 3 Heater controls

CAUTION • Never remove the cable(s) from the heater controls except when the control cable(s) needs to be replaced. Failure to observe this may damage the claws of the cable clip.

Installation sequence Follow the removal sequence in reverse.

55-8

55 Work before removal Adjustment: Temperature control knob • Before disconnecting the control cables, turn the temperature control knob of the heater controls to the MAX-COOL position.

Removal procedure Removal: Control cables • Before disconnecting the cables from the levers, put pairing marks on each cable and its lever. • Disconnect the control cables from the heater unit.

• In order that the control cables can be pulled back at the time of installation, attach string to the ring parts of the cables as shown in the illustration.

55-9

HEATER CONTROL • Remove the heater controls from the instrument panel. (See Gr52.) • Use snap ring pliers to disconnect the cable(s) from the heater controls.

Work before installation Adjustment: Heater controls knobs • At the heater controls, turn the temperature control knob to the MAX-COOL position and turn the mode selector knob to the face position before reconnecting the control cables.

Installation procedure Installation: Air mix control cable • Install one end of the air mix control cable to the heater controls. • Set the control’s temperature control knob to MAX HOT. • Pull back the control cable using the string attached at the removal procedure. • Install the other end of the air mix control cable to the lever on the heater unit. • Align the locating ring of the air mix control cable with the side of the clip. Push the cable into the clip. • Move the temperature control knob to MAX COOL and MAX HOT. Make sure that the lever moves to the corresponding MAX COOL and MAX HOT positions. If not, repeat the above sequence to correctly install the cable. Also, make sure that the cable being installed is in the correct color.

55-10

55 Installation: Mode selection control cable • Install one end of the mode selection control cable to the heater controls. • Set the control’s mode control knob to FACE. • Pull back the control cable using the string attached at the removal procedure. • Install the other end of the mode selection control cable to the lever on the heater unit. • With the mode selection control cable connected to the lever, pull the cable in the direction of the arrow. Clip the cable into position. • Move the mode control knob to FACE and DEF. Make sure that the lever moves to the corresponding FACE and DEF positions. If not, repeat the above sequence to correctly install the cable. Also, make sure that the cable being installed is in the correct color.

55-11

AIR DUCT

Removal sequence 1 2 3 4 5 6

55-12

Center duct Driver face duct Center face duct Passenger face duct Clip ( × 7) Front defroster duct

7 8 9 10 11 12

Side defroster duct Passenger foot duct Center foot duct Foot duct bracket Driver foot duct B Driver foot duct A

55 Installation sequence Follow the removal sequence in reverse.

Installation procedure Installation: Front defroster duct • Insert the front defroster duct flanges into the instrument panel ribs. • Insert the instrument panel studs into the front defroster duct holes and clip them together.

55-13

HEATER UNIT, BLOWER Heater Unit Blower

55-14

55 Removal sequence 1 2 3 4 5 6 7

Heater hose (outlet) Heater hose (return) Air filter Air filter Fresh/recirculation changeover motor Resistor Blower motor and fan

8 9 10 11 12 13 14

Blower Blower bracket Heater bracket Joint duct Heater unit (See later section.) Heater bracket Heater bracket

Installation sequence Follow the removal sequence in reverse.

55-15

HEATER UNIT, BLOWER Heater Unit

Disassembly sequence 1 Case cover 2 Cover 3 Heater core

Assembly sequence Follow the disassembly sequence in reverse.

55-16

4 Resist plate 5 Heater unit case

For Egypt

Shop Manual chassis

APRIL 2014 454 (H)

For Egypt

Pub.No.00ELT0061, APRIL 2014

Pub.No.00ELT0061, APRIL 2014

Shop Manual